influence of tool-pin profile on properties of friction

11
Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling Gagandeep Singh Dhaliwal 1* and Pardeep Kumar 2 1 Research Scholar, Mech.Engg.Section, YCoE, Punjabi University GK Campus, Talwandi Sabo, Distt.Bathinda, Punjab-151302, India 2 Mech.Engg.Section, YCoE, Punjabi University GK Campus, Talwandi Sabo, Distt.Bathinda, Punjab – 151302, India * corresponding author e-mail: [email protected] Abstract - Aluminium alloys, possessing good strength to weight ratio, are extensively employed in various fields of technology. Friction stir processing (FSP) is an allied process of friction stir welding (FSW) that is used to transform the material properties. FSP performed on surface can transform the surface properties of certain material and can also transform the mechanical properties, if carried out in bulk of material. Investigations have been carried out by number of researchers to see the influence of FSP parameters and the simultaneous cooling on different properties of different materials. In the present research work, the work was carried out to see the influence of tool-pin profile on the properties of aluminium alloy AA2014, under natural and flood cooling conditions. AA2014 is commonly used in aerospace industry and in defence equipment. AA2014 was friction stir processed with three types of tool-pin profiles and freezing the other process parameters of FSP, on the basis of literature. The processed specimens were characterized with X-ray radiography and microstructure analysis. Micro-hardness and the tensile strength of the processed specimens were also tested. Among the processed specimens, the highest hardness was obtained with square tool-pin profile under flood cooling conditions. The refinement in microstructure has been observed to be the reason of the same. Keywords: Friction stir processing, microstructure, micro- hardness, tool-pin profile, flood cooling. 1. INTRODUCTION Aluminium and aluminium alloys have a wide range of applications, due to its many outstanding attributes including good corrosion and oxidation resistance, high electrical and thermal conductivities, low density, high reflectivity, high ductility and reasonably high strength, and relatively low cost (Pushpanathan et al., 2012; Kapoor et al., 2013;Vagh and Pandya, 2012). Aluminium and its alloys are used commonly in aerospace and transportation industries because of their low density and high strength to weight ratio. Aluminium alloys are generally classif ed as non-weldable because of the poor solidif cation microstructure and porosity in the fusion zone. These factors make the joining of these alloys by conventional welding processes unattractive. Some aluminium alloys can be resistance welded, but the surface preparation is expensive, with surface oxide being a major problem. Friction stir welding (FSW) was invented at The Welding Institute (TWI) of UK in 1991 as a solid-state joining technique and it was initially applied to aluminium alloys. The basic concept of FSW is remarkably simple. Recently friction stir processing (FSP) has come up as a solid state technique for microstructure modif cation, based on the basic principles of FSW (Misra and Ma, 2005; Pushpanathan et al., 2012; Elangovan and Balasubramanian, 2008). In FSW, a non-consumable rotating tool with a specially designed pin and shoulder is inserted into the abutting edges of plates, to be joined and then traversed along the line of joint, while shoulder touches the plates. Due to stirring action of the tool-pin, the friction heats both the materials at the joint. The two materials in visco-plastic state on solidification give a good welded joint. Thus, a welding joint is produced in solid state by localized heat from the friction between the tool and work piece and plastic deformation of the material. In FSP, the same process is used for modification of the material properties by the process of friction stirring in the single material only. Then the tool is plunged into the material at pre-determined rotational speed and traversed across it, as shown in Fig. 1. The heat is generated by the friction between the tool-pin and work piece. The localized heating softens the material around the pin. The combination of tool rotation and translation cause the movement of material from front to the back of the pin, which results in the processing of the material (Misra and Ma, 2005). Fig. 1: Schematic representation of FSP principle (Yadav and Bauri, 2012). 32 ARME Vol.3 No.2 July - December 2014

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Page 1: Influence of Tool-Pin Profile on Properties of Friction

Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling

Gagandeep Singh Dhaliwal1* and Pardeep Kumar2 1Research Scholar, Mech.Engg.Section, YCoE, Punjabi University GK Campus, Talwandi Sabo,

Distt.Bathinda, Punjab-151302, India 2Mech.Engg.Section, YCoE, Punjabi University GK Campus, Talwandi Sabo, Distt.Bathinda, Punjab – 151302, India

* corresponding author e-mail: [email protected]

Abstract - Aluminium alloys, possessing good strength to weight ratio, are extensively employed in various fields of technology. Friction stir processing (FSP) is an allied process of friction stir welding (FSW) that is used to transform the material properties. FSP performed on surface can transform the surface properties of certain material and can also transform the mechanical properties, if carried out in bulk of material. Investigations have been carried out by number of researchers to see the influence of FSP parameters and the simultaneous cooling on different properties of different materials. In the present research work, the work was carried out to see the influence of tool-pin profile on the properties of aluminium alloy AA2014, under natural and flood cooling conditions. AA2014 is commonly used in aerospace industry and in defence equipment. AA2014 was friction stir processed with three types of tool-pin profiles and freezing the other process parameters of FSP, on the basis of literature. The processed specimens were characterized with X-ray radiography and microstructure analysis. Micro-hardness and the tensile strength of the processed specimens were also tested. Among the processed specimens, the highest hardness was obtained with square tool-pin profile under flood cooling conditions. The refinement in microstructure has been observed to be the reason of the same. Keywords: Friction stir processing, microstructure, micro-hardness, tool-pin profile, flood cooling.

1. INTRODUCTION Aluminium and aluminium alloys have a wide range of applications, due to its many outstanding attributes including good corrosion and oxidation resistance, high electrical and thermal conductivities, low density, high reflectivity, high ductility and reasonably high strength, and relatively low cost (Pushpanathan et al., 2012; Kapoor et al., 2013;Vagh and Pandya, 2012). Aluminium and its alloys are used commonly in aerospace and transportation industries because of their low density and high strength to weight ratio. Aluminium alloys are generally classif ed as non-weldable because of the poor solidif cation microstructure and porosity in the fusion zone. These factors make the joining of these alloys by conventional welding processes unattractive. Some aluminium alloys can be resistance welded, but the surface preparation is expensive, with surface oxide being a major problem. Friction stir welding (FSW) was invented at The Welding Institute (TWI) of UK in 1991 as a solid-state joining technique and it was initially applied to aluminium alloys. The basic concept of FSW is remarkably simple. Recently friction stir processing (FSP) has come up as a solid state

technique for microstructure modif cation, based on the basic principles of FSW (Misra and Ma, 2005; Pushpanathan et al., 2012; Elangovan and Balasubramanian, 2008). In FSW, a non-consumable rotating tool with a specially designed pin and shoulder is inserted into the abutting edges of plates, to be joined and then traversed along the line of joint, while shoulder touches the plates. Due to stirring action of the tool-pin, the friction heats both the materials at the joint. The two materials in visco-plastic state on solidification give a good welded joint. Thus, a welding joint is produced in solid state by localized heat from the friction between the tool and work piece and plastic deformation of the material. In FSP, the same process is used for modification of the material properties by the process of friction stirring in the single material only. Then the tool is plunged into the material at pre-determined rotational speed and traversed across it, as shown in Fig. 1. The heat is generated by the friction between the tool-pin and work piece. The localized heating softens the material around the pin. The combination of tool rotation and translation cause the movement of material from front to the back of the pin, which results in the processing of the material (Misra and Ma, 2005).

Fig. 1: Schematic representation of FSP principle (Yadav and Bauri, 2012).

32ARME Vol.3 No.2 July - December 2014

Page 2: Influence of Tool-Pin Profile on Properties of Friction

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Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling

33 ARME Vol.3 No.2 July - December 2014

Page 3: Influence of Tool-Pin Profile on Properties of Friction

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Gagandeep Singh Dhaliwal and Pardeep Kumar

34ARME Vol.3 No.2 July - December 2014

Page 4: Influence of Tool-Pin Profile on Properties of Friction

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Fig. 7 Effect of c

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Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling

35 ARME Vol.3 No.2 July - December 2014

Page 5: Influence of Tool-Pin Profile on Properties of Friction

3Mfcocs 3MIcodmscldFsb(fttdhigtoT

3.3 MicrostrucMicrostructureform surface fcooling condition the microscooling has besubsections res

3.3.1 Effect MicrostructureIn microstructucooling are aoptical microsdetails. Fig. microstructure square, hexagocooling respeclarge grains distribution of Fig.11. The sursuch as square,brighter than t(2013) observefriction stir protool have signithe processed deformation phomogeneous, improve the mgrain refinemethis can be attrobservations mTable 2 and 3.

F

TABLE 2 MIC

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Squar

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for all tool-pinions were captstructure of deen analysed aspectively.

of Tool-pine ure analysis, s

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onal and rounctively. The pa

of non-unifof coarse secondrfaces of specim, hexagonal andthe parent meted same result ocessing, rotatificant effects surface. The m

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Fig. 11 Microstruc

CROSTRUCTURCOND

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re Fine

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RE OBSERVATIODITION

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2

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ool-pin profile

Square

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UCTURE OBSEROOLING CONDI

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Fine andequiaxed structure Medium gr

More hostructure

-pin profile oned specimense shown in Fig

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RVATION UNDERITION

Observation

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omogeneous

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20µ

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R FLOOD

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µm

µm

Gagandeep Singh Dhaliwal and Pardeep Kumar

36ARME Vol.3 No.2 July - December 2014

Page 6: Influence of Tool-Pin Profile on Properties of Friction

(c)

Fig. 12 Microstructure images of AA2014 processed under dry condition with different tool-pin profiles (a) square (b) hexagonal and (c) round.

(a)

(b)

(c)

Fig.13 Microstructure images of AA2014 processed with FSP under flood cooling condition with different tool-pin profiles (a) square (b) hexagonal

and (c) round. From the analysis of microstructure images, it can be inferred that the microstructure can be controlled by changing the tool-pin profile and formation of defects free friction stir processed surface is also a function of tool-pin profile. From the above investigation, the processed region of specimens, show a fine recrystallized grain structure due to heavy plastic deformation, which is due to dynamic recrystallization due to thermo mechanical processing by the square tools. It can also be seen that sample processed by square tool-pin profile has finer equiaxed grain structure relative to sample processed by the other pin profiles as shown in Fig. 12(a) and Fig. 13(a). These results are in conformance with Elangovan and Balasubramanian (2008) in the case of aluminium alloy. The grain refinement is attributed to the higher number of pulsating action experienced in the stirring zone of square pin profile as compared to that in other tool-pin profiles. 3.3.2 Effect of Cooling on the Microstructure The FSP process under the cooling conditions changed the coarse and inhomogeneous microstructure of specimen to a fine and uniform microstructure. The cooling process decreases grain size and increased its uniform distribution. Reduction of the process temperature with cooling system and lowering the total time of cooling process results more uniform and similar grain size microstructure. The similar result was observed by Darras and Kishta (2006) in submerged friction stir processing of AZ31.Nia et al., (2013) also observed that cooling process decreased grain size and increased its uniform distribution. So that FSP under flood cooling have a fine and equiaxed grain structure than that of FSP dry conditions as shown in Fig. 14, 15 and 16 respectively.

20µm

20µm20µm

20µm

Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling

37 ARME Vol.3 No.2 July - December 2014

Page 7: Influence of Tool-Pin Profile on Properties of Friction

(a) (b)

Fig. 14 Microstructure images of AA2014 processed with FSP with square tool-pin profile, under (a) natural cooling, (b) flood cooling.

(a) (b)

Fig. 15 Microstructure images of AA2014 processed with FSP with hexagonal tool-pin profile, under (a) natural cooling, (b) flood cooling

(a) (b)

Fig. 16 Microstructure images of AA2014 processed with FSP with round tool-pin profile, under (a) natural cooling, (b) flood cooling.

20µm 20µm

20µm20µm

Gagandeep Singh Dhaliwal and Pardeep Kumar

38ARME Vol.3 No.2 July - December 2014

Page 8: Influence of Tool-Pin Profile on Properties of Friction

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Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling

39 ARME Vol.3 No.2 July - December 2014

Page 9: Influence of Tool-Pin Profile on Properties of Friction

tcs2MtFaped

tool-pin proficomplements tseen that ultim200 to 217 MPMPa in case othere is drasticFSP, as maximagainst nominaprofile. Wen eexhibits highedry/flood cooli

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respectively.

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remarkable tion. The reduce the ramatically graphically the tensile processed

Gagandeep Singh Dhaliwal and Pardeep Kumar

40ARME Vol.3 No.2 July - December 2014

Page 10: Influence of Tool-Pin Profile on Properties of Friction

TDLY(pc

(

The authors areDevelopment CLudhiana and Yadavindra C(Bathinda), Puprocessing andcarry out this re

(c)Fig. 20 Effect o

ACKNOWLE

e grateful to thCentre for Bicyalso to Mech

College of Eunjab for extend material testesearch work.

of cooling on the e

EDGEMENT

he Department ycle and sewinhanical EngineEngineering, nding the facilting laboratory

0

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and rts, of

abo rial

to

[1] ASMeCon

[2] ASTesCon

[3] Bal‘Inv

ool-pin profile

od cooling)

ol-pin profile

od cooling) H

ool-pin profile

lood cooling)

onal and (c) round

TM-E3-11.(2011)etallographic Spnshohocken, PA. TM-E8 / E8M. (sting of Metallnshohocken, PA. lamurugan K., Mvestigation on th

11.07

Square(Dry)

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Hexagonal(dry)

8.11Round(Dry)

d tool-pin profiles

REFERENC

), "Standard Gpecimens", AS

(2013a), " Standalic Materials,"

Mahadevan K. ahe changes effec

)

respectively.

CES

Guide for PrepSTM Internatio

ard Test Methods ASTM Internati

and Pushpanathancted by the tool

paration of onal, West

for Tension ional, West

n D., 2012, l profile on

Influence of Tool-Pin Profile on Properties of Friction Stir Processed AA 2014 Under Natural and Flood Cooling

41 ARME Vol.3 No.2 July - December 2014

Page 11: Influence of Tool-Pin Profile on Properties of Friction

mechanical and tribological properties of friction stir processed AZ31B magnesium’, Mechanical andcivil Engineering, vol.2, pp.44-47.

[4] Balamurugan K. and Mahadevan K., 2013, ‘Investigtion on the changed effect of tool shoulder profile on the mechanical and tribological properties of friction stir processed AZ31 megnesium alloy’,Manufacturing process, vol.56, pp45-57.

[5] Elangovan K. and Balasubramanian V., 2008a, ‘Influence of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminum alloy’, Material and design, vol.29, pp.362-373.

[6] Elangovan K. and Balasubramanian V., 2008b, ‘Influence of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminum alloy’, Meterial processing technology, vol.200, pp.163-175.

[7] Kapoor R., Kandasamy K., Misra R.S., Baumann J.A. and Grant G., 2013, ‘Effect of friction stir processing on the tensile and fatigue behaviourof a cast A206 alloy’,Material science and technology, vol.561, pp.159-166.

[8] Kurt A., Uygur I. and Cete E., 2011, ‘Surface modification of aluminium by friction stir processing’, Material processing technology, vol.211, pp.313-317.

[9] Misra R. S. and Ma Z.Y., 2005, ‘Friction stir welding and processing’, Material science and engineering, vol.50, pp.1-78.

[10] Ma Z.Y., Sharma S.R. and Misra R.S., 2006, ‘Effect of multi pass friction stir processing on the microstructure and tensile properties of a cast alumium-silicon alloy’, Scripta materialia, vol.54, pp.1623-1626.

[11] Nia A., Omidvar H. and Nourbakhsh S.H., 2013, ‘Investigation of effects of thread pitch and water cooling action on the mechanical strength and microstructure of friction stir processed AZ31’, Material and design, vol.52, pp.615-620.

[12] Nataka K., Kim Y.G., Fujii H., Tsumura T. and Komazaki T., 2006, ‘Improvement of mechanical properties of aluminium die casting alloy bu multi-pass friction stir processing’, Material science and engineering, vol.437, pp.274-280.

[13] Pushpanathan D., GanesaBalamurugan K. and Mahadevan K., 2012, ‘Investigation on the change effected by the tool type on the hardness of friction stir processed AA6063 aluminium alloy’, Applied science, vol.12, no.10, pp.1067-1070.

[14] Ramanjaneyulu K., Reddy G., Rao A. and Markandeya R., 2013, ‘Structure-property correlation of AA2014 friction stir welds: Role of tool pin profile’,ASM international, vol.22, no.8, pp.2224-2240.

[15] Wen W., Kuaishe W., Qiang G. and Nan W., 2012, ‘Effect of friction stir processing on microstructure and mechanical properties of Cast AZ31 Magnesium alloy’, Material science and engineering, vol.41, no.9, pp.1522-1526.

[16] Xu W., Liu j., Zhu H., and Fu Li., 2013, ‘Influence of welding parameters and tool pin profile on the microstructure and mechanical properties along the thickness in a friction stir welded aluminum alloy’, Material and design, vol.47, pp.599-606.

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Gagandeep Singh Dhaliwal and Pardeep Kumar

42ARME Vol.3 No.2 July - December 2014