Abstract: 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.
Abstract: The synergistic effect of properties of metals and fibers reinforced laminates has diverted attention of the world towards use of robust composite materials known as fiber-metal laminates in many high performance applications. In this study, modification of an adhesively bonded joint as a single lap joint of carbon fibers based CARALL FML has done to increase interlaminar shear strength of the joint. The effect of different configurations of joint designs such as spews, stepped and modification in adhesive by addition of nano-fillers was studied. Both experimental and simulation results showed that modified joint design have superior properties as maximum force experienced stepped joint was 1.5 times more than the simple lap joint. Addition of carbon nano-tubes as nano-fillers in the adhesive joint increased the maximum force due to crack deflection mechanism.
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.
Abstract: Mechanical fasteners especially bolting is commonly
used in joining carbon-fiber reinforced polymer (CFRP) composite
structures due to their good joinability and easy for maintenance
characteristics. Since this approach involves with notching, a proper
progressive damage model (PDM) need to be implemented and
verified to capture existence of damages in the structure. A three
dimensional (3D) failure criteria of Puck is established to predict the
ultimate bearing failure of such joint. The failure criteria incorporated
with degradation scheme are coded based on user subroutine executed
in Abaqus. Single lap joint (SLJ) of composite bolted joint is used as
target configuration. The results revealed that the PDM adopted here
could sufficiently predict the behaviour of composite bolted joint up
to ultimate bearing failure. In addition, mesh refinement near holes
increased the accuracy of predicted strength as well as computational
effort.
Abstract: A composite material with carbon fiber and polymer
matrix has been used as adherent for manufacturing adhesive joints.
In order to evaluate different fiber orientations on joint performance,
the adherents with the 0°, ±15°, ±30°, ±45° fiber orientations were
used in the single lap joint configuration. The joints with an overlap
length of 25 mm were prepared according to the ASTM 1002
specifications and subjected to tensile loadings. The structural
adhesive used was a two-part epoxy to be cured at 70°C for an hour.
First, mechanical behaviors of the adherents were measured using
three point bending test. In the test, considerations were given to
stress to failure and elastic modulus. The results were compared with
theoretical ones using rule of mixture. Then, the joints were
manufactured in a specially prepared jig, after a proper surface
preparation. Experimental results showed that the fiber orientations
of the adherents affected the joint performance considerably; the
joints with ±45° adherents experienced the worst shear strength, half
of those with 0° adherents, and in general, there was a great
relationship between the fiber orientations and failure mechanisms.
Delamination problems were observed for many joints, which were
thought to be due to peel effects at the ends of the overlap. It was
proved that the surface preparation applied to the adherent surface
was adequate. For further explanation of the results, a numerical
work should be carried out using a possible non-linear analysis.
Abstract: 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.
Abstract: Riveting process is one of the important ways to keep
fastening the lap joints in aircraft structures. Failure of aircraft lap
joints directly depends on the stress field in the joint. An important
application of riveting process is in the construction of aircraft
fuselage structures. In this paper, a 3D finite element method is
carried out in order to optimize residual stress field in a riveted lap
joint and also to estimate its fatigue life. In continue, a number of
experiments are designed and analyzed using design of experiments
(DOE). Then, Taguchi method is used to select an optimized case
between different levels of each factor. Besides that, the factor which
affects the most on residual stress field is investigated. Such
optimized case provides the maximum residual stress field. Fatigue
life of the optimized joint is estimated by Paris-Erdogan law. Stress
intensity factors (SIFs) are calculated using both finite element
analysis and experimental formula. In addition, the effect of residual
stress field, geometry and secondary bending are considered in SIF
calculation. A good agreement is found between results of such
methods. Comparison between optimized fatigue life and fatigue life
of other joints has shown an improvement in the joint’s life.
Abstract: The dissimilar joint between aluminum/titanium
alloys (Al 6082 and Ti G2) were successfully achieved by CO2 laser
welding with a single pass and without filler material using the
overlap joint design. Laser welding parameters ranges combinations
were experimentally determined using Taguchi approach with the
objective of producing welded joint with acceptable welding profile
and high quality of mechanical properties. In this study a joining of
dissimilar Al 6082 / Ti G2 was resulted in three distinct regions
fusion area in the weldment. These regions are studied in terms of its
microstructural characteristics and microhardness which are directly
affecting the welding quality.
The weld metal was mainly composed of martensite alpha prime.
In two different metals in the two different sides of joint HAZ, grain
growth was detected. The microhardness of the joint distribution also
has shown microhardness increasing in the HAZ of two base metals
and a varying microhardness in fusion zone.
Abstract: This paper discusses effects of adhesive thickness,
overlap length and material combinations on the single-lap
joints strength from the point of singular stress fields. A useful
method calculating the ratio of intensity of singular stress is
proposed using FEM for different adhesive thickness and
overlap length. It is found that the intensity of singular stress
increases with increasing adhesive thickness, and decreases
with increasing overlap length. The increment and decrement
are different depending on material combinations between
adhesive and adherent.
Abstract: In this paper, the effect of bolt clamping force on the fatigue behavior of bolted single lap joints of aluminum alloy 2024- T3 have been studied using numerical finite element method. To do so, a three dimensional model according to the bolted single lap joint has been created and numerical analysis has been carried out using finite element based package. Then the stress distribution and also the slip amplitudes have been calculated in the critical regions and the outcome have been compared with the available experimental fatigue tests results. The numerical results show that in low applied clamping force, the fatigue failure of the specimens occur around the stress concentration location (the bolted hole edge) due to the tensile stresses and thus fatigue crack propagation, but with increase of the clamping force, the fatigue life increases and the cracks nucleate and propagate far from the hole edge because of fretting fatigue. In other words, with the further increase of clamping force value of the joint, the fatigue life reduces due to occurrence of the fretting fatigue in the critical location where the slip amplitude is within its critical occurs earlier.
Abstract: In this paper the fatigue crack initiation location of double shear lap joints, treated by interference fit and bolt clamping, have been investigated both experimentally and numerically. To do so, using the fracture section of available fatigue tested specimens of interference fitted and torque tightened Aluminum 2024-T3 plates, the crack initiation location was determined. The stress distribution attained from the finite element analysis was used to help explain the results observed in the experimental tests. The results showed that the fatigue crack initiation location changes from top and mid plane at the hole edge to somewhere far from the hole edge (stress concentration region) in different combination of clamping force, interference fit size and applied cyclic load ranges. It is worth mentioning that the fatigue crack initiation location affects the fatigue life of the specimens too.
Abstract: Adhesively bonded joints are preferred over the
conventional methods of joining such as riveting, welding, bolting
and soldering. Some of the main advantages of adhesive joints
compared to conventional joints are the ability to join dissimilar
materials and damage-sensitive materials, better stress distribution,
weight reduction, fabrication of complicated shapes, excellent
thermal and insulation properties, vibration response and enhanced
damping control, smoother aerodynamic surfaces and an
improvement in corrosion and fatigue resistance. This paper presents
the behavior of adhesively bonded joints subjected to combined
thermal loadings, using the numerical methods. The joint
configuration considers aluminum as central adherend with six
different outer adherends including aluminum, steel, titanium, boronepoxy,
unidirectional graphite-epoxy and cross-ply graphite-epoxy
and epoxy-based adhesives. Free expansion of the joint in x
direction was permitted and stresses in adhesive layer and interfaces
calculated for different adherends.