Bhardwaj Kulkarni

Marathwada Agricultural University

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Sandeep Pankade

Dr. Babasaheb Ambedkar Marathwada University

Saurabh Tayde

Suhas Gade

S.R. Andhale

Dr. Babasaheb Ambedkar Marathwada University

Santosh Bhosle

Savitribai Phule Pune University

Ganesh Aher

Ajinkya Satdive

Institute of Chemical Technology

C. L. Gogte

Dr. Babasaheb Ambedkar Marathwada University

Cooperative Institutions

Dr. Babasaheb Ambedkar Marathwada University

Savitribai Phule Pune University

Institute of Chemical Technology

University of Mumbai

MIT Art, Design and Technology University

Wockhardt (India)

Moscow Institute of Thermal Technology

Massachusetts Institute of Technology

Visvesvaraya National Institute of Technology

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Comparative Study of Corrosion, Mechanical and Electrical Characteristics of Tungsten inert Gas and Friction Stir Welded Joints

Research Square (Research Square) (2023)

Bhardwaj Kulkarni Sandeep Pankade

Abstract Aluminium alloys are welded using both tungsten inert gas welding (TIG) and friction stir welding (FSW). FSW doesn’t need any filler material and shielding gas which results in reduced degradation of the environment. In the present study, joints with FSW and TIG processes were compared in terms of microstructure, corrosion resistance, mechanical, and electrical properties. With a microstructural study, the average grain size of various regions was determined. Coarse grain increases the rate of exfoliation corrosion. The fine grain structure in the FSW stir zone increases the hardness. The coarse grains are a prerequisite for enhanced electrical conductivity. The coarse grains in the heat-affected zone and thermomechanically affected zones of FSW joints increase electrical conductivity. In the case of friction stir welded joints, there is an inverse relationship between hardness and electrical conductivity. As hardness increases, electrical conductivity decreases, and vice versa. Hence, in the case of FSW hardness test can be substituted by an electrical conductivity test. In the case of TIG, no relation was found between hardness and electrical conductivity. High Silicon content at the weld region of TIG significantly reduces electrical conductivity.

Inert gas

Friction Stir Welding

10.21203/rs.3.rs-2646289/v1

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Citations (1)

Effect of backing plate material diffusivity on microstructure, mechanical properties of friction stir welded joints: A Review

Procedia Manufacturing (2018)

Bhardwaj Kulkarni Sandeep Pankade S.R. Andhale C. L. Gogte

Friction stir welding is a widely used solid state joining process for soft materials such as aluminium alloys as it avoids/minimizes common problems of fusion welding processes such as distortion, porosity, solidification and liquation cracking etc. Improper selection of parameters such as welding speed, rotational speed, forge force, back plate material etc. affects the weld quality. Thermal boundary condition at the bottom of the work pieces to be joined is important in determining the resulting weld quality and properties. For a given alloy type, tool geometry and selected process parameters (welding speed, rotational speed etc.), which results in good quality weld depends on thermal boundary conditions at the bottom of the work piece. These thermal boundary conditions are governed by the back plate material used. This paper critically reviews several effects of back plate material on microstructure and mechanical properties of friction stir welded aluminium joints.

Liquation

Fusion welding

Friction Stir Welding

Friction Welding

10.1016/j.promfg.2018.02.008

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Citations (19)

Comparative Study of Corrosion, Mechanical and Electrical Characteristics of Tungsten inert Gas and Friction Stir Welded Joints

Petroleum and Chemical Industry International (2023)

Bhardwaj Kulkarni Sandeep Pankade

Aluminium alloys are welded using both tungsten inert gas welding (TIG) and friction stir welding (FSW). FSW doesn’t need any filler material and shielding gas which results in reduced degradation of the environment. In the present study, joints with FSW and TIG processes were compared in terms of microstructure, corrosion resistance, mechanical, and electrical properties. With a microstructural study, the average grain size of various regions was determined. Coarse grain increases the rate of exfoliation corrosion. The fine grain structure in the FSW stir zone increases the hardness. The coarse grains are a prerequisite for enhanced electrical conductivity. The coarse grains in the heat-affected zone and thermomechanically affected zones of FSW joints result in increased electrical conductivity. In the case of friction stir welded joints, there is an inverse relationship between hardness and electrical conductivity. As hardness increases, electrical conductivity decreases, and vice versa. Hence, in the case of FSW hardness test can be substituted by an electrical conductivity test. In the case of TIG, no relation was found between hardness and electrical conductivity. High Silicon content at the weld region of TIG significantly reduces electrical conductivity

Friction Stir Welding

Inert gas

10.33140/pcii.06.02.03

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Citations (0)

Optimizing Brake Lever Design for Electric Two-Wheelers: A Comparative Study of 3D Printed Polymers

Research Square (Research Square) (2024)

Ganesh Aher Suhas Gade Bhardwaj Kulkarni Ajinkya Satdive Saurabh Tayde

Abstract The utilization of 3D printing technology has extended its reach across diverse fields, including aerospace, healthcare, the food industry, and construction. This research aims to develop a lightweight brake lever for an electric two-wheeler using fused deposition modelling (FDM) technology, replacing traditional metallic materials with a polymer to reduce both cost and weight. The brake lever was designed using Solid Edge software, converted into a .stl file using Anycubic Slicer, and printed with polylactic acid (PLA) material via the FDM process. Tensile tests were conducted on samples per ASTM D638 standards. Additionally, materials like ABS, polycarbonate, and polypropylene were evaluated using ANSYS software for their suitability as brake lever materials. This study presents a comprehensive approach to utilizing FDM technology for developing critical automotive components, showcasing significant advancements in cost-efficiency and weight reduction.

Lever

3d printed

10.21203/rs.3.rs-5396565/v1

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Effects of different backing plates and tool design on the flash defect developed during friction stir welding of AA6061 aluminium alloy

Research Square (Research Square) (2022)

Bhardwaj Kulkarni Sandeep Pankade

Abstract The growing need for lightweight and higher strength materials, like aluminium alloys, in aircraft, ship construction, and railways has influenced manufacturers to adopt friction stir welding (FSW) due to the excellent mechanical properties of FSW joints as compared to other conventional welding processes. Friction stir welding (FSW) is defined by diverse interactions of thermal, mechanical, and tool geometry effects. The backing plate material is crucial for effective temperature control during the FSW process. Inappropriate FSW process parameters can result in flash defects. Due to extreme heat input, flash may be generated in FSW welds. This investigation aims to determine appropriate process parameters (backing plate thermal diffusivity, welding speed, and tool rotational speed) along with proper tool design to achieve flash defect-free joints. Visual observations indicate that the aluminium backing plate results in flash defect-free joints as compared to other backing plates.

10.21203/rs.3.rs-1968882/v1

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Citations (1)

Corrosion and Mechanical Aspects of Friction Stir Welded AA6061 Joints: Effects of Different Backing Plates

Journal of Materials Engineering and Performance (2023)

Bhardwaj Kulkarni Sandeep Pankade Saurabh Tayde Santosh Bhosle

Friction Stir Welding

10.1007/s11665-023-07900-x

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Citations (7)