Parameter Sensitivity and Process Time Reduction for Friction Element Welding of 6061-T6 Aluminum to 1500 MPa Press-Hardened Steel

2018 ◽  
Vol 12 (1) ◽  
pp. 41-56
Author(s):  
Brandt J. Ruszkiewicz ◽  
Jamie D. Skovron ◽  
Saheem Absar ◽  
Hongseok Choi ◽  
Xin Zhao ◽  
...  
Keyword(s):  
Hardened Steel ◽  
Parameter Sensitivity ◽  
Process Time ◽  
Friction Element ◽  
Time Reduction ◽  
Friction Element Welding

Investigation of the Cleaning and Welding Steps From the Friction Element Welding Process

2017 ◽  
Author(s):  
Jamie D. Skovron ◽  
Brandt J. Ruszkiewicz ◽  
Laine Mears ◽  
Tim Abke ◽  
Ankit Varma ◽  
...  
Keyword(s):  
Weld Zone ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Process Time ◽  
Friction Element ◽  
Joint Quality ◽  
Head Height ◽  
Friction Element Welding ◽  
Step Parameters

The requirement of increased fuel economy standards has forced automakers to incorporate multi-materials into their current steel dominant vehicles in order to lightweight their fleets. Technologies such as Self Piercing Rivets and Flow Drill Screws are currently implemented for joining aluminum to high-strength steels but only one-technology is viable for joining aluminum to ultra-high-strength steels without pre-holes, namely Friction Element Welding. This study is aimed at investigating how variations in the cleaning and welding steps of the Friction Element Welding process influence joint quality. A design of experiment was conducted to understand the influence of key process parameters (endload, spindle RPM, and relative distance) during these steps on the pre-defined joint quality metrics of head height, weld zone diameter, under-head fill area, temperature, and microhardness. It is found that cleaning step parameters have the greatest influence on process time and energy consumption, while welding step parameters greatly influence maximum torque on the element, head height, and underhead fill, with both cleaning force and weld force influencing weld diameter, all parameters influence temperature.

Chipping Reduction Using Thermally-Assisted Friction Element Welding

2021 ◽  
Author(s):  
Amit B. Deshpande ◽  
Tyler J. Grimm ◽  
Laine Mears
Keyword(s):  
Aluminum Alloys ◽  
Chip Formation ◽  
High Strength ◽  
Energy Utilization ◽  
Process Time ◽  
Friction Element ◽  
Novel Method ◽  
High Strength Aluminum Alloys ◽  
Future Work ◽  
Friction Element Welding

Abstract The use of multiple material in the structural components of a vehicle allows for significant weight reduction. Friction element welding (FEW) is a novel method that allows the joining of two or more dissimilar material sheets. A limitation of this process is the chip formation in high strength aluminum alloys, which is observed as the protrusion of thin aluminum segments from under the head of the fastener. Chipping can degrade the joint’s strength over time due to accelerated crevice corrosion. A novel method is proposed to eliminate chip formation using thermal assistance. A grading scheme is developed to quantify the severity of chip formation. The effect of thermal assistance on chipping is analyzed. An investigation is also carried out to validate that the thermal assistance does not negatively affect the process time, energy, and joint strength. Thermal assistance is proposed to be a novel method of overcoming this limitation to allow more widespread use of the FEW process for higher-strength aluminum alloys. Future work will include the development of feasible, rapid methods of heating and measurement of energy utilization for implementation in the industrial environment.

Conduction Heat Assisted Friction Element Welding

2021 ◽  
Author(s):  
Tyler J. Grimm ◽  
Gowtham V. Parvathy ◽  
Laine Mears
Keyword(s):  
High Strength ◽  
Aluminum Sheet ◽  
Process Time ◽  
Friction Element ◽  
Critical Areas ◽  
Localized Heating ◽  
High Strength Aluminum Alloys ◽  
Friction Weld ◽  
Future Work ◽  
Friction Element Welding

Abstract Increasing awareness of global warming and strict government regulations have required the automotive industry to pursue lightweighting as an avenue towards increased vehicle efficiency. Lightweight designs typically rely heavily on multi-material use, which enables selective strengthening of critical areas without additional, unnecessary mass. Joining these materials during manufacturing has proven to be a challenging endeavor. Friction element welding (FEW) is one process that is capable of joining aluminum to steel. This two-sided joining technique utilizes a fastener to secure the aluminum sheet by creating a friction weld with the steel sheet. While this process is extremely robust for most materials, the FEW process can result in the extrusion of material from underneath the head of the fastener, termed chipping, which leads to corrosion and aesthetic issues. This behavior is typically seen in high strength aluminum alloys, such as 7075. A solution to chipping is implemented herein, which utilizes a modified downholder to conductively heat the aluminum sheet prior to the FEW process. This heating method was explored experimentally and through various numerical analyses. This method was found to be a viable option for relieving chipping. While the process time was only increased by a maximum of 2.5 seconds, faster, more localized heating should be targeted for future work.

scholarly journals Total Cost Analysis of Process Time Reduction as a Green Machining Strategy

2012 ◽  
pp. 299-304 ◽  
Author(s):  
Moneer Helu ◽  
Benjamin Behmann ◽  
Harald Meier ◽  
David Dornfeld ◽  
Gisela Lanza ◽  
...  
Keyword(s):  
Cost Analysis ◽  
Process Time ◽  
Total Cost ◽  
Machining Strategy ◽  
Green Machining ◽  
Time Reduction ◽  
Total Cost Analysis

Energy and Time Efficient Microwave Curing for CFRP Parts Manufactured by Filament Winding

2015 ◽  
Vol 825-826 ◽  
pp. 741-748
Author(s):  
Stefan Betz ◽  
Fabian Köster ◽  
Vasileios Ramopoulos
Keyword(s):  
New Technologies ◽  
Fibre Volume ◽  
Filament Winding ◽  
Current Status ◽  
Process Time ◽  
Process Technology ◽  
Volumetric Heating ◽  
Microwave Curing ◽  
Positive Effects ◽  
Time Reduction

Process time reduction and energy/cost savings are usually in the focus of production process improvements. New technologies provide possibilities to achieve significant enhancements for relevant operation figures.Curing cycle times for CFRP manufacturing depend on several requirements: Type of resin, requested glass transition temperature, used equipment and energy source as well as sample size, weight, fibre volume ratio, fibre orientation etc. Conventional methods are mostly based on heat conduction while microwaves offer a selective and volumetric heating of the samples. Process time reduction and energy saving are the positive effects of the microwave curing technology.This paper will give an overview of the current status of this process technology not only focussing on technical aspects but also covering the process and economic effects.This work has been performed under the German BMBF project 02PJ2131, FLAME under the program Energy Efficient Light Weight Construction.

scholarly journals Characterization of aluminum flow during friction element welding

2021 ◽  
Vol 53 ◽  
pp. 107-117
Author(s):  
Tyler J. Grimm ◽  
Ankit Varma ◽  
Amit B. Deshpande ◽  
Laine Mears ◽  
Xin Zhao
Keyword(s):  
Friction Element ◽  
Friction Element Welding

scholarly journals Process Limits in High Performance Peel Grinding of Hardened Steel Components With Coarse CBN Grinding Wheels

2021 ◽  
Author(s):  
Berend Denkena ◽  
Alexander Kroedel ◽  
Michael Wilckens
Keyword(s):  
Material Removal ◽  
High Performance ◽  
Hardened Steel ◽  
Wear Behaviour ◽  
Process Time ◽  
Turning Process ◽  
Grinding Wheels ◽  
Removal Rates ◽  
Grain Sizes ◽  
Very High

Abstract Recent developments in the production processes for cubic boron nitride (CBN) abrasive grains have led to commercially available grain sizes larger than lg > 300 µm. These superabrasive grains allow higher material removal rates during grinding of hardened steel components. Currently, these components are pre-machined by turning processes before being hardened and eventually finished by grinding. However, the turning process can be substituted by grinding with coarse CBN-grains since higher depths of cut are achievable when machining hardened components. This paper investigates the process behaviour of vitrified and electroplated grinding wheels with large grain sizes during the machining of hardened steel components. Process forces, wear behaviour and workpiece surface roughness are investigated for three different grain sizes and the process limits of both bond types are examined.The investigations show that the vitrified tools do not fully suit the demands for peel grinding process with very high material removal rates since wear by means of bond breakage occurs. The electroplated tools on the other hand are capable of very high material removal rates. Their wear behaviour is characterized by clogging of the chip space if the process limit is reached. Even so, both tools outperform a standard hard-turning process in terms of process time by 74 % and 94 % respectively.

Thermal-Mechanical Numerical Modeling of the Friction Element Welding Process

2018 ◽  
Author(s):  
Ankit Varma ◽  
Saheem Absar ◽  
Xin Zhao ◽  
Hongseok Choi ◽  
Tim Abke ◽  
...  
Keyword(s):  
Automobile Industry ◽  
Weight Ratio ◽  
Welding Process ◽  
Dissimilar Materials ◽  
High Strength ◽  
Element Model ◽  
Friction Element ◽  
Physical Mechanisms ◽  
Friction Element Welding ◽  
Good Agreement

To improve the fuel economy, the automobile industry is vigorously shifting towards using a mix of lightweight materials which offers high strength-to-weight ratio. Dissimilar material joining is of critical importance in this area. Friction element welding (FEW) has been proposed for dissimilar materials, with the capability of joining high strength materials of varying thickness in minimal time with low input energy. A coupled thermal-mechanical finite element model is developed in this work to better understand the physical mechanisms involved in the process and predict the evolution of parameters such as temperature, stress, material flow, and weld quality. The Coupled Eulerian-Lagrangian (CEL) approach is adopted to capture the severe plastic deformation of both the tool and the workpiece. The material deformation and temperature evolution are analyzed at different steps, and good agreement are shown between the simulation results and the experimental data.

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