Asian Journal of Engineering and Applied Technology ISSN 2249-068X Vol. 7 No. S2, 2018, pp. 48- 51 © The Research Publication, www.trp.org.in Friction Crush Welding of Similar Metals: An Overview Prem Singh 1 , Dharmpal Deepak 2 and Gurinder Singh Brar 3 1 Department of Mechanical Engineering, Guru Nanak Dev Engineering College, Ludhiana, Punjab, India 2 Mechanical Engineering Department, Punjabi University, Patiala., Punjab, India 3 Department of Mechanical Engineering, National Institute of Technology, Srinagar (Garhwal) Uttarakhand, India E-mail: er.premsingh@gmail.com Abstract - Friction Crush Welding (FCW) is a newly developed technique which can be used for welding of similar materials with or without filler metal. In this process, welding between two work pieces occurs due to relative motion between work pieces and rotating cylindrical tool, which causes crushing of material to produce weld. Similar weld which include welds of aluminium, steel and copper and their alloy have been successfully produced by few researchers. This review covers the work conducted in the field of FCW and throws light on the future use of FCW for welding similar and dissimilar materials. Keywords: Friction Crush welding, Aluminum, Steel, Microstructure, Scanning Electron Microscope. I. INTRODUCTION Friction Crush Welding (FCW) is a newly developed technique by Besler et al. (2016) using crushing of metal and was initially applied to weld simlilarsheet metals of aluminium, steel and copper without filler material. In this process, welding between two work pieces occurs due to relative motion between work pieces and rotating cylindrical tool having specific profile shape as shown in Fig. 1. Fig. 1 Schematic illustration of FCW [1,2,3,4] The workpieces having flanges on it are positioned adjacent to each other with a gap. The relative motion between tool and workpieces causes crushing of material and crushed material is filled into the gap between the two workpieces through the tool and produces weld. FCW joints commonly consists of different microstructural zones as shown in Fig. 2. Which consists of unaffected material or original material, the heat affected zone (HAZ), thermo-mechanically affected zone (TMAZ) and crushing zone (CZ). Fig. 2 Illustration of different microstructural regions in the transverse cross section of a FCW material (Steel) [2] Prior to the development of FCW, conventional fusion welding processes along with friction stir welding (FSW) processes were used to join similar and dissimilar materials. Reviews have been conducted on various aspects of FSW by different researchers. This paper presents a review of published literature in FCW of similar materials. The review was conducted by focusing on FCW between similar material of aluminum, steel and copper. II. FRICTION CRUSH WELDING MECHANISM Friction crush welding mainly depends upon a) frictional heat produce due to relative motion Fig. 3: Mechanism of friction crush welding [1,2] between the work piece and the tool and b) crushing forces were developed by tool movement due to variation in 48 AJEAT Vol.7 No.S2 November 2018