Pub Date : 2024-06-20DOI: 10.1016/j.jajp.2024.100236
Hyo-Nam Choi , Jeong-Won Choi , Heon Kang , Hidetoshi Fujii , Seung-Joon Lee
This study aims to elucidate the effect of stacking fault energy (SFE) on the microstructural evolution and related hardening mechanisms of Fe−18Mn−0.6C−(0 and 1.5)Al and Fe−30Mn−3Al−3Si (wt.%) twinning−induced plasticity (TWIP) steels during friction stir welding (FSW) using a high−resolution electron backscattered diffractometer. With increasing SFE, the intensities of the Goss, CuT, and Brass components increased via active dynamic recrystallization (DRX) accompanied by twinning. The 30Mn weld, which had the highest SFE, exhibited the highest recrystallization fraction (94.8 %) and an increasing rate of hardness (40.9 %). This is because a higher SFE can enhance dislocation mobility, leading to an active rate of continuous DRX as well as discontinuous DRX. Consequently, the refinement of the recrystallized grains effectively assisted the hardening of the 30Mn weld after FSW. Hence, we concluded that SFE should be considered to improve the properties of TWIP steels after FSW.
{"title":"Effect of stacking-fault energy on dynamic recrystallization, textural evolution, and strengthening mechanism of Fe−Mn based twinning-induced plasticity (TWIP) steels during friction-stir welding","authors":"Hyo-Nam Choi , Jeong-Won Choi , Heon Kang , Hidetoshi Fujii , Seung-Joon Lee","doi":"10.1016/j.jajp.2024.100236","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100236","url":null,"abstract":"<div><p>This study aims to elucidate the effect of stacking fault energy (SFE) on the microstructural evolution and related hardening mechanisms of Fe−18Mn−0.6C−(0 and 1.5)Al and Fe−30Mn−3Al−3Si (wt.%) twinning−induced plasticity (TWIP) steels during friction stir welding (FSW) using a high−resolution electron backscattered diffractometer. With increasing SFE, the intensities of the Goss, CuT, and Brass components increased via active dynamic recrystallization (DRX) accompanied by twinning. The 30Mn weld, which had the highest SFE, exhibited the highest recrystallization fraction (94.8 %) and an increasing rate of hardness (40.9 %). This is because a higher SFE can enhance dislocation mobility, leading to an active rate of continuous DRX as well as discontinuous DRX. Consequently, the refinement of the recrystallized grains effectively assisted the hardening of the 30Mn weld after FSW. Hence, we concluded that SFE should be considered to improve the properties of TWIP steels after FSW.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100236"},"PeriodicalIF":3.8,"publicationDate":"2024-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000529/pdfft?md5=e6671d015e66fa13f220e57320998bdb&pid=1-s2.0-S2666330924000529-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141543691","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 : 2024-06-19DOI: 10.1016/j.jajp.2024.100234
Dario Croccolo , Massimiliano De Agostinis , Stefano Fini , Mattia Mele , Sayed Nassar , Giorgio Olmi , Chiara Scapecchi , Muhammad Yasir Khan , Muhammad Hassaan Bin Tariq
Lubrication is essential to ensure the proper performance of threaded joints subjected to multiple tightenings. Previous research has investigated the effectiveness of various mineral and synthetic lubricants, but no studies have been conducted on those derived from renewable sources. In this study, the performances of sesame, sunflower, coconut, and castor oil are compared to traditional VG46 oil and MoS grease. First, the rheological properties of the oils have been characterized. Then, tightening tests have been carried out to measure the coefficients of friction at the underhead and thread. The results demonstrate that vegetable oils outperform mineral VG46, especially in terms of repeatability. In particular, fractionated coconut oil exhibits exceptionally low coefficients of friction, which are not influenced by the tightening speed, unlike all other tested lubricants.
{"title":"Replacing non-renewable lubricants with vegetables oils in threaded joints","authors":"Dario Croccolo , Massimiliano De Agostinis , Stefano Fini , Mattia Mele , Sayed Nassar , Giorgio Olmi , Chiara Scapecchi , Muhammad Yasir Khan , Muhammad Hassaan Bin Tariq","doi":"10.1016/j.jajp.2024.100234","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100234","url":null,"abstract":"<div><p>Lubrication is essential to ensure the proper performance of threaded joints subjected to multiple tightenings. Previous research has investigated the effectiveness of various mineral and synthetic lubricants, but no studies have been conducted on those derived from renewable sources. In this study, the performances of sesame, sunflower, coconut, and castor oil are compared to traditional VG46 oil and MoS<span><math><msub><mrow></mrow><mn>2</mn></msub></math></span> grease. First, the rheological properties of the oils have been characterized. Then, tightening tests have been carried out to measure the coefficients of friction at the underhead and thread. The results demonstrate that vegetable oils outperform mineral VG46, especially in terms of repeatability. In particular, fractionated coconut oil exhibits exceptionally low coefficients of friction, which are not influenced by the tightening speed, unlike all other tested lubricants.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100234"},"PeriodicalIF":3.8,"publicationDate":"2024-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000505/pdfft?md5=0fe4881aa94d22efd195a455d7a99e71&pid=1-s2.0-S2666330924000505-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141479437","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 : 2024-06-14DOI: 10.1016/j.jajp.2024.100235
M. Seibold , K. Schricker , L. Schmidt , D. Diegel , H. Friedmann , P. Hellwig , F. Fröhlich , F. Nagel , P. Kallage , A. Rack , H. Requardt , Y. Chen , J.P. Bergmann
Pulsed laser beam welding is primarily used to join thin-walled components. The use of 6xxx group aluminum alloys is characterized by good mechanical properties but these alloys are prone to hot cracking during solidification, i.e., requirements regarding strength and tightness, as increasingly important for electromobility related applications, cannot be fulfilled. The solidification rate has been identified as dominant factor in pulsed conduction welding which can be adjusted by the pulse shape, i.e., by varying the beam power over time for a single pulse.
Pulse shapes with different, linear ramp-down slopes were studied to describe the interaction between beam power and resulting solidification rate for spot welds. Based on rotationally symmetric conditions of the spot welds, the solidification rate can be measured in radial and vertical directions. The welding process of EN AW 6082 alloy was examined by in situ high-speed synchrotron X-ray imaging at the European Synchrotron Radiation Facility (ESRF) for this reason. Frame rates up to 120,000 Hz and subsequent image analysis allowed in-depth analysis of the solidification processes, their dependence on different spatial directions, and the resulting effects on hot crack formation.
脉冲激光束焊接主要用于连接薄壁部件。使用 6xxx 组铝合金具有良好的机械性能,但这些合金在凝固过程中容易产生热裂纹,因此无法满足强度和密封性方面的要求,而这对于电动汽车相关应用来说越来越重要。凝固速率已被确定为脉冲传导焊接中的主导因素,可通过脉冲形状进行调节,即通过改变单个脉冲的束功率随时间的变化来调节凝固速率。根据点焊的旋转对称条件,可在径向和纵向测量凝固速率。为此,我们在欧洲同步辐射设施(ESRF)利用原位高速同步 X 射线成像技术对 EN AW 6082 合金的焊接过程进行了研究。通过高达 120,000 Hz 的帧频和后续图像分析,可以深入分析凝固过程、凝固过程对不同空间方向的依赖性以及由此对热裂纹形成的影响。
{"title":"Temporal and spatial determination of solidification rate during pulsed laser beam welding of hot-crack susceptible aluminum alloys by means of high-speed synchrotron X-ray imaging","authors":"M. Seibold , K. Schricker , L. Schmidt , D. Diegel , H. Friedmann , P. Hellwig , F. Fröhlich , F. Nagel , P. Kallage , A. Rack , H. Requardt , Y. Chen , J.P. Bergmann","doi":"10.1016/j.jajp.2024.100235","DOIUrl":"10.1016/j.jajp.2024.100235","url":null,"abstract":"<div><p>Pulsed laser beam welding is primarily used to join thin-walled components. The use of 6xxx group aluminum alloys is characterized by good mechanical properties but these alloys are prone to hot cracking during solidification, i.e., requirements regarding strength and tightness, as increasingly important for electromobility related applications, cannot be fulfilled. The solidification rate has been identified as dominant factor in pulsed conduction welding which can be adjusted by the pulse shape, i.e., by varying the beam power over time for a single pulse.</p><p>Pulse shapes with different, linear ramp-down slopes were studied to describe the interaction between beam power and resulting solidification rate for spot welds. Based on rotationally symmetric conditions of the spot welds, the solidification rate can be measured in radial and vertical directions. The welding process of EN AW 6082 alloy was examined by in situ high-speed synchrotron X-ray imaging at the European Synchrotron Radiation Facility (ESRF) for this reason. Frame rates up to 120,000 Hz and subsequent image analysis allowed in-depth analysis of the solidification processes, their dependence on different spatial directions, and the resulting effects on hot crack formation.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100235"},"PeriodicalIF":3.8,"publicationDate":"2024-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000517/pdfft?md5=671fe0d549916cdad86564cd55cbc805&pid=1-s2.0-S2666330924000517-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141401503","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}
The feasibility of welding a CuAlBe SMA by continuous drive friction welding was evaluated. The metallurgical state (annealed/quenched) before welding and frictional pressure (5 and 10 MPa) were varied and their effects on joint quality were analyzed. Static tensile tests, microhardness, thermal analysis by DSC, and optical microscopy were carried out to characterize the welded joint. The results indicated joints of excellent thermomechanical quality. The welding zones are well-defined, narrow, and have a very refined microstructure compared to the base metal. The phase transition temperatures along the welded assemblies were not changed when welding was performed on the quenched samples, except in the welding zone of the sample welded with 10 MPa. Maximum tensile strength was obtained by using maximum friction pressure during welding of the annealed alloy (quenching after welding). To fill the gap in bibliographical research in this field of study, this work innovatively presents the possibility of welding Cu-based SMAs by rotary friction, including the welding of quenched parts without the need for subsequent heat treatments and without compromising the shape memory effect.
评估了通过连续驱动摩擦焊焊接 CuAlBe SMA 的可行性。改变了焊接前的冶金状态(退火/淬火)和摩擦压力(5 和 10 兆帕),并分析了它们对接头质量的影响。对焊接接头进行了静态拉伸试验、显微硬度、DSC 热分析和光学显微镜检查。结果表明,焊点具有优异的热机械质量。与母材相比,焊接区轮廓分明、狭窄,并且具有非常精细的微观结构。在淬火试样上进行焊接时,除 10 兆帕焊接试样的焊接区外,焊接组件沿线的相变温度没有变化。在退火合金焊接过程中使用最大摩擦压力(焊后淬火)可获得最大抗拉强度。为了填补这一研究领域的文献空白,这项工作创新性地提出了通过旋转摩擦焊接铜基 SMA 的可能性,包括焊接淬火部件,而无需进行后续热处理,也不会影响形状记忆效果。
{"title":"Rotary friction welding applied to Cu11.8Al0.45Be shape memory alloy","authors":"A.A.de Albuquerque , H. Louche , D.F.de Oliveira , I.C.A. Brito","doi":"10.1016/j.jajp.2024.100233","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100233","url":null,"abstract":"<div><p>The feasibility of welding a CuAlBe SMA by continuous drive friction welding was evaluated. The metallurgical state (annealed/quenched) before welding and frictional pressure (5 and 10 MPa) were varied and their effects on joint quality were analyzed. Static tensile tests, microhardness, thermal analysis by DSC, and optical microscopy were carried out to characterize the welded joint. The results indicated joints of excellent thermomechanical quality. The welding zones are well-defined, narrow, and have a very refined microstructure compared to the base metal. The phase transition temperatures along the welded assemblies were not changed when welding was performed on the quenched samples, except in the welding zone of the sample welded with 10 MPa. Maximum tensile strength was obtained by using maximum friction pressure during welding of the annealed alloy (quenching after welding). To fill the gap in bibliographical research in this field of study, this work innovatively presents the possibility of welding Cu-based SMAs by rotary friction, including the welding of quenched parts without the need for subsequent heat treatments and without compromising the shape memory effect.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100233"},"PeriodicalIF":4.1,"publicationDate":"2024-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000499/pdfft?md5=02c3b41a224ce56ef8cf188c0b1cc15d&pid=1-s2.0-S2666330924000499-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141333146","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}
In this study, submerged friction stir welding (SFSW) was performed to weld 6 mm thick AZ31B Mg alloy plates, aiming to explore the impact of rotation speed on microstructure and tensile behavior. The water medium was used to submerge the samples. The SFSW was conducted at three different speeds (815, 960, and 1200 rpm), to assess the impact of rotation speed on SFSWed joint performance. As the rotation speed increased from 815 to 960 rpm, tensile strength increased plateauing over a range of the rotation speed. However, a significant drop in tensile strength occurred at 1200 rpm due to the formation of void defects. The SZ exhibits a size and width increment in the lower part with increasing rotation speed. The hardness of the stir zone (SZ) gradually rose with increasing rotation speed from 815 to 960 rpm. Fracture locations were observed in the thermal-mechanically affected zone (TMAZ) adjacent to the SZ at a rotation speed of 815 rpm, and in the heat-affected zone (HAZ) adjacent to the TMAZ at a rotation speed of 960 rpm. The joint welded at 1200 rpm fractured within the SZ. This study offers valuable insights into the welding and joining field, particularly regarding their mechanical characteristics.
{"title":"Investigation on submerged friction stir welding of AZ31B magnesium alloy under the influence of rotation speed","authors":"Kishan Fuse , Kiran Wakchaure , Vishvesh Badheka , Vivek Patel","doi":"10.1016/j.jajp.2024.100232","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100232","url":null,"abstract":"<div><p>In this study, submerged friction stir welding (SFSW) was performed to weld 6 mm thick AZ31B Mg alloy plates, aiming to explore the impact of rotation speed on microstructure and tensile behavior. The water medium was used to submerge the samples. The SFSW was conducted at three different speeds (815, 960, and 1200 rpm), to assess the impact of rotation speed on SFSWed joint performance. As the rotation speed increased from 815 to 960 rpm, tensile strength increased plateauing over a range of the rotation speed. However, a significant drop in tensile strength occurred at 1200 rpm due to the formation of void defects. The SZ exhibits a size and width increment in the lower part with increasing rotation speed. The hardness of the stir zone (SZ) gradually rose with increasing rotation speed from 815 to 960 rpm. Fracture locations were observed in the thermal-mechanically affected zone (TMAZ) adjacent to the SZ at a rotation speed of 815 rpm, and in the heat-affected zone (HAZ) adjacent to the TMAZ at a rotation speed of 960 rpm. The joint welded at 1200 rpm fractured within the SZ. This study offers valuable insights into the welding and joining field, particularly regarding their mechanical characteristics.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100232"},"PeriodicalIF":4.1,"publicationDate":"2024-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000487/pdfft?md5=727bc0e32442b8924646b246cfe9ce1a&pid=1-s2.0-S2666330924000487-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141326224","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 : 2024-06-07DOI: 10.1016/j.jajp.2024.100231
Seungbeom Jang , Wonjoo Lee , Yuhyeong Jeong , Yunfeng Wang , Chanhee Won , Jangwook Lee , Jonghun Yoon
Automatic welding equipment has replaced human welders in the nuclear industry for safety issues and uniform and high welding quality. However, automatic welding equipment cannot predict porosity defects. So, the weldment must be inspected by non-destructive testing. This inspection was a costly and time-consuming process, and it applies to each weldment even if it welded same material. To improve the welding efficiency, a weld porosity detection system of the same weld material with different material thicknesses was needed. This paper proposed a machine-learned porosity detection system for 3.0 mm plates with welding arc sound data from the pulsed gas tungsten arc welding (P-GTAW) process of 1.6 mm plates. Ensemble-Empirical Mode Decomposition (EEMD) was used to divide the arc sound signal according to the pulse period of P-GTAW. Fast Fourier transform (FFT) was used to convert the arc sound into frequencies for features extraction according to porosity. The validity of these weld frequency features was confirmed through k-fold cross-validation across various machine learning techniques, with evaluation of F-1 scores against experimental weld sounds.
{"title":"Machine learning-based weld porosity detection using frequency analysis of arc sound in the pulsed gas tungsten arc welding process","authors":"Seungbeom Jang , Wonjoo Lee , Yuhyeong Jeong , Yunfeng Wang , Chanhee Won , Jangwook Lee , Jonghun Yoon","doi":"10.1016/j.jajp.2024.100231","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100231","url":null,"abstract":"<div><p>Automatic welding equipment has replaced human welders in the nuclear industry for safety issues and uniform and high welding quality. However, automatic welding equipment cannot predict porosity defects. So, the weldment must be inspected by non-destructive testing. This inspection was a costly and time-consuming process, and it applies to each weldment even if it welded same material. To improve the welding efficiency, a weld porosity detection system of the same weld material with different material thicknesses was needed. This paper proposed a machine-learned porosity detection system for 3.0 mm plates with welding arc sound data from the pulsed gas tungsten arc welding (P-GTAW) process of 1.6 mm plates. Ensemble-Empirical Mode Decomposition (EEMD) was used to divide the arc sound signal according to the pulse period of P-GTAW. Fast Fourier transform (FFT) was used to convert the arc sound into frequencies for features extraction according to porosity. The validity of these weld frequency features was confirmed through k-fold cross-validation across various machine learning techniques, with evaluation of F-1 scores against experimental weld sounds.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100231"},"PeriodicalIF":4.1,"publicationDate":"2024-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000475/pdfft?md5=aa20a67e4b54d518290f96b1d5b30986&pid=1-s2.0-S2666330924000475-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141326223","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}
Shaft-shaped parts work normally in wear-resistant conditions. Over time, the shaft might experience wear and fail to maintain the required size, affecting its workability and efficacy. This study examines the hardfacing layer quality of a restored steel shaft obtained through resistance welding. The researchers of this study designed nine welding conditions according to Taguchi's experimental matrix and applied each to experimentally weld steel shaft samples. A recovery welding machine system, which includes a resistance seam welding machine combined with a designed fixture, was used to weld the samples. The experimental results revealed that the welding layers’ surface is flat and has no surface defects. Meanwhile, the hardfacing layer and the retorted shaft surface have good cohesion, as observed through macrostructure photography. The hardness and wear resistance of the hardfacing layer were relatively high and closely resembled those of a new high-frequency quenched steel shaft. The influence level and the relationship of the welding parameters on hardness and wear resistance were also considered in this study. In addition, this study proposes the appropriate welding conditions for obtaining the highest hardness and the smallest worn metal weight. The findings presented in this study offer valuable insights for mechanical manufacturers engaged in the reconditioning process of shafts, aiding in time and cost savings.
{"title":"An experimental study on the quality of hardfacing layer through resistance seam welding","authors":"Minh-Tan Nguyen, Van-Nhat Nguyen, Van-The Than, Thi-Thao Ngo","doi":"10.1016/j.jajp.2024.100230","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100230","url":null,"abstract":"<div><p>Shaft-shaped parts work normally in wear-resistant conditions. Over time, the shaft might experience wear and fail to maintain the required size, affecting its workability and efficacy. This study examines the hardfacing layer quality of a restored steel shaft obtained through resistance welding. The researchers of this study designed nine welding conditions according to Taguchi's experimental matrix and applied each to experimentally weld steel shaft samples. A recovery welding machine system, which includes a resistance seam welding machine combined with a designed fixture, was used to weld the samples. The experimental results revealed that the welding layers’ surface is flat and has no surface defects. Meanwhile, the hardfacing layer and the retorted shaft surface have good cohesion, as observed through macrostructure photography. The hardness and wear resistance of the hardfacing layer were relatively high and closely resembled those of a new high-frequency quenched steel shaft. The influence level and the relationship of the welding parameters on hardness and wear resistance were also considered in this study. In addition, this study proposes the appropriate welding conditions for obtaining the highest hardness and the smallest worn metal weight. The findings presented in this study offer valuable insights for mechanical manufacturers engaged in the reconditioning process of shafts, aiding in time and cost savings.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"9 ","pages":"Article 100230"},"PeriodicalIF":4.1,"publicationDate":"2024-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000463/pdfft?md5=b318b4667c92487b229bacdfee58f024&pid=1-s2.0-S2666330924000463-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141243931","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 : 2024-05-22DOI: 10.1016/j.jajp.2024.100229
Jie Sheng , Fanrong Kong , Wei Tong
There are still some technical issues involved in laser welding of aluminum alloys, such as porosity, cracking, deformation, and so forth. In this study, AA6061-T6 sheets of 2.54 mm in thickness were welded by a disk laser in the bead-on-plate with two different welding parameter sets. Full penetration depths were achieved with decent surface appearances for both cases. The digital image correlation method was successfully applied in experiments to identify material model parameters of tensile welded specimens from various weldment regions. The identified parameters were utilized to numerically simulate the uniaxial tensile tests of laser-welded specimens. The effect of welded joint geometry on global tensile responses was investigated in experimentally-guided finite element modeling. With the help of X-ray computed microtomography, internal defects of the welded bead were detected and used as an input variable in the simulations. Strain development was observed through experimental and numerical data. The results showed that axial deformation was initiated at the top surface of welded metals. The considerable axial deformation occurred at the bottom surface (weld root) of the welded joint just before failure. The numerical results indicated that the geometry of welded joints greatly affected tensile responses. The results also concluded that the diameter of a single void significantly influenced tensile responses compared to its distributed location and the total volume of multiple voids with smaller sizes. Compared between the two sets of welding parameter sets used in this study, the welded joints of this particular AA6061-T6 material with the first parameter set of 2.40 kW laser power and 1.27 m/min traveling speed employed could give better tensile properties and be verified by both experimental and numerical results.
{"title":"Experimentally-guided finite element modeling on global tensile responses of AA6061-T6 aluminum alloy joints by laser welding","authors":"Jie Sheng , Fanrong Kong , Wei Tong","doi":"10.1016/j.jajp.2024.100229","DOIUrl":"https://doi.org/10.1016/j.jajp.2024.100229","url":null,"abstract":"<div><p>There are still some technical issues involved in laser welding of aluminum alloys, such as porosity, cracking, deformation, and so forth. In this study, AA6061-T6 sheets of 2.54 mm in thickness were welded by a disk laser in the bead-on-plate with two different welding parameter sets. Full penetration depths were achieved with decent surface appearances for both cases. The digital image correlation method was successfully applied in experiments to identify material model parameters of tensile welded specimens from various weldment regions. The identified parameters were utilized to numerically simulate the uniaxial tensile tests of laser-welded specimens. The effect of welded joint geometry on global tensile responses was investigated in experimentally-guided finite element modeling. With the help of X-ray computed microtomography, internal defects of the welded bead were detected and used as an input variable in the simulations. Strain development was observed through experimental and numerical data. The results showed that axial deformation was initiated at the top surface of welded metals. The considerable axial deformation occurred at the bottom surface (weld root) of the welded joint just before failure. The numerical results indicated that the geometry of welded joints greatly affected tensile responses. The results also concluded that the diameter of a single void significantly influenced tensile responses compared to its distributed location and the total volume of multiple voids with smaller sizes. Compared between the two sets of welding parameter sets used in this study, the welded joints of this particular AA6061-T6 material with the first parameter set of 2.40 kW laser power and 1.27 m/min traveling speed employed could give better tensile properties and be verified by both experimental and numerical results.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"9 ","pages":"Article 100229"},"PeriodicalIF":4.1,"publicationDate":"2024-05-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000451/pdfft?md5=1c789b10c1aa9caaa4e30af38506c673&pid=1-s2.0-S2666330924000451-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141095588","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 : 2024-05-15DOI: 10.1016/j.jajp.2024.100228
M. Rohe, M. Knester, J. Hildebrand, J.P. Bergmann
During the layer-by-layer build-up in the Direct Energy Deposition (DED) - Arc additive manufacturing (AM) process, the distance between the contact tube and the workpiece, effectively the welded layer, changes. Since the weld paths are predefined by the path planning software, a constant Contact Tube to Workpiece Distance (CTWD) and weld bead height is assumed. However, even small changes in geometry, such as crossovers of weld paths, result in higher weld beads than assumed. Similarly, an incorrectly assumed bead height as input to the path planning will result in a change in the CTWD. The sum of the deviations of the real weld geometries from the assumed ones in the path planning can greatly influence the CTWD. This implies that the dimensional accuracy may be significantly compromised. This research presents an approach for a general indirect measurement method using the welding current to obtain the CTWD during the actual welding process. A real-time process control method is implemented and validated using the mechanically controlled short arc and the pulsed arc process. Varying process parameters are used to validate the general applicability for a specific material. For the mechanically controlled short arc process, the model underestimates the measured CTWD by a mean error of 3.4 mm. The pulse process is overestimated by a mean error of 2.2 mm. The standard deviation for the pulse process with 1.3 mm is slightly smaller than for the short arc process with 1.7 mm.
{"title":"Development of an indirect measurement method for the Contact Tube to Workpiece Distance (CTDW) in the Direct Energy Deposition – Arc (DED-ARC) process for different arc types","authors":"M. Rohe, M. Knester, J. Hildebrand, J.P. Bergmann","doi":"10.1016/j.jajp.2024.100228","DOIUrl":"10.1016/j.jajp.2024.100228","url":null,"abstract":"<div><p>During the layer-by-layer build-up in the Direct Energy Deposition (DED) - Arc additive manufacturing (AM) process, the distance between the contact tube and the workpiece, effectively the welded layer, changes. Since the weld paths are predefined by the path planning software, a constant Contact Tube to Workpiece Distance (CTWD) and weld bead height is assumed. However, even small changes in geometry, such as crossovers of weld paths, result in higher weld beads than assumed. Similarly, an incorrectly assumed bead height as input to the path planning will result in a change in the CTWD. The sum of the deviations of the real weld geometries from the assumed ones in the path planning can greatly influence the CTWD. This implies that the dimensional accuracy may be significantly compromised. This research presents an approach for a general indirect measurement method using the welding current to obtain the CTWD during the actual welding process. A real-time process control method is implemented and validated using the mechanically controlled short arc and the pulsed arc process. Varying process parameters are used to validate the general applicability for a specific material. For the mechanically controlled short arc process, the model underestimates the measured CTWD by a mean error of 3.4 mm. The pulse process is overestimated by a mean error of 2.2 mm. The standard deviation for the pulse process with 1.3 mm is slightly smaller than for the short arc process with 1.7 mm.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"9 ","pages":"Article 100228"},"PeriodicalIF":4.1,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S266633092400044X/pdfft?md5=2f6040ed480623a7ee1554ff6ca1cfd7&pid=1-s2.0-S266633092400044X-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141029816","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}
Semitubular self-piercing riveting is an important and well-established mechanical joining process. A new approach, which involves the use of high strain hardening rivet materials, has the potential advantage of increasing resource efficiency in rivet production by eliminating the normally necessary post-treatment of the rivets by means of heat treatment and coating. However, as the high strain hardening of the rivet materials leads to extraordinarily high tool loads during rivet forming, process fluctuations can be particularly critical. For example, fluctuations in the dimensions of the semi-finished products used can influence the forming process itself, but also the quality of the formed rivets, which in turn can affect the subsequent joining process and the joint formation. An increased reject rate or premature tool failure caused by this is detrimental to the resource efficiency of the entire process chain. Therefore, a fundamental knowledge of the cross-process chain cause-and-effect relationships in conjunction with fluctuating billet dimensions is needed and is acquired within this research work. The investigations show that the forming and the joining process as well as the manufactured components themselves are influenced by the billet dimensions. The forming forces and tool stresses rise with increasing billet volume. Tool failure due to excessive or uneven stress can be the result. As the billet volume increases, the head diameter and the head thickness of the rivets increase. Consequently, the joining process and the joint are also indirectly influenced by the billet volume. With increasing volume, the joining force rises and, due to the increase in the head diameter, so does the joint strength. Knowledge of the detailed relationships is therefore highly relevant for the successful use of high strain hardening rivet materials.
{"title":"Cross-process chain influence of process variations in self-piercing riveting with regard to semi-finished product dimensions","authors":"Clara-Maria Kuball , Benedikt Uhe , Gerson Meschut , Marion Merklein","doi":"10.1016/j.jajp.2024.100227","DOIUrl":"10.1016/j.jajp.2024.100227","url":null,"abstract":"<div><p>Semitubular self-piercing riveting is an important and well-established mechanical joining process. A new approach, which involves the use of high strain hardening rivet materials, has the potential advantage of increasing resource efficiency in rivet production by eliminating the normally necessary post-treatment of the rivets by means of heat treatment and coating. However, as the high strain hardening of the rivet materials leads to extraordinarily high tool loads during rivet forming, process fluctuations can be particularly critical. For example, fluctuations in the dimensions of the semi-finished products used can influence the forming process itself, but also the quality of the formed rivets, which in turn can affect the subsequent joining process and the joint formation. An increased reject rate or premature tool failure caused by this is detrimental to the resource efficiency of the entire process chain. Therefore, a fundamental knowledge of the cross-process chain cause-and-effect relationships in conjunction with fluctuating billet dimensions is needed and is acquired within this research work. The investigations show that the forming and the joining process as well as the manufactured components themselves are influenced by the billet dimensions. The forming forces and tool stresses rise with increasing billet volume. Tool failure due to excessive or uneven stress can be the result. As the billet volume increases, the head diameter and the head thickness of the rivets increase. Consequently, the joining process and the joint are also indirectly influenced by the billet volume. With increasing volume, the joining force rises and, due to the increase in the head diameter, so does the joint strength. Knowledge of the detailed relationships is therefore highly relevant for the successful use of high strain hardening rivet materials.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"9 ","pages":"Article 100227"},"PeriodicalIF":4.1,"publicationDate":"2024-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000438/pdfft?md5=34f5518001a16f8bcc4be851bd15a5f3&pid=1-s2.0-S2666330924000438-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141040273","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}