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.

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.

An investigation on the effect of nanoparticle reinforcement and weld surface shape on bending behavior of rotary friction-welded high-density polyethylene

2021 ◽  
pp. 146442072110441
Author(s):  
Vahid Asghari ◽  
Abdolvahed Kami ◽  
Abbasali Bagheri
Keyword(s):  
High Density Polyethylene ◽  
Joint Strength ◽  
Bending Strength ◽  
Welded Joint ◽  
High Density ◽  
Surface Shape ◽  
Bending Tests ◽  
Three Point Bending ◽  
Rotary Friction Welding ◽  
Bending Behavior

In this research, high-density polyethylene rods were joined together using rotary friction-welding. The effects of nanoparticle reinforcement and weld surface shape on the welded joint strength were investigated. To this aim, high-density polyethylene rods with a length of 50 mm and a diameter of 22 mm were machined, and three weld surface shapes, that is, flat, step, and conic shapes (on male and female counterparts), were created. The high-density polyethylene rods were rotary friction-welded with the addition of ZnO and SiO2 nanoparticles. The bending strength of rotary friction-welded rods was assessed by conduction of three-point bending tests. The results showed that both the weld surface shape and nanoparticles influence the bending strength of the welded joints. It was found that the step sample welds have higher bending strength (average bending depth and force of 6.27 mm and 2027.8 N, respectively). Furthermore, except for the case of flat samples, the addition of the reinforcement nanoparticles resulted in the improvement of the bending strength of the rotary friction-welded rods.

The influence of the shoulder depth on the properties of the thin sheet joint made by FSW technology

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Rafał Burek ◽  
Dawid Wydrzyński ◽  
Andrzej Kubit ◽  
Waldemar Łogin
Keyword(s):  
Aluminium Alloy ◽  
Joint Strength ◽  
Welding Process ◽  
Lap Joints ◽  
Numerical Control ◽  
Thick Sheet ◽  
Content Type ◽  
Friction Stir ◽  
Tool Shoulder ◽  
The Face

Purpose This paper aims to experimentally determine the influence of the tool shoulder depth value on the structural and strength properties of the single lap joints made of 7075-T6 aluminium alloy made with friction stir welding (FSW) technology. The aim of the preliminary tests is to optimize the parameters of joining process of thin-walled structures such as the skin-stringer joint or skin-frame joint of the aircraft fuselage. The tests were carried out for materials commonly used in such structures, i.e. 1.6 mm thick sheet 7075–T6 aluminium alloy with cladding on both sides (cladding thickness 4% per each side). The layer of clad protects plates from corrosion. Design/methodology/approach This study shows the results of the investigation for the joining of 7075–T6 ALCLAD aluminium alloy sheets. The welding process was carried out on a computer numerical control milling machine SOLARUCE TA–20A. Linear FSW welding was performed using a commercial tool from RSS SCHILLING with the symbol 10–K–4–Z–M–O, which is fabricated of hot work tool steel. Constant parameters of the technological process were applied. The welding process was executed for different values of the shoulder depth ZS. Findings This paper investigated the dependence between the thinning of the welded material and the depth value of the tool shoulder during the FSW process. The influence of the depth value of tool shoulder on joint strength in the static tensile/shear test was also performed. With the increase of the depth of the tool, the size of flash and structures of the face of the joint changes as well (its annular surface resulting from the tool’s work and the accompanying process of material flow on the run-off side). Such conditions in the process require a proper tool depression to reduce the occurrence of flash and minimize material thinning to achieve high joint strength and maintain the conditions for plasticizing the material. Practical implications Based on the experimental tests carried out, a number of guidelines for the correct conduct of the welding process can be outlined. Originality/value Taking into account the various aspects of the process, the optimal range of the tool depth into the material is a value of approximately 0.06 mm. At this value, the face of the weld is not porous; the flash is easily removed; and the strength of the joint and the deformation of contact line are at an acceptable quality level.

Tribological modification of high-density polyethylene by using carbon soot from diesel combustion

2016 ◽  
Vol 68 (5) ◽  
pp. 603-610 ◽  
Author(s):  
X.A. Cao ◽  
G.Q. Shao ◽  
K.H. Hu
Keyword(s):  
Abrasive Wear ◽  
Amorphous Carbon ◽  
Tribological Properties ◽  
High Density Polyethylene ◽  
Friction Pair ◽  
High Density ◽  
Exhaust Emission ◽  
Content Type ◽  
Transmission Electron ◽  
Carbon Soot

Purpose The purpose of this paper is to explore the tribological properties of high-density polyethylene (HDPE) modified by carbon soot from the combustion of No. 0 diesel. Design/methodology/approach Carbon soot is characterized using X-ray diffraction, transmission electron microscopy and scanning electronic microscopy. The tribological properties of HDPE samples with carbon soot are investigated on a materials surface tester with a ball-on-disk friction pair. Findings The collected carbon soot mainly comprises amorphous carbon nanoparticles of 50-100 nm in diameter. The main wear behaviours of pure HDPE include abrasive wear and plastic deformation. After adding carbon soot nanoparticles to HDPE, HDPE wear decreases. The appropriate carbon soot content is 8 per cent in HDPE under the selected testing conditions. Compared with other HDPE samples, HDPE with 8 per cent carbon soot has higher melting temperature, lower abrasive wear and better wear resistance. The lubrication of HDPE with carbon soot is due to the formation of a transferring film composed of HDPE, amorphous carbon and graphite carbon. Originality/value The paper reveals the HDPE modification and lubrication mechanisms by using carbon soot from the combustion of diesel. Related research can perhaps provide a potential approach for the treatment of carbon soot exhaust emission.

Reinforcing high-density polyethylene by polyacrylonitrile fibers

2018 ◽  
Vol 47 (1) ◽  
pp. 86-94 ◽  
Author(s):  
Lien Zhu ◽  
Di Wu ◽  
Baolong Wang ◽  
Jing Zhao ◽  
Zheng Jin ◽  
...  
Keyword(s):  
Tensile Strength ◽  
High Density Polyethylene ◽  
Flexural Modulus ◽  
High Density ◽  
Degree Of Crystallinity ◽  
Content Type ◽  
Resistance To Deformation ◽  
Different Content ◽  
The Degree Of Crystallinity ◽  
Pan Fibers

Purpose The purpose of this paper is to find a new method to reinforce high-density polyethylene (HDPE) with polyacrylonitrile fibers (PAN). Furthermore, the crystallinity, viscoelasticity and thermal properties of HDPE composites have also been investigated and compared. Design/methodology/approach For effective reinforcing, samples with different content fillers were prepared. HDPE composites were prepared by melt blending with double-screw extruder prior to cutting into particles and the samples for testing were made using an injection molding machine. Findings With the addition of 9 Wt.% PAN fibers, it was found that the tensile strength and flexural modulus got the maximum value in all HDPE composites and increased by 1.2 times than pure HDPE. The shore hardness, storage modulus and vicat softening point of the composites improved continuously with the increase in the proportion of the fibers. The thermal stability and processability of composites did not change rapidly with the addition of PAN fibers. The degree of crystallinity increased with the addition of PAN fibers. In general, the composites achieve the best comprehensive mechanical properties with the fiber content of 9 Wt.%. Practical implications The fibers improve the strength of the polyethylene and enhance its ability to resist deformation. Originality/value The modified HDPE by PAN fibers in this study have high tensile strength and resistance to deformation and can be used as an efficient material in engineering, packaging and automotive applications.

Process Characteristics of Laser Brazing Aluminium Alloys

2005 ◽  
Vol 6-8 ◽  
pp. 135-142 ◽  
Author(s):  
Fritz Klocke ◽  
A. Castell-Codesal ◽  
D. Donst
Keyword(s):  
Aluminium Alloys ◽  
Smooth Surface ◽  
Joint Strength ◽  
Processing Time ◽  
Laser Brazing ◽  
Working Temperature ◽  
Process Characteristics ◽  
Laser Joining ◽  
Brazed Joints ◽  
Joining Process

Compared to welding, laser brazing offers a suitable possibility to lower the working temperature and to join unweldable material combinations, while maintaining the numerous advantages of the laser joining process. Beside an acceptable joint strength, the brazed joints are characterised by a smooth surface and seams with almost no pores. As a result of this laser brazing combines the advantages of conventional brazing and laser welding. Within the scope of this paper the laser brazing process and its characteristics are explained in detail. In particular the interrelation of temperature progress, available processing time for brazing/diffusion and the thickness of the diffusion layer is discussed. Subsequently the material specific particularities of laser brazing aluminium alloys are described and discussed with respect to recently gained results.

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