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.

scholarly journals Self-Piercing Riveted Joint of Vibration-Damping Steel and Aluminum Alloy

2019 ◽  
Vol 9 (21) ◽  
pp. 4575 ◽  
Author(s):  
Dong-Hyuck Kam ◽  
Taek-Eon Jeong ◽  
Min-Gyu Kim ◽  
Joonghan Shin
Keyword(s):  
Aluminum Alloy ◽  
Mechanical Performance ◽  
Vibration Damping ◽  
Tensile Shear ◽  
Taper Angle ◽  
Joint Configuration ◽  
Geometrical Characteristics ◽  
Pull Out ◽  
Riveted Joint ◽  
First Time

In this study, the self-piercing rivet (SPR) joining of vibration-damping steel and aluminum alloy (Al5052-H32) is successfully carried out, for the first time to our knowledge, and the effects of die type and joint configuration on the mechanical performance, failure mode, and geometrical characteristics of the new joint are investigated. The vibration-damping steel and Al5052-H32 SPR joint exhibits the largest tensile–shear load when a flat die is used. An increase in the die taper angle and diameter decreases the mechanical performance of the joint due to the increase in volume of the die, leading to a smaller interlock width of the joint. The joint configuration with Al5052-H32 as a top sheet has superior mechanical performance compared with the reverse configuration, owing to the increase of the interlock width. All SPR joints of vibration-damping steel and Al5052-H32 show consistent rivet pull-out failure, regardless of the joint configuration, because of relatively small interlock width. It is also found that these SPR joints show better mechanical performance than those of SPFC590DP (a skin material of the vibration-damping steel) and Al5052-H32 under the Al5052-H32–top configuration.

scholarly journals Study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3

2018 ◽  
Vol 7 (4.1) ◽  
pp. 3037
Author(s):  
Isam Tareq Abdullah ◽  
Zaman Khalil Ibrahim ◽  
Ahmed Ibrahim Razooqi
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Carbon Steel ◽  
Spot Welding ◽  
Dwell Time ◽  
Dissimilar Materials ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tensile Shear ◽  
Friction Stir

Friction stir spot welding-FSSW has been suggested as effectual process to welding difficult materials such as dissimilar materials and thin sheet of metal alloys. In this study, using dissimilar materials were welded carbon steel-1006 on upper plate and aluminum alloy AA2024-T3 on lower plate. Macrostructure, micro-structural analysis and mechanical properties of the joints are done. The effect of penetration depth, dwell time and spindle speed on tensile shear load are investigated with invariable of other parameter during welding process. The maximum tensile shear load (3.31KN) was occurred when using 0.4mm of penetration depth, 10 sec of dwell time and 1400 rpm of spindle speed. Also, two type of failure shape was observed interfacial fracture of carbon steel sheet and pull-out fracture of AA2024-T3 sheet.

Mechanical Characterization of 2219 Aluminum Alloy Welded Joints Under Bi-Axial Loading

2019 ◽  
Vol 11 (08) ◽  
pp. 1950077 ◽  
Author(s):  
Guanglong Cao ◽  
Cheng Huang ◽  
Tong Li ◽  
Yahui Zhang ◽  
Mingfa Ren
Keyword(s):  
Aluminum Alloy ◽  
Welded Joints ◽  
Mechanical Characterization ◽  
Axial Loading ◽  
Failure Behavior ◽  
Shear Load ◽  
Tensile Shear ◽  
2219 Aluminum Alloy ◽  
Mechanical Performances

The mechanical performances of welded joints under bi-axial loading are significant to the reliability of various engineering structures. However, the protocol for the mechanical characterization of welded joints still needs to be improved to represent the mechanical performances of welded joints under complex loading conditions. In this work, an experimental design is proposed for the mechanical characterization of 2219 aluminum alloy welded joints. The target is to investigate the effects of combined tensile-shear load on the mechanical responses and failure behavior of 2219 aluminum alloy welded joints. The tensile-shear characterization was then conducted using a newly developed U-notch aluminum alloy welded joints specimen. In addition, standard tensile test and standard shear test were conducted to validate of the U-notch specimen design. This newly proposed experimental protocol is suitable to obtain mechanical properties of 2219 aluminum alloy welded joints subjected to tensile-shear load.

Properties of Resistance Spot Welded Joint between Mild Steel and Aluminum Alloy with an Interlayer of AlCu28

2014 ◽  
Vol 675-677 ◽  
pp. 15-18 ◽  
Author(s):  
Long Long Hou ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Jun Qing Guo
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Mild Steel ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welded Joint ◽  
Welding Parameters ◽  
Shear Load ◽  
Tensile Shear ◽  
Resistance Spot

Aluminum alloy A6061 and mild steel Q235 was welded using resistance spot welding with an interlayer of AlCu28. The mechanical properties of the joint were investigated; the effects of various welding parameters on nugget diameter and tensile shear load of the joints were systematically discussed. The results reveal that it is effective to weld aluminum alloy and mild steel using resistance spot welding with an interlayer of AlCu28.

Properties of Light Metal Joint Welded by Thermal Compensation Resistance Spot Welding

2011 ◽  
Vol 230-232 ◽  
pp. 1084-1088
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Hua Yu ◽  
Ke Ke Zhang
Keyword(s):  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Light Metal ◽  
Welding Parameters ◽  
Shear Load ◽  
Thermal Compensation ◽  
Tensile Shear ◽  
Resistance Spot

A new technique of thermal compensation resistance spot welding was used to weld light metal such as aluminum alloy sheet and magnesium alloy. The effects of welding parameters on the tensile shear strength of joint and nugget diameter were investigated. The tensile shear load and nugget of the joint increased with the increasing of welding time, whereas that of the joint decreased with the increasing of electrode force. The joint with the maximum tensile shear load of approximately 5 kN was obtained at the condition of 12 kA and 11 kA welding current for aluminum alloy and magnesium alloy, respectively. The results reveal that the thermal compensation resistance spot welding is a feasible method to weld aluminum alloy and magnesium alloy..

scholarly journals Process Optimization of Friction Welded Spot Aluminum Alloy Using ANOVA

2020 ◽  
Author(s):  
Armansyah . ◽  
Hwi-Chie Ho ◽  
Juri Saedon ◽  
Hasan Hariri ◽  
Shahriman Adenan
Keyword(s):  
Aluminum Alloy ◽  
Shear Test ◽  
Angular Speed ◽  
Shear Load ◽  
Optimal Parameters ◽  
Tensile Shear ◽  
Light Material ◽  
Main Effects ◽  
The Impact ◽  
Do So

The parameter of angular speed, depth of tool, and time of dwell of friction welded spot was studied on the alloy of aluminium. To do so, the impact from parameters was investigated through tensile shear test on the welded alloy and using the design of experiment (L8). ANOVA is then used to see important factors and contributions via main effects plots. It was found that angular speed of tool had a big impact on tensile shear load with 45 %, time of dwell 34 %, depth of tool 10 %. The angular speed of 1 400 rpm, time of dwell 9 s, and depth of tool 3.5 mm were the optimal parameters in this study. Keywords: light material welding, optimize weld process, weld softened material

scholarly journals Effects of Lap Configuration on Mechanical Properties and Composition Distribution of Three-layer Overlapped Laser Weldments on Al/Cu Dissimilar Materials

2022 ◽  
Author(s):  
Joonghyeon Shin ◽  
Minjung Kang
Keyword(s):  
Mechanical Properties ◽  
Laser Welding ◽  
Solidification Rate ◽  
Intermetallic Phase ◽  
Dissimilar Materials ◽  
Welding Parameters ◽  
Shear Load ◽  
Tensile Shear ◽  
Stress Concentrations ◽  
Composition Distribution

Abstract Battery cells are connected via bus-bars to meet performance requirements, such as power and capacity, and multiple layers of dissimilar materials functioning as anodes, cathodes, or bus-bars are overlapped and welded together. In laser welding, the formation of brittle intermetallic phases in the weld joint is inevitable and, in turn, deteriorates the mechanical properties. To obtain the desirable joint performance, appropriate welding parameters to avoid intermetallic phase formations and joint designs to release stress concentrations must be obtained. This study investigates the effects of lap configurations and process parameters on the tensile-shear load, T-peel load, and composition distribution when multi-layered joints of dissimilar materials are produced by laser welding. Two layers of 0.4 mm Al sheets were welded with a single 0.2 mm Cu sheet, which was emulated using electric vehicle battery interconnects. The results show that the penetration depth varied in accordance with the lap configuration even under the same heat input condition. The lap configuration and welding parameters influenced the composition distribution of the welds, as they altered the solidification rate, number of Cu/Al contact interfaces, and location of the high-density material. The failure load of the T-peel specimens was always lower than that of the tensile-shear specimens except for the Cu−Al−Al lap configuration. The T-peel load of the Cu−Al−Al lap configuration was similar to that of the tensile-shear load. When the stress-concentrated joint was homogeneous, it was more robust.

Performance Prediction for Ultrasonically Welded Dissimilar Materials Joints

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Liang Xi ◽  
Mihaela Banu ◽  
S. Jack Hu ◽  
Wayne Cai ◽  
Jeffrey Abell
Keyword(s):  
Failure Modes ◽  
Mechanical Performance ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Lithium Ion ◽  
Microscopic Analysis ◽  
Lap Shear ◽  
Physical Attributes ◽  
Assembly Operations ◽  
Metal Welding

Ultrasonic metal welding has been used to join multiple layers of battery tabs with the bus bar in lithium-ion battery assembly operations. This paper describes joint performance models for ultrasonic metal welds of multiple layers of dissimilar battery tab materials, i.e., aluminum and copper. Finite element (FE) models are developed to predict the mechanical performance of the ultrasonically welded joints. The models predict peak shear load, energy absorption capability, and failure modes, which are necessary for modeling product performance and defining process requirements for the welds. The models can be adjusted to represent different quality of welds created in conditions of underweld (UW), normal-weld (NW), or overweld (OW) using physical attributes observed through microscopic analysis. The models are validated through lap shear tests, which demonstrate excellent agreement for the maximum force in the NW condition and good agreement for the UW and OW conditions. The models provide in-depth understanding of the relationship among welding process parameters, physical weld attributes, and the weld performance. The models also provide significant insight for further development of ultrasonic welding process for battery tabs and help optimize welding process for more than four-layered joints.

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