Abstract

The purpose of this paper is to develop AA5052 aluminum alloy solid disc from machining wastes via friction stir consolidation (FSC) process & optimize its parameters: die rotational speed, pre-compact aspect ratio and processing time. At first, the required dedicated tooling is designed and built. Then, solid discs are fabricated from AA5052 aluminum alloy chips using FSC process. Taguchi L9 orthogonal array is used to analyze and optimize the process. Experimental parameters and their levels considered are rotational speed (315, 400 and 500 rpm), pre-compact aspect ratio (25.4/7, 25.4/5 and 25.4/3) and processing time (30, 45 and 60 sec). Using standard tests, compressive strength, hardness and microstructure of the consolidated solid disc are evaluated. The results reveal that solid discs are successfully fabricated using FSC using dedicated tooling, and rotational speed (500 rpm), pre-compact aspect ratio (25.4/3) and processing time (60 sec) are optimal processing conditions. Microstructure examination of the solid disc shows finer and fully recrystallized grains in axial cross section orientation. Moreover, the results show compressive strength and hardness of the solid disc are comparable to that of forged or cast disc and suitable for most engineering structural applications.

Keywords

Machining wastes, Friction stir consolidation, Hardness, Compressive strength, Microstructure,

Downloads

Download data is not yet available.

References

  1. F. Jovane, H. Yoshikawa, L. Alting, C.R. Boër, E. Westkamper, D. Williams, M. Tseng, G. Seliger and AM. Paci, The incoming global technological and industrial revolution towards competitive sustainable manufacturing, CIRP Annals – Manufacturing Technology, 57(2) (2008) 641–659. https://doi.org/10.1016/j.cirp.2008.09.010
  2. AE Tekkaya, M Schikorra, D. Becker, D. Biermann, N. Hammer, K. Pantke. Hot Profile Extrusion of AA-6060 Aluminum Chips, Journal of Materials Processing Technology, 209(7) (2009) 3343-3350. https://doi.org/10.1016/j.jmatprotec.2008.07.047
  3. W. Tang, & AP. Reynolds, Production of wire via friction extrusion of aluminum alloy machining chips, Journal of Materials Processing Technology, 210(15) (2019) 2231-2237. http://dx.doi.org/10.1016/j.jmatprotec.2010.08.010
  4. TG. Gutowski, JM. Allwood, C. Herrmann, S. Sahni, A Global Assessment of Manufacturing: Economic Development, Energy Use, Carbon Emissions, and the Potential for Energy Efficiency and Materials Recycling, Annu. Rev. Environ. Resour., 38(1) (2013) 81- 106. https://doi.org/10.1146/annurev-environ-041112-110510
  5. G. Hanko, H. Antrekowitsch, P. Ebner, Recycling automotive magnesium scrap, JOM, 54(2) (2002) 51–54. https://doi.org/10.1007/BF02701075
  6. M. Stern, Method for treating aluminum or aluminium alloy scrap, Google patents, United States Patent office, N.Y. Serial No. 445.19g, (1945).
  7. J. Gronostajski, & A. Matuszak, The recycling of metals by plastic deformation: an example of recycling of aluminium and its alloys chips, Journal of Materials Processing Technology, 92-93 (1999) 35-41. https://doi.org/10.1016/S0924-0136(99)00166-1
  8. J. Gronostajski, H. Marciniak & A. Matuszak, New methods of aluminum and aluminum-alloy chips recycling, Journal of Materials Processing Technology, 106(1-3) (2000) 34-39. https://doi.org/10.1016/S0924-0136(00)00634-8
  9. S. Shamsudin, MA. Lajis, & ZW. Zhong, Evolutionary in solid state recycling techniques of aluminium: a review, Procedia CIRP, 40 (2016) 256-261. https://doi.org/10.1016/j.procir.2016.01.117
  10. WM. Thomas, ED. Nicholas & SB. Jones, Friction Extrusion. Metal Working, Google Patents, https://www. google.com/patents/US5262123, Google Scholar, (1993). https://www.google.com/patents/US5262123
  11. E. Oberg, FD. Jones, HL. Horton, HH. Ryffel, & JH. Geronimo, Machinery's, Handbook 29th edn, Industrial Press, New York 10018, 1207-1209.
  12. ASTM B209, Standards Specification for Aluminum and Aluminum - Alloy Sheet and Plate, ASTM International. Designation: B 209-96, PA 19428-2959, (1996).
  13. X. Li, D. Baffari, & AP. Reynolds, Frictions stir consolidation of aluminum machining chips, The International Journal of Advanced Manufacturing Technology. 94(5-8) (2018) 2031-2042. https://doi.org/10.1007/S00170-017-1016-4
  14. JE. Shigley, (2011), Shigley's Mechanical Engineering Design, Tata McGraw-Hill Education, New York, United States.
  15. PJ. Ross, (1996), Taguchi Techniques for Quality Engineering: Loss Function, Orthogonal Experiments, Parameter and Tolerance Design, 2nd Edition, McGraw-Hill, New York.
  16. Abhijeet Bhowmik and Dilip Mishra, A Comprehensive Study of an Aluminum Alloy Al-5052, Advance Physics Letter, 3(1) (2016) 20-22.