Relevant bibliographies by topics / Aluminium - copper welds

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  1. Journal articles
  2. Dissertations / Theses
  3. Book chapters
  4. Conference papers
  5. Reports

Academic literature on the topic 'Aluminium - copper welds'

Author: Grafiati
Published: 6 September 2023

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Journal articles on the topic "Aluminium - copper welds"

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Leal, Rui M., Carlos Leitão, Altino Loureiro, and Dulce M. Rodrigues. "Imaging characterization of friction stir welds in the AA 5182-H111 aluminium alloy." Microscopy and Microanalysis 15, S3 (July 2009): 81–82. http://dx.doi.org/10.1017/s1431927609990869.

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AbstractThe environmentally friendly friction stir welding (FSW) process is being increasingly used in joining similar and dissimilar aluminium and copper alloys and other soft materials. In this process a rotating tool promotes significant shear strain and frictional heating of the base materials, in order to stir them into a highly plasticized weld region, at the trailing side of the tool. Due to the intense plastic deformation, complex material flow patterns, such as vortices, swirls and whorls occur during welding. In dissimilar welds, these patterns are readily revealed by differential etching and the respective microstructures characterized. However, in similar welds, such as the welds between plates of AA 5182-H111 aluminium alloy, it is hard to distinguish the different features in the welds and characterize their microstructures. Fig. 1 illustrates optical and TEM micrographs of a weld in this alloy. In the optical image of the weld, at the top of the image, it is possible to distinguish three main areas signalized by numbers: the weld nugget (1), with a very fine grain structure with 2.8 um mean grain size, and a transition region (2) between the nugget and the base material (3), which is usually called the Thermomechanical Affected Zone (TMAZ).
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Galvão, Ivan, Carlos Leitão, Altino Loureiro, and Dulce Rodrigues. "Friction Stir Welding of very thin plates." Soldagem & Inspeção 17, no. 1 (March 2012): 02–10. http://dx.doi.org/10.1590/s0104-92242012000100002.

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The results obtained in present research, relative to friction stir welding of 1 mm thick plates of aluminium, copper, copper-zinc and zinc alloys, prove that the application of the process in the joining of very thin plates is feasible and desirable. In fact, independently of the base material, the welds produced presented very good morphological characteristics and significant grain refinement in the nugget. Tensile and hardness tests proved that all the welds were at least in even-match relative to the base material properties. Based on the AA 5182 aluminium alloy results it was also possible to conclude that augmenting the welding speed, which improves process productivity, increases grain refinement in the nugget, improving the mechanical properties of the welds.
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Titilayo, Akinlabi Esther, Madyira Daniel Makundwaneyi, and Akinlabi Stephen Akinwale. "Reconfiguration of a Milling Machine to Achieve Friction Stir Welds." Applied Mechanics and Materials 232 (November 2012): 86–91. http://dx.doi.org/10.4028/www.scientific.net/amm.232.86.

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This paper reports on the reconfiguration of a milling machine to produce friction stir welds of aluminium and copper and friction stir processing of 6086 aluminium alloy. Friction stir welding tools were designed and manufactured from tool steel. The tools were inserted into the chuck of the milling machine. A backing plate was also specially designed and manufacturedfrom mild steel to protect the milling machine table and was placed on the bed with the use of T-nuts. The plates were secured firmly on the backing plate with the use of specially designed clamping fixtures. The varied welding speeds and the rotational speeds were achieved using the control system on the vertical milling machine. The reconfigured milling machine was successfully employed to produce friction stir processing of aluminium and friction stir welds of aluminium and copper. An optimum joint strength of 74% was achieved.
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Carvalho, G. H. S. F. L., I. Galvão, R. Mendes, R. M. Leal, and A. Loureiro. "Influence of base material properties on copper and aluminium–copper explosive welds." Science and Technology of Welding and Joining 23, no. 6 (December 27, 2017): 501–7. http://dx.doi.org/10.1080/13621718.2017.1417783.

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Marya, M., and S. Marya. "Interfacial microstructures and temperatures in aluminium–copper electromagnetic pulse welds." Science and Technology of Welding and Joining 9, no. 6 (December 15, 2004): 541–47. http://dx.doi.org/10.1179/174329304x8685.

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Singh, Prem, Dharmpal Deepak, and Gurinder Singh Brar. "Friction Crush Welding of Similar Metals: An Overview." Asian Journal of Engineering and Applied Technology 7, no. 2 (October 5, 2018): 48–51. http://dx.doi.org/10.51983/ajeat-2018.7.2.957.

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Friction Crush Welding (FCW) is a newly developed technique which can be used for welding of similar materials with or without filler metal. In this process, welding between two work pieces occurs due to relative motion between work pieces and rotating cylindrical tool, which causes crushing of material to produce weld. Similar weld which include welds of aluminium, steel and copper and their alloy have been successfully produced by few researchers. This review covers the work conducted in the field of FCW and throws light on the future use of FCW for welding similar and dissimilar materials.
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Silva, Rafael Gomes Nunes, Sylvia De Meester, Koen Faes, and Wim De Waele. "Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding." Journal of Manufacturing and Materials Processing 6, no. 1 (January 1, 2022): 6. http://dx.doi.org/10.3390/jmmp6010006.

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The demand for joining dissimilar metals has exponentially increased due to the global concerns about climate change, especially for electric vehicles in the automotive industry. Ultrasonic welding (USW) surges as a very promising technique to join dissimilar metals, providing strength and electric conductivity, in addition to avoid metallurgical defects, such as the formation of intermetallic compounds, brittle phases and porosities. However, USW is a very sensitive process, which depends on many parameters. This work evaluates the impact of the process parameters on the quality of ultrasonic spot welds between copper and aluminium plates. The weld quality is assessed based on the tensile strength of the joints and metallographic examination of the weld cross-sections. Furthermore, the welding energy is examined for the different welding conditions. This is done to evaluate the influence of each parameter on the heat input resulting from friction at the weld interface and on the weld quality. From the obtained results, it was possible to optimise parameters to achieve satisfactory weld quality in 1.0 mm thick Al–Cu plate joints in terms of mechanical and metallurgical properties.
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Demonie, Wim, Koen Faes, and Wim De Waele. "Influence of process parameters on the weld quality of dissimilar Cu-Al magnetic pulse welded sheets." International Journal Sustainable Construction & Design 7, no. 1 (October 21, 2016): 8. http://dx.doi.org/10.21825/scad.v7i1.3637.

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Little is known about the influence of the main geometrical parameters (overlap, stand-off and free length) and the energy input on welds formed by electromagnetic pulse welding. The Taguchi experimental design method was applied for determining the underlying relations for dissimilar sheet welding of copper and aluminium. The weld quality was evaluated based on four output parameters: the weld length, the size of the interfacial layer, the lap shear strength and the thickness reduction of the flyer sheet. The influence of the overlap and free length showed to be non-negligible; this in contrast to the small amount of attention these parameters receive in other publications.
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Avettand-Fènoël, Marie Noëlle, Roland Taillard, Christophe Herbelot, and Abdellatif Imad. "Structure and Mechanical Properties of Friction Stirred Beads of 6082-T6 Al Alloy and Pure Copper." Materials Science Forum 638-642 (January 2010): 1209–14. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.1209.

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Friction stir welding (FSW) is a quite recent welding method which takes advantage of being performed in the solid state. Compared with the usual welding processes, it therefore presents many benefits such as a lower heat-input, a reduction of residual stresses and an elimination of the solidification defects etc.. Up to now, it has essentially been applied to aluminium alloys and far more recently to a small number of bimaterials. The present study deals with three kinds of beads between pure copper and a 6082 aluminium alloy. Both materials were butt joined by FSW. The welds differ by the location of the tool which was placed either at the interface between the two metals or on the copper or the 6082 side of this surface. Their structure was characterized at a multi-scale level by using a number of techniques. Tensile and microhardness tests were also performed. The tool place is shown to govern the microstructure and the ensuing mechanical behaviour of the weld. Its influence on the plastic flow with its repercussions on i) welding defects and ii) mechanical properties is going to be demonstrated. Some ways of improvement of the welding process will finally be suggested.
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Demirorer, Mete, Wojciech Suder, Supriyo Ganguly, Simon Hogg, and Hassam Naeem. "Development of laser welding of high strength aluminium alloy 2024-T4 with controlled thermal cycle." MATEC Web of Conferences 326 (2020): 08005. http://dx.doi.org/10.1051/matecconf/202032608005.

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An innovative process design, to avoid thermal degradation during autogenous fusion welding of high strength AA 2024-T4 alloy, based on laser beam welding, is being developed. A series of instrumented laser welds in 2 mm thick AA 2024-T4 alloys were made with different processing conditions resulting in different thermal profiles and cooling rates. The welds were examined under SEM, TEM and LOM, and subjected to micro-hardness examination. This allowed us to understand the influence of cooling rate, peak temperature, and thermal cycle on the growth of precipitates, and related degradation in the weld and heat affected area, evident as softening. Although laser beam welding allows significant reduction of heat input, and higher cooling rates, as compared to other high heat input welding processes, this was found insufficient to completely supress coarsening of precipitate in HAZ. To understand the required range of thermal cycles, additional dilatometry tests were carried out using the same base material to understand the time-temperature relationship of precipitate formation. The results were used to design a novel laser welding process with enhanced cooling, such as with copper backing bar and cryogenic cooling.
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Dissertations / Theses on the topic "Aluminium - copper welds"

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Akinlabi, Esther Titilayo. "Characterisation of dissimilar friction stir welds between 5754 Aluminium alloy and C11000 copper." Thesis, Nelson Mandela Metropolitan University, 2010. http://hdl.handle.net/10948/1536.

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Friction Stir Welding (FSW) is a solid state welding process invented and patented by The Welding Institute (TWI) in 1991, for joining ferrous and non-ferrous materials1. The FSW of Aluminium and its alloys has been commercialised; and recent interest is focused on joining dissimilar materials. However, in order to commercialise the process, research studies are required to characterise and establish process windows. This research work through material characterisation of the welded joints establishes a process window for the Friction Stir welding of 5754 Aluminium Alloy and C11000 Copper. Furthermore, preliminary studies83,85 on the FSW of aluminium and copper have revealed the presence of intermetallic compounds which are detrimental to the weld qualities. This research work is also aimed at establishing process parameters that will result in limited or no intermetallic formation in the weld. The joint integrity of the resulting welds will also be correlated with the input process parameters. Based on the preliminary investigations conducted, a final weld matrix consisting of twenty seven welds was produced by varying the rotational speed between 600 and 1200 rpm, and the feed rate between 50 and 300 mm/min using three different shoulder diameter tools – 15, 18 and 25 mm to compare the heat input into the welds and to achieve the best results. The welds were characterised through microstructural evaluation, tensile testing, microhardness profiling, X-Ray Diffraction analysis, electrical resistivity and statistical analysis – in order to establish the interrelationship between the process parameters and the weld qualities. viii Microstructural evaluation of the weld samples revealed that the interfacial regions are characterised by mixture layers of aluminium and copper; while 33 percent of the tensile samples are within the acceptable range (> 75 percent joint efficiency). High Vickers microhardness values were measured at the joint interfaces, which corresponded with the intermetallic compounds. The Energy Dispersive Spectroscopy analysis revealed the presence of thin layers of intermetallics in nanoscale at the interfacial regions. The diffractograms of the X-Ray Diffraction analysis showed small peaks for intermetallics in some of the welds. Low electrical resistivities were measured at the joint interfaces. The statistical analysis showed that the downward vertical force, (Fz) can significantly influence the resulting weld qualities. An overall summary of the analysis of the weld qualities - with respect to the shoulder diameter tools employed showed that the 18 mm shoulder diameter tool is most appropriate among the three shoulder diameters considered, and a process window of medium spindle speed of 950 rpm and low-to-medium feed rate between 50 and 150 mm/min is established for FSW of Aluminium and Copper. Welds produced at 1200 rpm and 300 mm/min with low heat input did not have intermetallics formed at the joint interface.
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Clarke, Jo Ann Marie. "Columnar-to-equiaxed grain transition in gas tungsten arc welds in aluminum-copper alloys." Thesis, National Library of Canada = Bibliothèque nationale du Canada, 1998. http://www.collectionscanada.ca/obj/s4/f2/dsk2/tape17/PQDD_0013/NQ30596.pdf.

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Rajendran, Anbukkarasi. "Studies on Friction Stir Welding of Aluminium AA2024 Alloy to Pure Copper." Thesis, 2018. http://etd.iisc.ac.in/handle/2005/4197.

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Aluminium-copper joints are widely used in electrical applications due to their unique properties. However, joining of these metals by conventional welding techniques is restricted due to the formation of brittle (bulk size) intermetallic phases.As the other solid-state welding techniques are restricted to a particular joint geometry and they are time-consuming, Friction Stir Welding (FSW) technique is used in the present work to join AA2024 and pure Cu, which resulted in distribution of Cu particles in the stir zone. The nature and distribution of these particles, along with the nature and thickness of the intermetallic layer at the interface, would dictate the strength of the joint. However, they depend on the various process parameters. Therefore, the objective of the current work was to optimize the various FSW parameters to obtain better properties by controlling the size of particles in the SZ. For the given purpose, the experiments are done with AA2024 on advancing side and Cu on retreating side and vice versa. Then the other parameters such as tool rotation speed and tool traverse speed are also optimized. These experiments are performed for varying interface positions by using a tapered plain tool and tapered threaded tool. The optimum weld was achieved by a plain tool when the tool was offset towards the advancing side i.e.AA2024 side of the weld. The weld contains a thin continuous intermetallic layer at the interface,due to which maximum joint strength was achieved. From three-point bend test; it was found that the root of this weld was the weakest region. The weakest region of the optimum weld (single side weld) was eliminated by double side weld, where the weld was repeated from the backside of the previous weld. As the intrinsic microstructure of the AA2024-pure Cu weld can change due to heating when the weld is used as a current carrying system, the effects of heating on the optimum weld were also studied. In case of the threaded tool also the optimum weld was obtained, whentool was offset towards the advancing side i.e AA2024 side of the weld. This weld contained high volume fraction of fine Cu particles in AA2024 matrix. This lead to increase in ductility of joint as compared to plain tool weld. Further, Zn and Ni interlayers were used to modify the composition of the particles formed in eth weld nugget. This further increased the ductility of the joint due to the formation of binary/ternary intermetallics. From this work, it is concluded that the expected desirable morphology of metallic and intermetallic particles can be achieved by optimum tool geometry and tool offset position. Due to this optimization considerable improvement in the mechanical properties of the AA2024-pure Cu welds was observed.
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Book chapters on the topic "Aluminium - copper welds"

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Mubiayi, Mukuna Patrick, and Esther T. Akinlabi. "Measurement of Residual Stresses in Aluminium to Copper Friction Stir Spot Welds." In Advances in Material Sciences and Engineering, 319–26. Singapore: Springer Singapore, 2019. http://dx.doi.org/10.1007/978-981-13-8297-0_34.

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Zubiri, Fidel, María del Mar Petite, Jaime Ochoa, and María San Sebastian. "Welding Optimization of Dissimilar Copper-Aluminum Thin Sheets with High Brightness Lasers." In Cracking Phenomena in Welds IV, 219–28. Cham: Springer International Publishing, 2016. http://dx.doi.org/10.1007/978-3-319-28434-7_11.

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Sarrafi, R., A. H. Kokabi, M. Abbasi Gharacheh, and B. Shalchi. "Evaluation of Microstructure and Mechanical Properties of Aluminum to Copper Friction Stir Butt Welds." In Friction Stir Welding and Processing VI, 253–64. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2011. http://dx.doi.org/10.1002/9781118062302.ch31.

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Varkey, Merrin, Josme Maria Jose, Steffi Sebi Joseph, Abin Antony, Charles Baburaj, Sherin Thampi, and Krishna Priya Yagati. "Gas Metal Arc Weld-Brazing of Aluminum to Copper using Tin Interlayer." In Emerging Technologies for Sustainability, 533–38. CRC Press, 2020. http://dx.doi.org/10.1201/9780429353628-69.

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Bauser, Martin. "Metallurgical Principles." In Extrusion, 141–94. 2nd ed. ASM International, 2006. http://dx.doi.org/10.31399/asm.tb.ex2.t69980141.

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Abstract This chapter explains the basic terminology and principles of metallurgy as they apply to extrusion. It begins with an overview of crystal structure in metals and alloys, including crystal defects and orientation. This is followed by sections discussing the development of the continuous cast microstructure of aluminum and copper alloys. The discussion provides information on billet and grain segregation and defects in continuous casting. The chapter then discusses the processes involved in the deformation of pure metals and alloys at room temperature. Next, it describes the characteristics of pure metals and alloys at higher temperatures. The processes involved in extrusion are then covered. The chapter provides details on how the toughness and fracture characteristics of metals and alloys affect the extrusion process. The weld seams in hollow profiles, the production of composite profiles, and the processing of composite materials, as well as the extrusion of metal powders, are discussed. The chapter ends with a discussion on the factors that define the extrudability of metallic materials and how these attributes are characterized.
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Conference papers on the topic "Aluminium - copper welds"

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Mubiayi, Mukuna Patrick, Esther titilayo Akinlabi, and Mamookho Elizabeth Makhatha. "Microstructure and electrical resistivity properties of copper and aluminium friction stir spot welds." In 2017 8th International Conference on Mechanical and Intelligent Manufacturing Technologies (ICMIMT). IEEE, 2017. http://dx.doi.org/10.1109/icmimt.2017.7917432.

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Mubiayi, Mukuna Patrick, Esther titilayo Akinlabi, and Mamookho Elizabeth Makhatha. "Effect of process parameters on tensile strength and morphology of friction stir spot welds of aluminium and copper." In 2017 8th International Conference on Mechanical and Intelligent Manufacturing Technologies (ICMIMT). IEEE, 2017. http://dx.doi.org/10.1109/icmimt.2017.7917433.

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Esme, Ugur, and AyCa Cakmak. "The Effect of Electrode Shape and Force on the Contact Resistance of Spot Welded Joints." In ASME 2005 International Mechanical Engineering Congress and Exposition. ASMEDC, 2005. http://dx.doi.org/10.1115/imece2005-79166.

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Contact resistance is an important parameter in the control of electrical spot welding. Here, a large current is passed through two water cooled copper electrodes which also clamp the sheets to be welded [1]. The contact resistance should not be too high, otherwise too much current is diverted to previously formed, neighbouring spot welds, and can make nugget formation difficult to control in the early part of the welding cycle. However, if it is too low, nugget formation is not completed at the interface. Therefore, the parameters that affect the contact resistance must be known and it must be compatible with the welding conditions [2]. The present paper reports the relationship between contact resistance, force, and electrode shape. A series of experiments were carried out using aluminium and steel specimens with different thicknesses to measure the faying surface and electrode-workpiece contact resistances.
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Vivek, Anupam, Steven R. Hansen, Bert C. Liu, and Glenn S. Daehn. "Vaporizing Foil Actuator Welding of AA6061 With Cu110: Effect of Heat Treatment Cycles on Mechanical Properties and Microstructure." In ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/msec2014-4118.

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This work aims to study the effect of microstructure of the weld between aluminum alloy AA6061 and commercially pure copper, Cu 110, on its mechanical properties. AA6061-T6 and T4 aluminum sheets of 1 mm thickness were launched towards copper targets using the Vaporizing Foil Actuator (VFA) tool operating at 8 kJ input energy level. Flyer plate velocities, measured via photonic Doppler velocimetry (PDV), were observed to be approximately 800 m/s. All the welded samples were subjected to instrumented peel testing, microhardness testing, energy-dispersive x-ray spectroscopy (EDS), and SEM. The welded joints had cracks which ran through the continuous intermetallic layers and stopped upon encountering a ductile metallic wave. The welds created with T6 temper flyer sheets were found to have smaller regions with wavy interfaces free of intermetallics as compared to those created with T4 temper flyer sheets. Peel strength tests of the two types of welds resulted in failure along the interface in case of the T6 flyer welds, while the failure generally occurred in the parent aluminum in the case of the T4 flyer welds. Half of the T4 flyer welds were subjected to aging for 18 hours at 160 °C to convert the aluminum sheet back to T6 condition. Although the flyer material did not attain the hardness of the original T6 material, it was found to be significantly stronger than the T4 material. These welds retained their strengths after the aging process and diffusion across the interface was insignificant.
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Payton, Lewis N. "Friction Stir Welding of Aluminum 6061-T6 and Multi-Purpose Copper 11000 Alloy." In ASME 2017 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/imece2017-71411.

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Friction Stir Welding (FSW) is a solid-state joining process invented by The Welding Institute (TWI, United Kingdom) in 1991 in partnership with the National Aeronautics Space Agency. The process is emerging as one of the preferred alternative methods to permanently join materials that are difficult to join with traditional fusion methods (e.g., MIG, TIG, etc.). The welding of various copper alloys to various aluminum alloys is of great interest to the nuclear industry and the electrical distribution industry. The very different melting points of these two alloys preclude traditional fusion welding. Since the pin tool is simultaneously rotating and traversing through the work piece, flow around the tool is asymmetrical. This has led to designating one side of the tool as advancing and the opposite side as retreating. On the advancing side of the weld, the tool has a tangential velocity in the same direction as the weld is being created. The retreating side of the weld tool is the opposite. It can be can expected that asymmetric heating and deformation will occur in the weld due to this advancing/retreating nature of the FSW pin tool. Although previous studies have been performed that have observed this asymmetric behavior in both similar and dissimilar materials, the resulting welds have been of a poor quality. Large statistical experiments were conducted locally to study the effects of tool geometry, process parameters, and material composition have upon the friction stir butt welding of aluminum alloy 6061-T6 to copper alloy 11000 using a modern conventional 3-axis CNC vertical mill. The research seeks to determine (1) which direction a dissimilar metal friction stir weld between aluminum and copper should be executed, (2) the optimal shoulder diameter to be used when friction stir welding aluminum and copper on a CNC mill, and (3) the addition of a third material to act as an aide. The extensive statistical interactions between these parameters is also documented. A weld schedule was developed that resulted in an ultimate tensile strength (UTS) surpassing (greater than 90% of the weaker, more ductile copper alloy UTS strength) what has been documented in the current literature despite the machine limitations of the CNC vertical mill. Proper optimization of the welding schedule developed may approach 100 percent of the basic copper 11000 properties across the welded zone into the aluminum 6061-T6 alloy.
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MUBIAYI, MUKUNA P., and ESTHER T. AKINLABI. "MICROSTRUCTURAL CHARACTERIZATION OF FRICTION STIR SPOT WELDS OF ALUMINUM AND COPPER." In International MultiConference of Engineers and Computer Scientists (IMECS 2015) & World Congress on Engineering (WCE 2015). WORLD SCIENTIFIC, 2016. http://dx.doi.org/10.1142/9789813142725_0028.

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Lai, Wei-Jen, Jwo Pan, and Van-Xuan Tran. "Stress Intensity Factor Solutions for Welds Between Two Sheets of Different Materials and Thicknesses Under Plane Strain Conditions." In ASME 2013 Pressure Vessels and Piping Conference. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/pvp2013-97736.

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In this paper, analytical stress intensity factor solutions for welds in lap-shear specimens of different materials and thicknesses under plane strain conditions are presented in the normalized forms. The stress intensity factor solutions for welds are expressed in terms of the structural stresses based on a strip model. The analytical stress intensity factor solutions are selectively verified by the results of the two-dimensional finite element analyses. The interface crack parameters for the stress intensity factor solutions for welds in lap-shear specimens of dissimilar steel, aluminum, magnesium, and copper sheets are listed for different thickness ratios. The analytical stress intensity factor solutions are obtained and selectively presented in the normalized forms as functions of the specimen thickness ratio for the combination of aluminum and steel sheets for fracture and fatigue analyses.
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Manisegaran, Lohappriya V., Nurainaa Ayuni Ahmad, Nurnadhirah Nazri, Amirul Syafiq Mohd Noor, Vignesh Ramachandran, Muhammad Tarmizizulfika Ismail, Ku Zarina Ku Ahmad, and Dian Darina Indah Daruis. "Optimizing friction stir weld parameters of aluminum and copper using conventional milling machine." In 8TH INTERNATIONAL CONFERENCE ON NANOSCIENCE AND NANOTECHNOLOGY 2017 (NANO-SciTech 2017). Author(s), 2018. http://dx.doi.org/10.1063/1.5034544.

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Velukkudi Santhanam, Senthil Kumar, Harinivas Selvaraju, and Mystica Augustine Michael Duke. "Evaluation of Weld Quality Through Non-Destructive Testing and Weld Property Analysis of Friction Stir Welded AA2014 Under Submerged Condition." In ASME 2022 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/imece2022-94518.

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Abstract Aluminum Alloy2014 is one of the strongest aluminum alloys and is a copper-based alloy that has a high strength-to-weight ratio. Poor corrosion resistance, porosity, cracking, and element loss makes the alloy difficult to weld in gas and arc welding techniques. To overcome these difficulties, the most suitable method for joining aluminum alloy2014 is Friction Stir Welding. Due to its high strength, aluminum alloy2014 is joined using Friction Stir Welding in aerospace industries in fuel tanks of spaceships and other automotive industries in making complex shapes. In the current study, aluminum alloy2014 alloy is friction stir welded under submerged conditions employing graphene nanofluid. The welding was carried out under the optimized process parameter of tool rotational speed 1200 rpm and a transverse speed of 72 mm/min. A hardened square pin tool of length 5.5 mm and diameter of 4 mm is used for joining the aluminum alloy2014. The graphene nanofluid is developed using the two-step method constituting water as the base fluid. Water is suspended with 0.5 wt% of graphene nanoparticles. In this investigation, Radiography analysis, surface roughness, microhardness, tensile behavior and Facture analysis under two different conditions, normal welding and submerged welding was determined.
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Zhao, Nanzhu, Wei Li, Wayne W. Cai, and Jeffrey A. Abell. "A Method to Study Fatigue Life of Ultrasonically Welded Lithium-Ion Battery Tab Joints Using Electrical Resistance." In ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/msec2014-4159.

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The fatigue life of ultrasonically welded lithium-ion battery tab joints is studied for electric and hybrid-electric vehicle applications. Similar to metallic materials, the electrical resistance of these ultrasonic welds strongly depends on their quality and the crack growth under fatigue loading. A fatigue life model is developed using the continuum damage mechanics formulation, where the damage variable is defined using the electrical resistance of ultrasonic welds. Fatigue tests under various loading conditions are conducted with aluminum-copper battery tab joints made under various ultrasonic welding conditions. It is shown that the electrical resistance of ultrasonic welds increases characteristically during the fatigue life test. There is a threshold for the damage variable, after which the ultrasound welds fail rapidly. Due to welding process variation, welds made under the same process settings may have different fatigue performance. This quality difference may be classified using two parameters estimated from the fatigue life model. By monitoring the electrical resistance, it is possible to predict the remaining life of ultrasonically welded battery tab joints using only a portion of the fatigue test data. The prediction is more reliable by incorporating data beyond the half-life of the joints during the fatigue test.
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Reports on the topic "Aluminium - copper welds"

1

Gray. L51567 Influence of Filler Wire Carbon and Residual Element Content on the Mechanical Properties. Chantilly, Virginia: Pipeline Research Council International, Inc. (PRCI), June 1998. http://dx.doi.org/10.55274/r0010565.

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Abstract:
This study was conducted to determine the interactive roles of carbon, oxygen, and nitrogen and residual elements such as titanium, chromium, copper, sulfur, phosphorous, aluminum, tin, antimony, and arsenic on weld metal mechanical properties in pipeline steels. Eleven seamless, flux-core electrodes were fabricated with varying compositions and deposited in girth welds in a 24-inch diameter, API 5LX-65 pipe using the gas-metal-arc-weld (GMAW) process. The results of Charpy V-notch and crack-tip opening displacement tests indicate that desirable toughness properties may require the addition of alloying elements (e.g., nickel) that promote the formation of acicular-ferrite microstructures. In addition, small variations in sulfur content were shown to cause significant variability in notch toughness.
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2

Ruschau. L51961 Coating Compatibility at Thermite Welds and Keyhole Excavations. Chantilly, Virginia: Pipeline Research Council International, Inc. (PRCI), December 2002. http://dx.doi.org/10.55274/r0010247.

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Abstract:
Patching and repairing high performance pipeline coatings requires a high performance repair material to ensure the integrity of the coating system. The application conditions are not optimized as they are during plant applications, so it is imperative that repair coatings applied to mainline coatings will adhere to all coated surfaces so that resources can be focused on optimizing application methods. Compatibility of repair coatings applied to thermite weld components may be inadequate for optimum field performance. When combined with the limiting factors of keyhole excavations it is important to use coatings which are not only compatible with the thermite welds but also are suitable for the keyhole application procedure. A series of 14 pipeline repair coatings were evaluated for their compatibility with the components of a thermite weld. Chemical compatibility was determined in terms of adhesion with the thermite weld individual components: polyethylene wire insulation, polyvinylchloride wire insulation, copper wire, steel, and copper/aluminum thermite alloy. The same coatings were evaluated for their suitability for application by keyhole excavation procedures. A keyhole excavation was simulated using a scaffold over filled soil boxes (dry soil) containing buried pipe sections, and each of the repair coatings was applied by a commercial keyhole excavation company. The ease of application and general suitability was rated. After backfilling and aging for six months, the samples were removed from the soil boxes and the coatings evaluated.
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