Crack repair using hybrid additive manufacturing and friction stir processing

Fadi Al-Badour; Ibrahim H. Zainelabdeen; Rami K. Suleiman; Akeem Adesina

doi:10.1115/pvp2019-93688

Crack repair using hybrid additive manufacturing and friction stir processing

Fadi Al-Badour^*, Ibrahim H. Zainelabdeen, Rami K. Suleiman, Akeem Adesina

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

1 Scopus citations

Abstract

A hybrid additive manufacturing (AM) and friction stir processing (FSP) was used to heal a crack in 6 mm thick Al 6061-T6 aluminum alloy. AL-6061 is usually used in H2 high-pressure vessel fabrication as well as aerospace applications. In this work, Al-Si powder was utilized to fill the crack, then FSP was applied to consolidate and stir the powder with the base metal to fill and close the crack zone. Effect of FSP parameters including welding speed and tool rotation speed on the quality of repair was studied. Various mechanical tests, as well as characterization techniques such as hardness test, optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS), were employed to study the newly developed hybrid process on the quality of the repair. The investigation revealed that low rotational speed of 800 rpm results in minimum variation in microhardness. Moreover, the impact of welding speed on microhardness is smaller as compared to rotational speed.

Original language	English
Title of host publication	Materials and Fabrication
Publisher	American Society of Mechanical Engineers (ASME)
ISBN (Electronic)	9780791858974
DOIs	https://doi.org/10.1115/pvp2019-93688
State	Published - 2019

Publication series

Name	American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP
Volume	6A-2019
ISSN (Print)	0277-027X

Bibliographical note

Publisher Copyright:
Copyright © 2019 ASME.

ASJC Scopus subject areas

Mechanical Engineering

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1115/pvp2019-93688

Cite this

Al-Badour, F., Zainelabdeen, I. H., Suleiman, R. K., & Adesina, A. (2019). Crack repair using hybrid additive manufacturing and friction stir processing. In Materials and Fabrication Article pvp2019-93688 (American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP; Vol. 6A-2019). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/pvp2019-93688

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title = "Crack repair using hybrid additive manufacturing and friction stir processing",

abstract = "A hybrid additive manufacturing (AM) and friction stir processing (FSP) was used to heal a crack in 6 mm thick Al 6061-T6 aluminum alloy. AL-6061 is usually used in H2 high-pressure vessel fabrication as well as aerospace applications. In this work, Al-Si powder was utilized to fill the crack, then FSP was applied to consolidate and stir the powder with the base metal to fill and close the crack zone. Effect of FSP parameters including welding speed and tool rotation speed on the quality of repair was studied. Various mechanical tests, as well as characterization techniques such as hardness test, optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS), were employed to study the newly developed hybrid process on the quality of the repair. The investigation revealed that low rotational speed of 800 rpm results in minimum variation in microhardness. Moreover, the impact of welding speed on microhardness is smaller as compared to rotational speed.",

author = "Fadi Al-Badour and Zainelabdeen, {Ibrahim H.} and Suleiman, {Rami K.} and Akeem Adesina",

note = "Publisher Copyright: Copyright {\textcopyright} 2019 ASME.",

year = "2019",

doi = "10.1115/pvp2019-93688",

language = "English",

series = "American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP",

publisher = "American Society of Mechanical Engineers (ASME)",

booktitle = "Materials and Fabrication",

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Al-Badour, F, Zainelabdeen, IH, Suleiman, RK & Adesina, A 2019, Crack repair using hybrid additive manufacturing and friction stir processing. in Materials and Fabrication., pvp2019-93688, American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP, vol. 6A-2019, American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/pvp2019-93688

Crack repair using hybrid additive manufacturing and friction stir processing. / Al-Badour, Fadi; Zainelabdeen, Ibrahim H.; Suleiman, Rami K. et al.
Materials and Fabrication. American Society of Mechanical Engineers (ASME), 2019. pvp2019-93688 (American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP; Vol. 6A-2019).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Crack repair using hybrid additive manufacturing and friction stir processing

AU - Al-Badour, Fadi

AU - Zainelabdeen, Ibrahim H.

AU - Suleiman, Rami K.

AU - Adesina, Akeem

PY - 2019

Y1 - 2019

N2 - A hybrid additive manufacturing (AM) and friction stir processing (FSP) was used to heal a crack in 6 mm thick Al 6061-T6 aluminum alloy. AL-6061 is usually used in H2 high-pressure vessel fabrication as well as aerospace applications. In this work, Al-Si powder was utilized to fill the crack, then FSP was applied to consolidate and stir the powder with the base metal to fill and close the crack zone. Effect of FSP parameters including welding speed and tool rotation speed on the quality of repair was studied. Various mechanical tests, as well as characterization techniques such as hardness test, optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS), were employed to study the newly developed hybrid process on the quality of the repair. The investigation revealed that low rotational speed of 800 rpm results in minimum variation in microhardness. Moreover, the impact of welding speed on microhardness is smaller as compared to rotational speed.

AB - A hybrid additive manufacturing (AM) and friction stir processing (FSP) was used to heal a crack in 6 mm thick Al 6061-T6 aluminum alloy. AL-6061 is usually used in H2 high-pressure vessel fabrication as well as aerospace applications. In this work, Al-Si powder was utilized to fill the crack, then FSP was applied to consolidate and stir the powder with the base metal to fill and close the crack zone. Effect of FSP parameters including welding speed and tool rotation speed on the quality of repair was studied. Various mechanical tests, as well as characterization techniques such as hardness test, optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS), were employed to study the newly developed hybrid process on the quality of the repair. The investigation revealed that low rotational speed of 800 rpm results in minimum variation in microhardness. Moreover, the impact of welding speed on microhardness is smaller as compared to rotational speed.

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M3 - Conference contribution

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T3 - American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP

BT - Materials and Fabrication

PB - American Society of Mechanical Engineers (ASME)

ER -

Crack repair using hybrid additive manufacturing and friction stir processing

Abstract

Publication series

Bibliographical note

ASJC Scopus subject areas

UN SDGs

Access to Document

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Cite this