MIG and TIG Joining of AA1070 Aluminium Sheets with Different Surface Preparations

In this work, AA1070 aluminium alloy sheets are joined using TIG and MIG welding after three different edge preparations. Shearing, water jet and plasma-cut processes were used to cut sheets, subsequently welded using ER5356 and ER4043 filler metals for TIG and MIG, respectively. Mechanical properties of the obtained sheets were assessed through tensile tests obtaining a relation between sheet preparation and welding tightness. Micro-hardness measures were performed to evaluate the effects of both welding and cutting processes on the micro-hardness of the alloy, highlighting that TIG welding gives rise to inhomogeneous micro-hardness behaviour. After tensile tests, surface fractures were observed employing scanning electron microscopy to highlight the relation between tensile properties and edge preparations. Fractures show severe oxidation in the water jet cut specimens, ductile fractures and gas porosities.

Shearing Characteristics of Cu-Cu Joints Fabricated by Two-Step Process Using Highly -Oriented Nanotwinned Cu

Cu-Cu bonding has the potential to break through the extreme boundary of scaling down chips’ I/Os into the sub-micrometer scale. In this study, we investigated the effect of 2-step bonding on the shear strength and electrical resistance of Cu-Cu microbumps using highly <111>-oriented nanotwinned Cu (nt-Cu). Alignment and bonding were achieved at 10 s in the first step, and a post-annealing process was further conducted to enhance its bonding strength. Results show that bonding strength was enhanced by 2–3 times after a post-annealing step. We found 50% of ductile fractures among 4548 post-annealed microbumps in one chip, while the rate was less than 20% for the as-bonded counterparts. During the post-annealing, interfacial grain growth and recrystallization occurred, and the bonding interface was eliminated. Ductile fracture in the form of zig-zag grain boundary was found at the original bonding interface, thus resulting in an increase in bonding strength of the microbumps.

Effect of 580 °C (20 h) Heat Treatment on Mechanical Properties of 25Cr2NiMo1V Rotor-Welded Joints of Oscillating Arc (MAG) Narrow Gap Thick Steel

The thick plate narrow gap welding of 25Cr2NiMo1V rotor steel is achieved by metal active gas arc welding, in which the weld gap was 18.04–19.9 mm. After welding, the weldment was heat treated at 580 °C (20 h). The impact and tensile properties in the as-welded and heat-treated were studied. The results show that after heat treatment, the coarse carbides in the center of the weld were transformed into fine granular carbides distributed along the grain boundaries, and the quantity of carbide precipitates in the weld near the fusion line was reduced. The tensile fracture mode changed from a ductile fracture to a combination of brittle and ductile fractures, and the tensile strength of the weld metal changed from 605 MPa to 543 MPa. After heat-treated, the radiation zone of the weld center changed from a brittle fracture to a combination of brittle and ductile fractures, and the impact energy changed from 141 J to 183 J; the characteristics of the brittle fracture in the radial zone of the fusion line were more obvious, and the impact energy changed from 113 J to 95 J. Therefore, after heat treatment, the toughness of the welded metal was improved, without reducing the strength and hardness of the welded metal to a large extent.

Analysis of Deformation, the Stressed State and Fracture Predictions for Cogging Shafts with Convex Anvils

In this article, a new manner of cogging a forging (type: shaft), consisting in the application of a two-stage process composed of preliminary shaping in convex anvils, and also principal forging in flat or shaped anvils, is presented. A new manner of forging brought about the formation of favorable conditions for achieving the maximum values of the effective strain in the central part of a forging, accompanied by a simultaneous absence of tensile stresses, which was exerting a favorable influence upon reforging the axial zone of an ingot. What was determined, was the effective geometric shapes of convex anvils; the efficiency of different technological parameters in the case of the intensity of reforging the axial zone of an ingot was analyzed as well. The investigations were complemented by means of predicting the formation of ductile fractures in the course of forging with the application of three different ductile fracture criteria. The comparison of theoretical and experimental outcomes of investigations indicates a good level of being commensurate.

STUDY ON MICROMECHANICAL FRACTURE MODELS OF STRUCTURAL STEEL AND ITS WELDS

Steel structures have been widely used in constructions due to their advantages of lightweight, high strength, short construction time and high recycling and reuse potential. Fracture failure in steel structures should be prevented to avoid collapse of the whole structures. Micromechanical fracture models can capture the fracture initiation mechanisms and therefore can be used to predict ductile fractures in steel. Twelve smooth round bars were carried out to obtain the material properties and 36 notched round bars were tested to calibrate the parameters of stress modified critical strain (SMCS) model and the void growth model (VGM) for structural steels (Q235B and Q345B) and the corresponding welds. Specimens were extracted from the base metal, the weld metal and the heat affected zone (HAZ) to investigate fracture behaviour in different parts of the welded joint. Scanning electron microscope (SEM) measurements were taken and finite element models were developed to calibrate the models. The test results and calibrated parameters are reported. Moreover, the calibrated models are applied to analyses the fracture behaviour of welded joints and their accuracy are validated. The calibrated and validated models can be used for further numerical fracture analysis in welded steel structures.

Microstructural Features of Freezing and Thawing-Creep Damages for Concrete Mixed with Fly Ash

The macroscopic morphology characteristics, pore structure characteristics, and microfracture morphology of concrete with fly ash subjected to the freeze-thaw-creep effect were analyzed via scanning electron microscopy (SEM). The results revealed that the macrosection of a specimen subjected to freeze-thaw cycling evolves from a regular to an irregular morphology in which the degree of fragmentation increases. Four specimen pore structure types characterized by single holes, nonconnected hole clusters, connected hole clusters, and fly ash holes, respectively, were identified. The microfracture morphology of the concrete was found to include five types of brittle fractures—river, step, cascade, hemispherical, and irregular patterns—and two types of ductile fractures—dimple and peak forest patterns. Two sets of experiments in which (1) the fly ash content ( m = 35 % ) was kept constant and the number of freeze-thaw cycles increased, and (2) the number of freeze-thaw cycles ( n = 120 ) was kept constant, and the fly ash content was increased were carried out. In both cases, the number of connected hole clusters increased and a surrounding skeleton structure with a needle filamentous or flaky appearance was produced. In addition, the degree of deterioration of the pore structure increased and the fracture features changed from brittle to ductile.

Analysis of Deformation and Prediction of Cracks in the Cogging Process for Die Steel at Elevated Temperatures

In this paper, an analysis of a three-dimensional state of strain and stress in the case of the hot cogging process of X32CrMoV12-28 die steel with the application of the finite element method is presented. The results of the investigations connected with the simulation of the kinematics of metal flow and thermal phenomena are presented, accompanied by prognosing the formation of ductile fractures in the course of the hot cogging process conducted with the application of three different shape tools and of a proposed deformation criterion of the loss of cohesion. The applied anvils were found to be highly effective in the aspects of distribution of effective strains and stresses, absence of tensile stresses in the axial zones of a forging, and also of a significant thermal stability in the internal layers of a deformed material. The developed course of changes in the deformation of the damage factor in the case of forging in the investigated anvils renders it possible to predict the situation and the phase of deformation in which the loss of cohesion by a deformed material will occur. The comparison between the predicted and the experimental results showed a good agreement.

The Microstructure and Mechanical Properties of Dual-Spot Laser Welded-Brazed Ti/Al Butt Joints with Different Groove Shapes

Laser welding-brazing was performed to join Ti and Al together. The dual-spot laser beam mode was selected as the heat source in this study. Ti-6Al-4V and 6061-T6 Al alloys were selected as the experimental materials. Al-12Si welding wire was selected as the filler material. The effect of groove shape on the weld appearance, microstructure, temperature field, and mechanical performance of Ti/Al welded-brazed butt joints was investigated. The interfacial intermetallic compound (IMC) layer at the Ti/Weld brazing interface was inhomogeneous in joints with I-shaped and Y-shaped grooves. In Ti/Al joints with V-shaped grooves, the homogeneity of temperature field and IMC layer was improved, and the maximum thickness difference of IMC layer was only 0.20 μm. Nano-sized granular Ti7Al5Si12, Ti5Si3, and Ti(Al,Si)3 constituted the IMCs. The tensile strength of Ti/Al joints with V-shaped grooves was the highest at 187 MPa. The fracture mode transformed from brittle fractures located in the IMC layer to ductile fractures located in the Al base metal, which could be attributed to the improvement of the IMC layer at the brazing interface.

Effect of Tool Pin Profile on the Hook Geometry and Mechanical Properties of a Friction Stir Spot Welded AA6082-T6 Aluminum Alloy

AA6082-T6 alloy was joined by friction stir spot welding using five different pin profiles, such as a cylindrical, conical, triangular, hexagonal and cylindrical with two grooves, at different dwell time. The joints welded by cylindrical pins had larger effective weld width. But, grooves on the cylindrical pin decreased the effective weld width. The hook was bent downward from the interface of the sheets in the weld made with hexagonal pin, which had the smallest effective weld width. When conical pin was used, effective weld width increased with increasing the dwell time. In the case of using tools with cylindrical and conical pins, HAZ hardness was relatively lower. With increasing dwell time, HAZ hardness of the joints made with conical pin decreased. Effective weld width determined the weld strength under the tensile shear loading condition: Larger effective weld width resulted in higher weld strength. Weld strength of the joints made with cylindrical pin was higher. The joints fabricated with hexagonal pin had the lowest weld strength. In general, higher dwell time led to higher weld strength. The welds with the higher strength experienced both brittle and ductile fractures, while the joints with the lower strength exhibited completely brittle fracture.