Resistance spot welding (RSW) is a complicated process, which involves the interaction of electrical, thermal, mechanical, and metallurgical phenomena. In this research we used two types of material (UNS G10050 carbon steel and UNS C10010 copper) and welded them in similar and dissimilar condition with four variables welding current, pressure, squeeze time and welding time. The results of the tensile-shear force were analyzed statistically by the Design of experiments (DOE) utilizing Taguchi method. Tensile-shear test used for counting the strength of the joint, maximum strength was found in similar joining condition for carbon steel, also it is interesting to note that the strength of dissimilar joint is stronger than copper joining in similar condition.
The objective of this work is to investigate the chemical composition, mechanical, and metallurgical properties of welded the carbon steel plates by electrode E7Cr utilize a shielded metal arc welding (SMAW) to weld three cases include one, two, and three passes. The material of the carbon steel plate was of type AISI 1050 with a thickness of 18mm, the diameter of the electrode was 3.2mm. A surface welding was used as a deposit on the surface of base metal with welding parameters of welding current = 90-140A, voltage = 21V. The welded workpiece was tested by a chemical composition analysis, Vickers hardness test, and microstructure test. The results refer that the chemical composition analysis of deposited weld metal achieved an increase in the alloying element of C, Cr, and Mn. The microstructure test of welding zone gives the microstructure different of the base metal, which it consists of a mixture of fine-grain Ferrite, dendrite, coarse dendrites, and Cr-carbide, especially in the third pass. The Vickers hardness test of the third layer had an estimate much higher than of the other layers.
The goal of this research is to use a Friction Spot Joining (FSpJ) is a new technique which used for joining hybrid structures of metal-polymer composite. The FSpJ was proposed to join sheets of aluminum alloy of type AA6061-T6 and polymer of type polyvinyl chloride (PVC). The aluminum alloys sheets were of 3mm thickness, while the polymer sheets were of 5mm thickness. All sheets were manufactured with dimensions of 25*100 mm2. The aluminum sheets were drilled with two holes: the first of 8mm diameter with 1mm depth, the second hole was of the same pervious hole center with a penetrating hole diameter of d mm (2,4 and 6) the aluminum holes were made at a the center of the lap joint area. The process parameters included the rotating speed of the tool of 710, 900, 1120, 1400 and 1800 RPM, plunging depth of the tool of 0.1, 0.2, 0.3, 0.4 and 0.5 mm and pre-heating time of 5, 10, 15, 20 and 25 sec. The results indicated that all the specimens were joined successfully. The tested sample indicated that the failure of FSpJ joints occurred at two locations; the first at polymer side and the second was occurred by shearing the lap joint of specimens. The first type of failure indicated that the shear strength of the joined samples exceeded the shear strength of the polymer with a shear strength joint efficiency of more than 100%. The specimens that failed by shearing the polymer at the lap joint region were failed without dislocation the molten polymer from the aluminum hole cup. The shear force of the AL-PVC joints ranged from (704-1664N). The hole diameter exhibited the highest effect on the joint shear force followed by the plunging depth, rotating speed and pre-heating time of the rotating tool. The macrostructure examination and SEM tests indicate that a macro mechanical interlocking formed between the metal and filled hole which attributed to the main joining mechanism at the common surface.
Objective - The objective of this study is to join Aluminum alloy type (AA6061-T6) of (1.5) mm thickness to pre-threaded pure copper of (2) mm thickness applying the frictional spot lap joining (FSpLJ) technique. Styling - All specimen aluminium and copper was prepared by cutting them by dimensions (100×25) mm, pure copper samples (2) mm thickness were pre-punctured with a diameter of (4) mm and then threaded it with a diameter of (4.8) mm, a tooth step (1) mm, a rotational instrument with a (10) mm diameter was used for the joining operation. Configuration - The threaded copper was put in the mold channel, placing aluminum on top of the copper, putting the fastener over the sample, and placing the top cover of the template and fixation it with three bolts. Approach - The process parameters [rotating speed (RPM), plunging depth (mm), and pre-heating time (sec.)] was optimized by using Taguchi style, there were four levels for each parameter. The influence of the operation parameters on the joint shear strength was analyzed. The tests [Visual examination, shear force, macrostructure, and the microstructure of the joint were applied]. Results – AA6061 was extruded through the pure copper hole and its interlock with the thread slot. As a result, it was obtained mechanical overlap between the extruded aluminum and the copper. The plunging depth parameter had the greatest influence on the shear strength of the joint. Increasing the plunging depth and the rotational speed of the tool was gradually increased the efficiency of the joint. The results showed that the samples failed to test shear in the zone of the lap joint. The highest shear force is (2176) N.
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