Download or read book Aspects of Vaporizing Foil Actuator Welding for Practical Automotive Applications written by Angshuman Kapil and published by . This book was released on 2020 with total page 195 pages. Available in PDF, EPUB and Kindle. Book excerpt: Driven by the need for global carbon footprint reduction, the automotive industries are increasingly focusing on lightweighting of vehicles. Use of multi-material combinations for body-in-white applications is one of the practical ways of accomplishing the broader goal of lightweighting. Over the past decade, the vehicular structure has seen progressive replacement of the more conventional low-carbon mild steels with a variety of advanced and ultrahigh-strength steels including Dual Phase (DP), high-strength low-alloy (HSLA) and boron, and also extensive integration of light metals, such as Al alloys. Development of strong, repeatable and dependable joints is crucial for the effective implementation of these multi-material combinations. Direct welding of disparate Al-steel combination is difficult to impossible through conventional fusion welding routes. Mechanical fastening and clinching techniques provide alternatives to fusion welding, however, there are stack-up feasibility limitations and addition of an externally exposed joining element adds weight and negates the larger goal of lightweighting as well as increases the susceptibility of the joint to galvanic corrosion. Solid-state welding technologies are good substitutes to fusion welding and mechanical fastening and clinching techniques and are currently being employed on a small scale in industries. Here, Vaporizing Foil Actuator Welding (VFAW), a variant of solid-state impact welding technique is being utilized to produce similar and dissimilar joints with materials relevant to the automotive industries. VFAW, a high-speed impact welding technique utilizes the very high pressures generated due to the rapid vaporization of a foil actuator to cause the impact of metal sheets to form nominally solid-state joints with little to no presence of heat affected zone, providing the process the ability to join a wide array of similar and dissimilar material pairs. The present study applies an adaptation of the VFAW technique to develop impact spot welding of similar and dissimilar Al and steel pairs. The VFAW process was benchmarked through mechanical testing (quasistatic and cyclic), microhardness mapping and microstructural comparison with resistance spot welding (RSW) for JSC590R-JSC590R and 6061-T6-6061-T6 joints. The results indicated that the VFAW welds had improved quasistatic mechanical properties and comparable fatigue strength compared to RSW joints for both the material combinations. Microhardness measurements in VFAW joints showed constant hardness values across the weld length signifying the absence of a heat affected zone, whereas softening was observed in RSW joints. Optical imaging revealed the homogeneity in microstructure of VFAW joints and the inhomogeneous distribution of the microstructure in RSW joints. Fatigue strength scaled with static strength in a predictable way and was mostly affected by the shape and type of notch formed at the end of the nugget. Following this, the effect of material age and different heat treatments (replicating the industrial procedures) on the weldability, joint properties and weld interface characteristics was studied for similar AA6111-T4-AA6111T4 pair. Lap-shear tests indicated that even after aging and varied heat treatments all samples had repeatable button pullout failure, the failure being governed by the thinning and tearing of the base metal around the weld nugget. The strength of the welds and the energy absorbed corresponding to the peak load varied with the heat treatments. Optical and scanning electron microscopy revealed re-solidified molten zones in the weld interface, and the extent and size of these zones varied with the heat treatments. Nanoindentation showed softening in these zones signifying presence of weld defects in the weld interior. After the successful implementation of the process for similar material joints, the work was focused on understanding the process-structure-property relationships in dissimilar Al-steel welds and also development of novel approaches for joining of high strength and ultrahigh-strength steels with a variety of faying surface conditions to heat treatable Al alloys. The process was characterized for Al6022-T4-DP980 welds via quantification of the incident angle and velocity of the flyer plate and their relations to the structure and properties of the joint were assessed. It was revealed that lower impact angles and higher impact velocities promoted interfacial failure due to increased melting, higher intermetallic thickness and lower wave amplitude and wavelength, whereas higher impact angles and lower velocities led to desirable button pullout failure. Based on these results, a new approach (asymmetric predeformation of target sheet) was developed that enabled for the first-time direct spot welding of coated steels (galvanized HSLA 350 and galvannealed DP590) to Al 6022-T4. The produced joints had better performance in most cases compared with other joining techniques, however the biggest outcome of this approach was the ability to weld without the use of inserts/interlayers and without any prior surface preparation. However, the developed approach produced joints with a protruded external surface and was limited to lower flyer sheet thicknesses. To alleviate these issues, another novel approach was developed wherein a pocket was machined on the faying surface of either of the mating members prior to welding. This approach allowed welding of bare, hot-dip galvanized and e-coated HSLA 340 steel to AA6111-T4, high pressure vacuum die cast Al alloy (Aural 2) to hot-dip galvanized HSLA 340 steel as well of ultrahigh-strength boron steel (Usibor 1500®) to Al 6022-T4 alloy. All the produced joints had repeatable failure loads and modes (button pullout) and comparable and in some cases better performance than other competing welding techniques. A significant outcome of the machined pocket welding approach was the ability to produce joints exhibiting flat external target surfaces with unperturbed coating, a potential enabler for mixed metal joining applications involving pre-treated, e-coated, or painted materials. The results presented in this thesis show that there are various ways to develop the VFAW process to create configurations that are both manufacturable and have outstanding design attributes. The conducted work indicates excellent promise for the development of robust welding pairs consisting a various grades of high and ultrahigh-strength steels and heat treatable and cast Al alloys. Future work will focus on ways of reducing the size of the weld spot to match industrial standards. Efforts will focus on utilizing the approach presented here to develop capability for welding on flanges, with the goal of achieving minimum possible flange length/width with maximum possible weld strength. VFAW compatibility with corrosion mitigation strategies including sealers/adhesives is critical and will be evaluated.

Download or read book Joining Dissimilar Structural Alloys by Vaporizing Foil Actuator Welding written by Bert C. Liu and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The continual push for vehicle weight reduction has called for the incorporation of non-conventional automotive alloys, such as advanced high-strength steels, aluminum alloys, and even magnesium alloys and titanium alloys. The advent of these new alloys calls for new joining technologies. Resistance Spot Welding and Arc Welding have served the automotive industry well in joining steel components. However, because these are fusion-based processes involving high heat, they are not suitable for joining combinations of dissimilar metals or high-performance alloys. Thus the search continues for a technique capable of joining the said metals effectively, economically, and flexibly. The work featured in this dissertation aims to explore and develop Vaporizing Foil Actuator Welding (VFAW) as a promising technique for dissimilar-metal joining. VFAW is a form of solid-state impact welding that was developed in the Ohio State University in 2011. In this work, some 20 dissimilar-metal combinations of industrially relevant structural alloys were screened for weldability by VFAW. Successful welds were obtained for some 10 combinations, many of which were Al/Fe pairs, which are a most popular material pair for automotive weight reduction.

Download or read book Systematic Optimization of Vaporizing Foil Actuator Welding and Dynamic Science written by Yu Mao (Ph. D. in materials science) and published by . This book was released on 2021 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Lightweighting by material substitution has been a key strategy to improve fuel economy and achieve restricted global gas emissions. Coupled with lightweight designs, lightweight metals such as high-strength steel, aluminum alloys and magnesium alloys are increasingly applied in the automotive world. However, conventional joining technologies are not as capable for these new materials. Fusion based welding and friction stir welding are limited by the formation of heat affected zones (HAZ) and intermetallic compounds (IMC) for dissimilar joints, which dramatically downgrades the properties of the parent materials. Mechanical joining such as rivets incurs poor fatigue properties due to stress concentration and additional labor cost. Vaporizing Foil Actuator Welding (VFAW) is a novel impact welding technique for metal joining of moderate to small length scales developed at The Ohio State University. Via VFAW, similar and dissimilar metals can be joined with minimal to no melting at the interface, resulting in no HAZ and suppressed formation of IMC, and therefore the mechanical properties of the parent metals can be preserved. In this research, VFAW is comprehensively optimized in terms of welding capability, system and control, and processing characterization. Approaches including use of an intermediate layer, innovation of weld design, and adoption of chemical explosives are studied. With improved weld capability, high-strength dissimilar joining of various commercial high strength aluminum alloys (Al 5754, Al 5052, Al 5182, Al 6061, Al 7075, Aural 2) of at least 3 mm with high strength steel (HSLA 340, HSLA 420, 22MnB5) has been achieved. Welds of Al 7075 with metal matrix compound and self-joining of 3.175 mm thick full hardened stainless steel were also created with remarkable mechanical performance. Characterization including Lap shear test, tension-tension fatigue test, micro-hardness test, scanning electron microscopy, and photonic Doppler velocimetry (PDV) are being applied to analyze the process. A vaporizing foil actuator driving projectile based rapid throughput system has been developed for shock and impact. Planar impact of S7 steel surface of 612 m/s and Al 6061 surface of 953 m/s have been accomplished. Applications including dynamic powder compaction (CP-Ti powder), impact welding (Cu110 with SS304), and impact weld based ballistic additive (BAM) manufacturing have been achieved. A numerical simulation method was developed with a Coupled Eulerian Language domain; using this approach, in-situ features including strain, stress, temperature and shape revolution during VFA BAM process were discovered. Additionally, the concept of impact based dynamic hardness has been studied with numerical methods including coupled Eulerian-Lagrangian finite element method and smoothed-particle hydrodynamics technique. The effects of impact velocity and size of the indenter on the dynamic hardness has been discovered.

Download or read book Welding and Other Applications of the Vaporizing Foil Actuator VFA Tool written by Anupam Vivek and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Resistance Spot Welding written by Menachem Kimchi and published by Springer Nature. This book was released on 2022-05-31 with total page 115 pages. Available in PDF, EPUB and Kindle. Book excerpt: The early chapters of this book provide thorough coverage of resistance spot welding fundamentals and principles. Topics covered include lobe and current range curves, contact resistance vs. electrode force, dynamic resistance, heat balance, nugget growth, etc. Equipment issues such as machine types, power supplies, and electrodes are addressed. Subsequent chapters focus on specific spot welding challenges to modern automotive manufacturing. Approaches to welding modern materials including advanced high-strength steels, coated steels, and aluminum alloys are covered in much detail. The final chapters focus on many common production and quality control issues, such as electrode wear, monitoring and testing, computational modeling, and welding codes. The overall goal of the book is to provide a comprehensive resource for automotive engineers and technicians who work with modern spot welding equipment and automotive materials.

Download or read book Resistance Spot Welding written by Menachem Kimchi and published by Morgan & Claypool Publishers. This book was released on 2017-09-08 with total page 129 pages. Available in PDF, EPUB and Kindle. Book excerpt: This is a comprehensive practical resource for automotive engineers and technicians who work with modern spot welding equipment and automotive materials. The early chapters of this book provide thorough coverage of resistance spot welding fundamentals and principles. Topics covered include lobe and current range curves, contact resistance vs. electrode force, dynamic resistance, heat balance, nugget growth, etc. Equipment issues such as machine types, power supplies, and electrodes are addressed. Subsequent chapters focus on specific spot welding challenges to modern automotive manufacturing. Approaches to welding modern materials including advanced high-strength steels, coated steels, and aluminum alloys are covered in much detail. The final chapters focus on many common production and quality control issues, such as electrode wear, monitoring and testing, computational modeling, and welding codes.

Download or read book Benchmarking and Refining the Vaporizing Foil Actuator Spot Welding Process written by A. Vivek and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Automotive Applications of Spot Welding written by Materials Information Editors and published by . This book was released on 2004-01-01 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Forming the Future written by Glenn Daehn and published by Springer Nature. This book was released on 2021-07-10 with total page 2890 pages. Available in PDF, EPUB and Kindle. Book excerpt: In this collection, scientists and engineers from across industry, academia, and government present their latest improvements and innovations in all aspects of metal forming science and technology, with the intent of facilitating linkages and collaborations among these groups. Chapters cover the breadth of metal forming topics, from fundamental science to industrial application.

Download or read book Welding Processes Handbook written by Klas Weman and published by Woodhead Publishing. This book was released on 2003 with total page 208 pages. Available in PDF, EPUB and Kindle. Book excerpt: Welding processes handbookis an introductory guide to all of the main welding processes. It is specifically designed for students on EWF courses and newcomers to welding and is suitable as a textbook for European welding courses in accordance with guidelines from the European Welding Federation. Welding processes and equipment necessary for each process are described so that they can be applied to all instruction levels required by the EWF and the important areas of welded joint design, quality assurance and costing are also covered in detail.

Download or read book Light Metals 2015 written by Margaret Hyland and published by John Wiley & Sons. This book was released on 2015-02-18 with total page 1303 pages. Available in PDF, EPUB and Kindle. Book excerpt: The 2015 collection will include papers from the following symposia: Alumina and Bauxite Aluminum Alloys: Fabrication, Characterization and Applications Aluminum Processing Aluminum Reduction Technology Cast Shop for Aluminum Production Electrode Technology for Aluminum Production Strip Casting of Light Metals

Download or read book Explosive Welding Forming and Compaction written by T.Z. Blazynski and published by Springer Science & Business Media. This book was released on 2012-12-06 with total page 410 pages. Available in PDF, EPUB and Kindle. Book excerpt: The last two decades have seen a steady and impressive development, and eventual industrial acceptance, of the high energy-rate manufact turing techniques based on the utilisation of energy available in an explo sive charge. Not only has it become economically viable to fabricate complex shapes and integrally bonded composites-which otherwise might not have been obtainable easily, if at all-but also a source of reasonably cheap energy and uniquely simple techniques, that often dispense with heavy equipment, have been made available to the engineer and applied scientist. The consolidation of theoretical knowledge and practical experience which we have witnessed in this area of activity in the last few years, combined with the growing industrial interest in the explosive forming, welding and compacting processes, makes it possible and also opportune to present, at this stage, an in-depth review of the state of the art. This book is a compendium of monographic contributions, each one of which represents a particular theoretical or industrial facet of the explosive operations. The contributions come from a number of practising engineers and scientists who seek to establish the present state of knowledge in the areas of the formation and propagation of shock and stress waves in metals, their metallurgical effects, and the methods of experimental assessment of these phenomena.

Download or read book Materials Design and Manufacturing for Sustainable Environment written by Santhakumar Mohan and published by Springer Nature. This book was released on 2021-02-06 with total page 909 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book comprises the select proceedings of the International Conference on Materials, Design and Manufacturing for Sustainable Environment (ICMDMSE 2020). The primary focus is on emerging materials and cutting-edge manufacturing technologies for sustainable environment. The book covers a wide range of topics such as advanced materials, vibration, tribology, finite element method (FEM), heat transfer, fluid mechanics, energy engineering, additive manufacturing, robotics and automation, automobile engineering, industry 4.0, MEMS and nanotechnology, optimization techniques, condition monitoring, and new paradigms in technology management. Contents of this book will be useful to students, researchers, and practitioners alike.

Download or read book Airframe and Powerplant Mechanics Airframe Handbook written by United States. Flight Standards Service and published by . This book was released on 1976 with total page 620 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Automotive Development Processes written by Julian Weber and published by Springer Science & Business Media. This book was released on 2009-06-22 with total page 321 pages. Available in PDF, EPUB and Kindle. Book excerpt: The global crisis the automotive industry has slipped into over the second half of 2008 has set a fierce spotlight not only on which cars are the right ones to bring to the market but also on how these cars are developed. Be it OEMs developing new models, suppliers integerating themselves deeper into the development processes of different OEMs, analysts estimating economical risks and opportunities of automotive investments, or even governments creating and evaluating scenarios for financial aid for suffering automotive companies: At the end of the day, it is absolutely indispensable to comprehensively understand the processes of auto- tive development – the core subject of this book. Let’s face it: More than a century after Carl Benz, Wilhelm Maybach and Gottlieb Daimler developed and produced their first motor vehicles, the overall concept of passenger cars has not changed much. Even though components have been considerably optimized since then, motor cars in the 21st century are still driven by combustion engines that transmit their propulsive power to the road s- face via gearboxes, transmission shafts and wheels, which together with spri- damper units allow driving stability and ride comfort. Vehicles are still navigated by means of a steering wheel that turns the front wheels, and the required control elements are still located on a dashboard in front of the driver who operates the car sitting in a seat.

Download or read book Materials and Processes written by Barrie D. Dunn and published by Springer. This book was released on 2015-12-29 with total page 677 pages. Available in PDF, EPUB and Kindle. Book excerpt: The objective of this book is to assist scientists and engineers select the ideal material or manufacturing process for particular applications; these could cover a wide range of fields, from light-weight structures to electronic hardware. The book will help in problem solving as it also presents more than 100 case studies and failure investigations from the space sector that can, by analogy, be applied to other industries. Difficult-to-find material data is included for reference. The sciences of metallic (primarily) and organic materials presented throughout the book demonstrate how they can be applied as an integral part of spacecraft product assurance schemes, which involve quality, material and processes evaluations, and the selection of mechanical and component parts. In this successor edition, which has been revised and updated, engineering problems associated with critical spacecraft hardware and the space environment are highlighted by over 500 illustrations including micrographs and fractographs. Space hardware captured by astronauts and returned to Earth from long durations in space are examined. Information detailed in the Handbook is applicable to general terrestrial applications including consumer electronics as well as high reliability systems associated with aeronautics, medical equipment and ground transportation. This Handbook is also directed to those involved in maximizing the relia bility of new materials and processes for space technology and space engineering. It will be invaluable to engineers concerned with the construction of advanced structures or mechanical and electronic sub-systems.

Download or read book Mechatronics written by Godfrey Onwubolu and published by Elsevier. This book was released on 2005-05-25 with total page 668 pages. Available in PDF, EPUB and Kindle. Book excerpt: Mechatronics is a core subject for engineers, combining elements of mechanical and electronic engineering into the development of computer-controlled mechanical devices such as DVD players or anti-lock braking systems. This book is the most comprehensive text available for both mechanical and electrical engineering students and will enable them to engage fully with all stages of mechatronic system design. It offers broader and more integrated coverage than other books in the field with practical examples, case studies and exercises throughout and an Instructor's Manual. A further key feature of the book is its integrated coverage of programming the PIC microcontroller, and the use of MATLAB and Simulink programming and modelling, along with code files for downloading from the accompanying website.*Integrated coverage of PIC microcontroller programming, MATLAB and Simulink modelling*Fully developed student exercises, detailed practical examples*Accompanying website with Instructor's Manual, downloadable code and image bank