Study the effect process of parameters on friction welding of dissimilar metals AISI 304 steel and AA 2219 aluminium

Friction welding is a solid state welding process to produce the joint by utilizing heat generated by friction at the interface and with axial pressure. Friction welding process is non consumable and reusable in manufacturing process. This method produces the joint between similar and dissimilar metals without much effecting heat affected zone. The conventional welding technique is very difficult to join dissimilar metals as they are differing in their thermal and metallurgical properties. Welding of dissimilar metals is very much interested in automotive, aerospace and other industrial applications. The aluminium alloy in combination with steel bodies has significant reduction in weight and cost saving. In this present work a continuous drive friction welding process was performed on dissimilar material AA2219 aluminium alloy and AISI 304 austenitic stainless steel. The study was carried on process parameters like rotational speed, Heating Pressure, Upsetting Pressure, Heating time, and Upset time that are influenced on friction welding process. The experiment was conducted for different combination of process parameter to identify the optimal. The strength of the welded joints is varied with heating pressure and increasing with upset pressure at constant upset time and friction time. The welded joints strength was examined with tensile strength and was tabulated. The hardness distribution at the joint interface was noted and plotted a hardness peak was observed at interface. Micro structural observation was also done characterize the joint. It was observed that burn of length is one parameter that plays vital role on wastage metal in the welding process.