Study of the Effect of Preheating on Tool Wear in the Process of Joining Dissimilar Materials (Al6061/AISI304L) using Simultaneous Friction Drilling

Currently, dissimilar metal joining processes are receiving considerable attention in various industries. The objective is to create composite structures that are both high-strength and lightweight, ultimately reducing the weight of the final product. Researchers have recently proposed friction drilling as a new method for creating joints between dissimilar metal sheets. This innovative technique offers potential advantages in achieving the desired outcomes. In this process, metal sheets are placed on top of each other and simultaneously subjected to friction drilling. As a result, this process not only creates an effective space for tapping but also establishes a frictional joint between the two sheets. Research has shown that preheating up to 350°C can have desirable effects on reducing the gap between the two sheets in the vicinity of the created joint between aluminum and stainless steel using the above-mentioned method. In the upcoming work, the effect of preheating on tool wear in simultaneous friction drilling of aluminum sheet AA6061T6 and stainless steel AISI304L using a tungsten carbide drilling tool has been experimentally analyzed, and the findings indicate that increasing the preheating temperature up to 350°C leads to a 13.77% increase in tool adhesive wear and a 0.46% increase in tool abrasive wear.