اثر سرعت جوشکاری بر تنش پسماند در طول جوشکاری قوس با الکترود تنگستن تحت پوشش گاز

Influence of welding speed and power on residual stress during gas tungsten arc welding (GTAW) of thin sections

with constant heat input: A study using numerical simulation and experimental validation

اثر سرعت جوشکاری و توان بر تنش پسماند

در طول جوشکاری قوسی الکترود تنگستن (GTAW) مقاطع نازک با ورودی گرمای ثابت

مطالعه ای با استفاده از شبیه سازی و اعتبارسنجی تجربی

ABSTRACT

The temperature distribution and residual stresses for a GTAW circumferential butt joint of AISI 304 stainless steel using numerical simulation have been evaluated. For evaluation of weld induced residual stresses, the analysis of heat source fitting was carried out with heat inputs ranging from 200 to 500 J/mm to arrive at optimal heat input for obtaining proper weld penetration and heat affected zone (HAZ). For this chosen heat input, the influence of different weld speeds and powers on the temperature distribution and the residual stresses is studied. The heat source analysis revealed the best choice of heat input as 300 J/mm. The residual stresses on the inner and outer surfaces, and along the radial direction were computed. Increase in temperature distribution as well as longitudinal and circumferential residual stresses was observed with the increase in weld speed and power. The validity of the results obtained from numerical simulation is demonstrated with full scale shop floor welding experiments.

   

ابزار جوشکاری اصطکاکی اغتشاشی friction stir welding tools

friction stir welding tools

ابزار جوشکاری اصطکاکی اغتشاشی

ABSTRACT

Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. Commercial feasibility of the FSW process for harder alloys such as steels and titanium alloys awaits the development of cost effective and durable tools which lead to structurally sound welds consistently. Material selection and design profoundly affect the performance of tools, weld quality and cost. Here we review and critically examine several important aspects of FSW tools such as tool material selection, geometry and load bearing ability, mechanisms of tool degradation and process economics.

اتصال با استفاده از تغییرشکل پلاستیک

Joining by plastic deformation

اتصال با استفاده از تغییرشکل پلاستیک

ABSTRACT

Vehicles such as aircraft and cars comprise a large number of mechanical parts produced by a variety of manufacturing processes. Cars generally consist of 10,000–30,000 parts, and the number of parts in aircraft is counted in millions. A trend in manufacturing such products is that both the number of parts and their complexity are increasing, including new combinations of dissimilar materials. Welding, adhesive bonding and mechanical fastening are typically used to join components during product assembly. In fusion welding, workpieces are joined by the application of an external heat source which melts material around the interface. Although the use of welding is widespread, the high temperatures required may reduce the quality, accuracy and reliability of joined parts. The strength of adhesively bonded and mechanically fastened joints is almost always lower than that achieved by welding. Commercial requirements for higher performance, higher productivity and lower cost in joining operations are becoming more demanding. In addition, strong joining of dissimilar materials is increasingly required. For example, high strength steel and aluminium sheets must be joined in some current car models, to allow weight reduction. There is therefore a need to identify new joining methods for new applications and materials.

 

سیلان مواد در طول جوشکاری اصطکاکی اغتشاشی Ti-6Al-V

Material Flow During Friction Stir Welding of Ti-6Al-4V

سیلان مواد در طول جوشکاری اصطکاکی اغتشاشی Ti-6Al-V

ABSTRACT

6 mm thick Ti-6Al-4V butt joints were produced with a tracer material embedded in the joint under a variety of process conditions, namely rotational speed and traversing speed, in an attempt to relate the welding process parameters to the material flow behavior via post weld radiographic and metallographic evaluations. It was found that by embedding refractory alloy powder into the joint line, welding through it, and subsequently x-raying the joint, the material flow patterns could be examined. The tracer material was distributed over a wider area in the weld zone relative to its starting position, implying a fair amount of mixing occurred even though little vertical movement of the tracer material was observed. There was minimal effect of material flow patterns as a function of welding parameters observed using the tracer material and radiographic examination, but defect formation in the root, where there was no tracer material, examined by cross sectional metallographic evaluations were found to be dependent on the rotational speed and traversing speed conditions. Lack of penetration defects were generally associated with relatively “cold” welding conditions (low rotational speed/high traversing speeds) and voids with “hot” conditions (high rotational speed/low traversing speeds).

 

اثر عملیات حرارتی در جوشکاری انفجاری فولاد زنگ نزن/مس

Effect of heat treatment on bonding interface in explosive welded
copper/stainless steel

اثر عملیات حرارتی روی فصل مشترک اتصال در جوشکاری انفجاری فولاد زنگ نزن/مس

ABSTRACT

In this investigation, explosive welding and heat treatment processes provided an effective method for manufacturing high-strength and high-ductility copper/ austenitic stainless steel couple. In order to improve diffusion in the interface of copper/stainless steel, first the tensile samples were provided from the welded part, then they were subjected to annealing at 300 C (below recrystallization temperature) for 8–32 h with 8 h intervals and then samples were cooled in the furnace. Optical microscopy (OM), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) were utilized to evaluate the possibility of diffusion in the joints. Moreover, in order to measure the hardness of the samples, microhardness test was performed. Microstructural evaluations showed that the stainless steel 304L had a wavy interface. Furthermore, the post heat treatment process resulted in great enhancement of diffusion. Microhardness measurements showed that the hardness of the sample near to the interface is greatly higher than other parts; this is due to plastic deformation and work hardening of copper and stainless steel 304L in these regions. The interface of samples with and without the post heat treatment was exhibited ductile and brittle fracture, respectively.

 

جوشکاری حالت جامد آلیاژ برنج Cu-Zn و فولاد

Solid-state bonding of alloy-designed Cu–Zn brass and steel

associated with phase transformation by spark plasma sintering

جوشکاری حالت جامد آلیاژ برنج Cu-Zn مخصوص و فولاد وابسته به استحاله فازی

به وسیله ی زینترینگ به کمک قوس پلاسما

ABSTRACT

Solid-state bonding between steel and a Cu alloy was studied to investigate fabrication of advanced bimetallic composites by using spark plasma sintering (SPS). In order to obtain proper bonding strength between the mating materials, Si and Al were alloyed to Cu–Zn brass to enhance interdiffusion with steel. The alloying elements diffused from the Cu alloy to steel, which transformed from the gamma to alpha phase during bonding. Owing to the phase stability of steel, the new columnar microstructure that evolved during the transformation across the joint interface showed high bonding strength between the mating alloys. The samples bonded without fracture, defects, or inhomogeneous deformation. Microstructural observations, elementary mapping, and mechanical testing demonstrated that the SPS technique and specific bonding parameters enhanced the interdiffusion between the metals. This novel method would be well suited to strengthen bonding between two dissimilar metals with different diffusion coefficients.

 

ارزیابی ساختار در اتصال نفوذی آلیاژ تیتانیوم/فولاد زنگ نزن

THE EVOLUTION CHARACTERISTICS AND NUMERICAL
ANALYSIS OF DIFFUSION BONDING INTERFACE
STRUCTURE OF TITANIUM ALLOY/Cu/STAINLESS STEEL

ارزیابی خصوصیات و آنالیز عددی ساختار در فصل مشترک اتصال نفوذی آلیاژ تیتانیوم/فولاد زنگ نزن

ABSTRACT

Carries on the investigation to the titanium alloy/Cu/stainless steel intermetallic compound of bonding interface in the meantime, to make a thermodynamic model of the interface element diffusion to have a numerical simulation of the diffusion distance and diffusion temperature, time. Using analysis methods of stretching test, microhardness test, SEM and EDS, to investigate and research the mechanical properties, the interface structure characteristic, the principal element atomic diffusion mechanism of joints thermal simulation and the vacuum diffusion bonding of Ti-6Al-4V/Cu/304, the reacting phases are produced and the distribution range . The results show that when bonding prssere is 5.0 MPa ، the joints tensile strength first increase and then decreases, with bonding temperature and time rising, When bonding temperature is 1223K, bonding time is 3.6 ks, there is a maximum tensile strength that is 162.73 MPa. However, it will is disadvantageous to performance of the joints, when bonding temperature and time extended overly. It formed multi-phase transition organizations by solid solution, intermetallic compounds in the bonding interface, such as Ti2Cu, TixCuy , Ti2Fe, TiFe2 and TiFe. Effect of TixFey on strength of the joints is slightly inferior the TixCuy compound. The fracture is mainly by the titanium alloy side region III for the source dehiscence, developing in the weak diffusion layer.

 

اتصال نفوذی آلیاژ مس به فولاد زنگ نزن تحت فشار ناگهانی

Impulse pressuring diffusion bonding of a copper alloy to a stainless

steel with/without a pure nickel interlayer

اتصال نفوذی آلیاژ مس به فولاد زنگ نزن تحت فشار ناگهانی همراه با یک لایه ی نیکل خالص بین آن ها و یا بدون آن

ABSTRACT

Impulse pressuring diffusion bonding of a copper alloy to a stainless steel was performed in vacuum. Using Ni interlayer of 12.5 lm, the joint produced at 825 C under 5–20 MPa for 20 min exhibited lower strength, which could result from the insufficient thermal excitation and plastic deformation. At 850 C under 5–20 MPa for 5–20 min, the strength of the joint improved with time. An optimized joint strength reached up to 217.2 MPa. Fracture occurred along the Cu–Ni reaction layer and the Ni layer and almost plastic fracture was confirmed by extensive dimples on the fracture surface. Using the interlayer of 50 lm, the fracture surface was similar. Without Ni assistance, under the same bonding condition, the joint strength was about 174.2 MPa. The lowered strength might be attributed to the appearance of some unbonded zones in the joint. Lots of brittle fracture areas appeared on the fracture surface.

  

ساختار اتصالات جوشکاری شده فولادهای هاردوکس

Structure and hardness changes in welded joints of Hardox steels

ساختار و تغییرات سختی در اتصالات جوشکاری شده فولادهای هاردوکس (Hardox)

ABSTRACT

In the article, the structure and change in hardness of the welded Hardox 400 and Hardox 500 steels have been presented. It has been shown that structures of lower wear resistance are being created as a result of welding those materials in the “as delivered” state (i.e. with the tempered martensite structure) within the heat-affected zones. They are as much as up to 90 mm wide, and that causes their non-uniform and fast wear in the anticipated applications. Based on microscopic tests and hardness measurements a method of thermal joints treatment has been proposed, consisting in their hardening and low-temperature tempering (self-tempering) at the heat-affected zones. It leads to reproduction of that area structure, similar to the native material structure. In the laboratory conditions, a heat treatment differing from the usual practice (stress-relief annealing or normalizing) has not led to welding incompatibilities (cracks).

 

اتصال آلیاژهای آلومینیوم 5083 و 6061 به روش جوشکاری اصطکاکی

Joining of 5083 and 6061 aluminum alloys by friction stir welding

اتصال آلیاژهای آلومینیوم 5083 و 6061 به روش جوشکاری اصطکاکی تلاطمی

ABSTRACT

Friction stir welding (FSW) has emerged as a new solid state joining technique [1], especially for aluminum alloys [2–6]. In this process, a rotating tool travels down the length of contacting metal plates, and produces a highly plastically deformed zone through the associated stirring action. The localized heating zone is produced by friction between the tool shoulder and the plate top surface, as well as plastic deformation of the material in contact with the tool [1].

At the present time, FSW is used mainly for joining similar materials. For dissimilar welding, there have been few systematic studies aimed at clarifying the effect of material combination and welding conditions on weld properties [7, 8].