Advanced Materials Research Vols. 984-985

Abstract: Friction welding is a solid state joining technique used for joining similar and dissimilar materials with high integrity. This new technique is being successfully applied to the aerospace, automobile, and ship building industries, and is attracting more and more research interest. Owing to the significance, thermal analysis on friction stud welding of mild steel and aluminium combination is carried out in the present work. In this study the temperature profiles at different locations are predicted mathematically by using one dimensional finite element method.

Abstract: Friction Stud Welding is primarily used to bond different material. Joining of aluminum alloys, stainless steels and composites with any other materials is required in many underwater welding applications. In the present work, a mathematical model has been developed for underwater friction stud welding. A thick AA6061 plate is welded with steel stud in a modified drilling machine. Transient analysis of heat conduction in the plate has been calculated numerically including heat generation due to friction between the materials. The conduction, convective and surface boundary conditions have been considered as per the developed model. Comparison has been made between welding performed in normal atmospheric condition and underwater condition. The temperature distribution in the work piece has been predicted using the developed mathematical model. It is found that there is steep fall in a heat flow during underwater welding condition. High weld strength can be achieved due to less heat affected zone in underwater welding.

Abstract: Friction plug welding, a recent variation of friction welding is a process of joining of two similar or dissimilar materials. The joint efficiency can be enhanced by applying external heat source or pre-heating at the work piece surfaces. Heat flux generation at intermediate surface is computed due to friction between the materials considering the co-efficient of friction. The land width is varied by varying the diameter of the plug to find its effect on the temperature profile. Analytical modeling is carried out with and without the effect of pre-heating. Temperature distribution in the work piece was calculated for different plug diameter with different values of pre-heating temperature ranging from 300oC-600oC. It is observed that while decreasing the land width there is a linear fall in temperature profile. With preheating, higher peak temperature is achieved at less friction time. High quality weld could be achieved with less processing time.

Abstract: In the Present paper, the effects of axial force, rotational speed of the FSW tool, welding speed and shoulder penetration on various mechanical properties of Aluminium alloy 6063 butt joint produced by Friction Stir Welding have been analyzed. The mechanical properties like tensile strength, Yield strength and % Elongation have been tested using 6 mm thickness plate. The tool used for conducting the experiment was Hot Die Steel (HDS). The welding quality can be improved by enhancing the mechanical properties and minimizing the defects. Hence, analysing & examining the mechanical or physical properties and other relevant significant factors would help to enhance the weld reliability. Tensile Strength (TS), Percentage of Elongation & Yield Strength (YS) of FSW Al 6063 alloy has been carried out under different processing condition using Taguchi’s experimental design. An optimum result has been obtained using main effects plot using S/N ratio values. The rotation speed of the FSW tool has been found dominant factor for TS followed by feed and shoulder penetration. Shoulder diameter shows the least effect on TS compared to parameters like Percentage of Elongation & Yield Strength (YS).

Abstract: In this work, frictions welding of AISI 1035 grade steel rods of 12 mm diameter were investigated with an aim to predict the value of tensile properties. Welds made with various process parameter combinations were subjected to tensile tests. Here, the three factors, five levels, central composite, rotatable design matrix are worn to limit the number of experiments. The mathematical models were developed by response surface method (RSM). The adequacies of the models were checked through ANOVA technique. From developed mathematical models, ultimate tensile strength (UTS) of the joints can be predicted by means of 95 percent confidence level. The integrity of the joints has been investigated using optical microscope.

Abstract: The solid-state joining process produces welds with improved mechanical properties and reduced distortion. Higher Carbon Steels are extensively used in different industrial applications such as shipbuilding and automobile industries due to their superior mechanical properties. In this work, friction welding of high carbon steel of Φ12mm dia extruded rod was studied with a plan to analysis the hardness behavior on the weldment. Welds are made with a high and low level range of process parameter combinations (incorporating ANOVA methods) which were subjected to Vickers Hardness tests. The Vickers Hardness of the welded joints has been reported.

Abstract: This paper gives the effects of single and multiple pore on the strength of AA2219 welds. Single and double pores are created on welded specimens and tested to study the effects. Also finite element analysis carriedout to correlate the experimental results with theory

Abstract: The present article introduces an approach that combines passive and active elements to improve the ride and passenger comfort. The main aim of vehicle suspension system should isolate the vehicle body from road unevenness for maintaining ride and passenger comfort. The ride and passenger comfort is improved by reducing the car body acceleration caused by the irregular road surface. The vehicle body along with the wheel system is modelled as two degrees of freedom one fourth of car model. The model is tested on road bump with severe peak amplitude excitations. In the conclusion, a comparison of active, semi-active and passive suspension is shown using MATLAB simulations.

Abstract: Magneto-rheological fluids are smart fluids displaying flow properties that can be adjusted by the introduction of magnetic fields. Conventional brakes require complex mechanical parts to dissipate energy, they are having more weight, produce less braking torque and the time of response is about 300-500 milliseconds and hence brake distance is high. A Magneto-rheological fluid brake is more efficient than conventional braking system in terms of the weight reduction, and response time. In this paper an improved MRB design is made, taking into account the temperature effects and more accurate description of the material properties as well. The proposed work is concerned with the development of a new Brake-by-wire system which employs MRF as working medium. The design procedure comprises the selection of materials for MRB, creating an analytical model for finding the braking torque produced by the MRB and Finite Element Analysis of the MRB. Finite element models are built to provide a means to analyze the performance of the magneto-rheological brake system. The formulation of these models (including the definition of the geometry, material properties, boundary conditions and meshing process, as well as necessary assumptions) are described. The results obtained with the finite element models are presented and analyzed using SolidWorks 2013^® and COMSOL Multiphysics 4.3b^®.

Abstract: High pressure die casting is the best suitable method for the manufacturing of Heavy Vehicle Engine Components. The design of feed system was done by Pro E wildfire 4.0 and the movement of molten metal inside the cavity was analyzed using the Magma software for an injection pressure of 600 kgf/cm^2. The die for the Heavy Vehicle Engine Components was designed and manufactured. The engine components were manufactured with the help of 250 T locking force capacity high pressure die casting machine. The radiographic inspections for some of the sample components were carried. The hardness of the Heavy Vehicle Engine Components and the porosity levels were evaluated. The component’s dimensions were checked by a co-ordinate measuring machine.