Joining of aluminium alloy to pre-holed carbon steel by aluminium extrusion using friction spot method

Abstract

Purpose The purpose of this paper is to join sheets of an aluminium alloy together with pre-holed carbon steel via friction spot technique. Design/methodology/approach An AISI 1006 steel sheet was a pre-holed with a 4.8 mm diameter and put under AA5052 sheet with a lap joint configuration. The joining process was carried out by extruding the aluminium through the steel hole using a rotating tool of 10 mm diameter. Furthermore, three process parameters (pre-heating time, rotating speed and plunging depth of the tool) with three values for each parameter were used to study their effects on the joints quality. In order to join samples, nine experiments were designed according to a Taguchi method. Shear strength, microstructure and X-ray diffraction tests of the joint were carried out. Findings The joining mechanism occurred by a mechanical interlock of the extruded aluminium with the inner surface of the steel hole. The tool plunging depth had a significant effect on the shear strength of the joint. The shear strength of two joints exceeded the shear strength of the wrought material (AA5052). All samples failed with two modes: pull-out and shearing of the extruded aluminium. Originality/value For the first time, the extrusion technique was used to join AA5052 sheet together with pre-holed carbon steel, with a perfect joint efficiency.

Lubricating materials as a novel approach to reduce defects of micro-deep drawing forming process

“…Steel was preheated at 850 °C after a period of heating at 1040 °C for about 40 min; then oil was as used as a quenching medium to cool these pieces to reach a temperature of 60±3 °C. After that, these pieces were cleaned to measure their hardness using Rockwell device type GNEHM (made in Russia), shown in Figure (9). Tempering was made to relieve the stress of steel at 590 °C for 30 min.…”

“…The process of deep drawing is a significant method in sheet metal forming. In recent years, product miniaturization has rapidly developed [4][5][6][7][8][9][10]. Therefore, the researchers promoted the field of micro deep drawing in advanced manufacturing applications of microproducts, focusing on decreasing their weight and volume.…”

“…Several defects are often found in micro-deep drawings, such as earing on the cup edge, folding and wrinkling in the flange and cup wall, and tearing in the corner radius [15,16]. Deep drawing, classified under sheet metal forming processes, is one of the most popular die manufacturing technologies [9]. The metal sheet, such as an aluminum sheet, is pressed through the die to form this metal with a O N L I N E F I R cavity shape.…”

An Investigation of Joining Polyamide (PA) to Stainless Steel AISI 316L by Hot Press Process

“…Carried out aluminium alloy (AA5754) to carbon fibre reinforced polymer (CFRP) joining by the ultrasonic metal welding process so that both mechanical interlocking and adhesive bonding are outset in the welding zone [13]. [14]. Near contact between the polymer and metal was acquired by mechanical interlocking, chemical bonding and physical happening at the interface.…”