Pub Date : 2025-01-10DOI: 10.1016/j.jajp.2025.100282
Hamed Razavi , Hamid Reza Masoumi
This study investigates the impact of ultrasonic vibrations on the press-fitting process, aiming to reduce the maximum press-fit force required in mechanical assemblies. Press-fitting involves inserting a pin into a bushing of a slightly smaller diameter, leading to high press-fit forces, which is crucial in the analysis and performance assessment of the process. The research investigates the effects of assembly speed and ultrasonic vibration power on the reduction of press-fit force. Through a series of 15 distinct experiments employing both conventional press-fitting (CPF) and ultrasonic-assisted press-fitting (UAPF), it was found that increasing the power of ultrasonic vibrations leads to a significant decrease in the maximum press-fit force, whereas reducing the assembly speed has a minor effect. The maximum press-fit force is reduced by over 80 % when utilizing maximum vibration power. The findings indicate that the UAPF method is a promising technique to reduce the maximum press-fit force, thus improving the feasibility of the press-fitting process. This research has significant implications for the manufacturing industry, enabling the assembly of sensitive parts without excessive force and improving the overall assembly performance.
{"title":"Ultrasonic-assisted press-fitting: A superior method for reducing press-fit force compared to conventional press-fitting","authors":"Hamed Razavi , Hamid Reza Masoumi","doi":"10.1016/j.jajp.2025.100282","DOIUrl":"10.1016/j.jajp.2025.100282","url":null,"abstract":"<div><div>This study investigates the impact of ultrasonic vibrations on the press-fitting process, aiming to reduce the maximum press-fit force required in mechanical assemblies. Press-fitting involves inserting a pin into a bushing of a slightly smaller diameter, leading to high press-fit forces, which is crucial in the analysis and performance assessment of the process. The research investigates the effects of assembly speed and ultrasonic vibration power on the reduction of press-fit force. Through a series of 15 distinct experiments employing both conventional press-fitting (CPF) and ultrasonic-assisted press-fitting (UAPF), it was found that increasing the power of ultrasonic vibrations leads to a significant decrease in the maximum press-fit force, whereas reducing the assembly speed has a minor effect. The maximum press-fit force is reduced by over 80 % when utilizing maximum vibration power. The findings indicate that the UAPF method is a promising technique to reduce the maximum press-fit force, thus improving the feasibility of the press-fitting process. This research has significant implications for the manufacturing industry, enabling the assembly of sensitive parts without excessive force and improving the overall assembly performance.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100282"},"PeriodicalIF":3.8,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133070","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
An innovative anti-loosening bolt with a double-thread mechanism (denoted as DTB-IIC) consisting of coaxial single and multiple coarse threads was previously devised and its structure and performance were optimized. The results of a previous study showed that increasing the bottom rise ratio , which is the ratio of the bottom rise for the multi-thread groove to the thread height, to 70 % significantly improved the formability during the thread-rolling process, but clearly reduced the loosening resistance. In the present study, an attempt was made to address this problem in a simple manner by inserting a left-handed spring washer (SW) between the inner multi-thread nut and the outer single-thread nut. The value of was set to 50 %, 60 %, or 70 %. Comparative Junker vibration loosening tests based on the ISO 16,130 standard were conducted and the change in the residual ratio for the axial load, , was evaluated. Without the SW, the final () for was above 90 %, while for and , it was approximately 73 % and 64 %, respectively. Attachment of the SW caused an increase in for all values, with a greater increase for larger , reaching 82 % for = 60 % and 75 % for = 70 %, respectively. It was found that the contact force between the nuts is an indicator for determining the degree of locking between the DTB-IIC and the nut. The initial loosening process was simulated using a three-dimensional finite element method model, and the curves obtained in the analysis agreed well with the experimental results by setting the gap between the inner multi-thread nut and the DTB-IIC bolt in the range 0.125–0.15 mm. The simulation results indicated that there were clear differences in mating state between the outer nut and the DTB-IIC depending on the value, and the use of a SW achieved a more robust locking state when was 50 %.
{"title":"Improvement of anti-loosening resistance of locking bolts based on single-coarse-thread/multiple-coarse-thread mechanism by using spring washer between nuts","authors":"Shuichi Amano , Toshinaka Shinbutsu , Yuki Okimoto , Teruie Takemasu , Toshihiko Kuwabara","doi":"10.1016/j.jajp.2025.100280","DOIUrl":"10.1016/j.jajp.2025.100280","url":null,"abstract":"<div><div>An innovative anti-loosening bolt with a double-thread mechanism (denoted as DTB-IIC) consisting of coaxial single and multiple coarse threads was previously devised and its structure and performance were optimized. The results of a previous study showed that increasing the bottom rise ratio <span><math><mi>β</mi></math></span>, which is the ratio of the bottom rise for the multi-thread groove to the thread height, to 70 % significantly improved the formability during the thread-rolling process, but clearly reduced the loosening resistance. In the present study, an attempt was made to address this problem in a simple manner by inserting a left-handed spring washer (SW) between the inner multi-thread nut and the outer single-thread nut. The value of <span><math><mi>β</mi></math></span> was set to 50 %, 60 %, or 70 %. Comparative Junker vibration loosening tests based on the ISO 16,130 standard were conducted and the change in the residual ratio for the axial load, <span><math><mi>κ</mi></math></span>, was evaluated. Without the SW, the final <span><math><mi>κ</mi></math></span> (<span><math><msub><mi>κ</mi><mi>f</mi></msub></math></span>) for <span><math><mrow><mi>β</mi><mo>=</mo><mn>50</mn><mspace></mspace><mo>%</mo></mrow></math></span> was above 90 %, while <span><math><msub><mi>κ</mi><mi>f</mi></msub></math></span> for <span><math><mrow><mi>β</mi><mo>=</mo><mn>60</mn><mspace></mspace><mo>%</mo></mrow></math></span> and <span><math><mrow><mi>β</mi><mo>=</mo><mn>70</mn><mspace></mspace><mo>%</mo></mrow></math></span>, it was approximately 73 % and 64 %, respectively. Attachment of the SW caused an increase in <span><math><msub><mi>κ</mi><mi>f</mi></msub></math></span> for all <span><math><mi>β</mi></math></span> values, with a greater increase for larger <span><math><mi>β</mi></math></span>, reaching 82 % for <span><math><mi>β</mi></math></span> = 60 % and 75 % for <span><math><mi>β</mi></math></span> = 70 %, respectively. It was found that the contact force between the nuts is an indicator for determining the degree of locking between the DTB-IIC and the nut. The initial loosening process was simulated using a three-dimensional finite element method model, and the <span><math><mi>κ</mi></math></span> curves obtained in the analysis agreed well with the experimental results by setting the gap <span><math><mi>δ</mi></math></span> between the inner multi-thread nut and the DTB-IIC bolt in the range 0.125–0.15 mm. The simulation results indicated that there were clear differences in mating state between the outer nut and the DTB-IIC depending on the <span><math><mi>β</mi></math></span> value, and the use of a SW achieved a more robust locking state when <span><math><mi>β</mi></math></span> was 50 %.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100280"},"PeriodicalIF":3.8,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Continuous drive friction welding (CDFW) is a highly efficient technique for fabricating large Polyether-ether-ketone (PEEK) components. However, the bending strength of welded specimens is often constrained by the formation of pores at the weld interface. Addressing this limitation, this study aims to enhance the bending strength of PEEK polymer cylinders by applying ultrasound-assisted continuous drive friction welding (UACDFW). To further improve joint performance, a novel post-compression technique is introduced and used after the welding process to increase the weld-bonded area. Additionally, image processing software is employed to evaluate and analyze the weld-bonded area ratio, comprehensively assessing the interfacial characteristics. Optimizing CDFW parameters increased the bending strength of the welded components from 201.6 MPa to 380.8 MPa and the joint area ratio from 77.54 % to 99.99 %. The optimized parameters include a rotational speed of 4000 rpm, a preheating time of 5 s, and a post-compression feed rate of 3.2 mm/s. The results demonstrate the potential of UACDFW and post-compression techniques as effective solutions for improving the mechanical performance and reliability of PEEK components in high-performance applications.
{"title":"Enhancing the weld quality of polyetheretherketone polymer cylinders using reducing pores in the weld interface","authors":"Chil-Chyuan Kuo , Xiao-Ze Xie , Chong-Xu Liao , Wen-Bin Huang , Yu-Jie Chen , Armaan Farooqui , Song-Hua Huang , Shih-Feng Tseng","doi":"10.1016/j.jajp.2025.100281","DOIUrl":"10.1016/j.jajp.2025.100281","url":null,"abstract":"<div><div>Continuous drive friction welding (CDFW) is a highly efficient technique for fabricating large Polyether-ether-ketone (PEEK) components. However, the bending strength of welded specimens is often constrained by the formation of pores at the weld interface. Addressing this limitation, this study aims to enhance the bending strength of PEEK polymer cylinders by applying ultrasound-assisted continuous drive friction welding (UACDFW). To further improve joint performance, a novel post-compression technique is introduced and used after the welding process to increase the weld-bonded area. Additionally, image processing software is employed to evaluate and analyze the weld-bonded area ratio, comprehensively assessing the interfacial characteristics. Optimizing CDFW parameters increased the bending strength of the welded components from 201.6 MPa to 380.8 MPa and the joint area ratio from 77.54 % to 99.99 %. The optimized parameters include a rotational speed of 4000 rpm, a preheating time of 5 s, and a post-compression feed rate of 3.2 mm/s. The results demonstrate the potential of UACDFW and post-compression techniques as effective solutions for improving the mechanical performance and reliability of PEEK components in high-performance applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100281"},"PeriodicalIF":3.8,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133072","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-02DOI: 10.1016/j.jajp.2024.100278
Nagaraju Doredla, Senthil Kumar N
Ferrite-Pearlite (α-P) steels like E350 steel were extensively used in pre-engineered structures like industrial warehouses, bridges, etc., owing to their special ductility property. Submerged arc welding is highly efficient in welding long-span prefabricated structures. In this paper, weld overlay and butt weld experimental investigations were performed to optimise the welding process by understanding the influence of heat input on residual stress generation, weld efficiency, microstructural and mechanical characteristics of the weld joint to match the filler wire with the base material characteristics. Trail runs were conducted using the Taguchi design optimisation approach. Taguchi method is useful to standardise and simplify the use of design of experiments. The weld quality was evaluated using non-destructive evaluations. Residual stress was tensile near the weld and transitioned to compressive further from the root. The intensity of residual stress decreased gradually with an increase in transverse distance from the weld root. Acicular ferrite, polygonal ferrite, and traces of lath bainite microstructure were observed in the weld zone. The weld microstructure became coarser toward the melting boundary of the welded joint with an increase in heat input greater than 1.09 kJ/mm. A notable decrease in weld brittleness was observed with an increase in heat input from 1.09–1.37 kJ/mm, and the fracture initiated away from the weld with ductile and quasi-ductile cleavages. The overall microstructure and mechanical characteristics of the welded joint were improved at a controlled heat input of 1.09–1.37 kJ/mm.
{"title":"Determination of heat input impact on residual stress, microstructure and mechanical characteristics of welded ferrite-pearlite (α-P) steel joints by using taguchi optimization approach","authors":"Nagaraju Doredla, Senthil Kumar N","doi":"10.1016/j.jajp.2024.100278","DOIUrl":"10.1016/j.jajp.2024.100278","url":null,"abstract":"<div><div>Ferrite-Pearlite (α-P) steels like E350 steel were extensively used in pre-engineered structures like industrial warehouses, bridges, etc., owing to their special ductility property. Submerged arc welding is highly efficient in welding long-span prefabricated structures. In this paper, weld overlay and butt weld experimental investigations were performed to optimise the welding process by understanding the influence of heat input on residual stress generation, weld efficiency, microstructural and mechanical characteristics of the weld joint to match the filler wire with the base material characteristics. Trail runs were conducted using the Taguchi design optimisation approach. Taguchi method is useful to standardise and simplify the use of design of experiments. The weld quality was evaluated using non-destructive evaluations. Residual stress was tensile near the weld and transitioned to compressive further from the root. The intensity of residual stress decreased gradually with an increase in transverse distance from the weld root. Acicular ferrite, polygonal ferrite, and traces of lath bainite microstructure were observed in the weld zone. The weld microstructure became coarser toward the melting boundary of the welded joint with an increase in heat input greater than 1.09 kJ/mm. A notable decrease in weld brittleness was observed with an increase in heat input from 1.09–1.37 kJ/mm, and the fracture initiated away from the weld with ductile and quasi-ductile cleavages. The overall microstructure and mechanical characteristics of the welded joint were improved at a controlled heat input of 1.09–1.37 kJ/mm.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100278"},"PeriodicalIF":3.8,"publicationDate":"2025-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133039","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-12-30DOI: 10.1016/j.jajp.2024.100279
John Cance, Afsaneh Rabiei
Metal foams are notable for their impressive impact and thermal energy absorption capabilities primarily when compared to bulk metals. Composite metal foams (CMF) exemplify these properties through unchallenged structural uniformity, enhanced by an arrangement of similar prefabricated hollow metal spheres suspended within a metallic matrix. CMF's extraordinary physical, thermal, and mechanical properties make it a prime candidate for replacing bulk materials in various structural applications. However, the use of CMF in larger structures requires the implementation of joining methods. Solid-state joining processes are particularly well-suited for metal foams as they can form solid bonds between porous workpieces without distorting their cellular structures. Previous success was achieved in joining CMF panels up to 2.5 cm thick through induction welding, though localized heating through induced Eddy currents could not fully permeate thicker samples. This limitation has caused a shift in focus to diffusion bonding of CMF panels thicker than 2.5 cm. This process utilizes a vacuum furnace, combining heat with intense pressure to facilitate atomic diffusion between workpieces. This study evaluates the suitability of diffusion bonding in joining CMF panels through a combination of uniaxial tensile tests and scanning electron microscopy (SEM) observations. Tensile testing indicated bond strength to be largely affected by sample density, and in turn, consistency of the steel powder used in CMF production. Overall, diffusion bonding of CMF was successful from thicknesses below 2.5 cm up to 5 cm, with material density and surface preparation being the apparent driving factors to successful bonding.
{"title":"Study on diffusion bonding of composite metal foams","authors":"John Cance, Afsaneh Rabiei","doi":"10.1016/j.jajp.2024.100279","DOIUrl":"10.1016/j.jajp.2024.100279","url":null,"abstract":"<div><div>Metal foams are notable for their impressive impact and thermal energy absorption capabilities primarily when compared to bulk metals. Composite metal foams (CMF) exemplify these properties through unchallenged structural uniformity, enhanced by an arrangement of similar prefabricated hollow metal spheres suspended within a metallic matrix. CMF's extraordinary physical, thermal, and mechanical properties make it a prime candidate for replacing bulk materials in various structural applications. However, the use of CMF in larger structures requires the implementation of joining methods. Solid-state joining processes are particularly well-suited for metal foams as they can form solid bonds between porous workpieces without distorting their cellular structures. Previous success was achieved in joining CMF panels up to <em>2.5</em> cm thick through induction welding, though localized heating through induced Eddy currents could not fully permeate thicker samples. This limitation has caused a shift in focus to diffusion bonding of CMF panels thicker than <em>2.5</em> cm. This process utilizes a vacuum furnace, combining heat with intense pressure to facilitate atomic diffusion between workpieces. This study evaluates the suitability of diffusion bonding in joining CMF panels through a combination of uniaxial tensile tests and scanning electron microscopy (SEM) observations. Tensile testing indicated bond strength to be largely affected by sample density, and in turn, consistency of the steel powder used in CMF production. Overall, diffusion bonding of CMF was successful from thicknesses below <em>2.5</em> cm up to <em>5</em> cm, with material density and surface preparation being the apparent driving factors to successful bonding.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100279"},"PeriodicalIF":3.8,"publicationDate":"2024-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133040","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-12-25DOI: 10.1016/j.jajp.2024.100275
Shoeib Karami , Mohammad Yousefieh , Homam Naffakh-Moosavy
In this study, the key findings of evaluating laser beam welding parameters on the multi-layered structure of 6061 aluminum alloys fabricating by accumulative roll bonding process are reported, considering fostering mechanical properties concerning the influence of filler metal and welding speed on the weld bead quality by taking into account reducing welding defects. Welding defects, including porosity and hot cracks, formed due to the evaporation of low-molten elements such as Mg, which can be reduced by adding filler metal to compensate for the vaporized Mg content. The optimal tensile strength is related to the laser beam welding using filler metal at the speed of 40 mm/s. Work-hardening behavior leading to fatigue life improvement is associated with the rearrangement and multiplication of dislocations in all samples. The related mechanisms responsible for the microstructural evolution during the cyclic deformation process were described by transmission electron microscopy observation. The fracture surface analyzed by scanning electron microscopy indicated that delamination contributing to local necking is the leading cause of fracture in accumulative roll-bonded 6061 aluminum alloy. However, the fracture morphology of laser-welded samples displays a heterogeneous distribution of equiaxed dimples along with negligible serpentine sliding, indicating a ductile fracture mode.
{"title":"The effect of laser welding parameters on mechanical properties and microstructure evolution of multi-layered 6061 aluminum alloy","authors":"Shoeib Karami , Mohammad Yousefieh , Homam Naffakh-Moosavy","doi":"10.1016/j.jajp.2024.100275","DOIUrl":"10.1016/j.jajp.2024.100275","url":null,"abstract":"<div><div>In this study, the key findings of evaluating laser beam welding parameters on the multi-layered structure of 6061 aluminum alloys fabricating by accumulative roll bonding process are reported, considering fostering mechanical properties concerning the influence of filler metal and welding speed on the weld bead quality by taking into account reducing welding defects. Welding defects, including porosity and hot cracks, formed due to the evaporation of low-molten elements such as Mg, which can be reduced by adding filler metal to compensate for the vaporized Mg content. The optimal tensile strength is related to the laser beam welding using filler metal at the speed of 40 mm/s. Work-hardening behavior leading to fatigue life improvement is associated with the rearrangement and multiplication of dislocations in all samples. The related mechanisms responsible for the microstructural evolution during the cyclic deformation process were described by transmission electron microscopy observation. The fracture surface analyzed by scanning electron microscopy indicated that delamination contributing to local necking is the leading cause of fracture in accumulative roll-bonded 6061 aluminum alloy. However, the fracture morphology of laser-welded samples displays a heterogeneous distribution of equiaxed dimples along with negligible serpentine sliding, indicating a ductile fracture mode.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100275"},"PeriodicalIF":3.8,"publicationDate":"2024-12-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133038","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Hollow aluminum panels are designed to be both rigid and lightweight, making them ideal for structural applications where material efficiency is critical. However, reliable welding techniques are essential to join these panels effectively. A common challenge during welding is the formation of porosity defects, caused by the varying solubility of hydrogen gas as aluminum transitions between liquid and solid states. While solid-state welding methods like Friction Stir Welding (FSW) are effective in minimizing porosity, they present difficulties when applied to thick materials such as extrusion panels. Thick structures often require multiple welding passes, resulting in increased production time and higher costs. To address these challenges, this study investigates the potential of an innovative one-step double-acting FSW technique. This novel method uses two tools operating simultaneously, providing dual sources of frictional heat and compressive force, a concept unexplored in traditional FSW methods. The research focuses on the influence of shoulder diameter—a critical parameter—on the physical and mechanical properties of AA6061 hollow aluminum panels. Experiments were conducted using shoulder diameters of 20, 22, and 24 mm, with process parameters set at a transverse speed of 30 mm/min, a rotational speed of 1500 rpm, and a tilt angle of 2°. The findings demonstrate that increasing the shoulder diameter significantly enhances the mechanical performance of the welded joints. The specimen welded with a 24 mm shoulder diameter achieved the best results, with a hardness value of 71.73 HVN, a load capacity of 15.51 kN, and a bending strength of 4.7 MPa. These results underline the effectiveness of the one-step double-acting FSW technique in improving the quality and efficiency of welding hollow aluminum panels, offering a practical solution to the limitations of conventional FSW in thick-structured materials.
{"title":"Effect of tool diameter on the joint properties of AA6061 hollow panels using a novel one-step double-acting Friction Stir Weld method","authors":"Nurul Muhayat, Rani Dwi Larasati, Ericha D.W.S. Putri, Eko Prasetya Budiana, Triyono","doi":"10.1016/j.jajp.2024.100277","DOIUrl":"10.1016/j.jajp.2024.100277","url":null,"abstract":"<div><div>Hollow aluminum panels are designed to be both rigid and lightweight, making them ideal for structural applications where material efficiency is critical. However, reliable welding techniques are essential to join these panels effectively. A common challenge during welding is the formation of porosity defects, caused by the varying solubility of hydrogen gas as aluminum transitions between liquid and solid states. While solid-state welding methods like Friction Stir Welding (FSW) are effective in minimizing porosity, they present difficulties when applied to thick materials such as extrusion panels. Thick structures often require multiple welding passes, resulting in increased production time and higher costs. To address these challenges, this study investigates the potential of an innovative one-step double-acting FSW technique. This novel method uses two tools operating simultaneously, providing dual sources of frictional heat and compressive force, a concept unexplored in traditional FSW methods. The research focuses on the influence of shoulder diameter—a critical parameter—on the physical and mechanical properties of AA6061 hollow aluminum panels. Experiments were conducted using shoulder diameters of 20, 22, and 24 mm, with process parameters set at a transverse speed of 30 mm/min, a rotational speed of 1500 rpm, and a tilt angle of 2°. The findings demonstrate that increasing the shoulder diameter significantly enhances the mechanical performance of the welded joints. The specimen welded with a 24 mm shoulder diameter achieved the best results, with a hardness value of 71.73 HVN, a load capacity of 15.51 kN, and a bending strength of 4.7 MPa. These results underline the effectiveness of the one-step double-acting FSW technique in improving the quality and efficiency of welding hollow aluminum panels, offering a practical solution to the limitations of conventional FSW in thick-structured materials.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100277"},"PeriodicalIF":3.8,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133026","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-12-18DOI: 10.1016/j.jajp.2024.100274
Petr Slepička , Klaudia Hurtuková , Silvie Rimpelová , Šárka Trhoňová , Jiří Martan , Michal Procházka , Václav Švorčík , Nikola Slepičková Kasálková
In this study, we investigated the effects of carbon layer deposition on titanium (Ti) and titanium alloy (TiAlV) substrates using "flash" vaporization and pulsed laser deposition (PLD) techniques. Raman spectroscopy revealed that the PLD method produced a higher sp3 carbon bond content than the evaporation method (61 vs. 47 %). Atomic force microscopy and surface wettability analyzes showed differences in surface roughness and contact angle, with PLD-deposited samples exhibiting enhanced hydrophilicity and wrinkled morphology. Subsequent laser annealing optimized surface properties by increasing hydrophobicity, which is critical for cell adhesion. Surface chemistry analysis via scanning electron microscopy and energy dispersive spectroscopy demonstrated significant carbon enrichment in the PLD-deposited samples, mainly for TiAlV substrate. Cytocompatibility tests using human osteosarcoma cells (U-2 OS) revealed varying cell adhesion and proliferation based on surface modification, with PLD-deposited layers promoting better cell interaction. Both carbon deposition techniques enhanced antibacterial effect. This suggests the potential of PLD-deposited carbon layers for biomedical applications, particularly in enhancing implant surfaces for improved cell growth and adhesion, and reduce bacteria, the nanostructured substrates may serve also for subsequent replication process into polymer.
{"title":"Ti and TiAlV foils enhanced with PLD and flash-deposited carbon: On cytocompatibility and antibacterial activity","authors":"Petr Slepička , Klaudia Hurtuková , Silvie Rimpelová , Šárka Trhoňová , Jiří Martan , Michal Procházka , Václav Švorčík , Nikola Slepičková Kasálková","doi":"10.1016/j.jajp.2024.100274","DOIUrl":"10.1016/j.jajp.2024.100274","url":null,"abstract":"<div><div>In this study, we investigated the effects of carbon layer deposition on titanium (Ti) and titanium alloy (TiAlV) substrates using \"flash\" vaporization and pulsed laser deposition (PLD) techniques. Raman spectroscopy revealed that the PLD method produced a higher sp3 carbon bond content than the evaporation method (61 vs<em>.</em> 47 %). Atomic force microscopy and surface wettability analyzes showed differences in surface roughness and contact angle, with PLD-deposited samples exhibiting enhanced hydrophilicity and wrinkled morphology. Subsequent laser annealing optimized surface properties by increasing hydrophobicity, which is critical for cell adhesion. Surface chemistry analysis via scanning electron microscopy and energy dispersive spectroscopy demonstrated significant carbon enrichment in the PLD-deposited samples, mainly for TiAlV substrate. Cytocompatibility tests using human osteosarcoma cells (U-2 OS) revealed varying cell adhesion and proliferation based on surface modification, with PLD-deposited layers promoting better cell interaction. Both carbon deposition techniques enhanced antibacterial effect. This suggests the potential of PLD-deposited carbon layers for biomedical applications, particularly in enhancing implant surfaces for improved cell growth and adhesion, and reduce bacteria, the nanostructured substrates may serve also for subsequent replication process into polymer.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100274"},"PeriodicalIF":3.8,"publicationDate":"2024-12-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133082","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-12-18DOI: 10.1016/j.jajp.2024.100276
Angshuman Kapil , Anupam Vivek , Glenn Daehn
This study investigates the influence of Zinc (Zn) coating on the mechanical properties of impact spot welded joints between Aluminum (Al) 6111 alloy and galvanized high-strength low-alloy (HSLA) 340 steel using vaporizing foil actuator welding (VFAW). The Zn coating significantly impacts the weld interface, leading to a heterogeneous structure with regions of retained Zn and trapped jetted material. These regions inhibit direct contact between Al and steel, preventing effective metallurgical bonding and reducing joint strength by 60 % compared to uncoated steel. While the Zn coating impedes bond formation in some areas, near-complete Zn removal in other zones promotes localized ductile tearing and partial bonding, slightly mitigating the overall negative effect. Additionally, a brazing effect outside the weld zone, resulting from the jetting and solidification of Zn and Al-Zn, provides some strength to the joint. The findings highlight the complex role of Zn coating in VFAW, demonstrating that a continuous Zn layer at the weld interface is more detrimental to joint performance than discrete and thin intermetallic compounds.
{"title":"Role of zinc coating on joint properties in impact spot welded Al 6111 aluminum alloy to galvanized high-strength low-alloy steel","authors":"Angshuman Kapil , Anupam Vivek , Glenn Daehn","doi":"10.1016/j.jajp.2024.100276","DOIUrl":"10.1016/j.jajp.2024.100276","url":null,"abstract":"<div><div>This study investigates the influence of Zinc (Zn) coating on the mechanical properties of impact spot welded joints between Aluminum (Al) 6111 alloy and galvanized high-strength low-alloy (HSLA) 340 steel using vaporizing foil actuator welding (VFAW). The Zn coating significantly impacts the weld interface, leading to a heterogeneous structure with regions of retained Zn and trapped jetted material. These regions inhibit direct contact between Al and steel, preventing effective metallurgical bonding and reducing joint strength by 60 % compared to uncoated steel. While the Zn coating impedes bond formation in some areas, near-complete Zn removal in other zones promotes localized ductile tearing and partial bonding, slightly mitigating the overall negative effect. Additionally, a brazing effect outside the weld zone, resulting from the jetting and solidification of Zn and Al-Zn, provides some strength to the joint. The findings highlight the complex role of Zn coating in VFAW, demonstrating that a continuous Zn layer at the weld interface is more detrimental to joint performance than discrete and thin intermetallic compounds.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100276"},"PeriodicalIF":3.8,"publicationDate":"2024-12-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133084","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Degradation is a common phenomenon in gas turbine components. Among additive manufacturing (AM) methods like direct laser deposition (DLD) and laser powder bed fusion (LPBF), DLD has been widely studied due to its ease in repair processes. However, LPBF offers higher dimensional accuracy, better surface quality, and reduced stress. This study employed LPBF of IN625 on an IN738 substrate for repair purposes. A wide range of process parameters (power at 100, 150, and 200 W and scan speeds between 100 mm/s to 2700 mm/s) was evaluated. The reasons behind process parameters' influence on defect formation, such as pores and cracks, were investigated, as these aspects have been less emphasized in prior studies. The relationship between process parameters, melt pool shape, pore formation, and changes in elemental concentration was explored. It was found that concentration peaks at the interface are the main factor in crack formation, enabling predictions of cracking behavior. Elements diffuse from rich to poor regions at the IN625/IN738 interface. At scan speeds ≤ 500 mm/s, increasing speed and power both increase elemental concentration at the interface, but speed promotes elemental accumulation behind the interface, while power enhances homogenization. The effect of process parameters on microhardness and cell size was also examined. It was determined that cracks do not form in softer nickel-based matrices where microhardness remains below the critical threshold of 256 HV.
{"title":"A new approach to the reasons for dependency of defects formation to the process parameters in laser powder bed fusion of IN625 on the IN738LC substrate","authors":"Amirhossein Riazi , Seyed Hossein Razavi , Alireza Khavandi , Mostafa Amirjan , Mohsen Ostad Shabani , Hossein Davarzani","doi":"10.1016/j.jajp.2024.100273","DOIUrl":"10.1016/j.jajp.2024.100273","url":null,"abstract":"<div><div>Degradation is a common phenomenon in gas turbine components. Among additive manufacturing (AM) methods like direct laser deposition (DLD) and laser powder bed fusion (LPBF), DLD has been widely studied due to its ease in repair processes. However, LPBF offers higher dimensional accuracy, better surface quality, and reduced stress. This study employed LPBF of IN625 on an IN738 substrate for repair purposes. A wide range of process parameters (power at 100, 150, and 200 W and scan speeds between 100 mm/s to 2700 mm/s) was evaluated. The reasons behind process parameters' influence on defect formation, such as pores and cracks, were investigated, as these aspects have been less emphasized in prior studies. The relationship between process parameters, melt pool shape, pore formation, and changes in elemental concentration was explored. It was found that concentration peaks at the interface are the main factor in crack formation, enabling predictions of cracking behavior. Elements diffuse from rich to poor regions at the IN625/IN738 interface. At scan speeds ≤ 500 mm/s, increasing speed and power both increase elemental concentration at the interface, but speed promotes elemental accumulation behind the interface, while power enhances homogenization. The effect of process parameters on microhardness and cell size was also examined. It was determined that cracks do not form in softer nickel-based matrices where microhardness remains below the critical threshold of 256 HV.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100273"},"PeriodicalIF":3.8,"publicationDate":"2024-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133037","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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