Sensor Fusion and On-Line Monitoring of Friction Stir Blind Riveting for Lightweight Materials Manufacturing

2021 ◽  
pp. 1-36
Author(s):  
Zhe Gao ◽  
Haris Khan ◽  
Jingjing Li ◽  
Weihong Guo
Keyword(s):  
Sensor Fusion ◽  
Failure Modes ◽  
Processing Parameters ◽  
Data Driven ◽  
Structure Property ◽  
Cross Sectional ◽  
Friction Stir ◽  
In Situ Data ◽  
Lap Shear

Abstract This research focused on developing a hybrid quality monitoring model through combining the data driven and key engineering parameters to predict the friction stir blind riveting (FSBR) joint quality. The hybrid model was formulated through utilizing the in-situ processing and joint property data. The in-situ data involved sensor fusion (force and torque signals) and key processing parameters (spindle speed, feed rate and stacking sequence) for data-driven modeling. The quality of the FSBR joints was defined by the tensile strength. Further, the joint cross-sectional analysis and failure modes in lap-shear tests were employed to confirm the efficacy of the proposed model and development of the process-structure-property relationship.

Dissimilar Friction Stir Lap Welding of AA2198 and AA7075 Sheets: Forces, Microstructure and Mechanical Properties

2021 ◽  
Author(s):  
Antonello Astarita ◽  
Fausto Tucci ◽  
Alessia Teresa Silvestri ◽  
Michele Perrella ◽  
Luca Boccarusso ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Welding Process ◽  
Processing Parameters ◽  
Processing Parameter ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Shear ◽  
Microstructure And Mechanical Properties ◽  
Lap Welding ◽  
Factorial Design Of Experiments

Abstract This paper deals with the dissimilar friction stir lap welding of AA2198 and AA7075 sheets. The influence of processing parameters, namely welding speed and tool rotational speed on joint features, microstructure, and mechanical properties were investigated implementing a full factorial design of experiments. During the welding process, axial and transversal forces were continuously measured using a dedicated sensed fixture aiming at the correlation of this processing parameter with the quality of the achieved joints. The reported outcomes showed a very narrow processing window in which it was possible to avoid the formation of defects while the formation of an hook was observed for all the joints welded. The influence of the weld bead morphology on the lap shear strength was elucidated proving that the strength is ruled by the hook morphology. A correlation between the process parameters and the forces arising was also attempted. The final microstructure of the joints was studied and explained and also compared with the microhardness results.

In-Situ Continuous Process for Bonding Glass-Fiber Reinforced Polypropylene to Wood

1999 ◽  
Author(s):  
Karthik Ramani ◽  
Michael Smith ◽  
Heming Dai
Keyword(s):  
Failure Modes ◽  
Continuous Process ◽  
Heating Time ◽  
Bond Line ◽  
Process Conditions ◽  
Processing Times ◽  
Lap Shear ◽  
Glass Fiber Reinforced ◽  
Anisotropic Fiber

Abstract Process conditions are developed for the manufacture of composite reinforcement for oak. Commingled glass and polypropylene fibers are consolidated in-situ on the surface of oak. Processing times from 30 to 120 seconds and pressures from .34 MPa to 1.4 MPa are tested. Micrographs of the composite and bond line reveal anisotropic fiber distribution in the composite, dry reinforcing fibers, voids, and incomplete consolidation. These microstructures are correlated with the processing problems which cause them, including insufficient heating time, poor matrix/glass mixing, and insufficient pressure to suppress void development. Lap shear strength and failure modes are related to microstructural features.

Effect of stirring time on the mechanical behavior of friction stir spot weld of Al 6061-T6 lap-shear configuration

2018 ◽  
Vol 233 (10) ◽  
pp. 3583-3591 ◽  
Author(s):  
Amirreza Shahani ◽  
Ali Farrahi
Keyword(s):  
Mechanical Behavior ◽  
Failure Modes ◽  
Static Strength ◽  
High Load ◽  
Welding Condition ◽  
Friction Stir ◽  
Al 6061 ◽  
Lap Shear ◽  
Low Load ◽  
Stirring Time

The effect of five different stirring times of friction stir spot welding on lap-shear specimens of Al 6061-T6 alloy has been experimentally analyzed. The welding condition with 2 s of stirring shows the optimum mechanical behavior in comparison to the others. The static strength and fatigue behavior of the joint are justified using the microhardness profiles. The static results prove that the increase of stirring time beyond the 2 s case has little effect on improving the static strength. The fatigue results reveal two different failure modes, which are shear fracture at high load levels and transverse crack growth at low load levels. At medium load levels, although the final failure is similar to high load levels, the transverse growth of the crack outside the welding zone, just like low load levels, is also observed.

scholarly journals In Situ and Post-Mortem Characterizations of Ultrasonic Spot Welded AZ31B and Coated Dual Phase 590 Steel Joints

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 899 ◽  
Author(s):  
Jian Chen ◽  
Yong Chae Lim ◽  
Donovan Leonard ◽  
Hui Huang ◽  
Zhili Feng ◽  
...  
Keyword(s):  
High Speed ◽  
Tensile Tests ◽  
Fatigue Tests ◽  
Image Correlation ◽  
Joint Interface ◽  
Welding Time ◽  
Cross Sectional ◽  
Welding Condition ◽  
Lap Shear

Ultrasonic spot welding using different welding conditions was applied to join dissimilar metals of galvanized DP590 steel and AZ31B magnesium sheets. In situ high-speed imaging, digital image correlation, and infrared thermography were utilized to quantitatively study the interfacial relative motion, surface indentation, and heat generation across the joint faying interface and the sheet/sonotrode interfaces under the welding condition of moderate welding power and short welding time. For welds made with high power and long welding time, lap shear tensile tests as well as fatigue tests were carried out. Different fracture modes were observed after the lap shear tensile tests and fatigue tests performed under different peak loads. Post-weld cross-sectional analysis with scanning electron microscopy coupled with energy dispersive X-Ray spectroscopy revealed the variation of morphology and chemical composition at the joint interface for welds made with different welding conditions.

Microstructure and Mechanical Properties of Refilled Friction Stir Spot Welding of Commercial Pure Aluminium

2013 ◽  
Vol 765 ◽  
pp. 776-780 ◽  
Author(s):  
S. Venukumar ◽  
S. Muthukumaran ◽  
Y. Swaroop
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
High Energy ◽  
Friction Stir Spot Welding ◽  
Pure Aluminium ◽  
Tool Rotational Speed ◽  
Cross Sectional ◽  
Friction Stir ◽  
Lap Shear ◽  
Probe Hole

Aluminium and magnesium alloys are expected to make considerable contributions in reducing the weight of automobiles as they are increasingly used as an alternative to steel; improving fuel economy and vehicle performance while simultaneously reducing emissions. Higher electrical and thermal conductivities of these materials make them difficult to weld using existing resistance spot welding leading to high energy consumption. Friction stir spot welding has proven to be a better alternative to weld these materials. But a probe hole left behind is the main problem in conventional Friction Stir Spot welding (FSSW). In the present work a new method has been developed to refill the probe hole using an additional filler plate known as Refill Friction Stir Spot welding (RFSSW). This new refilling technique and the conventional FSSW process were both used to weld commercially pure aluminium lap shear specimens and the results were compared. The effect of tool rotational speed on mechanical and metallurgical properties were studied in both cases. Static shear strength of RFSSW weld samples was found to be better than conventional FSSW process at higher tool rotational speed. This is explained in terms of effective increase in cross sectional area of weld nugget due addition of more material from the filler plate thereby eliminating the probe hole.

scholarly journals High‐Speed Atomic Force Microscopy: Large‐Range HS‐AFM Imaging of DNA Self‐Assembly through In Situ Data‐Driven Control (Small Methods 7/2019)

Small Methods ◽  
2019 ◽  
Vol 3 (7) ◽  
pp. 1970022
Author(s):  
Adrian P. Nievergelt ◽  
Christoph Kammer ◽  
Charlène Brillard ◽  
Eva Kurisinkal ◽  
Maartje M. C. Bastings ◽  
...  
Keyword(s):  
Atomic Force Microscopy ◽  
Self Assembly ◽  
High Speed ◽  
Large Range ◽  
Data Driven ◽  
Force Microscopy ◽  
In Situ Data ◽  
Atomic Force ◽  
Afm Imaging

Classification of Failure Modes in Friction Stir Blind Riveted Lap-Shear Joints With Dissimilar Materials

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Wei-Ming Wang ◽  
Haris Ali Khan ◽  
Jingjing Li ◽  
Scott F. Miller ◽  
A Zachary Trimble
Keyword(s):  
Failure Modes ◽  
Dissimilar Materials ◽  
Polymeric Composite ◽  
Tensile Tests ◽  
Great Promise ◽  
Lightweight Structures ◽  
Friction Stir ◽  
Lap Shear ◽  
Transportation Sector ◽  
Static Tensile

In transportation sector, there is an increasing need for joining dissimilar materials for lightweight structures; however, substantial barriers to the joining of dissimilar materials have led to an investigation and development of new joining techniques. Friction stir blind riveting (FSBR), a newly invented method, has shown great promise in joining complex structures with dissimilar materials. The process can be utilized more effectively if knowledge regarding the failure mechanisms of the FSBR joints becomes available. This research focuses on investigating the different mechanisms that lead to a failure in FSBR joints under lap-shear tensile tests. An in situ, nondestructive, acoustic emission (AE) testing method was applied during quasi-static tensile tests to monitor the initiation and evolution of damage in FSBR joints with different combinations of dissimilar materials (including aluminum, magnesium, and a carbon-fiber reinforced polymeric composite). In addition, a fractographic analysis was conducted to characterize the failure modes. Finally, based on the analysis, the distinct failure modes and damage accumulation processes for the joints were identified. An AE accumulative hit history curve was found to be efficient to discriminate the deformation characteristics, such as the deformation zone and failure mode, which cannot be observed through a traditional extensometer measurement method. In addition, the AE accumulative hit history curve can be applied to predict the failure extension or moment of FSBR joints through an identification of the changes in curve slope. Such slope changes usually occur around the middle of Zone II, which is defined in this study.

scholarly journals In Situ Computed Tomography—Analysis of a Single-Lap Shear Test with Clinch Points

Materials ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 1859
Author(s):  
Daniel Köhler ◽  
Robert Kupfer ◽  
Juliane Troschitz ◽  
Maik Gude
Keyword(s):  
Computed Tomography ◽  
Shear Test ◽  
Failure Modes ◽  
Lightweight Design ◽  
Ex Situ ◽  
Aluminum Sheets ◽  
Lap Shear ◽  
Lap Shear Test ◽  
Single Lap Shear Test

As lightweight design gains more and more attention, time and cost-efficient joining methods such as clinching are becoming more popular. A clinch point’s quality is usually determined by ex situ destructive analyses such as microsectioning. However, these methods do not yield the detection of phenomena occurring during loading such as elastic deformations and cracks that close after unloading. Alternatively, in situ computed tomography (in situ CT) can be used to investigate the loading process of clinch points. In this paper, a method for in situ CT analysis of a single-lap shear test with clinched metal sheets is presented at the example of a clinched joint with two 2 mm thick aluminum sheets. Furthermore, the potential of this method to validate numerical simulations is shown. Since the sheets’ surfaces are locally in contact with each other, the interface between both aluminum sheets and therefore the exact contour of the joining partners is difficult to identify in CT analyses. To compensate for this, the application of copper varnish between the sheets is investigated. The best in situ CT results are achieved with both sheets treated. It showed that with this treatment, in situ CT is suitable to properly observe the three-dimensional deformation behavior and to identify the failure modes.

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