FARES Khalfallah
فارس خلف الله
fares.khalfallah@univ-msila.dz
0661000000
- Common trunk material sciences
- Faculty of Sciences
- Grade MCB
About Me
Doctorat. in Université de Biskra
Research Domains
Friction welding
LocationMsila, Msila
Msila, ALGERIA
Code RFIDE- 2022
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Encaderement master
MAHDI Laid
Etude des propriétés des joints Acier inoxydable/Al soudés par friction
- 2020
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Encaderement master
DJAIDJA Latifa
Caractérisation des joints Acier inoxydable/Cuivre soudés par friction
- 05-03-2020
- 05-06-2005
- 06-06-2001
- 1979-12-18 00:00:00
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FARES Khalfallah birthday
- 2025-09-26
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2025-09-26
Rotary friction welding of 304L-310S austenitic stainless steels
The objective of this study is to examine the effect of rotational speed on the microstructure, texture, and mechanical properties of joints produced by rotary friction welding of two dissimilar austenitic stainless steels (AISI 304L and AISI 310S). The choice of AISI 304L and AISI 310S stainless steels is based on their complementary properties and industrial relevance. The study focuses on welding dissimilar stainless steels to meet industrial requirements. To achieve these objectives, optical microscopy, scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy, electron backscatter diffraction, Vickers microhardness testing, and tensile testing were used to characterize the welded joints. The joining of the two dissimilar stainless steels was successfully achieved. A microstructurally uniform welded zone was obtained at the highest rotational speed. At 1400 rpm and 2000 rpm, the welded joints achieved tensile strengths of approximately 507 MPa and 500 MPa, respectively, with weld-center hardness ranging from 220 to 230 HV. EBSD analysis revealed three distinct zones in the welded joint, characterized by different grain sizes and textures. With increasing rotational speed, unlike the central zone, adjacent zones underwent grain growth while retaining the same grain orientation as the central zone.
Citation
Fares KHALFALLAH , ABDELDJEBAR HADJI, EL-HADJ RAOUACHE, ZAKARIA BOUMERZOUG, FRANCOIS BRISSET, THIERRY BAUDIN, , (2025-09-26), Rotary friction welding of 304L-310S austenitic stainless steels, KOVOVE MATERIALY-METALLIC MATERIALS, Vol:63, Issue:3, pages:11, REDAKCIA KOVOVE MATERIALY
- 2025-06-11
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2025-06-11
Characterization of Friction Welded Joints between AA 2017A Aluminum Alloy and AISI 316L Stainless Steel
The joining of dissimilar metals, such as aluminum and steel, has received considerable attention in modern industry due to its ability to reduce weight, enhance energy efficiency, and promote environmental sustainability. Among modern welding processes, rotary friction welding (RFW) is a very effective process for joining dissimilar materials. In this solid-state process, welding heat is generated through mechanical friction between a rotating workpiece and a stationary one. The properties of RFW joints are influenced by parameters such as welding time, applied pressure, and rotational speed. This experimental study explores how variable rotational speed affects the thermal behavior and mechanical properties of dissimilar joints between AISI 316L stainless steel and AA 2017A aluminum alloy produced by RFW process. The welding was performed using a milling machine as a rotary friction stir welding machine with varying the rotation speeds across the different welds. To evaluate the properties of the joints, experimental tests were conducted including temperature measurement, tensile testing and microhardness measurements. The results confirmed the successful formation of dissimilar AISI 316L/AA 2017A joints through rotary friction welding and revealed a clear relationship between rotational speed and joint properties. Mechanical performance was significantly affected by changes in rotational speed, while thermal analysis provided insights into how maximum temperatures reached during welding are related to the resulting mechanical properties of the joints.
Citation
Fares KHALFALLAH , ,(2025-06-11), Characterization of Friction Welded Joints between AA 2017A Aluminum Alloy and AISI 316L Stainless Steel,3rd NATIONAL CONFERENCE ON MATERIALS SCIENCES AND ENGINEERING (MSE’25),University of Chlef
- 2025-05-06
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2025-05-06
Influence of Parabolic Solar Concentrator Diameter on Captured Energy Flux Distribution
Solar energy, which is clean and renewable, represents a sustainable alternative for electricity production. Among the available technologies, solar concentration systems are the most promising for industrial use. Parabolic concentrators focus the sun's rays on a specific point in order to produce high-temperature heat. This work studies the effect of the diameter of a parabolic concentrator on the distribution of the flux at the focal point. A larger diameter captures more radiation, influencing the density and distribution of thermal energy. Modeling was performed using Tonatiuh open source software, which specializes in optical simulations. The results show that the diameter affects not only the amount of energy concentrated, but also the uniformity of the heat flux. This analysis makes it possible to optimize the geometry of the collector to improve the energy efficiency of the system.
Citation
Fares KHALFALLAH , ,(2025-05-06), Influence of Parabolic Solar Concentrator Diameter on Captured Energy Flux Distribution,The First National Conference on Renewable Energies and Advanced Electrical Engineering (NC REAEE'25),University of M’Sila
- 2024-12-16
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2024-12-16
Thermo-mechanical simulation of the effect of tool welding speed on butt-joint friction stir welding (FSW) of AA6061
FSW is a welding method that joins pieces of material by rotating a non-consumable pin at high speeds (RPM) while moving it along the weld joint. The combination of this rotation and movement generates heat through friction between the tool and the sheets, facilitating the welding process without the requirement for filler metal. Developed by the British Welding Institute (TWI) in 1991, FSW is celebrated for producing strong, reliable welds and is extensively used in industries such as automotive and aerospace. In these sectors, aluminum alloys are essential due to their unique set of properties, making them highly suitable for FSW applications. In FSW, welding speed refers to the linear velocity at which the tool progresses along the joint line during the welding process. This parameter plays a pivotal role in controlling heat generation, material flow, and ultimately, the quality of the weld. The quantity of heat introduced to the plates directly influences the final weld quality, as well as the residual stresses and deformation observed in the workpieces. This research examines how different welding speeds affect temperature distribution, the width of the heat-affected zone, and the Von Mises stress distribution in welded aluminum alloy 6061 sheets. The aim of this study is to gain a comprehensive understanding of how these factors interact, with the ultimate goal of contributing to the optimization of FSW parameters and improving weld quality. The analysis was performed using finite element method and ALTAIR software, providing valuable insight into the effects of welding speed variations.
Citation
Fares KHALFALLAH , Kouachi Mohamed, Raouache Elhadj, Laouissi Aissa, Benderradji Razik, , (2024-12-16), Thermo-mechanical simulation of the effect of tool welding speed on butt-joint friction stir welding (FSW) of AA6061, Brazilian Journal of Technology, Vol:7, Issue:4, pages:22, Brazilian Journals Publicações de Periódicos e Editora Ltda
- 2024-09-25
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2024-09-25
Analysis of heat transfer by mixed convection in a ventilated cavity filled with hybrid nano-fluid: A numerical approach
In this numerical study, the focus was on analyzing the heat transfer by mixed convection in a ventilated cavity filled with a hybrid nano-fluid. The hybrid nano-fluid consists of nano-particles (copper (Cu) and alumina (Al2O3)) dispersed in a base fluid (water). The volume fraction of nano-particles is 4 %. The cavity housed a cold cylinder at its center and incorporated two gates (orifices) for the influx and efflux of the flow., with a fixed Reynolds number (Re) and varying Richardson numbers (Ri) set at 0.1, 1, 10, and 100. The cavity was subjected to isothermal heating by a heat source on the lower wall to maintain a constant temperature, while the remaining walls were kept adiabatic. The ventilated cavity is subjected to mixed convection, where both natural convection and forced convection effects are considered. The governing equations for the stationary laminar flow were solved numerically using the finite volume method. The numerical results revealed the significant impact of Ri on heat transfer within the ventilated cavity. Consequently, the heat transfer rate (expressed by Nusselt number Nu) demonstrated an upward trend with increasing Ri values. Overall, the results of this study were provide valuable insights for understanding the behavior and performance of systems that utilize hybrid nano-fluids in applications such as microelectronics cooling, heat exchangers, and energy storage devices.
Citation
Fares KHALFALLAH , ,(2024-09-25), Analysis of heat transfer by mixed convection in a ventilated cavity filled with hybrid nano-fluid: A numerical approach,6TH International Conference on Applied Engineering and Natural Sciences (ICAENS 2024),Konya, TURKEY
- 2024-03-19
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2024-03-19
Development and optimization of a prediction system model for mechanical properties in rotary friction-welded polyamide joints using the SVM approach and GA optimization
The objective of this experimental study is to utilize rotary friction welding (FW) for assembling similar polyamide materials. The application of the SVM approach enables the development of a predictive model for estimating mechanical properties in RFW processes. Furthermore, the optimization of RFW parameters through GA proves pivotal in selecting optimal welding conditions, providing a variety of choices. The welding parameters considered in this study included rotation speed at five levels and traverse speed at three levels. The strength of the welded samples was characterized by a tensile test. Additionally, temperature measurements were taken to determine the maximum temperature in the joint area. The results demonstrated the dependence of tensile strength and maximum temperature on the rotation speed. Maximum tensile strength is achieved at an optimal rotation speed. Moreover, analysis of variance (ANOVA) indicates that rotation speed is the parameter most influenced by tensile strength.
Citation
Fares KHALFALLAH , , (2024-03-19), Development and optimization of a prediction system model for mechanical properties in rotary friction-welded polyamide joints using the SVM approach and GA optimization, International Journal of Advanced Manufacturing Technology, Vol:132, Issue:, pages:13, SpringerLink
- 2023-05-10
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2023-05-10
Influence de la géométrie des pions sur la distribution de température pendant l’opération de soudage par friction malaxage (FSW)
Le soudage par friction-malaxage (FSW) est un procédé de soudage sans fusion qui utilise la chaleur et la pression générées par la friction et le malaxage pour unir deux matériaux. La présente étude porte sur la modélisation thermique de ce procédé et sur son implantation dans le code d’éléments finis COMSOL Multyphysiqus. Notre objectif est d’analyser les possibilités offertes par ce logiciel à travers l’étude de différents aspects essentiels à la description du procédé comme la thermique, les lois de comportement et de frottement, et plus particulièrement, la gestion du contact à l’interface pion/tôle.
Citation
Fares KHALFALLAH , Raouache Elhadj, Amel Benfradj, Abdelhamid Mkahal, ,(2023-05-10), Influence de la géométrie des pions sur la distribution de température pendant l’opération de soudage par friction malaxage (FSW),The First National Conference on Mechanical Engineering (NCME'23),University of Batna
- 2022
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2022
Soudage par friction rotative Céramique/Aluminium
Dans l’industrie moderne, les métaux et les céramiques sont parmi les matériaux les plus utilisables. Les métaux, qui se devisent en deux grandes familles, ferreux et non ferreux, ont des propriétés particulières telles que la bonne malléabilité, la grande ductilité et la conductivité électrique et thermique élevée. Les céramiques, et en particulier le céramiques techniques, possèdent certaines propriétés supérieures à celles des métaux, comme la dureté élevée, la résistance à l'usure, la bonne résistance mécanique et chimique, mais malgré ça leur usage est limité à cause de la fragilité et la faible résistance aux chocs. Pour éviter cette limitation d’usage, des joints dissimilaires métal/céramique on été développé a fin de combiner les caractéristiques des métaux et celles des céramiques.
Citation
Fares KHALFALLAH , ,(2022), Soudage par friction rotative Céramique/Aluminium,Journée de Métallurgie,Université Mohamed Khider-Biskra
- 2022
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2022
INFLUENCE OF ROTATIONAL SPEED ON THERMAL BEHAVIOR AND TENSILE STRENGTH OF FRICTION WELDED AISI 316L AND COPPER JOINTS
This experimental work aims to study the effect of variations of rotary friction welding parameters on the thermal behavior and mechanical properties of dissimilar joints stainless steel/copper. To achieve this objective, a rotary friction welding process of AISI 316L stainless steel rods with copper rods was carried out, using a milling machine as the friction welding machine, with changing the rotational speed, and measuring the temperature changes of the joints during the welding process. After welding, the joints were subjected to tensile tests to evaluate their mechanical strength. The experimental results showed a strong relationship between the rotational speed and the thermal behavior of the joints, and the strength of the joints is also affected by the changes of the rotational speed.
Citation
Fares KHALFALLAH , L. DJAIDJA, E. RAOUACHE, Y. AOUABDIA, ,(2022), INFLUENCE OF ROTATIONAL SPEED ON THERMAL BEHAVIOR AND TENSILE STRENGTH OF FRICTION WELDED AISI 316L AND COPPER JOINTS,EUROASIA International Congress on Scientific Researches and Recent Trends-IX,Baku Euroasian University -Baku, Azerbaijan
- 2022
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2022
NUMERICAL STUDY OF HEAT TRANSFER BY MIXED CONVECTION IN A VENTILATED CAVITY FILLED WITH HYBRID NANO-FLUID
In this work, we carried out a numerical study of the stationary laminar flow by mixed convection in a ventilated two-dimensional cavity containing a cold cylinder in the center of the latter. The cavity is filled with different hybrid nano-fluids, (Water/Ag-TiO2) and (Water/Al2O3-TiO2)). The cavity containing two gates (Orifices) of entry and exit of the flow, for a Reynolds number (Re) fixed so that the Richardson number takes the values: Ri = 0.1, 1, 10 and 100, and a volume fraction of the nanoparticles comprised between (0% and 8%). The square cavity is heated isothermally by the surface of the lower wall by a heat source (The source is to maintain the lower wall at constant temperature), the other walls are maintained adiabatic. The equations, which govern the flow, have been solved numerically using the finite volume method. The results obtained show that the heat transfer increases with the increase in the volume fraction and the Richardson number. Thus the heat transfer rate (Nu) increases with the increase in Ri.
Citation
Fares KHALFALLAH , Razik BENDERRADJI , Meryem Brahimi , RAOUACHE El Hadj, ,(2022), NUMERICAL STUDY OF HEAT TRANSFER BY MIXED CONVECTION IN A VENTILATED CAVITY FILLED WITH HYBRID NANO-FLUID,1ST INTERNATIONAL CONFERENCE ON RENEWABLE MATERIALS AND ENERGIES ICRME2022,OUARGLA-ALGERIA
- 2021
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2021
Effect of Rotation Speed on Thermal Behavior and Mechanical Properties of Friction-Welded AA1100 Aluminum Alloy with Mild Steel
This experimental study aims to determine the effect of rotational speed on the properties of friction welded joints of mild steel and AA1100 aluminum alloy. The welding process was developed by a continuous drive friction welding machine and the effect of the rotational speed was investigated through temperature measurements in the aluminum part, strength tests and microhardness measurements. The results show that the properties of the seals are affected by variations in rotational speed. The thermal analysis helped to understand the relationship between the maximum temperatures reached during the welding process and the mechanical properties of the joints.
Citation
Fares KHALFALLAH , Z. BOUMERZOUG, E. Raouache, S. RAJAKUMAR, ,(2021), Effect of Rotation Speed on Thermal Behavior and Mechanical Properties of Friction-Welded AA1100 Aluminum Alloy with Mild Steel,1st International Visio Conference on Materials Science and Engineering ICMSE’21,University of Khenchela - Algeria
- 2020
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2020
Optimization by RSM on rotary friction welding of AA1100 aluminum alloy and mild steel
The objective of this work is to investigate the rotary friction welding of AA1100 aluminum alloy with mild steel, and to optimize the welding parameters of these dissimilar materials, such as friction pressure/time, forging pressure/time and rotational speed. The optimization of the welding parameters was deduced by applying Response Surface Methodology (RSM). An empirical relationship was also applied to predict the welding parameters. Tensile test and micro-hardness measurements were used to determine the mechanical properties of the welded joints. Some joints were analyzed by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) in order to investigate the formation of intermetallic compound (IMC) layer at the weld interface. Experimentally, the tensile strength of the weld increases with increasing the forging pressure/time, while the low level of forging pressure/time allows the formation of an IMC layer which reduces the tensile strength of the weld.
Citation
Fares KHALFALLAH , Z. BOUMERZOUG, S. RAJAKUMAR, E. RAOUACHE, , (2020), Optimization by RSM on rotary friction welding of AA1100 aluminum alloy and mild steel, International Review of Applied Sciences and Engineering, Vol:11, Issue:1, pages:34–42, Akademiai Kiado
- 2020
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2020
Investigation by Thermal Cycle Simulation of Heat Affected Zone in Welded AA2014 Aluminum Alloy
This paper is a contribution to the study of weld ability of AA2014 aluminum alloy by using thermal cycle simulation. It presents the microstructures obtained after thermal cycle simulation of welding by rapid heating and cooling treatments in a specific simulation equipment. Optical microscopy, X-ray diffraction, and micro hardness measurements were used as characterization techniques. Micro structural and mechanical details of the heat affected zone of the real welded joint realized by TIG welding process were compared to the simulated heat affected zone by the thermal cycle simulation in specific equipment.
Citation
Fares KHALFALLAH , Elhadj Raouache, Zakaria Boumerzoug, Fabienne Delaunois, , (2020), Investigation by Thermal Cycle Simulation of Heat Affected Zone in Welded AA2014 Aluminum Alloy, Research & Development in Material Science, Vol:13, Issue:3, pages:1407-1411, Crimson Publishers
- 2020
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2020
Soudage par friction de l’acier avec du céramique
Le but de ce travail est d’obtenir des joints dissimilaires acier/céramique en utilisant le soudage par friction rotative. Dans cette étude, le soudage par friction des tiges en acier doux avec des tiges en alumine (Al2O3) a été réalisé en utilisant un alliage d'aluminium 1100 comme une couche intermédiaire d'épaisseur de 3 mm. Le processus de soudage a été effectué en deux phases. Tout d'abord, les tiges d'acier et les tiges d'aluminium ont été soudées par friction, et les joints résultants ont été usinés pour former la couche intermédiaire. Ensuite, ces joints ont été soudés par friction aux tiges d’alumine. Dans la première phase, les paramètres de soudage par friction acier doux/aluminium 1100 ont été optimisés à l'aide de la méthode des surfaces de réponse (MSR) pour atteindre une résistance maximale des joints. Selon cette approche, des joints acier doux/aluminium AA1100 et acier doux / alumine ont été développés avec succès par un procédé de soudage par friction rotative et ont été évalués par des essais mécaniques, tel que l’essai de traction, l’essai de flexion à trois points et les mesures de microdureté Vickers. La microstructure des joints résultants a été observée par microscopie optique (MO) et microscopie électronique à balayage (MEB), en particulier à la zone d’interface. Les joints ont également été examinés par spectroscopie par dispersion d'énergie (EDS). Sur la base des résultats du MSR, une relation empirique a été établie pour prédire les propriétés mécaniques des joints acier doux/aluminium 1100 soudés par friction. Les résultats expérimentaux ont montré que la résistance et la microstructure des joints acier doux/aluminium 1100 et acier doux/alumine dépendent largement des paramètres du procédé de soudage par friction.
Citation
FaresKHALFALLAH , ,(2020); Soudage par friction de l’acier avec du céramique,Université Mohamed Khider-Biskra,
- 2019
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2019
THERMAL MODELING AND EXPERIMENTAL ANALYSIS OF FRICTION WELDED AA1100 ALUMINUM ALLOY WITH MILD STEEL
In recent years, the joining of aluminum and steel has received considerable attention in the automotive industry with the aim of reducing the vehicle weight, energy saving and environmental protection by exploiting the advantages of steel, such as good mechanical properties, and those of aluminum, such as low weight and good corrosion resistance. The rotary friction welding (RFW) is one of the most suitable processes for joining aluminum to steel. It is a solid state joining process that generates heat through mechanical friction between a moving and a stationary work piece. A several parameters affect the quality of welds, such as welding time, pressure and rotational speed. In this study, the effect of friction time on the properties of AA1100 aluminum alloy-mild steel joints to obtained by rotary friction welding was investigated. The welding process was developed by a continuous drive friction welding machine. A series of experimental tests, such as microhardness measurements, strength tests and temperature measurements were performed in conjunction with a thermal modeling to predict the temporal variation of temperature in the aluminum part. The numerical simulation was developed by Finite Element Analysis (COMSOL) software, and the numerical predictions were compared with thermocouple data recorded from real welds conducted under identical conditions. The results show that the properties of joints are affected by the friction time variations. Thermal analysis also helped to understand the relationship between the maximum temperatures reached and the mechanical properties of the joints as well as the quality of the weld. From the simulation results, the predicted and measured temperature values are in fair agreement.
Citation
Fares KHALFALLAH , ZAKARIA BOUMERZOUG, ELHADJ RAOUACHE, SELVARAJAN RAJAKUMAR, ,(2019), THERMAL MODELING AND EXPERIMENTAL ANALYSIS OF FRICTION WELDED AA1100 ALUMINUM ALLOY WITH MILD STEEL,The International Conference of Materials and Engineering Technology (TICMET’19),Gaziantep University - Turkey
- 2019
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2019
EFFECT OF ROTATIONAL SPEED ON THE PROPERTIES OF FRICTION WELDED COPPER/ALUMINIUM DISSIMILAR JOINTS
The friction welding technique has been widely used in modern manufacturing processes, due to its significant advantages like material saving, short production time and high quality of welded joints. There are several friction welding processes, rotary, linear, angular and orbital. In the rotary friction welding (RFW) process, one of the workpieces was axially pressed against the other which is turned. The generated heat, by the friction between the workpieces faces, leads to the plasticization of the surfaces in contact. When the surfaces are sufficiently plastics, the rotation halted and the axial pressure increased to forge and consolidate the formed joints. In the present work, an experimental device has been designed and mounted to perform a dissimilar friction welded joints copper/aluminum. The experiments were conducted in order to study the effect of rotational speed, as the variable welding parameter, on the mechanical properties and the thermal behavior of joints. The mechanical properties of the joints were evaluated by the three point bending test and microhardness measurements. In addition, temperature measurements were done to determine the peak temperature in the area nearly the weld. The results showed the strong dependence between the rotational speed and the properties of welded joints.
Citation
Fares KHALFALLAH , EL HADJ RAOUACHE, ZAKARIA BOUMERZOUG, Nejah JEMAL, ,(2019), EFFECT OF ROTATIONAL SPEED ON THE PROPERTIES OF FRICTION WELDED COPPER/ALUMINIUM DISSIMILAR JOINTS,The International Conference of Materials and Engineering Technology (TICMET’19),Gaziantep University - Turkey
- 2018
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2018
Optimization by RSM of Reinforced Concrete Beam Process Parameters
Reinforced concrete beams must have an adequate safety margin against bending and shear forces. Therefore, it will perform effectively during its service life. The aim of this work is to optimize the parameters of strength reinforced concrete beam, such as strength concrete, of stirrup spacing, and stirrup inclined presenting the techniques of characterization. An optimization of the reinforced concrete beam parameters was developed using the Response Surface Methodology (RSM). A flexural test was performed on reinforced concrete beam, and an empirical relationship was developed and used to predict the optimized strength reinforced concrete beam parameters.
Citation
Fares KHALFALLAH , Elhadj Raouache, Logzit Nacer, Zied Driss, , (2018), Optimization by RSM of Reinforced Concrete Beam Process Parameters, American Journal of Mechanical Engineering, Vol:6, Issue:2, pages:66-74, Science and Education Publishing
- 2018
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2018
Effect of FSW process parameters on strength and peak temperature for joining high-density polyethylene (HDPE) sheets
The aim of this experimental work is the joining of similar materials of High Density Polyethylene (HDPE) using the friction stir welding process. A Full-factorial design was used as a statistical approach to analyze the effect of processing parameters on mechanical behavior of welded joint. The welding parameters considered in this study were rotational speed in five levels and traverse speeds in three levels. The strength of welded samples was characterized by tensile test. In addition, temperature measurements were carried out to determine the peak temperature in the joining zone. The results have showed the dependence of tensile strength and peak temperature on rotational speed. A maximum tensile strength was achieved at optimum rotational speed value. Moreover, the analysis of variance (ANOVA) indicates that rotational speed is the most influenced parameter in strength of joints.
Citation
Fares KHALFALLAH , Elhadj Raouache, Zakaria Boumerzoug, Selvarajan Rajakumar, , (2018), Effect of FSW process parameters on strength and peak temperature for joining high-density polyethylene (HDPE) sheets, Revue des composites et des matériaux avancés, Vol:28, Issue:2, pages:149-160, International Information and Engineering Technology Association
- 2018
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2018
Effect of Friction Time on Mechanical and Microstructure Properties of Aluminum – Ceramic Dissimilar Joints
The ceramic-Aluminum contact has strongly existed in modern tools, due to the particular combination of metal properties such as ductility, high electrical and thermal conductivity and the ceramics properties like the high hardness, the corrosion and the wear resistance. In recent years, a several techniques have been developed to achieve good contact or total bonding between these materials such as diffusion bonding, brazing, ultrasonic joining and friction welding. In this experimental work, AA1100 aluminum alloy rods was friction welded to Alumina 99.9 wt% ceramic rods, and the effect of friction time on mechanical and structural properties of welded joints are investigated. The welding process was carried out by a direct friction welding machine. The welding specimens were rotated at a constant rotational speed of 900 rpm, a friction pressure of 20 MPa, a forging force of 18 MPa and a forging time of 3 sec. Three different friction times were applied 4, 5 and 6 seconds. Three point bending test and Vickers microhardness measurements are used to evaluate the strength of joints and study the mechanical properties in weld region. The microstructures of joints and fracture surface of the joint interface were examined by optical microscopy, SEM and EDS. The experimental results show that bending strength increases with increasing friction time. The SEM observation shows that the increase in friction time led to the appearance of cracks in the microstructure of the interface area, which means that the long heating rate influenced the microstructure of the weld.
Citation
Fares KHALFALLAH , Zakaria BOUMERZOUG, Selvarajan RAJAKUMAR, Elhadj Raouache, ,(2018), Effect of Friction Time on Mechanical and Microstructure Properties of Aluminum – Ceramic Dissimilar Joints,5thINTERNATIONAL CONFERENCE ON COMPUTATIONAL AND EXPERIMENTAL SCIENCE AND ENGINEERING,Turkey
- 2018
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2018
NUMERICAL SIMULATION ON JOINING OF CERAMICS WITH ALUMINUM DISSIMILAR JOINTS BY FRICTION WELDING
Dissimilar metal joining offers the potential to utilize the advantages of different materials often providing unique solutions to engineering requirements. The main reasons for dissimilar joining are due to the combination of good mechanical properties of one material and either low specific weight or good corrosion resistance or good electrical properties of second material. Consequently, joining processes for dissimilar materials have received considerable attention in the recent years. Much of this activity has focused on the transportation industries such as aerospace, aviation, shipbuilding, railway transportation. This is especially in the automotive industry due to the potential weight reduction of both vehicle components and structures. Friction welding is a joining technique used to joint various materials in manufacturing process. The method has widespread use since 1950, it is a solid state joining process that generates heat through mechanical friction between a moving work piece and a stationary component. This paper presents a numerical simulation on thermal analysis of friction welded ceramic/aluminum joint by Finite Element Analysis (COMSOL) software. The selected materials are AA1100 aluminum alloy and Alumina as a ceramic. The considered geometry for simulation is rods of 12 mm diameter and 60 mm length. In order to validate the numerical model, a similar experimental work was developed by a direct friction welding machine. Just the effect of rotational speed on temperatures variation was investigated, which means that the other welding parameters were kept constants, and only the results of temperature measurements at aluminum interface were done. Using the numerical heat generation, the predicted temperatures matched closely to the experimental data. Moreover, the experimental results show a maximum interfacial temperature of ~ 350 °C below the melting point of aluminum (650°C). The ceramic-aluminum bond is strongly present in industrial tools, due to the need to combine the properties of metals, such as ductility, thermal and electrical conductivity, with ceramic properties like high hardness, corrosion and wear resistance. In recent years, some joining techniques have been developed to achieve a good bonding between these materials such as brazing, diffusion bonding, ultrasonic joining and friction welding.
Citation
Fares KHALFALLAH , El Hadj Raouache, Zakaria Boumerzoug, Selvarajan Rajakumar, ,(2018), NUMERICAL SIMULATION ON JOINING OF CERAMICS WITH ALUMINUM DISSIMILAR JOINTS BY FRICTION WELDING,5thINTERNATIONAL CONFERENCE ON COMPUTATIONAL AND EXPERIMENTAL SCIENCE AND ENGINEERING,Turkey