Mounarik - Research interest and projects

Research Interest

Reduction of fuel consumption and harmful emission most of the practical industrial components requires to be manufactured by incorporating lightweight non-ferrous materials and ultra high strength thin ferrous materials. Manufacturing such structures sincerely involves the welding and forming process. To address the above issue while quantifying its benefits and success my research work is focused on the mentioned topics below

1) Friction stir welding and processing of steel, aluminum, magnesium, copper

2) Friction stir assisted simultaneous joining and forging of bimetallic components

3) Laser aided manufacturing

4) Material characterization tools (optical microscopy, SEM, EBSD, TEM, EPMA)

5) Mechanical testing

Ongoing and accomplished research works

1) Characterization of Friction Stir Welded Joint of Low Nickel Austenitic Stainless Steel and Modified Ferritic Stainless Steel

Friction stir welding (FSW) of dissimilar stainless steels, low nickel austenitic stainless steel and 409M ferritic stainless steel, is experimentally investigated. Process responses during FSW and the microstructures of the resultant dissimilar joints are evaluated. Material flow in the stir zone is investigated in detail by elemental mapping. Elemental mapping of the dissimilar joints clearly indicates that the material flow pattern during FSW depends on the process parameter combination. Dynamic recrystallization and recovery are also observed in the dissimilar joints. Among the two different stainless steels selected in the present study, the ferritic stainless steels show more severe dynamic recrystallization, resulting in a very fine microstructure, probably due to the higher stacking fault energy.

2) Local enhancement of the material properties of aluminium sheets by a combination of additive manufacturing and friction stir processing

Friction stir processing (FSP) is combined with additive manufacturing (AM) with selective laser melting to locally enhance the material properties of a metallic part. A groove inside aluminium 1060 alloy sheet is filled with an aluminium 7075 alloy powder by AM. FSP is then applied to the AMed region along the groove. The suggested technique creates a heterogeneous microstructure with alternating reinforcement-enriched and matrix-enriched regions. While the overall hardness of the stir zone (SZ) increases significantly, the heterogeneous microstructure results in a unique uneven hardness distribution in the SZ. Tensile tests confirm the effectiveness of the suggested technique.

3) Manufacturing of magnesium/aluminum bimetallic ring components by friction stir assisted simultaneous forging and solid‑state joining

A bimetallic ring component is forged by a friction stir assisted forging (FS-forging). A cylindrical bimetallic blank, magnesium AZ31 cylinder (Mg core) tightly fitted inside an aluminum 6061-T6 tube (Al skin), is used. In the FS-forging, the frictional heat and stirring of the rotating tool forge the blank into the desired shape, while simultaneously generating a solid-state joint between the Mg core and the Al skin, without additional external heating, as confirmed by the microstructural analysis and mechanical tests. The microstructural analysis also shows that the characteristics of the solid-state joint can be different depending on the process parameters.

4) Friction Stir Dissimilar Butt Welding of Mild Steel and Aluminum 5052-O Alloy

5) Characterization of friction stir spot welded dissimilar ultra high strength dual phase (DP) and complex phase (CP) steels

6) Simultaneous friction stir joining and forging for manufacturing of aluminum/copper bimetallic ring components

7) Friction stir welding of AA3003-clad AA6013: microstructure, tensile properties, and fatigue behavior

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