Search results for " Welding"

Modeling of the plastic characteristics of AA6082 for the friction stir welding process

2015

Focus of this paper is to model the plastic forming behavior of AA6082, in order to develop the numerical FE analysis of the friction stir welding processes and the simulation of subsequent forming processes. During the friction stir welding process, the temperatures reached can range up to 500 °C and have a fundamental role for the correct performance of the process, so the material data has to show a temperature dependency. Because of the tool rotation a strain rate sensitivity of the material has to be respected as well. In this context, the general material characteristics of AA6082 were first identified for different stress states. For the uniaxial state the standard PuD-Al used in the…

Using a neural network for qualitative and quantitative predictions of weld integrity in solid bonding dominated processes

2014

Solid-state bonding occurs in several manufacturing processes, as Friction Stir Welding, Porthole Die Extrusion and Roll Bonding. Proper conditions of pressure, temperature, strain and strain rate are needed in order to get effective bonding in the final component. In the paper, a neural network is set up, trained and used to predict the bonding occurrence starting from the results of specific numerical models developed for each process. The Plata-Piwnik criterion was used in order to define a quantitative parameter taking into account the effectiveness of the bonding. Excellent predictive capability of the network is obtained for each process.

Analytical bonding criteria for joint integrity prediction in friction stir welding of aluminum alloys

2014

Abstract In this study, two bonding criteria, previously used for porthole die extrusion, are applied to FSW starting from the local value of the main field variables calculated through a specifically developed 3D numerical model of the process. Their applicability and effectiveness have been assessed through an experimental and numerical campaign carried out with the main process parameters varying in a wide range. The pressure–time–flow criterion was demonstrated to be better suited for FSW processes when large welding speed is used.

Solid State Joining of Thin Hybrid Sandwiches Made of Steel and Polymer: a Feasibility Study

2020

Abstract The growing demand for more environmentally friendly vehicles has led to an increased use of light materials in the transportation industry with the aim to reduce structural weight, fuel consumption, and gas emissions, thereby boosting cost-effectiveness and recyclable properties. Complex multi-material steel-based components would allow to improve mechanical properties and minimize weight even further. In particular, new sandwich materials made by steel outer skins and a polymeric internal layer seems very promising for obtaining mechanical performance and lightness at the same time. Unfortunately, traditional welding techniques, like arc welding, laser welding, and resistance spo…

Mechanical and metallurgical properties of titanium alloy friction stir welded butt joints

2011

A case study on the evaluation of friction stir welds by ultrasonic inspection technique

2015

Friction stir welding (FSW) is an innovative process that has been successfully used in joining aluminum alloys, normally difficult to weld. Important advantages over fusion welding are better retention of baseline material properties, lower residual stresses and excellent mechanical properties. Defects that occur in FSW joints are due to improper tooling or setup. Non-destructive techniques used to inspect FSW joints are X-rays, eddy current, conventional ultrasonic testing and dye penetrant proper only for surface breaking defects. Currently there is no non-destructive technique that can guarantee absence of flaws in friction welds during manufacturing. In this work, non-destructive remot…

Mappe di Lavorabilita’ per Giunti Misti di Alluminio Mediante Processo di Saldatura Linear Friction Welding

2014

Il Linear Friction Welding è un processo di saldatura allo stato solido in cui una parte fissa è forzata contro una parte che si muove con moto lineare alternato per generare calore attraverso l’attrito. Nel presente lavoro viene descritto lo studio effettuato per la realizzazione della giunzione mista mediante processo di Linear Friction Welding tra due leghe di alluminio che presentano proprietà meccaniche differenti, come la lega AA2011 e AA6082. Lo studio è stato condotto analizzando due differenti configurazioni determinate dalla posizione relativa delle leghe costituenti i provini da saldare. Per la realizzazione del processo è stata utilizzata una macchina prototipale dotata di senso…

Optimizing the Shape of Welded Constructions Made through the Technique “Temper Bead Welding”

2020

Welded constructions are subject to high stresses during operation. One solution for improving the behavior in exploitation of welded constructions in various cases is to use the welding technique “temper bead welding” (TBW). In the paper, the optimization of the geometry of the welded joints by the TBW technique was performed. Thus, corner welded joints made of S355 steel were analyzed. To make the welded joints, three layers of welding seams were deposited, and the intermediate layers were processed through cutting with various radii. To analyze the influence of the size of these rays on the behavior of welded constructions, a research program based on factorial experiences wa…

Augmentation of weld penetration by flux assisted TIG welding and its distinct variants for oxygen free copper

2021

Abstract A comparative study to investigate the influences of single component fluxes on the depth-to-width ratio (DWR) of oxygen free copper was carried out with novel variants of tungsten inert gas (TIG) welding namely Activated TIG (A-TIG), Flux Bounded TIG (FB-TIG) and Flux Zoned TIG (FB-TIG) processes. The experiments to identify the fluxes delivering the higher DWRs in A-TIG welding among thirteen distinct fluxes were followed by the trials with FB-TIG and FZ-TIG employing those identified DWR fluxes. The fluxes which outperformed with all the techniques were MoO3 & MgO. Reversed Marangoni and arc constriction mechanisms were perceived to be opt for such an increase in DWR. Metallurgi…

A Comparative Study of Mechanical and Microstructural Behavior for Metal Active Gas and Friction Stir Welded Micro-Alloyed Structural Steel

2022

Manufacturing tiny components into gigantic structures seems unimaginable without welding connections, whether it is for materials, parts, structures, or equipment. In the recent competitive market scenario, manufacturing industries are desperately looking for a viable alternative to fusion-based conventional material joining technologies, to improve upon cost-effectiveness along with performance. The present investigation is to evaluate the performance of structural steel thick plate joints prepared by advanced solid-state friction stir welding (FSW) over conventional metal active gas welding (MAG). The FSW experiments were carried out with different tool designs and configurations. The ou…