Department of Mechanical engineering

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Author: search.filters.author.Sinhmar, SunilSubject: search.filters.subject.Friction stir welding (FSW)

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    Enhancement of mechanical properties and corrosion resistance of friction stir welded joint of AA2014 using water cooling
    (Elsevier, 2017-01) Sinhmar, Sunil
    An investigation on the microstructure, mechanical properties, and corrosion behavior of friction stir welded joint of AA2014 in natural cooled (NC) and water cooled (WC) conditions have been reported. Optical microscopy, field emission scanning electron microscopy (FESEM) with Energy dispersive X-ray spectroscopy (EDS), Vicker's microhardness, tensile testing, X-ray diffraction (XRD), and electrochemical potentiodynamic polarization corrosion test (Tafel curve) were carried out to characterize the friction stir weld joints in both the cooling conditions. Water cooling resulted in higher strength and microhardness of friction stir weld joint compared to the natural cooling. The width of heat affected zone was reduced by the use of water cooling during friction stir welding (FSW) and minimum hardness zone was shifted towards weld center. The corrosion test was performed in 3.5% NaCl solution. Corrosion resistance of water cooled joint was found higher than natural cooled FSW joint. The precipitation behavior of weld nugget and heat affected zone impacts the corrosion resistance of FSW joint of AA 2014. Hardness, tensile, and corrosion properties of FSW joints produced under NC and WC conditions have been discussed in the light of microstructure.
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    Effect of weld thermal cycle on metallurgical and corrosion behavior of friction stir weld joint of AA2014 aluminium alloy
    (Elsevier, 2019-01) Sinhmar, Sunil
    Friction stir welding of AA2014 aluminium alloy was performed at seven different speed combinations. Weld thermal cycles were measured at all the speed parameters and corresponding peak temperatures were observed at higher tool rotation speed and lower welding speed. Hardness and tensile tests were performed to study the mechanical properties of the weld joints. Corrosion behavior was studied using immersion, Tafel and electrochemical impedance spectroscopy tests. Optical microscopy, FESEM, XRD and transmission electron microscopy were used to investigate the metallurgical behavior of the weld joints. Microhardness and corrosion resistance were found higher at low rotation speed and high traverse speed. Corrosion behavior has been discussed in light of microstructure.
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    Mechanical behavior of FSW joint welded by a novel designed stationary shoulder tool
    (Elsevier, 2020-03) Sinhmar, Sunil
    A novel stationary shoulder friction stir welding (SSFSW) tool was developed with provision for automatic removal of plasticized material entering into the shoulder during the welding. Main objective of this tool design was to obtain a symmetrical weld joint with narrow heat affected zone. Mechanical and metallurgical properties of AA2014 aluminium alloy SSFSW joint were compared with the conventional FSW joint. Sound weld joint with enhanced mechanical properties were obtained by the stationary shoulder tool. Optical microscopy, FESEM analysis along with EDS, transmission electron microscopy, XRD analysis, microhardness and toughness test were performed on both types of weld joint. Weld thermal cycle and heat generation were analyzed for stationary shoulder and conventional FSW tool and it was found that the SSFSW tool shoulder generates lesser heat than conventional FSW tool.
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    Investigation of mechanical and corrosion behavior of friction stir weld joint of aluminium alloy
    (Elsevier, 2019) Sinhmar, Sunil
    Friction stir welding of AA2014 aluminium alloy was performed at 931 rpm and 41 mm/min speed. Weld joint properties were compared with the base metal. Optical microstructure and FESEM analysis with energy dispersive spectroscopy (EDS) were performed. Microhardness and tensile tests were performed to study the mechanical behavior of base metal and FSW joint. Direct current based corrosion test was carried out to study the corrosion behavior. Mechanical performance of AA2014 was reduced after the welding. Corrosion resistance of the weld joint was higher than the base metal. Presence of precipitates affected the performance of base metal and weld joint.
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    Mechanical and Corrosion Behavior of Pure Aluminium Added Friction Stir Weld Joint of Aluminium Alloy
    (Trans Tech Publications Ltd., 2019-09) Sinhmar, Sunil
    Friction stir welding (FSW) of AA2014 aluminium alloy was performed by sandwiching pure aluminium (Al) in the form of strip between the abutting surfaces. Mechanical and corrosion behavior of weld joint with and without pure aluminium addition was compared. Friction stir welding was carried out at rotational speed of 931 rpm and traverse speed of 41 mm/min. Pure aluminium strip of 1 mm thickness was used for incorporating Al in weld nugget zone. Microstructure analysis was carried out using optical microscope and FESEM with energy dispersive spectroscopy (EDS). Microhardness and tensile testing were performed on the weld joints. Corrosion behavior was investigated using electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (Tafel) test. FESEM analysis was performed before and after corrosion test. Traces of pure aluminium strip were observed in the microstructure. The incorporated strip was found not to be uniformly distributed in the nugget zone. Pure aluminium addition reduced the extent of formation of the second phase particle in the nugget zone as compared to the normal FSW joint i.e. without Al addition. This metallurgical homogeneity resulted in better corrosion resistance of the Al added weld joint than the normal FSW joint.