VISVESVARAYA TECHNOLOGICAL UNIVERSITYBELAGAVI-590 018

PROJECT REVIEWON

“AMMC’S FABRICATED BY FRICTION STIR PROCESSING”Bachelor Of Engineering

InMECHANICAL ENGINEERING

AN

Department of Mechanical EngineeringS.E.A COLLEGE OF ENGINEERING AND

TECHNOLOGYBENGALURU-560049

Submitted by:ANAND SHIRAMAI (Isp13me009)IRFAN PASHA (Isp13ME031)JAISON CYRIL (Isp13ME033)JEEVAN KUMAR AS (Isp13ME034)

UNDER THE GUIDNESS OF:

ASST.PROF ANAND KUMAR V

INVESTIGATION OF MECHANICAL, STRUCTURAL

AND TRIBOLOGICAL PROPERTIES OF ALUMINIUM METAL MARTIX COMPOSITE (AMMC’S) FRABRICATED BY

FRICTION STIR PROCESSING(FSP)

INTRODUCTION ON FSP It is a method of changing the properties of a metal through intense,

localized plastic deformation. This deformation is produced by forcibly inserting a non-consumable

tool into the work piece. The friction stir welding, is used to join multiple pieces of metal

without creating the heat affected zone typical of fusion welding. When ideally implemented, this process mixes the material without

changing the phase (by melting or otherwise) and creates a microstructure with fine, equated grains.

This homogeneous grain structure, separated by high-angle boundaries, allows some aluminium alloys to take on superplastic properties.

Friction stir processing also enhances the tensile strength and fatigue strength of the metal.

OBJECTIVES OF FSP To summarize the composite of friction stir processing technology.

Prepare design matrix to trial run of friction stir processing using design of experiments which varies welding parameters.

Preparation of Nano powders using anyone available synthesis technique.

Fabrication of weldment with reinforced or doping. Nanoparticle into matrix material using optimal speed, transvers speed, tool pin profile or characterisation of friction stir processing joints.

Characterisation of mechanical, structural and tribological properties of friction stir processing joints.

According to Rittner (2001)Applications of metal matrix composites in defence, aerospace and light vehicles have been reported . She has concluded that the scope for AMMC in all the above areas were optimistic and suggested further improvement in processes, selection of alloy, selection of reinforcement and selection of components to reduce the cost of end product.

Robert (2001) has presented various forms of aluminium alloys and their applications. Based on his survey on the growth of aluminium alloys, he concluded that 32.2 % of the aluminium was consumed in transport industry in different forms.

LITERATURE SURVEY ABOUT AMMC’S

Foltz and Charles (1991) have presented various matrix alloys, reinforcements and their applications in space, defence , automotive and electronic packaging They also presented the possible applications of MMCs in making automotive components like pistons, cylinder sleeve, connecting rod and brake discs.

Many Researchers (Suresh et al. 1993; Kevorkijan1999; Rohatgi 1991; Nakanishi et al. 2002) have presented the applications of AMMCs for the automotive components and the feasibility of manufacturing these materials.

Surappa (2003) has presented an overview of aluminium matrix composite material systems on aspects relating to processing, microstructure, properties and applications.

FRICTION STIR PROCESS

A specially designed non- consumable cylindrical tool is rotated and plunged into the selected area, to process the required location within a plate or sheet

Tool has a small diameter pin with a concentric larger diameter shoulder

Tool shoulder and length of entry probe control the penetration depth

FRICTION STIR PROCESS When tool descended to the part, the

rotating pin contacts the surface, rapidly friction produced between tool pin and metal surface heats and softens a small column of metal

Rotating tool provides:Continuous heating of work piecePlasticizing metalTransporting metal from the leading face

of the pin to its trailing edge

FRICTION STIR PROCESS

When the shoulder contacts the metal surface, its rotation creates additional frictional heat and plasticizes a larger cylindrical metal column around the inserted pin

The shoulder additionally provides a forging force that contains the upward metal flow caused by the tool pin

FRICTION STIR PROCESS During FSP, work piece and the tool are moved

relative to each other such that the tool

traverses, with overlapping passes, until the

required area is processed

The processed zone cools, without

solidification, as there is no liquid, forming a

defect-free recrystallized, fine grain

microstructure

SELECTION OF AA5083-H111 5083 aluminium alloy is an aluminium alloy with magnesium and

traces of manganese and chromium. It is highly resistant to attack by seawater and industrial chemical

Alloy 5083 retains exceptional strength after welding. It has the highest strength of the non-heat treatable alloys, but is not recommended for use in temperatures in excess of 65°C.

For AA 5083 alloy, the stages of porous structure development are substantially identical with that of pure aluminum, although an increase in oxide growth rate and high conductance of the oxide film were observed.

AA5083-H111 5083 aluminium alloy is an aluminium alloy with

magnesium and traces of manganese and chromium.

Composition of AA5083-H111 (%weight)

Alloy Mg Mn Ti Cr Zn Fe Si Cu

5083 4.0-4.9

0.40-1.0

0.15 0.05-0.25

0.25 0.40 0.40 0.10

PHYSICAL PROPERTIES OF AA5083-H111

DENSITY 265g/cm³

MELTING POINT 570ºc

THERMAL EXPANSION 25*10^-6/k

THERMAL CONDUCTIVITY 121w/mk

MODULUS OF ELASTICITY 72 Gpa

ELECTRICAL RESISTANCE 0.088*10^-6Ωm

MECHANICAL PROPERTIES OF AA5083-

H111Sheet thickness 0.2-6.3mm

Proof stress 125 Mpa min

Tensile strength 275-350 mpa

Brinell hardness 75HB

elongation 12%min

WELDABLITY OF AA5083-H111

FABRICATION OF AA5083-H111

Weldabilty Gas, average

Weldabilty Arc, excellent

Weldabilty Resistance, excellent

Soldabilty poor

Workability(for cold) Average

machinability poor

APPLICATIONS OF AA5083-H111

SHIPBUILDING

Low weight

Good mechanical resistance

Good corrosion

resistance

VEHICLE BODIES

Today, the new revolution in car design is the use of new materials in the vehicle structure.

Aluminium is about 3 times lighter than steel

The first production vehicle to move to an Al frame was the Audi A8 in 1994.

This allowed Audi to make their full-size car lighter than the competitions (BMW, Mercedes, Lexus...), thus giving them the edge in performance & handling

DRILLING RINGS

The application opportunities of aluminium alloy drill pipe (ADP) in geothermal drilling environments.

The geothermal drilling

industry is under high demand and is being tested to drill deeper , faster, and at reduced costs

MARINE APPLICATIONS

TV ANDCOMMUNICATIONTOWERS

TRANSPORTATION EQUIPMENT’S

ADVANTAGES Aluminium 5083 is known for exceptional performance environment.]

Aluminium 5083 is highly resistance to attack by sea water and industrial chemical environment

Al 5083 also retains exceptional strength after welding .

It has the highest strength after welding.

It has a highest strength of non heat treatable alloy, but is not recommended for use in the temperature in excess of 65º c.

Al 5083 is generally supplied as a flat rolled product in plate and sheet form.

DISADVANTAGE

As aluminium is a soft material, there is always a possibility of loose contacts.

Due, to the insulating property of aluminium oxide formed on the surface, it is difficult to solder aluminium wires.

However for applications like winding of electrical machines and transformers, it is difficult to substitute aluminium for copper.

Aluminium wires have lower tensile strength than that of copper.

THANK YOU