DOCSLIB.ORG

Developing Effective Parameters for Simulation of Self-Pierce Rivet Insertion

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Developing Effective Parameters for Simulation of Self-Pierce Rivet Insertion DEVELOPING EFFECTIVE PARAMETERS FOR SIMULATION OF SELF-PIERCE RIVET INSERTION By: Zuzana Kotercova Faculty of Civil and Structural Engineering University of Sheffield A thesis submitted in partial fulfilment of the requirements for the degree of Doctor of Philosophy Submission Date: May 2020 DECLARATION I, the author, confirm that the Thesis is my own work. I am aware of the University’s Guidance on the Use of Unfair Means (www.sheffield.ac.uk/ssid/unfair-means). This work has not been previously been presented for an award at this, or any other, university. This work includes nothing, which is the outcome of work done in collaboration except where specifically indicated in the text. It has not been previously submitted, in part or whole, to any university of institution for any degree, diploma, or other qualification. All sources of information have been acknowledged by references. Signed:______________________________________________________________ Zuzana Kotercova Date: 14th November 2019 i ABSTRACT The car manufacturing industry is going through a time of significant change under pressure to provide stronger crash safe structures while at the same time making car bodies lighter to enable electric drive. This is forcing car designers to choose very high strength materials and to use a mixture of steel for strength and aluminium for lightness. The result is a large number of riveted joint stack configurations on one car body each requiring different riveting parameters. The amount of physical testing required to find solutions has now become much bigger than the testing time available on the vehicle design programs. To solve this car manufacturers are keen to switch from physical lab testing to simulated joint testing. There is also pressure on rivet suppliers to rapidly develop new rivets designs for making the new joint stack combinations which are increasingly evolving into higher and higher strength materials. Simulation of rivet designs is needed to accelerate rivet development projects and to conduct process window testing to check the proposed new designs can cope with production variables. This project first created a validated base model for simulating rivet insertion and then applied this model to a number of research tasks. Through testing a large number of variety of rivet types, this work developed a set of friction parameters that have proven to work reliably for two different coatings, a standard SPR plating as well as low friction lubricant. The project also focused on accurately replicating the mid- clamping method used by AC setters with promising results. The developed base model been succesfully used to simulate several completely new SPR products that have not been simulated to date such as tubular rivets for standard and narrow flange and solid (swage) riveting. It has also been utilized in studies focusing on creating a process window for materials to account for manufacturing variables. And finally, the model was used in a study supporting rivet design by bringing together the worst possible combination of lowest rivet manufacturing tolerances in order to predict the worst case scenario in rivet production. The results of this study were particularly accurate and allowed for mitigation of the worst combination of tolerances by informing subsequent rivet geometry amendments. Following completion of this project, the simulation can be seen as particularly useful tool in design of new products by predicting trends and mapping out process windows for manufacturing variables of both geometries and materials and can potentially replace a large part of physical testing. ii ACKNOWLEDGEMENTS I would like to thank Atlas Copco IAS UK Ltd and EPSRC for sponsoring this PhD project via a EPSRC Case Award. I would also like to extend my thanks to the people that gave me technical guidance, including the academic supervisor Prof Luca Susmel, the industrial supervisor Dr Paul Briskham, and the team of riveting engineers in the applications lab and the R&D lab at the Atlas Copco site in Deeside who allowed me to conduct simulations on the live company projects, enabling me to ensure the PhD work was focussed on the latest new and novel aspects of benefit SPR technology. iii Word Template by Friedman & Morgan 2014 Morgan & Friedman by Word Template CONTENTS 1 INTRODUCTION & OBJECTIVES 1 1.1 Trend towards aluminium and mixed metal car bodies 1 1.2 PhD Objectives 4 1.2.1 Objective 1 – Selection and Evaluation of the simulation software. 4 1.2.2 Objective 2 – Development of the base model 4 1.2.3 Objective 3 – Application of base model 5 1.2.4 Objective 4 – Utilization of validated simulation models 7 1.3 Overview of the thesis structure 8 2 REVIEW OF SELF PIERCE RIVETING (SPR) 10 2.1 Self-Pierce Riveting - Introduction 10 2.2 Evolution of SPR from 1970 to present day 14 2.3 Rivet types 19 2.3.1 Rivet length 19 2.3.2 Rivet Types and Head Styles 20 2.3.3 Rivet diameter 21 2.3.4 Rivet hardness 21 2.3.5 Rivet hole style 23 2.4 Die types 23 2.5 Rivet Insertion Equipment types 24 2.5.1 Simulation of different rivet insertion equipment 24 2.5.2 Rivet insertion equipment used in this study for the physical lab tests 25 2.5.3 RivLite Portable Battery Tool 25 2.5.4 Hydraulic double acting and pre-clamping tools 25 2.5.5 Servo tools 26 2.6 Advantages and disadvantages of SPR 27 2.6.1 Versatility 27 2.6.2 Joint Strength and Fatigue Durability 28 2.6.3 Costs 30 2.6.4 Access 30 2.6.5 High force 31 2.6.6 Process limitations 31 iv 2.6.7 Permanency of the joint 31 2.6.8 Use of consumable (i.e. rivet) 32 2.6.9 Appearance 32 2.6.10 Not suitable for brittle materials 32 2.6.11 Each joint needs individual configuration 32 2.7 Physical joint assessment 33 2.7.1 Visual inspection of a joint 33 2.7.2 Cross sectioning 34 2.7.3 Force displacement curves 38 2.7.4 Tensile Strength 39 2.8 Types of testing in SPR 41 2.8.1 Feasibility testing 41 2.8.2 Further assessments 41 2.9 Current use of SPR 42 2.10 SPR innovations 42 2.10.1 Laser assisted SPR (LSPR) 43 2.10.2 Friction SPR (F-SPR) 44 2.10.3 Hydro-formed SPR (HF-SPR) 45 2.10.4 Adjustable die option 45 2.10.5 Kerb Konus Solid SPR (S-SPR) 45 3 REVIEW OF FINITE ELEMENT ANALYSIS (FEA) 47 3.1 What is Finite Element Analysis - Introduction 47 3.2 Brief history of Finite Element Analysis 48 3.3 Finite Element Analysis stages 48 3.3.1 Stage 1 – Pre-processing 48 3.3.2 Stage 2 – Solution 49 3.3.3 Stage 3 – Post-processing 49 3.4 Types of FEA 50 3.4.1 Static analysis 50 3.4.2 Dynamic analysis 51 3.4.3 Quasi static analysis 51 3.4.4 Implicit analysis 52 3.4.5 Explicit analysis 52 v Word Template by Friedman & Morgan 2014 Morgan & Friedman by Word Template 3.5 Specific methods used by Simufact software 53 4 REVIEW OF FEA IN CONTEXT OF SPR 58 4.1 Parameters to consider in FE analysis of SPR 58 4.1.1 Simulation process parameters 59 4.1.2 Process description 79 4.1.3 Material characterization 86 4.1.4 Rivets’, dies’, sheets’ and tools’ geometries 117 4.1.5 Friction, lubrication and coatings 119 4.2 FEA of SPR to date – Current state of the art 130 4.2.1 Software types 134 4.2.2 Different types of materials in simulation 135 4.2.3 Optimisation of rivet and die geometries 136 4.2.4 Areas for future development 137 5 RESEARCH METHODS 138 5.1 Physical SPR tests 138 5.2 FE analysis 140 5.3 Validation of simulation by experimental tests 142 6 EXPERIMENTAL STAGE 143 6.1 Simulation assessment and accuracy tolerances 144 6.1.1 Simulation assessment – Joint measurements 144 6.1.2 Simulation assessment – Joint visual attributes 146 6.1.3 Simulation assessment – Agreeability scorecard 147 6.2 Software selection 151 6.2.1 Evaluation of the software 152 6.3 Simulation process description 156 6.3.1 Friction 156 6.3.2 Clamping 184 6.3.3 Press selection 191 6.3.4 Mesh 202 6.3.5 Damage mechanics 209 6.3.6 Temperature effects 213 vi 6.3.7 Materials characterisation 224 6.3.8 Influence of geometries 243 6.4 Summary 253 7 PRACTICAL APPLICATIONS 257 7.1 Simulation of process window for sheet and rivet properties for BG rivet joining UHSS. 257 7.2 Simulation to aid design of fully tubular rivet for narrow flange joining 264 7.2.1 Test 1 – Narrowing down tolerance band 265 7.2.2 Test 2 – Coupled effect of rivet hardness and tip geometry 267 7.2.3 Test 3 – Process capability 271 7.2.4 Test 4 – Coupled effect of improved tip geometry and flare angle 274 7.3 Simulation of Solid SPR riveting joining process (Swage riveting) 275 7.3.1 Development of the swage simulation model 277 7.3.2 Validation of the swage model 281 7.4 Summary 286 8 DISCUSSION 289 8.1 Introduction 289 8.2 Selection and evaluation of out of the box version of the selected software (Objective 1A and 1B) 289 8.3 Development of the base simulation model (Objective 2) 290 8.3.1 Development of friction parameters (Objective 2A) 290 8.3.2 Effect of different joint clamping methods (Objective 2B) 292 8.4 Simulation of fully tubular rivets (Objective 3A) 294 8.5 Mixed material riveting of UHSS to aluminium and Process window for sheet and rivet properties (Objective 3B & 4A) 295 8.6 Simulation to aid design optimisation of new 4mm shank diameter T-rivets in combination with new narrow flange equipment (Objective 3C & 4B) 296 8.7 Swage solid SPR riveting joining process (Objective 3D) 298 9 CONCLUSIONS 299 vii Word Template by Friedman & Morgan 2014 Morgan & Friedman by Word Template 9.1 Conclusions 299 9.2 Recommendations for Future Work 305 10 REFERENCES 307 viii LIST OF TABLES TABLE 1, RIVET LENGTH AVAILABILITY TABLE (ATLAS COPCO RIVET BROCHURE 2019) ............................................
Load more

Recommended publications
  • Evaluation of Tensile Shear Strength Under Salt Spray Test on Dissimilar Metal Spot Welding of Aluminum Alloy and Galvannealed Steel Sheet
    applied sciences Article Evaluation of Tensile Shear Strength under Salt Spray Test on Dissimilar Metal Spot Welding of Aluminum Alloy and Galvannealed Steel Sheet Sung-Min Joo 1, Young-Gon Kim 2 and Min-Suk Oh 3,* 1 Department of Naval Architecture and Ocean Engineering, Chosun University, Gwangju 61452, Korea; [email protected] 2 Gwangju Ppuri Technology Support Center, Korea Institute of Industrial Technology, Gwangju 61012, Korea; [email protected] 3 Division of Advanced Materials Engineering, Jeonbuk National University, Jeonju 54896, Korea * Correspondence: [email protected]; Tel.: +82-63-270-2305 Received: 26 October 2020; Accepted: 13 November 2020; Published: 16 November 2020 Abstract: In order to reduce the weight of parts in the automobile and electronic industries, various research on dissimilar welding techniques of aluminum and steel is being carried out. Since dissimilar materials have different physical and electrochemical characteristics, joining through conventional fusion welding is challenging, and there is a high probability of a decrease in strength of the welded joints. To solve this problem, a mechanical fastening method is mainly applied to join dissimilar parts with different material properties, but this process has disadvantages in terms of productivity improvement and cost reduction because additional consumables, such as rivets, are required. In this research, we investigated the optimization of the weld bonding conditions of joints using epoxy-based adhesive bonding and DeltaSpot welding for Al/Fe dissimilar materials. For each experimental condition, the corrosion resistance and tensile shear strength of the welded joints were evaluated according to salt spray test times of 0 h, 640 h, 1280 h, and 1920 h.
    [Show full text]
  • The Role of Zinc Layer During Wetting of Aluminium on Zinc-Coated Steel in Laser Brazing and Welding
    Available online at www.sciencedirect.com ScienceDirect Physics Procedia 56 ( 2014 ) 730 – 739 8th International Conference on Photonic Technologies LANE 2014 The role of zinc layer during wetting of aluminium on zinc-coated steel in laser brazing and welding M. Gatzena,*, T. Radela, C. Thomya, F. Vollertsena aBIAS – Bremer Institut fuer angewandte Strahltechnik GmbH, Klagenfurter Str. 2, 28359 Bremen, Germany Abstract The zinc layer of zinc-coated steel is known to be a crucial factor for the spreading of liquid aluminium on the coated surface. For industrial brazing and welding processes these zinc-coatings enable a fluxless joining between aluminium and steel in many cases. Yet, the reason for the beneficial effect of the zinc to the wetting process is not completely understood. Fundamental investigations on the wetting behaviour of single aluminium droplets on different zinc-coated steel surfaces have revealed a distinct difference between coated surfaces at room temperature and at elevated temperature regarding the influence of different coating thicknesses. In this paper the case of continuous laser brazing and welding processes of aluminium and commercial galvanized zinc-coated steel sheets are presented. It is shown that in the case of bead-on-plate laser beam brazing, the coating thickness has a measureable effect on the resulting wetting angle and length but does not have a significant impact in case of overlap laser beam welding. This might be linked to different heat transfer conditions. The results also strongly indicate that proper initial breakup of oxide layers is still required to accomplish good wetting on zinc-coated surfaces. © 2014 Published by Elsevier B.V.
    [Show full text]
  • Controlling Interfacial Reaction in Aluminium to Steel Dissimilar Metal Welding
    Controlling Interfacial Reaction in Aluminium to Steel Dissimilar Metal Welding A thesis submitted to the University of Manchester for the degree of Doctor of Philosophy in the faculty of Engineering and Physical Sciences 2015 Lei Xu School of Material Content CONTENTS List of Figures ......................................................................................................................... 6 List of Tables ......................................................................................................................... 21 List of Publications ............................................................................................................... 22 Abstract ................................................................................................................................ 23 Declaration ........................................................................................................................... 24 Copyright .............................................................................................................................. 25 Acknowledgements .............................................................................................................. 26 Chapter 1 Introduction ......................................................................................................... 27 1.1 State of the Art and Motivation ................................................................................. 27 1.1.1 Greenhouse Gas Emissions ................................................................................
    [Show full text]
  • Experimental Study and Numerical Simulation of Heat Transfer and Fluid Flow in Laser Welded and Brazed Joints
    Southern Methodist University SMU Scholar Mechanical Engineering Research Theses and Dissertations Mechanical Engineering Spring 2020 Experimental Study and Numerical Simulation of Heat Transfer and Fluid Flow in Laser Welded and Brazed Joints Masoud Mohammadpour [email protected] Follow this and additional works at: https://scholar.smu.edu/engineering_mechanical_etds Recommended Citation Mohammadpour, Masoud, "Experimental Study and Numerical Simulation of Heat Transfer and Fluid Flow in Laser Welded and Brazed Joints" (2020). Mechanical Engineering Research Theses and Dissertations. 24. https://scholar.smu.edu/engineering_mechanical_etds/24 This Dissertation is brought to you for free and open access by the Mechanical Engineering at SMU Scholar. It has been accepted for inclusion in Mechanical Engineering Research Theses and Dissertations by an authorized administrator of SMU Scholar. For more information, please visit http://digitalrepository.smu.edu. EXPERIMENTAL STUDY AND NUMERICAL SIMULATION OF HEAT TRANSFER AND FLUID FLOW IN LASER WELDED AND BRAZED JOINTS Approved by Dr. Radovan Kovacevic Dr. Blair Carlson Dr. Xin-Lin Gao Dr. Wei Tong Dr. Xu Nie EXPERIMENTAL STUDY AND NUMERICAL SIMULATION OF HEAT TRANSFER AND FLUID FLOW IN LASER WELDED AND BRAZED JOINTS A Dissertation Presented to the Graduate Faculty of the Bobby B. Lyle School of Engineering Southern Methodist University in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy With a Major in Mechanical Engineering by Masoud Mohammadpour (B.S., Tabriz Azad University, Iran, 2010) (M.S., Urmia University, Iran, 2012) May 16 , 2020 Copyright (2020) Masoud Mohammadpour All Rights Reserved ACKNOWLEDGEMENTS My sincere gratitude goes to Professor Radovan Kovacevic, my advisor, for his continuous support and guidance in my research and completing this dissertation.
    [Show full text]
  • Maintenance Work Programmed Specification (MWPS) for Housing New Zealand: M-215
    Maintenance Work Programmed Specification (MWPS) for Housing New Zealand: M-215 Date: 1 July 2016 VERSION 3 SPECIFICATION of work to be done and materials to be used in carrying out the PBMC works scoped and as shown on any accompanying drawings © Housing New Zealand. This document has been developed by Housing New Zealand. Reproduction, adaptation or utilisation either in part or in whole without the prior written consent of Housing New Zealand is prohibited. M-215 Maintenance Work Programmed Specification V3 2016-17 Version 3 1 July 2016 Page 1 of 332 People and Property Team Maintenance Work Programmed Specification (MWPS) for Housing New Zealand TABLE OF CONTENTS 1013 DOCUMENT CONTROL ...................................................................................................... 4 1232 INTERPRETATION & DEFINITIONS .................................................................................. 5 1233 REFERENCED DOCUMENTS ............................................................................................ 7 1237 WARRANTIES ..................................................................................................................... 9 1250 ESTABLISHMENT & TEMPORARY WORKS ...................................................................11 1260 PROJECT MANAGEMENT ...............................................................................................15 1270 CONSTRUCTION ..............................................................................................................20 2110 DEMOLITION WORKS
    [Show full text]
  • Friction Stir Welding Contents
    Technical Handbook Friction Stir Welding Contents page page Introduction 4Equipment 37 Full-scale automation for Process principles 6 high-volume applications 37 Weldable alloys 6 Modular flexibility for Process characteristics 7 “standard” applications 37 Welding parameters 7 Robotised for more complex applications 37 Tools 7 Design principles 8 Tools for steels 8 Quality and enviromental aspects 39 Retractable pin tool 8 Environmental aspects of Friction Stir Welding 39 Bobbin tool 10 Less weld-seam preparation 39 Process speed 10 Fewer resources 39 Aluminium 13 Noise, an underestimated health threat 39 Energy saving FSW process 39 Application areas 15 Less post-treatment and impact Aerospace 15 on the environment 39 Space industry 15 Friction Stir Welded components offer Civil aviation 16 through-life environmental gains 40 Aerospace R&D 16 Quality 40 Shipbuilding 18 Application advances 18 Economics 41 Parts and components 19 Example of cost analysis 42 Automotive industry 21 Compared to arc welding 44 Automotive applications 22 Tailor welded blanks (TWB´s) 27 Conclusions 46 Superplastic forming 27 Extruders and extrusions – with special focus on rolling-stock panels 28 Steel and other high-temperature materials 30 Application examples 32 Case study: Swedish Nuclear 32 Case study: Marine Aluminium a.s, Norway 35 DISCLAIMER Whilst all reasonable efforts have been made to ensure the accuracy of the information contained in this handbook at the time of going to press, ESAB gives no warranty with regard to its accuracy or completeness. It is the responsibility of the reader to check the accuracy of the information contained in this handbook, read product labels and equipment instructions and comply with current regulations.
    [Show full text]
  • Paper on Comparision of Conventional Welding Methods with Solid-State Welding Techniques
    International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 10 | Oct -2016 www.irjet.net p-ISSN: 2395-0072 PAPER ON COMPARISION OF CONVENTIONAL WELDING METHODS WITH SOLID-STATE WELDING TECHNIQUES 1V. prasanna Associate Professor ,Department of Mechanical Engineering, NITS, Hyderabad 2S. Narsing Rao , DGM Midhani, Hyderabad --------------------------------------------------------------------------------------------------------------------------------- Abstract:-The aim of the present study was to compare Arc welding (AW) Friction Stir Welding (FSW) method which is an innovative It is a fusion welding process in which heating of metals is solid-state welding technique with conventional welding accomplished by an electric arc. In most arc welding methods. Nowadays, the technologies are toward eco- processes, filler metal is added during the operation to friendly system. The eco-friendly systems represent increase the volume and strength of the weld joint. As the reduction the potential threat and waste to the earth. electrode is moved along the joint, the molten weld pool Friction Stir Welding (FSW) is a new kind of welding solidifies in its wake. method that was invented by The Welding Institute (TWI). It is different from conventional welding methods and also Resistance Welding (RW) different from other old solid welding process. The method It utilizes a combination of heat and pressure to utilizes rotating welding tools to generate friction heat for accomplish coalescence. The heat required is generated heating the parent metal until the metal merge. The by electrical resistance to current flow at the interface of process is called Solid-state joining process, which is the two parts to be welded. original metal characteristics have not changes.
    [Show full text]
  • A Study on the Joining Technology of Copper-Aluminium Composite Heat-Dissipating Components
    Journal of Manufacturing Engineering, June 2021, Vol. 16, Issue. 2, pp 066-069 A STUDY ON THE JOINING TECHNOLOGY OF COPPER-ALUMINIUM COMPOSITE HEAT-DISSIPATING COMPONENTS *BIAN Yan-fei, SHI Jian-zhou, XIE Ming-jun, and CAI Meng The 54th Research Institute of China Electronics Technology Group Corporation, Shijiazhuang 050081, China ABSTRACT Copper-aluminium composite heat dissipation components have both the high thermal conductivity of copper and the low density of aluminium. Copper and aluminium are dissimilar materials as they have significant differences in physical and chemical properties, and hence it is not easy to weld them together. In this paper, the joining of copper to aluminium is studied by using the ultrasonic brazing technique. The results show that the copper and aluminium can be connected by ultrasonic brazing, and it is found that the bonding of the copper side interface is the weak link of the entire joint, but the joint strength can still reach 95MPa. Keywords: Copper aluminium composite structure, Radiator, Heat exchange, Heat sink, Ultrasonic brazing. composite structure, but the strength and rigidity are 1. Introduction low, and it is not easy to ensure the tightness of the water channel. With the development of electronic devices The ultrasonic brazing method[9] is suitable for towards high frequency and integration, the rapid dissimilar welding materials such as aluminium and increase of heat production will inevitably bring urgent copper. Because of its unique welding method and demand for heat dissipation [1,2]. Aluminum does not flexibility of operation, ultrasonic brazing can complete conduct heat fast enough to transfer heat from the inside the precision welding of unique and complex structures.
    [Show full text]
  • Aluminium Fusion Welding
    EAA Aluminium Automotive Manual – Joining 2. Characteristics of aluminium in fusion welding Content: 2. Characteristics of aluminium in fusion welding 2.0 Introduction 2.1 Welding of aluminium 2.1.1 The aluminium oxide film 2.2 Weld preparation 2.3 The welding zone 2.3.1 Solidification in the fusion zone 2.3.2 Crack formation in the fusion zone 2.3.3 Gas absorption and pore formation 2.4 Filler materials 2.4.1 Selection of filler materials 2.5 Shielding gases for welding aluminium 2.6 Joint design for fusion welding 2.7 Characteristics of the weld zone 2.8 Imperfections in fusion welds 2.9 Work environment and safety 2.10 Simulation of fusion welding Version 2015 ©European Aluminium Association ([email protected]) 1 2.0 Introduction Fusion welding of wrought and cast aluminium components is a key joining technology in automotive engineering. Fusion welding is characterised by partial melting of the work pieces to form a molten metal pool that solidifies and results, after subsequent cooling, in a firm joint. For quality reasons, a filler material is added sometimes. Different energy sources are used to produce the weld, including electricity, laser, electron beam and friction. Various fusion welding processes have been adapted or specifically developed for fusion welding of aluminium which are described in subsequent chapters: - 3. Arc welding - 4. Beam welding - 5. Resistance welding - 6. Brazing - 7. Solid state welding. The present chapter considers some general aspects of the various fusion welding methods. In order to achieve sound and efficient weld joints of aluminium parts, the choice of joint design, welding parameters, procedures and processes must consider: Welding characteristics of the alloys to be joined Characteristics of the applied fusion welding process Joint configuration and surface characteristics of the joining zone (weld preparation).
    [Show full text]
  • Non-Fusion Joining of Aluminium
    Non-fusion joining of aluminium P. BASAK, B. K. SAXENA and B. N. DAS OINING of aluminium is now a well established SYNOPSIS J technology. Successful joining can be done by TIG and MIG welding, pressure welding processes, This paper deals with various processes for non fusion brazing and soldering processes. Conventional fusion joining of aluminium . The processes of soldering have processes of joining aluminium are well known and are been dealt in details suggesting various soft solder flux widely used in India by all major fabricators. On the combinations , hard solder flux combinations for flux other hand, though non-fusion joining processes like soldering , friction soldering and reaction soldering. Brief soldering, brazing and pressure welding have wide field details of brazing alloys and fluxes have also been given. of applications the correct process and material required Usefulness of pressure welding in joining electrical are not very well known ; as such there is a specific conductors and other small items has been discussed need in India, at present, to disseminate the knowledge giving details of the process and types of pressure welding on joining of aluminium especially by these processes equipments available commercially . Brief mention has been which a small fabricator can handle. made to newer processes like ultrasonic and explosive Since small industries are called to fabricate com- joining. ponents from commercial grade aluminium only and most of the fabrications, by such fabricators, are that the joint does not require a high strength like a welded aluminium is attributed, as mentioned earlier, to a joint, attention has mainly been focussed to the soldering tenacious oxide layer which forms very rapidly and processes.
    [Show full text]
  • EAA Aluminium Automotive Manual – Joining
    EAA Aluminium Automotive Manual – Joining Content 1. Introduction 2. Characteristics of aluminium in fusion welding 3. Arc welding 4. Beam welding 5. Resistance welding 6. Brazing 7. Solid state welding 8. Mechanical joining 9. Adhesive bonding 10. Hybrid joining 11. Joining dissimilar materials Version 2015 ©European Aluminium Association ([email protected]) 1 1. Introduction Joining is a most important fabrication technology in automobile manufacturing. The standard joining technique for the production of conventional steel car bodies has been resistance spot welding. With the advancement of new, innovative joining technologies and the simultaneous introduction of high and ultra-high strength steel grades, additional joining methods have found limited application. However, resistance spot welding still remains the dominating joining technique for steel cars. On the other hand, joining of aluminium components by resistance spot welding of aluminium presents some problems. When substituting steel by aluminium, the sensitivity of the mechanical properties of work-hardened and age-hardened aluminium alloys to heat input generated during the welding process and their specific physical characteristics ask for specific attention in design and engineering as well as production planning (equipment and process parameters). Consequently, the growing application of lightweight aluminium solutions in automobiles posed significant challenges both for the automobile manufacturer as well as for the supplier of the aluminium materials and components. The key enabler for the use of aluminium in automotive applications proved to be the series application of non-heat involving joining techniques like mechanical joining and adhesive bonding. Today, appropriate qualitatively outstanding and highly efficient joining methods are available for aluminium and will be described below in more detail.
    [Show full text]
  • Effects of Process Parameters Joining the Dissimilar Materials AA6082-T6
    Effects of Process Parameters Joining the dissimilar materials AA6082-T6 and AISI 316Ti by Friction Stir Welding Aluminium -Steel materials in butt joint Victor Mello Callil configuration Projeto de Graduação apresentado ao Curso de Engenharia Naval e Oceânica da Escola Politécnica, Universidade Federal do Rio de Janeiro, como parte dos requisitos necessários à obtenção de título de Engenheiro Orientador(es): Jean David Job E.M.Caprace Luciano Andrei Bergmann Marcelo Igor L. de Souza Rio de Janeiro Janeiro de 2020 FSWed DISSIMILAR ALUMINIUM/STEEL MATERIALS 6 mm THICK IN BUTT JOINT CONFIGURATION Victor Mello Callil PROJETO DE GRADUAÇÃO SUBMETIDO AO CORPO DOCENTE DO CURSO DE ENGENHARIA NAVAL E OCEÂNICA DA ESCOLA POLITÉCNICA DA UNIVERSIDADE FEDERAL DO RIO DE JANEIRO COMO PARTE DOS REQUISITOS NECESSÁRIOS PARA A OBTENÇÃO DE GRAU DE ENGENHEIRO NAVAL. Examinado por: Prof. Jean David Job E.M.Caprace Prof. Marcelo Igor L. de Souza Prof. Murilo A. Vaz Prof. Julio Cesar R. Cyrino RIO DE JANEIRO, RJ – BRASIL JANEIRO DE 2020 Mês de 2018 ii Callil, Victor Mello FSWed dissimilar aluminium/steel materials 6 mm thick in butt joint configuration / Victor Mello Callil – Rio de Janeiro: UFRJ/Escola Politécnica, 2018. Xii, 44 p.: il; 29,7 cm. Orientador(es): Jean-David J. E. M. Caprace Luciano Andrei Bergmann Marcelo Igor L. de Souza Projeto de Graduação – UFRJ / Escola Politécnica / Curso de Engenharia Naval e Oceânica, 2018. Referências Bibliográficas: p 58-61. 1. FSW 2. Dissimilar Joints 3. Butt joint configuration 4. Experimental Tests 5. AISI 316 Ti / AA 6082 – T6 I. Caprace, Jean David et al.II.
    [Show full text]