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 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 Impact Welding Structural Aluminium Alloys to High Strength Steels Using Vaporizing Foil Actuator written by B. Liu 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 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 Joining Processes for Dissimilar and Advanced Materials written by Pawan Kumar Rakesh and published by Woodhead Publishing. This book was released on 2021-11-13 with total page 694 pages. Available in PDF, EPUB and Kindle. Book excerpt: Joining Processes for Dissimilar and Advanced Materials describes how to overcome the many challenges involved in the joining of similar and dissimilar materials resulting from factors including different thermal coefficients and melting points. Traditional joining processes are ineffective with many newly developed materials. The ever-increasing industrial demands for production efficiency and high-performance materials are also pushing this technology forward. The resulting emergence of advanced micro- and nanoscale material joining technologies, have provided many solutions to these challenges. Drawing on the latest research, this book describes primary and secondary processes for the joining of advanced materials such as metals and alloys, intermetallics, ceramics, glasses, polymers, superalloys, electronic materials and composites in similar and dissimilar combinations. It also covers details of joint design, quality assurance, economics and service life of the product. - Provides valuable information on innovative joining technologies including induction heating of metals, ultrasonic heating, and laser heating at micro- and nanoscale levels - Describes the newly developed modelling, simulation and digitalization of the joining process - Includes a methodology for characterization of joints

Download or read book High Strength Impact Welding of Structural and Functional Materials written by Jianxiong Li (Ph. D. in materials science) and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Dissimilar material welding has grown in popularity in the lightweight design of biomedical, automotive, and aerospace products. However, welding of two or more different materials presents difficulties due to their notable mismatch in chemical, physical and mechanical properties. Some traditional joining methods are undesirable due to the formation of intermetallic compounds and thermally induced defects. These defects make the dissimilar welds unable to reliably serve in actual applications. Vaporizing Foil Actuator Welding (VFAW), an impact welding method, can minimize the abovementioned defects and join various dissimilar metals in solid state with reliable properties. This dissertation focuses on developing VFAW to join three metal pairs including Ti/stainless steel (SS), NiTi/SS, and NiTi/brass alloy. The process, microstructure, and properties of these dissimilar impact welds were explored through advanced techniques and compared with traditional welding methods. This work also introduces a new additive manufacturing method based on impact welding, called Ballistic Additive Manufacturing (BAM). The potential applications and overall long term vision of BAM were demonstrated. The results show that VFAW was effective in joining Ti and stainless steel. Ti/SS impact welds have reproducible macro- and micro-structure and show spatial heterogeneities at large and small length scales. Simulation shows that strength and failure modes are not affected adversely by the size of the central unbonded zone. Since mufflers in automobile could encounter thermal exposure ranging from 300 to 800 °C, a Nb interlayer was introduced to improve the thermal resistance. Both types of bonds give base metal failure in lap shear tests in as-welded condition. Guidelines for the production, properties and applications of these classes of welds are provided. High strength and fatigue resistant impact welds were produced between a NiTi shape memory alloy and dissimilar metals including SS and brass alloy for the first time. Good retention of the superelastic property and strength in the VFAW nitinol welds could be ascribed to the lack of heat affected zone formation, the solid-state bonding interfaces and the grain refinement near the interfaces. The unparalleled performance of these high-strength solid-state similar and dissimilar welds is a solution to the increasing demands of applications in various industrial fields including the medical, automotive, aerospace and electronic sectors. BAM is a new class of additive manufacturing processes achieved by the sequential solid-state impact welding of elements. In this work, BAM was found to be a promising technology that can be used to carry out crack repair and groove filling by either combined shearing and welding method or directly welding of thin flyer sheets to a pre-machined part. The overall long-term vision for BAM is to automate the manufacturing system so that quick and efficient repairment of damaged parts, impact fill welding of dissimilar metals, and fabrication of arbitrary shapes with graded compositions can be achieved at low process energies.

Download or read book Dissimilar Metal Welding written by Pierpaolo Carlone and published by MDPI. This book was released on 2019-12-12 with total page 288 pages. Available in PDF, EPUB and Kindle. Book excerpt: The combination of distinct materials is a key issue in modern industry, whereas the driving concept is to design parts with the right material in the right place. In this framework, a great deal of attention is directed towards dissimilar welding and joining technologies. In the automotive sector, for instance, the concept of “tailored blanks”, introduced in the last decade, has further highlighted the necessity to weld dissimilar materials. As far as the aeronautic field is concerned, most structures are built combining very different materials and alloys, in order to match lightweight and structural performance requirements. In this framework, the application of fusion welding techniques, namely, tungsten inert gas or laser welding, is quite challenging due to the difference in physical properties, in particular the melting point, between adjoining materials. On the other hand, solid-state welding methods, such as the friction stir welding as well as linear friction welding processes, have already proved to be capable of manufacturing sound Al-Cu, Al-Ti, Al-SS, and Al-Mg joints, to cite but a few. Recently, promising results have also been obtained using hybrid methods. Considering the novelty of the topic, many relevant issues are still open, and many research groups are continuously publishing valuable results. The aim of this book is to finalize the latest contributions on this topic.

Download or read book Welding of 2024 and 7075 Aluminum Alloys by Vaporizing Foil Actuator written by Z. Meng and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

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 Sustainable Smart Manufacturing Processes in Industry 4 0 written by Ramesh Kumar and published by CRC Press. This book was released on 2023-10-13 with total page 283 pages. Available in PDF, EPUB and Kindle. Book excerpt: The text discusses both theoretical and technological aspects of the Industry 4.0–based manufacturing processes. It covers important topics such as additive manufacturing, laser-based manufacturing processes, electromagnetic welding and joining processes, green manufacturing processes, and friction welding processes. Illustrates sustainable manufacturing aspects in robotics and aerospace industries. Showcases additive manufacturing processes with a focus on innovation and automation. Covers environment-friendly manufacturing processes resulting in zero waste and conserves natural resources. Synergizes exploration related to the various properties and functionalities through extensive theoretical and experimental modeling. Discusses impact welding for joining of dissimilar materials. The text discusses the recent manufacturing techniques and methodologies such as impact welding for joining of dissimilar materials. It further covers techniques such as additive manufacturing and electromagnetic manu- facturing, resulting in minimum or negligible waste. The text elaborates important topics such as friction stir welding energy consumption analysis, and industry waste recycling for sustainable development. It will serve as an ideal reference text for senior undergraduate, graduate students, and researchers in the fields including mechanical engineering, aerospace engineering, manufacturing engineering, and production engineering.

Download or read book Light Metals 2021 written by Linus Perander and published by Springer Nature. This book was released on 2021-02-23 with total page 1049 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Light Metals symposia at the TMS Annual Meeting & Exhibition present the most recent developments, discoveries, and practices in primary aluminum science and technology. The annual Light Metals volume has become the definitive reference in the field of aluminum production and related light metal technologies. The 2021 collection includes contributions from the following symposia: · Alumina and Bauxite · Aluminum Alloys, Processing, and Characterization · Aluminum Reduction Technology · Aluminum Reduction Technology Across the Decades: An LMD Symposium Honoring Alton T. Tabereaux, Halvor Kvande and Harald A. Øye · Cast Shop Technology · Electrode Technology for Aluminum Production

Download or read book Collision Welding of Tungsten Alloy 17D and Copper Using Vaporizing Foil Actuator Welding written by A. Vivek and published by . This book was released on 2014 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Modern Manufacturing Processes written by Muammer Koç and published by John Wiley & Sons. This book was released on 2019-09-04 with total page 549 pages. Available in PDF, EPUB and Kindle. Book excerpt: Provides an in-depth understanding of the fundamentals of a wide range of state-of-the-art materials manufacturing processes Modern manufacturing is at the core of industrial production from base materials to semi-finished goods and final products. Over the last decade, a variety of innovative methods have been developed that allow for manufacturing processes that are more versatile, less energy-consuming, and more environmentally friendly. This book provides readers with everything they need to know about the many manufacturing processes of today. Presented in three parts, Modern Manufacturing Processes starts by covering advanced manufacturing forming processes such as sheet forming, powder forming, and injection molding. The second part deals with thermal and energy-assisted manufacturing processes, including warm and hot hydrostamping. It also covers high speed forming (electromagnetic, electrohydraulic, and explosive forming). The third part reviews advanced material removal process like advanced grinding, electro-discharge machining, micro milling, and laser machining. It also looks at high speed and hard machining and examines advances in material modeling for manufacturing analysis and simulation. Offers a comprehensive overview of advanced materials manufacturing processes Provides practice-oriented information to help readers find the right manufacturing methods for the intended applications Highly relevant for material scientists and engineers in industry Modern Manufacturing Processes is an ideal book for practitioners and researchers in materials and mechanical engineering.

Download or read book Material Forming written by Anna Carla Araujo and published by Materials Research Forum LLC. This book was released on 2024-05-20 with total page 2957 pages. Available in PDF, EPUB and Kindle. Book excerpt: These ESAFORM 2024 conference proceedings cover a wide range of topics: Additive manufacturing; Composites forming processes; Extrusion and drawing; Forging and rolling; Formability of metallic materials; Friction and wear in metal forming; Incremental and sheet metal forming; Innovative joining by forming technologies; Optimization and inverse analysis in forming; Machining, Cutting and severe plastic deformation processes; Material behavior modelling; New and advanced numerical strategies for material forming; Non-conventional processes; Polymer processing and thermomechanical properties; Sustainability on material forming. Keywords: WAAM Technology, Fused deposition Modeling (FDM), Fiber Composite Printers, Ultrasonic Powder Atomization, Finite Element Modeling (FEM), Laser Powder Bed Fusion (L-PBF), Rapid Prototyping in Additive Manufacturing, Directed Energy Deposition (DED), GTAW Droplet Deposition, Deep Learning, Thermoplastic Pultrusion, Textile Reinforcements, Thermoforming Simulation, New Sustainable Materials, Non-Crimp Fabrics, CFRP Scraps, PEEK Composites, Thermoplastic Sheets, Flax/PP Composites.

Download or read book Impact Welding of Materials written by Ivan Galvao and published by Mdpi AG. This book was released on 2021-06 with total page 210 pages. Available in PDF, EPUB and Kindle. Book excerpt: Recent industrial criteria increasingly require the production of multi-material components. However, the manufacturing requirements of these components are not met by conventional welding techniques. Alternative solid-state technologies, such as impact-based processes, must be considered. The impact welding family is composed of several processes, such as explosion welding, magnetic pulse welding, vaporizing foil actuator welding, and laser impact welding. These processes present very different length scales, providing the impact welding family with a broad applicability range. A sample of the cutting-edge research that is being conducted on the multidisciplinary field of impact welding is presented in this book.

Download or read book Dissimilar Metal Welding written by Pierpaolo Carlone and published by . This book was released on 2019 with total page 288 pages. Available in PDF, EPUB and Kindle. Book excerpt: The combination of distinct materials is a key issue in modern industry, whereas the driving concept is to design parts with the right material in the right place. In this framework, a great deal of attention is directed towards dissimilar welding and joining technologies. In the automotive sector, for instance, the concept of “tailored blanks”, introduced in the last decade, has further highlighted the necessity to weld dissimilar materials. As far as the aeronautic field is concerned, most structures are built combining very different materials and alloys, in order to match lightweight and structural performance requirements. In this framework, the application of fusion welding techniques, namely, tungsten inert gas or laser welding, is quite challenging due to the difference in physical properties, in particular the melting point, between adjoining materials. On the other hand, solid-state welding methods, such as the friction stir welding as well as linear friction welding processes, have already proved to be capable of manufacturing sound Al-Cu, Al-Ti, Al-SS, and Al-Mg joints, to cite but a few. Recently, promising results have also been obtained using hybrid methods. Considering the novelty of the topic, many relevant issues are still open, and many research groups are continuously publishing valuable results. The aim of this book is to finalize the latest contributions on this topic.

Download or read book Automotive Vehicle Assembly Processes and Operations Management written by He Tang and published by SAE International. This book was released on 2017-01-30 with total page 296 pages. Available in PDF, EPUB and Kindle. Book excerpt: Proven technologies and processes are explored in this examination of modern automotive manufacturing. Fundamentals and applications, as well as new advances are discussed as the author bridges the gap between academic research and industrial practice. Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author presents a concise understanding that reflects both technical and managerial perspectives with the aim of providing improvement through practical methods. Each chapter includes review questions and research topics, and, in addition, analysis problems are often included that comprehensively address: • Automotive Industry and Competition • Manufacturing Operations • Joining and Paint Processes • Production Operations and Quality Management • Performance Improvement Directly extracted and summarized from automotive manufacturing practices, this book serves as a fundamental manual. The subject is complemented by the author’s second book, Manufacturing System and Process Development for Vehicle Assembly, which provides even greater depth to the subject of modern automotive manufacturing.