A support system for evaluating a suitable joining method in the production of sheet metal goods

This report illustrates a comparative study of various joining methods involved in sheet metal production. In this report it shows the selection of joining methods, which includes comparing the advantages and disadvantages of a method over the other ones and choosing the best method for joining. On the basis of various joining process from references, a table is generated containing set of criterion that helps in evaluation of various sheet metal joining processes and in selecting the most suitable process for a particular product. Three products are selected and a comprehensive study of the joining methods is analyzed with the help of various parameters. The table thus is the main part of the analysis process of this study and can be advanced with the beneficial results. It helps in a better and easy understanding and comparing the various methods, which provides the foundation of this study and analysis. The suitability of the joining method for various types of cases of different sheet metal products can be tested with the help of this table. The sections of the created table display the requirements of manufacturing. The important factor has been considered and given focus in the table, as how the usage of these parameters is important in percentages according to particular or individual case. The analysis of the methods can be extended or altered by changing the parameters according to the constraint. The use of this table is demonstrated by pertaining the cases from sheet metal production.

Tuulivoimalan staattoripakan puristusrakenteen kehittäminen

Diplomityössä tutkittiin voidaanko tuulivoimalan generaattorin staattoripakan puristamisessa hyödyntää komposiittista rakenneratkaisua. Tyypillisesti generaattorissa staattorin teräslevyt puristetaan erilaisilla teräsrakenteilla toisiaan vasten. Tavoitteena oli selvittää, voidaanko puristavan komposiittirakenteen osana hyödyntää liimaliitosta tai laminoitua liitosta. Tarkoitus oli etsiä rakenteeseen soveltuva liima ja liimaliitoksen arvot tai laminoitu rakenne ja sille soveltuvat materiaalit ja suoritustapa. Työssä on perehdytty erilaisiin tuulivoimalatyyppeihin, sekä niissä käytettäviin kesto- ja vierasmagnetoituihin generaattorityyppeihin. Tämän lisäksi on tarkasteltu niissä käytettävien staattorien valmistusvaihtoehtoja ja syitä miksi niissä olevat teräslevyt on puristettava toisiaan vasten. Samalla on luotu katsaus nykyisin käytössä oleviin rakenteisiin, joilla puristus voidaan toteuttaa. Liimauksesta on käsitelty perusteoriaa, sekä seikkoja jotka vaikuttavat liimaliitoksen kestoon. Työssä tutkittavaan liitokseen soveltuvien liimojen ominaisuuksia on käsitelty. Myös laminoituun liitokseen jo aiemmin kovettuneeseen komposiittiin on perehdytty. Tutkittavaan rakenteeseen soveltuvia hartsi- ja lasikuitutyyppejä on esitelty. Komposiittien mekaaniseen liittämiseen on lyhyesti perehdytty. Työssä suoritettiin useita vetokokeita, joilla selvitettiin puristusrakenteen tutkimista varten valmistettujen koekappaleiden suurin vetokuormankesto. Vetokokeiden perusteella voitiin valita soveltuvin rakenne staattorin puristamiseksi.

Diseño y comportamiento de uniones estructurales mecánicas y adhesivas. Condiciones superficiales y operacionales

Las uniones estructurales mecánicas y adhesivas requieren la combinación de un número importante de parámetros para la obtención de la continuidad estructural que exigen las condiciones de diseño. Las características de las uniones presentan importantes variaciones, ligadas a las condiciones de ejecución, tanto en uniones mecánicas como especialmente en uniones adhesivas y mixtas (unión mecánica y adhesiva, también conocidas como uniones híbridas). Las propiedades mecánicas de las uniones adhesivas dependen de la naturaleza y propiedades de los adhesivos y también de muchos otros parámetros que influyen directamente en el comportamiento de estas uniones. Algunos de los parámetros más significativos son: el acabado superficial de los materiales, área y espesor de la capa adhesiva, diseño adecuado, secuencia de aplicación, propiedades químicas de la superficie y preparación de los sustratos antes de aplicar el adhesivo. Los mecanismos de adhesión son complejos. En general, cada unión adhesiva solo puede explicarse considerando la actuación conjunta de varios mecanismos de adhesión. No existen adhesivos universales para un determinado material o aplicación, por lo que cada pareja sustrato-adhesivo requiere un particular estudio y el comportamiento obtenido puede variar, significativamente, de uno a otro caso. El fallo de una junta adhesiva depende del mecanismo cohesión-adhesión, ligado a la secuencia y modo de ejecución de los parámetros operacionales utilizados en la unión. En aplicaciones estructurales existen un número muy elevado de sistemas de unión y de posibles sustratos. En este trabajo se han seleccionado cuatro adhesivos diferentes (cianoacrilato, epoxi, poliuretano y silano modificado) y dos procesos de unión mecánica (remachado y clinchado). Estas uniones se han aplicado sobre chapas de acero al carbono en diferentes estados superficiales (chapa blanca, galvanizada y prepintada). Los parámetros operacionales analizados han sido: preparación superficial, espesor del adhesivo, secuencia de aplicación y aplicación de presión durante el curado. Se han analizado tanto las uniones individuales como las uniones híbridas (unión adhesiva y unión mecánica). La combinación de procesos de unión, sustratos y parámetros operacionales ha dado lugar a la preparación y ensayo de más de mil muestras. Pues, debido a la dispersión de resultados característica de las uniones adhesivas, para cada condición analizada se han ensayado seis probetas. Los resultados obtenidos han sido: El espesor de adhesivo utilizado es una variable muy importante en los adhesivos flexibles, donde cuanto menor es el espesor del adhesivo mayor es la resistencia mecánica a cortadura de la unión. Sin embargo en los adhesivos rígidos su influencia es mucho menor. La naturaleza de la superficie es fundamental para una buena adherencia del adhesivo al substrato, que repercute en la resistencia mecánica de la unión. La superficie que mejor adherencia presenta es la prepintada, especialmente cuando existe una alta compatibilidad entre la pintura y el adhesivo. La superficie que peor adherencia tiene es la galvanizada. La secuencia de aplicación ha sido un parámetro significativo en las uniones híbridas, donde los mejores resultados se han obtenido cuando se aplicaba primero el adhesivo y la unión mecánica se realizaba antes del curado del adhesivo. La aplicación de presión durante el curado se ha mostrado un parámetro significativo en los adhesivos con poca capacidad para el relleno de la junta. En los otros casos su influencia ha sido poco relevante. El comportamiento de las uniones estructurales mecánicas y adhesivas en cuanto a la resistencia mecánica de la unión puede variar mucho en función del diseño de dicha unión. La resistencia mecánica puede ser tan grande que falle antes el substrato que la unión. Las mejores resistencias se consiguen diseñando las uniones con adhesivo cianoacrilato, eligiendo adecuadamente las condiciones superficiales y operacionales, por ejemplo chapa blanca aplicando una presión durante el curado de la unión. La utilización de uniones mixtas aumenta muy poco o nada la resistencia mecánica, pero a cambio proporciona una baja dispersión de resultados, siendo destacable para la superficie galvanizada, que es la que presenta peor reproducibilidad cuando se realizan uniones sólo con adhesivo. Las uniones mixtas conducen a un aumento de la deformación antes de la rotura. Los adhesivos dan rotura frágil y las uniones mecánicas rotura dúctil. La unión mixta proporciona ductilidad a la unión. Las uniones mixtas también pueden dar rotura frágil, esto sucede cuando la resistencia del adhesivo es tres veces superior a la resistencia de la unión mecánica. Las uniones híbridas mejoran la rigidez de la junta, sobre todo se aprecia un aumento importante en las uniones mixtas realizadas con adhesivos flexibles, pudiendo decirse que para todos los adhesivos la rigidez de la unión híbrida es superior. ABSTRACT The mechanical and adhesive structural joints require the combination of a large number of parameters to obtain the structural continuity required for the design conditions. The characteristics of the junctions have important variations, linked to performance conditions, in mechanical joints as particular in mixed adhesive joints (mechanical and adhesive joints, also known as hybrid joints). The mechanical properties of the adhesive joints depend of the nature and properties of adhesives and also of many other parameters that directly influence in the behavior of these joints. Some of the most significant parameters are: the surface finished of the material, area and thickness of the adhesive layer, suitable design, and application sequence, chemical properties of the surface and preparation of the substrate before applying the adhesive. Adhesion mechanisms are complex. In general, each adhesive joint can only be explained by considering the combined action of several adhesions mechanisms. There aren’t universal adhesives for a given material or application, so that each pair substrate-adhesive requires a particular study and the behavior obtained can vary significantly from one to another case. The failure of an adhesive joint depends on the cohesion-adhesion mechanism, linked to the sequence and manner of execution of the operational parameters used in the joint. In the structural applications, there are a very high number of joining systems and possible substrates. In this work we have selected four different adhesives (cyanoacrylate, epoxy, polyurethane and silano modified) and two mechanical joining processes (riveting and clinching). These joints were applied on carbon steel with different types of surfaces (white sheet, galvanized and pre-painted). The operational parameters analyzed were: surface preparation, thickness of adhesive, application sequence and application of pressure during curing. We have analyzed individual joints both as hybrid joints (adhesive joint and mechanical joint). The combination of joining processes, substrates and operational parameters has resulted in the preparation and testing of over a thousand specimens. Then, due to the spread of results characteristic of adhesive joints, for each condition analyzed we have tested six samples. The results have been: The thickness of adhesive used is an important variable in the flexible adhesives, where the lower the adhesive thickness greater the shear strength of the joint. However in rigid adhesives is lower influence. The nature of the surface is essential for good adherence of the adhesive to the substrate, which affects the shear strength of the joint. The surface has better adherence is preprinted, especially when there is a high compatibility between the paint and the adhesive. The surface which has poor adherence is the galvanized. The sequence of application has been a significant parameter in the hybrid junctions, where the best results are obtained when applying first the adhesive and the mechanical joint is performed before cured of the adhesive. The application of pressure during curing has shown a significant parameter in the adhesives with little capacity for filler the joint. In other cases their influence has been less relevant. The behavior of structural mechanical and adhesive joints in the shear strength of the joint can vary greatly depending on the design of such a joint. The shear strength may be so large that the substrate fails before the joint. The best shear strengths are achieved by designing the junctions with cyanoacrylate adhesive, by selecting appropriately the surface and operating conditions, for example by white sheet applying a pressure during curing of the joint. The use of hybrid joints no increase shear strength, but instead provides a low dispersion of results, being remarkable for the galvanized surface, which is the having worst reproducibility when performed bonded joints. The hybrid joints leading to increased deformation before rupture. The joints witch adhesives give brittle fracture and the mechanics joints give ductile fracture. Hybrid joint provides ductility at the joint. Hybrid joint can also give brittle fracture, this happens when the shear strength of the adhesive is three times the shear strength of the mechanical joint. The hybrid joints improve stiffness of joint, especially seen a significant increase in hybrid joints bonding with flexible adhesives, can be said that for all the adhesives, the hybrid junction stiffness is higher.

Mechanical Strength and Analysis of Fracture of Titanium Joining Submitted to Laser and Tig Welding

This study compared the tensile strength and fracture mechanism of tungsten inert gas (TIG) welds in cylindrical rods of commercially pure titanium (cp Ti) with those of laser welds and intact samples. Thirty dumbbell-shaped samples were developed by using brass rods as patterns. The samples were invested in casings, subjected to thermal cycles, and positioned in a plasma arc welding machine under argon atmosphere and vacuum, and titanium was injected under vacuum/pressure. The samples were X-rayed to detect possible welding flaws and randomly assigned to three groups to test the tensile strength and the fracture mechanism: intact, laser welding, and TIG welding. The tensile test results were investigated using ANOVA, which indicated that the samples were statistically similar. The fracture analysis showed that the cpTi samples subjected to laser welding exhibited brittle fracture and those subjected to TIG welding exhibited mixed brittle/ductile fracture with a predominance of ductile fracture with the presence of microcavities and cleavage areas. Intact samples presented the characteristic straightening in the fracture areas, indicating the ductility of the material.

Acrylic adhesives in the polyolefins joining

The mechanical behaviour of single lap adhesive joints was characterized, using two commercial acrylic adhesives. For this purpose the surfaces were cleaned and abraded using fine grit abrasives. The effect of temperature and moisture in the mechanical strength was, also, evaluated. For this characterization, mechanical tests were carried out according procedure and geometry foreseen by ASTM D3163-01 [1] and ASTM D4501-01 [2] standards. The results show that it is possible to get good strengths without great surface preparation. The temperature and moisture effect observed don’t seem to be relevant for the mechanical behaviour.

Microstructure, mechanical properties and chemical degradation of brazed AISI 316 stainless steel/alumina systems

The main aims of the present study are simultaneously to relate the brazing parameters with: (i) the correspondent interfacial microstructure, (ii) the resultant mechanical properties and (iii) the electrochemical degradation behaviour of AISI 316 stainless steel/alumina brazed joints. Filler metals on such as Ag–26.5Cu–3Ti and Ag–34.5Cu–1.5Ti were used to produce the joints. Three different brazing temperatures (850, 900 and 950 °C), keeping a constant holding time of 20 min, were tested. The objective was to understand the influence of the brazing temperature on the final microstructure and properties of the joints. The mechanical properties of the metal/ceramic (M/C) joints were assessed from bond strength tests carried out using a shear solicitation loading scheme. The fracture surfaces were studied both morphologically and structurally using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction analysis (XRD). The degradation behaviour of the M/C joints was assessed by means of electrochemical techniques. It was found that using a Ag–26.5Cu–3Ti brazing alloy and a brazing temperature of 850 °C, produces the best results in terms of bond strength, 234 ± 18 MPa. The mechanical properties obtained could be explained on the basis of the different compounds identified on the fracture surfaces by XRD. On the other hand, the use of the Ag–34.5Cu–1.5Ti brazing alloy and a brazing temperature of 850 °C produces the best results in terms of corrosion rates (lower corrosion current density), 0.76 ± 0.21 μA cm−2. Nevertheless, the joints produced at 850 °C using a Ag–26.5Cu–3Ti brazing alloy present the best compromise between mechanical properties and degradation behaviour, 234 ± 18 MPa and 1.26 ± 0.58 μA cm−2, respectively. The role of Ti diffusion is fundamental in terms of the final value achieved for the M/C bond strength. On the contrary, the Ag and Cu distribution along the brazed interface seem to play the most relevant role in the metal/ceramic joints electrochemical performance.

Correlation between the mechanical cycling behavior and microstructure in laser welded joints using NiTi memory shape alloys

Dissertação para obtenção do Grau de Mestre em Engenharia de Materiais

Joining copper to stainless steel by friction stir diffusion process

Dissertação apresentada na Faculdade de Ciências e Tecnologia da Universidade Nova de Lisboa para obtenção do Grau de Mestre em Engenharia Mecânica

Mechanical and elemental characterization of solder joints and welds using a gold-palladium alloy

Purpose. This study was conducted to determine whether newer infrared or laser welding technologies created joints superior to traditional furnace or torch soldering methods of joining metals. It was designed to assess the mechanical resistance, the characteristics of the fractured surfaces, and the elemental diffusion of joints obtained by four different techniques: (1) preceramic soldering with a propane-oxygen torch, (2) postceramic soldering with a porcelain furnace, (3) preceramic and (4) postceramic soldering with an infrared heat source, and (5) laser welding. Material and methods. Mechanical resistance was determined by measuring the ultimate tensile strength of the joint and by determining their resistance to fatigue loading. Elemental diffusion to and from the joint was assessed with microprobe tracings. Scanning electron microscopy micrographs of the fractured surface were also obtained and evaluated. Results. Under monotonic tensile stress, three groups emerged: The laser welds were the strongest, the preceramic joints ranged second, and the postceramic joints were the weakest. Under fatigue stress, the order was as follows: first, the preceramic joints, and second, a group that comprised both postceramic joints and the laser welds. Inspection of the fractographs revealed several fracture modes but no consistent pattern emerged. Microprobe analyses demonstrated minor diffusion processes in the preceramic joints, whereas significant diffusion was observed in the postceramic joints. Clinical Implications. The mechanical resistance data conflicted as to the strength that could be expected of laser welded joints. On the basis of fatigue resistance of the joints, neither infrared solder joints nor laser welds were stronger than torch or furnace soldered joints.

Mechanical and tribological properties of PVD-coated cemented carbide as evaluated by a new multi-pass scratch testing method

A new test method based on multipass scratch testing has been developed for evaluating the mechanical and tribological properties of thin, hard coatings. The proposed test method uses a pin-on-disc tribometer and during testing a Rockwell C diamond stylus is used as the “pin” and loaded against the rotating coated sample. The influence of normal load on the number of cycles to coating damage is investigated and the resulting coating damage mechanisms are evaluated by posttest scanning electron microscopy. The present study presents the test method by evaluating the performance of Ti0.86Si0.14N, Ti0.34Al0.66N, and (Al0.7Cr0.3)2O3 coatings deposited by cathodic arc evaporation on cemented carbide inserts. The results show that the test method is quick, simple, and reproducible and can preferably be used to obtain relevant data concerning the fatigue, wear, chipping, and spalling characteristics of different coating-substrate composites. The test method can be used as a virtually nondestructive test and, for example, be used to evaluate the fatigue and wear resistance as well as the cohesive and adhesive interfacial strength of coated cemented carbide inserts prior to cutting tests.

Analysis of the Mechanical Properties of Multicrystalline and Monocrystalline Silicon Wafers Manufactured by Casting Methods

Quasi-monocrystalline silicon wafers have appeared as a critical innovation in the PV industry, joining the most favourable characteristics of the conventional substrates: the higher solar cell efficiencies of monocrystalline Czochralski-Si (Cz-Si) wafers and the lower cost and the full square-shape of the multicrystalline ones. However, the quasi-mono ingot growth can lead to a different defect structure than the typical Cz-Si process. Thus, the properties of the brand-new quasi-mono wafers, from a mechanical point of view, have been for the first time studied, comparing their strength with that of both Cz-Si mono and typical multicrystalline materials. The study has been carried out employing the four line bending test and simulating them by means of FE models. For the analysis, failure stresses were fitted to a three-parameter Weibull distribution. High mechanical strength was found in all the cases. The low quality quasi-mono wafers, interestingly, did not exhibit critical strength values for the PV industry, despite their noticeable density of extended defects.

The Crosslinking Degree Controls The Mechanical, Rheological, And Swelling Properties Of Hyaluronic Acid Microparticles.

Viscosupplements, used for treating joint and cartilage diseases, restore the rheological properties of synovial fluid, regulate joint homeostasis and act as scaffolds for cell growth and tissue regeneration. Most viscosupplements are hydrogels composed of hyaluronic acid (HA) microparticles suspended in fluid HA. These microparticles are crosslinked with chemicals to assure their stability against enzyme degradation and to prolong the action of the viscosupplement. However, the crosslinking also modifies the mechanical, swelling and rheological properties of the HA microparticle hydrogels, with consequences on the effectiveness of the application. The aim of this study is to correlate the crosslinking degree (CD) with these properties to achieve modulation of HA/DVS microparticles through CD control. Because divinyl sulfone (DVS) is the usual crosslinker of HA in viscosupplements, we examined the effects of CD by preparing HA microparticles at 1:1, 2:1, 3:1, and 5:1 HA/DVS mass ratios. The CD was calculated from inductively coupled plasma spectrometry data. HA microparticles were previously sized to a mean diameter of 87.5 µm. Higher CD increased the viscoelasticity and the extrusion force and reduced the swelling of the HA microparticle hydrogels, which also showed Newtonian pseudoplastic behavior and were classified as covalent weak. The hydrogels were not cytotoxic to fibroblasts according to an MTT (3-[4,5-dimethylthiazol-2-yl]-2,5-diphenyltetrazolium bromide) assay. © 2014 Wiley Periodicals, Inc. J Biomed Mater Res Part A, 2014.

Assessment Of The Fixation Of Mandibular Symphysis Fractures Using Conical Cannulated Screws: Mechanical And Photoelastic Tests.

The aim of this study was to use mechanical and photoelastic tests to compare the performance of cannulated screws with other fixation methods in mandibular symphysis fractures. Ten polyurethane mandibles were allocated to each group and fixed as follows: group PRP, 2 perpendicular miniplates; group PLL, 1 miniplate and 1 plate, parallel; and group CS, 2 cannulated screws. Vertical linear loading tests were performed. The differences between mean values were analyzed with the Tukey test. The photoelastic test was carried out using a polariscope. The results revealed differences between the CS and PRP groups at 1, 3, 5, and 10 millimeters of displacement. The photoelastic test confirmed higher stress concentration in all groups close to the mandibular base, whereas the CS group showed it throughout the region assessed. Conical cannulated screws performed well in mechanical and photoelastic tests.

Peripheral P2x7 Receptor-induced Mechanical Hyperalgesia Is Mediated By Bradykinin.

P2X7 receptors play an important role in inflammatory hyperalgesia, but the mechanisms involved in their hyperalgesic role are not completely understood. In this study, we hypothesized that P2X7 receptor activation induces mechanical hyperalgesia via the inflammatory mediators bradykinin, sympathomimetic amines, prostaglandin E2 (PGE2), and pro-inflammatory cytokines and via neutrophil migration in rats. We found that 2'(3')-O-(4-benzoylbenzoyl)adenosine 5'-triphosphate triethylammonium salt (BzATP), the most potent P2X7 receptor agonist available, induced a dose-dependent mechanical hyperalgesia that was blocked by the P2X7 receptor-selective antagonist A-438079 but unaffected by the P2X1,3,2/3 receptor antagonist TNP-ATP. These findings confirm that, although BzATP also acts at both P2X1 and P2X3 receptors, BzATP-induced hyperalgesia was mediated only by P2X7 receptor activation. Co-administration of selective antagonists of bradykinin B1 (Des-Arg(8)-Leu(9)-BK (DALBK)) or B2 receptors (bradyzide), β1 (atenolol) or β2 adrenoceptors (ICI 118,551), or local pre-treatment with the cyclooxygenase inhibitor indomethacin or the nonspecific selectin inhibitor fucoidan each significantly reduced BzATP-induced mechanical hyperalgesia in the rat hind paw. BzATP also induced the release of the pro-inflammatory cytokines tumor necrosis factor α (TNF-α), interleukin (IL)-1β, IL-6 and cytokine-induced neutrophil chemoattractant-1 (CINC-1), an effect that was significantly reduced by A-438079. Co-administration of DALBK or bradyzide with BzATP significantly reduced BzATP-induced IL-1β and CINC-1 release. These results indicate that peripheral P2X7 receptor activation induces mechanical hyperalgesia via inflammatory mediators, especially bradykinin, which may contribute to pro-inflammatory cytokine release. These pro-inflammatory cytokines in turn may mediate the contributions of PGE2, sympathomimetic amines and neutrophil migration to the mechanical hyperalgesia induced by local P2X7 receptor activation.

Mechanical Properties And Fracture Dynamics Of Silicene Membranes.

As graphene has become one of the most important materials, there is renewed interest in other similar structures. One example is silicene, the silicon analogue of graphene. It shares some of the remarkable graphene properties, such as the Dirac cone, but presents some distinct ones, such as a pronounced structural buckling. We have investigated, through density functional based tight-binding (DFTB), as well as reactive molecular dynamics (using ReaxFF), the mechanical properties of suspended single-layer silicene. We calculated the elastic constants, analyzed the fracture patterns and edge reconstructions. We also addressed the stress distributions, unbuckling mechanisms and the fracture dependence on the temperature. We analysed the differences due to distinct edge morphologies, namely zigzag and armchair.