Search results for "Aluminum Alloy"
showing 10 items of 52 documents
An Innovative Friction Stir Welding Based Technique to Produce Dissimilar Light Alloys to Thermoplastic Matrix Composite Joints
2016
Abstract Aluminum sheets can be joined to composite materials with different techniques. Each of them has advantages and weak points over the others. In literature, new techniques and patents are continuously developed to overcome these difficulties. In the paper a new Friction Stir Welding based approach is proposed to mechanically join AA6082-T6 to self-reinforced polypropylene. The aluminum sheet is pre-holed along both the sides of the weld line. A pinless tool generates the heat and pressure needed to activate back-extrusion of the composite. Joints have been produced with varying hole diameter and pitch. The mechanical resistance of the joint has been evaluated and the different failu…
Design and development of a new machine tool for continuous friction stir extrusion
2023
In the present paper the Continuous Friction Stir Extrusion process (CFSE), derived from the already known Friction Stir Extrusion (FSE), is proposed for effective solid-state recycling of metal scraps. A new dedicated machine tool was designed and developed. A Lagrangian implicit thermomechanical numerical model was set up and used to determine the proper ranges of the most relevant process parameters. An effective case study is proposed, involving the actual extrusion of a recycled wire in a continuous way. Metallurgical observations and mechanical characterization tests were carried out on the obtained specimen showing the potential of the process and its industrial feasibility.(c) 2023 …
RESHAPING AS NOVEL CIRCULAR ECONOMY STRATEGY FOR SHEET METAL BASED END-OF-LIFE COMPONENTS
2022
Making materials consumes about 21% of the global energy demand a specifically metals production, it accounts for about 8% of total global energy consumption. In fact, in the past few decades, the use of lightweight alloys has become increasingly widespread in many major industrial sectors thanks to the weight reduction associated with their applications. Most lightweight materials like aluminum alloys are characterized by high-energy demands primary production cycles that are responsible for a relevant share of the global CO2 emissions. Circular economy strategies such us longer life, more intense use, repair, product upgrades, modularity, remanufacturing, component re-use and open/closed …
A Comparison of Mechanical Properties and Microstructure in Friction Stir Welded and MIG Welded Light Alloys
2012
Joining technologies are in a very interesting phase today due to some relevant innovations concerning new techniques. Friction Stir Welding (FSW) is a relatively new process, patented by TWI in 1991, able to weld through a solid state bonding materials considered difficult to be welded or unweldable by more traditional fusion welding techniques. By using this process welded joints are obtained with no external heat supplier, generating the required temperature increase by means of a revolving pin that follows a proper trajectory partially sunk in the workpiece surface. As for today, although first examples of industrial application can be found in the aeronautical and aerospace fields, the…
Progresses in multi-materials billet manufacturing out of metal scraps through friction stir consolidation
2023
Abstract. The evolution of Friction Stir Consolidation (FSC) from recycling towards upcycling technique proved to be one of the excellent solid-state methods for manufacturing functionally graded billets. Multi-material Functional Graded Materials (FGMs) represent a novel class of materials characterized by a gradual change in properties and functions which can be tailored to enhance components performance. Manufacturing techniques play a critical role in achieving the designed compositional and microstructural distribution. Specifically, FSC allows the manufacturing of FGM billets out of metallic chips; the mixing of different metallic chips offers mutually exclusive mechanical properties …
Comparative evaluation of the effect of the substrate thickness and inherent process defects on the static and fatigue performance of FSW and adhesiv…
2021
Abstract This work aims at evaluating the mechanical performance of joints in an AA6016 alloy, manufactured by means of two alternative processes: friction stir welding and adhesive bonding. Given its wide use in industrial fields such as automotive and aeronautics, an overlap configuration of joints was selected for the study, and a specific method based on the overlap length evaluation has been developed to allow comparisons among the cases. Two substrate thicknesses are considered in order to vary the overall joint stiffness, and the effect of such geometrical parameter on the mechanical behavior of the joined system is experimentally investigated. The experimental findings highlight tha…
On the improvement of material formability in SPIF operation through tool stirring action
2012
Single-point incremental forming (SPIF) is a quite new sheet-forming process which offers the possibility to deform complex parts without dedicated dies using a single-point tool and a standard three-axis CNC machine. The process mechanics enables higher strains with respect to traditional sheet-forming processes, but particular attention must be given to the maximum forming angle. In this paper, a new approach is proposed to enhance the material formability through a localized sheet heating as a consequence of the friction work caused by elevated tool rotational speeds. AA1050-O, AA1050-H24, and AA6082-T6 were utilized, and the reached temperatures were recorded by thermocouples, fixed to …
Material flow analysis in dissimilar friction stir welding of AA2024 and Ti6Al4V butt joints
2016
The complex material flow occurring during the weld of dissimilar AA2024 to Ti6Al4V butt and lap joints was highlighted through a dedicated numerical model able to take into account the effects of the different materials as well as the phase transformation of the used titanium alloy.
A novel linear friction welding based approach for sheet-bulk joining
2019
In the last decades, the development of new, flexible manufacturing processes caused the increase of the demands for highly customized complex functional parts in many industrial fields. The peculiar design of these components often overcome conventional sheet metal and bulk metal forming processes capabilities. In order to face this issue, new hybrid techniques, capable of exploit key advantages of different processes, have to be developed. In this paper, a novel approach based on the Linear Friction Welding process is proposed to obtain sheet-bulk joints. The feasibility of the technique on high specific strength alloys is investigated through an experimental campaign.In the last decades,…
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.