Joining of AA6061 to polyvinyl chloride via hot extrusion

2019 ◽  
Vol 11 (2) ◽  
pp. 286-302
Author(s):  
Isam Tareq Abdullah ◽  
Sabah Khammass Hussein ◽  
Abbas Khammas Hussein
Keyword(s):  
Shear Strength ◽  
Polyvinyl Chloride ◽  
Process Parameters ◽  
Base Material ◽  
Hot Extrusion ◽  
Element Model ◽  
Hole Diameter ◽  
Joint Shear Strength ◽  
Content Type ◽  
Rotating Speed

Purpose The purpose of this paper is to join aluminium alloy AA6061 with polyvinyl chloride (PVC) sheets using the friction spot technique. Design/methodology/approach The AA6061 specimen was drilled with a semi-conical hole and put over the PVC specimen with a lap configuration. A friction spot technique was used to generate the required heat to melt and extrude the PVC through the aluminium hole. In this study, three process parameters were used: time, plunging depth and rotating speed of the tool. Thermal finite element model was built to analyse the process temperature. Effect of the process parameters on the joint shear strength and temperature was analysed using the design of experiments method. The microstructure investigation of the joint cross section was examined. Findings The input heat melted and extruded the polymer into the aluminium hole with the aid of tool pressure. A mechanical interlock was observed at the interface line between the polymer and aluminium. The scattered aluminium fragments into the molten polymer increased the shear strength of the joint. The hole diameter exhibited the highest effect on the joint strength compared with the other parameters. Specimen of minimum hole diameter recorded the maximum shear strength of 224 MPa. The proposed model gave a good agreement with the experimental data. Originality/value For the first time, the PVC was joined with AA6061 by the hot extrusion using the friction spot technique. The shear strength of joint reached 7.5 times of the base material (PVC).

Spot lap joining of AA5052 to AISI 1006 by aluminium extrusion via friction forming technique

2019 ◽  
Vol 15 (6) ◽  
pp. 1337-1351 ◽  
Author(s):  
Sabah Khammass Hussein ◽  
Isam Tareq Abdullah ◽  
Abbas Khammas Hussein
Keyword(s):  
Shear Strength ◽  
Process Parameters ◽  
Maximum Temperature ◽  
Joint Shear Strength ◽  
Content Type ◽  
Pull Out ◽  
Modes Of Failure ◽  
Joint Efficiency ◽  
Joint Shear ◽  
Joining Process

Purpose The purpose of this paper is to join AA5052 to AISI 1006 steel sheets using the spot friction forming technique. Design/methodology/approach A steel sheet was pre-holed with a diameter of 4.8 mm and pre-threaded with a single internal M6 thread. Lap joint configuration was used so that the aluminium specimen was put over steel. A rotating tool with a 10 mm diameter was used for the joining process. A Taguchi method was used to design three process parameters (plunging tool depth, rotating speed and preheating time), with three levels for each parameter. The effect of the process parameters on the joint shear strength was analysed. The macrostructure, microstructure and scanning electron microscope of the joint were investigated. The temperature distribution during the joining process was recorded. Findings The formed aluminium was extruded through the steel hole and penetrated through the thread slot. A mechanical interlock was achieved between the extruded aluminium and the steel. The plunging depth of the tool exhibited a significant effect on the joint shear strength. The joint efficiency increased gradually as the plunging depth increased. Two modes of failure were found shear and pull-out. The maximum temperature during the process reached 50 per cent of aluminium’s melting point. Originality/value For the first time, AA5052 was joined with AISI 1006 steel using a friction spot forming technique with an excellent joint efficiency.

Shear strength and temperature distribution model of friction spot lap joint of high density polyethylene with aluminum alloy 7075

2019 ◽  
Vol 10 (4) ◽  
pp. 469-483 ◽  
Author(s):  
Isam Tareq Abdullah ◽  
Sabah Khammass Hussein
Keyword(s):  
Shear Strength ◽  
Temperature Distribution ◽  
High Density Polyethylene ◽  
Contact Region ◽  
High Density ◽  
Distribution Model ◽  
Lap Joint ◽  
Content Type ◽  
Rotating Speed ◽  
Model Of Friction

Purpose The purpose of this paper is to join a sheet of the AA7075 with the high-density polyethylene (HDPE) by a lap joint using friction spot processing and investigate the temperature distribution of joint during this process using the finite element method (FEM). Design/methodology/approach A semi-conical hole was manufactured in the AA7075 specimen and a lap joint configuration was prepared with the HDPE specimen. A rotating tool was used to generate the required heat to melt the polymer by the friction with the AA7075 specimen. The applied tool force moved the molten polymer through the hole. Four parameters were used: lower diameter of hole, rotating speed, plunging depth and time. The results of shear test were analyzed using the Taguchi method. A FEM was presented to estimate the temperature distribution of joint during the process. Findings All specimens failed by shearing the polymer at the lap joint region without dislocation. The specimens of the smallest diameter exhibited the highest shear strength at the lap joint. The maximum ranges of temperature were recorded at the contact region between the rotating tool and the AA7075 specimen. The tool plunging depth recorded the highest effect on the generated heat compared with the rotating speed and plunging time. Originality/value For the first time, the AA7075 sheet was joined with the HDPE sheet by friction spot processing. The temperature distribution of this joint was simulated using the FEM.

Exterior RC joints subjected to monotonic and cyclic loading

2020 ◽  
Vol 37 (7) ◽  
pp. 2319-2336 ◽  
Author(s):  
Yasmin Murad ◽  
Haneen Abdel-Jabar ◽  
Amjad Diab ◽  
Husam Abu Hajar
Keyword(s):  
Shear Strength ◽  
Cyclic Loading ◽  
Axial Load ◽  
Monotonic Loading ◽  
Concrete Compressive Strength ◽  
Joint Shear Strength ◽  
Content Type ◽  
Loading Case ◽  
Joint Shear ◽  
Test Points

Purpose The purpose of this study is to develop two empirical models that predict the shear strength of exterior beam-column joints exposed to monotonic and cyclic loading using Gene expression programming (GEP). Design/methodology/approach The GEP model developed for the monotonic loading case is trained and validated using 81 data test points and that for cyclic loading case is trained and validated using 159 data test points that collected from different 9 and 39 experimental programs, respectively. The parameters that are selected to develop the cyclic GEP model are concrete compressive strength, joint aspect ratio, column axial load and joint transverse reinforcement. The monotonic GEP model is developed using concrete compressive strength, column depth, joint width and column axial load. Findings GEP models are proposed in this paper to predict the joint shear strength of beam-column joints under cyclic and monotonic loading. The predicted results obtained using the GEP models are compared to those calculated using the ACI-352 code formulations. A sensitivity analysis is also performed to further validate the GEP models. Originality/value The proposed GEP models provide an accurate prediction for joint shear strength of beam-column joints under cyclic and monotonic loading that is more fitting to the experimental database than the ACI-352 predictions where the GEP models have higher R2 value than the code formulations.

Joining of aluminium alloy to pre-holed carbon steel by aluminium extrusion using friction spot method

2019 ◽  
Vol 11 (6) ◽  
pp. 849-860
Author(s):  
Isam Tareq Abdullah ◽  
Sabah Khammass Hussein ◽  
Abbas Khammas Hussein
Keyword(s):  
Shear Strength ◽  
Carbon Steel ◽  
Aluminium Alloy ◽  
Heating Time ◽  
X Ray Diffraction ◽  
Content Type ◽  
Rotating Speed ◽  
Pull Out ◽  
Aluminium Extrusion ◽  
First Time

Purpose The purpose of this paper is to join sheets of an aluminium alloy together with pre-holed carbon steel via friction spot technique. Design/methodology/approach An AISI 1006 steel sheet was a pre-holed with a 4.8 mm diameter and put under AA5052 sheet with a lap joint configuration. The joining process was carried out by extruding the aluminium through the steel hole using a rotating tool of 10 mm diameter. Furthermore, three process parameters (pre-heating time, rotating speed and plunging depth of the tool) with three values for each parameter were used to study their effects on the joints quality. In order to join samples, nine experiments were designed according to a Taguchi method. Shear strength, microstructure and X-ray diffraction tests of the joint were carried out. Findings The joining mechanism occurred by a mechanical interlock of the extruded aluminium with the inner surface of the steel hole. The tool plunging depth had a significant effect on the shear strength of the joint. The shear strength of two joints exceeded the shear strength of the wrought material (AA5052). All samples failed with two modes: pull-out and shearing of the extruded aluminium. Originality/value For the first time, the extrusion technique was used to join AA5052 sheet together with pre-holed carbon steel, with a perfect joint efficiency.

Laser Transmission Welding of Nylon Tubes and Plates

2010 ◽  
Vol 132 (5) ◽  
Author(s):  
A Kritskiy ◽  
G. Zak ◽  
P. J. Bates
Keyword(s):  
Shear Strength ◽  
Laser Beam ◽  
Process Parameters ◽  
Laser Power ◽  
Angular Speed ◽  
Joint Shear Strength ◽  
Laser Transmission Welding ◽  
Joint Shear ◽  
Number Of Passes ◽  
Conical Mirror

In this study, nylon tubes were welded to nylon plaques using laser transmission welding. A conical mirror inserted inside the tube was used to guide the laser beam along the weld path around the inner circumference of the tube. The effect of beam location with respect to the tip of conical mirror on beam distortion was modeled and assessed experimentally. The effects of the laser power, the angular speed, and the number of passes on the joint shear strength were examined. Process parameters that gave good joint strengths were identified.

Investigation of the Mandrel’s Stress States and Wear Conditions during Tube Hot Extrusion of IN690 Superalloy

2014 ◽  
Vol 622-623 ◽  
pp. 111-118
Author(s):  
Jing Yang ◽  
Qing Jun Zhou ◽  
Chao Yang Sun ◽  
Dong Liu
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Hot Extrusion ◽  
Element Model ◽  
Extrusion Process ◽  
Wear Model ◽  
Extrusion Speed ◽  
Preheating Temperature ◽  
Stress States ◽  
Symmetric Finite Element

A 2D axi-symmetric finite element model for tube hot extrusion process has been established by consideration of the billet transfer, glass lubrication, constitutive equation of IN690 superalloy and modified Archard wear model. The influence of extrusion process parameters on the stress state and wear conditions of the mandrel surface has been investigated. The results show that under the optimal extrusion process parameters of the extrusion speed of 250 mm/s, the friction factor of 0.05 and the billet preheating temperature of 1250 ̊C, the mandrel can be reused 200 times when it is fixed and 500 times when it moves with the ram.

scholarly journals Vibration characteristics of triple-gear-rotor system in compressed air energy storage under variable torque load

2021 ◽  
Vol 104 (1) ◽  
pp. 003685042098705
Author(s):  
Xinran Wang ◽  
Yangli Zhu ◽  
Wen Li ◽  
Dongxu Hu ◽  
Xuehui Zhang ◽  
...  
Keyword(s):  
Large Scale ◽  
Three Dimensional ◽  
Element Model ◽  
Rotor System ◽  
Dynamic Responses ◽  
System Response ◽  
Rotating Speed ◽  
Torque Load ◽  
Set Up ◽  
Two Stages

This paper focuses on the effects of the off-design operation of CAES on the dynamic characteristics of the triple-gear-rotor system. A finite element model of the system is set up with unbalanced excitations, torque load excitations, and backlash which lead to variations of tooth contact status. An experiment is carried out to verify the accuracy of the mathematical model. The results show that when the system is subjected to large-scale torque load lifting at a high rotating speed, it has two stages of relatively strong periodicity when the torque load is light, and of chaotic when the torque load is heavy, with the transition between the two states being relatively quick and violent. The analysis of the three-dimensional acceleration spectrum and the meshing force shows that the variation in the meshing state and the fluctuation of the meshing force is the basic reasons for the variation in the system response with the torque load. In addition, the three rotors in the triple-gear-rotor system studied show a strong similarity in the meshing states and meshing force fluctuations, which result in the similarity in the dynamic responses of the three rotors.

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

scholarly journals Corrosion Behavior, Microstructure and Mechanical Properties of Novel Mg-Zn-Ca-Er Alloy for Bio-Medical Applications

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 519
Author(s):  
Devadas Bhat Panemangalore ◽  
Rajashekhara Shabadi ◽  
Manoj Gupta
Keyword(s):  
Mechanical Properties ◽  
Corrosion Behavior ◽  
Base Material ◽  
Hot Extrusion ◽  
Secondary Phases ◽  
Zinc Alloys ◽  
Alloying Additions ◽  
Degradation Rates ◽  
Master Alloys ◽  
Melt Deposition

In this study, the effect of calcium (Ca) and erbium (Er) on the microstructure, mechanical properties, and corrosion behavior of magnesium-zinc alloys is reported. The alloys were prepared using disintegrated melt deposition (DMD) technique using the alloying additions as Zn, Ca, and Mg-Er master alloys and followed by hot extrusion. Results show that alloying addition of Er has significantly reduced the grain sizes of Mg-Zn alloys and also when compared to pure magnesium base material. It also has substantially enhanced both the tensile and the compressive properties by favoring the formation of MgZn2 type secondary phases that are uniformly distributed during hot-extrusion. The quaternary Mg-Zn-Ca-Er alloy exhibited the highest strength due to lower grain size and particle strengthening due to the influence of the rare earth addition Er. The observed elongation was a result of extensive twinning observed in the alloys. Also, the degradation rates have been substantially reduced as a result of alloying additions and it is attributed to the barrier effect caused by the secondary phases.

scholarly journals Geometrical Effects on Ultrasonic Al Bump Direct Bonding for Microsystem Integration: Simulation and Experiments

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 750
Author(s):  
Jun-Hao Lee ◽  
Pin-Kuan Li ◽  
Hai-Wen Hung ◽  
Wallace Chuang ◽  
Eckart Schellkes ◽  
...  
Keyword(s):  
Shear Strength ◽  
Joint Strength ◽  
Maximum Stress ◽  
Geometrical Parameters ◽  
Experimental Demonstration ◽  
Joint Shear Strength ◽  
Element Analysis ◽  
Ultrasonic Bonding ◽  
Simulation Results ◽  
Geometrical Effects

This study employed finite element analysis to simulate ultrasonic metal bump direct bonding. The stress distribution on bonding interfaces in metal bump arrays made of Al, Cu, and Ni/Pd/Au was simulated by adjusting geometrical parameters of the bumps, including the shape, size, and height; the bonding was performed with ultrasonic vibration with a frequency of 35 kHz under a force of 200 N, temperature of 200 °C, and duration of 5 s. The simulation results revealed that the maximum stress of square bumps was greater than that of round bumps. The maximum stress of little square bumps was at least 15% greater than those of little round bumps and big round bumps. An experimental demonstration was performed in which bumps were created on Si chips through Al sputtering and lithography processes. Subtractive lithography etching was the only effective process for the bonding of bumps, and Ar plasma treatment magnified the joint strength. The actual joint shear strength was positively proportional to the simulated maximum stress. Specifically, the shear strength reached 44.6 MPa in the case of ultrasonic bonding for the little Al square bumps.

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