Scholarly

The Experimental and Numerical Analysis of the Joining Processes for Air Conditioning Systems

Year: 2019 Volume: 13 Issue: 2 88 - 93 Pages

Abstract: In the paper the results of welding of car’s air-conditioning elements are presented. These systems based on, mainly, the environmental unfriendly refrigerants. Thus, the producers of cars will have to stop using traditional refrigerant and to change it to carbon dioxide (R744). This refrigerant is environmental friendly. However, it should be noted that the air condition system working with R744 refrigerant operates at high temperature (up to 150 °C) and high pressure (up to 130 bar). These two parameters are much higher than for other refrigerants. Thus new materials, design as well as joining technologies are strongly needed for these systems. AISI 304 and 316L steels as well as aluminium alloys 5xxx are ranked among the prospective materials. As a joining process laser welding, plasma welding, electron beam welding as well as high rotary friction welding can be applied. In the study, the metallographic examination based on light microscopy as well as SEM was applied to estimate the quality of welded joints. The analysis of welding was supported by numerical modelling based on Sysweld software. The results indicated that using laser, plasma and electron beam welding, it is possible to obtain proper quality of welds in stainless steel. Moreover, high rotary friction welding allows to guarantee the metallic continuity in the aluminium welded area. The metallographic examination revealed that the grain growth in the heat affected zone (HAZ) in laser and electron beam welded joints were not observed. It is due to low heat input and short welding time. The grain growth and subgrains can be observed at room temperature when the solidification mode is austenitic. This caused low microstructural changes during solidification. The columnar grain structure was found in the weld metal. Meanwhile, the equiaxed grains were detected in the interface. The numerical modelling of laser welding process allowed to estimate the temperature profile in the welded joint as well as predicts the dimensions of welds. The agreement between FEM analysis and experimental data was achieved.

Studying the Possibility to Weld AA1100 Aluminum Alloy by Friction Stir Spot Welding

Year: 2017 Volume: 11 Issue: 9 660 - 666 Pages

Abstract: Friction stir welding is a modern and an environmentally friendly solid state joining process used to joint relatively lighter family of materials. Recently, friction stir spot welding has been used instead of resistance spot welding which has received considerable attention from the automotive industry. It is environmentally friendly process that eliminated heat and pollution. In this research, friction stir spot welding has been used to study the possibility to weld AA1100 aluminum alloy sheet with 3 mm thickness by overlapping the edges of sheet as lap joint. The process was done using a drilling machine instead of milling machine. Different tool rotational speeds of 760, 1065, 1445, and 2000 RPM have been applied with manual and automatic compression to study their effect on the quality of welded joints. Heat generation, pressure applied, and depth of tool penetration have been measured during the welding process. The result shows that there is a possibility to weld AA1100 sheets; however, there is some surface defect that happened due to insufficient condition of welding. Moreover, the relationship between rotational speed, pressure, heat generation and tool depth penetration was created.

Methodologies for Crack Initiation in Welded Joints Applied to Inspection Planning

Year: 2016 Volume: 10 Issue: 11 1462 - 1469 Pages

Abstract: Crack initiation and propagation threatens structural integrity of welded joints and normally inspections are assigned based on crack propagation models. However, the approach based on crack propagation models may not be applicable for some high-quality welded joints, because the initial flaws in them may be so small that it may take long time for the flaws to develop into a detectable size. This raises a concern regarding the inspection planning of high-quality welded joins, as there is no generally acceptable approach for modeling the whole fatigue process that includes the crack initiation period. In order to address the issue, this paper reviews treatment methods for crack initiation period and initial crack size in crack propagation models applied to inspection planning. Generally, there are four approaches, by: 1) Neglecting the crack initiation period and fitting a probabilistic distribution for initial crack size based on statistical data; 2) Extrapolating the crack propagation stage to a very small fictitious initial crack size, so that the whole fatigue process can be modeled by crack propagation models; 3) Assuming a fixed detectable initial crack size and fitting a probabilistic distribution for crack initiation time based on specimen tests; and, 4) Modeling the crack initiation and propagation stage separately using small crack growth theories and Paris law or similar models. The conclusion is that in view of trade-off between accuracy and computation efforts, calibration of a small fictitious initial crack size to S-N curves is the most efficient approach.

An Evaluation of TIG Welding Parametric Influence on Tensile Strength of 5083 Aluminium Alloy

Year: 2013 Volume: 7 Issue: 11 2333 - 2336 Pages

Abstract: Tungsten Inert Gas (TIG) welding is a high quality welding process used to weld the thin metals and their alloy. 5083 Aluminium alloys play an important role in engineering and metallurgy field because of excellent corrosion properties, ease of fabrication and high specific strength coupled with best combination of toughness and formability. TIG welding technique is one of the precise and fastest processes used in aerospace, ship and marine industries. TIG welding process is used to analyze the data and evaluate the influence of input parameters on tensile strength of 5083 Al-alloy specimens with dimensions of 100mm long x 15mm wide x 5mm thick. Welding current (I), gas flow rate (G) and welding speed (S) are the input parameters which effect tensile strength of 5083 Al-alloy welded joints. As welding speed increased, tensile strength increases first till optimum value and after that both decreases by increasing welding speed further. Results of the study show that maximum tensile strength of 129 MPa of weld joint are obtained at welding current of 240 Amps, gas flow rate of 7 Lt/min and welding speed of 98 mm/min. These values are the optimum values of input parameters which help to produce efficient weld joint that have good mechanical properties as a tensile strength.

Microstructure and Mechanical Behaviuor of Rotary Friction Welded Titanium Alloys

Year: 2007 Volume: 1 Issue: 11 679 - 681 Pages

Abstract: Ti-6Al-4V alloy has demonstrated a high strength to weight ratio as well as good properties at high temperature. The successful application of the alloy in some important areas depends on suitable joining techniques. Friction welding has many advantageous features to be chosen for joining Titanium alloys. The present work investigates the feasibility of producing similar metal joints of this Titanium alloy by rotary friction welding method. The joints are produced at three different speeds and the performances of the welded joints are evaluated by conducting microstructure studies, Vickers Hardness and tensile tests at the joints. It is found that the weld joints produced are sound and the ductile fractures in the tensile weld specimens occur at locations away from the welded joints. It is also found that a rotational speed of 1500 RPM can produce a very good weld, with other parameters kept constant.

Weld Defect Detection in Industrial Radiography Based Digital Image Processing

Year: 2007 Volume: 1 Issue: 2 307 - 310 Pages

Abstract: Industrial radiography is a famous technique for the identification and evaluation of discontinuities, or defects, such as cracks, porosity and foreign inclusions found in welded joints. Although this technique has been well developed, improving both the inspection process and operating time, it does suffer from several drawbacks. The poor quality of radiographic images is due to the physical nature of radiography as well as small size of the defects and their poor orientation relatively to the size and thickness of the evaluated parts. Digital image processing techniques allow the interpretation of the image to be automated, avoiding the presence of human operators making the inspection system more reliable, reproducible and faster. This paper describes our attempt to develop and implement digital image processing algorithms for the purpose of automatic defect detection in radiographic images. Because of the complex nature of the considered images, and in order that the detected defect region represents the most accurately possible the real defect, the choice of global and local preprocessing and segmentation methods must be appropriated.

Three-dimensional Finite Element Analysis of the Front Cross Member of the Peugeot 405

Year: 2010 Volume: 4 Issue: 8 571 - 574 Pages

Abstract: Undoubtedly, chassis is one of the most important parts of a vehicle. Chassis that today are produced for vehicles are made up of four parts. These parts are jointed together by screwing. Transverse parts are called cross member. This study reviews the stress generated by cyclic laboratory loads in front cross member of Peugeot 405. In this paper the finite element method is used to simulate the welding process and to determine the physical response of the spot-welded joints. Analysis is done by the Abaqus software. The Stresses generated in cross member structure are generally classified into two groups: The stresses remained in form of residual stresses after welding process and the mechanical stress generated by cyclic load. Accordingly the total stress must be obtained by determining residual stress and mechanical stress separately and then sum them according to the superposition principle. In order to improve accuracy, material properties including physical, thermal and mechanical properties were supposed to be temperature-dependent. Simulation shows that maximum Von Misses stresses are located at special points. The model results are then compared to the experimental results which are reported by producing factory and good agreement is observed.

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