Influence of wire feed rate on mechanical and microstructure characteristics of aluminum to galvanized steel laser brazed joint

2019 ◽  
Vol 39 ◽  
pp. 271-281 ◽  
Author(s):  
D. Narsimhachary ◽  
S.M. Shariff ◽  
G. Padmanabham ◽  
A. Basu
Keyword(s):  
Feed Rate ◽  
Galvanized Steel ◽  
Microstructure Characteristics ◽  
Brazed Joint ◽  
Wire Feed

Multi-Objective Optimisation of Laser Deposition of Metal Matrix Composites for Surface Coating Using Principal Component Analysis

2018 ◽  
Vol 40 ◽  
pp. 9-21 ◽  
Author(s):  
Peter Kayode Farayibi
Keyword(s):  
Feed Rate ◽  
Surface Coating ◽  
Laser Power ◽  
Traverse Speed ◽  
Laser Deposition ◽  
Powder Feed Rate ◽  
Multi Objective ◽  
Powder Feed ◽  
Output Characteristics ◽  
Wire Feed

Laser deposition is an advanced manufacturing technology capable of enhancing service life of engineering components by hard-facing their functional surfaces. There are quite a number of parameters involved in the process and also desirable output characteristics. These output characteristics are often independently optimised and which may lead to poor outcome for other characteristics, hence the need for multi-objective optimisation of all the output characteristics. In this study, a laser deposition of Ti-6Al-4V wire and tungsten carbide powder was made on a Ti-6Al-4V substrate with a view to achieve a metallurgical bonded metal matrix composite on the substrate. Single clads were deposited with a desire to optimise the composite clad characteristics (height, width and reinforcement fraction) for the purpose of surface coating. Processing parameters (laser power, traverse speed, wire feed rate, powder feed rate) were varied, the experiment was planned using Taguchi method and output characteristics were analysed using principal component analysis approach. The results indicated that the parameters required for optimised clad height, width, and reinforcement fraction necessary for surface coating is laser power of 1800 W, traverse speed of 200 mm/min, wire feed rate 700 mm/min and powder feed rate of 30 g/min. The powder feed rate was found to most significantly contribute 43.99%, followed by traverse speed 39.77%, laser power 15.87% with wire feed rate having the least contribution towards the multi-objective optimisation. Confirmation results showed that clad width and reinforcement fraction were significantly improved by the optimised parameters. The multi-objective optimisation procedure is a useful tool necessary to identify the process factors required to enhance output characteristics in laser processing.

scholarly journals Influence of Preheating Temperature on Cold Metal Transfer (CMT) Welding–Brazing of Aluminium Alloy/Galvanized Steel

2018 ◽  
Vol 8 (9) ◽  
pp. 1659 ◽  
Author(s):  
Youqiong Qin ◽  
Xi He ◽  
Wenxiang Jiang
Keyword(s):  
Aluminium Alloy ◽  
Interfacial Layer ◽  
Metal Transfer ◽  
Galvanized Steel ◽  
Load Force ◽  
Cold Metal Transfer ◽  
Preheating Temperature ◽  
Cmt Welding ◽  
Brazed Joint ◽  
Cold Metal

Bead-on-plate cold metal transfer (CMT) brazing and overlap CMT welding–brazing of 7075 aluminium alloy and galvanized steel at different preheating temperatures were studied. The results indicated that AlSi5 filler wire had good wettability to galvanized steel. The preheating treatment can promote the spreadability of liquid AlSi5. For the overlap CMT welding–brazed joint, the microstructure of the joint was divided into four zones, namely, the interfacial layer, weld metal zone, zinc-rich zone, and heat affected zone (HAZ). The load force of the joints without preheating and 100 °C preheating temperature was 8580 N and 9730 N, respectively. Both of the joints were fractured in the fusion line with a ductile fracture. Further increasing the preheating temperature to 200 °C would decrease the load force of the joint, which fractured in the interfacial layer with a brittle fracture.

scholarly journals Empirical Investigations during WEDM of Ni-27Cu-3.15Al-2Fe-1.5Mn Based Superalloy for High Temperature Corrosion Resistance Applications

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3470 ◽  
Author(s):  
Vivek Aggarwal ◽  
Catalin Iulian Pruncu ◽  
Jujhar Singh ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov
Keyword(s):  
Feed Rate ◽  
Research Work ◽  
Spark Gap ◽  
Nickel Copper ◽  
Cutting Rate ◽  
Response Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Monel K-500, a nickel–copper based alloy, is a very hard and tough material. Machining of such hard and tough materials always becomes a challenge for industry and this has been resolved by wire electric discharge machining (WEDM), a popular non-conventional machining method used for machining tough and hard materials having complex shapes. For the first time reported in this present research work is an experimental investigation executed on Ni-27Cu-3.15Al-2Fe-1.5Mn based superalloy using WEDM to model cutting rate (CR) and surface roughness (SR) using response surface methodology (RSM). The process parameters have been selected as pulse-on time, pulse-off time, spark-gap voltage and wire-feed rate. Experiments have been planned according to the central composite design (CCD). The results show that pulse-on time has a direct effect on CR while the pulse-off time has a reverse effect. The CR increases as pulse-on time increases, and decreases as pulse-off time increases. SR increases as pulse-on time increases, and decreases as pulse-off time increases. Furthermore, increase in spark-gap voltage decreases CR and SR both. The wire feed-rate has a negligible effect for both the response parameters. The optimized values of CR and SR achieved through multi-response optimization are 2.48 mm/min and 2.12 µm, respectively.

Experimental investigation of process parameters for WEDM of Ti-6Al-4V/TiN composites

2015 ◽  
Vol 22 (6) ◽  
Author(s):  
Levent Urtekin
Keyword(s):  
Feed Rate ◽  
Physical Vapor Deposition ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Performance Tests ◽  
Electric Discharge Machining ◽  
Food Industries ◽  
Heat Treated ◽  
Wire Electric Discharge Machining ◽  
Wire Feed

AbstractTi-6Al-4V alloys are difficult-machine materials. These alloys are extensively used in medicine, chemical units, marine and food industries, and particularly in the aerospace industry. Machinability of Ti-6Al-4V in wire electric discharge machining (WEDM) has been empirically investigated. WEDM performance tests were conducted on TiN coated Ti-6Al-4V alloy with physical vapor deposition (PVD) method, which is harder and has higher wear resistance. The performance of machinability of Ti-6Al-4V and Ti-6Al-4V/TiN materials was analyzed. The most important performance characteristics of WEDM cutting are surface roughness, machining gap, and cutting speed. The tests were conducted under cutting parameters including varying pulse durations (300, 500, 700 μs), tension (50, 100 V) and wire feed rate (5, 8 m/min). Based on tension, pulse duration, and wire feed rate of heat-treated uncoated samples when compared to untreated samples and coated samples, feed rates were found to be at the highest value.

scholarly journals Gas brazing of thin-sheet galvanized steel with aluminum solders

2021 ◽  
Vol 5 (2) ◽  
Author(s):  
Vitaliy Polishchuk ◽  
Nataliya Strelenko ◽  
Vladyslav Kovalenko
Keyword(s):  
Base Metal ◽  
Thin Sheet ◽  
Zinc Coating ◽  
Base Material ◽  
Galvanized Steel ◽  
Liquid Solder ◽  
Physicochemical Processes ◽  
Brazed Joint ◽  
Coated Layer ◽  
Qualitative Characteristics

. In this work, the first stage of experimental research was carried out to estimate the main physicochemical processes that determine the qualitative characteristics of a brazed joint made of thin sheet galvanized steel during gas brazing with aluminum solder systems. In particular, an estimation was made of the ability of spreading and wetting of aluminum solders (AlSi5, AlSi12) on the surface of thin sheet galvanized steel ( DX56D + Z of 0.4 mm thick and zinc-coated layer of 45–65 microns) at a step-by-step increase in the heating area of the base metal in the presence and absence of flux (Al-Flux 726). The aluminum alloys was heated “not directly,” but through the base metal to maximize the preservation of the anticorrosive zinc coating at the interface between the liquid solder and the base material.

An Optimization Design for Coefficient of Weld Reinforcement in Rapid Prototyping Based on Robotic Pulse MAG Forming

2012 ◽  
Vol 217-219 ◽  
pp. 2148-2153
Author(s):  
Xue Wei Huang ◽  
Sun Ing Bao ◽  
Jing Wang
Keyword(s):  
Rapid Prototyping ◽  
Process Parameters ◽  
Welding Speed ◽  
Feed Rate ◽  
Optimization Design ◽  
Orthogonal Design ◽  
Arc Length ◽  
Range Analysis ◽  
Pulse Correction ◽  
Wire Feed

During the process of rapid prototyping based on robotic pulse MAG forming, the coefficient of weld reinforcement is crucial to the geometric accuracy and mechanical property of metallic parts. The orthogonal design method, as well as the range analysis and variance analysis, were applied in this article to study the effects of wire feed rate, welding speed, pulse correction and arc length correction on coefficient of weld reinforcement, finding out the factors which were significant to the coefficient of weld reinforcement and optimizing the process parameters. The experimental results show that the order of the significance of parameters is as following: the welding speed, the arc length correction, the wire feed rate, and the pulse correction. Among them, the welding speed and arc length correction have the greatest influence on the coefficient of weld reinforcement, as is 0.025. The optimal process parameters are: arc length correction 8%, welding speed 14mm/s, wire feed rate 7.2m/min and pulse correction 0. At the same time, the coefficient of weld reinforcement is between 2.94 and 3.00, as the degree of confidence is 97.5%.

scholarly journals Effect of the Addition of Nitrogen through Shielding Gas on TIG Welds Made Homogenously and Heterogeneously on 300 Series Austenitic Stainless Steels

2021 ◽  
Vol 5 (3) ◽  
pp. 72
Author(s):  
Rohit Kshirsagar ◽  
Steve Jones ◽  
Jonathan Lawrence ◽  
Jamil Kanfoud
Keyword(s):  
Fatigue Life ◽  
Stainless Steels ◽  
Feed Rate ◽  
Welding Process ◽  
Austenitic Stainless Steels ◽  
Interaction Effects ◽  
Bead Geometry ◽  
Filler Wire ◽  
Shielding Gas ◽  
Wire Feed

Tungsten inert gas (TIG) welding of austenitic stainless steels is a critical process used in industries. Several properties of the welds must be controlled depending on the application. These properties, which include the geometrical, mechanical and microstructural features, can be modified through an appropriate composition of shielding gas. Researchers have studied the effects of the addition of nitrogen through the shielding gas; however, due to limited amount of experimental data, many of the interaction effects are not yet reported. In this study, welds were made homogeneously as well as heterogeneously with various concentrations of nitrogen added through the shielding gas. The gas compositions used were 99.99%Ar (pure), 2.5% N2 + Ar, 5% N2 + Ar and 10% N2 + Ar. Additionally, the welding process parameters were varied to understand different interaction effects between the shielding gas chemistry and the process variables such as filler wire feed rate, welding current, etc. Strong interactions were observed in the case of heterogeneous welds between the gas composition and the filler wire feed rate, with the penetration depth increasing by nearly 30% with the addition of 10% nitrogen in the shielding gas. The interactions were found to influence the bead geometry, which, in turn, had an effect on the mechanical properties as well as the fatigue life of the welds. A nearly 15% increase in the tensile strength of the samples was observed when using 10% nitrogen in the shielding gas, which also translated to a similar increase in the fatigue life.

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