SURFACE MODIFICATION BY FRICTION

STIR PROCESSING OF LEADED TIN BRONZE

A PROJECT REPORT
Submitted by

MADHAN R ( 171ME194 )
MANIKANDAN S (171ME200)
PONNARASAN V (171ME218)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

BANNARI AMMAN INSTITUTE OF TECHNOLOGY

(An Autonomous Institution Affiliated to Anna University , Chennai)

SATHYAMANGALAM-638401

ANNA UNIVERSITY: CHENNAI 600 025

AUGUST 2020
 BONAFIDE CERTIFICATE

Certified that this project report “ SURFACE MODIFICATION BY

FRICTION STIR PROCESSING OF LEADED TIN BRONZE ” is the
bonafide work of MADHAN R (171ME194 ) , MANIKANDAN S (171ME200)
PONNARASAN V (171ME218) who carried out the project work under my
supervision.

SIGNATURE SIGNATURE

Dr.C.SASIKUMAR Mr.DINESH D

PROFESSOR ASSISTANT PROFESSOR (II)

HEAD OF THE DEPARTMENT SUPERVISOR

Department of Mechanical Engineering Department of Mechanical Engineering

Bannari Amman Institute of Technology Bannari Amman Institute of Technology

Erode-638401 Erode-638401

Submitted for Project Viva Voce Examination held on ………………

INTERNAL EXAMINER EXTERNAL EXAMINER

 DECLARATION

We affirm that the project work titled “SURFACE

MODIFICATION BY FRICTION STIR PROCESSING OF LEADED TIN
BRONZE” being submitted in partial fulfillment for the award of the
degree of BACHELOR OF ENGINEERING in MECHANICAL
ENGINEERING is the record of original work done by us under the guidance
of Mr.DINESH D, Assistant Professor (II), Department of Mechanical
Engineering. It has not formed a part of any other project work(s) submitted for
the award of any degree or diploma, either in this or any other University.

MADHAN R MANIKANDAN S PONNNARASAN V

(171ME194) (171ME200) (171ME218)

I certify that the declaration made above by the candidates is true.

DINESH D
Assistant Professor (II)
 ACKNOWLEDGEMENT

We would like to enunciate heartfelt thanks to our esteemed Chairman

Dr.S.V.Balasubramaniam and the respected Director Dr.M.P.Vijayakumar
for providing excellent facilities and support during the course of study in this
institute.

We are grateful to Dr.C.Sasikumar , Professor & Head of the

Department, Department of Mechanical Engineering for his valuable
suggestions to carry out the project work successfully.

We wish to express our sincere thanks to Dr.G.Kumaresan, Associate

Professor for his encouragement and much needed technical support extended to
complete our project work.

We wish to express our sincere thanks to the Faculty guide Mr.K.Kamal

Basha,Assistant Professor(I), Department of Mechanical Engineering for his
constructive ideas, inspirations, encouragement, excellent guidance and much
needed technical support extended to complete our project work.

We would like to thank our friends, faculty and non-teaching staff who
have directly and indirectly contributed to the success of this project.

MADHAN R

MANIKANDAN S

PONNARASAN V

iv
 ABSTRACT

Friction stir processing (FSP) is a promising plastic deformation solid state

surface engineering technique used to improve the properties of surface instead
of bulk material which works on the basis of the process of Friction stir welding
(FSW)which is done by a non-consumable tool rotating and also travelling
along the surface plate. High leaded copper-based alloy has been focused in this
study used for bearing and bushing application as a lining material to achieve
moderately high strength and low wear rate. FSP has been performed at a tool
rotating at 1000 rpm and 1500 rpm at a traversing speed of 20 and 40mm/min
with a 18mm shoulder diameter,6mm pin diameter, and hexagonal tool profile is
used Microstructure observation through Scanning electron microscope (SEM)
of the processed high leaded tin bronze which contains α phase is rich in copper
and then it contains lubricating lead particles and then the intermetallic
compound of Cu-Sn is formed. It is confirmed through EDS Analysis that no
tool material transfer has been occurred on to the surface interface. Hardness of
the material on the surface is increased to about 40% in compared to base metal.

Keywords: Friction Stir Processing(FSP),Scanning Electron Microscope(SEM),

Energy Dispersive Spectroscopy(EDS)

v
 TABLE OF CONTENTS
CHAPTER TITLE PAGE
No. No.

ABSTRACT i

TABLE OF CONTENTS ii

LIST OF FIGURES vi

LIST OF TABLES vii

1 INTRODUCTION 1

1.1 FRICTION STIR WELDING 1

1.2 FRICTION STIR PROCESSING 2

1.3 PROCESS 3

1.4 TOOL 4

1.4.1 Effects Of Various Tool Profiles 5

1.5 APPLICATIONS 6

1.5.1 Casting 6

1.5.2 Powder Metallurgy 6

1.5.3 Fabrication Of MMC 7

2 LITERATURE SURVEY 8

3 PROBLEM IDENTIFICATION 15
3.1 FSP ON DIFFERENT MATERIALS 15

3.1.1 FSP on Aluminium Alloy 15

3.1.2 FSP on Mg-Al-Zn Alloy 16

3.1.3 FSP on Copper Alloy 17

4 METHODOLOGY 18
4.1 MATERIAL SELECTION 19

vi
 4.2 MATERIAL PROPERTIES 20

4.2.1 Properties of Copper 20

4.2.1.1 Physical Properties 20

4.2.1.2 Chemical Properties 20

4.2.2 Properties of Lead 21

4.2.2.1 Physical Properties 21

4.2.2.2 Chemical Properties 21

4.2.3 Properties of Tin 21

4.2.3.1 Physical Properties 21

4.2.3.2 Chemical Properties 22

4.3 TOOL SELECTION 22

4.3.1 DOUBLE TEMPERING 22

4.4 FSP PROCESS 23

5 EXPERIMENTAL WORK 24

5.1 TOOL SPECIFICATIONS 24

5.2 SPECIMEN MATERIAL SPECIFICATIONS 26

5.3 PARAMETERS OPTIMISATION 27

5.4 PROCESSED SPECIMEN 28

6 RESULTS 29
6.1 HARDNESS TEST 29

6.1.1 Results Tables 30

6.2 MICROSTRUCTURAL ANALYSIS BY SEM 33

6.2.1 Microstructure of Base Metal 33

6.2.2 Microstructure of Processed Specimens 35

vii
7 BILL OF MATERIALS 44

8 CONCLUSION 45
REFERENCE 46

vii
i
 LIST OF FIGURES

FIGURE No. DESCRIPTION PAGE No.

1.1 FRICTION STIR WELDING 1

1.2 FRICTION STIR PROCESSING 2

1.3 VARIOUS TOOL PROFILES 4

4.1 MATERIAL COMPOSITION REPORT 19

4.2 FSP PROCESS ON THE BASE METAL 23

5.1 SOLIDWORKS DRAFT OF THE TOOL 24

5.2 TOOL PROFILE 25

5.3 PIN PROFILE 25

5.4 CAD DRAWING OF THE SPECIMEN 26

5.5 PROCESSED SPECIMEN 28

ix
 LIST OF TABLES

TABLE No. DESCRIPTION PAGE No.

1.1 EFFECTS OF VARIOUS TOOL PROFILES 5

3.1 MATERIAL COMPOSITION OF AA5083-O 15

5.1 PARAMETERS FOR THE PROCESS 27

7.1 BILL OF MATERIALS 44

x
 CHAPTER 1

INTRODUCTION

1.1.FRICTION STIR WELDING :

Friction Stir welding is a welding process which is done in the solid state by
stirring the interfacing edges of the workpiece by friction. This does not melt the
welding area as the heat produced is not enough to melt the metal, but this
process leads to a zone which is softened and then plasticization occurs to
produce the weld. This process was invented by Wayne Thomas in the year
1991. This process is used to join either metals or plastics. But the heat and also
the pressure used to produce the friction on the plastic surface is much lower
than the heat and pressure used on the metal surfaces. The schematic working
diagram of the Friction Stir Welding is given below.

Fig 1.1 Friction Stir Welding

1
1.2.FRICTION STIR PROCESSING :

Friction stir processing (FSP) is the process of modifying the surface properties
of a metal by plastic deformation at that localised area. This is an energy
efficient process , eco-friendly and also a versatile process. This process is more
beneficial than the modification of the bulk material as it is a very tedious
process and also involves a lot of labour and cost. This process is inherited from
the process Friction Stir Welding where the rotating tool travels along the
joining edge of the two work pieces and stirs the area through friction thereby
producing the weld. But in this process the surface modification is produced by
inserting a non- consumable revolving tool into the work piece in a rotatory
motion as well as it is moved in the lateral direction through the work piece. A
schematic diagram of the process is shown in Fig 1.1

Fig 1.2 Friction Stir Processing

2
1.3.PROCESS :
In friction stir processing (FSP), a rotating tool with a pin and a shoulder is used
on a piece of metal plate to enhance the properties, such as improving the
toughness of the material, and also the micro-structure of the material by
improvising the grain of a second material which in turn improvises the first
material. The tool is inserted in a vertical centered rotating machine and the
workpiece is fixed in the anvil using vises. Here we can alter the rotating speed
of the tool and also the velocity with which the tool traverses along the
workpiece. Since the rotating tool stirs the workpiece, it will cause vibrations
which is to be removed accordingly by fixing the workpiece strongly by the
vise. As a result of the stirring process by the tool on the workpiece, friction is
produced between the tool and work piece, the work piece softens and
plasticizes. The processed zone cools and there will be no solidification process
as there is no liquid metal, which results in the formation of a defect-free
recrystallized fine grain microstructure. Due to the friction produced the
material gets processed from the front end to the rear end. During this process,
the material undergoes intense plasticization and this results in significant grain
refinement. While mixing with the second material with the first, the grain
refinement occurs on the base material. This improves the base material’s
properties.
The Friction stir process can also distinguished by the number of passes that is
done on the material. Increase in the number of passes enhances the grain
structure refinement more and we can obtain an increase in the properties when
compared to single pass FSP. This allows for a variety of materials to be
enhanced to make the changes for things that may require other difficult to
acquire conditions. This process is a branch of friction stir welding (FSW)
which applies the same technique to weld two pieces of different materials
together without heating, melting, or having to change the materials physical
state.
3
1.4.TOOL :
The tool plays a vital role in the processing of the final product. It has two main
functions:
1. Localized heating
2. Material flow
As the tool plays a significant role in the process, there are different tool profile
which plays a variety of roles in the process. Various tool profiles are described
below with a diagram.

Plain Threaded Tri-flute Triangle Square Hexagonal

cylindrical cylindrical profile profile profile profile
profile profile

Fig 1.3 Various Tool Profiles

4
1.4.1.EFFECTS OF VARIOUS TOOL PROFILES :

TOOL
S.No EFFECTS
PROFILE

At low rotational speed, no stirring action is

Plain produced because the speed is not adequate to stir
1
Cylindrical the material for processing and also insufficient heat
is produced
which results in an irregular surface in processing.
The processed surface has a reasonably good finish
and a good stirring action has been done on the
Threaded
2 surface which is indicated by the compression of
Cylindrical
materials on the top surface. Flash is produced
during
the plunge
The finish and processing of the surface is better even
3 Tri-flute at low input condition and it also resulted in less flash
during the plunge.

Due to the triangular profile, there is an inadequate

4 Triangle movement over the surface of the material and there
is not enough heat to produce the stirring action.

The finish and the compression produced due to the

5 Square stirring action is better and this profile of tool
produced more heat and also flash

Comparing all the other profile, this particularprofile

of the tool produced a good surface finish and also
6 Hexagonal
the necessary heat and flash to result in a good
compression of the material.

5
Table 1.1 Effects of Tool profiles

6
1.5.APPLICATIONS :
The Friction stir processing is used where the surface properties of a metal is to
be modified by using another metal which is used as a tool to improve the
properties of the first. This process proves to be a major upliftment in the
aerospace and automobile industries where new materials are to be introduced to
enhance the resistance to creep, wear and also fatigue. Some of the fields where
Friction stir processing is employed are
1. Casting
2. Powder Metallurgy
3. Fabrication of metal matrix composites
1.5.1.CASTING :
When a metal part is fabricated by the casting process, it may be an inexpensive
process but the part which is produced by casting will always suffer from
metallurgical flaws such as porosity and also some microstructural defects.
Friction Stir processing can be introduced into the casted metal part which may
be of any material and it proves helpful in eliminating the defects. When the
casted metal part is vigorously stirred by Friction stir processing it homogenizes
the surface and reduces the size of the grain while the strength and ductility are
increased.

1.5.2.POWDER METTALURGY :

The microstructural properties of the powder metal objects can be improved by

Friction stir processing. In particular while dealing with aluminium powder
metal objects, a film of aluminium oxide is produced on the top layer which
determines the fatigue properties, ductility and also the fracture toughness of the
metal piece. Some of the conventional techniques like extrusion and forging is
used to remove the film earlier,but now Friction stir processing is widely used to
provide localized treatment where it is desired to be done. While comparing to
forging
7
and extrusion, friction stir processing is cheaper and does’nt involve much labor
and cost.
1.5.3.FABRICATION OF METAL MATRIX COMPOSITES :

Fabrication of Metal Matrix Composites at the nugget zone where we need the
change in the physical properties can be done by Friction Stir Processing. Some
of the successfully fabricated composites are Al5052/SiC , AA 7075, etc..
Fabrication of nano composites is also possible by this process.

8
 CHAPTER 2

LITERATURE SURVEY

Tuomo Nyyssönen et al. (2012) performed pin-on-disk wear tests of

Continuously cast, centrifugally cast, and sand casted leaded tin bronze
samples with varying lead content under dry conditions. It was proposed that
the casting method has a significant effect on the wear behaviour of leaded tin
bronzes. Coarseness of the distribution of lead particles in the copper matrix
was found to be the dominant wear mechanism. Sand casting produced a
coarse microstructure which promoted the formation of transfer layers.
Continuous casting produced fine lead distribution that promoted micro-
cracking and rapid, stable wear with less friction. Increasing the lead content
lowered the friction coefficient in all the three cases and especially lowered
the wear rate also in the case of continuous cast alloy. Centrifugally casted
samples exhibited two wear mechanisms, i.e., rapid wear through micro-
cracking and transfer layer formation.

Louisa Meshi et al. (2010) performed wear test using rings of hardened
AISI 51100 steel which were made to slide against block of pure copper by
using six drops of synthetic oil PAO-4 per minute as lubricant. A variation in
load between 90 and 420 N was provided along with variation of sliding
velocity in the range of 0.1 – 1 m/s. The Boundary lubrication and Elasto-
Hydrodynamic regimes of Virgin Copper and after friction were studied and
the plastic and elastic properties of the surfaces were compared. The
deformation hardening of surface layers, friction coefficients and wear rate of
BL regime was high when compared to EHL regime which was attributed to
severe direct asperity contact that caused plowing of soft layers of the copper
and delamination of wear particles in the BL region

9
 E. Huttunen-Saarivirta (2019) compared the tribocorrosion behaviour of
Aluminium Bronze (Cu-10Al-5Fe-5Ni) and leaded tin bronze (Cu-10Sn-10Pb)
in simulated sea water. The alloys were machined into discs and an alumina ball
of 10 mm diameter was used as the counterbody in a pin-on-disk tribometer.
The tests were performed in an electrochemical cell attached to the tribometer
and filled with 3.5 wt.% NaCl solution. The disc specimen fastened to the
specimen holder was used as the electrode, platinum ring at the cell periphery
acted as the counter electrode and Ag/AgCl was the reference electrode. The
tests were performed under two conditions: with alumina counterbody and
without alumina counterbody to evaluate the relation between corrosion and
wear processes. Leaded tin bronze had more tribocorrosive losses than
aluminium bronze under identical test conditions. The predominant wear
mechanism for both alloys was wear included corrosion. Also, the
dissolution rate of leaded tin bronze was much higher than that of aluminium
bronze

Alexey Moshkovich et al. (2011) performed wear test using block-on-ring

setup where the rings were made from hardened AISI 51100 steel and block
material was pure Copper. The friction and wear results were made into a
Stribeck curve by considering the Boundary lubrication, Elasto-hydrodynamic
and Mixed lubrication regimes. The friction coefficient and wear rate increased
in the following order: EHL < ML < BL. The low values in the EHL regime
have been attributed to the formation of a tribofilm which decreased the friction
between the surfaces, thereby reducing the damage to the surface of copper
during direct contact. It was also confirmed through XPS analysis that fresh
metallic regions get.exposed.regularly.

Daniel W. Gebretsadik et al. (2015) examined the tribological

performance of tin-based overlay and lead-based
10
overlay plated engine bearing
materials using a block-on-ring setup under mixed and boundary lubrication
condition. Three samples were taken as: Bi containing bronze lining with Sn
overlay, bronze lining with Sn overlay and Pb containing bronze lining and Pb
based overlay with Sn flash coating. Low sulphated ash, phosphorous and
sulphur and fully formulated engine oil was used as lubricant. Friction
coefficient was found to be decreasing with increase in rotational speed in all
the three samples and the transition in friction was also found to similar in both
Sn and Pb based overlays. Steady sate friction behaviour was found to be
similar and followed the same trend. Wear resistance of Sn and Pb based
overlays were more or less similar but at higher speeds, Pb overlay showed
higher wear. The worn surface of Pb overlay showed clusters of tiny spots of
material removed from the overlay along with compositional changes. Few parts
of Sn overlay exhibited abrasive wear and exposed interlayer due to adhesive
wear .

S. Baskar and G. Sriram (2014) performed experiments to study the

tribological behaviour of journal bearing material (Cu-34Zn-2Pb) under
lubricants such as SAE 20W40, Chemically Modified Rap-seed Oil (CMRO)
and Nano Additive Chemically Modified Rap-Seed Oil (NACMRO)using a pin-
on- disk tribometer. It was observed that the friction coefficient value and wear
value of specimen lubricated with CMRO was high when compared to that of
SAE 20W40 and NACMRO. Also, the friction coefficient value and wear value
decreased with adding more nano CuO particles to CMRO which was attributed
to the spherical rolling medium of nano CuO particles between the contacting
surfaces when boundary lubrication occurred. The increase in wear resistance na
decrease in frictional force was again attributed to the nano Cuo particles in
CMRO. It was also observed that the specimen lubricated with SAE 20W40 had
pits and cavities. The number of pits and cavities varied with lubricant used and
was found to ascend in the following 11
order: NACMRO < SAE 20W40 <
CMRO.

12
 B.K. Prasad (2012) performed wear test of leaded tin bronze bushing by
varying loads and test environments against a steel shaft. The lubricant was
added with solid lubricants such as lead, talc and mixture of both (1:3 to 3:1) to
alter the test environment. The wear response was superior in the case of
mixture of solid lubricants along with liquid lubricant, i.e., the wear rate,
frictional heating and friction coefficient reduced significantly. However,
increased fraction of lead in the mixture offered better wear performance of the
bushing. The wear rate, frictional heating and friction coefficient was found to
be directly proportional to the load and test duration. Also, the rate of change of
these parameters reduced at longer test durations. Adhesion was found to be an
important wear mechanism. The wear surfaces were smoother in general at
lower loads and in the presence of lead and/or talc in the liquid lubricant that led
to the improved wear performance and vice-versa.

Tuomo Nyyssönen et al. (2012) performed pin-on-disk wear tests of

Continuously cast, centrifugally cast, and sand casted leaded tin bronze samples
with varying lead content under dry conditions. It was proposed that the casting
method has a significant effect on the wear behaviour of leaded tin bronzes.
Coarseness of the distribution of lead particles in the copper matrix was found
to be the dominant wear mechanism. Sand casting produced a coarse
microstructure which promoted the formation of transfer layers. Continuous
casting produced fine lead distribution that promoted micro-cracking and rapid,
stable wear with less friction. Increasing the lead content lowered the friction
coefficient in all the three cases and especially lowered the wear rate also in the
case of continuous cast alloy. Centrifugally casted samples exhibited two wear
mechanisms, i.e., rapid wear through micro-cracking and transfer layer
formation

Marke Kallio et al. (2013) examined

13
and compared the tribological
behaviour of variety of bronze alloys, i.e., Copper-tin-lead alloy, copper-tin-
graphite alloy, and copper-tin-bismuth alloy. This experiment was performed in
order to look for a suitable replacement for lead in bronze alloy because of its
negative impact on the environment. Out of the selected alloys, lead was found
to have best solid lubrication properties which is the main advantage of lead
over other elements. With the initial percentage of bismuth selected in the alloy
composition, it was not able to perform to the level of lead. But with increased
percentage of bismuth percentage, it showed similar properties to that of lead
alloy and the reason was partially attributed to the higher hardness of bismuth
compared to lead. Also, the friction coefficient of bismuth bronze was higher
when compared to leaded bronze which caused adhesion wear mechanism
between the contact surfaces. In case of graphite bronze, the formation of
lubrication transfer layers was very weak and thin which may have vanished as
the load increased. In total, it was proposed that, a suitable replacement to
leaded tin bronze cannot be found just by replacing lead with bismuth or
graphite.

P. Senthil Kumar et al. (2013) examined the tribological behaviour of Cu-

Sn alloy containing Molybdenum disulphide which was added as a
reinforcement in various compositions and was compared with the base metal.
The samples were: Cu-Sn alloy without MoS 2, Cu-Sn-1%,5% and 7% of MoS 2.
Parameters such as load, reinforcement percentages, sliding speed and sliding
distance were varied to check the influence on specific wear rate and coefficient
of friction. The wear tests were performed using a pin-on-disk tribometer under
dry conditions. The base alloy exhibited high values of friction coefficient and
specific wear rate because of direct metal-to-metal contact. It was observed that
the friction coefficient and specific wear rate values decreased with increasing
load. The alloy with 7% of MoS2 was found to be the most wear resistant with least
friction coefficient and specific wear rate. This was because of formation of a
tribofilm between the contact surfaces that acted as a lubricant and also, strong
14
bond between the matrix and MoS2 protected the surface from severe wear. It was
also revealed from SEM studies that delamination wear was the major wear
mechanism for Cu-10 Sn-7 MoS2 . .

Rahul Gupta et al. (2015) examined the microstructure,

mechanical properties, and wear rate of high leaded tin bronze before and after
Multi Directional Forging (MDF) which was compared later. MDF was
performed up to 9 passes in all directions and MoS 2 was used as lubricant during
forging process. Polishing and etching was performed using a solution of 25 ml
ammonia hydroxide (NH4OH), 25-50 ml of 3% hydrogen peroxide (H 2O2) and
25 ml distilled water to prepare the samples for OM. The Optical Micrographs
also revealed that the increase in applied strain with number of passes
distributed the coarser lead particles and copper tin compound into finer grain
size. Pin-on-disk setup was used to perform dry sliding wear tests. Increase in
number of passes in MDF resulted in improved wear resistance. The wear rate
decreased with increase in sliding distance for both the cases. In the case of a
small distance, the wear rate was less, and it increased with increase in sliding
distance. It was also observed that the wear rate of sample with MDF was less
when compared to that without MDF which was attributed to the hardness and
refined grain structure obtained during MDF. The increase in hardness was
obtained by grain and crystal refinement process that increased the wear
resistance of the alloy
Gongjun Cui et al. (2012) performed sliding of Cu-6Sn-6Zn-
3Pb alloy against AISI321 stainless steel with sea water, distilled water as
lubricants and also in dry conditions to examine the tribological behaviour. The
specimens were cut using EDM process and prepared thoroughly before
performing the wear tests. It has been proposed that the testing environment
affects the behaviour of the material considerably. Friction coefficient was
observed to ascend in the following order: Dry sliding < Sea water < Distilled
15
water. In dry sliding and distilled water sliding, the wear mechanism was
microplough and plastic deformation, whereas in sea water sliding, the wear
mechanism was microplough, plastic deformation as well as corrosive. Sea
water exhibited lubricating effect, cooling effect and corrosive effect. Though
sea water reduced the friction coefficient of the specimen, it increased the
specific wear rate of the specimen, i.e., friction coefficient was newly found to
be inversely proportional to specific wear rate in sea water sliding conditions.
V. Ruusila et al. (2013) examined and compared the
tribological properties of leaded tin bronze by varying the lead content as well as
the casting method of the alloy. Experiments such as thrust bearing test, pin-on-
disk test as well as ball- on-disk test was performed to reveal different properties
of the alloys. The alloy samples were prepared using sand, centrifugal and
continuous casting methods to obtained varied microstructures. A steady state of
sliding was achieved rapidly in the case of Continuous cast alloy along with
low, stable friction coefficient. However, sand and centrifugally casted alloys
were characterised with irregular friction throughout the tests. Also, the wear
rate of continuous cast alloys was very high than the others. The casting method
did not have any significant difference on the performance in thrust bearing test.
It was also evident that the casting method had a significant effect on the wear
behaviour. The size and amount of lead had a significant effect on wear
behaviour in dry sliding conditions. Microcracking aided wear was observed in
pin-on-disk test. It was proposed from bearing test and pin-on-disk test that it
was possible to influence the behaviour of the material towards crack initiation
and delay the seizure of the bearing even with a small amount of lead. Ball-on-
disk tests confirm the capability of lead to smear across sliding surfaces,
preventing adhesion and limiting the friction and wear in the contact area

B.K. Prasad (2011) performed wear test of leaded tin bronze by making it
into a bearing. The bush was made with leaded tin bronze of 25.4 mm
16
diameter, 19.50 mm inner diameter and length of 19.50 mm. The shaft was made
using En24 steel which was roughly up to SAE 4340 steel. SAE 40 was used as
the liquid lubricant to which 0 – 10% of solid lubricants such as graphite, talc and
lead were added to perform wear tests where the percentage of these individual
solid lubricants significantly decided the wear behaviour of the bushes. As the
percentage of solid lubricant kept increasing, properties such as frictional heating,
wear loss and friction coefficient started decreasing and the vice-versa occurred
after reaching a percentage of about 3 – 5%.

17
 C HAPTER 3

IDENTIFICATION FSP ON DIFFERENT

MATERIALS :

There are many projects done on friction stir processing on various materials.
We have studied some of those existing materials and decided to do the work on
a copper based alloy due to the problems that arise while performing the process
with other materials . Some of the materials where we underwent a study are
given below.

FSP ON ALUMINIUM ALLOY :

The results of the friction stir processing of an aluminium alloy of AA5083-O
and AA7022-T6 are taken into account during the selection of our project. It
consisted of the following chemical compositions.
ELEMENT % COMPOSITION
Fe 0.40
Si 0.60
Mn 0.4-1.0
Cu 0.100
Mg 4.00 – 4.90
Ti 0.150
Zn 0.250
Cr 0.050 – 0.250
Al Balance

Table 3.1.Material Composition of AA5083-O

The above table gives the chemical composition of the aluminium of grade
AA5083-O.

The results of this work clearly indicates that a softened area of the material has
evidently occurred in welded joints by frictionally stirring them and the AA5083
aluminum alloy exhibited the tensile properties of the processed zone are lower
18
when compared to those of the base material. The parameters used for the
welding play a significant role on the tensile behavior and fracture spots of the
joints. When the rotational pitch value is above the specific value, some void
defects takes place at the joints, and so the tensile behavior of the joints
extensively deteriorate, and the joints get fractured at the nugget edge of the
weld on the advancing side. But on the other side, when the rotary pitch is below
the specific value, no defects were observed over the joints, and the tensile
behavior of the joints are also at a comparatively higher level, and the joints gets
nearly fractured in the weld center. At an optimized revolutionary pitch value of
0.03 mm/r, the peak strength of the joint is observed to be equivalent to 73%
than that of the base material.
FSP ON Mg-Al-Zn ALLOY :
When the casted product of a Mg–Al–Zn alloy was exposed to friction stir
processing and consequent aging process, it lead to a substantial breakup in the
casted product and the coarse particles got dissolved and a eutectic b-Mg17Al12
phase dispersed like a network at the grain boundaries and significant
refinement of grains occurs, leading to an improvement significantly in the
tensile behavior of the casting. The friction stir processed Mg–Al–Zn specimen
showed an ultimate tensile strength of about 338 MPa and an elongation of
about 10% that of the pure one. When friction stir processing is combined with
aging it proves to be a simple and an effective way to boost the mechanical
behavior of Mg–Al– Zn casting. This work on the casted Mg–Al–Zn alloy
proves to be a failure one in terms of enhancing the properties of the material
both in mechanical and tribological ways.
FSP ON COPPER ALLOY :
The material with the compositions mentioned in Table 3.2 is studied, And it
had been found that the grain size of the copper alloy processed by FSP was
refined microstructure by the extraordinary plastic deformation. FSP method

19
improved

20
and increased microhardness property of copper alloy than unprocessed copper
alloy. the upper hardness of materials method by FSP causes a better mass loss
than within the as-received material and this appears to be inconsistent with the
standard Friction stir method may be a sensible material process that may be use
in industrial applications.

21
 CHAPTER 4

METHODOLOGY

LITERATURE SURVEY

PROBLEM IDENTIFICATION

MATERIAL SELECTION FOR

TOOL AND BASE METAL

OPTIMIZING THE PARAMETERS

FSP ON THE BASE METAL

MATERIAL TESTING

RESULT ANALYSIS

22
MATERIAL SELECTION :
By referring to the various journals, the material to be processed was finalized
to copper based bearing alloy as the other materials produced flaws during the
course of the process. The material composition was investigated through a lab
and the chemical analysis report is given below

Fig 4.1 Material Composition Report

23
 MATERIAL PROPERTIES :
The properties of the major constituents of the selected alloy are given below.
The major constituents are Copper (Cu), Lead (Pb) and Tin (Sn).
PROPERTIES OF COPPER :
PHYSICAL PROPERTIES :
Copper is located in the column eleven of the periodic table and it has only one
s-orbital electron on the top of a packed d-electron shell and then it is
characterized by high plasticity, and electrical and thermal conducting
properties. The softness of the copper material is the main reason behind the
high electrical and thermal conducting properties of copper.Copper can be
readily joined or processed with other elements effortlessly. At the
macroscopical scale, introduction of extended defects to the Bravais lattice, like
grain boundaries, hinders flow of the fabric underneath applied stress, thereby
increasing its hardness. For this reason, copper is typically provided in an
exceedingly fine- grained crystalline type, that has bigger strength than mono-
crystalline forms.The softness of copper part explains its high electrical physical
phenomenon (59.6×106 S/m) and high thermal physical phenomenon, second
highest (second solely to silver) among pure metals at temperature. this is often
as a result of the ohmic resistance to negatron transport in metals at temperature
originates primarily from scattering of electrons on thermal vibrations of the
lattice, that area unit comparatively weak in an exceedingly soft metal.
CHEMICAL PROPERTIES :
Copper doesn't react with water, however it will slowly react with atmospherical
air to make a layer of brown-black oxide that, not like the rust that forms on iron
in wet air, protects the underlying metal from additional corrosion . A
inexperienced layer of copper carbonate will typically be seen on previous
copper structures, like the roofing of the many older buildings.

24
 PROPERTIES OF LEAD :
PHYSICAL PROPERTIES :
Pure lead encompasses a bright silvery look with a touch of blue. It tarnishes on
contact with wet air, and takes on a uninteresting look the hue of that depends
on the prevailing conditions. Characteristic properties of lead embody high
density, plasticity, and high resistance to corrosion (due to passivation).
Lead's compact face-centered cubical structure and high relative atomic mass
end in a density of eleven.34 g/cm3, that is bigger than that of common metals
like iron (7.87 g/cm3), copper (8.93 g/cm3), and Zn (7.14 g/cm3). This density
is that the origin of the idiom to travel over sort of a lead balloon.
CHEMICAL PROPERTIES :
Bulk lead exposed to wet air forms a protecting layer of variable composition.
white lead could be a common constituent and a few quantities of the sulphate
or chloride may additionally be gift in urban or maritime settings. This layer
makes bulk lead effectively with chemicals inert within the air. Finely powdery
lead, like several metals, is pyrophoric, and burns with a bluish-white flame.
PROPERTIES OF TIN :
PHYSICAL PROPERTIES :
Tin is a delicate, pliant, flexible and exceptionally crystalline shiny white metal.
At the point when a bar of tin is twisted, a snapping sound known as the "tin
cry" can be gotten notification from the twinning of the gems. Tin dissolves at
the low temperature of around 232 °C (450 °F), the most minimal in bunch 14.
The dissolving point is additionally brought down to 177.3 °C (351.1 °F) for 11
nm particles. β-tin (the metallic structure, or white tin). Interestingly, α-tin
(nonmetallic structure, or dim tin), which is steady underneath 13.2 °C (55.8
°F), is fragile. The gem structure of α-tin is a precious stone cubic gem
structure, like jewel, silicon or germanium. α-tin has no metallic properties
at all since its

25
 molecules structure a covalent structure. It is a dull-dark fine material with no
regular uses other than a couple of specific semiconductor applications.

CHEMICAL PROPERTIES :
Tin opposes erosion from water, however can be assaulted by acids and soluble
bases and can be profoundly cleaned and is utilized as a defensive coat for
different metals. A defensive oxide (passivation) layer avoids further oxidation,
a similar that structures on pewter and other tin amalgams. Tin goes about as an
impetus when oxygen is in arrangement and quickens concoction assault.
TOOL SELECTION :
After briefly studying various journals about the profile of the pin of the tool
and their parameters, we selected the profile of the pin to be a hexagonal pin
profile with a pin diameter of 6 mm and the shoulder diameter to be 18 mm.The
tool was fabricated with a Tungsten Carbide tool steel which is double tempered
and it provides high resistance to heat. The profile of the pin was selected to be
a hexagon profile because of its efficiency and smoothness which this profile
provides over the surface while undergoing the process. Other dimensions were
set according to the tool holder of the vertical machining center to be used for
the process.
DOUBLE TEMPERING :
It is the process where the samples undergo another set of the following process:
Austenitizing Tempering Oil quenching routine : Slowly heat to
1010ºC ; Room temp 200 ºC 400 ºC 800 ºC 1010 ºC.
Soak(hold) for half hour at 1010 ºC. Remove from furnace; oil quench to about
50 ºC -60 ºC. Immediately place in furnace already steadied at required
tempering temperature, hold for 2 hr. Remove from furnace ; air cool at room
temperature, at least one hr. Place in furnace steadied at the same tempering
temperature as before; hold for 2 hr. Remove from furnace ; air cool to room
temperature.

26
FSP PROCESS :

Fig 4.2 FSP Process on The Base Metal

The above figure shows the FSP process done on the base metal. This process
was done in the Vertical spindle milling machine which has a maximum
rotational speed of 4200 rpm at Coimbatore Institute of Technology on
06/01/2020.Various combinations of rotational and traverse speed were given as
inputs for the trial run and the process was observed. The rotational speed was
finally set to 1000 and 1500 rpm and the traverse speed was set to 20 and 40 m/s
and the final process was done.

27
 CHAPTER 5

EXPERIMENTAL WORK

TOOL SPECIFICATIONS :

All Dimensions are in mm

Fig 5.1 Solidworks Draft of Tool

The above figure depicts the diagrammatic details of the tool which is to be used
for the process

28
Fig 5.2 Tool profile

Pin

Fig 5.3 Pin profile

29
SPECIMEN MATERIAL SPECIFICATION :

All Dimensions are in mm

Fig 5.4 CAD Drawing of Specimen

The specifications of the Copper based specimen plate is represented in the

diagram above.

30
PARAMETERS OPTIMISATION:
After conducting various trial run’s, the parameters were finalized to the data
given below

Traverse
Specimen No. Load(kN) Rotational Speed(rpm)
Speed(mm/min)

1 1000
20
2 1500
30
3 1000
40
4 1500

Table 5.1 Parameters for the Process

The above combinations of rotational speed and traverse speed was used for the
process and various processed surfaces was produced. Different tests such as
Hardness and Microstructural analysis by SEM were carried out on the
processed zones.

31
PROCESSED SPECIMEN :

Fig 5.5 Processed Sample Specimen

After the completion of the Friction stir processing on the material , the
specimens were tested and analyzed by the following tests.
 The Vicker’s microhardness test was performed in Bannari Amman
Institute of Technology on 18/02/2020.
 The microstructural analysis of the specimens are carried out by using a
Scanning Electron Microscope (SEM) available at PSG college of
technology on 11/03/2020

32
 CHAPTER 6
RESULTS
HARDNESS TEST :

 With reference to the Table 5.1, different processed zones are obtained.
The processed zones are cut in a dimension of 10*10*8 mm by the help
of Wire EDM and these cut samples are used for the hardness test.
 The Hardness are carried out for five samples which are labelled as BM,
SM1, SM2, SM3, SM4 which is indicated in the processed specimen in
the Fig 5.5.
 Vickers Hardness test is carried out for obtaining the microhardness of
the various processed and unprocessed zone to obtain a clarification
between the effect of the process on the samples.
 The Vickers hardness test is carried out on ASTM standards using a
diamond type 10mm ball intender with a load of 5 kgf and a dwell time of
10 sec.
 The results of the Vickers Hardness test performed on the various
samples and the various zones of the specimen are listed below in the

1 - Retreating side

2 - Pin travel zone

3 - Advancing side

1 2 3 29

tables.
RESULTS TABLE :
Specimen No: 1

Zone Hardness (HV)

Base Metal 92.5

1 86.3

2 142.5

3 101

Table 6.1 Hardness result for Specimen No.1

Specimen No: 2

Zone Hardness (HV)

Base Metal 70.24

1 91.0

2 173.0

3 73.1

Table 6.2 Hardness result for Specimen

30
 Specimen No: 3

Zone Hardness (HV)

Base Metal 96.3

1 94.0

2 178

3 95.0

Table 6.3 Hardness result for Specimen No.3

Specimen No: 4

Zone Hardness (HV)

Base Metal 74.8

1 89.0

2 259.0

3 108.0

Table 6.4 Hardness result for Specimen No.4

31
The Vickers hardness test was performed for all the four samples at different
ones and we can infer some details from the results found. Some of the
inferences made are:
1. We can observe that at the pin travel zone the hardness value obtained is
higher than the other zones of the sample space, since the plasticization is
more at the pin stirring zone the hardness is higher than the other areas.
2. The hardness of the zones improve as the combination of speed increases
as the friction produced due to stirring action is more than that of at lower
speeds.

32
 MICROSTRUCTURE ANALYSIS BY SEM:
MICROSTRUCTURE AND XRD OF BASE METAL:

Fig 6.1 Microstructure of the base metal

33
Fig 6.2 XRD result of the base metal

34
MICROSTRUCTURE AND XRD OF PROCESSED SPECIMENS:

Fig 6.3 Microstructure of the Specimen No.1

35
Fig 6.4 XRD result of the Specimen No.1

36
Fig 6.5 Microstructure of the Specimen No.2

37
Fig 6.6 XRD result of the Specimen No.2

38
Fig 6.7 Microstructure of the Specimen No.3

39
Fig 6.8 XRD result of the Specimen No.3

40
Fig 6.9 Microstructure of the Specimen No.4

41
Fig 6.10 XRD result of the Specimen No.4

42
The Microstructural analysis results are established above for the Base metal
and the processed specimens.

Here there are different colored zones in the images which are represented in the
table.

The Black region in the microstructure image indicates the

Black
amount of Tin in the surface.

The White region indicates the amount of Lead in the

White
surface

The remaining zone in the surface is the alpha rich copper

Grey
on the surface.

The microstructural analysis provides us the details of the grain refinement and
the improvement in the grain size. Due to the strain hardening process that takes
place due to the friction due to stirring action, the zone plasticizes and plastic
deformation occurs. But there is no inter-metallic compound formation on the
surface matrix of the alloy. From the microstructural analysis images we can
infer that the zone has been plasticized well and the hardness has also been
improved.

43
 CHAPTER 7

BILL OF MATERIALS

AMOUNT
S.No CONTENT SPECIFICATIONS QUANTITY
(Rs.)

Copper Alloy
1 100*100*8 mm 3 Kg’s 4,000
plate

Wire EDM , FSP

2 Machining Cost - 3,500
Process

Fabrication of H13 (double

3 1 1,500
tool tempered)

4 SEM and - 5,310

XRD Tests -

Total - 14,310

Table 7.1 BILL OF MATERIALS

44
 CHAPTER 8

CONCLUSION

The Friction stir processing on various specimens had been carried out at
different combinations of rotational speed of the tool and also traverse velocity.
The results obtained by this process clearly indicates that the hardness and grain
structure of the top surface of the specimen have improvised. An uniform and
refined grain structure is obtained. On carrying out Vicker’s hardness test , the
micro-hardness has been obtained and we can clearly infer that the hardness has
been improved compared to that of the base metal. Since this a surface
modification technique , the bulk material is not involved and extensively
reducing the cost and amount of labour involved.

45
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