DOCSLIB.ORG

Diffusion Bonding of Zirconia to Austenitic Stainless Steel

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Diffusion Bonding of Zirconia to Austenitic Stainless Steel Diffusion bonding of zirconia to austenitic stainless steel -Master thesis- A.T J. van Helvoort Supervisor: ir. R.H. Vegter Professor: Prof Dr. G. den Ouden Laboratory for Materials Science and Engineering Section Welding Technology and Non-Destructive Testing April 1999 I Summary This research deals with diffiision bonds of zirconia to AISI 316 and zirconia to zirconia using an AISI 316 foil, which were produced under various process conditions. Zirconia is an interesting technical ceramic with some excellent properties such as good mechanical strength at elevated temperatures, good corrosion resistance and a low thennal conductivity. To use these properties in structural applications and by­ pass the poor properties such as a low toughness, it is desirable to bond the ceramic to a metal. AISI 316 austenitic stainless steel is a common type of stainless steel with some Mo to improve its properties at elevated temperatxires, for instance the creep resistance. Diffusion bonding is a possible sohd state bonding technique to join zhconia to AISI 316. Experiments were carried out in which the bonding temperature (1000°C-1250°C), the bonding time (30,90 and 360 minutes) and the bonding pressure (2 and 15 MPa) were varied to determine the influences of these bonding parameters on the bond quality. The produced bonds were analysed by optical microscopy, scarming electron microscopy (SEM), X-ray diffraction technique (XRD) and electron probe microanalysis (EPMA). The shape of the AISI 316 part was varied to determine whether this could improve the bond strength. The different bonding geometries were modelled by finite element method (FEM) to determine the residual stress levels after cooling ofthe samples. The experimental results show that all zirconia / AISI 316 combinations produced have a poor bond strength and that changes in the sample geometry does not result in a better bond quality. Experiments were also carried out on zirconia / AISI 316 foil / zirconia combinations. These bonds appear to have a higher bond strength. The experimental results can be explamed usmg the FEM calculations of the residual stresses. n It was also found that during the cooling phase of the bonding process the tetragonal zirconia adjacent to the interface partly transforms to monoclinic zirconia, resulting in a constraint surface layer. The transformation appears to have a negative effect on the bond strength. During the bonding process Fe diffused into the zirconia. The tetragonal-monoclinic phase transformation and the diffusion of Fe result in a black layer on the zirconia interface. The layer thickness increases with increasing bonding temperature, bonding time and bonding pressure. in Samenvatting Dit onderzoek betreft het diffiisielassen van zirconia aan AISI 316 en zirconia aan zirconia met behulp van een AISI 316 tussenlaag. Zirconia is een interessant en veelbelovend technisch keramisch materiaal. Het heeft enkele uitstekende eigenschappen zoals een goede hoge temperatuur sterkte, een goede corrosieweerstand en een lage thermische geleiding. Om in praktische toepassingen optimaal van deze eigenschappen gebmik te maken en minder goede eigenschappen van het zirconia, zoals bijvoorbeeld de brosheid te omzeilen, is het veelal wenselijk het zirconia te verbinden met metalen. AISI 316 is een veel gebruikte austenitische roestvaste staalsoort dat een kleine hoeveelheid Mo bevat om de hoge temperatuur eigenschappen, bijvoorbeeld de kruipbestendigheid, te verbeteren. Diffiisielassen is een mogelijke manier om zirconia duurzaam aan AISI 316 duurzaam te verbinden. Experimenten werden uitgevoerd waarbij het effect van de procesparameters op de laskwaliteit onderzocht zijn door de lastemperatuur (1000°C-1250°C), de lastijd (30, 90 en 360 minuten) en de aandrukkracht (2 en 15 MPa) te variëren. De lassen zijn onderzocht met behulp van optische microscopie, elektronenmicroscopie (SEM), Röntgendiffiractie (XRD) en röntgenmicroanalyse (EPMA). De vorm van het staalgedeelte is systematisch gevarieerd om na te gaan of deze aanpassing tot een betere verbinding leidt. De verschillende geometrieën zijn gemodelleerd met de eindige elementen methode (FEM) om de restspannüigen te bepalen. Uit de experimenten blijkt dat de zirconia / AISI 316 combinaties een lage verbindingssterkte hebben. Het varieren van de geometrie bleek niet tot betere verbindingen te leiden. De zirconia / AISI 316 fohe / zirconia combinaties hebben een redelijke sterkte. De experimentele resultaten zijn te verklaren met behulp van de uitgevoerde eindige elementenberekeningen. IV Tijdens het afkoelen vanaf de procestemperatuur naar kamertemperatuur transformeert een deel van het tetragonaal zirconia aan het grensvlak tot monoklien zirconia, waardoor er een oppervlaktedruklaag gevormd wordt. Deze fasetransformatie is slecht voor de verbindingssterkte. Tijdens het proces diffundeert Fe in het zirconia. De fasetransformatie en de diffusie van ijzer in het zirconia leiden tot de vorming van een zwarte laag aan het zirconiaoppervlak. Deze laag neemt in dikte toe bij toenemende lastemperatuur, lastijd en aandrukkracht. V Contents: Summary I Samenvatting (Dutch summary) III Contents V 1. Introduction 1 2. Theoretical Background 3 2.1. An mtroduction to diffusion bonding 3 2.2. Stages during bonding 4 2.3. Diffusion 7 2.4. Thermal stresses 9 2.5. Zirconia 10 2.6. AISI 316 stainless steel 12 3. Equipment and materials 13 3.1. Equipment 13 3.2. Materials and preparation 13 3.3. Testing device and analytic techniques 14 3.4. Finite Elements Method (FEM) 16 4. Results 18 4.1. Optical analysis 19 4.1.1. Visual analysis 19 4.1.2. The bonding surfaces 19 4.1.3. Cross sections 22 4.2. X-ray diffraction (XRD) and electron probe microanalyses (EPMA) 24 4.2.1. XRD results 24 4.2.2. EPMA results 25 4.3. Results FEM 26 4.3.1. "End-to-end" bonds 26 4.3.2. Notches 27 4.3.3. Foils 28 4.3.4. Summary 28 5. Discussion, conclusions and recommendations for further research 30 References 37 Appendix A: EPMA Appendix B: FEM Diffusion bonding of zirconia to austenitic stainless steel 1 1. Introduction Each material has its own weak and strong specific properties. Ceramics can be used imder severe circumstances as high temperature or in an aggressive environment and have some specific optical and electrical properties. A disadvantage is the brittle character of this type of materials. Metals are tough and strong and have proven their use in many applications, but in general their corrosion and high temperature properties are rather poor. Combining of ceramics and metals is expected to lead to better (combined) properties and is therefore an important topic in materials research. A method to join ceramics with metals is diffusion bonding. In this master thesis, the possible application of this technique is investigated for the combination zirconia / AISI 316 stainless steel. Zirconia is a very interesting technical ceramic. It has a low heat conduction coefficient, good mechanical and chemical properties at high temperatures, which makes it interesting for protecting metal against high temperatures, for instance in turbines. The thermal expansion coefficient is relatively high compared to that of other ceramics, which makes the material interesting for this bonding technique. The main feature of zirconia is that controlling the tetragonal-monoclinic phase transformation, the zirconia can be toughened. AISI 316 is a very important austenitic stainless steel with a small amount of Mo to make it less susceptible for creep. A literature study [1] on diffusion bonding of zirconia to metals showed that the interesting diffusion bonding combination zirconia/AISI 316 was hardly studied in detail so far. However, a study by Derby [2] mdicates that good bondmg results should be expected for the zirconia/AISI316/zirconia diffusion couple. The aim of this study is the determination ofthe possibihties of bonding zirconia to AISI 316 stainless steel by diffusion bonding. The influence of the bonding temperature, bonding time Diffusion bonding of zirconia to austenitic stainless steel 2 and bonding pressure on the bond quality was investigated to estabhsh the opthnal process conditions. Special interest was therefore paid to the physical phenomena that occur during the bonding process at the interface and during cooling from the bonding temperature to room temperature. In this study, emphasis is put on the microstructure ofthe zirconia. With the finite elements method (FEM) the cooling is simulated to determine the residual thennal stress levels. Different geometries of the steel part in the zirconia / AISI 316 combination have been modelled by FEM and experimentally tested to determine the best geometry for the diffiision bond. The bonds made were studied by different techniques such as electron probe microanalyses (EPMA), scanning electron microscopy (SEM), optical microscopy and X-ray diffraction (XRD). The theory of diffusion bonding is given in chapter 2. In this chapter the specific properties of zirconia that play a role in the process are also given. The experimental set-up and the equipment for analysing the bonds are discussed in chapter 3. The results of the bonding experiments and the FEM calculations are presented in chapter 4. In chapter 5 the results are discussed, summarised and conclusions are drawn. Recommendations for further research on this topic are also given in this chapter. Diffusion bonding of zirconia to austenitic stainless steel 3 2. Theoretical Background 2.1. An introduction to diffusion bonding During the
Load more

Recommended publications
  • Fundamentals of Joining Processes
    Outline ME3072 – MANUFACTURING ENGINEERING II BSc Eng (Hons) in Mechanical Engineering • Introduction to Welding Semester - 4 • Fusion-Welding Processes • Solid-State Welding Processes Fundamentals of Joining • Metallurgy of Welding Processes • Weld Quality • Brazing & Soldering Prepared By : R.K.P.S Ranaweera BSc (Hons) MSc Lecturer - Department of Mechanical Engineering University of Moratuwa 2 (for educational purpose only) Joining Processes Classification of Joining Processes 3 4 1 Introduction to Welding • Attention must be given to the cleanliness of the metal surfaces prior to welding and to possible • Is a process by which two materials, usually metals oxidation or contamination during welding process. are permanently joined together by coalescence, which is induced by a combination of temperature, • Production of high quality weld requires: pressure and metallurgical conditions. Source of satisfactory heat and/or pressure Means of protecting or cleaning the metal • Is extensively used in fabrication as an alternative Caution to avoid harmful metallurgical effects method for casting or forging and as a replacement for bolted and riveted joints. Also used as a repair • Advantages of welding over other joints: medium to reunite metals. Lighter in weight and has a great strength • Types of Welding: High corrosion resistance Fusion welding Fluid tight for tanks and vessels Solid-state (forge) welding Can be altered easily (flexibility) and economically 5 6 • Weldability has been defined as the capacity of • Steps in executing welding: metal to be welded under the fabrication conditions Identification of welds, calculation of weld area by stress imposed into a specific, suitably designed structure analysis, preparation of drawings & to perform satisfactorily in the intended service.
    [Show full text]
  • Recommendations for Design and Fabrication of Diffusion Bonded Joints in Reinforcing Bars Using Amorphous Metal Foil
    CONCRETE LIBRARY OF JSCE NO. 27, JUNE l996 RECOMMENDATIONS FOR DESIGN AND FABRICATION OF DIFFUSION BONDED JOINTS IN REINFORCING BARS USING AMORPHOUS METAL FOIL - DRAFT - (Translation from the CONCRETE LIBRARY No.77 published by JSCE, February 1994) JSCE Research Subcomittee on Diffusion Bonded Joints in Reinforcing Bars Using Amorphous Metal Foil Shoji IKEDA, Chairman Takeshi HIGAI, Secretary Members Taisuke AKIMOTO Yoshinobu NOBUTA Takao ENDO Noboru SAEKI Takashi IDEMITSU Satoru SEIMIYA Kiyoshi IIZAKA Kenzo SEKIJIMA Manabu FUJII Noriaki TANAKA Yasuaki HIRABAYASHI Yukikazu TSUJI Tomoj i HIRUKAWA Kimitaka UJI Kosuke HORIKAWA Hidetaka UMEHARA Toru KASAMA Keij i YAMAGATA Fumio KIKUCHI Takashi YAMANAKA Hirotaka KOHNO Minoru YASUDA Hiroshi KOJIMA Takao YOKOGAWA Takashi MIURA Asuo YONEKURA Yukio MIYAMOTO Members from Sponsoring Organizations Kazuo FUJISAWA Kenji KITANO Yasuto FUKADA Yuichi KOMIZO Tetsuya HIGUCHI Atsushi RONDO Shinichi IGUCHI Takao SHIMIZU Nobunori KISHI Masatoshi TOMABECHI - 1 - Recomendations for the Design and Fabrication of Diffusion Bonded Joints in Reinforcing Bars Using Amorphous Metal Foil which have been drafted for the first time in Japan, are presented. This is a new joining process whic h utilizes the principle of diffusion of elements from an amorphous metal foil that is inserted and melted between the ends of the reinforcing bars together with application of pressure. The materials using for joining, design of joints, joining equipment, fabrication and inspection methods, etc.are described. Keywords: design and fabrication code, reinforcing bar, joining diffusion bonding, amorphous metal foil Shoji IKEDA is a professor of Civil Engineering at Yokohama National University. He is a member of the committee on concrete and the corrmittee on structural engineering in JSCE.
    [Show full text]
  • Fluidizing Media for Bulk Powder Handling and Processing
    FluidizingFluidizing mediamedia forfor bulkbulk powderpowder handlinghandling andand processingprocessing Copyright 1999 MKI All Rights Reserved The high-strength cleanable easily fabricated porous metal sheet for all fluidizing applications NO ONE BUT MKI CAN GIVE YOU: LFMTM and HFMTM media are abrasion and puncture Dynapore controlled permeability Dynapore resistant and will not chip, flake media are constructed of multiple layers of carefully or shed fibers. Depending upon load, Dynapore can selected stainless steel wire mesh, laminated by withstand continuous operating temperatures up to precision sintering (diffusion bonding ) and calendering. 1000˚F with intermittent spikes of 1200˚F. The The resultant monolithic structure is permanently bonded abrasion, corrosion, and temperature resisting properties and has highly uniform flow characteristics. Dynapore of Dynapore media are superior to that of polyester, laminates are ideal for even flow distribution of gases in metal felts, or sintered powder metals. fluidizing and aeration applications. LFM and HFM air flow ratings is constructed of 100% AISI Dynapore and pressure drop curves are Dynapore type 316 stainless steel. Other temperature and corrosion resisting alloys are available presented on the adjacent page. LFM 3-layer media range on special request. Custom laminates offering enhanced in air flow from 5 to 25 scfm/sf @ 2 in. water column mechanical strength are also available. pressure drop. HFM 2-layer media range from 50 to 400 scfm/sf @ 2 in. water column. Custom permeabilities are available on special request. media are easily sheared, Dynapore Dynapore formed, punched, welded and For more information, cleaned using standard equipment and methods. request the following Bulletins: Dynapore laminates are available from stock in 401 Mechanical Properties convenient 24”x 48” and 36” x 36” sheets.
    [Show full text]
  • Diffusion Bonding of Stainless ASTM A240 Grade 304 in Double Side Flux Cored Arc Welding
    Journal of Metals, Materials and Minerals. Vol.18 No.1 pp. 63-68, 2008 Diffusion Bonding of Stainless ASTM A240 Grade 304 in Double Side Flux Cored Arc Welding Sombat PITAKNORACHON1and Bovornchok POOPAT 2 King Mongkut’s University of Technology Thonburi, Toongkru, Bangkok 10140 Abstract Received Mar. 3, 2008 Accepted May. 2, 2008 Double side flux cored arc welding (DS-FCAW) has been developed from conventional flux cored arc welding (FCAW). DS-FCAW, dual torches are used by placing an opposite to each other and welding on both sides simultaneously. The objective of this research paper is to investigate diffusion bonding effect due to DS-FCAW. Stainless steel ASTM A240 Grade 304 was studied. Other welding parameters were set constant except welding current and voltage. Diffusion bonding was observed even though weld profiles from macro inspection showed lack of penetration by weld metal in all experiments. It can be concluded that, at certain conditions, the welds can pass both mechanical test and microstructure examination because diffusion bonding process was completely developed due to high contraction stress and high temperature. The advantage of DS-FCAW is that the required joint mechanical properties can be achieved in single welding which results in reduction of welding time and cost. Key Words : Double side flux cored arc welding (DS-FCAW), Diffusion Introduction deformation to the parts.(2) Figure1. shows the joining surfaces which are separated to three parts. Conventional flux cored arc welding (FCAW) The first one is called “Base metal”, the second is the most widely used welding process in the “Cold work layer”, the last “Surface oxide and (3) construction work, for example ship building, pressure Contaminant film”.
    [Show full text]
  • JOINING PROCESSES a FOCUSSED APPROACH Joining Processes
    AMIE(I) STUDY CIRCLE(REGD.) MANUFACTURING TECHNOLOGY JOINING PROCESSES A FOCUSSED APPROACH Joining Processes Welding is defined as the joining of metals by heat with or without pressure, and with or without the addition of other (filler) materials, to obtain a homogeneous and interlocking or fused joint. The strength of the joint is often equal to that of the base materials. Many processes are classified under the definition of welding. Soldering is not included because the strength of joints depends upon adhesion rather than fusion. Cold welding may be properly called ‘welding’ when the molecules actually interlock to form a homogeneous joints. WELDING JOINTS USE OF HEAT IN WELDING PROCESSES There are two general ways of applying heat. The first method applies “concentrated heat” to a limited and localized area near the joint, and thus restricts the expansion and contraction of the material. This is done in most electrical processes, such as metallic arc welding, electron beam welding and the resistance welding methods. The second method applies a general heat to the material near the joint, which raises the temperature to that required to join the parts. Thus when the material cools, there are no localized stresses that will tend to pull the joint apart. Furnace brazing, dip brazing, forge welding and preheating for arc and gas welding are used in the second method. WELDABILITY Weldability denotes the relative ease of producing a weld which is free from defects such as cracks, hard spots, porosity or non-metallic inclusions. Weldability depends on one or more of following major factors: 1.
    [Show full text]
  • 1 Supplementary Materials This Supplementary Contains the Cost
    Supplementary Materials This supplementary contains the cost and environmental impact analysis results for Scenarios 2-6 from: An Economic and Environmental Assessment Model for Microchannel Device Manufacturing: Part 2 – Application Qi Gao1, Jair Lizarazo-Adarme2, Brian K. Paul1, Karl R. Haapala1* 1 School of Mechanical, Industrial, and Manufacturing Engineering, 204 Rogers Hall, Oregon State University, Corvallis, OR, USA 97331 2 Battelle/Pacific Northwest National Laboratory, Microproducts Breakthrough Institute, 1000 NE Circle Boulevard, Suite 11101, Corvallis, OR, USA 97330 1. Cost Results 1.1 Scenario 2 cost results In Scenario 2, HRUs are patterned by PCM and then bonded by diffusion brazing. As annual production volume increases from 1,000 to 500,000, the total manufacturing cost decreases, from $1,307.54 to $531.66 for many of the same reasons expressed above. Figure S1a exhibits the cost breakdown for the defined cost categories showing similar findings as above. At high production rate, raw materials and consumables become the main cost drivers, accounting for 42.3% and 40.2% of the total cost, respectively. 1,400 Raw Materials 1,400 Interconnect Utilities 1,200 1,200 Singulation Consumables Bonding 1,000 Maintenance 1,000 Patterning Labor Raw Materials 800 Facility 800 Cost ($/Device) Tool 600 Cost ($/Device) 600 400 400 200 200 0 0 1000 2000 5000 1,000 2,000 5,000 10000 20000 50000 10,000 20,000 50,000 100000 200000 500000 100,000 200,000 500,000 Production Volume Production Volume (Devices/Year) (Devices/Year) a) b) Figure S1. Cost breakdown for Scenario 2 by a) Cost category and b) Process type and raw materials Figure S1b demonstrates the cost breakdown by process type and raw material, where there is no difference of interconnect and singulation processes between Scenario 1 and Scenario 2.
    [Show full text]
  • Determination of Optimal Parameters for Diffusion Bonding of Semi-Solid Casting Aluminium Alloy by Response Surface Methodology
    MATEC Web of Conferences 26, 002 01 (2015) DOI: 10.1051/matecconf/20152600201 C Owned by the authors, published by EDP Sciences, 2015 Determination of Optimal Parameters for Diffusion Bonding of Semi-Solid Casting Aluminium Alloy by Response Surface Methodology Somsak Kaewploya, Chaiyoot Meengamb Program of Engineering, Faculty of Industrial Technology, Songkhla Rajabhat University, Songkhla, Thailand 90000. Abstract. Liquid state welding techniques available are prone to gas porosity problems. To avoid this solid state bonding is usually an alternative of preference. Among solid state bonding techniques, diffusion bonding is often employed in aluminium alloy automotive parts welding in order to enhance their mechanical properties. However, there has been no standard procedure nor has there been any definitive criterion for judicious welding parameters setting. It is thus a matter of importance to find the set of optimal parameters for effective diffusion bonding. This work proposes the use of response surface methodology in determining such a set of optimal parameters. Response surface methodology is more efficient in dealing with complex process compared with other techniques available. There are two variations of response surface methodology. The one adopted in this work is the central composite design approach. This is because when the initial upper and lower bounds of the desired parameters are exceeded the central composite design approach is still capable of yielding the optimal values of the parameters that appear to be out of the initially preset range. Results from the experiments show that the pressing pressure and the holding time affect the tensile strength of jointing. The data obtained from the experiment fits well to a quadratic equation with high coefficient of determination (R2 = 94.21%).
    [Show full text]
  • All-Position Cladding by Friction Stir Additive
    DEC 2 – 3, 2020 All-Position Cladding by Friction Stir Additive Manufacturing (FSAM) Award Number: CA-16-TN-OR-0604-04 Award Dates: Oct 2016 to March 2021 PI: Zhili Feng (ORNL) Team Members: ORNL: David Frederick, Xue Wang EPRI: , David Gandy, Greg Frederick Outline • Project goal/objectives • Background • R&D plan • Progress and status • Next activities • Summary AMM TECHNICAL REVIEW MEETING (FY-20) DEC 2 – 3, 2020 Project Objectives and Goals • To develop and demonstrate a novel solid-state friction stir additive manufacturing (FSAM) process for high productivity surface cladding − Improve erosion, corrosion and wear resistance, − >20% reduction in cost and improvement in productivity and quality. • Focus on two targeted applications − Cladding of reactor internals − Fabrication of the transition layer of dissimilar metal welds • Support on-site repair in addition to construction of new reactors − Cladding of corrosion resistance barrier for MSR • Demonstrate feasibility of solid-state additive manufacturing of nuclear reactor structural materials with improved properties AMM TECHNICAL REVIEW MEETING (FY-20) DEC 2 – 3, 2020 Background • Cladding and surface modifications are extensively used in fabrication of nuclear reactor systems. It essentially involves adding a layer of different material to component surface. − Cladding of reactor vessel internals to improve erosion, corrosion, and wear resistance − Build a buffer layer for dissimilar metal weld (hundreds of them) • Fusion welding based processes, i.e. various arc welding processes,
    [Show full text]
  • Development of Diffusion Bonding Joints Between Oxgen Free Copper
    Proceedings of IPAC’10, Kyoto, Japan THPEB042 DEVELOPMENT OF DIFFUSION BONDING JOINTS BETWEEN OXYGEN FREE COPPER AND AISI 316L STAINLESS STEEL FOR ACCELERATOR COMPONENTS O. R. Bagnato#, D. V. Freitas, F. R. Francisco and F. E. Manoel LNLS, Campinas, Brazil T. Alonso, LNLS and USF, Campinas, Brazil Abstract (usually vacuum or inert gas) and diffusion time. Some of the characteristics of the diffusion bonding The purpose of this work was to show some of the process between different materials are the non existence various possibilities of diffusion welding involving of plastic deformation and the absence of a region not stainless steel AISI 316L, determine the mechanical thermically affected by the weld bead. That makes it a strength of unions of samples and make a correlation with very interesting process for the production of components the microstructure observed on the surface of the joints for particle accelerators. The process is being study at the and their neighbourhoods. LNLS aiming at the new developments related to the new SIRIUS light source. As part of the studies, samples of MATERIALS AND METHODS stainless steel were bounded to samples of stainless steel Materials (SS), aluminium and copper under different conditions of time (30, 45 and 60 minutes), temperature (700 to The materials used for the diffusion welding tests 1100˚C) and applied load (ranging from 20 to 60kN). In joining SS/SS, SS/Copper and SS/Aluminium the this work we present the results of tests performed using AISI 316L stainless steel alloy (alloy with 0.3% C, 2% the diffusion bonding welding performed at the LNLS.
    [Show full text]
  • Bond Improvement of Al/Cu Joints Created by Very High Power Ultrasonic Additive Manufacturing
    Bond Improvement of Al/Cu Joints Created by Very High Power Ultrasonic Additive Manufacturing THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Adam G. Truog, B.S.W.E Graduate Program in Welding Engineering The Ohio State University 2012 Master's Examination Committee: Professor Sudarsanam Suresh Babu, Advisor Professor John C. Lippold Copyright by Adam G. Truog 2012 ABSTRACT The extension of Ultrasonic Additive Manufacturing (UAM) to dissimilar materials allows for increased application in the aerospace, automotive, electrical and power generation industries. The benefit of UAM over standard ultrasonic welding is the ability to form complex geometries, such as, honeycomb structure and internal channels and also embed wires and sensors to create smart materials. UAM has had limited success bonding dissimilar materials and thus Very High Power Ultrasonic Additive Manufacturing (VHP UAM), which increases the amplitude (from 26μm to 52μm) and normal force (from 2.5kN to 33kN), has been introduced to address this deficiency. Al3003 and Cu110 dissimilar VHP UAM builds were heat treated at 350°C for ten minutes. A measure of maximum push-pin force revealed an improvement in the heat treated condition (from 23% to 49%) for all geometries. Intermetallic phase formation was noticed using the scanning electron microscope (SEM) backscatter detector. X-ray diffraction (XRD) was utilized to characterize the intermetallic layers through peak phase analysis. Al2Cu, AlCu and Al4Cu9 were found on the fracture surface of a heat treated build. It was determined that fracture occurred between the AlCu and Al4Cu9 intermetallic layers.
    [Show full text]
  • Metal Forming Progress Since 2000 CIRP Journal of Manufacturing
    CIRP Journal of Manufacturing Science and Technology 1 (2008) 2–17 Contents lists available at ScienceDirect CIRP Journal of Manufacturing Science and Technology journal homepage: www.elsevier.com/locate/cirpj Review Metal forming progress since 2000 J. Jeswiet a,*, M. Geiger b, U. Engel b, M. Kleiner c, M. Schikorra c, J. Duflou d, R. Neugebauer e, P. Bariani f, S. Bruschi f a Department of Mechanical Engineering, Queen’s University, Kingston, Ontario, Canada K7L 3N6 b University of Erlangen-Nuremberg, Germany c University of Dortmund, Germany d Katholiek Universiteit Leuven, Belgium e University of Chemnitz, Germany f University of Padua, Italy ARTICLE INFO ABSTRACT Keyword: Considerable changes have occurred in metal forming in the last decade. A record of these changes can be Metal forming found in keynote papers presented by the members of the Scientific Technical Committee—Forming, at the CIRP Annual General Meeting each year. The keynote papers are excellent references on important developments in metal forming and are used as a reference, globally. Not only is this paper a compendium of most of the keynotes presented, but from 2001 onward, it has updates on new information on five keynote subject areas. The authors of each keynote have written an update with new information that has developed since the writing of the keynote. The authors of each section are shown in order of presentation. ß 2008 CIRP. Contents 1. Introduction . 3 1.1. CIRP metal forming keynotes. 3 2. Microforming...................................................................................................... 3 2.1. Introduction . 3 2.2. Problems in the microworld . 4 2.3. Basic research—effects of miniaturisation .
    [Show full text]
  • Diffusion Bonding of Ti6al4v to Al2o3 Using Ni/Ti Reactive Multilayers
    metals Article Diffusion Bonding of Ti6Al4V to Al2O3 Using Ni/Ti Reactive Multilayers Marcionilo Silva Jr. 1,2,3, Ana S. Ramos 4 , M. Teresa Vieira 4 and Sónia Simões 2,3,* 1 Department of Mechanical Engineering, Federal University of Amazonas, General Rodrigo Octavio Jordão Ramos ST., Manaus 69067-005, Brazil; [email protected] 2 Department of Metallurgical and Materials Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal 3 LAETA/INEGI—Institute of Science and Innovation in Mechanical and Industrial Engineering, Rua. Dr. Roberto Frias, 4200-465 Porto, Portugal 4 Department of Mechanical Engineering, University of Coimbra, CEMMPRE, R. Luís Reis Santos, 3030-788 Coimbra, Portugal; sofi[email protected] (A.S.R.); [email protected] (M.T.V.) * Correspondence: [email protected]; Tel.: +35-12-2041-3113 Abstract: This paper aims to investigate the diffusion bonding of Ti6Al4V to Al2O3. The potential of the use of reactive nanolayered thin films will also be investigated. For this purpose, Ni/Ti multilayer thin films with a 50 nm modulation period were deposited by magnetron sputtering onto the base materials. Diffusion bonding experiments were performed at 800 ◦C, under 50 MPa and a dwell time of 60 min, with and without interlayers. Microstructural characterization of the interface was conducted through scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS). The joints experiments without interlayer were unsuccessful. The interface is characterized by the presence of a crack close to the Al2O3 base material. The results revealed that the Ni/Ti reactive multilayers improved the diffusion bonding process, allowing for sound joints to be obtained at 800 ◦C for 60 min.
    [Show full text]