A method for double-sided friction stir spot welding

A rotating anvil similar to a pinless friction stir welding (FSW) tool can be applied to friction stir spot welding (FSSW) of thin metal plates. FSSW is a solid-state joining process that is currently being used by automotive manufacturers as an alternative to rivets and traditional resistance spot welding. The principal detractor of this process is the keyhole left by pin extraction, which can be detrimental to the weld strength. A pinless tool can be used to eliminate the keyhole. However, this approach is limited to joining thin sheet (≤1 mm). Using a rotating anvil with the FSSW process permits the joining of thicker cross sections, improves the mechanical strength of the spot weld and reduces the reaction forces on the spot welding frame. A numerical model of the process, tensile shear tests and macrosection analysis are used to evaluate the spot welds.Macrosection and numerical analysis reveals that the material flow between the pinless tool and rotating anvil is complex and unique to this process. It has been found that the use of a rotating anvil for FSSW is a viable means to create quality spot welds in thicker weldments.     

Numerical simulation of residual stresses for friction stir welds in copper canisters

In an attempt to map the residual stress distributions after friction stir welding of copper canisters, a three-dimensional thermo-mechanical model has been formulated by coupling heat transfer and elasto-plasticity analyses. The transient temperature field around the tool is simulated by a moving heat source. The simulation shows that the residual stress distribution in a thick-wall copper canister is sensitive to the circumferential angle and asymmetrical to the weld line. Both tensile and compressive stresses emerge along the weld line and its vicinity. The maximum tensile stress appears in the circumferential direction on the outer surface. The maximum tensile stress, whether it is predicted by the finite element method or measured by the hole-drilling technique and the X-ray diffraction method, does not exceed 50 MPa in general.     

Simultaneous measurement of tool torque,traverse force and axial force in friction stir welding

Simultaneous measurement of the tool torque, traverse force and axial force during friction stir welding process is of great significance to the understanding of the underlying process mechanism and the optimizing of the process parameters. Different from the traditional measurement methods using load cell or rotating component dynamometer, an indirect but economical methodology is used in this study for the simultaneous measurement of the traverse force, axial force and tool torque by monitoring the output torques of the servo motors and main spindle three-phase AC induction motor inside the FSW machine. The values of the traverse force, axial force and tool torque are determined under different welding conditions, and the influencing factors are examined. The measured results in friction stir welding of AA2024-T4 aluminum alloys at different combinations of tool rotation speed and welding speed lay foundation for process optimization.     

Experimental investigation on flexural behavior of friction stir welded high density polyethylene sheets

Flexural strength is one of the main criteria in evaluation of the mechanical properties of polymeric joints. The flexural strength of thermoplastics, such as high density polyethylene (HDPE) sheets, is influenced by friction stir welding parameters. The determination of the welding parameters plays an important role in the weld strength. In the present study, the response surface method (RSM) was used as a statistical design of experiment technique to set the optimal welding parameters. The designed tool was consisted of a rotating pin, a stationary shoulder (shoe) and a heating system inside shoe. Rotational speed of the pin, tool traverse speed and shoe temperature were considered as varying parameters. Obtained results show a significant relationship between considered properties and processing parameters through an analysis of variance (ANOVA) study and the response surface method. It was found that welding at a high level of rotational speed and a lower level of tool travel speed increases weld flexural strength by reducing size of defects.     

Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas welding

The objective of this research is to investigate the mechanical properties including bonding, tensile strength, and impact resistance of pure copper welded using friction stir welding (FSW) method and compare them with that of tungsten inert gas (TIG) welding. Micro-hardness tests are performed on pure copper, TIG welded copper and FSW welded copper to determine the effect of heat on the hardness of welded coppers. Tensile strength tests and notch tensile strength tests are performed to determine the mechanical properties of different weld process.In this experiment, it is found that the notch tensile strength and the notch strength ratio for FSW (212 MPa, 1.10) are significantly higher than those (190 MPa, 1.02) of TIG welding. For the impact tests, the weld zone and heat-affected zone energy absorption values for FSW (2.87 J, 2.25 J) are higher than those (1.32 J, 0 J) of TIG welding. XRD tests are performed to determine components of copper before and after welding process for TIG and FSW.     

On the feasibility of producing polymer–metal composites via novel variant of friction stir processing

In this study a novel variant of friction stir processing was developed for producing of polymer metal surface or bulk composites in order to enhance the mechanical, electrical and thermal properties. For this purpose, a novel tooling system was designed consists of a rotating pin, a stationary shoulder and a heating system located inside the shoulder. In present paper, for preliminary study high-density polyethylene and copper powder was selected as polymeric matrix and metallic additive, respectively. Surface quality, microstructure, ultimate tensile strength and the modulus of elasticity were determined for each prepared sample. From experimental tests, it was found that this approach is an efficient method for producing of polymer–metal composites.     

Experimental analysis of friction stir forming for dissimilar material joining application

Mass reduction of automotive body structures is a critical part of achieving reduced CO₂ emissions in the automotive industry. There has been significant work on the application of ultra high strength steels and aluminum alloys. However, the next paradigm is the integrated use of both materials, which poses a challenge of how to join the dissimilar materials. Friction stir forming is a new manufacturing process for joining dissimilar materials. The concept of this process is stir heating one material and forming it into a mechanical interlocking joint with the second material. In this research the process was experimentally analyzed in a position controlled robotic friction stir welding machine between aluminum and steel workpieces. New tool geometries were evaluated toward the goal of optimizing joint strength. The significant process parameters were identified and their optimized settings for the current experimental conditions defined using a design of experiments methodology. A scanning electron microscope was used to characterize the bonding and joint structure for single and multi-pin configurations. Two failure modes, aluminum sheet peeling and bonding delamination, i.e. braze fracture, were identified. It was found that the presence of zinc coating on the steel and overall joint geometry greatly affected the joint strength. The aluminum–zinc braze joint appears to be the largest contributor to joint strength for the single-pin joint configuration. The multi-pin geometry enabled a distribution of load to the four pins following fracture of the braze for increased joint toughness and ductility. Thus, the FSF method has been shown to exhibit potential for joining of aluminum to steel.     

铝锂合金焊缝大气腐蚀行为研究

目的研究铝锂合金搅拌摩擦焊焊缝在大气环境中的腐蚀行为。方法采用电化学极化法、质量增加法、扫描电子显微镜、三维体式显微镜几种不同的表征手段对铝锂合金搅拌摩擦焊焊缝在模拟海洋大气环境中的腐蚀行为进行研究。结果焊缝部位存在较为严重的应力腐蚀开裂现象,腐蚀电位比基体部位负移约0.05 V,腐蚀速率比一般基体部位明显增大。结论搅拌摩擦焊虽具有较多优点,在其他领域得到一定应用,但针对铝锂合金在海军飞机方向的应用存在缺陷,不能直接裸露使用。     

Inertia welding for assembly of copper squirrel cages for electric motors

The automotive industry is developing designs and manufacturing processes for new generations of electric motors intended for use in hybrid and electric vehicles. There is interest in replacing the aluminum traditionally used in induction motor rotors with copper to improve motor capability. This paper focuses on solid-state welding to join copper end rings to copper spokes in the fabrication of copper rotors. Inertia friction welding was explored to examine weldability of these copper components. A better understanding of inertia welding characteristics will help the advancements in its application for induction rotors. The limitations of this application are discussed.     

拉延成形中拉延筋的摩擦分析

此文建立了一种用拉延筋单元模拟试验器测试拉延筋摩擦系数的方法,同时对成形中的摩擦润滑进行了试验研究和分析。     

污染源在线监测及运营管理存在的问题分析

结合大连市污染源在线监测系统建设实例,介绍了固定污染源在线监测组成及其分析仪器设备运行管理方式;通过在线监测与手工检测数据比对,验证在线监测的可行性;研究系统在建设和实际运行中存在的监测条件和环境不规范及在线监测数据传输的不稳定性等为环境保护的自动化污染源监测全面实施起到借鉴作用。     

沈阳市水污染物排放总量控制的研究

以沈阳市为实例，详细地介绍了城市水污染物排放总量控制的系统结构，探讨和论述了总量控制因子和总量控制目标的制定原则、方法，实现总量控制目标的措施，总量的考核与管理．     

电焊作业人员尘肺病的预防

通过某检修安装企业从事焊接作业人员职业健康检查.对肺功能及X线高仟伏胸片检查结果进行分析评价,探讨电焊烟尘对作业人员肺部X线改变和肺通气功能的影响,提出电焊工尘肺的预防措施.     

研究拉深成形过程中的摩擦系数分布

主要介绍利用探针和传感器测定拉深过程中摩擦系数的实验方法,据此获得变形区内摩擦系数的分布情况.该方法有助于进一步分析板材在拉深成形过程中的摩擦和润滑情况.同时对计算机数值模拟金属板材在拉深成形过程中,如何确定摩擦系数边界条件提供了一种实验方法.     

太湖水底摩擦系数的估算

利用１９９２年８月至１９９２年１０月在太湖马山地区测得的风，浪资料，采用浅水浪公式对太湖水底摩擦系数进行了估算，估算值为０．００２５。     

一种基于ActiveX Automation技术的报表表示方法

分析了企业中产品设计完成后,应用ActiveXAutomation技术生成产品的各种物料清单报表,建立了报表检查机制,较好地解决了企业图档管理中的报表自动校正生成问题。运用该方法开发的报表管理器,已经在多家企业得到应用,取得了很好的效果。     

基于含油污泥的搅拌反应器内气液两相流的数值模拟

采用安东帕流变仪对不同温度下含油污泥的流变性质进行测量,并通过拟合幂律方程得到相关流变参数。基于其流变特性,以空气-含油污泥为介质采用数值模拟方法研究了含油污泥温度以及反应器结构对气液两相流场、局部气含率分布以及通气搅拌功率的影响。结果表明:随着含油污泥温度升高,搅拌桨对液相扰动范围趋广,气含率分布趋于分散,气液两相混合程度愈加均匀,通气搅拌功率下降明显;对比4种不同反应器结构,双层桨分散性能最佳,液相平均流速最高,速度均匀度指数最低,在通气搅拌功率适宜的情况下其混合性能最佳。     

我国酸沉降控制策略

根据我国酸沉降污染的状况,借鉴国外酸沉降的经验,提出了我国酸沉降控制的指标、主要控制对象和综合控制对策。