scholarly journals Numerical investigation of friction crush welding aluminium and copper sheet metals with flanged edges

2021 ◽  
Vol 309 ◽  
pp. 01015
Author(s):  
Ashu Kumar ◽  
Gurinder Singh Brar
Keyword(s):  
Temperature Distribution ◽  
Mechanical Performance ◽  
Experimental Testing ◽  
Research Work ◽  
Dissimilar Materials ◽  
Copper Sheet ◽  
Thermomechanical Model ◽  
Nonlinear Transient ◽  
New Material ◽  
Stress Flow

Aluminum alloys are the most attractive solutions for many industries including aerospace, marine, and other transportation sectors where lightweight construction is required. Friction Crush Welding (FCW) is a new material joining process that simultaneously creates a mechanical lock and a metallurgical seal at the interface between similar and dissimilar materials. In this research work presents the development of numerical modelling to predict the temperature distribution and mechanical performance of aluminum and copper similar joints in the FCW of sheet metal section. An explicit nonlinear transient finite element thermomechanical model is develop using ABAQUS based on the coupled Euler-Lagrange method to simulate FCW of AW5754 and Cu-DHP alloys. The Johnson-Cook materials law is adopted in the FEM. Numerical investigations of the FCW process was performed to reduce experimental testing times, which can be long and expensive. Temperature distribution and von misses stress flow patterns are observed at the top surface of the weld. Numerical simulation data correlate with experimental data in the literature.

scholarly journals Recent Developments in Laser Welding of Aluminum Alloys to Steel

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 622
Author(s):  
Daniel Wallerstein ◽  
Antti Salminen ◽  
Fernando Lusquiños ◽  
Rafael Comesaña ◽  
Jesús del Val García ◽  
...  
Keyword(s):  
Laser Welding ◽  
High Performance ◽  
Mechanical Performance ◽  
Research Work ◽  
Dissimilar Materials ◽  
Material Design ◽  
Joint Interface ◽  
Laser Joining ◽  
Recent Developments ◽  
Steel Joints

The development of high-performance dissimilar aluminum–steel joints is necessary to promote the feasibility of multi-material design and lightweight manufacturing. However, joining aluminum to steel is a challenging task mainly due to the formation of brittle intermetallic compounds (IMC) at the joint interface. Laser welding is considered a very promising joining process for dissimilar materials, although its application in industry is still limited by the insufficient mechanical performance of the joints. The present paper aims to give a comprehensive review of relevant recent research work on laser joining of aluminum to steel, contributing to highlighting the latest achievements that could boost acceptance of laser joining of dissimilar materials by the modern industries. To this end, the most important challenges in laser joining of aluminum to steel are presented, followed by recent approaches to overcome these challenges, the state-of-art of comprehension of IMC formation and growth, and the different strategies to minimize them.

Microstructural and Mechanical Behaviour Evaluation of Mg-Al-Zn Alloy Friction Stir Welded Joint

2020 ◽  
Vol 17 (3) ◽  
pp. 8150-8159
Author(s):  
Kulwant Singh ◽  
Gurbhinder Singh ◽  
Harmeet Singh
Keyword(s):  
Heat Treatment ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Mechanical Performance ◽  
Fuel Efficiency ◽  
Research Work ◽  
Grain Structure ◽  
Tensile Fracture ◽  
Friction Stir ◽  
The Impact

The weight reduction concept is most effective to reduce the emissions of greenhouse gases from vehicles, which also improves fuel efficiency. Amongst lightweight materials, magnesium alloys are attractive to the automotive sector as a structural material. Welding feasibility of magnesium alloys acts as an influential role in its usage for lightweight prospects. Friction stir welding (FSW) is an appropriate technique as compared to other welding techniques to join magnesium alloys. Field of friction stir welding is emerging in the current scenario. The friction stir welding technique has been selected to weld AZ91 magnesium alloys in the current research work. The microstructure and mechanical characteristics of the produced FSW butt joints have been investigated. Further, the influence of post welding heat treatment (at 260 °C for 1 h) on these properties has also been examined. Post welding heat treatment (PWHT) resulted in the improvement of the grain structure of weld zones which affected the mechanical performance of the joints. After heat treatment, the tensile strength and elongation of the joint increased by 12.6 % and 31.9 % respectively. It is proven that after PWHT, the microhardness of the stir zone reduced and a comparatively smoothened microhardness profile of the FSW joint obtained. No considerable variation in the location of the tensile fracture was witnessed after PWHT. The results show that the impact toughness of the weld joints further decreases after post welding heat treatment.

Pneumatic Microextrusion-Based Additive Biofabrication of Polycaprolactone Bone Scaffolds: Part II – Investigation of the Influence of Polymer Flow Parameters

2021 ◽  
Author(s):  
Mohan Yu ◽  
Logan Lawrence ◽  
Pier Paolo Claudio ◽  
James B. Day ◽  
Roozbeh (Ross) Salary
Keyword(s):  
Mechanical Performance ◽  
Research Work ◽  
Biological Tissues ◽  
Direct Write ◽  
Bone Scaffolds ◽  
Flow Parameters ◽  
Material Deposition ◽  
Flow Pressure ◽  
Physical Phenomena ◽  
Head Temperature

Abstract Pneumatic micro-extrusion (PME), a direct-write additive manufacturing process, has emerged as a high-resolution method for the fabrication of a broad range of biological tissues and organs. However, the PME process is intrinsically complex, governed by complex physical phenomena. Hence, investigation of the effects of consequential parameters would be an inevitable need. The goal of this research work is to fabricate biocompatible, porous bone tissue scaffolds for the treatment of osseous fractures, defects, and eventually diseases. In pursuit of this goal, the objective of this study is to investigate the influence of material deposition factors — i.e., (i) deposition head temperature, (ii) flow pressure, and (iii) infill pattern — on the mechanical performance of PME-fabricated bone scaffolds. It was observed that the deposition head temperature as well as the flow pressure significantly affected scaffold diameter (unlike scaffold height). In addition, material deposition rate increased significantly as a result of an increase in the deposition temperature; this phenomenon stems from a reduction in Polycaprolactone (PCL) viscosity. Furthermore, there was a direct correlation between the amount of deposited mass and scaffold stiffness. Overall, the results of this study pave the way for future investigation of PME-deposited PCL scaffolds with optimal functional properties for incorporation of stem cells toward the treatment of osseous fractures and defects.

Linear Friction Welding of IN718 to Ti6Al4V

2016 ◽  
Vol 879 ◽  
pp. 2072-2077 ◽  
Author(s):  
Priti Wanjara ◽  
Javad Gholipour ◽  
Kosuke Watanabe ◽  
Koji Nezaki ◽  
Y. Tian ◽  
...  
Keyword(s):  
Friction Welding ◽  
Mechanical Performance ◽  
Fuel Efficiency ◽  
Intermetallic Phase ◽  
Dissimilar Materials ◽  
Ti Alloy ◽  
Linear Friction Welding ◽  
Linear Friction ◽  
Automated Technology ◽  
Base Superalloy

Linear friction welding (LFW), an emerging automated technology, has potential for solid-state joining of dissimilar materials (bi-metals) to enable tailoring of the mechanical performance, whilst limiting the assembly weight for increased fuel efficiency. However, bi-metallic welds are quite difficult to manufacture, especially when the material combinations can lead to the formation of intermetallic (brittle) phases at the interface, such as the case with assembly of Ti base alloys with Ni base superalloys. The intermetallic phase, once formed, lowers the performance of the as-manufactured properties and its growth during elevated temperature service can lead to unreliable performance. In this project, it was demonstrated that linear friction welding can be applied to join Ti-6%Al-4%V (workhorse Ti alloy) to INCONEL® 718 (workhorse Ni-base superalloy) with minimized interaction at the interface. Of particular merit is that no intermediate layer (between the Ti alloy and Ni-base superalloy) was needed for bonding. Characterization of the bi-metallic weld included macro-and microstructural examination of the flash and interface regions and evaluation of the hardness.

Joining sheets made from dissimilar materials by hole hemming

2022 ◽  
pp. 146442072110726
Author(s):  
Mohammad Mehdi Kasaei ◽  
Lucas FM da Silva
Keyword(s):  
Mechanical Properties ◽  
Research Work ◽  
Dissimilar Materials ◽  
Element Analysis ◽  
Lightweight Structures ◽  
Lap Shear ◽  
Gradual Failure ◽  
Peel Tests ◽  
Dp780 Steel ◽  
Joining Process

This research work presents a new joining process based on the hemming process for attaching sheets made from dissimilar materials with very different mechanical properties. The process is termed ‘hole hemming’ and consists in producing a mechanical interlock between pre-drilled holes which can be made anywhere on the sheets. The process is carried out in a two-stage operation including flanging the hole of an outer sheet and bending the flange over the hole of an inner sheet. First, the joining stages and the required tools are designed. Then, the joining of DP780 steel and AA6061-T6 aluminium alloy sheets, which are applied to manufacture lightweight structures in the automotive industries, is investigated using finite element analysis. Results show that the hole hemming process is able to successfully join these materials without fracture. The hole-hemmed joint withstood the maximum forces of 2.5 and 0.5 kN in single-lap shear and peel tests, respectively, and failed with hole bearing mode which is known as a gradual failure mode. The results demonstrate the applicability of the hole hemming process for joining dissimilar materials.

scholarly journals A Quality Study of a Self-Piercing Riveted Joint between Vibration-Damping Aluminum Alloy and Dissimilar Materials

2020 ◽  
Vol 10 (17) ◽  
pp. 5947
Author(s):  
Dong Hyuck Kam ◽  
Taek Eon Jeong ◽  
Jedo Kim
Keyword(s):  
Aluminum Alloy ◽  
Failure Modes ◽  
Mechanical Performance ◽  
Dissimilar Materials ◽  
Vibration Damping ◽  
Shear Load ◽  
Load Testing ◽  
Tensile Shear ◽  
Reinforced Plastic ◽  
Riveted Joints

This study investigates the quality of self-piercing riveted joints between vibration-damping aluminum (Al) and other dissimilar materials, namely aluminum alloy (AL5052-H32), steel alloy (GA590DP), and carbon-reinforced plastic (CFRP). The effects of die types (flat, cone, and nipple) on the geometrical characteristics and mechanical performance of the joints are studied using a cross-section examination and tensile shear load testing. The failure modes of each joint are also presented, showing the nature of the forces leading to the joint failures. The results indicate that, for all configurations, adequate joining between vibration-damping Al with AL5052-H32 is expected with a maximum shear load up to 3.28 kN. A shear load up to 3.6 kN was measured for the joints with GA590DP panels with acceptable top and bottom seal characteristics. A vibration-damping Al panel can only be positioned at the bottom when riveting with CFRP due to the brittle nature of CFRP. A tensile shear load up to 2.26 kN was found, which is the lowest amongst the materials tested in this study.

Study of the Proper Sintering Conditions of Anionically-Polymerized Polyamide 6 Matrices for the Fabrication of Greencomposites

2012 ◽  
Vol 713 ◽  
pp. 121-126
Author(s):  
A. Alfonso ◽  
J. Andrés ◽  
J.A. García
Keyword(s):  
Material Characterization ◽  
Mechanical Performance ◽  
In Situ Polymerization ◽  
Research Work ◽  
Polyamide 6 ◽  
Liquid Composite Molding ◽  
Thermoplastic Matrix ◽  
Composite Molding ◽  
Long Fiber Thermoplastic

The present research work assesses the manufacture of long fiber thermoplastic matrix composite materials (GreenComposites). Thermoplastic matrices are too viscous to be injected into the conventional LCM (Liquid Composite Molding) molds, and then epoxy, polyester or vinylester resins are used. Nevertheless, the groundbreaking anionic polymerization of caprolactam allows such a synthesis of a thermoplastic APA6 matrix inside the mold. This matrix is sintered from the starting monomers, and presents high mechanical performance and recyclability. In order to do the reactive injection in a LCM mold, it is necessary to control the polymerization mechanism of such a thermoplastic matrix. This paper puts special emphasis on detecting and solving all problems which arose during synthesis. For instance, moisture values were assessed for all starting reactants, since humidity keeps polymerization from occurring. It is thought that once the synthesis and the resulting material characterization are well controlled, the manufacture of GreenComposites through in situ polymerization, as well as addition of state-of-the-art fabrics such as basalt, can proceed successfully.

SUSTAINABLE ULTRA-HIGH-PERFORMANCE GLASS CONCRETE FOR INFRASTRUCTURES

2017 ◽  
Vol 4 (1) ◽  
Author(s):  
Arezki Tagnit-Hamou ◽  
Nancy A. Soliman
Keyword(s):  
High Performance ◽  
Glass Powder ◽  
Mechanical Performance ◽  
High Performance Concrete ◽  
Low Cost ◽  
Research Work ◽  
High Strength ◽  
Quartz Powder ◽  
Ultra High Performance Concrete ◽  
Powder Particles

This paper presents research work on the development of a green type of ultra-high-performance concrete using ground glass powders with different degrees of fineness (UHPGC). This article presents the development of an innovative, low-cost, and sustainable UHPGC through the use of glass powder to replace cement, and quartz powder particles. An UHPGC with a compressive strength (fc) of up to 220 MPa was prepared and its fresh, and mechanical properties were investigated. The test results indicate that the fresh UHPGC properties were improved when the cement and quartz powder were replaced with non-absorptive glass powder particles. The strength improvement can be attributed to the glass powder’s pozzolanicity and to its mechanical performance (very high strength and elastic modulus of glass). A case study of using this UHPGC is presented through the design and construction of a footbridge. Erection of footbridge at University of Sherbrooke Campus using UHPGC is also presented as a full-scale application.

Investigation of a Duct Burner Design Using CFD in Comparison With Full-Scale Experiments

2003 ◽  
Author(s):  
Michael A. Lorra ◽  
Carol A. Schnepper ◽  
Stephen Somers
Keyword(s):  
Experimental Testing ◽  
Full Range ◽  
Research Work ◽  
Operating Conditions ◽  
Cfd Modeling ◽  
Exhaust Gas ◽  
Ongoing Research ◽  
Water Steam ◽  
Duct Burner ◽  
Turbine Exhaust

Most new duct burners are supplied to heat recovery steam generator (HRSG) manufacturers for use in cogeneration systems. Key components of a simple cycle cogeneration plant include a turbine, generator, turbine exhaust gas duct, duct burner (optional), HRSG and downstream flue gas cleaning equipment. New developments in gas turbine technology are changing the boundary conditions for supplemental firing. In response, John Zink has an ongoing research project for the development of new duct burners achieving ultra low NOx emissions maintaining a good flame quality. The scope of this research work includes computational fluid dynamic modeling (CFD) and experimental testing of current design duct burner to obtain baseline data comparable with CFD results, and various experimental configurations through a full range of expected operating conditions. Experimental testing is performed in a test furnace at John Zink Company, Tulsa. Turbine exhaust gas (TEG) is simulated using John Zink Duct burners, which are supplied with air from a combustion air fan. Different O2 levels can be achieved by a combined water/steam injection. The temperature level of the TEG to the test burner can be adjusted with an air-cooled heat exchanger. Temperature and concentration measurements can be made at the test burner location and in the stack. Flame length, as well as NOx and CO emissions were measured for each data point. CFD modeling focused on the performance effects of turbine exhaust gas flow mal-distribution and the investigation on how reliable CFD models are, regarding flame stability calculations and NOx production. The results of this comprehensive testing and results from the CFD calculations will be compared and presented.

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