Effect of tool speeds during friction stir lap welding on mode of fracture and fracture strength of Al 6060-T5 joints

Friction stir lap welding (FSLW) of an age hardened Al alloy and evaluations of how FS speeds affected hooking and how hooking and softening due to FS affected fracture strength of the lap welds have been conducted. It was found that increasing rotation speed and reducing welding speed (v) increased the stir zone size (AB-SZ) and also hook size (h), although a maximum value of h (hMax) reached. The features of hooks for the observed - AB-SZ-h relationships are presented and explained. It was found that when h increased to a value of ~ 0.9 mm (for the 3 mm alloy sheets), it started to invoke a significant effect on reducing fracture strength. Factors such as FS softening and insufficient joining, limited the fracture strength of the lap welds for small h values and these are presented and discussed.

Fracture strengths of Mg alloy AZ31B-H24 friction stir lap welds

The effects of selected friction stir lap welding parameters on fracture strength of Mg alloy AZ31B-H24 welds have been studied. Rotation speed has been found to affect significantly the flow related hook size formation. Furthermore, fracture strength decreased almost linearly with hook size. A small amount of softening was detected in fracture location that was outside the nugget zone and thus this softening may only adversely affect the fracture strength slightly. Finally, simulation results are presented to show the uneven stress distribution in a lap geometry which together with the relative brittleness of the stir material must be the cause to have significantly reduced the fracture strength.

A new sliding mode-based learning control scheme

 A new sliding mode-based learning control scheme for a class of SISO dynamic systems is developed in this paper. It is seen that, based on the most recent information on the closed-loop stability, a recursive learning chattering-free sliding mode controller can be designed to drive the closed-loop dynamics to reach the sliding mode surface in a finite time, on which the desired closed-loop dynamics with the zero-error convergence can be achieved.

Mechanical properties of Al and Mg alloy welds made by friction stir lap welding

The unfavourable effect of hooking or softening, respectively, on fracture strength of joints made using friction stir lap welding (FSLW) is known but the combined effect on the magnitude of strength reduction is not clear. In this study, FSLW experiments using AA6060-T5 and AZ31B-H24 alloys were conducted. For both alloys, rotation speed has a dominant effect on increasing the hook size due to increasing the stir flow volume thus lifting more the original lapping surfaces. In AA6060 welds, FS softening has limited the strength, when hook size approaches zero. Meanwhile hook starts to reduce the strength significantly, when its size reaches a critical value. The maximum strength of AA6060 FSL welds reaches ~ 70% of the base metal UTS when hook size approaches zero. This is in contract to ~30% for AZ31B FSL welds. This can be explained by the local plastic deformation behaviour during lap tensile testing.

A new design of sliding mode control systems

A new sliding mode control technique for a class of SISO dynamic systems is presented in this chapter. It is seen that the stability status of the closed-loop system is first checked, based on the approximation of the most recent information of the first-order derivative of the Lyapunov function of the closed-loop system, an intelligent sliding mode controller can then be designed with the following intelligent features: (i) If the closed-loop system is stable, the correction term in the controller will continuously adjust control signal to drive the closed-loop trajectory to reach the sliding mode surface in a finite time and the desired closed-loop dynamics with the zero-error convergence can then be achieved on the sliding mode surface. (ii) If, however, the closed-loop system is unstable, the correction term is capable of modifying the control signal to continuously reduce the value of the derivative of the Lyapunov function from the positive to the negative and then drives the closed-loop trajectory to reach the sliding mode surface and ensures that the desired closed-loop dynamics can be obtained on the sliding mode surface. The main advantages of this new sliding mode control technique over the conventional one are that no chattering occurs in the sliding mode control system because of the recursive learning control structure; the system uncertainties are embedded in the Lipschitz-like condition and thus, no priori information on the upper and/or the lower bounds of the unknown system parameters and uncertain system dynamics is required for the controller design; the zero-error convergence can be achieved after the closed-loop dynamics reaches the sliding mode surface and remains on it. The performance for controlling a third-order linear system is evaluated in the simulation section to show the effectiveness and efficiency of the new sliding mode control technique.

Tribological behaviour of pure Ti with a nanocrystalline surface layer under different loads

Surface mechanical attrition treatment (SMAT), a novel surface severe plastic deformation method, was carried out for titanium (Ti) to create a gradient-structured Ti (SMAT Ti). The tribological behaviour was studied under different loads and dry sliding conditions. The results showed that the deformation layer of SMAT Ti was about 160 μm. The friction and wear results showed that the wear resistance of SMAT Ti was enhanced compared to the coarse-grained (CG) counterpart. SMAT Ti showed abrasive wear under 1 and 5 N, and exhibited abrasive and adhesive wear under 2 N. While CG Ti showed abrasive and adhesive wear under 1-2 N, and exhibited abrasive wear under 5 N for the work hardening effects.

Effects of multiple laser shock processing (LSP) impacts on mechanical properties and wear behaviors of AISI 8620 steel

The aim of this paper was to address the effects of multiple laser shock processing (LSP) impacts with different pulse energy on mechanical properties and wear behaviors of AISI 8620 steel. Wear analyses were conducted by means of calculation of volume loss and scanning electron microscope (SEM) of the wear surface. Surface profiles, roughness and micro-hardness were measured. The micro-structures in the surface layer of the untreated and LSPed samples (treated by multiple LSP impacts) were investigated by using transmission electron microscopy (TEM) observations. Experimental results and analyses indicated that multiple LSP impacts can remarkably improve the wear resistance of AISI 8620 steel, and the wear mechanism of multiple LSP impacts on AISI 8620 steel was also entirely revealed. The wear process of the unpolished sample subjected to multiple LSP impacts can be described as follows: the wear rate was big at the beginning of sliding dry wear, but then decreased after the micro-indention in the sample surface was polished to the disappear. This phenomenon can be attributed to the fact that multiple LSP impacts generate many micro-indents in the sample surface.

The boundary lubrication of chemically grafted and cross-linked hyaluronic acid in phosphate buffered saline and lipid solutions measured by the surface forces apparatus

High molecular weight hyaluronic acid (HA) is present in articular joints and synovial fluid at high concentrations; yet despite numerous studies, the role of HA in joint lubrication is still not clear. Free HA in solution does not appear to be a good lubricant, being negatively charged and therefore repelled from most biological, including cartilage, surfaces. Recent enzymatic experiments suggested that mechanically or physically (rather than chemically) trapped HA could function as an “adaptive” or “emergency” boundary lubricant to eliminate wear damage in shearing cartilage surfaces. In this work, HA was chemically grafted to a layer of self-assembled amino-propyl-triethoxy-silane (APTES) on mica and then cross-linked. The boundary lubrication behavior of APTES and of chemically grafted and cross-linked HA in both electrolyte and lipid 1,2-dioleoyl-sn-glycero-3-phosphocholine (DOPC) solutions was tested with a surface forces apparatus (SFA). Despite the high coefficient of friction (COF) of μ ≈ 0.50, the chemically grafted HA gel significantly improved the lubrication behavior of HA, particularly the wear resistance, in comparison to free HA. Adding more DOPC lipid to the solution did not improve the lubrication of the chemically grafted and cross-linked HA layer. Damage of the underlying mica surface became visible at higher loads (pressure >2 MPa) after prolonged sliding times. It has generally been assumed that damage caused by or during sliding, also known as “abrasive friction”, which is the main biomedical/clinical/morphological manifestation of arthritis, is due to a high friction force and, therefore, a large COF, and that to prevent surface damage or wear (abrasion) one should therefore aim to reduce the COF, which has been the traditional focus of basic research in biolubrication, particularly in cartilage and joint lubrication. Here we combine our results with previous ones on grafted and cross-linked HA on lipid bilayers, and lubricin-mediated lubrication, and conclude that for cartilage surfaces, a high COF can be associated with good wear protection, while a low COF can have poor wear resistance. Both of these properties depend on how the lubricating molecules are attached to and organized at the surfaces, as well as the structure and mechanical, viscoelastic, elastic, and physical properties of the surfaces, but the two phenomena are not directly or simply related. We also conclude that to provide both the low COF and good wear protection of joints under physiological conditions, some or all of the four major components of joints—HA, lubricin, lipids, and the cartilage fibrils—must act synergistically in ways (physisorbed, chemisorbed, grafted and/or cross-linked) that are still to be determined.

Adaptive mechanically controlled lubrication mechanism found in articular joints

Articular cartilage is a highly efficacious water-based tribological system that is optimized to provide low friction and wear protection at both low and high loads (pressures) and sliding velocities that must last over a lifetime. Although many different lubrication mechanisms have been proposed, it is becoming increasingly apparent that the tribological performance of cartilage cannot be attributed to a single mechanism acting alone but on the synergistic action of multiple "modes" of lubrication that are adapted to provide optimum lubrication as the normal loads, shear stresses, and rates change. Hyaluronic acid (HA) is abundant in cartilage and synovial fluid and widely thought to play a principal role in joint lubrication although this role remains unclear. HA is also known to complex readily with the glycoprotein lubricin (LUB) to form a cross-linked network that has also been shown to be critical to the wear prevention mechanism of joints. Friction experiments on porcine cartilage using the surface forces apparatus, and enzymatic digestion, reveal an "adaptive" role for an HA-LUB complex whereby, under compression, nominally free HA diffusing out of the cartilage becomes mechanically, i.e., physically, trapped at the interface by the increasingly constricted collagen pore network. The mechanically trapped HA-LUB complex now acts as an effective (chemically bound) "boundary lubricant"-reducing the friction force slightly but, more importantly, eliminating wear damage to the rubbing/shearing surfaces. This paper focuses on the contribution of HA in cartilage lubrication; however, the system as a whole requires both HA and LUB to function optimally under all conditions.

Adaptive fast finite-time multiple-surface sliding control for a class of uncertain non-linear systems

This paper concerns the adaptive fast finite-time multiple-surface sliding control (AFFTMSSC) problem for a class of high-order uncertain non-linear systems of which the upper bounds of the system uncertainties are unknown. By using the fast control Lyapunov function and the method of so-called adding a power integrator merging with adaptive technique, a recursive design procedure is provided, which guarantees the fast finite-time stability of the closed-loop system. Further, it is proved that the control input is bounded.

Sliding mode-like learning control for SISO complex systems with T-S fuzzy models

In this paper, a sliding mode-like learning control scheme is developed for a class of single input single output (SISO) complex systems. First, the Takagi-Sugeno (T-S) fuzzy modelling technique is employed to model the uncertain complex dynamical systems. Second, a sliding mode-like learning control is designed to drive the sliding variable to converge to the sliding surface, and the system states can then asymptotically converge to zero on the sliding surface. The advantages of this scheme are that: 1) the information about the uncertain system dynamics and the system model structure is not required for the design of the learning controller; 2) the closed-loop system behaves with a strong robustness with respect to uncertainties; 3) the control input is chattering-free. The sufficient conditions for the sliding mode-like learning control to stabilise the global fuzzy model are discussed in detail. A simulation example for the control of an inverted pendulum cart is presented to demonstrate the effectiveness of the proposed control scheme.

DSP-based sliding-mode control for electromagnetic-levitation precise position system

This paper investigates the robust tracking control problem for a bipolar electromagnetic-levitation precise-position system. The dynamic model of the precise-position device is derived by conducting a thorough analysis on the nonlinear electromagnetic forces. Conventional sliding-mode control and terminal sliding-mode control strategies are developed to guarantee asymptotic and finite-time tracking capabilities of the closed-loop system. A lumped uncertainty estimator is proposed to estimate the system uncertainties. The estimated information is then used to construct a smooth uniformly ultimately bounded sliding-mode control. An exact estimator is also proposed to exactly estimate the unknown uncertainties in finite time. The output of the exact estimator is used to design a continuous chattering free terminal sliding-mode control. The time taken for the closed-loop system to reach zero tracking error is proven to be finite. Experiment results are presented, using a real time digital-signal-processor (DSP) based electromagnetic-levitation system to validate the analysis.