Abstract
This present work investigates the effect of adding novel biochar microparticle into the welding zone of dissimilar friction stir welding of AISI-SAE 1010 (steel)–CDA 101 (copper) alloys. The primary aim of this work was to produce efficient weld joints in AISI-SAE 1010–CDA 101 alloys using biochar as solid lubricant via friction stir welding process. The biochar particles were prepared from rice husk biomass via carbonization process. The welding was performed using tapered pin profiled tool with rotational speed of 900 rpm, traverse speed of 30 mm/min, axial load of 5 KN, dwell time of 5s, plunging depth of 0.2mm, and biochar additions of 0.5, 1, 2, and 4wt%. The highest tensile strength of 205 MPa, elongation of 44%, yield strength of 177MPa, strain value of 36, and Vickers hardness of 121 were observed for FSW joints made using 2wt% of biochar content. Large addition of biochar up to 4wt% marginally affects the properties. Similarly, the fatigue strength of 157MPa was observed for weld made using 2wt% of biochar. The microstructure of biochar-assisted weld nugget shows highly refined less thermally affected grains. The grains were in equiaxial with distortion-free. The EDAX report confirms the presence of copper, iron, and carbon on the weld nugget, which indicates fine mixing of parent metals with solid lubricant. These mechanical properties improved environmental friendly dissimilar welding method could be used in industrial applications such as automobile, aerospace, construction, defense, medical, energy where high strength with high durable weld joints are required to meet the current technology demand, and process economy.
Similar content being viewed by others
References
Sivabalan S, Sridhar R, Sathishkumar G, Prakash M (2019) Mechanical behaviour of friction stir welded dissimilar aluminium alloy AA 6082 and AA 2014. Int J Veh Struct Syst 11(3):294–296
Dhanesh Babu SD, Sevvel P, Senthil Kumar R, Vijayan V, Subramani J (2021) Development of thermo mechanical model for prediction of temperature diffusion in different FSW tool pin geometries during joining of AZ80A Mg alloys. J Inorg Organomet Polym Mater. https://doi.org/10.1007/s10904-021-01931-4
Jayabalakrishnan D, Balasubramanian M (2017) Friction stir weave welding (FSWW) of AA6061 aluminium alloy with a novel tool-path pattern. Aust J Mech Eng. https://doi.org/10.1080/14484846.2017.1373584
Satheesh C, Sevvel P, Senthil Kumar R (2020) Experimental identification of optimized process parameters for FSW of AZ91C Mg alloy using quadratic regression models. StrojniskiVestnik/J Mech Eng 66(12):736–751
Sahu SK, Pal K, Mahto RP, Dash P (2019) Monitoring of friction stir welding for dissimilar Al 6063 alloy to polypropylene using sensor signals. Int J Adv Manuf Technol 104(1-4):159–177
DhaneshBabu SD, Sevvel P, Senthil Kumar R (2020) Simulation of heat transfer and analysis of impact of tool pin geometry and tool speed during friction stir welding ofAZ80A Mg alloy plates. J Mech Sci Technol 34(10):4239–4250
Jayabalakrishnan D, Balasubramanian M (2018) Friction stir welding of dissimilar butt joints with novel joint geometry. Acta Physica Polonica, A 133(1):94–100. https://doi.org/10.12693/APhysPolA.133.94
Sevvel P, SD DB, Senthil Kumar R (2020) Peak temperature correlation and temperature distribution during joining of AZ80A Mg alloy by FSW – a numerical and experimental investigation. Strojniškivestnik - J Mech Eng 66(6):395–407
Balasubramanian M, Jayabalakrishnan D (2020) Influence of pin offset and weave pattern on the performance of Al-Cu joints reinforced with graphene particles. Int J Automot Mech Eng 17(3):8186–8196
Jayabalakrishnan D, Balasubramanian M (2019) Effect of square wave tool path pattern on mechanical and microstructure properties of friction stir welded AA6061-Cu dissimilar alloys. J Chin Soc Mech Eng 40(6):711–717
Ahmad Shah LH, Sonbolestan S, Midawi ARH, Walbridge S, Gerlich A (2019) Dissimilar friction stir welding of thick plate AA5052-AA6061 aluminum alloys: effects of material positioning and tool eccentricity. Int J Adv Manuf Technol 105:889–904. https://doi.org/10.1007/s00170-019-04287-9
Joshi GR, Badheka VJ (2017) Microstructures and properties of copper to stainless steel joints by hybrid FSW. Metallogr Microstruct Anal 6:470–480. https://doi.org/10.1007/s13632-017-0398-x
Jafari M, Abbasi M, Poursina D, Gheysarian A, Bagheri B (2017) Microstructures and mechanical properties of friction stir welded dissimilar steel-copper joints. J Mech Sci Technol 31(3):1135–1142
Wang T, Shukla S, Nene SS, Frank M, Wheeler RW, Mishra RS (2018) Towards obtaining sound butt joint between metallurgically immiscible pure Cu and stainless steel through friction stir welding. Metall Mater Trans A 49:2578–2582. https://doi.org/10.1007/s11661-018-4637-9
Vibin R, JulyesJaisingh S, Ramesh G, Jayabalakrishnan D, Arunprakash VR (2020) Effect of nanosilica and weave geometry on weld properties of friction stir welded nylon 6–6 thick plates. Silicon 1–9
Sevvel P, Satheesh C, Senthil Kumar R (2020) Generation of regression models and multi-responseoptimization of friction stir welding technique parameters during the fabrication of AZ80A Mg alloy joints. Trans Can Soc Mech Eng 44(2):311–324
Jayabalakrishnan D, Balasubramanian M (2018) Eccentric-weave FSW between Cu and AA 6061-T6 with reinforced Graphene nanoparticles. Mater Manuf Process 33(3):333–342
Abdollahzadeh A, Shokuhfar A, Cabrera JM, Zhilyaev AP, Omidvar H (2019) In-situ nanocomposite in friction stir welding of 6061-T6 aluminum alloy to AZ31 magnesium alloy. J Mater Process Technol 263:296–307
Mohammed S, Birru AK (2019) Friction stir welding of AA6082 thin aluminium alloy reinforced with Al2O3 nanoparticles. Trans Indian Ceram Soc 78(3):137–145
Dawood HI, Musa KM, Abbas RK, Alshemary KKH, Uday MB, Jaddan RI, Taklef LJ (2020) Effect of friction stir welding on microstructure and mechanical properties of the 6061 aluminium alloy/15vol% SiCp reinforcement. IOP Conf Ser: Mater Sci Eng 870(1):012162. IOP Publishing
Anand R, Sridhar VG (2020) Effects of SiC and Al2O3 reinforcement of varied volume fractions on mechanical and micro structure properties of interlock FSW dissimilar joints AA7075-T6-AA7475-T7. Silicon 1–13
Murigendrappa SM, Kumar H (2019) Experimental investigation on effects of varying volume fractions of SiC nanoparticle reinforcement on microstructure and mechanical properties in friction-stir-welded dissimilar joints of AA2024-T351 and AA7075-T651. J Mater Res 34(7):1229–1247
Sevvel P, Satheesh C (2018) Role of tool rotational speed in influencing microstructural evolution, residual-stress formation and tensile properties of friction-stir welded AZ80A Mg alloy. Mater Technol 52(5):607–614
Das SK, Ghosh GK, Avasthe R (2020) Application of biochar in agriculture and environment, and its safety issues. Biomass Conv Bioref. https://doi.org/10.1007/s13399-020-01013-4
Liu L, Zhou M, Jin L, Li L, Mo Y, Guoshi S, Li X, Zhu H, Yu T (2019) Recent advances in friction and lubrication of graphene and other 2D materials: Mechanisms and applications. Friction 7(3):199–216
Jagatheesan K, Babu K (2020) Taguchi optimization of minimum quantity lubrication turning of AISI-4320 steel using biocharnanofluid. Biomass Conv Bioref. https://doi.org/10.1007/s13399-020-01111-3
Sevvel P, Jaiganesh V (2017) Investigation on evolution of microstructures and characterization during FSW of AZ80A Mg alloy. Arch Metall Mater 62(3):1779–1785
Kumar R, Balasubramanian M (2015) Experimental investigation of Ti–6Al–4V titanium alloy and 304L stainless steel friction welded with copper interlayer. Defence Technol 11(1):65–75
Sinha VC, Kundu S, Chatterjee S (2016) Microstructure and mechanical properties of similar and dissimilar joints of aluminium alloy and pure copper by friction stir welding. Perspect Sci 8:543–546
Mehta KP, Badheka VJ (2015) Influence of tool design and process parameters on dissimilar friction stir welding of copper to AA6061-T651 joints. Int J Adv Manuf Technol 80(9):2073–2082
Zareie O, Mousavizade SM, Ezatpour HR, Zareie H, Farmanbar N (2020) Effect of plunging depth and dwelling time on microstructure and mechanical properties of 6061 aluminum alloy welded by protrusion friction stir spot welding. Welding World 1–21
Al-Shahrani A, Wynne BP (2010) Effect of dwell time on friction stir spot welded dual phase steel. Adv Mater Res 83:1143–1150. Trans Tech Publications Ltd
Sevvel P, Jaiganesh V (2017) Influence of the arrangement of materials and microstructural analysis during FSW of AZ80A & AZ91C Mg alloys. Arch Metall Mater 62(3):1795–1801
Aghajani Derazkola H, Elyasi M, Hossienzadeh M (2016) Effects of friction stir welding tool plunge depth on microstructure and texture evolution of AA1100 to A441 AISI joint. ADMT J 9(1)
Rajadurai A (2016) Thermo-mechanical characterization of siliconized E-glass fiber/hematite particles reinforced epoxy resin hybrid composite. Appl Surf Sci 384:99–106
Derazkola H, Aghajani H, Aval J, Elyasi M (2015) Analysis of process parameters effects on dissimilar friction stir welding of AA1100 and A441 AISI steel. Sci Technol Weld Join 20(7):553–562
Karrar G, Galloway A, Toumpis A, Li H, Al-Badour F (2020) Microstructural characterisation and mechanical properties of dissimilar AA5083-copper joints produced by friction stir welding. J Mater Res Technol 9(5):11968–11979
Sevvel P, Satheesh C, Jaiganesh V (2019) Influence of tool rotational speed on microstructural characteristics of dissimilar Mg alloys during friction stir welding. Trans Can Soc Mech Eng 43(1):132–141
Medhi T, Roy BS, Saha SC (2020) An experimental investigation on the influence of rotational speed on microstructure and mechanical properties of friction stir welded dissimilar Al-Cu joints. Int J Mater Prod Technol 60(2-4):236–259
Abdullah IT, Hussein SK (2018) Improving the joint strength of the friction stir spot welding of carbon steel and copper using the design of experiments method. Multidiscip Model Mater Struct. https://doi.org/10.1108/MMMS-02-2018-0025
Güleryüz G (2020) Relationship between FSW parameters and hardness of the ferritic steel joints: modeling and optimization. Vacuum 178:109449
Rodríguez A, Calleja A, de Lacalle LNL, Pereira O, González H, Urbikain G, Laye J (2019) Burnishing of FSW aluminum Al–Cu–Li components. Metals 9(2):260
Sevvel P, Jaiganesh V (2015) Effect of tool shoulder diameter to plate thickness ratio on mechanical properties and nugget zone characteristics during FSW of dissimilar Mg alloys. Trans Indian Inst Metals 68(S1):41–46
Texier D, Atmani F, Bocher P, Nadeau F, Jie C, Zedan Y, Vanderesse N, Demers V (2018) Fatigue performances of FSW and GMAW aluminum alloys welded joints: competition between microstructural and structural-contact-fretting crack initiation. Int J Fatigue 116:220–233
Salvati E, Everaerts J, Kageyama K, Korsunsky AM (2019) Transverse fatigue behaviour and residual stress analyses of double sided FSW aluminium alloy joints. Fatigue Fract Eng Mater Struct 42(9):1980–1990
Cetkin E, Çelik YH, Temiz S (2019) Microstructure and mechanical properties of AA7075/AA5182 jointed by FSW. J Mater Process Technol 268:107–116
Jaiganesh V, Sevvel P (2015) Effect of process parameters in the microstructural characteristics and mechanical properties of AZ80A Mg alloy during friction stir welding. Trans Indian Inst Metals 68(S1):99–104
Milagre MX, Mogili NV, Donatus U, Giorjão RAR, Terada M, Araujo JVS, Machado CSC, Costa I (2018) On the microstructure characterization of the AA2098-T351 alloy welded by FSW. Mater Charact 140:233–246
Wahid MA, Siddiquee AN, Khan ZA, Sharma N (2018) Analysis of cooling media effects on microstructure and mechanical properties during FSW/UFSW of AA 6082-T6. Mater Res Express 5(4):046512
Sevvel P, Jaiganesh V (2016) Impact of process parameters during friction stir welding of AZ80A Mg alloy. Sci Technol Weld Join 21(2):83–90
Sahlot P, Jha K, Dey GK, Arora A (2018) Wear-induced changes in FSW tool pin profile: effect of process parameters. Metall Mater Trans A 49(6):2139–2150
Hasieber M, Grätzel M, Bergmann JP (2020) A novel approach for the detection of geometric-and weight-related FSW tool wear using stripe light projection. J Manuf Mater Process 4(2):60
Stephan Thangaiah IS, Sevvel P, Satheesh C, Mahadevan S (2018) Experimental study on the role of tool geometry in determining the strength & soundness of wrought AZ80a Mg alloy joints during FSW process. FME Trans 46(4):612–622
Rashid M, Yuvraj N, Singh SK (2016) Micro structural and mechanical behaviours of nano-TiC-reinforced AA6082 FSW joints. Fusion Sci Technol:18–22
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Giridharan, K., Sevvel, P., Gurijala, C. et al. Biochar-assisted copper-steel dissimilar friction stir welding: mechanical, fatigue, and microstructure properties. Biomass Conv. Bioref. 13, 4021–4031 (2023). https://doi.org/10.1007/s13399-021-01514-w
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13399-021-01514-w