Friction Welding of Cast Iron and Phosphor Bronze

There is sometimes a need to fabricate machine parts that have the best properties of multiple materials while being economical at the same time. A prime example of such a scenario is with gears. Gears made out of cast iron are a poor choice because cast iron has poor impact resistance and is vulner...

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Bibliographic Details
Published in:Journal of the Institution of Engineers (India) Series C 2020-04, Vol.101 (2), p.347-354
Main Authors: Raghav, Anand K., Vaira Vignesh, R., Kalyan, Kota Pavan, Govindaraju, M.
Format: Article
Language:English
Subjects:
Acceptable noise levels
Aerospace Technology and Astronautics
Cast iron
Corrosion resistance
Dissimilar material joining
Dissimilar materials
Engineering
Friction welding
Gears
Impact resistance
Industrial and Production Engineering
Mechanical Engineering
Mechanical properties
Metallurgy
Original Contribution
Phosphor bronzes
Welded joints
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Summary:There is sometimes a need to fabricate machine parts that have the best properties of multiple materials while being economical at the same time. A prime example of such a scenario is with gears. Gears made out of cast iron are a poor choice because cast iron has poor impact resistance and is vulnerable to corrosion. The addition of phosphor bronze as an annulus to the cast iron hub in a composite gear provides the gear with those valuable resistances along with a superior intermeshing with mated gears. However, joining dissimilar materials such as cast iron to phosphor bronze is challenging when conventional welding techniques are employed. To overcome it, applying friction welding to join cast iron to phosphor bronze is focused in this thesis. The obtained results are analyzed and optimized for this particular combination of materials to facilitate their use in gears. The results show that there is an increased accumulation of graphite at the weld joints between cast iron and phosphor bronze for trials at higher (rotational) welding speeds, which leads to less favorable mechanical properties. At lower welding speeds, sound joints with acceptable mechanical and metallurgical properties were obtained.
ISSN:2250-0545
2250-0553
DOI:10.1007/s40032-019-00553-7