scholarly journals A Novel Approach for the Detection of Geometric- and Weight-Related FSW Tool Wear Using Stripe Light Projection

2020 ◽  
Vol 4 (2) ◽  
pp. 60
Author(s):  
Michael Hasieber ◽  
Michael Grätzel ◽  
Jean Pierre Bergmann
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Weld Seam ◽  
Negative Impact ◽  
Experimental Tests ◽  
Tensile Tests ◽  
Industrial Applications ◽  
Robotic Welding ◽  
Friction Stir ◽  
Wide Range

Friction stir welding (FSW) has become an up-and-coming joining method with a wide range of industrial applications. Besides the unique weld seam properties, recent investigations have focused on the process-related tool wear of shoulder and probe, which can have detrimental economic and technological effects. This paper presents a systematic quantitative characterization of FSW tool wear using stripe light projection as a novel method to detect weight and form deviations of shoulder and probe. The investigations were carried out with a robotic welding setup in which AA-6060 T66 sheets, with a thickness of 8 mm, were joined by weld seams up to a total length of 80 m. During the experimental tests, geometrical deviations of the tool induced by wear were detected for varying weld seam lengths and different measuring points on the probe and shoulder. It was shown that wear depended on welding length which in turn caused significant deviations and weight losses on shoulder and probe. Furthermore, it was demonstrated that the wear on shoulder and probe can be considered separately. It was found that there is a progressive wear rate on the shoulder and a degressive wear rate on the probe depending on the weld seam length. To demonstrate the negative impact of tool wear on shoulder and probe after 80 m weld seam length, visual and metallographic inspections and tensile tests were carried out to detect resultant irregularities in the weld seam.

Investigations on the Mechanical Properties and Formability of Friction Stir Welded Tailored Blanks

2007 ◽  
Vol 344 ◽  
pp. 143-150 ◽  
Author(s):  
Gianluca Buffa ◽  
Livan Fratini ◽  
Marion Merklein ◽  
Detlev Staud
Keyword(s):  
Mechanical Properties ◽  
Stress Condition ◽  
Research Effort ◽  
High Strength Steels ◽  
High Strength ◽  
Tensile Tests ◽  
Friction Stir ◽  
Tailored Blanks ◽  
Sheet Stamping ◽  
Wide Range

Tight competition characterizing automotive industries in the last decades has determined a strong research effort aimed to improve utilized processes and materials in sheet stamping. As far as the latter are regarded light weight alloys, high strength steels and tailored blanks have been increasingly utilized with the aim to reduce parts weight and fuel consumptions. In the paper the mechanical properties and formability of tailored welded blanks made of a precipitation hardenable aluminum alloy but with different sheet thicknesses, have been investigated: both laser welding and friction stir welding have been developed to obtain the tailored blanks. For both welding operations a wide range of the thickness ratios has been considered. The formability of the obtained blanks has been characterized through tensile tests and cup deep drawing tests, in order to show the formability in dependency of the stress condition; what is more mechanical and metallurgical investigations have been made on the welded joints.

scholarly journals Experimental Investigation and Numerical Simulation of C-Shape Thin-Walled Steel Profile Joints

Buildings ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 636
Author(s):  
George Taranu ◽  
Ionut-Ovidiu Toma
Keyword(s):  
Negative Impact ◽  
Strain Curve ◽  
Experimental Tests ◽  
Tensile Tests ◽  
Elastic Behavior ◽  
Experimental Program ◽  
Static Structure ◽  
Solid Models ◽  
Low Mass ◽  
Thin Walled

The versatility of steel, its high resistance in relation to its low mass, as well as the easily accessible technology in the context of using recyclable materials and the low negative impact on the environment represent important arguments in using thin-walled steel profiles to make structures for buildings with a low height regime. This paper presents the results of an experimental program that investigated the behavior of three types of joints in a T-shape form made of thin-walled steel profiles to make shear wall panels or truss beam floors. Due to the small dimensions of the C-profiles of 89 × 41 × 12 × 1 mm, and of the technology of their joining, manufacturers prefer the hinged connections of elements with self-drilling screws. The purpose of the research presented in this paper is to assess the maximum capacity of the joints, the elastic and post-elastic behavior until failure, and also the mechanisms failure. The types of joints analyzed are commonly used in the production of structural systems for houses. The experimental program, which consisted of testing 5 specimens for each type of joint in tension (shear on screws), showed different behavior in terms of load-displacement. The experimental, tested models were analyzed by finite element simulations in an ANSYS nonlinear static structure with 3D solid models. The materials were defined by a bilinear true stress–strain curve obtained after some experimental tensile tests of the steel. The results of the experimental tests showed that the main failure mechanism is a yielding of the holes where the screws were mounted and a shearing of the profile walls. Adding an additional screw on each side increases the capacity of the joints, but not until a yield loss is obtained. In conclusion, it is shown that the solution is suitable for a low level of loading in a static manner; however, additional studies are necessary in order to develop and verify other solutions, thus improving the strength of the connection.

Analysis of tool wear and deformation in friction stir welding of unequal thickness dissimilar Al alloys

2020 ◽  
pp. 146442072097176
Author(s):  
Tanveer Majeed ◽  
Yashwant Mehta ◽  
Arshad Noor Siddiquee
Keyword(s):  
Friction Stir Welding ◽  
Tool Wear ◽  
Tilt Angle ◽  
Dissimilar Materials ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Process Forces ◽  
Wide Range ◽  
Lower Tool

Friction stir welding between plates of unequal thickness, which are made from similar or dissimilar materials, finds wide range of applications in the aerospace and automotive sectors. Friction stir welding of plates made from dissimilar materials having unequal thicknesses is challenging. One of the major challenges is the control of rapid tool degradation which occurs during welding. This work reports a maiden study on tool degradation of high thickness ratio unequal thickness dissimilar material joints made between 6.3 mm thick AA2024-T3 and 2.5 mm thick AA7475-T7 plates. The degradation of friction stir welding tool made of T4 tool steel having tapered cylindrical pin and scrolled shoulder was analyzed. The geometry of tool (before and after welding) was compared; the degradation was categorized, characterized, and analyzed in the light of measured welding temperature, process forces, and process parameters. It was found that the pin undergoes significant degradation in the form of wear and deformation compared to the tool shoulder. The experimental results demonstrated that lower flow stresses caused by higher process temperature leads to lower tool wear and deformation, and vice versa. In addition to temperature and process forces, the surface tilt angle was found to significantly affect the pin deformation. The higher surface tilt angle caused an increase in tool wear and deformation.

scholarly journals Multi-Performance Characteristics of AA5052 + 10% SiC Surface Composite by Friction Stir Processing

2020 ◽  
Vol 4 (2) ◽  
pp. 36 ◽  
Author(s):  
Rungwasun Kraiklang ◽  
Jariyaporn Onwong ◽  
Charuayporn Santhaweesuk
Keyword(s):  
Tensile Strength ◽  
Wear Rate ◽  
Tool Wear ◽  
Rotational Speed ◽  
Performance Characteristics ◽  
Aluminum Surface ◽  
Tool Wear Rate ◽  
Friction Stir ◽  
Surface Composite ◽  
Fabrication Parameters

In this paper, optimization of the fabrication parameters of an aluminum surface composite with respect to tensile strength and tool wear rate is reported. The surface layer was reinforced with SiC particles to improve the tribological properties of AA-5052. The Taguchi design with orthogonal array L8 was used for the experimental design, which included three processing parameters: the number of passes, rotational speed, and traversal speed. The experiment used optimal fabrication parameter searching to produce a multi-response prediction of both the tensile strength and tool wear rate. The experimental result was determined by grey relational analysis for multi-performance characteristics. Afterward, the prediction result of the optimal fabrication parameters was confirmed by repeated experiments to confirm the selection of optimal process parameters. The results revealed that the optimal fabrication parameters for multi-performance characteristics are two passes, rotational speed of 1000 revolutions per minute (RPM), and traversal speed of 30 mm/min (condition N2R1T2). These showed high tensile strength (229.90 MPa), low tool wear rate (0.0851), and a uniform distribution of SiC particles in the matrix. In addition, grey relational analysis showed that the parameter priority was 51.68% for rotational speed (the most significant process parameter), 36.18% for transversal speed, and 7.05% for the number of passes. Therefore, the grey-based orthogonal array Taguchi method can optimize multi-performance characteristics through the setting of process parameters for friction stir processing of an aluminum surface composite.

scholarly journals Mechanical Properties of Hydrogen Free Diamond-Like Carbon Thin Films Deposited by High Power Impulse Magnetron Sputtering with Ne

Coatings ◽  
2018 ◽  
Vol 8 (11) ◽  
pp. 385 ◽  
Author(s):  
Asim Aijaz ◽  
Fabio Ferreira ◽  
Joao Oliveira ◽  
Tomas Kubart
Keyword(s):  
Thin Films ◽  
Wear Rate ◽  
Magnetron Sputtering ◽  
High Power ◽  
Mass Density ◽  
Industrial Applications ◽  
Diamond Like Carbon ◽  
Mechanical And Tribological Properties ◽  
Process Gas ◽  
Wide Range

Hydrogen-free diamond-like carbon (DLC) thin films are attractive for a wide range of industrial applications. One of the challenges related to the use of hard DLC lies in the high intrinsic compressive stresses that limit the film adhesion. Here, we report on the mechanical and tribological properties of DLC films deposited by High Power Impulse Magnetron Sputtering (HiPIMS) with Ne as the process gas. In contrast to standard magnetron sputtering as well as standard Ar-based HiPIMS process, the Ne-HiPIMS lead to dense DLC films with increased mass density (up to 2.65 g/cm3) and a hardness of 23 GPa when deposited on steel with a Cr + CrN adhesion interlayer. Tribological testing by the pin-on-disk method revealed a friction coefficient of 0.22 against steel and a wear rate of 2 × 10−17 m3/Nm. The wear rate is about an order of magnitude lower than that of the films deposited using Ar. The differences in the film properties are attributed to an enhanced C ionization in the Ne-HiPIMS discharge.

Friction Stir Welding Lap Joint Resistance Optimization Through Gradient Techniques

2007 ◽  
Vol 129 (6) ◽  
pp. 985-990 ◽  
Author(s):  
L. Fratini ◽  
V. Corona
Keyword(s):  
Friction Stir Welding ◽  
Optimization Procedure ◽  
Experimental Tests ◽  
Industrial Applications ◽  
Fusion Welding ◽  
Lap Joint ◽  
Rotating Speed ◽  
Friction Stir ◽  
Gradient Technique ◽  
Lightweight Alloys

In recent years, scientific interest on friction stir welding (FSW) has grown more and more since such a joining technique allows one to weld lightweight alloys that are rather difficult to weld or even “unweldable” with the classic fusion welding operations. Furthermore, few industrial applications of the process are already known in different manufacturing fields. In this paper, the optimization problem of a FSW lap joint for automotive applications is investigated, taking into account process parameters such as the tool rotating speed and the tool feed rate; a numerical gradient technique is applied for the optimization procedure reducing the number of experimental tests to be developed.

Initial tool wear behavior in high-speed turning of Inconel 718

2020 ◽  
Vol 44 (3) ◽  
pp. 395-404
Author(s):  
Morvarid Memarianpour ◽  
Seyed Ali Niknam ◽  
Sylvain Turenne ◽  
Marek Balazinski
Keyword(s):  
Steady State ◽  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Industrial Applications ◽  
Wide Range ◽  
Tool Wear Mechanism

Three distinctive regions of tool wear, known as initial wear, steady-state wear, and accelerated wear, are well understood. However, the effects of cutting parameters on the initial tool wear mechanism, morphology, and size have received less attention as compared to the other two regions. Knowing that adequate control of initial tool wear may lead to extended tool life, in particular in hard-to-cut metals such as superalloys, this topic has become a source of attention. Amongst superalloys, Inconel 718 is considered as one of the most difficult to cut materials, which has a wide range of industrial applications. This study intends to evaluate the effects of cutting parameters on initial tool wear, as well as tool wear progression, when turning Inconel 718. Therefore, microstructural evaluation of the initial tool wear mode under various cutting conditions, as well as tool wear measurements, were conducted. It was observed that certain elements of the workpieces were migrated to the insert flank face. This is evidence of adhesion at the initial moments of the cutting process. In contrast to many other easy-to-cut materials, the steady-state wear period when turning Inconel 718 is significantly short under a higher level of cutting speed and feed rate.

scholarly journals Effect of FSW welding parameters on the tensile strength of aluminum alloys

2019 ◽  
Vol 39 (1) ◽  
pp. 41-45
Author(s):  
Mohamed Serier ◽  
Mohamed Berrahou ◽  
Affaf Tabti ◽  
Seif-E Bendaoudi
Keyword(s):  
Mathematical Model ◽  
Tensile Strength ◽  
Aluminum Alloys ◽  
Weld Seam ◽  
Welding Process ◽  
Experimental Tests ◽  
Welding Parameters ◽  
Steel Alloys ◽  
Friction Stir ◽  
Welding Operation

Abstract The friction stir welding process is an innovative technique for joining metals using plasticity, without presenting the fusion. It was first applied to aluminum alloys, for example copper, steel alloys, polymers and others. In this work the effects of the rotational speed, the speed of travel and the axial force of the tool were grouped in a mathematical model to quantify their influences on the weld seam. In this context and with of the experimental tests, the desired objective through this study is to describe the tensile strength of the cord resulting from this welding operation, for the qualification of this type of parts with an optimum adapted to a given application.

scholarly journals Low Temperature Strain Rate Sensitivity of Titanium Alloys

2016 ◽  
Vol 258 ◽  
pp. 570-573 ◽  
Author(s):  
Héloise Vigié ◽  
Thalita de Paula ◽  
Martin Surand ◽  
Bernard Viguier
Keyword(s):  
Strain Rate ◽  
Titanium Alloys ◽  
Strain Rate Sensitivity ◽  
Constant Strain Rate ◽  
Rate Sensitivity ◽  
Tensile Tests ◽  
Industrial Applications ◽  
Sustained Load ◽  
Dwell Fatigue ◽  
Wide Range

Titanium alloys are widely used in many industrial applications such as in aeronautics due to their combination of good mechanical properties, excellent corrosion resistance and low density. The mechanical behaviour of titanium alloys is known to exhibit a peculiar dependence on both deformation temperature and strain rate. Titanium alloys show significant room temperature creep and they are very sensitive to dwell fatigue and sustained load cracking. This behaviour is related to the viscosity of plastic deformation in titanium alloys, which can be represented by a strain rate sensitivity (SRS) parameter. The present study aims to compare the tensile behavior of two different titanium alloys, Ti-6Al-4V and β21S, which exhibit dissimilar microstructures. Results of tensile tests, performed under constant strain rate and including strain rate changes, are reported in terms of flow stress, ductility and SRS over a wide range of temperatures.

scholarly journals Development and Experimental Validation of a Supercapacitor Frequency Domain Model for Industrial Energy Applications Considering Dynamic Behaviour at High Frequencies

Energies ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1156 ◽  
Author(s):  
Gustavo Navarro ◽  
Jorge Nájera ◽  
Jorge Torres ◽  
Marcos Blanco ◽  
Miguel Santos ◽  
...  
Keyword(s):  
Energy Storage ◽  
High Frequency ◽  
Electrochemical Impedance ◽  
Storage System ◽  
Electric Circuit ◽  
Experimental Tests ◽  
Internal Resistance ◽  
Industrial Applications ◽  
Domain Model ◽  
Wide Range

Supercapacitors, one of the most promising energy storage technologies for high power density industrial applications, exchange the energy mostly through power electronic converters, operating under high frequency components due to the commutation. The high frequency produces important effects on the performance of the supercapacitors in relation to their capacitance, inductance and internal resistance (ESR). These parameters are fundamental to evaluate the efficiency of this energy storage system. The aim of the paper is to obtain an accurate model of two supercapacitors connected in series (functional and extrapolated unit) to represent the frequency effects for a wide range of frequencies. The methodology is based on the definition of an appropriate equivalent electric circuit with voltage dependance, obtaining their parameters from experimental tests, carried out by means of electrochemical impedance spectroscopy (EIS) and the use of specific software tools such as EC-Lab® and Statgraphics Centurion®. The paper concludes with a model which reproduces with accuracy both the frequency response of the model BCAP3000 supercapacitors, provided by the manufacturer, and the experimental results obtained by the authors.

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