Joining Performance Of Aluminum T6063 Using GMAW Welding.
UNIVERSI TI TEKNIKAL MALAYSIA (UTeM)
Joining Performance of Aluminum T6063 Using
GMAW Welding
Dissertation Submitted of the Faculty of Manufacturing Engineering in
Partial Fulfillment of the requirement for The Awards of the Degree of
Bachelor of Manufacturing Engineering (Manufacturing Design)
Mohd.Azme1 Bin Aziz
APRIL 2008
UTeM Library (Pind.112007)
fe
*C
A
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
*%"
-
JOINING PERFORMANCE OF ALUMINUM T6063 USING
GMAW WELDING
JUDUL
:
SESl PENGAJIAN
a ~ a
-
2005 2008
MOHDAZMEL BIN AZlZ
mengaku membenarkan tesis (PSMISarjanalDoktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
.
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **%la tandakan (4)
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
SULK
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
TlDAK TERHAD
M.
(TANDATANGAN PENULIS)
Alamat Tetap:
N0.185-A KG TIT1 BESI,
06200 KEPALA BATAS,
ALOR STAR, KEDAH DARUL AMAN.
Tarikh:
3 a \ 5 / ~ d ~ &
I
'
Tarikh:
>a
I$
/JO~$
" Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau
disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
'"Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan
denqan menvatakan sekali sebab dan temwh tesis ini perlu dikelaskan sebaqai SULIT atau TERMD.
UECLAKA'I'IUN
"I hereby declare that thrs wrltlng IS my ortglnal work except tor quotatlons and
summaries, each one of which I have clearly stated its source"
Author's Name
MUW.ALMbL BIN ALlL
AYJ'KUVAL
"1 hereby declare that 1 have read the content ot the thes~sand In my oplnlon, the
content of the thesis have fulfilled the scope and quality for the purpose of achieving
the Degree ot Bachelor ot Manutactunng Englneenng (Manutactunng Ueslgn)"
Signature
Supervisor
Weldlng charactenstlcs ot Alumrnum '1'60b3 plate speclmen ot
l Omm
thickness by a Gas Metal Arc Welding (GMAW) were studied. Generally, the
composltron tor thls senes whrch are 0.9% Magnes~umand 0.6Y0 Silicon are the
highest alloying elementq. The type ol'joining was studied in this research is Butt
Jolnt and thls research are also to be studled about their performance and capablllty.
These specimens wcrc welded by certiticd and skillful bvcldcr from Nautical Line
(M) Sdn-Bhd. In thls research, there are 3 characterlstlcs 01 Alumlnum '1'6063to be
studied; impact, hardness and the defects in the joining. To perform this research,
Impact 'l'estmg Machlne, Kockwell Hardness Mach~ne,and Ultrasonic 'I'estlng
Machine are used to cany out the data to be analyzed.
Mengkaji tentang sitat-sitat bahan Alum~nium'1'6063 setebal l0mm apabila
ianya dikimpal menerusi kimpalan arka gas lengai (GMAW). Secara umumnya,
komposlsi kimia yang terbesar bag1 bahan in1 adalah 0.YYo Magnesium and 0.6Y0
Silicon. Penyambungan jenis 'temu' adalah yg di gunakan untuk penyelidikan ini
bag1 mengkajl tentang prestasi dan juga kebolehupayaanya. Spesimen yang dl
gunakan untuk diujikaji telah disediakan oleh Nautical Line (M) Sdn.Rhd menerusi
pengimpal yang berkemahiran dan juga terlatlh. VI dalam penyelidikan ini, tiga (3)
sifkt-sifat Aluminuim T6063 akan di kenalpasti iaitu daripada segi kekuatan impak,
kekerasan, dan juga kecacatan pada bahagian tempat penyambungan. Untuk
mengaplikasikan ujikaji ini, mesin-mesin yang digunakan adalah seperti Mesin Ujian
Impak, Mesin Ujian Kekerasan Kockwell, danjuga Mesin Ujian Ultrason~c.
k'irst oj all, all the praises and thanks he to Allah S. W. 7'jorHis Love,
This thesis is dedicated to my.family,
1 b my beloved parent, Aziz Bin Harun & Juriah Ut Ahmad
And my truely lovely person, Norita bt Md Nusir
1hankyou vety muchjor your unstinting help and encouragement.
In the name of Allah, the most Gracious aud most Compassionate
Firstly, 1 want to to thank Allah Almlghty for blesslng me and glvlng me
strength to accomplish this thesis. I would like also to take this opportunity to gather
all my most slncere gratitude towards my gracious and benevolent supervisor, Mr.
Syahrul Aman bin Suandi
for his proper guidance and generous assistance
throughout the accompl~shmentof the work contarn In the thesis. 1 have benetltted
through his kind help, valucablc suggcstion and encouragcmcnt in completing my
work and complllng thts thesls.
1 would llke to express my earnest appreclatlon and thanks to Mr. Hadzley
bin Abu Bakar for providing helpful and significant information when i needed him
most. Many thank to all of the technlclans especially Mr. Azhar for their cooperation
and assisting me in the various laboratory tasks.
Last but not least, to those who contribute towards the accompl~shmentof thls
thesis especially Apit Kacak, Mud4 Arin, Wak Din, Aman, Wan, and all my family
members, 1 ofler my deepest and genulne gratefulness for thew support, oplnlon and
suggestion.
'I'ABLEUP' CVN'I'EN'I'S
.....................................................................................
..
Approval .........................................................................................
Abstract.. .......................................................................................
Abstrak ..........................................................................................iv
Uedication.......................................................................................v
Ackr~owlcdgement.............................................................................vi
'I'ableof Contents.. ...........................................................................vii
List of Figures.................................................................................. xi
List of 'l'ables.................................................................................
List uf Symbols...............................................................................xiv
List of Abbreviation ..........................................................................xv
List of Appcndiccs.. ..........................................................................
xvi
9eclaration..
I
11
...
IIB
...
XIII
1.1
Background.. .........................................................................I
1.2 Problem Statement.. ................................................................,2
1.3
ObJectlves.. ........................................................................ ..-2
1.4
Scope...................................................................................2
CHAYI'EK 2 : L1'l'k;KA'I'UKEKEVIEW
............................................................... ..3
2.1 - 1 Characteristics of Aluminum ...................................................4
2.1.2 Mechanical Properties of Alumlnum .........................................-3
2.1.3 Applicatiotls.. .....................................................................
6
2.2 'I'he Senal ot Alumlnum Alloys..................................................... 6
2.1
What IS Aluminum..
2.3 Aluminum Boat ........................................................................8
2.3.1 Introduction....................................................................... 8
2.3.2 Why Used Aluminum ............................................................Y
2.4 Mechaitical PI-opertiesBackground ...............................................
10
2.4.1 General Uetinttton ot mechanical Yropertles................................ 1 1
2.5 Welding ...............................................................................I2
2.3.1 Introductton ..................................................................... 12
2.5.2 Gas Metal Arc Welding (GMAW) ...........................................13
2.3.2.1 Yllnctple ....................................................................-13
14
2.5.2.2 Ftquipments..................................................................
2.3.2.3 CiMAW Weldtng Shleldtng Gas.......................................... I3
2.5.2.4 Advatltages and Disadvantages of GMAW ............................. 15
2.6
lest ....................................................................................16
2.6.1
Destructive 'l'est (NUI') .......................................................16
2.6.2
NonUestruct1ve'I'est(NU'1')
................................................. 16
2.7
lirlpact Test
.........................................................................17
2.1.
Advantages and Utsadvantages ot Impact 'l'est............................1'1
2.7.2
Theory ............................................................................18
2.8
U ltrasonlc 'I'est...................................................................... 1 Y
2.8.1 Introduction......................................................................19
2.8.2 'I'heory............................................................................ I Y
2.8.3 Advantagcs and Disaclvantages of Ultrasonic Test .........................21
2.9
Hardness 'I 'est........................................................................ ZL
2.9.1 Advantages of Hardriess Test ..................................................22
2.9.2 Factors Involve Yertormed Hardness 'l'est...................................ZZ
2.9.3 Types of Indcntcr...............................................................23
2.9.4 Hardness Scale..................................................................24
2.10 Matcrial at~dStandards............................................................26
CHAPTER 3 : METHODOLOGY
3.1
lntroduction ......................................................................... 27
3.2 Experimental Apparatus ...........................................................28
3.2.1 GMAW Welding Machine ....................................................28
3.2.2 Band Saw Machine ............................................................30
3.2.3 Shielding Gas ................................................................... 31
Filler Rod ........................................................................31
3.2.4
3.3 Personal Protective Equipments (PPE) ..........................................32
Shielding Mask .................................................................32
3.3.1
3.3.2 Leather Glove ...................................................................33
3.3.3 Apron .............................................................................33
3.4 Testing Machines................................................................... 34
Standard Operation Procedure (SOP) of Hardness ........................34
3.4.1
3.4.2 Standard Operation Procedure (SOP) of Impact ............................36
3.5 Experimental Methods ............................................................-37
Design of Experiment (DOE) ................................................38
3.5.1
3.5.1.1 Specimens.................................................................... -38
3.5.2 Material Selection ...............................................................39
3.5.2.1
Introduction ..................................................................39
3.5.2.2 What is Aluminum T6063 .................................................. 39
3.5.2.3 The Composition of Aluminum T6063 ................................... 40
3.5.3
Welding Parameter ...............................................................41
3 S.3.1 Welding Procedure ............................................................ 41
3.5.4 Specimen Preparation ............................................................46
CHAPTER 4 : RESULT AND DATA ANALYSIS
4.1 Result of Impact Test ................................................................
47
4.1.1 Charpy Impact Test ............................................................-48
4.1.2 Izod Impact Test ................................................................ 53
4.1.3 Summary....................................................................... -57
4.2 Result of Rockwell Hardness Test................................................ 58
4.3 Result of Non Destructive Test...................................................65
4.4 Final Result ..........................................................................70
CHAPTER 5 : DISCUSSION.............................................................................. 71
CHAPTER 6 : CONCLUSION..........................................................76
CHAPTER 7 : SUGGESTION AND RECOMMENDATION.....................78
REFERENCES ................................................................................ 79
Appendix A : Figure and Table
Appendix B : Calculation For Impact Test
Appendix C : Result For Impact Test
LIST OF FIGURES
ITEMS
NO
PAGES
2.3.1
Aluminum Boat
8
2.5.1
Welding Process
12
2.5.2
GMAW Welding Schematic Process
13
2.5.2.2
GMAW Welding Equipments
14
2.7 (a)
Izod Test
17
2.7 (b)
Charpy Test
17
Schematic Diagram of Impact Test
18
2.8.2 (a)
Incomplete of Fusion
20
2.8.2 (b)
Incomplete of Penetration
20
2.8.2 (c)
Porosity
21
3.2.1
GMAW Welding Machine
28
3.2.2
Band Saw Machine
30
3.2.4
Filler Rod
32
3.3.1
Shield Mask model S939
32
3.3.2
Leather Glove
33
3.3.3
Apron
33
3.4.1
Rockwell Machine
35
3.4.4
Impact Test Machine
36
3.5
Experimental Methods
37
3.5.1.1 (a)
Specimen for Impact Test
38
3.5.3.1 (1)
C02 Fire Extinguisher
41
3.5.3.1 (2)
Wire Installation
42
3.5.3.1 (3)
Setting the Roller Tensioner
42
3.5.3.1 (4)
Setting the Wire Reel Tensioner
43
3.5.3.1 (5)
Parameter Setup
43
3.5.3.1 (6)
Practice Before Welding
44
2.7.2
3.5.3.1 (7)
Examine the Welds
44
3.5.3.1 (8)
Removing the Oxide Layer
45
3.5.4 (ii)
Cut off Raw Material Using Band Saw
46
3.5.4 (iii)
Tap Well Process
46
3.5.4 (iv)
Finished Product
46
Specimen for Izod Impact Test
47
49
4.2 (a)
Graph of Impact Energy versus Specimen for Charpy
Impact Test
Graph of Impact Strength versus Specimen for Charpy
Impact Test
Graph of Impact Energy versus Specimen for Izod
Impact Test
Graph of Impact Strength versus Specimen for Izod
Impact Test
Specimen Tested
4.2 (b)
Ball Indenter 1/16
58
4.2 (c)
Graph Result of Rockwell Hardness Test
59
4.2 (d)
Graph of Average Hardness Value by Point of Specimen
61
4.2 (e)
Graph Specimen 1B
62
4.2 (f)
Graph Specimen 1C
63
4.2 (g)
Graph of Average Hardness Value by Specimen
64
4.3 (a)
Specimen
65
Specimen Cross Section
73
4.1
4.11 (a)
4.11 )
4.1.2 (a)
4.1.2 (b)
5
51
54
56
58
LIST OF TABLES
ITEMS
TABLE
PAGES
1
Characteristics of Aluminum
4
2
The Serial of Aluminum Alloys
6
3
Definition of Mechanical Properties
11
4
Advantages and Disadvantages of GMAW
15
5
Advantages and Disadvantages of Impact Test
17
6
Advantages and Disadvantages of Ultrasonic Test
21
7
Factors Involve Performed Hardness Test
22
8
Types of Indenter
23
9
Material and Standards
26
10
GMAW Machine Specification
29
11
Band Saw Machine Specification
30
12
Recommended Shielding Gas
31
13
The Composition of Aluminum T6063
40
14
Welding Parameter
41
15
Data Collection of Charpy Impact Test
48
16
Data to Calculate Impact Strength for Charpy Impact Test
50
17
Data to Calculate Impact Energy for Izod Impact Test
53
18
Data to Calculate Impact Strength for Izod Impact Test
55
19
Result for Impact Test
58
20
Parameter for Hardness Test
59
21
Result of Rockwell Hardness Test
61
22
Result of Non Destructive Test
69
23
Result of Mechanical Properties for Aluminum T6063
71
24
Result for Impact Test
73
25
Recommended Parameter Setting for Joining Aluminum
Using GMAW
Parameter Setting for Joining Aluminum Using GMAW at
Nautical Line (M) Sdn.Bhd.
75
26
xiii
76
LIST OF SYMBOLS
Yo
Percentage
O
c
Degree Celsius
MPa
Megapasal
Al
Aluminum
>
Bigger
<
Smaller
C02
Carbon Dioxide
0 2
Oxygen
H
Height of Pendulum
91
Degree of Pendulum
92
Degree After Impact
m
Mass
Gravity
H
Height
0
Degree
Kilogram
millimeter
Voltage
Ampere
Hertz
Rotational Per Minute
Kilowatt
Diameter
Joule
Joule per Meter Square
Meter Square
LIST OF ABBREVIATIONS AND SPECIALIZED NOMENCLATURE
GMAW
Gas Metal Arc Welding
DT
Destructive Test
NDT
Non Destructive Test
UTeM
Universiti Teknikal Malaysia Melaka
GTAW
Gas Tungsten Arc Welding
CPU
Central Processing Unit
MIG
Metal Inert Gas
DC
Direct Current
TIG
Tungsten Inert Gas
SMAW
Stick Metal Arc Welding
AC
Alternate Current
NDE
Non Destructive Evaluation
NDI
Non Destructive Inspection
HB
Brinell Hardness Number
HK
Knoop Hardness Number
HR
Rockwell Hardness Number
HV
Vickers Hardness Number
UTS
Ultimate Tensile Strength
PPE
Personal Protective Equipment
SOP
Standard Operation Procedure
DOE
Design of Experiment
SEM
Scanning Electron Microscope
UTM
Universal Testing Machine
ASME
American Society of Mechanical Engineering
ASTM
American Society of Testing for Materials
HAZ
Heat Affected Zone
LIST OF APPENDICES
Appendix A : Figure and Table
Appendix B : Calculation For Impact Test
Appendix C : Result For Impact Test
CHAPTER 1
INTRODUCTION
1.1
Background
Nowadays, Aluminum is widely used in many sector or industries such as
automotive, aircraft, watercraft, and others. This research is to study about the welding
performance of specific parts in boat manufacturing. Beside that, it also focuses about
the joining in terms of hardness, impact, strength, and metallurgy. For the joining, Gas
Metal Arc Welding (GMAW) is used to join the material before proceeds to the next
stage. The type of joining is focused to Butt join. It is because; this joining is mostly
used in boat manufacturing. Aluminum T6063 is used for this research because the
material is provided by the boat manufacturer, Nautical Line (M) Sdn.Bhd, Kedah.
Mechanical properties for materials are important to be tested in order to make
sure the products that to be produced have a good quality and good physical strength
which depend on the material used. The properties are referring to the ability of the
material to get through any stress or defection which can affect the product physically.
There are several testing involve in this research. For Destructive Test (DT), impact test
and hardness test are used. While Ultrasonic for Non Destructive Test (NDT).
1.2
Problem Statement
The Aluminum boat in Malaysia is still lacking in terms of the use of welding
techniques as well as joining performance testing. The present research will describe the
details information about welding performance of specifics parts in boat manufacturing.
Previously, there is no standard testing to evaluate the stability of boat especially in
materials effect of joined parts. Thus, the research will focus on the analysis of specific
joining parts in terms of hardness and impact strength. The materials Aluminum T6063
will be provided by the boat manufacturer, Nautical Line (M) Sdn. Bhd, Kedah and the
testing evaluation will be held in UTeM.
1.3
(a)
Objectives
To be able to analyze the characteristics of Gas Metal Arc Welding
(GMAW) of Aluminum T6063 in terms of hardness and impact.
(b)
To be able to compare the welding performance between experimental
method and industrial practice.
1.4
Scope
(a)
Details study on Aluminum T6063 in application for boat industries.
(b)
Details study on material testing of joining products such as impact test,
hardness test, and nondestructive test (NDT).
(c)
Welding practical to produce the required product
CHAPTER 2
LITERITURE REVIEW
2.1
What is Aluminum?
Aluminum is the most common metallic element on earth. This material is
making up about 8% of the earth's crust and it's concentrated in the outer 16 km. Only
Oxygen and Silicon are more abundant. Evolution of life and human civilization has
developed Aluminum in rich environment. It is the most widely used non-ferrous metal
today. Aluminum never occurs in its metallic form in nature. It occurs in various forms
in most rocks and soils and is also present in gemstones like topaz and garnet. It can be
found in vegetation and in all of the earth's water. Aluminum is also present in all clays,
so it has been a constituent of cooking vessels since earliest civilizations.
The naturally occurring forms of Aluminum are usually stable and do not interact
with the biological processes of living organisms. Under acidic conditions Aluminum
may be released from rocks and soils in a soluble form which is more available for
uptake by plants and animals. However, uptake of this soluble form is limited by the
presence of natural agents such silicates and fluorides.
Joining Performance of Aluminum T6063 Using
GMAW Welding
Dissertation Submitted of the Faculty of Manufacturing Engineering in
Partial Fulfillment of the requirement for The Awards of the Degree of
Bachelor of Manufacturing Engineering (Manufacturing Design)
Mohd.Azme1 Bin Aziz
APRIL 2008
UTeM Library (Pind.112007)
fe
*C
A
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
*%"
-
JOINING PERFORMANCE OF ALUMINUM T6063 USING
GMAW WELDING
JUDUL
:
SESl PENGAJIAN
a ~ a
-
2005 2008
MOHDAZMEL BIN AZlZ
mengaku membenarkan tesis (PSMISarjanalDoktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
.
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **%la tandakan (4)
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
SULK
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
TlDAK TERHAD
M.
(TANDATANGAN PENULIS)
Alamat Tetap:
N0.185-A KG TIT1 BESI,
06200 KEPALA BATAS,
ALOR STAR, KEDAH DARUL AMAN.
Tarikh:
3 a \ 5 / ~ d ~ &
I
'
Tarikh:
>a
I$
/JO~$
" Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau
disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
'"Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan
denqan menvatakan sekali sebab dan temwh tesis ini perlu dikelaskan sebaqai SULIT atau TERMD.
UECLAKA'I'IUN
"I hereby declare that thrs wrltlng IS my ortglnal work except tor quotatlons and
summaries, each one of which I have clearly stated its source"
Author's Name
MUW.ALMbL BIN ALlL
AYJ'KUVAL
"1 hereby declare that 1 have read the content ot the thes~sand In my oplnlon, the
content of the thesis have fulfilled the scope and quality for the purpose of achieving
the Degree ot Bachelor ot Manutactunng Englneenng (Manutactunng Ueslgn)"
Signature
Supervisor
Weldlng charactenstlcs ot Alumrnum '1'60b3 plate speclmen ot
l Omm
thickness by a Gas Metal Arc Welding (GMAW) were studied. Generally, the
composltron tor thls senes whrch are 0.9% Magnes~umand 0.6Y0 Silicon are the
highest alloying elementq. The type ol'joining was studied in this research is Butt
Jolnt and thls research are also to be studled about their performance and capablllty.
These specimens wcrc welded by certiticd and skillful bvcldcr from Nautical Line
(M) Sdn-Bhd. In thls research, there are 3 characterlstlcs 01 Alumlnum '1'6063to be
studied; impact, hardness and the defects in the joining. To perform this research,
Impact 'l'estmg Machlne, Kockwell Hardness Mach~ne,and Ultrasonic 'I'estlng
Machine are used to cany out the data to be analyzed.
Mengkaji tentang sitat-sitat bahan Alum~nium'1'6063 setebal l0mm apabila
ianya dikimpal menerusi kimpalan arka gas lengai (GMAW). Secara umumnya,
komposlsi kimia yang terbesar bag1 bahan in1 adalah 0.YYo Magnesium and 0.6Y0
Silicon. Penyambungan jenis 'temu' adalah yg di gunakan untuk penyelidikan ini
bag1 mengkajl tentang prestasi dan juga kebolehupayaanya. Spesimen yang dl
gunakan untuk diujikaji telah disediakan oleh Nautical Line (M) Sdn.Rhd menerusi
pengimpal yang berkemahiran dan juga terlatlh. VI dalam penyelidikan ini, tiga (3)
sifkt-sifat Aluminuim T6063 akan di kenalpasti iaitu daripada segi kekuatan impak,
kekerasan, dan juga kecacatan pada bahagian tempat penyambungan. Untuk
mengaplikasikan ujikaji ini, mesin-mesin yang digunakan adalah seperti Mesin Ujian
Impak, Mesin Ujian Kekerasan Kockwell, danjuga Mesin Ujian Ultrason~c.
k'irst oj all, all the praises and thanks he to Allah S. W. 7'jorHis Love,
This thesis is dedicated to my.family,
1 b my beloved parent, Aziz Bin Harun & Juriah Ut Ahmad
And my truely lovely person, Norita bt Md Nusir
1hankyou vety muchjor your unstinting help and encouragement.
In the name of Allah, the most Gracious aud most Compassionate
Firstly, 1 want to to thank Allah Almlghty for blesslng me and glvlng me
strength to accomplish this thesis. I would like also to take this opportunity to gather
all my most slncere gratitude towards my gracious and benevolent supervisor, Mr.
Syahrul Aman bin Suandi
for his proper guidance and generous assistance
throughout the accompl~shmentof the work contarn In the thesis. 1 have benetltted
through his kind help, valucablc suggcstion and encouragcmcnt in completing my
work and complllng thts thesls.
1 would llke to express my earnest appreclatlon and thanks to Mr. Hadzley
bin Abu Bakar for providing helpful and significant information when i needed him
most. Many thank to all of the technlclans especially Mr. Azhar for their cooperation
and assisting me in the various laboratory tasks.
Last but not least, to those who contribute towards the accompl~shmentof thls
thesis especially Apit Kacak, Mud4 Arin, Wak Din, Aman, Wan, and all my family
members, 1 ofler my deepest and genulne gratefulness for thew support, oplnlon and
suggestion.
'I'ABLEUP' CVN'I'EN'I'S
.....................................................................................
..
Approval .........................................................................................
Abstract.. .......................................................................................
Abstrak ..........................................................................................iv
Uedication.......................................................................................v
Ackr~owlcdgement.............................................................................vi
'I'ableof Contents.. ...........................................................................vii
List of Figures.................................................................................. xi
List of 'l'ables.................................................................................
List uf Symbols...............................................................................xiv
List of Abbreviation ..........................................................................xv
List of Appcndiccs.. ..........................................................................
xvi
9eclaration..
I
11
...
IIB
...
XIII
1.1
Background.. .........................................................................I
1.2 Problem Statement.. ................................................................,2
1.3
ObJectlves.. ........................................................................ ..-2
1.4
Scope...................................................................................2
CHAYI'EK 2 : L1'l'k;KA'I'UKEKEVIEW
............................................................... ..3
2.1 - 1 Characteristics of Aluminum ...................................................4
2.1.2 Mechanical Properties of Alumlnum .........................................-3
2.1.3 Applicatiotls.. .....................................................................
6
2.2 'I'he Senal ot Alumlnum Alloys..................................................... 6
2.1
What IS Aluminum..
2.3 Aluminum Boat ........................................................................8
2.3.1 Introduction....................................................................... 8
2.3.2 Why Used Aluminum ............................................................Y
2.4 Mechaitical PI-opertiesBackground ...............................................
10
2.4.1 General Uetinttton ot mechanical Yropertles................................ 1 1
2.5 Welding ...............................................................................I2
2.3.1 Introductton ..................................................................... 12
2.5.2 Gas Metal Arc Welding (GMAW) ...........................................13
2.3.2.1 Yllnctple ....................................................................-13
14
2.5.2.2 Ftquipments..................................................................
2.3.2.3 CiMAW Weldtng Shleldtng Gas.......................................... I3
2.5.2.4 Advatltages and Disadvantages of GMAW ............................. 15
2.6
lest ....................................................................................16
2.6.1
Destructive 'l'est (NUI') .......................................................16
2.6.2
NonUestruct1ve'I'est(NU'1')
................................................. 16
2.7
lirlpact Test
.........................................................................17
2.1.
Advantages and Utsadvantages ot Impact 'l'est............................1'1
2.7.2
Theory ............................................................................18
2.8
U ltrasonlc 'I'est...................................................................... 1 Y
2.8.1 Introduction......................................................................19
2.8.2 'I'heory............................................................................ I Y
2.8.3 Advantagcs and Disaclvantages of Ultrasonic Test .........................21
2.9
Hardness 'I 'est........................................................................ ZL
2.9.1 Advantages of Hardriess Test ..................................................22
2.9.2 Factors Involve Yertormed Hardness 'l'est...................................ZZ
2.9.3 Types of Indcntcr...............................................................23
2.9.4 Hardness Scale..................................................................24
2.10 Matcrial at~dStandards............................................................26
CHAPTER 3 : METHODOLOGY
3.1
lntroduction ......................................................................... 27
3.2 Experimental Apparatus ...........................................................28
3.2.1 GMAW Welding Machine ....................................................28
3.2.2 Band Saw Machine ............................................................30
3.2.3 Shielding Gas ................................................................... 31
Filler Rod ........................................................................31
3.2.4
3.3 Personal Protective Equipments (PPE) ..........................................32
Shielding Mask .................................................................32
3.3.1
3.3.2 Leather Glove ...................................................................33
3.3.3 Apron .............................................................................33
3.4 Testing Machines................................................................... 34
Standard Operation Procedure (SOP) of Hardness ........................34
3.4.1
3.4.2 Standard Operation Procedure (SOP) of Impact ............................36
3.5 Experimental Methods ............................................................-37
Design of Experiment (DOE) ................................................38
3.5.1
3.5.1.1 Specimens.................................................................... -38
3.5.2 Material Selection ...............................................................39
3.5.2.1
Introduction ..................................................................39
3.5.2.2 What is Aluminum T6063 .................................................. 39
3.5.2.3 The Composition of Aluminum T6063 ................................... 40
3.5.3
Welding Parameter ...............................................................41
3 S.3.1 Welding Procedure ............................................................ 41
3.5.4 Specimen Preparation ............................................................46
CHAPTER 4 : RESULT AND DATA ANALYSIS
4.1 Result of Impact Test ................................................................
47
4.1.1 Charpy Impact Test ............................................................-48
4.1.2 Izod Impact Test ................................................................ 53
4.1.3 Summary....................................................................... -57
4.2 Result of Rockwell Hardness Test................................................ 58
4.3 Result of Non Destructive Test...................................................65
4.4 Final Result ..........................................................................70
CHAPTER 5 : DISCUSSION.............................................................................. 71
CHAPTER 6 : CONCLUSION..........................................................76
CHAPTER 7 : SUGGESTION AND RECOMMENDATION.....................78
REFERENCES ................................................................................ 79
Appendix A : Figure and Table
Appendix B : Calculation For Impact Test
Appendix C : Result For Impact Test
LIST OF FIGURES
ITEMS
NO
PAGES
2.3.1
Aluminum Boat
8
2.5.1
Welding Process
12
2.5.2
GMAW Welding Schematic Process
13
2.5.2.2
GMAW Welding Equipments
14
2.7 (a)
Izod Test
17
2.7 (b)
Charpy Test
17
Schematic Diagram of Impact Test
18
2.8.2 (a)
Incomplete of Fusion
20
2.8.2 (b)
Incomplete of Penetration
20
2.8.2 (c)
Porosity
21
3.2.1
GMAW Welding Machine
28
3.2.2
Band Saw Machine
30
3.2.4
Filler Rod
32
3.3.1
Shield Mask model S939
32
3.3.2
Leather Glove
33
3.3.3
Apron
33
3.4.1
Rockwell Machine
35
3.4.4
Impact Test Machine
36
3.5
Experimental Methods
37
3.5.1.1 (a)
Specimen for Impact Test
38
3.5.3.1 (1)
C02 Fire Extinguisher
41
3.5.3.1 (2)
Wire Installation
42
3.5.3.1 (3)
Setting the Roller Tensioner
42
3.5.3.1 (4)
Setting the Wire Reel Tensioner
43
3.5.3.1 (5)
Parameter Setup
43
3.5.3.1 (6)
Practice Before Welding
44
2.7.2
3.5.3.1 (7)
Examine the Welds
44
3.5.3.1 (8)
Removing the Oxide Layer
45
3.5.4 (ii)
Cut off Raw Material Using Band Saw
46
3.5.4 (iii)
Tap Well Process
46
3.5.4 (iv)
Finished Product
46
Specimen for Izod Impact Test
47
49
4.2 (a)
Graph of Impact Energy versus Specimen for Charpy
Impact Test
Graph of Impact Strength versus Specimen for Charpy
Impact Test
Graph of Impact Energy versus Specimen for Izod
Impact Test
Graph of Impact Strength versus Specimen for Izod
Impact Test
Specimen Tested
4.2 (b)
Ball Indenter 1/16
58
4.2 (c)
Graph Result of Rockwell Hardness Test
59
4.2 (d)
Graph of Average Hardness Value by Point of Specimen
61
4.2 (e)
Graph Specimen 1B
62
4.2 (f)
Graph Specimen 1C
63
4.2 (g)
Graph of Average Hardness Value by Specimen
64
4.3 (a)
Specimen
65
Specimen Cross Section
73
4.1
4.11 (a)
4.11 )
4.1.2 (a)
4.1.2 (b)
5
51
54
56
58
LIST OF TABLES
ITEMS
TABLE
PAGES
1
Characteristics of Aluminum
4
2
The Serial of Aluminum Alloys
6
3
Definition of Mechanical Properties
11
4
Advantages and Disadvantages of GMAW
15
5
Advantages and Disadvantages of Impact Test
17
6
Advantages and Disadvantages of Ultrasonic Test
21
7
Factors Involve Performed Hardness Test
22
8
Types of Indenter
23
9
Material and Standards
26
10
GMAW Machine Specification
29
11
Band Saw Machine Specification
30
12
Recommended Shielding Gas
31
13
The Composition of Aluminum T6063
40
14
Welding Parameter
41
15
Data Collection of Charpy Impact Test
48
16
Data to Calculate Impact Strength for Charpy Impact Test
50
17
Data to Calculate Impact Energy for Izod Impact Test
53
18
Data to Calculate Impact Strength for Izod Impact Test
55
19
Result for Impact Test
58
20
Parameter for Hardness Test
59
21
Result of Rockwell Hardness Test
61
22
Result of Non Destructive Test
69
23
Result of Mechanical Properties for Aluminum T6063
71
24
Result for Impact Test
73
25
Recommended Parameter Setting for Joining Aluminum
Using GMAW
Parameter Setting for Joining Aluminum Using GMAW at
Nautical Line (M) Sdn.Bhd.
75
26
xiii
76
LIST OF SYMBOLS
Yo
Percentage
O
c
Degree Celsius
MPa
Megapasal
Al
Aluminum
>
Bigger
<
Smaller
C02
Carbon Dioxide
0 2
Oxygen
H
Height of Pendulum
91
Degree of Pendulum
92
Degree After Impact
m
Mass
Gravity
H
Height
0
Degree
Kilogram
millimeter
Voltage
Ampere
Hertz
Rotational Per Minute
Kilowatt
Diameter
Joule
Joule per Meter Square
Meter Square
LIST OF ABBREVIATIONS AND SPECIALIZED NOMENCLATURE
GMAW
Gas Metal Arc Welding
DT
Destructive Test
NDT
Non Destructive Test
UTeM
Universiti Teknikal Malaysia Melaka
GTAW
Gas Tungsten Arc Welding
CPU
Central Processing Unit
MIG
Metal Inert Gas
DC
Direct Current
TIG
Tungsten Inert Gas
SMAW
Stick Metal Arc Welding
AC
Alternate Current
NDE
Non Destructive Evaluation
NDI
Non Destructive Inspection
HB
Brinell Hardness Number
HK
Knoop Hardness Number
HR
Rockwell Hardness Number
HV
Vickers Hardness Number
UTS
Ultimate Tensile Strength
PPE
Personal Protective Equipment
SOP
Standard Operation Procedure
DOE
Design of Experiment
SEM
Scanning Electron Microscope
UTM
Universal Testing Machine
ASME
American Society of Mechanical Engineering
ASTM
American Society of Testing for Materials
HAZ
Heat Affected Zone
LIST OF APPENDICES
Appendix A : Figure and Table
Appendix B : Calculation For Impact Test
Appendix C : Result For Impact Test
CHAPTER 1
INTRODUCTION
1.1
Background
Nowadays, Aluminum is widely used in many sector or industries such as
automotive, aircraft, watercraft, and others. This research is to study about the welding
performance of specific parts in boat manufacturing. Beside that, it also focuses about
the joining in terms of hardness, impact, strength, and metallurgy. For the joining, Gas
Metal Arc Welding (GMAW) is used to join the material before proceeds to the next
stage. The type of joining is focused to Butt join. It is because; this joining is mostly
used in boat manufacturing. Aluminum T6063 is used for this research because the
material is provided by the boat manufacturer, Nautical Line (M) Sdn.Bhd, Kedah.
Mechanical properties for materials are important to be tested in order to make
sure the products that to be produced have a good quality and good physical strength
which depend on the material used. The properties are referring to the ability of the
material to get through any stress or defection which can affect the product physically.
There are several testing involve in this research. For Destructive Test (DT), impact test
and hardness test are used. While Ultrasonic for Non Destructive Test (NDT).
1.2
Problem Statement
The Aluminum boat in Malaysia is still lacking in terms of the use of welding
techniques as well as joining performance testing. The present research will describe the
details information about welding performance of specifics parts in boat manufacturing.
Previously, there is no standard testing to evaluate the stability of boat especially in
materials effect of joined parts. Thus, the research will focus on the analysis of specific
joining parts in terms of hardness and impact strength. The materials Aluminum T6063
will be provided by the boat manufacturer, Nautical Line (M) Sdn. Bhd, Kedah and the
testing evaluation will be held in UTeM.
1.3
(a)
Objectives
To be able to analyze the characteristics of Gas Metal Arc Welding
(GMAW) of Aluminum T6063 in terms of hardness and impact.
(b)
To be able to compare the welding performance between experimental
method and industrial practice.
1.4
Scope
(a)
Details study on Aluminum T6063 in application for boat industries.
(b)
Details study on material testing of joining products such as impact test,
hardness test, and nondestructive test (NDT).
(c)
Welding practical to produce the required product
CHAPTER 2
LITERITURE REVIEW
2.1
What is Aluminum?
Aluminum is the most common metallic element on earth. This material is
making up about 8% of the earth's crust and it's concentrated in the outer 16 km. Only
Oxygen and Silicon are more abundant. Evolution of life and human civilization has
developed Aluminum in rich environment. It is the most widely used non-ferrous metal
today. Aluminum never occurs in its metallic form in nature. It occurs in various forms
in most rocks and soils and is also present in gemstones like topaz and garnet. It can be
found in vegetation and in all of the earth's water. Aluminum is also present in all clays,
so it has been a constituent of cooking vessels since earliest civilizations.
The naturally occurring forms of Aluminum are usually stable and do not interact
with the biological processes of living organisms. Under acidic conditions Aluminum
may be released from rocks and soils in a soluble form which is more available for
uptake by plants and animals. However, uptake of this soluble form is limited by the
presence of natural agents such silicates and fluorides.