The need for joining dissimilar materials is increasing rapidly in manufacturing industries.
Therefore, a successful weld of dissimilar metals by Friction Stir Welding (FSW) process
becomes a topic of interest for many investigators. FSW research topics have been used for Manufacturing Engineering students at Virginia State University as undergraduate research projects. The purpose of this study was to investigate intermetallic characteristics between aluminum and copper at the transition zone in the FSW process. The effects of process parameters on heat affected zone (HAZ) have been examined to find the optimal tool rotational speed, axial force, and transverse speed. A metallographic study was conducted to investigate the quality of intermetallic bonding at the interfaces. It was observed that using optimized process parameters for experimental setup resulted in a very good quality of the welds.
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Effect of Process Parameters on Interfacial Temperature and Shear Strength of Ultrasonic Additive Manufacturing of Carbon Steel 4130
Abstract Ultrasonic additive manufacturing (UAM) is a solid state manufacturing process capable of producing near-net-shape metal parts. Recent studies have shown the promise of UAM welding of steels. However, the effect of weld parameters on the weld quality of UAM steel is unclear. A design of experiments study based on a Taguchi L16 design array was conducted to investigate the influence of parameters including baseplate temperature, amplitude, welding speed, and normal force on the interfacial temperature and shear strength of UAM welding of carbon steel 4130. Analysis of variance (ANOVA) and main effects analyses were performed to determine the effect of each parameter. A Pearson correlation test was conducted to find the relationship between interfacial temperature and shear strength. These analyses indicate that a maximum shear strength of 392.8 MPa can be achieved by using a baseplate temperature of 400°F (204.4°C), amplitude of 31.5 μm, welding speed of 40 in/min (16.93 mm/s), and normal force of 6000 N. The Pearson correlation coefficient is calculated as 0.227, which indicates no significant correlation between interfacial temperature and shear strength over the range tested.
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- Award ID(s):
- 1738723
- NSF-PAR ID:
- 10432775
- Date Published:
- Journal Name:
- Journal of Manufacturing Science and Engineering
- Volume:
- 144
- Issue:
- 8
- ISSN:
- 1087-1357
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Purpose Ultrasonic additive manufacturing (UAM) is a solid-state joining technology used for three-dimensional printing of metal foilstock. The electrical power input to the ultrasonic welder is a key driver of part quality in UAM, but under the same process parameters, it can vary widely for different build geometries and material combinations because of mechanical compliance in the system. This study aims to model the relationship between UAM weld power and system compliance considering the workpiece (geometry and materials) and the fixture on which the build is fabricated. Design/methodology/approach Linear elastic finite element modeling and experimental modal analysis are used to characterize the system’s mechanical compliance, and linear system dynamics theory is used to understand the relationship between weld power and compliance. In-situ measurements of the weld power are presented for various build stiffnesses to compare model predictions with experiments. Findings Weld power in UAM is found to be largely determined by the mechanical compliance of the build and insensitive to foil material strength. Originality/value This is the first research paper to develop a predictive model relating UAM weld power and the mechanical compliance of the build over a range of foil combinations. This model is used to develop a tool to determine the process settings required to achieve a consistent weld power in builds with different stiffnesses.more » « less
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When subjected to the lap shear testing, spot welds created by brazing, resistance welding, or other techniques may fail either by a plug failure mode (also called pull-out mode) or an interfacial shear failure mode. In the past, plug failure mode was thought to be depend- ent on base metal ultimate tensile strength, spot diameter and plate thickness, while interfacial failure can be determined by interface shear strength and spot area. No fracture mechanics model or failure process is invoked in such an approach, and its predictive capability is often doubted compared to realistic experiments. This work conducts a parametric study to assess the failure behavior as a function of dominant three-dimensional geometric parameters based on the Gurson-Tvergaard-Needleman (GTN) damage mechanics model and no-damage mod- el respectively. Different necking conditions are considered as precursors to the two failure modes in the no-damage model. It is found out that a small ratio of spot diameter to plate thickness promotes interfacial shear failure while a large ratio favors plug failure. Other geometric parameters such as the filler interlayer thickness, if used, play a secondary role. The calculated peak force Fwt is not much different between the GTN and no-damage analyses, and better agreement is shown in the small nugget region. Normalized peak force calculated from the GTN model with the porosity f0 set to 0.01 showed the best agreement with pervious tensile shear tests on spot-welded DP980 lap joints in comparison to that calculated from the GTN model with f0 at 0.02 and the no-damage model. Note that heterogeneous distribution of materi- al strength across the joint region was considered in the GTN model, which was estimated based on the hardness map measured across the joint cross section.more » « less
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When subjected to the lap shear testing, spot welds created by brazing, resistance welding, or other techniques may fail either by a plug failure mode (also called pull-out mode) or an interfacial shear failure mode. In the past, plug failure mode was thought to be depend- ent on base metal ultimate tensile strength, spot diameter and plate thickness, while interfacial failure can be determined by interface shear strength and spot area. No fracture mechanics model or failure process is invoked in such an approach, and its predictive capability is often doubted compared to realistic experiments. This work conducts a parametric study to assess the failure behavior as a function of dominant three-dimensional geometric parameters based on the Gurson-Tvergaard-Needleman (GTN) damage mechanics model and no-damage mod- el respectively. Different necking conditions are considered as precursors to the two failure modes in the no-damage model. It is found out that a small ratio of spot diameter to plate thickness promotes interfacial shear failure while a large ratio favors plug failure. Other geometric parameters such as the filler interlayer thickness, if used, play a secondary role. The calculated peak force Fwt is not much different between the GTN and no-damage analyses, and better agreement is shown in the small nugget region. Normalized peak force calculated from the GTN model with the porosity f0 set to 0.01 showed the best agreement with pervious tensile shear tests on spot-welded DP980 lap joints in comparison to that calculated from the GTN model with f0 at 0.02 and the no-damage model. Note that heterogeneous distribution of materi- al strength across the joint region was considered in the GTN model, which was estimated based on the hardness map measured across the joint cross section.more » « less
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1115/1.4053278
