PhD students

Elias Salloum

RMIT University (Supervisor: Ivan Cole)

Optimizing friction-stir welding and alloy design to ensure the durability of light weight carriages in the rail fleet

Research summary

The move to light weight structures and metals in rail fleet has significant advantages in terms of weight reduction but may have consequences in terms of joining methods and the durability of joining. This research involves the optimization of friction stir welding parameters to allow this form of welding to be an effective and durable joining method for light weight structures.

Expected completion date

September 2021

Key achievements

• After identifying that a friction stir welding machine is basically a vertical milling machine with added specialised components, creation of a friction stir welding machine specially for RMIT University.
• One of the research goals was to investigate the use of twin roll casting technology to promote ideal mechanical and physical in both the base material and weld zone. All the necessary mechanical testing and material characterisation has been conducted, with a research paper being written about the findings.
• At the start of 2020, a scope shift meant beginning to investigate the corrosions and stress corrosion cracking mechanics of friction stir welded aluminium alloys. Preliminary experimental work began in early March on the corrosion behaviour of Al-Mg-Sc alloys, and future work will focus on stress corrosion cracking susceptibility. The crux of the project is to improve the durability of friction stir welded alloys and to uncover a systematic approach in understanding how the corrosion and stress corrosion of Al-Mg alloys can be improved by processing (Twin roll casting, hot working) and alloying techniques (with valve metals).

No publications to-date