Key Engineering Materials Vols. 554-557

Abstract: Friction stir welding (FSW) has received increasing attention in recent years thanks to its advantages over traditional welding processes, reducing distortion and eliminating solidification defects. Since melting does not take place and joining occurs below the melting temperature of the material, this welding process allows to obtain a weld characterized by very high quality with low heat input, minimal distortion, no filler material, and no fumes. FSW is also highly efficient and it is characterized by improved environmental performance if compared to traditional welding methods. For instance, FSW is particularly advantageous in the pipeline industry because this innovative welding process usually entails reduction in energy usage of up to 80% if compared to conventional fusion welding processes. Moreover, also alloys normally difficult to be welded can be considered with this technique. The objective of the present study is to establish and to study the weldability of aluminum tubes by means of FSW process. The study shows preliminary results on circumferential FSW of AA6060-T6 aluminum tubes and the influence of the welding process on weld quality. The experimental campaign was performed on tubes having a thickness equal to 5 mm and an external diameter equal to 80 mm. Tubes were welded by means of a four axes CNC machine tool. Particular care was paid to the fabrication of the inner support for the tube. The mandrel was designed in order to guarantee limited bending during the welding process. Some preliminary tests were carried out by varying the welding parameters, namely feed rate (f) and rotational speed (S). A tool having conical shoulder and cylindrical pin was used. The weld quality investigation was based on tensile tests, microhardness and macrostructure analysis of the joints.

Abstract: In aeronautics and aerospace construction, whenever a seam is needed between aluminum alloy parts, riveting, nailing or bolting are the preferred methods of junction. Friction stir welding technology has made possible the realization of high strength aluminum alloy joints, which are normally considered non-weldable with conventional welding techniques.

Abstract: This paper presents a systematic investigation of the influence of sandblasting pretreatment parameters on the surface roughness and mechanical characteristics of adhesive-bonded joints. The preliminary surface treatment in a bonding process has two important aims: first of all, it eliminates contaminants (dust, grease, humidity and corrosion products) which can modify the wettability of the substrate, then it increases surface roughness and, consequently, the contact area between substrate and adhesive, creating a mechanical interlocking that maximizes adhesion. To enhance the strength and avoid the de-adhesive failure of the joint, it is therefore advisable to increase the contact substrate-adhesive by a mechanical treatment of sanding, grinding or preferably sandblasting, usually considered one of the most effective methods to control the desired level of surface roughness and joint strength. This process, apparently easy to manage, is controlled by a great number of operating parameters, which all contribute to creating a good result. With the aim of evaluating the influence that some of these parameters have on the mechanical characteristics of adhesive-bonded joints, an experimental campaign was carried out. In particular, a steel substrate, an epoxy adhesive and various types of sand, different in nature and granulometry were used. The variable parameters for the execution of blasting are sand, impact angle and pressure. The assessments departed from an investigation into their effect on surface roughness and thereafter the mechanical properties of the bonded joints were analyzed.

Abstract: Friction stir welding is known for his capability to achieve a linear weld. However, more investigation on a curved friction stir weld trajectory is still required to industrialize this promising process. In the same perspective, this study is aimed at analyzing the influence of nonlinear tool trajectory in friction stir welding. The study considers a variety of circular trajectories on the plane plate and uses them for experimentation while considering different welding parameters of rotation speed feed speed, axial force and tilt angle.In FSW, the tool is generally needed to be tilted with a constant angle in the travel direction during welding process. Therefore, for circular trajectory, an adequate roll and pitch angle are assigned to the spindle in all tool positions. The paper presents the effect of circular trajectory on longitudinal and transversal forces generated during circular welding. The results are then compared with the experimental results which are obtained using linear FSW. Furthermore, the experimental investigation includes relationship between tool trajectory and weld quality.

Abstract: Friction stir welding (FSW) is a relatively new solid-state joining technology for metals. It shows no solidification-related joint imperfections which makes it utmost suitable for hard-to-weld highly alloyed aerospace aluminium grades, like AA 2xxx and AA 7xxx. These alloys are often cladded with a thin layer of pure aluminium for corrosion protection. Friction stir welding of such materials requires removal of the clad layer prior to welding to prevent weakening of the joint by the soft clad material. This leaves the welded region vulnerable to corrosion after the joining process. Post-weld restoration of the clad layer is required to restore the protective action of the clad layer and as such to enhance the life expectancy of the welded construction. In this work the deposition of thin layers of pure aluminium on AA 2xxx and AA 7xxx alloys is studied employing an innovative FSW tool. The tool shoulder is equipped with strategically placed internal channels that allow delivery of filler type of material into the weld zone. Depending on the channel architecture used, filler material can be deposited on top of the work piece surface and/or mixed with the work piece surface region. The cladding is done in the solid state avoiding many problems with solidification and interface reactivity often observed with other surface modification techniques, such as laser surface engineering, plasma spraying or casting. Here, the filler material is deposited on top of the work piece; the modified tool is not equipped with a tool pin. The work comprises an in depth study of the influence of process conditions on the microstructural changes in the underlying work piece and on the quality of the bonding of the clad material (99.5 % aluminium) to the work piece material. Apart from the usual process conditions, such as tool rotation speed, translation speed, down force and tool angle also the delivery pressure and rate of the filler supply system can be varied. The influence of the usual process conditions on the microstructure of the underlying work piece is similar to that observed with “traditional” FSW. Changes in hardness can be related to the amount of heat generated by the welding process. Shape and dimensions of the microstructural zones found are typical for welds made without a tool pin. The effect of the small amount of clad material deposited on top of the work piece on the temperature distribution is small. The amount of heat required to heat it up is negligible to the heat required to heat up the work piece and the tool. The quality of the bonded clad layer is dependent on the amount of heat and plastic deformation generated at the interfaces between the tool, the filler material and the work piece. Tool angle, tool shape and supply rate of the filler supply system determine the layer thickness.

Abstract: In recent years, remarkable interest has been focused on the Friction Stir Welding (FSW) process, by academic as well as industrial research groups. Conceptually, the FSW process is quite simple: a non-consumable rotating tool is plunged between the adjoining edges of the parts to be welded and moved along the desired weld line. Frictional and viscous heat generation increases the work piece temperature, softening the processing material and forcing it to flow around the pin. Although FSW has been effectively applied in welding of several materials, such as copper, steel, magnesium, and titanium, considerable attention is still focused on aluminum welding, in particular for transport applications. Recent literature clearly evidenced microstructural variations in the stir zone, imputable to continuous dynamic recrystallization phenomena, leading to the formation of a finer equiaxed grains. Moreover, depending on the specific alloy, thermal cycles can induce coarsening or dissolution of precipitates in the thermo-mechanically affected zone (TMAZ) and in the heat affected zone (HAZ). The influence of the aforementioned microstructural aspects on mechanical properties and formability of FSWed assemblies is also well recognized. The aim of this paper is to numerically and experimentally investigate the influence of process parameters, namely rotating speed and welding speed, on microstructural aspects in AA2024-T3 friction stir butt welds. A three-dimensional Computational Fluid Dynamic (CFD) model has been implemented to simulate the process. A viscoplastic material model, based on Wright and Sheppard modification of the constitutive model initially proposed by Sellars and Tegart has been implemented in the commercial package ANSYS CFX, considering an Eulerian framework. Tool-workpiece interaction has been modeled assuming partial sticking/sliding condition, and incorporating both frictional and viscous contributions to the heat generation. Microstructural aspects have been numerically predicted using the Zenner-Holloman parameter and experimentally measured by means of conventional metallographic techniques. Satisfactory agreement has been found between simulated and experimental results. The influence of process parameters on mechanical properties has also been highlighted.

Abstract: Self-Piercing Riveting (SPR) is receiving more recognition as a possible and effective solution to join body panels and structures. For example self-piercing riveting is still the first choice for the most well-known automotive car industries when considering the intensive use of aluminum alloy. To combine the advantages of the two joints techniques, in the last years hybrid joints combining a classical mechanical fastening (riveting) and a classical adhesive bonding, or a co-cured joint, have attracted great interest.In the present paper the static behavior of single-lap hybrid joints (SPR-bonded) between GFRP and aluminum through experimental tests. In particular, tensile strength, energy absorption and failure modes of studied joints were investigated through tensile tests.

Abstract: Electrical contact crimping is a mechanical fastening process commonly used in aeronautical and aero spatial applications. In order to ensure the perfect electrical conduction and acceptable mechanical properties, the assembly have to fullfil some drastic holding force criteria. This outfit is directly dependent on the indentation depth at the end of crimping. The feedback generally reveals that an over crimping will lead to the cable breakage whereas an under crimping will be characterized by the cable sliding into the contact during pulling. The optimal behavior is a combinaison of both phenomena : the cable must become thinner before slipping into the contact. Numerical simulation is an efficient tool to limit the tedious experimental tests. It is the main topic of our work. This paper deals with prediction of the failure type and the force level required to tear out a contact crimped on multistrand cable for different indentation depths. The determination of optimal crimping condition is determined. In order to simulate the contact tensile test, crimping simulation has to be performed. The first step is then to be able to simulate accurately the crimping stage by using appropriate behavior laws and realistic conditions. One difficulty is linked to the small size of our objects. The first one is a 19 strands cable, in which each strand is about 0.15 mm diameter. The second sample is a 1 mm diameter cylindrical copper contact measuring 7 mm long. Adapted testing devices are described. Geometries and mechanical fields are obtained and then exported in the mechanical holding model to ensure realistic prediction [1]. Impact of crimping conditions on the pulling results is discussed. Pulling simulation results are compared to experimental values. The prediction of breakage mechanisms is also studied. Keywords: Crimping process, mechanical fastening operation, finite element computations, mechanical strength, breakout force, tensile test. [1] Fayolle, S., 2008, Etude de la modélisation de la pose et de la tenue mécanique des assemblages par déformation plastique : application au rivetage auto poinçonneur, Thèse de l'Ecole des Mines de Paris.

Abstract: In this study a numerical simulation model was designed for representing the joining process of carbon fiber-reinforced plastics (CFRP) and aluminum alloy with semi-tubular self-piercing rivet. The first step towards this goal is to analyze the piercing process of CFRP numerical and experimental. Thereby the essential process parameters, tool geometries and material characteristics are determined and in finite element model represented. Subsequently the finite element model will be verified and calibrated by experimental studies. The next step is the integration of the calibrated model parameters from the piercing process in the extensive simulation model of self-piercing rivet process. The comparison between the measured and computed values, e.g. process parameters and the geometrical connection characteristics, shows the reached quality of the process model. The presented method provides an experimental reliable characterization of the damage of the composite material and an evaluation of the connection performances, regarding the anisotropic property of CFRP.

Abstract: The heating distribution assessment on similar and dissimilar friction stir welded joints in AA6082 and AA5754 aluminium alloy sheets was investigated. The FSW experiments were carried out using constant rotational and welding speeds of 1500 rpm and 60 mm/min, respectively. Temperature was locally measured by means of K-type thermocouples inserted into thin grooves located on the bottom side of the sheets, in fixed positions, very close to the welding line. It was observed that the mechanical properties of joints are related to the heat distribution. In order to obtain a completely non intrusive temperature monitoring, that was able to follow the process dynamic, a non-contact measurement system based on infrared thermography was also developed. Such system, used for the experimental evaluation of temperature on the upper surface of the joints, is also able to detect the presence of flow defects with a non-destructive method, demonstrating its effectiveness as a diagnostic instrument for the on-line quality control of welded joints.