Optimization of Friction Welding Parameters to Maximize the Tensile Strength of Magnesium Alloy with Aluminum Alloy Dissimilar Joints Using Genetic Algorithm

The friction rotary welding (FRW) of magnesium alloy to aluminum alloy was presented in a paper due to significant interest in the manufacturing industry. A genetic algorithm (GA) method for optimizing FRW process parameters of dissimilar light alloys was presented. After obtaining the welding parameters by GA method, it was possible to determine the best tensile strength of the friction joint. The obtained joints were subjected to tensile strength. The highest tensile strength TS = 178 MPa was found using a genetic algorithm for the following friction welding parameters: friction force FF = 16 kN, friction time FT = 4 s, and upsetting force UF = 44 kN. The optimized values were compared with the experimental results. The application of the genetic algorithm method allowed increasing the tensile strength joint from 88 to 180 MPa. The maximum tensile strength of the friction welded magnesium alloy-aluminum alloy joints was 73% of the base AZ31B metal. The relationship between welding parameters and strenght of welds was also demonstrated in this study.

A Muscle-First, Electromechanical Hybrid Gait Restoration System in People With Spinal Cord Injury

The development of a hybrid system for people with spinal cord injuries is described. The system includes implanted neural stimulation to activate the user's otherwise paralyzed muscles, an exoskeleton with electromechanical actuators at the hips and knees, and a sensory and control system that integrates both components. We are using a muscle-first approach: The person's muscles are the primary motivator for his/her joints and the motors provide power assistance. This design philosophy led to the development of high efficiency, low friction joint actuators, and feed-forward, burst-torque control. The system was tested with two participants with spinal cord injury (SCI) and unique implanted stimulation systems. Torque burst addition was found to increase gait speed. The system was found to satisfy the main design requirements as laid out at the outset.

Microstructural Investigation of a Friction-Welded 316L Stainless Steel with Ultrafine-Grained Structure Obtained by Hydrostatic Extrusion

The paper presents the microstructural investigation of a friction-welded joint made of 316L stainless steel with an ultrafine-grained structure obtained by hydrostatic extrusion (HE). Such a plastically deformed material is characterized by a metastable state of energy equilibrium, increasing, among others, its sensitivity to high temperatures. This feature makes it difficult to weld ultra-fine-grained metals without losing their high mechanical properties. The use of high-speed friction welding and a friction time of <1 s reduced the scale of the weakening of the friction joint in relation to result obtained in conventional rotary friction welding. The study of changes in the microstructure of individual zones of the friction joint was carried out on an optical microscope (OM), scanning electron microscope (SEM), transmission electron microscope (TEM) and electron backscattered diffraction (EBSD) analysis system. The correlation between the microstructure and hardness of the friction joint is also presented. The heat released during the high-speed friction welding initiated the process of dynamic recrystallization (DRX) of single grains in the heat-affected zone (HAZ). The additional occurrence of strong plastic deformations (in HAZ) during flash formation and internal friction (in the friction weld and high-temperature HAZ) contributed to the formation of a highly deformed microstructure with numerous sub-grains. The zones with a microstructure other than the base material were characterized by lower hardness. Due to the complexity of the microstructure and its multifactorial impact on the properties of the friction-welded joint, strength should be the criterion for assessing the properties of the joint.

A rough surface damping contact model and its application in spatial variable stator vane mechanism with dry friction joint

For the mechanical system without oil lubrication, the impact or collision often occurs in the joint clearance, such as the variable stator vane (VSV) mechanism. In the dry friction joint, the damping of the contact bodies has a significant effect on the simulation stability of the tribo-dynamics calculation process. In order to investigate the effect of contact damping and joint clearance on the VSV mechanism performance, this paper proposes a damping contact model on rough surfaces to calculate the clearance contact force between the trunnion and bushing, and the spatial tribo-dynamics of VSV is established by combining this model with spatial dynamics. In addition, the effect of clearance size on the tribo-dynamics is analyzed. The results show that the contact damping must be included in the contact force model of dry friction joints, otherwise the calculation process will oscillate or even not converge, but the contact damping effect can be ignored in the case of lubricating oil. The movement of the trunnion in the bushing is affected by the adjustment drive and the aerodynamic drag, which leads to the wear concentrated on the edge of the bushing. The clearance size affects the distribution of the damping forces and the rigid forces in the contact process, and the damping forces ensure the stability of the VSV tribo-dynamics simulation process. Moreover, with the increase of clearance, the adjustment accuracy of the VSV mechanism is reduced, and the wear of the bushing is intensified.

THE INFLUENCE OF KINEMATIC CONDITION AND LUBRICANT PROPERTIES ON FRICTION IN COMPLEX SLIDE–ROLL MOTION

The paper presents the results of preliminary studies into the influence of selected lubricants (greases) and the variable temperature of the friction joint on the value of friction during complex slide-roll motion. The experiment was carried out for three different types of lubricants: bentonite grease (Benterm 2), lithium grease (GREASEN ŁT4S2), and calcium grease with the addition of graphite (GREASEN GRAFIT) at different temperatures. Tribological investigations were carried out in a roller-plate system at a wide range of plate dislocation velocities and at a constant slip rate; rheological investigations consisted in determining the changes in shear stress as a function of shear time at constant average shear velocity of 50 mm/s. The results showed a significant influence of kinematic conditions on the value of friction. Four different cases of lubricant flow during friction were identified. The least resistance to motion was found when the lubricant was applied in the same direction along the surface of the roller and plate. It has been shown that the greatest influence of the kinematics of working elements on friction occurs at low temperatures, i.e. at -10°C. This phenomenon is closely related to the rheological properties of the lubricant. It was also found that the lubricant thickened with bentonite is the most susceptible to kinematic changes of the friction joint.