scholarly journals Microstructuring of joining areas in aluminum alloy sheets by Jet Electrochemical Machining

2018 ◽  
Vol 1 (2) ◽  
Author(s):  
Rene Schimmelpfennig ◽  
Matthias Hackert-Oschätzchen ◽  
André Martin ◽  
Andreas Schubert
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Ultrasonic Vibration ◽  
Cross Sections ◽  
Electrochemical Machining ◽  
Limited Area ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Aluminum Sheets ◽  
Jet Electrochemical Machining

In this work the increase of the tensile shear strength by means of microstructuring of the metallic part for ultrasonic vibration assisted joining of hybrid compounds is presented. The aluminum alloy EN AW-5083 and a carbon fibre-reinforced plastic (CFRP) from Bond Laminates are used as a material combination. A suitable method is electrochemical processing (ECM). The microstructuring is carried out with continuous electrolyte free jet machining (Jet-ECM): Characteristic of this technology is the restriction of the electric current to a limited area of the electrolyte jet. After describing the materials and sample geometry used, the Jet-ECM technology and the ultrasonic vibration assisted joining process are explained. The strength of the joint is assessed by means of a tensile shear test. The determined results of the tensile shear strength for hybrid connections between microstructured aluminum sheets and CFRP are compared with those of unstructured aluminum sheets. Furthermore, the influence of the microstructure on the tensile shear strength achieved is discussed using metallographic cross-sections of the joining area.

scholarly journals Resistance Spot Welding Optimization Based on Artificial Neural Network

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
Thongchai Arunchai ◽  
Kawin Sonthipermpoon ◽  
Phisut Apichayakul ◽  
Kreangsak Tamee
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Shear Strength ◽  
Aluminum Alloy ◽  
Parameter Optimization ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot

Resistance Spot Welding (RSW) is processed by using aluminum alloy used in the automotive industry. The difficulty of RSW parameter setting leads to inconsistent quality between welds. The important RSW parameters are the welding current, electrode force, and welding time. An additional RSW parameter, that is, the electrical resistance of the aluminum alloy, which varies depending on the thickness of the material, is considered to be a necessary parameter. The parameters applied to the RSW process, with aluminum alloy, are sensitive to exact measurement. Parameter prediction by the use of an artificial neural network (ANN) as a tool in finding the parameter optimization was investigated. The ANN was designed and tested for predictive weld quality by using the input and output data in parameters and tensile shear strength of the aluminum alloy, respectively. The results of the tensile shear strength testing and the estimated parameter optimization are applied to the RSW process. The achieved results of the tensile shear strength output were mean squared error (MSE) and accuracy equal to 0.054 and 95%, respectively. This indicates that that the application of the ANN in welding machine control is highly successful in setting the welding parameters.

Joining Dissimilar Metals between Steel and Aluminum by TIG Welding

2015 ◽  
Vol 819 ◽  
pp. 45-49 ◽  
Author(s):  
Shamsul Baharin Jamaludin ◽  
Mohd Zahir Abd Latif ◽  
Mohd Noor Mazlee ◽  
Kamarudin Hussin
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Welding Current ◽  
Tig Welding ◽  
Inert Gas ◽  
Dissimilar Metals ◽  
Tensile Shear Strength ◽  
Tensile Shear

The effect of welding current on the joining of mild steel and aluminum 6063 has been investigated. The joining was carried using a tungsten inert gas (TIG) welding. The welding currents used were 30 A to 80 A. The formation of intermetallic reaction layers (IML) and tensile shear strength of the joining were investigated. The result showed that tensile shear strength increased as welding current increased up to 55 A. Microstructural analysis showed that intermetallic reaction layer was formed at the interface between steel and aluminum alloy during welding process. The thickness of IML was decreased with decreasing welding current.

Experimental Research and Analysis of Mechanical Properties of Aluminum Alloy 6063 Adhesive Bonding

2012 ◽  
Vol 271-272 ◽  
pp. 156-162
Author(s):  
Hui Ling Wei ◽  
Qun Gao ◽  
Zhi Jian Zong
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Shear Test ◽  
Adhesive Bonding ◽  
Great Influence ◽  
Surface Treatments ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Adhesive Thickness ◽  
Aluminum Alloy 6063

The different geometric sizes, different adhesive thickness and different surface treatments have great influence on the properties of aluminum alloy 6063 bonding joints. This paper takes single lap joint for object, adopts the tensile shear test, takes the tensile shear strength as the judgment basis, and exploresthe variation inperformance of aluminum alloy 6063 bondingjoints. The test results show that: Aluminum alloy 6063 bonding joints occur serrated yielding phenomenon inthe tensile shear test; In a certain layer thickness range, tensile shear strength of aluminum alloy 6063 bondingjoints correspondingly increaseswiththe thickness of samples increasing; Different surface treatments on aluminum alloy 6063 have a great influence on tensile-shear strength, and mechanical polishing and skim can significantly improve tensile shear strength of aluminum alloy 6063 bonding joints.

Behavior and Quality Evaluation of Electroplastic Self-Piercing Riveting of Aluminum Alloy and Advanced High Strength Steel

2013 ◽  
Vol 135 (1) ◽  
Author(s):  
Ming Lou ◽  
YongBing Li ◽  
YaTing Li ◽  
GuanLong Chen
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
High Strength Steel ◽  
High Strength ◽  
Tensile Shear Strength ◽  
Advanced High Strength Steel ◽  
Tensile Shear ◽  
Cold Forming ◽  
Riveting Process ◽  
Cross Tension

The hybrid use of dissimilar lightweight materials, such as aluminum alloy and advanced high strength steel (AHSS), has become a critical approach to reduce the weight of ground transportation vehicles. Self-piercing riveting (SPR) as a preferred cold-forming fastening method is facing problems like weak interlocking and insufficient penetration, due to the reduced formability of AHSS. In this paper, a new process named electroplastic self-piercing riveting (EP-SPR) was proposed to reduce the deformation resistance of AHSS DP780, by applying a direct current (dc) to it during the riveting process. The influence of dc on force and displacement characteristics throughout the riveting process, joint physical attributes and quasi-static performances for two sheet combinations, e.g., AA6061-T6 to DP780 (combination 1) and DP780 to AA6061-T6 (combination 2), were studied and compared with the traditional SPR joints. The results showed that compared with the traditional SPR joints, the EP-SPR ones increased by 12.5% and 23.3% in tensile-shear strength and cross-tension strengths for combination 1, respectively. For combination 2, even though the EP-SPR joints decreased by 5.8% in tensile-shear strength, it could reduce the penetration risk of bottom AA6061-T6, and present a better energy absorption capability for the increased undercut amount. In addition, the corresponding cross-tension strength of EP-SPR joints still increases by 6.1%.

Effects of Welding Time and Alloy Elements on Mechanical Properties of Aluminum/SPCC Joint Using Resistance Spot Welding

2012 ◽  
Vol 602-604 ◽  
pp. 2123-2129
Author(s):  
Nan Wang ◽  
Tomiko Yamaguchi ◽  
Kazumasa Nishio
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Intermetallic Compound ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Time ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot

In this study, effects of welding time and elements Mg, Si and Cu in aluminum alloys on hardness and tensile shear strength of aluminum alloys/steel joints in resistance spot welding have been investigated. The welding current was kept a constant 10.5kA and electrode force was 1kN. Welding time was increased from 0.067s up to 0.2s with a rise of 0.033s. Two intermetallic compound layers were generated at weld interfacial zones between aluminum alloys and steel during welding process, and the major phases were FeAl3 adjacent and directing to aluminum alloy and Fe2Al5 adjacent and directing to the steel. Diffusion of Si in aluminum alloy occurred at the interface, whereas the diffusion of Mg and Cu was not observed at the interface according to the EPMA analysis results. Hardness of intermetallic compound layers was 13.8GPa, which was about 12 times as much as that of the aluminum alloy. The largest tensile-shear strength was obtained on the condition of 0.134 and 0.167s welding time.

Mechanical and Microstructural Properties of Dissimilar Friction Spot Welded Aluminum Alloy

2008 ◽  
Vol 580-582 ◽  
pp. 389-392
Author(s):  
Chang Keun Chun ◽  
Heung Ju Kim ◽  
Hyeon Jin Cho ◽  
Teuk Ki Kim ◽  
Woong Seong Chang
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Dwell Time ◽  
Microstructural Properties ◽  
Tensile Shear Strength ◽  
Plate Material ◽  
Tensile Shear ◽  
Rotating Speed ◽  
Mechanical And Microstructural Properties ◽  
Spot Welded

Dissimilar friction spot lap joining of Al5052 and Al6022 sheet has been investigated using a combination of joining parameters, thickness and upper plate material. The joining parameters such as tool rotating speed, plunging depth and joining time have been considered. The maximum tensile shear strength has been observed at tool rotating speed of 1000rpm, dwell time of 2.5sec, plunging depth of 1.8 mm and Al 6022 as upper plate. The maximum tensile shear fractured load of the joint was about 80% of that of the similar Al 5052 alloys joint.

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