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) %(40,30,20 .
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Friction Stir Welding Of Porous Al-Si Alloy

Abstract
The aim of this research is to study the ability of joining porous (Al-Si) alloy to
solid Aluminum using Friction Stir Welding Method . The porous alloy is fabricate
using casting method by adding(20,30,40) weight percent of Poly- athelin as space
holder materials. The welding process is done using different welding speed
(30,40and60)mm/min, with constant rotational speed (900) rpm.
Microstructure evaluation showed that it is possible to weld porous alloy to aluminum
in the solid state welding by friction stir process . Hardness test results showed that the
welding zone hardness is higher than that of welded materials, and the weld zone
hardness increased with increasing welding speed .The tensile test results showed that
the bonding strength increased with increasing welding speed at constant space holder
weight percentage, and it decreases with increasing addition percentage of space
holder.

) Porous
(Materials
) (matrix

] .[1
)(High strength

* , / .

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 282010 6

].[2

) (Acoustic damping

)(Impact


)(Crash box

].[3


] [4,5
].[6

Friction Stir Welding
.

].[5



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) (shoulder
) pin .[8,7](probe

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.



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.


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) (

) (1 ]. [7
- 2


) (Al-7Si
) (space holder method
) ( 1
.
) ()(1
(Cyanoacrylate

) adhesives
) (2*2*6
)%(20,30,40 ). (Al-7Si
)(0.5
)(1
) (carbolite
)(30/ o
) (590 , o

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 282010 6

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(space holder
)o(150 .

)o(300
.
) (
.


)(10
.

].[10

) (2


) (5

)(0,0001
)w1( ,

)w2(.
) (1/ 3

]:[11
)(3

= w1 w2

)(4

)-(

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) CNC Milling Machine
.

)( -



) (

.
) (12.5 ) (6
) (4 .
) (900/ ,

) ( .


) (60,40,30/
.

:
:






.
:
) (5

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 282010 6

.

) (
)(60,40,30/
)(900/.
:


)(3
) (4 .
- 3


.
) (CarelZeiss
.

) Micro
(Hardness

) (Vickers hardness

)(0.5 )(30.

] .[12

)-(

. ) (5
.
)(500
)(0.5/ .
.
-4

) (6
) (Effective porosity




.



) (Al-7Si
) (%30
)(


),(7


.:
)(Nugget Zone

) .(7

) (refining

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 282010 6

)(re crystallization

.

)(
) (8








.

,) (9






].[14,13
) (9


) (grains

))(Advanced Side

(

)-(

))(Retarding Side

(



) (
)(8

.



.
)30/(







) (
.
)( HAZ


.


Al- 7Si

) (%30

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 282010 6

) (10

) ( 60,40,30/ .



)) (pin
(
.
) (Grain Refining



.




(Thermo mechanical Heat Affected

) Zone
.




) (10



) (Al-7Si

.


)(HV=120
) (HV=127) (
.

)-(

) (10


]. [9 )(11


.
) (10

.


)(60/



.
)(60/



.

) (12


.

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 282010 6

) (.


) (60/
) (900/ ) %(30




.







.
.

) (60/ ) %(20

.


) (60/.
-5

)- (


:
.

)-(

.


.
:
.


.

)(
) (160HV
)(60/ .


)
(
) (.



) (140N
)(60/
) %(30
.



)(70N
) %(40
)(30
/.

.[1].M.F.Ashby & N.A.Fleck Metal

Foams and Porous Metal Structure 1st.
Edition, Bremen, 1999, USA.

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2010 6 28

( - )

.[7]. R.S.Mishra & Z.Y.Ma Fiction

Stir
Welding and Processing,
Materials Science and Engineering,
Reports Review Journal ,R50, pp.1-78,
2005. .[8]. A. Simar Y. Rechet , B.
Meester, "Microstructure, local and
global mechanical properties of
Friction Stir Welds in Aluminum alloy
6005A-T6", Materials Science and
Engineering A, Vol. 486, (2008),pp.
8595. .[9].A.Barcellona & G.Buuf
On Micro structural Occurring in
Friction Stir Welding of Aluminum
Alloys
Journal
of
Materials
Processing Technology, No.177, 2006,
pp.340-343.
.[10].E.Brandes Semithelles Light
Metal Metal Handbook, Lowe State
University, 1998.
.[11].J.M.Tulliani, I.Montanaro,
"American
Ceramic
Socity",ASTM,1999
.[12].H.William
Properties
and
Selection: Non Ferrous Alloys and
Pure Materials Metal Handbook,
Vol.9, 1985.

.[2].L. Rausch and J. Banhart,"

Mechanical Properties Of Highly
Ordered Nan porous Anodic Alumina
Membranes", Advanced Materials
Science, Vol. 6, No.11, 2004.
.[3].F.Bamga
&
I.Durate
Industrialization of Powder Compact
Foaming
Process,
journal
of
Advanced
Engineering
Materials,
Vol.4, No.3, 1993, pp.30-39.
.[4].C.korner & R.Singer Processing
of Metal Foams Challenges and
Opportunities Journal of Advanced
Engineering Materials, Vol.2, No.4,
1999, pp.159-165.
[5].ALUMINUM NSWER, "The
Joining Process" ,www.aluminum org
,Test Research,2007
[6] D. Rodrigues, A. Loureiro ,
C.Leitao " Influence of friction stir
welding
parameters
on
the
microstructural
and
mechanical
properties of AA 6016-T4 thin welds",
Materials and Design, Vol. 30 ,(2009)
pp.19131921.

(- ( ) 1)
Si
7

Mg
0.39

Fe
0.07

Mn
0.03

Cu
0.05

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)(6
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)(N

20
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) (12 )(.

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