Process Characteristics of Friction Bonding of Stainless Steel 430, Aluminum 1100 and 3003

Friction bonding process is a method of joining two or more metal sheets by using heat and force to soften and yield an atomic adhesion between the two work layers. Using the insufficient heat and force, it can result in a non-bonded section or delamination, where a gap is appeared in between the two metal sheets after the process. With a very limited knowledge in relation to the friction bonding process, this study aims at revealing the effect of work temperature and force on the size of non-bonded section. Stainless steel 430, aluminum 1100 and 3003 sheets were bonded in this study, where the non-destructive ultrasonic testing method was employed to measure the defect size beneath the bonded sample. The results showed that a reduction in defect size can be obtained by increasing the work temperature as well as the stamping force. In addition, the optimal condition of the study case is also obtained through the experimental design. It can be concluded from the analysis that at the voltage of 595 Volt, 65 Watt and the stroke distance of 80 mm which is equivalent to 540 Celcius and force of 2590 kN provide the smallest delamination size. The regression model was also developed to show the relationship of factors to the delamnation size. This equation can be used to predict the mentioned delmination size at various conditions.