Abstract: The quality of laser welded-brazed (LWB) joints were strongly dependent on the main process parameters, therefore the effect of laser power (3.2–4 kW), welding speed (60–80 mm/s) and wire feed rate (70–90 mm/s) on mechanical strength and surface roughness were investigated in this study. The comprehensive optimization process by means of response surface methodology (RSM) and desirability function was used for multi-criteria optimization. The experiments were planned based on Box– Behnken design implementing linear and quadratic polynomial equations for predicting the desired output properties. Finally, validation experiments were conducted on an optimized process condition which exhibited good agreement between the predicted and experimental results. AlSi3Mn1 was selected as the filler material for joining aluminum alloy 6022 and hot-dip galvanized steel in coach peel configuration. The high scanning speed could control the thickness of IMC as thin as 5 µm. The thermal simulations of joining process were conducted by the Finite Element Method (FEM), and results were validated through experimental data. The Fe/Al interfacial thermal history evidenced that the duration of critical temperature range (700–900 °C) in this high scanning speed process was less than 1 s. This short interaction time leads to the formation of reaction-control IMC layer instead of diffusion-control mechanisms.
Abstract: Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.
Abstract: 12.7-mm thick plates of 6061-T6511 aluminum alloy and high hardness steel (528 HV) were successfully joined by a friction stir bonding process using a tungsten-rhenium stir tool. Process parameter variation experiments, which included tool design geometry, plunge and traverse rates, tool offset, spindle tilt, and rotation speed, were conducted to develop a parameter set which yielded a defect free joint. Laboratory tensile tests exhibited yield stresses which exceed the strengths of comparable AA6061-to-AA6061 fusion and friction stir weld joints. Scanning electron microscopy and energy dispersive X-ray spectroscopy analysis also show atomic diffusion at the material interface region.
Abstract: Friction Stir Welding is a solid state welding technique which can be used to produce sound welds between similar and dissimilar materials. Dissimilar welds which include welds between the different series of aluminium alloys, aluminium to magnesium, steel and titanium has been successfully produced by many researchers. This review covers the work conducted in the above mentioned materials and further concludes by showing the need to fully understand the FSW process in order to expand the latter industrially.
Abstract: in dissimilar material joints, failure often occurs
along the interface between two materials due to stress singularity.
Stress distribution and its concentration depend on materials and
geometry of the junction. Inhomogenity of stress distribution at the
interface of junction of two materials with different elastic modules
and stress concentration in this zone are the main factors resulting in
rupture of the junction. Effect of joining angle in the interface of
aluminum-polycarbonate will be discussed in this paper. Computer
simulation and finite element analysis by ABAQUS showed that
convex interfacial joint leads to stress reduction at junction corners in
compare with straight joint. This finding is confirmed by photoelastic
experimental results.
Abstract: Friction Stir Welding (FSW) is a solid state welding
process invented and patented by The Welding Institute (TWI) in the
United Kingdom in 1991 for butt and lap welding of metals and plastics. This paper highlights the benefits of friction stir welding
process as an energy efficient and a green technology process in the
field of welding. Compared to the other conventional welding processes, its benefits, typical applications and its use in joining
similar and dissimilar materials are also presented.
Abstract: Structural behavior of ring stiffened thick walled
cylinders made of functionally graded materials (FGMs) is
investigated in this paper. Functionally graded materials are inhomogeneous composites which are usually made from a mixture
of metal and ceramic. The gradient compositional variation of the
constituents from one surface to the other provides an elegant solution to the problem of high transverse shear stresses that are
induced when two dissimilar materials with large differences in material properties are bonded. FGM formation of the cylinder is
modeled by power-law exponent and the variation of characteristics is supposed to be in radial direction.
A finite element formulation is derived for the analysis. According to the property variation of the constituent materials in the radial
direction of the wall, it is not convenient to use conventional elements to model and analyze the structure of the stiffened FGM
cylinders. In this paper a new cylindrical super-element is used to model the finite element formulation and analyze the static and
modal behavior of stiffened FGM thick walled cylinders. By using
this super-element the number of elements, which are needed for
modeling, will reduce significantly and the process time is less in comparison with conventional finite element formulations. Results for static and modal analysis are evaluated and verified by
comparison to finite element formulation with conventional
elements. Comparison indicates a good conformity between results.