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Towards criteria for sustainable process selection: On the modelling of pure subtractive versus additive/subtractive integrated manufacturing approac…
2017
Additive Manufacturing (AM) processes can be counted among the disruptive technologies that are capable of transforming conventional manufacturing routes. The ability to create complex geometries, the reduction in material scraps during manufacturing, and the light-weighting due to the think-additive redesign of the components represent the main points of strength of AM. However, for some applications (such as the production of metal components for the automotive and aerospace industries), the surface finishing and dimensional/geometrical part tolerancing that can be achieved via AM processes might not be adequate to satisfy the imposed product specifications, and finish machining operation…
Effect of the mutual position between weld seam and reinforcement on the residual stress distribution in Friction Stir Welding of AA6082 skin and str…
2016
Abstract In the paper, a numerical and experimental study was carried out to highlight the effect of the distance d between the weld seam and the reinforcement on the residual stress distribution in Friction Stir Welded AA6082-T6 structures. An L-shaped profile was welded to a sheet metal with varying tool rotation and distance d from the weld seam. The Cut Compliance method was used to determine the resulting longitudinal residual stress. A dedicated FE model for FSW was set up, validated and utilized to predict the longitudinal residual stress in the assembled part. The analysis allowed the identification of a few design guidelines in order to reduce the detrimental effects of the residua…
A Pareto optimal design approach for simultaneous control of thinning and springback in stamping processes
2009
One of the most relevant research issues in automotive field is focused on the reduction of stamped parts weight also increasing their strength. In this way, a strong research effort is developed on high strength steels which are widely utilized and they require a proper springback control. Springback reduction in sheet metal forming is a typical goal to be pursued which is conflicting with thinning reduction for instance. Thus, such problems can be considered as multi-objective ones characterized by conflicting objectives. What is more, nowadays, a great interest would be focused on the availability of a cluster of possible optimal solutions instead of a single one, particularly in an indu…
Consensus-Based Distributed State Estimation of Biofilm in Reverse Osmosis Membranes by WSNs
2017
The appearance of biofilm has become a serious problem in many reverse osmosis based systems such as the ones found in water treatment and desalination plants. In these systems, the use of traditional techniques such as pretreatment or dozing biocides are not effective when the biofilm reaches an irreversible attachment phase. In this work, we present a framework for the use of a WSN as an estimator of the biofilm evolution in a reverse osmosis membrane so that effective solutions can be applied before the irreversible phase is attained. This design is addressed in a complete distributed and decentralized fashion, and subject to realistic constraints where cooperation between nodes is perfo…
Enhancement of mechanical properties of FSWed AA7075 lap joints through in-situ fabrication of MMC
2017
Abstract Friction Stir Processing (FSP) has been demonstrated feasible to create local Metal Matrix Composites (MMCs) in light alloys matrix. In this research, local MMCs were produced contextually to the weld using Friction Stir Welding (FSW). SiC particles were added to AA7075 lap joints by creating a proper groove on the top surface of the bottom sheet. Different welds were produced with increasing number of tool passes. The effect of the multiple passes was investigated through shear tests, macro and micro observations, average grain size and microhardness measurements. The welded joints were compared to a reference weld produced with no reinforcements. It was found that poor mixing bet…
Using infrared thermography in order to compare laser and hybrid (laser plus MIG) welding processes
2009
International audience; In order to deepen the understanding of the differences between laser and laser-arc hybrid welding, comparisons were undertaken using thermography. The experiments were carried out for a T assembly of aluminium alloy plates. Modelling, based on the finite element method approach, was realized using IR temperature measurements and seam geometry. For a value of the power supply, depicted as a surface source in the hybrid case, agreement was found between simulated and measured temperatures. The arc power supply efficiency value is similar to the usually used value.
The use of exploratory experimental designs combined with thermal numerical modelling to obtain a predictive tool for hybrid laser/MIG welding and co…
2011
Abstract While hybrid laser welding and coating processes involve a large number of physical phenomena, it is currently impossible to predict, for a given set of influencing factors, the shape of the molten zone and the history of temperature fields inside the parts. This remains true for complex processes, such as the hybrid laser/MIG welding process, which consists in combining a laser beam with a MIG torch. The gains obtained result essentially from the synergy of the associated processes: the stability of the process, the quality of the seam realized, and the productivity are increased. This article shows how, by means of a reduced number of experiments (8), it is possible to predict th…
Effect of active heating and cooling on microstructure and mechanical properties of friction stir–welded dissimilar aluminium alloy and titanium butt…
2019
A butt joint configuration of AA6061–pure Ti was welded using friction stir welding (FSW) with an assisted cooling and heating conditions, aiming to attain a flawless joint. Cooling-assisted friction stir welding (CFSW) was carried out with a different cooling medium such as CO2, compressed air and water at controlled flow rate. However, heating-assisted friction stir welding (HFSW) was performed with heating source of GTAW torch just before FSW tool at different current density. Prepared specimens were subjected to optical microscopy (OM), scanning electron microscopy (SEM) and electrodischarge spectroscopy (EDS) for microstructural characterizations. The tensile strength and microhardness…
Magnetic field-assisted single-point incremental forming with a magnet ball tool
2021
Abstract This paper describes magnetic field-assisted single-point incremental forming (M-SPIF) with a Nd-Fe-B magnet ball tool. In M-SPIF, the tool driven by magnetic force plastically deforms a sheet. The polarity of the magnet tool helps to make the magnetic force (i.e., forming force) more controllable. In creating a truncated cone, the direction of the magnetic force gradually points more outward as the process progresses, and material is forced outwards from the cone center, increasing thinning in M-SPIF, while the cone center remains undeformed in traditional SPIF. Moreover, M-SPIF creates less localized plastic strain than traditional SPIF while forming the desired geometry.
Friction Stir Welding of Ti6Al4V complex geometries for aeronautical applications: a feasibility study
2020
Abstract While Friction Stir Welding (FSW) of aluminium alloys can be considered a mature technology, even for complex joint morphologies, as T joints welded “in transparency”, welding of hard material still presents several open issues. In fact, welding of titanium alloys is a challenging process due to the chemical, mechanical and thermal characteristics of such materials which are subjected to atmosphere contamination resulting in joint hydrogen, oxygen and nitrogen embrittlement; additionally, due to the high melting temperature, large distortion and residual stress are found in joints obtained by traditional fusion welding processes as gas metal arc welding, electron beam welding and l…