Parameter optimization of laser welding of steel to Al with pre-placed metal powders using the Taguchi-response surface method
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Fusion welding
Brittleness
Flash welding
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Gas metal arc welding(GMAW)of X80 steel was conducted with optimized WER70 welding wire in the condition of same heat input of pipeline steel welding as usually used in actual girth welding.The average impact energy of weld metal at-20℃ reaches as high as 181J,and the welded joint has ideal microstructure.The butt weld and the wire deposited metal have almost equivalent mechanical properties.
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Welding is metallurgical fusion process. Here, the interface of two part to be joint are brought to a temperature above the melting point and then allowed to solidify so that a permanent joining take place. Because of permanent nature of joint and its strength being equal to or sometimes greater than that of parent material, Resistance welding is fusion welding process in which a low voltage and very high current is pass through joint for a very short time. This high amperage heats the joint due to the contact resistance at the joint and melts it. The pressure on the joint is continuously maintained and the metal fuses together under this pressure. In this paper we are going to discus on multi point electrode (plate) to increase the productivity in minimum time, by reducing human fatigue , and man and machine hour.
Fusion welding
Welding joint
Cold welding
Upset welding
Contact resistance
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Many kinds of welding methods were introduced for Al/Cu dissimilar materials,including fusion welding,pressure welding,friction welding,explosive welding,diffusion welding,ultrasonic welding,stored energy welding,resistance welding,brazing,and so on.The characteristics and present research situation of these welding methods were expounded.Fusion welding isn't mostly applied because it is greatly difficult to weld Al/Cu dissimilar materials by the fusion welding.The joint quality is excellent by heat pressure welding,friction welding,ultrasonic welding,and so on,but the cost is very high.At present,resistance welding has obtained the huge success to weld Al/Cu dissimilar material tubes and is applied in the many factories.In recent years,brazing becomes the hot research spot by many fine characteristics.Resistance welding and brazing possibly become the development trend.
Fusion welding
Friction Welding
Explosion welding
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The paper reviews a variety of conventional welding methods in recent years(including pressure welding,friction stir welding,brazing and fusion welding),and states that the key of welding aluminum and steel is to control the thickness of the intermetallic phase layer.It introduces in detail the advantages of controlling the thickness of the intermetallic phase layer,while at the same time,it indicates the disadvantages of the welding methods in practical production and prospects the research direction of welding the two materials.
Fusion welding
Friction Welding
Cold welding
Explosion welding
Brazing
Flash welding
Butt welding
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The research work deals with to join two dissimilar aluminum alloys by solid state welding process compared to fusion welding processes and compared with fusion welding process, fusion welds tend to produce more defects while joining dissimilar materials. The major problem of the two dissimilar metals involve in welding process have different mechanical properties and microstructures which in turn may affect welding parameters like weld current, hold time, weld force etc. In order to overcome these issues, Friction Stir Welding (FSW) can be used to get rid of defects since it uses a non-consumable tool and also produces defect free welds compared to other welding processes. This thesis work aims to joining an aluminum alloy of 2024 and aluminum alloy of 6061. The plates are joined by means of octagon probe tool made of high carbon high chromium steel (D2 tool steel). Other issues while welding dissimilar aluminum alloys are phase transformation change and selection of welding parameters (rotational speed, transvers speed, pin diameter, shoulder diameter, D/d ratio and etc.) From conducted trail experiment aluminum alloy of 2024 and aluminum alloy of 6061 by using octagon probe tool made by HC-HCR tool it was observed that a lower welding speed 500 rpm at starting stage lack of filling took place and after thermo-mechanical heating took place that produce better weld while compared to weld at higher speeds (710 rpm, and 1000 rpm) with same transvers speed of 20 mm/min.
Fusion welding
Friction Stir Welding
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Friction Welding
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Abstract Ultrasonic metal welding process has received noticeable attention throughout the last few years because of their proper application in comparison to the conventional fusion welding process. Fusion welding of dissimilar metals like copper and nickel, copper and aluminum alloy is always a difficult task due to the different physical, chemical, thermal properties, poor control of grain size and it has a deleterious effect on mechanical properties. Automotive industries have been widely accepted the ultrasonic metal welding process for assembling lithium-ion battery tabs. The aim of this current work is to investigate the weldability of two dissimilar metals namely aluminum (AA1060) and cupronickel (UNS C71500) sheets at various levels of welding time, vibration amplitudes and welding pressures with a fixed ultrasonic frequency of 20 kHz. The highest ultimate tensile shear strength test of joint achieved at highest vibration amplitude with moderate welding pressure and weld time. Weld quality determining characterization is introduced for the weld region to establish a relationship between physical attributes with the microstructural phenomenon.
Fusion welding
Ultrasonic welding
Weldability
Cold welding
Spot welding
Plastic welding
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The dissimilar metal welding always challenges. The different alloys have different physical and mechanical properties. In the case of the electronic component of the car, it needs to establish a joint between dissimilar metals. The useful metals are for this application are copper and aluminium. Even that has good conductivity, corrosion resistance and formability. By fusion welding technologies these thin metal workpiece joining is not a simple technology. To use a solid state welding technology can be a suitable solution to establish a cohesion joint in case of this task. It well-known much suitable technologies, even that all of them has advantages and disadvantages. The choice of solid-state technology is the ultrasonic welding process. In the case of this process, we use pressure and high-frequency vibration for welding. Besides this process, the friction and vibration generated heat is lower than the metal melting temperature. The base of this technology is the ultrasound-assisted high-level formability. The optimization of this dissimilar joining technology parameters needs many pre-welding and testing process. In this work, we wanted to introduce this empirical optimization process.
Fusion welding
Plastic welding
Friction Welding
Cold welding
Ultrasonic welding
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The research work deals with to join two dissimilar aluminum alloys by solid state welding process compared to fusion welding processes and compared with fusion welding process, fusion welds tend to produce more defects while joining dissimilar materials. The major problem of the two dissimilar metals involve in welding process have different mechanical properties and microstructures which in turn may affect welding parameters like weld current, hold time, weld force etc. In order to overcome these issues, Friction Stir Welding (FSW) can be used to get rid of defects since it uses a non-consumable tool and also produces defect free welds compared to other welding processes. This thesis work aims to joining an aluminum alloy of 2024 and aluminum alloy of 6061. The plates are joined by means of octagon probe tool made of high carbon high chromium steel (D2 tool steel). Other issues while welding dissimilar aluminum alloys are phase transformation change and selection of welding parameters (rotational speed, transvers speed, pin diameter, shoulder diameter, D/d ratio and etc.) From conducted trail experiment aluminum alloy of 2024 and aluminum alloy of 6061 by using octagon probe tool made by HC-HCR tool it was observed that a lower welding speed 500 rpm at starting stage lack of filling took place and after thermo-mechanical heating took place that produce better weld while compared to weld at higher speeds (710 rpm, and 1000 rpm) with same transvers speed of 20 mm/min.
Fusion welding
Friction Stir Welding
Cold welding
Friction Welding
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This report relates to a fusion upset welding method effected using molten slag as resistance-exo-thermic medium.It is known that most of conventional welding methods effect their welding by means of molten deposit metal formed in a number of ways, but it may also happen that, in the case of welding ordinary and special steels, mechanical properties of deposited metal invariably drop to a considerable extent under all circumstances. On the other hand, the resistance butt welding and flash butt welding methods in which no metal is deposited, necessitate provision of large capacity power source facilities, so that it is difficult to weld a large cross section using normal welding facilities in these welding systems.The objective of developing this new welding method is to solve above mentioned problems. This method enables effective welding of large cross sectional materials with I-shape welding grooves under small current densities, utilizing the resistance-exothermic heat developed as a small current passes through the molten slag.
Upset welding
Fusion welding
Flash welding
Butt welding
Upset
Slag (welding)
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Abstract With the rapid development in the technological, industrial, and defense industries, the joining of metallic materials used becomes very important. Various problems may arise in metallic materials joined by traditional fusion welding methods. The friction welding technique, which is one of the solid-state welding types that contains minimum welding defects and creates minimum internal stresses after welding, can be used in order to reduce the negativities in different steel joining. Thus, the negativities in fusion welding methods are reduced. The friction welding is a plastic deformation and extrusion process that uses heat to convert mechanical energy generated by friction between the interfaces of these two material pairs as a result of one material rotating at a stationary speed and the other rotating at a rotary speed into thermal energy. The heating phase (friction phase) is the time until the end of the welding process. During this time, the surfaces are under pressure. The formation of temperature in steel is between 900 and 1300 °C, and this temperature is reached in a very short time. Thus, parts are joined together by the pressing force. Materials that are very difficult to join with fusion welding can be joined more easily by friction welding.
Fusion welding
Friction Welding
Cold welding
Plastic welding
Explosion welding
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