Download or read book Distortion of Refill Friction Stir Spot Welding written by Sanjay Kumar Madras Karunamurthy and published by . This book was released on 2020 with total page 71 pages. Available in PDF, EPUB and Kindle. Book excerpt: Refill Friction Stir Spot Welding (RFSSW) produces a solid-state lap joint between sheet metals, preferably aluminum alloys, without leaving any exit holes in the materials. This process was derived from Friction Stir Spot Welding (FSSW). RFSSW has been demonstrating a potential for replacing conventional joining techniques for providing better joining strength and better corrosion resistance. The goal of the research is to study distortion of Aluminum Alloy 6013 and Aluminum Alloy 2029 welded together. The experimentation involves two stages. In Stage 1, the objective is to find the optimum welding parameters for joining AA 6013 and AA 2029 through a method of Design of Experiments, where single-spot-weld coupons were produced and experimented. In Stage 2, by using the best optimum welding parameter obtained in Stage 1, the objective is to produce 10-spot coupons of AA 2029 and AA 6013 with and without air cooling along with 5 different joining sequences.
Download or read book Refill Friction Stir Spot Welding of Dissimilar Alloys written by Yuyang Chen and published by . This book was released on 2015 with total page 62 pages. Available in PDF, EPUB and Kindle. Book excerpt: Lightweight alloy materials such as magnesium and aluminum alloys are frequently employed in the automotive and manufacturing industry in order to improve vehicle fuel economy. This creates a pressing need for joining of these materials to each other, as well as to steels. Given the drastic difference in thermal and mechanical properties of these materials and the limited solubility of aluminum or magnesium in steel, dissimilar alloy fusion welding is exceptionally difficult. Refill friction stir spot welding (RFSSW) is a solid-state joining technology which connects two materials together with minimal heat input or distortion. The RFSSW process involves a three-piece non-consumable tool with independently controlled sleeve and pin components, which rotate simultaneously at a constant speed with the sleeve penetrating into only the top sheet. Joining of Al 5754 alloy and DP 600 plate using friction stir seam welding is investigated. Two travel speeds of the shoulder are used to compare the mechanical and microstructural properties of the two kinds of welds made. Scanning electron microscopy (SEM) and optical microscopy are utilized to characterize the microstructure. Mechanical properties are evaluated using tensile testing. Joining of Al 6063-T6 and Zn coated DP 600 steel using RFSSW is studied. Spot welds could reach a maximum overlap shear load of 3.7 kN when using a tool speed of 2100 RPM, a 2.5 s welding time and 1.1 mm of penetration into the upper Al 6063 sheet. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) were conducted to characterize the interface, which revealed that zinc layer was displaced into the interface and upper sheet, which may facilitate the bonding between the two sheets. Microhardness measurements reveal that the fracture path propagates through the soft heat affected zone of the Al alloy during overlap shear testing. Joining of Mg alloys ZEK with Zn coated DP 600 steel sheets by RFSSW is also studied here. In joints between ZEK 100 and DP 600, the maximum overlap shear fracture load is 4.7 kN, when a 1800 RPM tool speed, 3.0 s welding time and 1.5 mm penetration into the upper ZEK 100 sheet is applied. SEM and transmission electron microscopy (TEM) revealed that a continuous layer of FeAl2 particles accommodate bonding of the ZEK 100 and DP 600 sheets, which appears to have originated from the galvanized coating on the DP 600. If the zinc layer is removed then the maximum overlap shear fracture load is 3.1 kN. X-ray diffraction analysis of the interface between the Mg alloy and the DP 600 steel on the Mg side also revealed that intermetallic (IMCs) such as FeAl2 existed as an interfacial layer between the two sheets. It can be revealed from the displacement curve that the absorbed energy of the weld made under the condition of 1800 RPM, 3.5s, and 1.5mm of plunge depth in tensile testing up to failure point is approximately 2.73J.
Download or read book Friction Stir Spot Welding written by Jeyaprakash Natarajan and published by CRC Press. This book was released on 2024-07-11 with total page 347 pages. Available in PDF, EPUB and Kindle. Book excerpt: Friction Stir Spot Welding offers an introduction to friction stir spot welding (FSSW) between both similar and dissimilar metals and materials. It explains the impact of the interlayer in FSSW of different metals with regard to mechanical, metallurgical, wear, thermo-mechanical, and chemical characteristics. Emphasizing the impact of interlayer on FSSW of different metals, this book discusses the influence of the interlayer in the process as a new technique. Using aerospace and automotive structures as examples, the book explains how their components successfully employ materials like dissimilar aluminium alloys, yielding increased electrical, thermal, and mechanical characteristics. It also considers the reinforcement, effect of tool geometry, wettability, and corrosion behavior of joints. This book is intended for mechanical, materials, and manufacturing professionals, researchers, and engineers working in the field of FSSW.
Download or read book Current Trends in Friction Stir Welding FSW and Friction Stir Spot Welding FSSW written by Mukuna Patrick Mubiayi and published by Springer. This book was released on 2018-06-14 with total page 216 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book provides an overview of friction stir welding and friction stir spot welding with a focus on aluminium to aluminium and aluminium to copper. It also discusses experimental results for friction stir spot welding between aluminium and copper, offering a good foundation for researchers wishing to conduct more investigations on FSSW Al/Cu. Presenting full methodologies for manufacturing and case studies on FSSW Al/Cu, which can be duplicated and used for industrial purposes, it also provides a starting point for researchers and experts in the field to investigate the FSSW process in detail. A variant of the friction stir welding process (FSW), friction stir spot welding (FSSW) is a relatively new joining technique and has been used in a variety of sectors, such as the automotive and aerospace industries. The book describes the microstructural evolution, chemical and mechanical properties of FSW and FSSW, including a number of case studies.
Download or read book Development of Refill Friction Stir Spot Welding RFSSW for Lightweight Applications written by Pedro Miguel de Sousa Santos and published by . This book was released on 2021 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:
Download or read book Increasing the Manufacturing Readiness of Refill Friction Stir Spot Welding written by Brigham Ammon Larsen and published by . This book was released on 2020 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Refill friction stir spot welding (RFSSW) is an emerging technology, capable of joining thin sheets of aluminum alloys. The present thesis comprises two studies which were conducted to address two challenges faced by RFSSW: the long cycle time traditionally associated with welding and the poor life of existing RFFSW tools. In the first study, welds were made in AA5052-H36, at various cycle times and with various process parameters. It was shown that RPM, cycle time, and material thickness, all have an effect on the machine response. Decreasing RPM or weld duration leads to increased force and torque response during welding. Welds with cycle times below one second were successfully made without severely impacting joint quality, suggesting that prior work may have been limited by machine capabilities rather than by phenomena inherent to the process. On average, the sub-one second welds caused a peak probe force of 9.81 kN, a plunge torque of 26.3 N*m, and showed average lap-shear strengths of 7.0kN; compared to a peak probe force of 5.14 kN, a plunge torque of 17.3 N*m, and lap-shear strength of 6.89kN for a more traditional four-second welding condition. In the second study, the life of a steel toolset was quantified as consecutive welds were made in AA5052-H36 until the toolset seized from material accumulation/growth. At a one-second welding condition, the toolset was only capable of producing 53 welds before seizure. At a two-second welding condition, the toolset was only capable of producing 48 welds. In subsequent temperature experiments, thermocouples were embedded into welding coupons at various locations near weld center, allowing novel temperature data to be collected for welds with varying cycle times and parameters. The collected temperature data shows that as cycle time increases, so does weld temperature. At weld center, temperatures in excess of 500°C were observed in welds with 4 second durations. At these temperatures, Fe-Al intermetallic growth is anticipated as a mechanism limiting the tool life observed. The results suggest that steel is not an appropriate choice for RFSSW tools, and future evaluation of other materials is merited.
Download or read book Friction Stir Welding and Processing VII written by Rajiv S. Mishra and published by John Wiley & Sons. This book was released on 2013-01-23 with total page 376 pages. Available in PDF, EPUB and Kindle. Book excerpt: Friction stir welding (FSW) and its variants, friction stir spot welding and friction stir processing, are used in numerous industrial applications and there is considerable activity in the development of FSW processes and their applications. This volume covers the seventh proceedings in this recurring TMS symposium, focusing on all aspects of the science and technology involved in friction stir welding and processing. An important reference for materials scientists and engineers, metallurgists, and mechanical engineers in such areas as shipbuilding, aerospace, automotive, and railway rolling stock.
Download or read book Damage Tolerance of Refill Friction Stir Spot Weld Application for the Aircraft Industry written by Robson Cristiano Brzostek and published by . This book was released on 2019 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Refill Friction Stir Spot Welding (Refill FSSW) is a solid-state process technology that is suitable for welding lightweight materials in similar or dissimilar overlapped configuration. It has proven to be a very promising new joining technique; especially, for high strength aluminum alloys, which has presented large advantages when compared to conventional welding processes. Currently, Refill FSSW is recognized as a potential alternative for riveted structure; it allows an increasing of the manufacturing cost effectiveness owing to sensible cost reduction and structural efficiency. The main aim of this work is to study the mechanical behavior and crack propagation in joints produced by Refill FSSSW. The study is focused on the application of the damage tolerance design philosophy in integral structures produced by Refill FSSSW in aluminum alloy AA2024-T3. Up to now the process development and the mechanical performance study has been mostly empirical. Thus, a transition to a science-based approach is highly necessary. The work presented here was conducted to stablish a relationship of experimental investigation and a set of numerical models that can be used for design optimization and fatigue crack growth analysis. Beforehand, the welded joints were assessed mechanically and metallurgically in order to investigate the mechanism and the optimization of the process parameters (rotation speed, welding time and plunge depth) in terms of quasi-static loading and fatigue loading. This investigation has assisted the development of the structural numerical models, where two structural models have been developed to study the design optimization. The first model covers the stress analysis, load transferred by friction, stress concentration and peak stress location; it was built considering the structural and cohesive approach. The second numerical model considers the embedded approach; it can be used for parametric studies with good accuracy. Then, the design optimization was developed considering the distances: number of spot welds rows, spot weld row spacing, spot weld pitch in row and distance of the spot weld from the sheet edge. The developments of the distances were performed considering its performance in quasi-static and fatigue loading. A fractography analysis at various fracture modes has been performed. This is necessary in order to understand and described the crack propagation according the fracture mechanics. Then, a numerical model has developed and calibrated in order to obtain stress intensity factors for the cracks described previously. The numerical model has been built with the eXtended Finite Element Method. Finally, the thesis deals with crack propagation and residual strength of Refill FSSW in thin panels for aircraft fuselage applications. Detailed experimental investigation has been carried out in panels FSSW in order to understand the crack propagation under different failure scenario. Moreover, the experimental results have been used to verify and calibrate the developed fatigue crack growth numerical model. The model has been used to simulate crack propagation in different joint configuration and initial cracks. The numerical model has been built with the eXtended Finite Element Method. The results have shown good agreement of the predict fatigue life with the experimental results. Then, both eXtended Finite Element Method models numerical models developed have been used for residual strength prediction of cracked unstiffened panels in terms of the stress intensity factor. The results obtained in the course of this study have shown the feasibility of Refill FSSW to produce high strength joints as well as the importance of the joint design, in which can be significantly improved by using the correct distances. The knowledge about the structural behavior and extent of crack propagation gained from the numerical models is valuable to understanding the influence of secondary bending on cracked panels and the development of residual strength diagrams.
Download or read book Material Interactions in a Novel Refill Friction Stir Spot Welding Approach to Joining Al Al and Al Mg Automotive Sheets written by Basem Al-Zubaidy and published by . This book was released on 2017 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:
Download or read book Numerical Simulation of Modified Refill Friction Stir Spot Welding Process Using FEM written by Sai Krishna Itapu and published by . This book was released on 2006 with total page 360 pages. Available in PDF, EPUB and Kindle. Book excerpt: The object of the work is to develop a three dimensional finite element model for plunge and three quarter retract phases of the modified refill Friction Stir Spot Welding process and also conduct qualitative experimental studies using markers to visualize the material flow in the process being modeled. An isothermal model is developed to understand the formulations and techniques required to simulate the process. As a preliminary effort, finite element model is developed by defining material properties at two different temperatures for plate. The model, based on a solid mechanics approach, was developed using the commercial finite element software ABAQUS/Explicit. The isothermal model was employed to obtain the deformations, stresses and strains induced in the plates being spot wilded. The numerical model developed assumes the pin, shoulder and clamp as rigid in nature, while the plate material is modeled as a 3-D deformable body. The dimensions provided by the Advanced Materials Processing and Joining Laboratory, SDSM & T are used to build the numerical model. Virtual tracers were included in the FEM model to visualize the material flow in the vicinity of pin. Qualitative experimental studies were performed using markers to visualize the material flow and also to validate the numerical model. Three full plunge tests were performed by placing marker rod at different locations with respect to pin's circumference. The process parameters used in the experiment were similar to the numerical model. Reaction forces on the pin and material flow are the desired outputs from this research work. The reaction forces from the numerical model were compared to the experimental values and found to be closer. The results from the numerical model are quite promising in nature. The numerical model was able to predict the flash formation during FSSW process. A comparison of results for material flow visualization using virtual tracers provided by the simulations with the experimental data shows that it gives an acceptable approximation but additional refinement of the model is needed.
Download or read book Magnesium 2021 written by Alan Luo and published by Springer Nature. This book was released on 2021-05-28 with total page 272 pages. Available in PDF, EPUB and Kindle. Book excerpt: This collection from the 12th International Conference on Magnesium Alloys and Their Applications (Mg 2021)—the longest running conference dedicated to the development of magnesium alloys—covers the breadth of magnesium research and development, from primary production to applications to end-of-life management. Authors from academia, government, and industry discuss new developments in magnesium alloys and share valuable insights. Topics in this volume include but are not limited to the following: Primary production Alloy development Solidification and casting processes Forming and thermo-mechanical processing Other manufacturing process development (including joining and additive manufacturing) Corrosion and protection Modeling and simulation Structural, functional, biomedical, and energy applications Advanced characterization and fundamental theories Recycling and environmental issues
Download or read book Static Test Simulation of Refill Friction Stir Spot Welded and Riveted Coupons Using Finite Element Analysis written by Gratias Fernandez Joseph Rosario and published by . This book was released on 2019 with total page 54 pages. Available in PDF, EPUB and Kindle. Book excerpt: Refill Friction stir spot welding (RFSSW) produces a solid-state lap joint between sheet metals, preferably aluminum alloys, without leaving behind an exit hole in the workpiece. This joining technique was derived from friction stir spot welding (FSSW). RFSSW has been demonstrating a potential for replacing conventional joining techniques, such as riveting, resistance spot welding, and fastening. The goal of the research is to compare stress distributions and failure mechanisms of the joints produced by RFSSW and riveting. The experimentation involved finite element simulations of static loads applied to RFSSW coupons and riveted coupons in the directions of lap shear and cross tension. To validate the simulation results, actual coupons were produced and mechanically tested. The study used a robotic RFSSW system developed by Kawasaki Heavy Industries (KHI) for producing RFSSW coupons. The stress distributions estimated by the finite element simulations were in a good agreement with the failure mechanisms demonstrated by actual coupons during mechanical tests. Keywords: Refill Friction Stir Spot Welding, Riveting, Aerospace, FEA, ABAQUS
Download or read book Friction Stir Welding and Processing VIII written by Rajiv Mishra and published by Springer. This book was released on 2016-12-01 with total page 292 pages. Available in PDF, EPUB and Kindle. Book excerpt: This collection focuses on all aspects of science and technology related to friction stir welding and processing.
Download or read book Advanced Joining Processes written by Lucas F. M. da Silva and published by Springer Nature. This book was released on 2020-03-31 with total page 178 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents recent material science-based and mechanical analysis-based advances in joining processes. It includes all related processes, e.g. friction stir welding, joining by plastic deformation, laser welding, clinch joining, and adhesive bonding, as well as hybrid joints. It gathers selected full-length papers from the 1st Conference on Advanced Joining Processes.
Download or read book Friction Stir Welding and Processing IV written by Rajiv S. Mishra and published by Wiley-TMS. This book was released on 2007-05-01 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Friction stir welding has seen significant growth in bothtechnology implementation and scientific exploration. This bookcovers all aspects of friction stir welding and processing, fromfundamentals to design and applications. It also includes an updateon the current research issues in the field of friction stirwelding, and a guide for further research. A collection of papers from the ahref="http://www.tms.org/Meetings/Annual-07/AnnMtg07Home.html"target="_blank"2007 TMS Annual Meeting & Exhibition/a heldin Orlando, Florida, February 25 - March 1, 2007.
Download or read book Friction Stir Welding written by Daniela Lohwasser and published by Elsevier. This book was released on 2009-12-18 with total page 437 pages. Available in PDF, EPUB and Kindle. Book excerpt: Friction stir welding (FSW) is a highly important and recently developed joining technology that produces a solid phase bond. It uses a rotating tool to generate frictional heat that causes material of the components to be welded to soften without reaching the melting point and allows the tool to move along the weld line. Plasticized material is transferred from the leading edge to trailing edge of the tool probe, leaving a solid phase bond between the two parts. Friction stir welding: from basics to applications reviews the fundamentals of the process and how it is used in industrial applications.Part one discusses general issues with chapters on topics such as basic process overview, material deformation and joint formation in friction stir welding, inspection and quality control and friction stir welding equipment requirements and machinery descriptions as well as industrial applications of friction stir welding. A chapter giving an outlook on the future of friction stir welding is included in Part one. Part two reviews the variables in friction stir welding including residual stresses in friction stir welding, effects and defects of friction stir welds, modelling thermal properties in friction stir welding and metallurgy and weld performance.With its distinguished editors and international team of contributors, Friction stir welding: from basics to applications is a standard reference for mechanical, welding and materials engineers in the aerospace, automotive, railway, shipbuilding, nuclear and other metal fabrication industries, particularly those that use aluminium alloys. Provides essential information on topics such as basic process overview, materials deformation and joint formation in friction stir welding Inspection and quality control and friction stir welding equipment requirements are discussed as well as industrial applications of friction stir welding Reviews the variables involved in friction stir welding including residual stresses, effects and defects of friction stir welds, modelling thermal properties, metallurgy and weld performance
Download or read book Innovative Design Analysis and Development Practices in Aerospace and Automotive Engineering I DAD 2018 written by U. Chandrasekhar and published by Springer. This book was released on 2018-12-20 with total page 553 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book gathers the best articles presented by researchers and industrial experts at the International Conference on “Innovative Design and Development Practices in Aerospace and Automotive Engineering (I-DAD 2018)”. The papers discuss new design concepts, analysis and manufacturing technologies, with an emphasis on achieving improved performance by downsizing; improving the weight-to-strength ratio, fuel efficiency, and operational capability at room and elevated temperatures; reducing wear and tear; and addressing NVH aspects, while balancing the challenges of Euro IV/Barat Stage IV emission norms and beyond, greenhouse effects, and recyclable materials. The innovative methods discussed here offer valuable reference material for educational and research organizations, as well as industry, encouraging them to pursue challenging projects of mutual interest.
