Theoretical and FE analysis of ultrasonic welding of aluminum alloy 3003

Ultrasonic welding (consolidation) process is a rapid manufacturing process that is used to join thin layers of metal at low temperature and low energy consumption. Experimental results have shown that ultrasonic welding is a combination of both surface (friction) and volume (plasticity) softening effects. In the presented work, an attempt has been made to simulate the ultrasonic welding of metals by taking into account these effects (surface and volume). A phenomenological material model has been proposed, which incorporates these two effects (i.e., surface and volume). The thermal softening due to friction and ultrasonic (acoustic) softening has been included in the proposed material model. For surface effects, a friction law with variable coefficient of friction that is dependent on contact pressure, slip, temperature, and number of cycles has been derived from experimental friction tests. The results of the thermomechanical analyses of ultrasonic welding of aluminum alloy have been presented. The goal of this work is to study the effects of ultrasonic welding process parameters, such as applied load, amplitude of ultrasonic oscillation, and velocity of welding sonotrode on the friction work at the weld interface. The change in the friction work at the weld interface has been explained on the basis of softening (thermal and acoustic) of the specimen during the ultrasonic welding process. In the end, a comparison between experimental and simulated results has been presented, showing a good agreement. Copyright © 2009 by ASME.

Parameter Optimization on Laser Welding of NiTi Wires by Taguchi Method

In this research, a preliminary study was done to find out the initial parameter window to obtain the full-penetrated NiTi weldment. A L27 Taguchi experiment was then carried out to statistically study the effects of the welding parameters and their possible interactions on the weld bead aspect ratio (or penetration over fuse-zone width ratio), and to determine the optimized parameter settings to produce the full-penetrated weldment with desirable aspect ratio. From the statistical results in the Taguchi experiment, the laser mode was found to be the most important factor that substantially affects the aspect ratio. Strong interaction between the power and focus position was found in the Taguchi experiment. The optimized weldment was mainly of columnar dendritic structure in the weld zone (WZ), while the HAZ exhibited equiaxed grain structure. The XRD and DSC results showed that the WZ remained the B2 austenite structure without any precipitates, but with a significant decrease of phase transformation temperatures. The results in the micro-hardness and tensile tests indicated that the mechanical properties of NiTi were decreased to a certain extent after fibre laser welding.

Modelling and characterization of ultrasonic consolidation process of Aluminium alloys

Ultrasonic consolidation process is a rapid manufacturing process used to join thin layers of metal at low temperatures and low energy consumption. In this work, finite element method has been used to simulate the ultrasonic consolidation of Aluminium alloys 6061 (AA-6061) and 3003 (AA-3003). A thermomechanical material model has been developed in the framework of continuum cyclic plasticity theory which takes into account both volume (acoustic softening) and surface (thermal softening due to friction) effects. A friction model based on experimental studies has been developed, which takes into account the dependence of coefficient of friction upon contact pressure, amount of slip, temperature and number of cycles. Using the developed material and friction model ultrasonic consolidation (UC) process has been simulated for various combinations of process parameters involved. Experimental observations are explained on the basis of the results obtained in the present study. The current research provides the opportunity to explain the differences of the behaviour of AA-6061 and AA-3003 during the ultrasonic consolidation process. Finally, trends of the experimentally measured fracture energies of the bonded specimen are compared to the predicted friction work at the weld interface resulted from the simulation at similar process condition. Similarity of the trends indicates the validity of the developed model in its predictive capability of the process. © 2008 Materials Research Society.

Microstrcutural evolution of SiC fibre embedded AA6061 matrix induced by ultrasonic consolidation

Ultrasonic consolidation (UC) uses high frequency (20-40KHz) mechanical vibrations to produce a solid-state metallurgical bond (weld) between metal foils. UC as a novel layered manufacturing technique is used in this research to embed reinforcing members such as silicon carbide fibers into the aluminium alloy 6061's matrices. It is known that UC induce volume and surface effect in the material it is acting on. Both effects are employed in embedding active/passive elements in the metal matrix. Whilst the process and the two effects are used and identified at macro level, what is happening at micro level is unknown and hardly studied. In this research we are investigating the phenomena occurring in the microstructure of the parts during UC process to obtain better understanding about how and why the process works. In this research, high-resolution electron backscatter diffraction is used to study the effects of the UC process on the evolution of microstructure in AA6061 with and without fibre elements. The inverse pole figures (IPF), pole figures (PF) and the correlated misorientation angle distribution of the mentioned samples are obtained. The characteristics of the crystallographic orientation, the grain structure and the grain boundary are analysed to find the effect of ultrasonic vibration and embedding fibre on the microstructure and texture of the bond. The ultrasonic vibration will lead to exceptional refinement of grains to a micron level along the bond area and affect the crystallographic orientation. Additional plastic flow occurs around the fibre which leads to the fibre embedding. © 2008 Materials Research Society.

Finite element analysis of ultrasonic insertion of SiC fibre in aluminium alloy 6061

In this work, a computational framework has been proposed to successfully simulate the fibre embedding using ultrasonic consolidation process. The main components of the proposed computational approach are a developed constitutive model and a friction model which are especially suitable for the condition of ultrasonic process. The effect of different process parameters, such as velocity of sonotrode, displacement amplitude of ultrasonic vibration and applied loads are studied. The presented work especially focuses on the quality of the developed weld and the fibre coverage due to the plastic flow around the fibre. The areas of maximum plastic flow predicted by the simulation are confirmed by the EBSD microstructural studies. © 2011 Inderscience Enterprises Ltd.

Evaluation of Cyclic Deformation Behavior of Laser-welded Shape Memory NiTi Alloys at Different Working Temperatures

Post-weld heat-treatment (PWHT) has been established as one of the cost-effective ways to improve the functional properties, namely shape memory and super-elastic effects (SME and SE), of laser-welded NiTi alloys. However, the functional performance of the laser-welded joint at different working temperatures has not been explored yet. The purpose of this study is to investigate the effect of different working temperatures on the functional properties of the laser-welded NiTi alloys before and after PWHT by applying cyclic deformation tests. Two laser-welded samples: as-welded and heat-treated sample (after PWHT at 350 oC or 623 K) were tested in this work at room temperature, 50 oC (or 323 K) and 75 oC (or 348 K) respectively. The samples were cyclically loaded and unloaded for 10 cycles up to 4 % strain. The critical stress to induce the martensitic transformation and the residual strain after the cyclic tests were recorded. The results indicate that the heat-treated sample exhibited better functional properties than the as-welded sample at room temperature and 50 oC (or 323 K). However, both the as-welded and heat-treated samples failed in the cyclic tests at 75 oC (or 348 K). These findings are important to determine the feasible working temperature range for the laser-welded NiTi components to exhibit desirable functional properties in engineering applications involving cyclic loading.

Corrosion Fatigue Behaviour of Laser-welded Shape Memory NiTi Wires in a Simulated Body Fluid

Corrosion fatigue is a fracture process as a consequence of synergistic interactions between the material structure, corrosive environment and cyclic loads/strains. It is difficult to be detected and can cause unexpected failure of engineering components in use. This study reveals a comparison of corrosion fatigue behaviour of laser-welded and bare NiTi wires using bending rotation fatigue (BRF) test coupled with a specifically-designed corrosion cell. The testing medium was Hanks’ solution (simulated body fluid) at 37.5 oC. Electrochemical impedance spectroscopic (EIS) measurement was carried out to monitor the change of corrosion resistance of sample during the BRF test at different periods of time. Experiments indicate that the laser-welded NiTi wire would be more susceptible to the corrosion fatigue attack than the bare NiTi wire. This study can serve as a benchmark for the product designers and engineers to understand the corrosion fatigue behaviour of the NiTi laser weld joint and determine the fatigue life safety factor for NiTi medical devices/implants involving laser welding in the fabrication process.

A Fuzzy-Wavelet Neural Network Model for the Detection of Meat Spoilage using an Electronic Nose

Food product safety is one of the most promising areas for the application of electronic noses. The performance of a portable electronic nose has been evaluated in monitoring the spoilage of beef fillet stored aerobically at different storage temperatures (0, 4, 8, 12, 16 and 20°C). This paper proposes a fuzzy-wavelet neural network model which incorporates a clustering pre-processing stage for the definition of fuzzy rules. The dual purpose of the proposed modeling approach is not only to classify beef samples in the respective quality class (i.e. fresh, semi-fresh and spoiled), but also to predict their associated microbiological population directly from volatile compounds fingerprints. Comparison results indicated that the proposed modeling scheme could be considered as a valuable detection methodology in food microbiology

Neuro-Fuzzy based Identification of Meat Spoilage using an Electronic Nose

Freshness and safety of muscle foods are generally considered as the most important parameters for the food industry. The performance of a portable electronic nose has been evaluated in monitoring the spoilage of beef fillet stored aerobically at different storage temperatures (0, 4, 8, 12, 16 and 20°C). An adaptive fuzzy logic system model that utilizes a prototype defuzzification scheme has been developed to classify beef samples in their respective quality class and to predict their associated microbiological population directly from volatile compounds fingerprints. Results confirmed the superiority of the adopted methodology and indicated that volatile information in combination with an efficient choice of a modeling scheme could be considered as an alternative methodology for the accurate evaluation of meat spoilage

Comportamento à fadiga de juntas soldadas de aços tipo 460M com fios fluxados

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Occupational risk in a glass manufacturing industry unit

Risk assessment is one of the main pillars of the framework directive and other directives in respect of health and safety. It is also the basis of an effective management of safety and health as it is essential to reduce work-related accidents and occupational diseases. To survey the hazards eventually present in the workplaces the usual procedures are i) gathering information about tasks/activities, employees, equipment, legislation and standards; ii) observation of the tasks and; iii) quantification of respective risks through the most adequate risk assessment among the methodologies available. From this preliminary evaluation of a welding plant and, from the different measurable parameters, noise was considered the most critical. This paper focus not only the usual way of risk assessment for noise but also another approach that may allow us to identify the technique with which a weld is being performed.

Estudo e otimização de juntas do tipo Tpeel soldadas, adesivas e híbridas

A necessidade de utilizar métodos de ligação que melhor satisfaçam as necessidades de projeto tem causado a crescente utilização das juntas adesivas, em detrimento dos métodos tradicionais tais como a soldadura, ligações aparafusadas e rebitadas. A sua utilização em diversas aplicações industriais justifica-se pela redução de peso, redução de concentrações de tensões, isolamento acústico e melhor resistência à corrosão. Contudo, também apresentam desvantagens, como a necessidade de preparação das juntas, a fraca resistência a esforços de arrancamento e a complexidade da previsão da sua resistência. As juntas híbridas são obtidas por combinação de uma técnica tradicional com uma ligação adesiva. As juntas híbridas adesivas-soldadas obtêm-se através da combinação da ligação adesiva com a ligação soldada, sendo a soldadura de resistência por pontos a técnica de soldadura mais usada no fabrico deste tipo de juntas. A sinergia entre ligação adesiva e soldadura por pontos oferece vantagens competitivas em relação às ligações adesivas, tais como superior resistência e rigidez, e maior resistência ao arrancamento e à fadiga. No presente trabalho é apresentado um estudo experimental e numérico de juntas T-peel soldadas, adesivas e híbridas (adesivas-soldadas) solicitadas ao arrancamento. Considerouse o adesivo frágil Araldite® AV138 e os adesivos dúcteis Araldite® 2015 e Sikaforce® 7752 e aderentes de aço (C45E). Foi realizada uma análise dos valores experimentais e efetuada uma comparação destes valores com os resultados obtidos pelo Método de Elementos Finitos (MEF) no software ABAQUS®, que incluiu uma análise de tensões na camada de adesivo e previsão do comportamento das juntas por MDC. Observou-se que, dos três adesivos em estudo, o adesivo Sikaforce® 7752 é o que apresenta o melhor desempenho na ligação de juntas T-peel. A boa concordância entre os resultados experimentais e numéricos permitiu validar a utilização de MDC para previsão da resistência de juntas T-peel adesivas e híbridas. Assim, o presente trabalho representa uma base para posterior aplicação no projeto deste tipo de ligação, com as vantagens decorrentes na redução do tempo de projeto e maior facilidade de otimização.

Photograph - Baie Comeau, welding railway line

A photograph of men working to weld the railway line at Baie Comeau. The caption reads, "Welding railway line as rails joined immediately behind the temporary staff house".

Influence of Interface Surface Geometries In The Tensile Characteristics Of Friction Welded Joints From Aluminium Alloys

Friction welding is a solid state joining process that produces coalescence in materials, using the heat developed between surfaces through a combination of mechanical induced rubbing motion and applied load. In rotary friction welding technique heat is generated by the conversion of mechanical energy into thermal energy at the interface of the work pieces during rotation under pressure. Traditionally friction welding is carried out on a dedicated machine because of its adaptability to mass production. In the present work, steps were made to modify a conventional lathe to rotary friction welding set up to obtain friction welding with different interface surface geometries at two different speeds and to carry out tensile characteristic studies. The surface geometries welded include flat-flat, flat-tapered, tapered-tapered, concave-convex and convex-convex. A comparison of maximum load, breaking load and percentage elongation of different welded geometries has been realized through this project. The maximum load and breaking load were found to be highest for weld formed between rotating flat and stationary tapered at 500RPM and the values were 19.219kN and 14.28 kN respectively. The percentage elongation was found to be highest for weld formed between rotating flat and stationary flat at 500RPM and the value was 21.4%. Hence from the studies it is cleared that process parameter like “interfacing surface geometries” of weld specimens have strong influence on tensile characteristics of friction welded joints

A Comparative Study Of Tensile And Microstructural Characteristics Of Friction Welded Joints And Conventionally Welded Joints Of Aluminium Alloy 6061

Welding of high strength and low weight materials like Aluminium Alloys without any defects by conventional welding techniques is a major challenge in industries. Hence research on solid state welding techniques like Friction stir welding and Friction welding techniques have got much importance in joining of Aluminium alloys. However most of the industries are not changing conventional techniques as skilled workers are available on that area. Most common conventional welding techniques used for joining of Aluminium alloys are Gas welding and Arc welding. Friction welding is a solid-state welding process that generates heat through mechanical friction between a moving and a stationary component with the addition of a lateral force called “upset” to plast ically displace and fuse the materials. In this work, experimental study on tensile and micro structural characteristics of welded joints formed from conventional welding techniques and Rotary friction welding(suitable for weld specimens with circular cross section) has been carried out and the same were compared. The process parameters for arc welding used was 50-70 Amp reverse polarity DC and electrodes of 2.3mm diameter. In Gas welding, the parameters were oxy acetylene neural flame at 3200°C and 3mm electrodes . In the case of friction welding an axial pressure loading of 3Mpa with 5 MPa as upsetting pressure and 500 rpm were used to obtain good welded joints. Tensile characteristic studies of Arc welded joints and Gas welded joints showed 48% and 60 % variations respectively from the maximum load bearing characteristics of parent metal. In the case of friction welded joint, the variation was found to 46%. Micro structural evaluation of conventionally welded joints exhibited clear distinct zones of various weld regions. In the case of friction welded joint micro structural photographs showed comparable features both in parent metal and welded region. Thus the tensile characteristic study and microstructure evaluations proved that friction welded joints are good in both aspects compared to conventionally welded joints.