Experimental investigation of rotational friction welding for EN AW-6082-20MnCr5 joints

authored by: Ahmed Dewidar, Alexej Verschinin, Norman Mohnfeld, H Wester, Sebastian Barton, Hans Jürgen Maier, J Uhe
Abstract: Rotary Friction welding is utilised in various industries, particularly for joining dissimilar materials in mass production, due to its advantages such as minimal material waste, low energy consumption, excellent static and dynamic bond strengths and short production times. This study investigates the effects of process parameters, including friction pressure (80 – 119.4 MPa), friction path (5 – 8 mm), forging pressure (175 – 225 MPa) and forging time (5 – 10 s), on the properties of friction-welded joints between EN AW-6082 and 20MnCr5. Experiments were conducted on cylindrical specimens (Ø 40 mm × 100 mm) using a KUKA Genius Plus RS30. Bond strength was measured using local and global tensile tests. In addition, eddy current testing was employed to investigate its potential in the assessment and prediction of the weld quality of dissimilar RFW joints. The results, analysed using analysis of variance (ANOVA), revealed that higher forging pressures significantly improved bond strength. Moreover, higher values of friction pressure slightly improved bond strength, whereas higher values of friction path negatively influenced it, compared to the respective lower values of the same parameter combination. However, their individual effects were less pronounced compared to forging pressure.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Institute of Materials Science
Non-Destructive Testing
Type: Article
Journal: Materials Research Proceedings
Volume: 54
Pages: 1479-1488
No. of pages: 10
Publication date: 07.05.2025
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: General Materials Science
Sustainable Development Goals: SDG 7 - Affordable and Clean Energy
Electronic version(s): https://doi.org/10.21741/9781644903599-160 (Access: Open)