Investigation in solid-state joining of Al/SiC/Al2O3 composite using Grey-based desirability (GBD) and response surface plots

Traditional fusion joining techniques are observed to produce undesirable mechanical and metallurgical changes in joints formed with aluminum alloys. The present work is focused toward the continuous drive friction welding (solid-state joining) of Al/SiC/Al2O3 composite rods which are used as drive shafts for light load vehicles, piston rods, and valve trains. The dominant friction welding parameters like frictional pressure, burn off length, upset pressure, and rotational speed are varied during welding experimentation. The tensile strength and elongation is observed during various welding trials, designed using Taguchi's L-9 orthogonal array. A combined methodology of Grey-based desirability is used to identify the optimal friction welding parameters. A mathematical model is also formed to find the temperature distribution near the weld interface. The model will assist in further studies related to the length of heat-affected zone, residual stress distribution, and formation of flash. The optimal condition is confirmed through proper validation experiments and the fractured surface is also examined through field emission scanning electron microscope (FESEM) images.