Search results for "Friction welding"
showing 10 items of 71 documents
Experimental and numerical study on Linear Friction Welding of AA2011 Aluminum Alloy
2014
COMPUTER AIDED ENGINEERING OF SOLID BONDING PHENOMENA
2014
Joining is a fundamental technological process in manufacturing used to create a single piece from two or more parts. Welding is still today one of the most popular joining techniques used in manufacturing allowing a permanent junction. Traditional welding processes are based on the melting of the materials to be joined. In this way, several defects may arise because of solidification problems, joints deformation due to elevated residual stress and metallurgical integrity of the joints (intermetallic, porosities, etc). As an example, some aluminum alloys present considerable problems the junction is carried out by traditional fusion welding methods. During the melting process, in fact, the …
Effective Linear Friction Welding Machine Redesign through Process Analysis
2014
Linear friction welding is a solid-state joining process developed for non-axisymmetric components in which the joining of the specimens is obtained through reciprocating motion and pressure. In the process, the friction forces work due to the high frequency oscillation and the pressure between the specimens is converted in thermal energy. In order to design an effective machine, relevant issues derive from the high frequency and the large inertial forces involved in the process. In this study, the authors describe the redesign of a preexisting prototypal machine for LFW processes. A machine redesign is needed when welding high resistant materials, i.e. steels or titanium alloys, with high …
Using a neural network for predicting the average grain size in friction stir welding processes
2009
In the paper the microstructural phenomena in terms of average grain size occurring in friction stir welding (FSW) processes are focused. A neural network was linked to a finite element model (FEM) of the process to predict the average grain size values. The utilized net was trained starting from experimental data and numerical results of butt joints and then tested on further butt, lap and T-joints. The obtained results show the capability of the AI technique in conjunction with the FE tool to predict the final microstructure in the FSW joints.
Continuous dynamic recrystallization phenomena modelling in friction stir welding of aluminium alloys: A neural-network-based approach
2007
The current paper focuses on the continuous dynamic recrystallization phenomena (CDRX) occurring in friction stir welding processes of AA6082 T6 aluminium alloys. In particular, in order to predict the average grain size, a properly trained neural network is linked to the finite element method (FEM) model of the process. The utilized net, which takes as inputs the local values of strain, strain rate, and temperature, was trained starting from experimental data and numerical results. The obtained results show the capability of the artificial intelligence (AI) technique in conjunction with the FE tool to predict the final microstructure in the joint section.
Comparative analysis of bonding mechanism in solid state metal working processes
2016
The Piwnik and Plata pressure-time bonding criterion was applied to Friction Stir Welding, Linear Friction Welding, Porthole Extrusion and Roll Bonding. A neural network was set up, trained and used to predict the bonding occurrence starting from the main field variable distributions calculated through specific numerical models developed for each process. The analysis of the results permitted to predict the occurrence of solid bonding and to highlight differences and analogies between the processes in order to obtain sound solid welds.
Numerical simulation of linear fiction welding (LFW) processes
2011
Solid state welding processes are becoming increasingly important due to a large number of advantages related to joining ''unweldable'' materials and in particular light weight alloys. Linear friction welding (LFW) has been used successfully to bond non-axisymmetric components of a range of materials including titanium alloys, steels, aluminum alloys, nickel, copper, and also dissimilar material combinations. The technique is useful in the research of quality of the joints and in reducing costs of components and parts of the aeronautic and automotive industries.LFW involves parts to be welded through the relative reciprocating motion of two components under an axial force. In such process t…
On the Solid Bonding Phenomena in Linear Friction Welding and Accumulative Roll Bonding Processes: Numerical Simulation Insights
2015
Solid Bonding based welding processes allow to obtain defect free joints with low residual stress and low distortion. However, the engineering and optimization of solid bonding processes is difficult and requires a large number of time and cost consuming test trials. In this way, proper numerical models are essential tools permitting effective process design. The aim of this research was the comparison of the material process conditions during two different manufacturing processes taking advantage of the same metallurgical phenomenon, namely solid bonding. Linear Friction Welding, used to weld non-axisymmetric components and Accumulative Roll Bonding, used to increase the mechanical propert…
Friction stir welding of stainless steel thin sheets in lap configuration
2013
New research trends for Friction Stir Welding include the use of highly resistant materials as steels and titanium alloys. In the paper a continuum based FEM model for Friction Stir Welding of lap joint made out of thin stainless steel sheets is proposed, that is 3D Lagrangian implicit, coupled, rigid-viscoplastic. The model, whose potential has been analyzed though temperature distribution comparisons, is able to predict temperature, strain and strain rate distributions, with varying process variables. In this way the FEM model can be applied for effective process and tool design.
Dissimilar Al/steel Friction stir welding lap joints for automotive applications
2016
A widespread usage of aluminum alloys for the fabrication of car-body parts is conditional on the employment of appropriate welding methods, especially if dissimilar welding must be performed with automotive steel grades. Dissimilar welding of aluminum alloys and steel grades poses some issues concerning the formation of brittle intermetallic compounds, difference in physical and chemical properties of the parent metals, and poor wetting behavior of aluminum. Friction stir welding is considered to be a reasonable solution to obtain sound aluminum/steel joints. A study on the join quality of dissimilar lap joints of steel and aluminum alloy sheets after friction stir welding is proposed here…