Corrosion Analysis and Interfacial Characterization of Al – Steel Metal Inert Gas Weld - Braze Dissimilar Joints by Micro Area X-Ray Diffraction Technique

Automotive light weighting is of major prominence in the current times due to its contribution in improved fuel economy and reduced environmental pollution. Various arc welding technologies are being employed in the production of automobile components with reduced weight. The present study is of practical importance since it involves preferential substitution of Zinc coated mild steel with a light weight alloy such as 6061 Aluminium by means of Gas Metal Arc Welding (GMAW) – Brazing technique at different processing parameters. However, the fabricated joints have shown the generation of Al – Fe layer at the interfacial regions which was confirmed by the Scanning Electron Microscope and Energy Dispersion Spectroscopy. These Al-Fe compounds not only affect the mechanical strength, but also predominantly deteriorate the corrosion resistance of the joints. Hence, it is essential to understand the phases formed in this layer and their crystal structure. Micro area X - ray diffraction technique has been exclusively used for this study. Moreover, the crevice corrosion analysis at the joint interfaces was done by exposing the joints to 5 wt.% FeCl3 solution at regular time intervals as per ASTM G 48-03. The joints have shown a decreased crevice corrosion resistance with increased heat intensity. Inner surfaces of welds have shown severe oxide cracking and a remarkable weight loss when exposed to concentrated FeCl3. The weight loss was enhanced with decreased filler wire feed rate and increased heat intensity. 

Parameter Optimization and Thermal Simulation in Laser Joining of Coach Peel Panels of Dissimilar Materials

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.

Thermo-Mechanical Analysis of Dissimilar Al/Cu Foil Single Lap Joints Made by Composite Metal Foil Manufacturing

The paper presents an additive manufacturing process for the production of metal and composite parts. It is termed as composite metal foil manufacturing and is a combination of laminated object manufacturing and brazing techniques. The process has been described in detail and is being used to produce dissimilar aluminum to copper foil single lap joints. A three dimensional finite element model has been developed to study the thermo-mechanical characteristics of the dissimilar Al/Cu single lap joint. The effects of thermal stress and strain have been analyzed by carrying out transient thermal analysis on the heated plates used to join the two 0.1mm thin metal foils. Tensile test has been carried out on the foils before joining and after the single Al/Cu lap joints are made, they are subjected to tensile lap-shear test to analyze the effect of heat on the foils. The analyses are designed to assess the mechanical integrity of the foils after the brazing process and understand whether or not the heat treatment has an effect on the fracture modes of the produced specimens.

FEM Investigation of Induction Heating System for Pipe Brazing

The paper deals with determination of electromagnetic and temperature field distribution of induction heating system used for pipe brazing. The problem is considered as coupled – time harmonic electromagnetic and transient thermal field. It has been solved using finite element method. The detailed maps of electromagnetic and thermal field distribution have been obtained. The good understanding of the processes in the considered system ensures possibilities for control, management and increasing the efficiency of the welding process.

The Computer Multimedia Instruction Package for Welding and Brazing

The objective of this project is to produce computer assisted instruction(CAI) for welding and brazing in order to determine the efficiency of the instruction package and the study accomplishment of learner by studying through computer assisted instruction for welding and brazing it was examined through the target group surveyed from the 30 students studying in the two year of 5-year-academic program, department of production technology education, faculty of industrial education and technology, king mongkut-s university of technology thonburi. The result of the research indicated that the media evaluated by experts and subject matter quality evaluation of computer assisted instruction for welding and brazing was in line for the good criterion. The mean of score evaluated before the study, during the study and after the study was 34.58, 83.33 and 83.43, respectively. The efficiency of the lesson was 83.33/83.43 which was higher than the expected value, 80/80. The study accomplishment of the learner, who utilizes computer assisted instruction for welding and brazing as a media, was higher and equal to the significance statistical level of 95%. The value was 1.669 which was equal to 35.36>1.669. It could be summarized that computer assisted instruction for welding and brazing was the efficient media to use for studying and teaching.