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.     

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.     

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 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.     

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.     

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.     

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。     

Modeling of the influence of sample preparation sequences when measuring selectively induced residual stress depth profiles

The selective introduction of compressive residual stresses is gaining increasing importance as design tool in today's manufacturing process chains. Manufacturing processes such as shot peening or hydraulic autofrettage are used to improve the surface integrity, and hence the fatigue life of the components. However, measuring the corresponding residual stress depth profiles is a challenging task as the results will always include the manufacturing and preparation history of the components. In this paper, results of residual stress measurements with X-ray diffraction and optical hole-drilling after autofrettage and sample preparation are presented and compared to a finite element analysis for two representative geometries. The presented approach can be used to predict the influence of the mandatory sample preparation procedure. As a consequence, the effectiveness of the manufacturing process to improve the surface integrity can be predicted more precisely and wrong interpretations of the measured residual stress depth profiles can be avoided.     

Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process

The evolution of mechanical components into smaller size generating a need for microwelding of these components using laser which offers better control as compared to arc and plasma processing. The present article describes the numerical simulation of laser micro-spot welding using finite element method. A two dimensional Gaussian distributed surface heat flux as a function of time is used to perform a sequentially coupled thermal and mechanical analysis. The model is used for simulating laser micro-spot welding of stainless steel sheet under different power conditions and configurations of mechanical constraints. The temperature dependent physical properties of SS304 have been considered for the simulation and an isotropic strain hardening model has been used. The simulated weld bead dimensions have been compared with experimental results and temperature profiles have been calculated. The maximum deformation of 0.02 mm is obtained with maximum laser power of 75 W. The thermal stress is more inducing factor to temperature induced residual stresses and plastic strain as compared to mechanical constraints. The plastic strain changes significantly by displacement constraints as compared to residual stress.     

露天堆场防风抑尘网临界孔隙率的数值模拟

应用Fluent6.3对防风抑尘网及料堆周围流场进行数值模拟,通过研究不同孔隙率抑尘网与料堆周围湍流特性及料堆表面剪切力分布规律,确定了临界孔隙率.结果显示:高孔隙率(0.3、0.4、0.6)流动状态与无网工况一致,来流风沿迎风面贴附向上,风速逐渐增大,堆顶达到最大;低孔隙率(0、0.2)流态与无网迥异,迎风面处于涡旋中,风速向下,孔隙率为0时涡旋中心高于堆顶3m,孔隙率为0.2时涡旋中心位于堆高2/3处.孔隙率30.3时,料堆各表面剪切力变化趋势一致,与无网工况来流风同向,最大剪切力出现在堆顶.孔隙率为0.2时,作为最大起尘量的迎风面,其表面剪切力随高度先增大后减小,最大剪切力处于堆高3/5处.孔隙率为0.25时,湍流结构和剪切力分布发生突变,迎风面为贴附和涡旋复合流动,表面剪切力最小.据此确定来流风速6m/s,运用该几何模型时,临界孔隙率为0.25.     

北京夏季近地面臭氧及其来源的数值模拟研究

高浓度的近地面臭氧一直是北京夏季面临的主要污染问题,本文利用自主发展的空气质量数值模式WRF-NAQPMS(Weather Research and Forecasting Model-Nested Air Quality Prediction Modelling System)以及生物源排放模式MEGAN(Model of Emission of Gases and Aerosols from Nature),数值模拟了2017年6月华北区域臭氧的时空分布,评估了生物源排放可挥发有机物对臭氧的影响,并对北京臭氧的关键源区和形成时间进行量化解析.结果发现:NAQPMS (Nested Air Quality Prediction Modelling System)模式合理再现了北京及其周边臭氧的时空演变规律,特别是生物源的加入有效改善臭氧浓度的模拟效果.生物源对北京6月臭氧浓度月均值的贡献为4%～6%,对最大1小时浓度的贡献最高可达8%以上.源解析结果发现,本地当天排放的臭氧前体物对北京城区浓度影响最大,对最大1小时浓度和8小时移动平均浓度的贡献达到50.2%和45.4%,远高于1～2天前排放污染物的影响.河北对北京的影响主要集中在当天和1天前排放的污染物,对最大1小时浓度的贡献分别为7.9%和6.5%.河南和山东对北京城区最大1小时浓度的贡献较小,分别为2.4%和3.7%,且主要为1～2天前排放的污染物在区域输送过程中的化学反应所贡献.对于北京区域平均来讲,本地的贡献率较城区明显偏小,河北的贡献显著增加,这也说明北京市臭氧来源的空间不均匀性较大.北京地区生成的臭氧沿怀柔区向北输送,到达承德市西侧,对月均值的贡献达到20～30μg·m~(-3).     

LNG接收站冷排水的温降及余氯对水环境影响的数值模拟——以湄洲湾东吴港区为例

LNG接收站运行过程中将冷排水排放到海域水体中,冷排水的温降及余氯对附近海域水环境的温度场和生物环境产生影响。为掌握冷排水在海域水体中的扩散规律,利用二维水动力-水质数值耦合模型(MIKE21),采用模型嵌套的方式精细化模拟了湄洲湾东吴港区LNG接收站冷排水对水环境的影响,在模型验证可靠的基础上,计算得到了LNG接收站冷排水在冬季、夏季的温降包络线及余氯包络线,从而判断该工程位置选取的合理性。结果表明:在温降大于0.5 ℃条件下,LNG接收站的冷排水影响范围为0.202 km²,距离湄洲岛生态系统重点保护区约2.81 km,距离最近的养殖区约0.53 km;在余氯浓度为0.01 mg/L条件下,LNG接收站的冷排水中余氯影响范围为0.434 km²,最大影响距离为0.628 km;LNG接收站冷排水的温降及余氯均未对周边敏感目标产生直接影响,该排水口位置选择合理。     

珠江三角洲秋季PM_(10)污染模拟与形成过程分析

利用Models-3/CMAQ模式系统对珠江三角洲2009年11月下半月的大气PM10污染状况进行模拟,重点针对23~29日期间的严重PM10污染事件,采用过程分析技术,探讨各种大气物理、化学过程对PM10浓度演变的作用规律.对代表性站点的分析结果表明,导致污染期间近地面PM10浓度升高的大气过程主要是源排放(例如麓湖、开平)和大气传输(万顷沙、金果湾),重要的PM10去除途径包括大气传输(麓湖、开平)、干沉降(万顷沙)和气溶胶过程(金果湾).空间分布上,PM10源排放强度较高的珠三角中部地区,同时也是向外输出PM10的主要区域和干沉降去除的高值地区.在近地面,气溶胶过程在珠三角中部主要起消耗PM10的作用,二次颗粒物的生成多发生在珠三角西部和南部;气溶胶过程对高空PM10主要表现为生成作用,尤其珠三角中部地区的生成速率相对更高.     

中国环渤海地区SO2和NO2干沉降数值模拟及影响因子分析

利用耦合了Wesely大叶阻力干沉降模型的嵌套网格空气质量预报系统NAQPMS,对环渤海地区SO2和NO2的干沉降敏感因子、干沉降通量、空气质量进行模拟分析.结果表明,大气稳定度、太阳辐射、季节、下垫面类型为干沉降的主要敏感因子.大气越稳定,干沉降速率越小.太阳辐射越强,干沉降速率越大.SO2早秋干沉速率最小,冬季最大;NO2春、夏、早秋、晚秋的干沉降速率大致相同,冬季最小.SO2的干沉降速率在水面上较大,在沙漠上较小;NO2的干沉降速率在农田上较大,在水面上较小.由于不同敏感因子的共同作用,使得环渤海大部分地区SO2干沉降通量密度为0.05~0.25mg/(m2×s),NO2干沉降通量密度均为0.05~0.30mg /(m2×s),高值区均主要分布在河北南部、山东西北部以及辽宁中部的部分地区.干沉降通量密度从大到小依次为秋季、春季、冬季和夏季,白天干沉降通量密度普遍大于夜间,且在渤海海面上也有一定的干沉降通量.由于干沉降、源排放、输送等作用的共同影响,使得环渤海地区SO2平均浓度为(5~20)′10-6,NO2平均浓度大致在(20~60)′10-6,高值区主要出现在河北南部、山东西北部以及辽宁中部的部分地区.夏季个别地区浓度较高,大部分地区浓度较低,春、秋、冬3季大部分地区浓度较高.