Abstract:The use of lightweight materials in the production of cryogenic tanks, spacecraft body etc. are becoming the need to develop dissimilar metal FSW joints. Friction stir welding (FSW) is a novel and inspired light metal joining process since it is not involved with the melting of the parent metal. In this work, two Aluminium 7020 plates were welded with Zn as an interlayer, using friction stir welding method. Different joints were made by varying the thickness of interlayer (Zn) and thereafter the characterizati… Show more
“…FSW structures are often subjected to severe repetitive loadings in service, causing abrupt failure due to the fatigue phenomenon. In an attempt to improve the fatigue resistance of friction stir welded joints, researchers have proposed several techniques including adding nano/micro particles to the weld nugget to create a local metal matrix composites (MMCs) [4][5][6][7], optimizing welding process parameters [8][9][10][11][12] through tool shape and operation rate, introducing novel welding tools with different geometrical features [13][14][15][16][17], inducing compressive residual stresses by means of different methods of cold working [18][19][20][21][22][23], and weld joint post-heat treatment [24][25][26].…”
Section: Introductionmentioning
confidence: 99%
“…Further techniques [4][5][6][7] improved the mechanical properties of the joints through the addition of sufficient amounts of powders/particles into the stirred zone (SZ) of FSW/FSSW joints. Enami et al [4] added alumina particles to the nugget zone of FSSW aluminum 2024-T3 joints.…”
Section: Introductionmentioning
confidence: 99%
“…They showed that addition of well-dispersed SiC powder in the SZ of the weld region could improve tensile strength and fatigue life of joints significantly. Through inserting thin metallic foils between the faying surfaces of Al 7020 weld segments, as shown by Lenin et al [7], particles of the foil material were dispersed in the SZ followed during the FSW operation, leading to an improvement in mechanical properties of joints. They showed that the alloying process through dispersing a 10 µm zinc foil in the weld region of Al 7020 FSW joints could enhance the tensile strength and impact energy of test specimens.…”
The present study examines the fatigue of friction stir welded (FSW) aluminum 6061, 7075, 1060 joints followed by (i) in situ and sequential rolling (SR) processes, (ii) plastic burnishing (iii) solution-treatment artificial aging (STA), (iv) local alloying through depositing thin copper foils, and (v) inserting alumina powder in the weld nugget zone (NZ). The microstructural features and fatigue life of post-processed joints were compared with those of as-welded joints. The in situ rolling technique offered simultaneous rolling and welding operations of aluminum joints, while through the sequential rolling process, the top surface of FSW joints was rolled after the welding process. The fatigue life of in situ rolled samples was increased as the ball diameter of welding tool increased. The fatigue life of friction stir welded joints after a low-plasticity burnishing process was noticeably promoted. The addition of 1 wt.% alumina in the NZ of joints resulted in a significant elevation on fatigue life of friction stir spot welded joints, while an increase in alumina powder to 2.5 wt.% adversely affected fatigue strength. Weld NZ was alloyed through the insertion of copper foils between the faying surfaces of joints. This localized alloy slightly improved the fatigue life of joints; however, its effects on fatigue life were not as influential as STA heat-treated or in situ rolled joints. The microstructure of weld joints was highly affected through post-processing and treatments, resulting in a substantial influence on the fatigue response of FSW aluminum joints.
“…FSW structures are often subjected to severe repetitive loadings in service, causing abrupt failure due to the fatigue phenomenon. In an attempt to improve the fatigue resistance of friction stir welded joints, researchers have proposed several techniques including adding nano/micro particles to the weld nugget to create a local metal matrix composites (MMCs) [4][5][6][7], optimizing welding process parameters [8][9][10][11][12] through tool shape and operation rate, introducing novel welding tools with different geometrical features [13][14][15][16][17], inducing compressive residual stresses by means of different methods of cold working [18][19][20][21][22][23], and weld joint post-heat treatment [24][25][26].…”
Section: Introductionmentioning
confidence: 99%
“…Further techniques [4][5][6][7] improved the mechanical properties of the joints through the addition of sufficient amounts of powders/particles into the stirred zone (SZ) of FSW/FSSW joints. Enami et al [4] added alumina particles to the nugget zone of FSSW aluminum 2024-T3 joints.…”
Section: Introductionmentioning
confidence: 99%
“…They showed that addition of well-dispersed SiC powder in the SZ of the weld region could improve tensile strength and fatigue life of joints significantly. Through inserting thin metallic foils between the faying surfaces of Al 7020 weld segments, as shown by Lenin et al [7], particles of the foil material were dispersed in the SZ followed during the FSW operation, leading to an improvement in mechanical properties of joints. They showed that the alloying process through dispersing a 10 µm zinc foil in the weld region of Al 7020 FSW joints could enhance the tensile strength and impact energy of test specimens.…”
The present study examines the fatigue of friction stir welded (FSW) aluminum 6061, 7075, 1060 joints followed by (i) in situ and sequential rolling (SR) processes, (ii) plastic burnishing (iii) solution-treatment artificial aging (STA), (iv) local alloying through depositing thin copper foils, and (v) inserting alumina powder in the weld nugget zone (NZ). The microstructural features and fatigue life of post-processed joints were compared with those of as-welded joints. The in situ rolling technique offered simultaneous rolling and welding operations of aluminum joints, while through the sequential rolling process, the top surface of FSW joints was rolled after the welding process. The fatigue life of in situ rolled samples was increased as the ball diameter of welding tool increased. The fatigue life of friction stir welded joints after a low-plasticity burnishing process was noticeably promoted. The addition of 1 wt.% alumina in the NZ of joints resulted in a significant elevation on fatigue life of friction stir spot welded joints, while an increase in alumina powder to 2.5 wt.% adversely affected fatigue strength. Weld NZ was alloyed through the insertion of copper foils between the faying surfaces of joints. This localized alloy slightly improved the fatigue life of joints; however, its effects on fatigue life were not as influential as STA heat-treated or in situ rolled joints. The microstructure of weld joints was highly affected through post-processing and treatments, resulting in a substantial influence on the fatigue response of FSW aluminum joints.
“…In our company fuel filler bracket assy is assembled with 3 main components which include 2 metal components stamped from 200TON NC stamping press and a plastic component that comes from 110TON injection moulding [1][2][3][4][5][6]. After stamping it goes to plating namely EBB plating and the mould parts go to laser printing for customer identification after injection moulding [7][8][9][10][11]. The 3 parts assembled by the manual method in PHA assy shop and are moved to our customer end.…”
In PHA India private limited fuel tank door relief handle lever (hdl) assembly part has more quality issue, also customer complaint periodically due to clip is mounted by hammering with hand.
Due to above-stated condition, the part has the following problem in pha.india.private limited as well as from our customer end. (Hyundai.motor India ltd)• Clip bracket improper seating with matching part.• Release mechanism not properly operated.• Clip bracket breaks often if more force applied.• Clip bracket comes out if less force applied.•
UPH very less. (unit per hour)• Operator fatigue increased.• It leads to hand injury.
“…Motoman has announced a dedicated welding controller ( with a servo or air gun. Internal extraction eliminates the need for support and the outer band rotation [11][12][13][14][15][16].…”
The main objective of our project is to reduce the false seam joints. There are many important issues, such as waiting for a lost robot, checking individual parts, unnecessary manual nutrition and increasing the cycle time of this soldering joint. When the cycle times are getting longer, the company's revenue decreases accordingly. Many large manufacturing companies have discovered this false weld defect at the end of the painting. In other words, in the field of quality, if an error is detected in the material during the inspection, it is completely lost. The content is processed or replayed until the entire row is stopped and the entire row is off. This manufacturer proves a defect in two ways. One is with a laser and another by ultrasound. Test equipment is placed in the mass zone for testing purposes. You can get 99% of the correct output. However, this is not necessary if the error is completely lost in the final stage, if the economic cost of these devices is high and if the skilled worker has to deal with this problem, our project, therefore, will use another device. To avoid this error in the initial phase, we found that the weld at the main point increased due to the poor solution in the drawer. Using simple Plc coding methods, we use light and automation sensors to develop devices that detect seat position changes. We use the Six Sigma method to eliminate this error. It is possible to eliminate the risk of wrong place welding and reduce the output defect by 100%.
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