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Keywords
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Adhesion Strength, Crack, Double-Layered Wire, Friction Stir Extrusion, Liquid Penetrant Testing
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Abstract
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In this paper, a new production method of aluminium/steel double-layered
wire is proposed using a modified friction stir extrusion process. The core and
coating were made of St37 steel and aluminium alloy, respectively. For extruded
specimens, the effects of the main process parameters including tool rotational speed
and feed rate were investigated on adhesion strength and surface cracks. The tool
rotational speed was studied at two levels of 300 and 600 rpm, and the feed rate at
two levels of 4 and 12 mm/min. Pull-out test was carried out using a tensile test
machine to evaluate the adhesion strength. Surface cracks were evaluated by the
liquid penetrant test. The results suggest that the modified friction stir extrusion
process can be used successfully to produce dissimilar double-layered wires. With
the right combination of tool rotational speed and feed rate levels, a dissimilar
double-layered wire can be produced with a high adhesion strength and good surface
quality. No cracks were observed in specimens produced with the feed rate of 12
mm/min and rotational speed of 600 rpm. The maximum adhesion strength was
2867.13 N that was achieved with a tool rotational speed of 300 rpm and feed rate
of 12 mm/min.
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