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Behrens, B. A., D. Gruß und A. Jenicek. „Stud welding within sheet metal working tools“. Production Engineering 5, Nr. 3 (01.04.2011): 283–92. http://dx.doi.org/10.1007/s11740-011-0304-3.
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Lacki, Piotr, Wojciech Więckowski, Grzegorz Luty, Paweł Wieczorek und Maciej Motyka. „Evaluation of Usefulness of AlCrN Coatings for Increased Life of Tools Used in Friction Stir Welding (FSW) of Sheet Aluminum Alloy“. Materials 13, Nr. 18 (16.09.2020): 4124. http://dx.doi.org/10.3390/ma13184124.
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The study presents the results of examinations of wear in tools made of 1.2344 steel without and with an anti-wear coating in the process of welding overlap joints of sheet metal made of 7075-T6 aluminum alloy using friction stir welding (FSW) technology. A commercial anti-wear AlCrN coating (Balinit® Alcrona Pro by Oerlikon Balzers Coating Poland Sp. z o.o., Polkowice, Poland) was examined, applied using physical vapor deposition (PVD) and used to improve tool life in metalworking processes. Wear tests for the tools were conducted in industrial conditions at specific parameters of the friction stir welding process. Tool wear was evaluated through examination of the tool working surface. The results of the static tensile strength tests and metallographic examinations of the joints were used to evaluate the effect of tool wear and the coating impact on joint quality. The results obtained in the study show that the tool made of 1.2344 steel was intensively worn after the welding of a joint with the length of 200 m, increasing the risk associated with further use of the tool and suggesting the tool’s low durability. The use of the AlCrN coating led to an increase in tool life. The coating limits the process of tool wear and can be used as an anti-wear coating for tools used in the FSW of aluminum alloys.
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Imam, Imam kholiq Imam. „PERANCANGAN MEJA PUTAR ROLL WELDING SEBAGAI ALAT BANTU PENGELASAN (STUDI KASUS : ART WELDING PT. MECO INOXPRIMA)“. MATRIK 20, Nr. 1 (30.09.2019): 57. http://dx.doi.org/10.30587/matrik.v20i1.952.
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Welding that produces a quality connection and is very possible to connect metal by welding in various shapes and positions. Therefore the welding process must require a practical material supporting device and in accordance with the needs of all welding positions which will facilitate and provide welder comfort in welding. So that the results of maximum and quality welds (good hasis las visually) are produced in this study the type of connection used is angular joints with the aim of designing and making tools to get the results of welding joints and comparing the distortions that occur between using desk tools rotate and without using tools. In this study Gtaw welding was used with the brand DC ARC WELDER with type Bz-300F-3 and filler type ER 308L, Voltage 20-30 V, travel speed 60 mm / min and variations of Flow (A) namely 100 A, 125 A and 150 A. with a diameter of 2.4 mm as a filler. The study was limited to the design and manufacture of tools and measurements of distortion carried out 20 times. Distortion measurement uses a dial indicator with a starting point / zero point on the end of the test object and the end point in the weld joint area. The results show that the use of roll welding tools can reduce the occurrence of distortion. The smallest value of distortion is obtained using a roll welding rotary table tool which is equal to 0.33 degrees, while the smallest value of distortion without using roll welding is 1.33 degrees. And the use of roll welding rotary table aids can reduce welding defects reduce setup time and can increase production volume which results in a decrease in production costs, making it quite feasible and efficient in terms of the economy.
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Amin, Samir Ali, Mohannad Yousif Hanna und Alhamza Farooq Mohamed. „Experimental Study the Effect of Tool Design on the Mechanical Properties of Bobbin Friction Stir Welded 6061-T6 Aluminum Alloy“. Al-Khwarizmi Engineering Journal 14, Nr. 3 (15.08.2018): 1–11. http://dx.doi.org/10.22153/kej.2018.01.003.
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Bobbin friction stir welding (BFSW) is a variant of the conventional friction stir welding (CFSW); it can weld the upper and lower surface of the work-piece in the same pass. This technique involves the bonding of materials without melting. In this work, the influence of tool design on the mechanical properties of welding joints of 6061-T6 aluminum alloy with 6.25 mm thickness produced by FSW bobbin tools was investigated and the best bobbin tool design was determined. Five different probe shapes (threaded straight cylindrical, straight cylindrical with 3 flat surfaces, straight cylindrical with 4 flat surfaces, threaded straight cylindrical with 3 flat surface and threaded straight cylindrical with 4 flat surfaces) with various dimensions of the tool (shoulders and pin) were used to create the welding joints. The direction of the welding process was perpendicular to the rolling direction for aluminum plates. Tensile and bending tests were performed to select the right design of the bobbin tools, which gave superior mechanical properties of the welded zone. The tool of straight cylindrical with four flats, 8 mm probe and 24 mm shoulders diameter gave better tensile strength (193 MPa), elongation (6.1%), bending force (5.7 KN), and welding efficiency (65.4%) according to tensile strength.
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Baskoro, Ario Sunar, A. A. D. Nugroho, D. Rahayu, Suwarsono, Gandjar Kiswanto und Winarto. „Effects of Welding Parameters in Micro Friction Stir Lap Welding of Aluminum A1100“. Advanced Materials Research 789 (September 2013): 356–59. http://dx.doi.org/10.4028/www.scientific.net/amr.789.356.
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Technology of Friction Stir Welding (FSW) as a technique for joining metal is relatively new. In some cases on Aluminum joining, FSW gives better results compared with the Arc Welding processes, including the quality of welds and less distortion. FSW can even use milling machine or drilling machine, by replacing the tools and the appropriate accessories. The purpose of this study is to analyze the effect of process parameters onmicro Friction Stir Lap Weldingto the tensile load of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. Tool shoulder diameter was 3 mm, while the diameter pin was 2 mm and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of spindle speed (2300, 2600, and 2900 rpm), variable oftooltilt angle(0, 1, 2 degree) and a variable ofFeed rate(50, 60, 70 mm/min). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the tensile load. Analysis and optimization parameters between the micro FSLW parameters with the tensile load of welds, is used aResponse Surface Methods(RSM). From the result of experiment and analysis, it is shown that the important welding parameter in Micro Friction Stir Lap welding process is tilt angle.
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Roudini, Ghodratollah, Sajad Gholami Shiri und Masoud Mohammadi Rahvard. „Tool Design and Speed Parameters Effects on Microstructure and Tensile Strength of Friction Stir Welding (FSW) 5052 Al Alloys“. Applied Mechanics and Materials 110-116 (Oktober 2011): 3165–70. http://dx.doi.org/10.4028/www.scientific.net/amm.110-116.3165.
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there are some parameters in friction stir welding (FSW) technique such as tool design, tool rotation speed and tool travel which can be controlled in a precise manner thus controlling the energy input into the system. In this study the effects of these parameters were investigated on microstructure and tensile strength of 5052 aluminum alloy. Roll sheets of this alloy were welded by FSW method at different rotation speeds (400, 800, 1600 and 2500 rpm), welding speeds (50 and 100 mm/min) and tools shoulder diameters (14 and 20 mm). The microstructure results showed that the stir zone (SZ) and thermo-mechanically affected zone (TMAZ) had dynamically recrystallized and recovered respectively. Also the tensile strength of samples welded at tool rotation speeds of 400 and 800 rpm, travel speed 50 mm/min and tools shoulder diameter of 20 mm is similar to that of base metal. The tool rotation speeds of 400 rpm have a good welding ability with higher travel speed and lower tools shoulder diameter.
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Hynek, Petr, Viktor Kreibich und Roman Firt. „SUITABLE PRODUCTION TOOLS SELECTION WITH THE USE OF EVOLUTIONARY ALGORITHMS“. Acta Polytechnica 60, Nr. 1 (02.03.2020): 56–64. http://dx.doi.org/10.14311/ap.2020.60.0056.
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This paper deals with the use of a production equipment simulation in the design of production systems, more specifically the welding equipment in the automotive industry. Based on the simulation results, a matrix, which defines the possibility of using given manufacturing tools (in this case welding guns are considered) to connect the plates using the electrical resistance spot welding process, is created. This matrix generates a set of several numbers of solutions depending on other parameters, such as the lowest price, the lowest number of used welding guns, etc. The goal is to solve this task. The solution is presented using mathematical programming. Specifically, the method of genetic evolutionary algorithms is being used. The Solver software is used to optimize the selection of the welding guns’ combination. The Solver is an add-on in MS Excel. The case study shows 15 welding points weldment on which the availability of 20 types of welding guns was simulated. The result is an ideal combination of 2 types of guns for the lowest price.
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Geçmen, İnan, Zarif Çatalgöl und Mustafa Kemal Bilici. „Effect of welding parameters on mechanical properties and microstructure of friction stir welded brass joints“. Matériaux & Techniques 106, Nr. 6 (2018): 606. http://dx.doi.org/10.1051/mattech/2018060.
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Friction stir welding is a method developed for the welding of high-alloy aluminum materials which are difficult to combine with conventional welding methods. Friction stir welding of MS 63 (brass) plates used different tools (tapered cylindrical, tapered threaded cylindrical), tool rotational speeds (1040, 1500, 2080 rpm) and traverse speeds (30,45,75,113 mm.min−1). Tensile, bending, radiography and microstructure tests were carried out to determine the mechanical properties of brass plates joined by friction stir welding technique. Microstructure characterization studies were based on optical microscope and SEM analysis techniques. In addition, after joining operations, radiographs were taken to see the internal structure failure. Brass sheets were successfully joined to the forehead in the macrostructure study. In the evaluation of the microstructure, it was determined that there were four regions of base metal, thermomechanically affected zone (TMEB), heat-affected zone (HAZ) and stir zone. In both welding tools, the weld strength increased with increasing tool rotation speed. The particles in the stir zone are reduced by increasing of the tool rotation speed. Given the strength and % elongation values, the highest weld strength was achieved with tapered pin tool with a tool rotation speed of 1040 rpm and a tool feed speed of 113 min−1.
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Hardjito, Agus, Imam Mashudi, Listiono Listiono und R. N. Akhsanu Takwim. „Preheat Temperature Analysis of Cutting Knife Coating Violence in the Hard Facing Process of Aisi A35 Carbon Steel“. Logic : Jurnal Rancang Bangun dan Teknologi 20, Nr. 3 (30.11.2020): 160–66. http://dx.doi.org/10.31940/logic.v20i3.2152.
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The hard facing process is the welding process of SMAW by using a hard facing DIN 888 electrode as a hard facing to replace conventional cutting tool material. The purpose of this analysis is to determine the effect of preheating temperature on the welding of hard coatings on AISI A35 low carbon steel. The results of this study are expected to obtain optimum hardness on coated steel, from variations in the temperature of the preheating. there will be a change in the hardness of the welding deposit, the deposit will be used as cutting tools. The results of this study can be used as guidelines for making cutting tools.
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Aldanondo, Egoitz, Javier Vivas, Pedro Álvarez und Iñaki Hurtado. „Effect of Tool Geometry and Welding Parameters on Friction Stir Welded Lap Joint Formation with AA2099-T83 and AA2060-T8E30 Aluminium Alloys“. Metals 10, Nr. 7 (01.07.2020): 872. http://dx.doi.org/10.3390/met10070872.
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In this paper the effect of tool geometry and welding parameters on friction stir welded lap joints with AA2099-T83 and AA2060-T8E30 aluminium alloys has been investigated through the study of the material flow and weld formation along with the reaction forces during friction stir welding (FSW) for various sets of welding parameters and two FSW tools with different geometrical features. The results showed that welding parameters and tool probe geometry strongly affect the characteristics of the typical defect features (hook and cold lap defects) of the friction stir welded lap joints. From the relationship established between the welding parameters, tool probe geometry and the hook and cold lap defect formation, some guidelines are concluded with the objective of guaranteeing appropriate FSW lap joint properties.
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Hatzky, Marcel, und Stefan Böhm. „Extension of Gap Bridgeability and Prevention of Oxide Lines in the Welding Seam through Application of Tools with Multi-Welding Pins“. Metals 11, Nr. 8 (30.07.2021): 1219. http://dx.doi.org/10.3390/met11081219.
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Friction stir welding has become important in many areas of production and is increasingly used for joining aluminum components. For long welding seams, conventional tools with only one welding pin reach their technical limitations due to low gap bridgeability. When welding aluminum, the stirred in surface layers, such as oxides, lead to a decrease in static and dynamic strength since linear accumulations are formed in the welding seam. The aim of the present study is to increase the gap bridgeability using tools with various welding pins and to prevent linear accumulation in the welding seam. The results show that a gap bridgeability of up to 2 mm for 4 mm material thickness is possible for the aluminum alloys EN AW 5083 H111 and EN AW 7020 T651. With the help of multi-pin tools, no impact of the gap width on the tensile strength was observed for joint gaps of up to 0.9 mm when using butt joint with a sheet thickness of 4 mm. Furthermore, the use of multi-pin tools showed significant influence on the prevention of linear accumulations in the welding seam. In addition, the oxide layers were finely distributed in welded joints using multi-pin tools.
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Kolnes, Mart, Jakob Kübarsepp, Fjodor Sergejev, Märt Kolnes, Marek Tarraste und Mart Viljus. „Wear Behavior of Ceramic-Metal Composites as Tool Material for FSW of Copper“. Solid State Phenomena 320 (30.06.2021): 144–49. http://dx.doi.org/10.4028/www.scientific.net/ssp.320.144.
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Friction stir welding (FSW) is employed primarily for metals characterized by poor weldability at fusion welding: aluminium, magnesium, titanium and copper alloys as well as stainless steels. The focus of the study was on the feasibility of application of WC-based hardmetal 85WC-Co and TiC-based cermet 80TiC-NiMo as potential tool materials for FSW of copper. The single-pass welding trials of Cu sheets were performed using a vertical milling machine. For better understanding of interactions between the tool and workpiece at welding temperature EDS line scans across the interfaces tool-workpiece after welding as well as after diffusion tests were performed. It was concluded that both tested ceramic-metal composites did not failure during multiple plunges and during the total transverse welding distance of 10 m. Also, significant tool wear was not observed after such a welding distance. The possibility of producing visually defect-free welds using tools from WC- and TiC- based ceramic-metal composites was proved and also mutual diffusion of elements across the interface tool-workpiece was discussed.
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Korkmaz, E., A. Gülsöz und C. Meran. „Investigations on the joint properties of the friction welding of aluminium alloy tube to tube plate using an external tool“. Journal of Achievements in Materials and Manufacturing Engineering 2, Nr. 81 (01.04.2017): 70–75. http://dx.doi.org/10.5604/01.3001.0010.2040.
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Purpose: Aluminium and its alloys are frequently used in structural applications due to their good welding ability as well as their high strength and corrosion resistance. Several developments have been observed on the welding of aluminium in last decade. The manufacturing of heat exchangers, economizers and boilers is highly cost progress due to tube to tube plate welding’s. The purpose of this study is investigation of friction weldability of tube to tube plate aluminium alloys using an external tools (FWTPET) which is a relatively newer solid state welding process used for joining tube to tube plate. Design/methodology/approach: First, preliminary experiments were carried out to determining suitable the tool rotational speed, pressure load and temperature. An experimental setup has been designed and manufactured to keep the pressure load constant during the preliminary tests. Then, by changing the weld mouth on the plate, the gap between the tube and the plate, and the tube projection parameters, the effects of all parameters on shear strength values, micro hardness values and the formation of internal structure of the weld zone were investigated. Findings: It was founded that aluminium tubes can successfully weld to tube plates with using an external tools. Also it is seen that vertical force between tool and sample, tube protection and temperature are very important parameters which are effect of welded joint properties. Practical implications: FWTPET which is new welding method has been used in industrial field in last few years. Originality/value: In the beginnings studies concentrate on non-ferrous metals such as Al, Cu, Mg etc. So this studies on FWTPET have remarkable importance.
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Nadikudi, Bhanodaya Kiran Babu. „Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates“. International Journal of Structural Integrity 12, Nr. 4 (08.03.2021): 562–68. http://dx.doi.org/10.1108/ijsi-10-2020-0097.
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PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.
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Andalib, Hossein, Mohammadreza Farahani und Moeen Enami. „Study on the new friction stir spot weld joint reinforcement technique on 5754 aluminum alloy“. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 232, Nr. 17 (11.09.2017): 2976–86. http://dx.doi.org/10.1177/0954406217729419.
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In this study, new friction stir spot welding method was developed using two different tools in order to create a spot weld without keyhole. The effects of process parameters and tool geometry were considered to improve the weld joint properties. The shear-tensile tests and microstructure study showed that the new method could offer superior performance in comparison to conventional friction stir spot welding. By controlling the process parameters, spot welds with strength about 37% higher than the conventional friction stir spot welds were obtained. The stir zone grain size of the prepared samples in the optimum welding conditions was decreased about four times than the base metal. It was observed that the tool plunge depth in both welding and refilling steps play a key role in creating a sound high strength welded joint. The failure load of the spot welds manufactured by concave shoulder was found to be about 7% higher than the failure load of the prepared spot welds by the flat shoulder.
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Yuslistyari, Eka Indah, und Aden Adhadin. „Perbaikan Postur Kerja Operator Pengelasan dengan Metode Quick Exposure Check (QEC)“. Jurnal INTECH Teknik Industri Universitas Serang Raya 4, Nr. 1 (27.11.2018): 17. http://dx.doi.org/10.30656/intech.v4i1.853.
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CV. Surya Teknik Mandiri is a company engaged in lathe and welding services located in Serang-Banten. Work is usually done such as screw making and welding of axle cages, where products are made according to customer orders. This study focused on one part of the work that has the highest level of fatigue through a fatigue questionnaire caused by squat work postures, namely the welding section involving two operators. This study aims to determine the measurement value of the exposure score, exposure level and to reduce MSDs complaints with the design of repair tools for welding operators in this study using the Quick Exposure Check (QEC) research method by distributing observer questionnaires and operators, and using the Anthropometry approach in measuring design tools for improving operator work posture. Based on the results of research on welding operators 1, the total exposure score was 106 with an exposure level of 59.55%. While for operator 2, there is a total exposure score of 124 and an exposure level of 69.66%. An action level for both operators needs further research and changes. Next, repairs are made to reduce the exposure level value in the welding work. Repairs are made with the aim of making the condition safe, comfortable and do not cause complaints MSDs when working, namely at the workstation standing by designing a tool in the form of a welding work desk. After implementing the welding workbench for the two operators and recalculating the QEC value, the operator one exposure level of 48.31% and for operator 2 49.43% with action levels need further research.
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Jayaprakash, S., S. Siva Chandran, T. Sathish, Bhiksha Gugulothu, R. Ramesh, M. Sudhakar und Ram Subbiah. „Effect of Tool Profile Influence in Dissimilar Friction Stir Welding of Aluminium Alloys (AA5083 and AA7068)“. Advances in Materials Science and Engineering 2021 (22.07.2021): 1–7. http://dx.doi.org/10.1155/2021/7387296.
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Friction stir welding is an innovative welding process for similar and dissimilar joining of the materials effectively. FSW simply modified the grain structure and also improved the strength of the joints for any type of alloying elements. This experimental study planned to carry out the joining process for dissimilar materials such as aluminium alloys 5083 and 7068. Three different types of tools are involved to find the ultimate tensile strength and Vickers hardness. The tool types are straight cylindrical tool, taper cylindrical tool, and triangular tool. The process factors for this investigation are a rotational speed of 800, 1000, 1200, and 1400 rpm, welding speed of 30, 40, 50, and 60 mm/min, axial force of 3, 4, 5, and 6 kN, and plate thickness of 5, 6, 7, and 8 mm. The hardness value and the ultimate tensile strength were increased in the welding zone, which proves the effects of tool profiles are efficiently utilized.
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Morales, Cindy Estefanía, Argelia Fabiola Miranda, Gladys Yerania Pérez und Eduardo Hurtado. „Evaluation of discontinuities in friction stir welds of aluminum matrix composites“. Aircraft Engineering and Aerospace Technology 90, Nr. 7 (01.10.2018): 1065–71. http://dx.doi.org/10.1108/aeat-01-2017-0024.
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Purpose The purpose of this paper is to evaluate the welding quality of the friction stir joints of Al-SiC with diverse shape of pin geometry tools. Design/methodology/approach Aluminum matrix composites are gaining unlimited interest and special position in aeronautical industry because of their properties enhanced by the presence of ceramic reinforcement, such as lower density, dimensional stability, exceptional wear and abrasion resistance. Friction stir welding arises as a promising welding process with more advantages than traditional fusion process in the joining of aeronautical components with the utilization of a non-consumable rotational tool shaped by a shoulder and a pin, which can be designed in as many possible geometries. However, the welding quality is not always achieved when varying these pin configurations. Findings The fabrication and implementation of different pin geometry tools to weld the plates of the material allows to study the behavior of the joints assessing some discontinuities produced in the welds. Practical implications To examine the microstructural evolution and its behavior in the different zones of the joint, the practical implication consists in the use of different characterization techniques like the optic microscopy and scanning microscopy, furthermore mechanical test such as the measurement of hardness. Originality/value The study of the joints uses different welding tool geometries that were fabricated at prototype scale contribute in the microstructural analysis as well as in the evaluation of the possible discontinuities that are presented.
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Wahyudi, Bambang Adi, Duwi Leksono Edy und Wiyono Wiyono. „Automation of Welding Fumes based on MQ-2 Sensor in Welding Laboratory.“ Jurnal Temapela 3, Nr. 1 (09.11.2020): 1–9. http://dx.doi.org/10.25077/temapela.3.1.1-9.2020.
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In practical welding activities, there are potential hazards that must be addressed. These potential hazards include exposure to toxic fumes and dust. Fumes in the welding process contain a lot of metal oxides and can cause chronic effects in the form of eye irritation, sensory irritation, and impaired lung physiological function. Therefore, an air intake sistem is needed to minimize the volume of fumes in the welding chamber . This study aims to design an automation of exhaust smoke using the sensor module, microcontroller and actuator. The resulting tool is equipped with a display of detected air quality conditions, and an alarm indicating that the air quality is in a dangerous level. The method used is experimental development with 3 main stages, namely: designing hardware and software, testing the tools and analyzing their work functions. The results obtained are that the MQ-2 sensor is able to detect changes in the concentration of welding smoke and can be used as an analog input to control the work of the indicator lights, alarms and exhaust fans. The average ability of the exhaust fan to absorb the smoke concentration in the welding chamber is 26.85 seconds for 33 ppm at 40 mm long welding and 29.51 seconds for 37 ppm at 80 mm long welding process. With this capability, this tool can be used as a technical solution related to Occupational Health and Safety in welding laboratories.
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Allart, Marion, Alexandre Benoit, Pascal Paillard, Guillaume Rückert und Myriam Chargy. „Metallurgical Study of Friction Stir Welded High Strength Steels for Shipbuilding“. Materials Science Forum 783-786 (Mai 2014): 2798–803. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.2798.
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Friction Stir Welding (FSW) is one of the most recent welding processes, invented in 1991 by The Welding Institute. Recent developments, mainly using polycrystalline cubic boron nitride (PCBN) tools, broaden the range of use of FSW to harder materials, like steels. Our study focused on the assembly of high yield strength steels for naval applications by FSW, and its consequences on the metallurgical properties. The main objectivewas to analyze the metallurgical transformations occurring during welding. Welding tests were conducted on three steels: 80HLES, S690QL and DH36. For each welded sample, macrographs, micrographs and micro-hardness maps were performed to characterize the variation of microstructures through the weld.
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Siddiquee, Arshad Noor, Sunil Pandey, Mustufa Haider Abidi, Abdulrahman Al-Ahmari, Noor Zaman Khan und Namrata Gangil. „Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel“. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, Nr. 5 (13.11.2019): 1031–43. http://dx.doi.org/10.1177/0954406219888238.
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Welding AISI 304 stainless steel is challenging, especially as fusion-based welding processes (such as arc welding) severely undermine the material's corrosion resistance due to sensitization. Solid-state friction stir welding is one of the most suitable alternatives. Friction stir welding of high-strength high-softening materials such as AISI 304 is difficult mainly because of the non-availability of affordable tools and tool life. In this study, AISI 304 stainless steel was successfully butt-welded by friction stir welding. The experiments were performed using Taguchi's L27 orthogonal array. Shoulder diameter, tool r/min, and traverse speed were selected as the most influential welding parameters. A Tungsten Carbide (WC) tool was employed with a tapered pin profile. Defect-free joints were fabricated successfully for all the welding conditions. Microstructural examinations using optical microscopy and scanning electron microscopy revealed significant grain refinement in the stir zone and the presence of distinct structural features such as stepped, dual, and ditch in various characteristics zones. The presence of precipitates was also observed in samples and was confirmed via energy-dispersive X-ray spectroscopy analysis. The in-process traverse force was measured by a special arrangement of force measuring units attached to the work fixture. The traverse force data were analyzed and optimized. The results of an analysis of variance reveal that the traverse speed was the most important parameter, followed by tool r/min, interaction between the tool shoulder diameter and traverse speed, interaction between the tool shoulder diameter and tool r/min, and, finally, the tool r/min.
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Aval, H. Jamshidi, S. Serajzadeh und A. H. Kokabi. „The influence of tool geometry on the thermo-mechanical and microstructural behaviour in friction stir welding of AA5086“. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 225, Nr. 1 (11.06.2010): 1–16. http://dx.doi.org/10.1243/09544062jmes2267.
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In this work, the effect of tool geometric parameters on thermo-mechanical behaviour in friction stir welding of AA5086 has been investigated. For doing so, the thermo-mechanical responses of material during welding with different tools have been predicted by a three-dimensional finite-element model using the finite-element code ABAQUS. In addition, welding experiments have been carried out to study the developed microstructures and the mechanical properties of welded alloy. The results show that tool geometry significantly affects the energy input, deformation pattern, plunge force, microstructures, and mechanical properties of the joint. The conical tool with the shoulder angle of 2° has been found to produce a larger deformation region as well as higher mechanical properties comparing with the cylindrical tools employed in this research. Additionally, tensile residual stresses are developed within the region around the weld centre-line, which gradually changes to compressive ones beyond the heat-affected zone. It is found that the ratio of heat generation from plastic to friction dissipation in the conical threaded pin is 44 per cent more than the cylindrical pin with similar shoulder diameter.
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Paramo, G., und A. Benitez. „Study of Heat Dissipation Generated in Tool Designed for Friction Stir Welding Process (FSW)“. Advanced Materials Research 1125 (Oktober 2015): 171–75. http://dx.doi.org/10.4028/www.scientific.net/amr.1125.171.
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Friction stir welding (FSW) is an alternative method of joining materials with low melting point, patented in 1991 by the American Welding Institute (UK). This method uses the heat generated by mechanical friction between two moving parts, one is the tool rotates and is fastened on the spindle of a conventional milling machine and the other is the part that is attached and is gagged on the bed of the machine. Among the variables identified as the most important for a successful run of the process are the revolutions per minute (RPM) at which the tool rotates, the speed advance at which the workpiece and the tool design as such moves [1]. In this paper the design of several tools applied to FSW process is studied in specific dissipation of heat generated by mechanical friction between the parts, its relation to tool design and qualities of successful meetings is presented, the methodology to achieve this goal was first identify the possible and applicable materials for the tools, second his respective designs to ensure the right function for operation, and finally define FSW technical parameters (RPM, Head angle, speed advance) for experimental tests. The findings and conclusions attribute a novel analysis in the design of tools for this innovative manufacturing process, in the analysis of the results obtained for each of the assemblies experimentation it was discovered that the use of rings at the parts are not decisive for a good weld even heat dispersion is not good.
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Zhang, Changqing, Weijie Wang, Xin Jin, Chen Rong und Zhuo Qin. „A Study on Microstructure and Mechanical Properties of Micro Friction Stir Welded Ultra-Thin Al-1060 Sheets by the Shoulderless Tool“. Metals 9, Nr. 5 (30.04.2019): 507. http://dx.doi.org/10.3390/met9050507.
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The welding tool is the key of micro friction stir welding (μFSW), which affects the heat input and the plastic forming of weld metal. In this paper, 0.8-mm-thick ultra-thin 1060-H24 aluminum sheets μFSW butt joints were used to compare and analyze the influence of the conventional tool and shoulderless tool on weld shaping, microstructure and mechanical properties. Besides, by measuring the axial force, transverse force and weld temperature in μFSW process, the influence of these two different tools on the heat input and metal flow mechanism of the weld were analyzed. The results show that the weld generated by the shoulderless tool has narrower width, less heat input and metal involved in plastic forming resulting in smaller HAZ (heat affected zone). The hardness of NZ (nugget zone) is obviously increased compared with that of the base metal. The highest tensile strength can reach 108.6 MPa, accounting for 78.6% of the base metal and 117.3% of the joint by the conventional tool. But the welding defects have to be overcome for industrial application of the shoulderless tool.
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Lämsä, Janne, Antti Järvenpää und Kari Mäntyjärvi. „Designing and Manufacturing of a Flexible Longitudinally Laminated Sandwich Panel Forming Tool“. Key Engineering Materials 611-612 (Mai 2014): 786–93. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.786.
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The main aim of the study was to develop forming tools for wide (over 1.2 meter) sandwich panels. Longitudinal laminating technology was selected for tool manufacturing due to its flexibility and cost efficiency. Laminating technology enables easy modification of the tool dimensions afterwards. The function to optimize or vary the dimensions of the tool was set as a secondary objective for the study. Forming tools for sandwich panels are usually complicated structures and joining of the plates can be difficult in some cases. Typically sandwich forming tools are capable to produce only narrow panels (less than 1 meter) and optimization must be done during designing of the tool. In this study, a rapid designing and manufacturing of a flexible sandwich panel forming tool was investigated. Sandwich panels are usually applied in light structures or voice covers due to their very low weight, high stiffness, durability and production cost savings. Designing of the forming tool was made by using a 3D CAD program. Conventional steel plates were used for the forming tool and the assembly was done by fixing the plate parts longitudinally together (laminating). Most important criterion for the forming tool was its capability to produce high quality geometry for the core. Laser welding assembly showed that the quality of the core was good enough for welding the lap joints properly. Both of the objectives were fulfilled: 1) forming tools were suitable for forming of wide cores (1.2 meter) and 2) the structure of the laminated tool enables to change or add new plate parts to change the dimensions of the final product.
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Britto Joseph, G., G. Murugesan, R. Prabhaharan und Tariq Mohammad Choudhury. „Investigations on the Effect of Tool Geometries on Friction Stir Welded 5052 H32 Aluminium Alloy“. Applied Mechanics and Materials 766-767 (Juni 2015): 712–20. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.712.
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Aluminium alloys are widely used in automotive, aerospace and ship industries as high strength-to-weight ratio materials. With the increasing demand for lightweight components, their application is becoming more extensive. To study the effect of Tool geometries on Metallurgical & mechanical properties of Aluminum alloy 5052 H32 using friction stir welding process. To briefly discuss about the conditions & conclude the suitable condition for Aluminium alloy 5052 H32. To plot and conclude the hardness values for various conditions. The tool material Mild Steel IS 2062 FE410 cone type and thread type has been selected for this research for various speeds to find suitable condition. The micro structure and macro structure have checking the structural formation of welded area in details to know it the strength of the joining. The present friction stir welding research is implementing the new tools for the current issues; here we try to implement new material for already available tools.
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Sabirin, Ahmad, und Purwantono Purwantono. „The Effect of Cast Iron Preheating on the Microstructure of Welding Results by Using Cin-2 Electrodes“. Teknomekanik 3, Nr. 2 (10.12.2020): 50–55. http://dx.doi.org/10.24036/teknomekanik.v3i2.6172.
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Cast iron is commonly found in engineering tools such as machine frames, vise, lathes, planers, pressing tools, V-belt pulleys and others. Cast iron is a metal which is relatively difficult to weld because it contains more than 0.3% carbon. As a matter of fact, a lot of welding workers still experience failure in welding the cast iron, so they require the proper procedures to perform welding on the cast iron like the heat treatment before the welding. This study was aimed at obtaining the effect of preheating variations on the weld joints in which the process of welding the material used the type of open V seam connection. The specimen used was a cast iron with a thickness of 10 mm and the electrode used was the JIS Z 3252 DFCNiFe electrode. The method applied in this research was the microstructure observation testing toward the welding result by using Shielded Metal Arc Welding (SMAW). Based on the results of the study, it can be concluded that by applying the preheating variation treatment on the cast iron welding, there was a change in the microstructure and it was dominated by pearlite-ferrite in the weld metal area. As a result, the rough graphite that looks like roots became smooth after experiencing the preheating treatment because the ferrite was evenly distributed in the heat affected area. To conclude, the most superior specimen for the cast iron preheating among the four specimens was the one with 425oC temperature.
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Kucukomeroglu, T., und S. M. Aktarer. „Microstructure, microhardness and tensile properties of FSWed DP 800 steel“. Journal of Achievements in Materials and Manufacturing Engineering 2, Nr. 81 (01.04.2017): 56–60. http://dx.doi.org/10.5604/01.3001.0010.2038.
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Purpose: Dual phase (DP) steels are widely used in the automotive industry due to their properties of a high balance of strength and formability. However, it is known that conventional welding of high strength steel leads to some undesirable results such as hardness decrease in the heat affected zone. Friction stir welding (FSW) is a new solid state joining method, which is used to join these steels due to its advantage of low heat input. The aim of this study is to evaluate the microstructural change and mechanical properties of friction stir welded DP800 steel. Design/methodology/approach: DP 800 steels with 1.5 mm thickness were subjected to friction stir welding, by using a tungsten carbide (WC) tool. The tool was tilted 2°, and downforce of the tool was kept constant at 6 kN. During processing, the tool rotation and traverse speed were fixed at 1600 rpm and 170 mm∙min-1, respectively. Findings: The friction stir welded region comprises martensite, bainite, refined ferrite. The average microhardness of stir zone has increased from 260 HV0.2 to about 450 HV0.2. The tensile sample shows a decrease in the ultimate tensile strength (σUTS) about 3%, from 827 MPa to 806 MPa for the joint. The yield strength (YS) of the joint is about 566 MPa and the value is near that of DP800. Research limitations/implications: The tungsten carbide tool used for the friction stir welding has suffered deterioration in the pin profile after 1 meter welding operation. It may be advisable to drill a pre-hole in the specimens for a longer tool life. Practical implications: Tool wear for industrial applications will be a major problem. Therefore, the use of tools with high wear resistance such as polycrystalline cubic boron nitride may be recommended. Originality/value: Works on friction stir welding of dual phase steels are limited and they mostly focus on spot welding. Also, this study systematically investigates the microstructure and mechanical properties of dual-phase 800 steels after the friction stir welding.
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Iqbal, Azam, Er Guru Sewak Kesharwani und Dr Ravish Kumar Srivastava. „AN EXTENSIVE REVIEW STUDY OF FRICTION STIR WELDING TOOLS AND ITS SPECIFICATIONS“. International Journal of Engineering Applied Sciences and Technology 5, Nr. 1 (31.05.2020): 725–31. http://dx.doi.org/10.33564/ijeast.2020.v05i01.128.
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Çam, G., G. İpekoğlu, T. Küçükömeroğlu und S. M. Aktarer. „Applicability of Friction Stir Welding to steels“. Journal of Achievements in Materials and Manufacturing Engineering 2, Nr. 80 (01.02.2017): 65–85. http://dx.doi.org/10.5604/01.3001.0010.2027.
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significant developments in joining technology to emerge in the last 30 years. The technique has originally been developed for joining difficult-to-fusion-weld Al-alloys, particularly for high strength grades and now widely used in various industrial applications, such as transport industries. On the other hand, the application of FSW to high temperature materials such as steels is hindered due to the problems associated with the stirring tools although there is a wide interest for the application of this technique to these materials. Design/methodology/approach: The aim of this review is to address the current state-of-the-art of FSW of steels, focusing particularly on microstructural aspects and the resulting properties of these joints and discuss the future prospects of this technique for steels. For instance, the use of FSW can be advantageous for joining steels in some special applications where conventional fusion welding processes fail to produce sound cost effective joints, and the high tooling costs of FSW can be justified (i.e. underwater joining of steel pipes or hot plate welding in steel mills). In this study, only structural steels (mainly plain C steels), ferritic stainless steels, austenitic stainless steels and duplex stainless steels will be considered and the other types of steels are out of the scope of this work although some examples are included in the discussion. Research limitations/implications: The tools experience high temperatures in FSW of steels, i.e., above 1000°C. The number of tool materials which can withstand such temperatures is very limited. In addition, the welding of many common steels can be readily conducted by various conventional fusion welding methods. These joining methods are very flexible, easy-to-perform and well established in industrial applications, which further prevents the application of FSW to these materials. These limitations are to be overcome for commercial exploitation of this technique for joining steels.
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El Ouafi, Abderrazak, Rudy Bélanger und Jean-François Méthot. „An On-Line ANN-Based Approach for Quality Estimation in Resistance Spot Welding“. Advanced Materials Research 112 (Mai 2010): 141–48. http://dx.doi.org/10.4028/www.scientific.net/amr.112.141.
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The aim of this study is to develop an effective on-line ANN-based approach for quality estimation in resistance spot welding. The proposed approach examines the welding parameters and conditions known to have an influence on weld quality, and builds a quality estimation model step by step. The modeling procedure begins by establishing relationships between welding parameters (welding time, welding current, electrode force and sheet metal thickness), welding conditions represented by typical characteristics of the dynamic resistance curve and welding quality indices (nugget diameter, nugget penetration, and indentation depth), and the sensitivity of these elements to the variation of the process conditions. Using these results and various statistical tools, three estimation models are developed. The first one is based exclusively on welding parameters. The second model is based on characteristics of the dynamic resistance curve. The third estimation model combines welding parameters and characteristics of dynamic resistance curves. In order to carry out the models building procedure, an extensive number of welding experiments are required. For this purpose, Taguchi’s efficient method of experimental planning is adopted. The results demonstrate that the developed models can provide an accurate on-line estimate of the weld quality, under different welding conditions.
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Chen, Kuan-Jen, Fei-Yi Hung, Truan-Sheng Lui und Yong-Ren Shih. „Wear Inducing Phase Transformation of Plasma Transfer Arc Coated Tools during Friction Stir Welding with Al Alloy“. Journal of Engineering 2019 (01.01.2019): 1–10. http://dx.doi.org/10.1155/2019/6413608.
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The friction stir welding process (friction stir welding/processing, FSW/FSP) has wear problems related to stirring tools. In this study, the plasma transfer arc (PTA) method was used with stellite 1 powders (Co-based) to coat on the head of a SKD61 stirring tool (SKD61-ST1) in order to investigate the wear performance and phase transformation of SKD61-ST1 after FSW. Under the same experimental parameters, the wear data were compared with the high-speed steel SKH51 (tempering material SKH51-T and annealed material SKH51-A) and tungsten-carbide cobalt (TCC). Results showed the PTA coating was a γ-Co solidification matrix with M7C3 and M23C6 carbides. After FSW, the wear resistance of SKD61-ST1 was better than that of SKH51-A and SKH51-T and lower than that of TCC. The SKD61-ST1, SKH51-A, and SKH51-T stirring tools exhibited sliding wear after FSP, where the pin and shoulder of the stirring tool formed a phase transfer layer on the surface, and the peeling of the phase transfer layer caused wear weight loss. The main phase of the phase transfer layer of the SKD61-ST1 tool was Al9Co2. The affinity and adhesion energy of the Co-Al phase was lower than that of Fe-Al phase, and the phase transfer layer of the SKD61-ST1 tool was thinner and had lower coverage, thereby increasing the wear resistance of the SKD61-ST1 stirring tools during FSW.
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Fanous, Ihab F. Z., Maher Y. A. Younan und Abdalla S. Wifi. „Study of the Effect of Boundary Conditions on Residual Stresses in Welding Using Element Birth and Element Movement Techniques“. Journal of Pressure Vessel Technology 125, Nr. 4 (01.11.2003): 432–39. http://dx.doi.org/10.1115/1.1613952.
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The structure in which the welding process is performed highly affects the residual stresses generated in the welding. This effect is simulated by choosing the appropriate boundary conditions in modeling the welding process. The major parameters of the boundary conditions are the method by which the base metal is being fixed and the amount of heat being applied through the torch. Other parameters may include the coefficients of thermal heat loss from the plate which may simulate the media in which the welding is taking place. In modeling the welding process, two-dimensional forms of approximation were developed in analyzing most of the models of such problem. Three-dimensional models analyzing the welding process were developed in limited applications due to its high computation time and cost. With the development of new finite element tools, namely the element movement technique developed by the authors, full three-dimensional analysis of the welding process is becoming in hand. In the present work, three different boundary conditions shall be modeled comparing their effect on the welding. These boundary conditions shall be applied to two models of the welding process: one using the element birth technique and the other using the element movement technique showing the similarity in their responses verifying the effectiveness of the latter being accomplished in a shorter time.
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Kolnes, Mart, Jakob Kübarsepp, Fjodor Sergejev, Märt Kolnes, Marek Tarraste und Mart Viljus. „Performance of Ceramic-Metal Composites as Potential Tool Materials for Friction Stir Welding of Aluminium, Copper and Stainless Steel“. Materials 13, Nr. 8 (24.04.2020): 1994. http://dx.doi.org/10.3390/ma13081994.
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The aim of the research was to disclose the performance of ceramic-metal composites, in particular TiC-based cermets and WC-Co hardmetals, as tool materials for friction stir welding (FSW) of aluminium alloys, stainless steels and copper. The model tests were used to study the wear of tools during cutting of metallic workpiece materials. The primary focus was on the performance and degradation mechanism of tool materials during testing under conditions simulating the FSW process, in particular the welding process temperature. Carbide composites were produced using a common press-and-sinter powder metallurgy technique. The model tests were performed on a universal lathe at the cutting speeds enabling cutting temperatures comparable the temperatures of the FSW of aluminium alloys, stainless steels and pure copper. The wear rate of tools was evaluated as the shortening of the length of the cutting tool nose tip and reaction diffusion tests were performed for better understanding of the diffusion-controlled processes during tool degradation (wear). It was concluded that cermets, in particular TiC-NiMo with 75–80 wt.% TiC, show the highest performance in tests with counterparts from aluminium alloy and austenitic stainless steel. On the other hand, in the model tests with copper workpiece, WC-Co hardmetals, in particular composites with 90–94 wt.% WC, outperform most of TiC-based cermet, including TiC-NiMo. Tools from ceramic-metal composites wear most commonly by mechanisms based on adhesion and diffusion.
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Wang, Zhong Tang, Shi Hong Zhang, Guang Xia Qi und Rong Hui Chang. „Tailor-Welded Blanks Manufactured and Stamping Properties of Magnesium Alloy“. Advanced Materials Research 148-149 (Oktober 2010): 241–44. http://dx.doi.org/10.4028/www.scientific.net/amr.148-149.241.
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Magnesium alloy tailor-welded blanks(MTWBs) of AZ31 and AZ80 sheet had been manufactured by gas tungsten arc welded(GTAW), which the thickness were 0.8mm. The welding properties of Magnesium alloy sheet had been analyzed, and the technology parameters of GTAW were determined by experiment study, which was that welding thread being Φ2.0mm, welding electricity 50A, welding voltage 9V, welding rate 12—13cm/min. The research results presented that the grain in welded seam was isometric crystal, and the grains were branching crystal in heat-affected zone (HAZ). For MTWBs of AZ31and AZ80 sheet which the thickness was 0.8mm, the forming parameters were that the forming temperature of AZ31 being 190-220°C, and forming temperature of AZ80 being 310°C-350°C, and the temperature of tools is 180°C~200°C.
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Lidam, Robert Ngendang A., Yupiter H. P. Manurung, M. Ridhwan, M. A. R. Ridzwan, M. Shahar S., M. Yusof Z., K. A. Sunhaji, T. Ghalib, E. Haruman und Y. C. Chan. „Angular Distortion Analysis on Multipassed Welding of Combined Joint Types Using Thermo-Elastic-Plastic FEM“. Advanced Materials Research 314-316 (August 2011): 315–18. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.315.
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A 2D and 3D thermo-elastic-plastic (TEP) FE Analysis has been developed to simulate the angular distortion induced by Gas Metal Arc Welding (GMAW) process on combination of butt and T-joint with thickness of 9 mm. The material used in this study was low alloy Manganese Carbon steel S355J2G3. In this research, SYSWELD 2010 with its computation management tool known as Multipassed Welding Advisor (MPA) was used to analyze the distortion behaviour of combined joint types. To model the heat source of GMAW, Goldak’s double ellipsoid representation which is available within this FEA code was selected. The final objective of this research is hence aimed to be base line study to provide preliminary information in preparing the tools or equipments for experimental investigation.
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Ragab, Mohamed, Hong Liu, Guan-Jun Yang und Mohamed M. Z. Ahmed. „Friction Stir Welding of 1Cr11Ni2W2MoV Martensitic Stainless Steel: Numerical Simulation Based on Coupled Eulerian Lagrangian Approach Supported with Experimental Work“. Applied Sciences 11, Nr. 7 (29.03.2021): 3049. http://dx.doi.org/10.3390/app11073049.
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1Cr11Ni2W2MoV is a new martensitic heat-resistant stainless steel utilized in the manufacturing of aero-engine high-temperature bearing components. Welding of this type of steel using fusion welding techniques causes many defects. Friction stir welding (FSW) is a valuable alternative. However, few investigations have been performed on the FSW of steels because of the high melting point and the costly tools. Numerical simulation in this regard is a cost-effective solution for the FSW of this steel in order to optimize the parameters and to reduce the number of experiments for obtaining high-quality joints. In this study, a 3D thermo-mechanical finite element model based on the Coupled Eulerian Lagrangian (CEL) approach was developed to study the FSW of 1Cr11Ni2W2MoV steel. Numerical results of metallurgical zones’ shape and weld appearance at different tool rotation rates of 250, 350, 450 and 550 rpm are in good agreement with the experimental results. The results revealed that the peak temperature, plastic strain, surface roughness and flash size increased with an increase in the tool rotation rate. Lack-of-fill defect was produced at the highest tool rotation rate of 650 rpm. Moreover, an asymmetrical stir zone was produced at a high tool rotation rate.
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Lidam, RN, HPM Yupiter, MR Redza, MR Rahim, MS Sulaiman, MY Zakaria, G. Tham, SK Abasa, E. Haruman und CY Chau. „Simulation Study on Multipassed Welding Distortion of Combined Joint Types using Thermo-Elastic-Plastic FEM“. Journal of Engineering Research [TJER] 9, Nr. 2 (01.12.2012): 1. http://dx.doi.org/10.24200/tjer.vol9iss2pp1-16.
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This paper investigates the angular distortion induced by the gas metal arc welding (GMAW) process on the combined butt and T-joint with a thickness of 9 mm. The material used in this study was low manganese carbon steel S355J2G3. A 2-D and 3-D thermo-elastic-plastic finite element (FE) analysis has been developed to simulate the induced distortion of multipassed welding. In this research, SYSWELD 2010 with its computation management tool, known as multipassed welding advisor (MPA), was applied to analyze the distortion behavior of combined joint types. To model the heat source of GMAW, Goldak's double ellipsoid representation, which is available within this finite element analysis (FEA) code was selected. Prior to the results discussion, this paper also shows the step-bystep procedures to simulate combined jointing which begins with metallurgical and customized heat source modeling, and is followed by creating geometrical mesh using Visual-Mesh 6.5 for analyzing and processing the results. Apart from 2-D and 3-D comparison analysis, the final objective of this research is also aimed to be a baseline study to provide preliminary information in preparing the tools and equipment for experimental investigation.
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Cabrol, Elodie, Christine Boher, Vanessa Vidal, Farhad Rezai-Aria und Fabienne Touratier. „A Wear Damage Assessment of High Temperature Forging Tool“. Advanced Materials Research 966-967 (Juni 2014): 103–10. http://dx.doi.org/10.4028/www.scientific.net/amr.966-967.103.
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High temperature forging tools are highly damaged by wear shearing under cyclic loading which reduces the life of tools. In real conditions, depending upon the tool areas, the level of wear can change. The surfaces of tools can be treated by cobalt-based hardfacing using different welding processes. This study focuses on tribological damages of Stellite 21 deposited by MIG process. Wear tests are carried out at room and high temperature on a ring on disc tribometer under high normal load. Different testing conditions are examined. The surface plastic strain due to the friction shear stresses is demonstrated by different methods like SEM observations, micro-hardness measurements and XRD analyses. More particularly, it is shown that the initial (200) crystallographic preferred orientation due to the welding process is modified into (111) crystallographic preferred orientation due to shear stresses regardless the loading. Moreover, a relationship between the gradient of the plastic shear strain at the friction subsurface and the level of the micro-hardness measurement has been established. In regard of the results, when the shear strain exceeds a threshold, the micro-hardness measurement is stabilised. The ultimate value could be induced by the stacking fault energy that is considered as weak in Stellites.
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Cui, Shao Hua, Jiang Ping Mei, Wei Li und Yun Ying Huang. „Study on Poor Welding of Anode Tab and Battery Case of 21700 Lithium Ion Battery“. Materials Science Forum 980 (März 2020): 126–35. http://dx.doi.org/10.4028/www.scientific.net/msf.980.126.
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The 21700 battery is a standard battery used by Tesla vehicles in the United States. It has the advantages of high energy density ratio, high output, low cost and high safety factor. The demand for 21700 battery is gradually increasing on the market. In order to meet the needs of new energy vehicles, the 21700 battery uses copper tab as the anode, which can minimize the internal resistance and improve the charge and discharge efficiency. However, the material of the battery case is steel, and the melting point of the steel is 452°C higher than that of copper. It is difficult to solder firmly using the traditional resistance welding process. In this paper, using TRIZ theory, through the causal analysis, technical conflict, material-field, physical conflicts and other tools, the 21700 battery anode resistance welding problem is analyzed in detail, and based on the analysis results to propose solutions: punching out the pitting on the tab forming a projection welding; inserting metal tungsten in the copper welding head; changing the welding pin head from the platform to the curved surface; introducing nitrogen gas. Under the premise of constant material and no increase in cost, the problem of poor welding of the anode and the battery case can be effectively solved.
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Ehiasarian, Arutiun, Yashodhan Purandare, Arunprabhu Sugumaran, Papken Hovsepian, Peter Hatto und Jeroen De Backer. „Improving the Quality of Friction Stir Welds in Aluminium Alloys“. Coatings 11, Nr. 5 (02.05.2021): 539. http://dx.doi.org/10.3390/coatings11050539.
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The Stationary Shoulder Friction Stir Welding (SS-FSW) technique benefits from reduced heat input, improved mechanical properties and surface finish of the weld, avoiding the need for post weld processing. Coatings on the tool probe and the shoulder for welding of aggressive Aluminium alloys have rarely been successful. Such coatings must be well adherent and inert. In this study, coated tools were used for SS-FSW of AA6082-T6 alloy. Performance of a nanoscale multilayer TiAlN/VN coating deposited by High Power Impulse Magnetron Sputtering (HIPIMS) technology was compared with amorphous Diamond Like Carbon (a-C:H) by Plasma Assisted Chemical Vapour Deposition (PACVD), AlTiN deposited by arc evaporation and TiBCN along with TiB2 produced by Chemical Vapour Deposition (CVD) methods. The TiAlN/VN coating was found to have low affinity to aluminium, acceptable coefficient of friction and provided excellent weld quality by inhibiting intermixing between the tool and workpiece materials resulting in a significant reduction in tool wear.
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Orozco Lozano, Willman Antonio, Jonathan Fábregas Villegas, Rafael Ramírez Restrepo, Javier Andrés Carpintero Durango und Jimy Unfried Silgado. „Multiphysics Coupling Method to Simulate the Friction Stir Welding Process“. Scientia et Technica 25, Nr. 1 (30.03.2020): 92–96. http://dx.doi.org/10.22517/23447214.23461.
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In In this work the methods are developed to perform simulations of the friction stir welding process using the ANSYS software working scheme, developing multiphysics couplings between computational fluid dynamics tools to Model the viscoplastic effect of the fluidity of the material when it is stirred by means of a solid tool modeled in the Transient Structure application that allows calculating the thermo-mechanical effects of the study process. The results show the validations corresponding to the modeled and experimentally performed analysis showing a lot of reliability in the proposed method. The torque reached in the process is maintained in the ranges of 14 Nm, the maximum temperature reached in the process was 540°C, this being 78.3% of the melting temperature of the material studied, having an adequate range for these studies.
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Buffa, Gianluca, Archimede Forcellese, Livan Fratini und Michela Simoncini. „Experimental and Numerical Analysis on FSWed Magnesium Alloy Thin Sheets Obtained Using “Pin” and “Pinless” Tool“. Key Engineering Materials 504-506 (Februar 2012): 747–52. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.747.
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The present investigation aims at studying the effect of different tool geometries and process parameters on FSW of thin sheets in AZ31 magnesium alloy. In particular two properly designed tools, with shoulder diameters equal to 8 and 19 mm, were used; each of them was manufactured both in pin and pinless configurations. The effect of the different tool configurations and sizes, and welding parameters on mechanical properties of FSWed joints were analyzed in detail. The results were compared with those obtained on the base material. It was shown that FSWed joints are characterized by strength and ductility values lower than those of base material. Furthermore, the pin tool configuration, with a shoulder diameter of 8 mm, leads to the obtaining of strength and ductility values higher than those provided by the pinless one. A strong beneficial effect is obtained by increasing the shoulder diameter from 8 to 19 mm using the pinless configuration, whilst the FSW with the pin tool is critically affected by the welding conditions. The experimental work was joined to a numerical investigation based on finite element method (FEM) in order to study the material flow occurring during the welding process as well as the distribution of temperature, with the aim to identify a input window of the process parameters within which sound joints can be obtained.
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Saadlaoui, Yassine, Julien Sijobert, Maria Doubenskaia, Philippe Bertrand, Eric Feulvarch und Jean-Michel Bergheau. „Experimental Study of Thermomechanical Processes: Laser Welding and Melting of a Powder Bed“. Crystals 10, Nr. 4 (26.03.2020): 246. http://dx.doi.org/10.3390/cryst10040246.
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In this study, an experimental approach was developed to analyze and better understand the laser welding and melting of a powder bed process. Different optical diagnostics tools (high-speed camera, infrared camera, pyrometer, etc.) were applied to measure different physical quantities (molten pool morphology, temperature field, residual stresses, and distortions). As a result, measurements during the laser welding process facilitated the building of a database of experimental results (experimental benchmarks). The study of the melting of a powder bed enabled a better understanding of the physics related to the formation and behavior of the molten pool. These results can be used by researchers to improve and validate numerical simulations of these processes.
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Azevedo, José, Virgínia Infante, Luisa Quintino und Jorge dos Santos. „Fatigue Behaviour of Friction Stir Welded Steel Joints“. Advanced Materials Research 891-892 (März 2014): 1488–93. http://dx.doi.org/10.4028/www.scientific.net/amr.891-892.1488.
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The development and application of friction stir welding (FSW) technology in steel structures in the shipbuilding industry provide an effective tool of achieving superior joint integrity especially where reliability and damage tolerance are of major concerns. Since the shipbuilding components are inevitably subjected to dynamic or cyclic stresses in services, the fatigue properties of the friction stir welded joints must be properly evaluated to ensure the safety and longevity. This research intends to fulfill a clear knowledge gap that exists nowadays and, as such, it is dedicated to the study of welded steel shipbuilding joints in GL-A36 steel, with 4 mm thick. The fatigue resistance of base material and four plates in as-welded condition (using several different parameters, tools and pre-welding conditions) were investigated. The joints culminate globally with defect-free welds, from which tensile, microhardness, and fatigue analyses were performed. The fatigue tests were carried out with a constant amplitude loading, a stress ratio of R=0.1 and frequency between 100 and 120 Hz. The experimental results show the quality of the welding process applied to steel GL-A36 which is reflected in the mechanical properties of joints tested.
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Lammlein, D. H., D. R. DeLapp, P. A. Fleming, A. M. Strauss und G. E. Cook. „The application of shoulderless conical tools in friction stir welding: An experimental and theoretical study“. Materials & Design 30, Nr. 10 (Dezember 2009): 4012–22. http://dx.doi.org/10.1016/j.matdes.2009.05.023.
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Gurčík, Tomáš, und Karel Kovanda. „WAAM TECHNOLOGY OPTIMIZED BY OFF-LINE 3D ROBOT SIMULATION“. Acta Polytechnica 59, Nr. 4 (31.08.2019): 312–21. http://dx.doi.org/10.14311/ap.2019.59.0312.
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WAAM (Wire + Arc Additive Manufacturing) is an alternative additive technology that combines an electric arc as a heat source, filler material in the form of a wire for welding and cladding individual weld passes so as to ultimately achieve the closest shape of produced components. Nowadays, when it is modern to digitize the manufacturing production, this process can also be designed using off-line programming tools and 3D simulations of the robot that welds the whole structure. This study deals with the comparison of three structured continuous welds using different weld metal transfers. From the results of the first two processes (dip transfer and IAC process), optimization was achieved using the CMT process and the welding path correction. As the filler material, the low-alloyed solid wire electrode for shielded arc welding of quenched and tempered fine grained structural steels, Böhler Union X 90 (G 89 6 M Mn4Ni2CrMo) with 1 mm in diameter, was used. Obtained samples were subjected to standard technological tests. The results of these tests are used to determine new parameters to ensure stability of this technology. The experiment confirmed that off-line programming will greatly influence the speed and quality of the welding track programs. The results prove that, by combining off-line welding path optimization with an optimized CMT welding process, we can achieve a stable WAAM process.
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Lin, Yuan Ching, Ju Jen Liu und Ben Yuan Lin. „Effect of Tool Geometry on Strength of Friction Stir Spot Welded Aluminum Alloys“. Advanced Materials Research 579 (Oktober 2012): 109–17. http://dx.doi.org/10.4028/www.scientific.net/amr.579.109.
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The effects of tool geometry on the microstructure and tensile shear strength of friction stir spot-welded A6061-T6 Al alloy sheets were investigated in the present study. Friction stir spot welding (FSSW) was carried out at a tool speed of 2500 rpm, plunging rate of 1 mm/s, and dwell time of 3 s. Four types of tools with the same shoulder shape and size, but different pin profiles (threaded cylindrical, smooth cylindrical, threaded triangular, and smooth triangular) were used to carry out FSSW. The mechanical and metallurgical properties of the FSSW specimens were characterized to evaluate the performance of the different tools. Experimental results show that the pin profile significantly alters the hook geometry, which in turn affects the tensile shear strength of the friction stir spot welds. The welds made using the conventional thread cylindrical tool have the largest elongation and yield the highest tensile strength (4.78 kN). The welds made using the smooth cylindrical tool have the lowest tensile strength. The welds made using the threaded triangular and smooth triangular tools both have a tensile-shear load of about 4 KN; however, the welds made using the threaded triangular tool have a better elongation than those made using the smooth triangular tool.
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Yohanes, Yohanes, und Novri Andri. „Performance of Dynamometer with Sensor Type Single Bar for Measuring Drive Power of Rotary Friction Welding Machine“. Journal of Ocean, Mechanical and Aerospace -science and engineering- (JOMAse) 64, Nr. 3 (30.11.2020): 73–80. http://dx.doi.org/10.36842/jomase.v64i3.146.
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This study aims to determine the performance of the dynamometer design as a measure of mechanical power on a rotary friction welding machine. The design of the dynamometer includes the design, manufacture, calibration, and testing of the dynamometer. The design and manufacture of strain dynamometers is adjusted to the motor of the rotary friction welding machine at the University of Riau's Mechanical Engineering Production Technology Laboratory. The design of the strain dynamometer has a dimension of 175 mm × 3 mm × 50 mm and serves to determine the motor torque value with the help of a 120 ohm strain gauge sensor. The device designed is equipped with an electrical microcontroller device and an optocoupler sensor to measure the angular speed of the motor. Next, the dynamometer performance testing is performed on the rotary friction welding machine. The results of testing in the rotary welding process, the greater the pneumatic pressure exerted during welding, the greater the measured power. The largest measured power value is 2452.92 Watt in the forging process, and the smallest measured power value is 2050.24 Watt in the first time of the initial motor rotation. After doing the research, it can be concluded that the tools designed and built can work and have a fairly good performance.
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Larose, Simon, Maxime Guérin und Priti Wanjara. „Process Window for Friction Stir Lap Welding of Aluminum Alloy 6061“. Materials Science Forum 783-786 (Mai 2014): 2839–44. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.2839.
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Precipitation-hardenable 6xxx series aluminum alloys are incorporated in many structural components with due consideration of their good combination of properties including a relatively high strength, outstanding extrudability and excellent corrosion resistance. Accordingly, AA6061 has been identified as a very good candidate material for structural lightweighting of transportation vehicles. However, the weldability of aluminum alloy (AA) 6061 by means of conventional technologies such as GMAW and GTAW methods is limited by sensitivity to solidification cracking. In this respect, friction stir welding (FSW) presents a tremendous potential for assembly of aluminum structures for the transportation industry due to the low heat involved that can mitigate crack formation and, thus, translate into improved mechanical performance of the assembly. In this work, FSW of 3.18 mm thick AA6061-T6 sheets in the lap joint configuration was investigated. This configuration is considered to be more challenging for assembly by FSW than the butt joint type due to the orientation of the interface with respect to the welding tools and the necessity to break the oxide layer on two aluminium alloy planar surfaces. Weld trials were performed to examine the influence of the FSW tool geometry and process parameters on the welding defects, microstructure, hardness and bend performance. Unacceptable material expulsion and/or significant thinning in one of the two overlapped sheets were produced under most conditions. A set of FSW tool geometries leading to a viable process operational window under which the risk of defects could be mitigated and/or eliminated was identified in this study.