A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061
Joining dissimilar materials is always a challenging and interesting topic for researchers and industries. Friction drill joining, as a solid-state process, is a novel approach to connecting similar and dissimilar materials. Dissimilar metals, especially ultra-high-strength steels and aluminum alloy...
| Main Authors: | , , , , |
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| Format: | Article |
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Multidisciplinary Digital Publishing Institute
2022
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| Online Access: | http://psasir.upm.edu.my/id/eprint/100265/ |
| _version_ | 1848863278230405120 |
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| author | Dehghan, Shayan Abbasi, Rasol Baharudin, B. T. Hang. Tuah b. Mousavi, Mohsen Loh Soury, Ehsan |
| author_facet | Dehghan, Shayan Abbasi, Rasol Baharudin, B. T. Hang. Tuah b. Mousavi, Mohsen Loh Soury, Ehsan |
| author_sort | Dehghan, Shayan |
| building | UPM Institutional Repository |
| collection | Online Access |
| description | Joining dissimilar materials is always a challenging and interesting topic for researchers and industries. Friction drill joining, as a solid-state process, is a novel approach to connecting similar and dissimilar materials. Dissimilar metals, especially ultra-high-strength steels and aluminum alloys, are used significantly for the mass reduction of automotive bodies, and to reduce CO2 emissions in the automotive industry. In the current work, a friction drill joining technique for joining AISI304 and Al6061 was experimentally and numerically studied. A technique for improving joint strength, load-clamping modification, and tool movement was also introduced. The required thrust force is measured, and it is proven that adding sheet layers does not significantly affect the required thrust force. To understand and identify the mechanism of the process, and its material behaviour, material stirring and formation in the joint region were analyzed. A thermo-mechanical finite element model was also developed, and the thermal stress, plastic strain, and temperature were studied. A numerical comparison between joints formed under normal and improvement conditions was conducted, and the significant effect of the improvement conditions on joint strength and formed-bush quality was found. Based on the findings, the great potential of using friction drill joining for joining dissimilar materials is confirmed. |
| first_indexed | 2025-11-15T13:30:22Z |
| format | Article |
| id | upm-100265 |
| institution | Universiti Putra Malaysia |
| institution_category | Local University |
| last_indexed | 2025-11-15T13:30:22Z |
| publishDate | 2022 |
| publisher | Multidisciplinary Digital Publishing Institute |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | upm-1002652024-07-09T03:38:58Z http://psasir.upm.edu.my/id/eprint/100265/ A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 Dehghan, Shayan Abbasi, Rasol Baharudin, B. T. Hang. Tuah b. Mousavi, Mohsen Loh Soury, Ehsan Joining dissimilar materials is always a challenging and interesting topic for researchers and industries. Friction drill joining, as a solid-state process, is a novel approach to connecting similar and dissimilar materials. Dissimilar metals, especially ultra-high-strength steels and aluminum alloys, are used significantly for the mass reduction of automotive bodies, and to reduce CO2 emissions in the automotive industry. In the current work, a friction drill joining technique for joining AISI304 and Al6061 was experimentally and numerically studied. A technique for improving joint strength, load-clamping modification, and tool movement was also introduced. The required thrust force is measured, and it is proven that adding sheet layers does not significantly affect the required thrust force. To understand and identify the mechanism of the process, and its material behaviour, material stirring and formation in the joint region were analyzed. A thermo-mechanical finite element model was also developed, and the thermal stress, plastic strain, and temperature were studied. A numerical comparison between joints formed under normal and improvement conditions was conducted, and the significant effect of the improvement conditions on joint strength and formed-bush quality was found. Based on the findings, the great potential of using friction drill joining for joining dissimilar materials is confirmed. Multidisciplinary Digital Publishing Institute 2022-05-27 Article PeerReviewed Dehghan, Shayan and Abbasi, Rasol and Baharudin, B. T. Hang. Tuah b. and Mousavi, Mohsen Loh and Soury, Ehsan (2022) A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061. Metals, 12 (6). art. no. 920. pp. 1-29. ISSN 2075-4701 https://www.mdpi.com/2075-4701/12/6/920 10.3390/met12060920 |
| spellingShingle | Dehghan, Shayan Abbasi, Rasol Baharudin, B. T. Hang. Tuah b. Mousavi, Mohsen Loh Soury, Ehsan A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 |
| title | A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 |
| title_full | A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 |
| title_fullStr | A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 |
| title_full_unstemmed | A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 |
| title_short | A novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials AISI304/AL6061 |
| title_sort | novel approach to friction drilling process: experimental and numerical study on friction drill joining of dissimilar materials aisi304/al6061 |
| url | http://psasir.upm.edu.my/id/eprint/100265/ http://psasir.upm.edu.my/id/eprint/100265/ http://psasir.upm.edu.my/id/eprint/100265/ |