scholarly journals Enhancement of the interface of friction welded steel-aluminium joints

2020 ◽  
Author(s):  
Bernd-Arno Behrens ◽  
Deniz Duran ◽  
Tim Matthias ◽  
Ingo Ross
Keyword(s):  
Joint Strength ◽  
Step Function ◽  
Inductive Heating ◽  
Destructive Testing ◽  
Welded Steel ◽  
Counter Pressure ◽  
Local Properties ◽  
Novel Concept ◽  
Tailored Forming ◽  
Joining Process

AbstractLightweight multi-material components are of great importance for the transport industry. Not only the component’s weight can be decreased, but also its local properties can be adapted to different loading profiles. Tailored Forming is a novel concept for producing multi-material components. By using a joining process, the creation of a bond between different materials takes place in the first step of the process chain. In the subsequent steps, multi-material workpieces are processed in their joined state while maintaining or improving the joint strength. This study focuses on steel-aluminium joints, which were created by friction welding and further processed by induction heating and impact extrusion. A counter pressure superposition mechanism was implemented in the extrusion tooling to control the stress state during plastic deformation. Flow behaviours of steel and aluminium are largely different at a given temperature, which necessitates a near step-function temperature distribution in the hybrid billet to obtain matching flow stresses. An inductive heating strategy was developed which led to a temperature gradient in the billets before extrusion. Extruded billets were analysed by destructive testing methods and metallography. The bond could be maintained after extrusion when counter pressure superposition was used; but no improvement could be obtained. Without counter force superposition, however, cracks were observed in the joining interface and the joint strength decreased. This paper discusses the aforementioned findings in the current process design and makes suggestions on how the involved processes should be reconfigured to improve the joint strength.

scholarly journals A Comparative Study of Ductile Damage Models Approaches for Joint Strength Prediction in Hot Shear Joining Process

2017 ◽  
Vol 207 ◽  
pp. 1689-1694 ◽  
Author(s):  
Mohanraj Murugesan ◽  
Seonggi Lee ◽  
Dongwook Kim ◽  
Youn-Hee Kang ◽  
Naksoo Kim
Keyword(s):  
Comparative Study ◽  
Joint Strength ◽  
Ductile Damage ◽  
Strength Prediction ◽  
Damage Models ◽  
Joining Process

scholarly journals Porosity Elimination in Modified Direct Laser Joining of Ti6Al4V and Thermoplastics Composites

2019 ◽  
Vol 9 (3) ◽  
pp. 411 ◽  
Author(s):  
Haipeng Wang ◽  
Yang Chen ◽  
Zaoyang Guo ◽  
Yingchun Guan
Keyword(s):  
Glass Fiber ◽  
Fracture Strength ◽  
Joint Strength ◽  
Surface Texturing ◽  
Practical Applications ◽  
Laser Joining ◽  
Glass Fiber Reinforced ◽  
Hybrid Joints ◽  
Direct Laser ◽  
Joining Process

Hybrid lightweight components with strong and reliable bonding qualities are necessary for practical applications including in the automotive and aerospace industries. The direct laser joining method has been used to produce hybrid joints of Ti6Al4V and glass fiber reinforced polyamide (PA66-GF30). Prior to the laser joining process, a surface texturing treatment is carried out on Ti6Al4V to improve joint strength through the formation of interlock structures between Ti6Al4V and PA66-GF30. In order to reduce the generated micro-pores in Ti6Al4V-PA66-GF30 joints, a modified laser joining method has been proposed. Results show that only very few small micro-pores are generated in the joints produced by the modified laser joining method, and the fracture strength of the joints is significantly increased from 13.8 MPa to 41.5 MPa due to the elimination of micro-pores in the joints.

Modeling and Optimization of Mask Assisted Laser Transmission Micro Joining Process

2014 ◽  
Vol 620 ◽  
pp. 10-16
Author(s):  
Zhen Guan Zhao ◽  
Hui Xia Liu ◽  
Ye Cai ◽  
Yan Wei Wu ◽  
Xiao Wang
Keyword(s):  
Mathematical Model ◽  
Response Surface Methodology ◽  
Experimental Design ◽  
Process Parameters ◽  
Joint Strength ◽  
Slit Width ◽  
Joint Width ◽  
The Mathematical Model ◽  
The Relationship ◽  
Joining Process

This article uses semiconductor laser for mask assisted laser transmission micro joining PET and PET with clear weld absorbents, the mask slit width is 0.3mm, using CCD to plan experimental design. The mathematical model of joining process parameters with joint strength and joint width was established using response surface methodology. Experimental verification was also done. The actual joint width was compared to mask slit width and the process parameters were optimized. The results show that the mathematical model can response the relationship between process parameters and joining quality, the mask can effectively control the joint width, reasonable process parameters can obtain high-precision, high-intensity joining quality.

Reliability Factors in Ceramic/Metal Joining

1993 ◽  
Vol 314 ◽  
Author(s):  
Katsuaki Suganuma
Keyword(s):  
Surface Roughness ◽  
Joint Strength ◽  
Applied Pressure ◽  
Great Influence ◽  
Thermal Expansion Mismatch ◽  
Large Scatter ◽  
Absolute Value ◽  
Solid State Joining ◽  
Joining Process ◽  
Processing Factors

AbstractThis paper reviews the processing factors in joining ceramics to metals concerning the reliability. Thermal expansion mismatch has a great influence not only on the absolute value of strength but also on the reliability of joints. Large thermal stress increases the scatter of joint strength because of the presence of defects induced during joining process. One should insert an appropriate interlayer to relax the stress between a ceramic and a metal. Surface roughness also has some influence on the reliability. A roughly ground bond face leads large scatter in strength. Scratches must be removed before joining. Unjoined area reduces joint strength especially in solid-state joining. In brazing, the homogeneity in the braze layer should be also controlled carefully. A slight applied pressure during brazing can preserve the integrity of joints.

scholarly journals Introduction to tailored forming

2021 ◽  
Author(s):  
B.-A. Behrens ◽  
J. Uhe
Keyword(s):  
Collaborative Research ◽  
Lightweight Design ◽  
Production Quality ◽  
Research Centre ◽  
Lightweight Construction ◽  
Forming Process ◽  
Process Chains ◽  
Finishing Processes ◽  
Tailored Forming ◽  
Joining Process

AbstractIn recent years, the requirements for technical components have been increasing steadily. This development is intensified by the desire for products with lower weight, smaller size and extended functionality, but at the same time higher resistance against specific loads. Mono-material components manufactured according to established processes reach their limits regarding conflicting requirements. It is, for example, hardly possible to combine excellent mechanical properties with lightweight construction using mono-materials. Thus, a significant increase in production quality, lightweight design, functionality and efficiency can only be reached by combining different materials in one component. The superior aim of the Collaborative Research Centre (CRC) 1153 is to develop novel process chains for the production of hybrid solid components. In contrast to existing process chains in bulk metal forming, in which the joining process takes place during forming or at the end of the process chain, the CRC 1153 uses tailored semi-finished workpieces which are joined before the forming process. This results in a geometric and thermomechanical influence on the joining zone during the forming process which cannot be created by conventional joining techniques. The present work gives an overview of the CRC and the Tailored Forming approach including the applied joining, forming and finishing processes as well as a short summary of the accompanying design and evaluation methods.

scholarly journals Laser Joining of Continuous Glass Fiber Composite Pre-Forms

2012 ◽  
Author(s):  
Huade Tan ◽  
Y. Lawrence Yao
Keyword(s):  
Joint Strength ◽  
Axial Direction ◽  
Fiber Bundles ◽  
Laser Fusion ◽  
Single Bundle ◽  
Filler Materials ◽  
Thickness Direction ◽  
Laser Joining ◽  
Joint Morphology ◽  
Joining Process

A laser fusion joining method is investigated for the purpose of through thickness strengthening of fiber pre-forms used in the vacuum infusion fabrication of thick composite structures. Laser joining is achieved without filler materials to replace adhesives, pins or stitches used in conventional composite fabrication. A two step joining process is developed to fuse fibers within a single bundle and between multiple fiber bundles. Finite element analysis is used to investigate the joint strength with respect to joint morphology. Joint strength is found to be a function of the fiber contact angle and packing density at the joint interface. Tensile tests show that laser joined fiber bundles exhibit higher strength than comparable fastening methods. Lessons learned from the axial joining of fiber bundles are applied to joining in the radial and thickness directions of 3d pre-form architectures. Flow induced joint morphology and densification effects observed in the axial direction indicate the need for a two step joining process in the thickness direction. Fiber compaction effects on joint strength in the axial direction motivate the need for high fiber packing fraction at joint interfaces in the thickness direction.

scholarly journals Simulation of the Flattening of High Frequency Induction Welded Tubes

2020 ◽  
Vol 22 (1) ◽  
pp. 273-284
Author(s):  
Abdelaziz Abboudi ◽  
Brahim Chermime ◽  
Salim Boulahrouz
Keyword(s):  
High Frequency ◽  
Experimental Tests ◽  
Non Destructive Testing ◽  
Destructive Testing ◽  
Steel Tubes ◽  
Welded Steel ◽  
Construction Plant ◽  
Experimental Process ◽  
Non Destructive ◽  
High Frequency Induction

AbstractThe process of destructive and non-destructive testing of the manufacture of high frequency induction welded steel tubes has always give better results at the Labiod-tèbessa Algeria tube construction plant such as tensile testing, folding, flaring and also the flattening tests whose limits of use were given by the experimental methods which have known deficiencies in measures in particular of the parameter of the height H which is given by the equation and that this difficulty is noted between the calculated and measured height levels. For these reasons it is necessary to find a numerical model of simulation which obviously replaces the experimental process to give reliable results with cheaper conditions in terms of cost and time which has been respected which allowed us to collect data. results and compare the different heights calculated and measure and often confirm the experimental tests.

Investigation of the Influence of Kinematic and Energy Parameters on the Structure and Strength of Explosion-Welded Steel-Aluminum Composite

2021 ◽  
Vol 316 ◽  
pp. 62-67
Author(s):  
V.I. Kuz'min ◽  
V.I. Lysak ◽  
E.V. Kuz’min
Keyword(s):  
Mechanical Properties ◽  
Joint Strength ◽  
Physical And Mechanical Properties ◽  
Explosive Loading ◽  
Explosion Welding ◽  
Aluminum Composite ◽  
Welded Steel ◽  
Energy Parameters

The work is devoted to a study of the probable causes of a decrease in joint strength during explosion welding of metals with sharply differing physical and mechanical properties. The influence of kinematic and energy parameters on the structure and strength of the steel-aluminum composite under various conditions of explosive loading is shown.

Friction spot lap joining of the anodized aluminium alloy 6061 with high-density polyethylene sheets

2019 ◽  
Vol 16 (4) ◽  
pp. 539-549 ◽  
Author(s):  
Ghadanfer Hussein Ali ◽  
Sabah Khammass Hussein
Keyword(s):  
Aluminium Alloy ◽  
High Density Polyethylene ◽  
Joint Strength ◽  
Processing Time ◽  
High Density ◽  
Frictional Heat ◽  
Lap Joint ◽  
Content Type ◽  
Tool Diameter ◽  
Joining Process

Purpose The purpose of this paper is to join an anodized aluminium alloy AA6061 sheet with high-density polyethylene (HDPE) using friction spot process. Design/methodology/approach The surface of AA6061 sheet was anodized to increase the pores’ size. A lap joint configuration was used to join the AA6061 with HDPE sheets by the friction spot process. The joining process was carried out using a rotating tool of different diameters: 14, 16 and 18 mm. Three tool-plunging depths were used – 0.1, 0.2 and 0.3 mm – with three values of the processing time – 20, 30 and 40 s. The joining process parameters were designed according to the Taguchi approach. Two sets of samples were joined: the as-received AA6061/HDPE and the anodized AA6061/HDPE. Findings Frictional heat melted the HDPE layers near the lap joint line and penetrated it through the surface pores of the AA6061 sheet via the applied pressure of the tool. The tool diameter exhibited higher effect on the joint strength than processing time and the tool-plunging depth. Specimens of highest and lowest tensile force were failed by necking the polymer side and shearing the polymer layers at the lap joint, respectively. Molten HDPE was mechanically interlocked into the pores of the anodized surface of AA6061 with an interface line of 18-m width. Originality/value For the first time, HDPE was joined with the anodized AA6061 by the friction spot process. The joint strength reached an ideal efficiency of 100 per cent.

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