Browse Topic: Manufacturing

Items (35,010)

Dependency of Gear Honing Machine Processing Accuracy on Machine Vibration and the Vibration Reduction Considering Contribution

2024-32-002004/18/2025

In recent years, accurate gear processing is required for various products to improve efficient power transmission and small noise and vibration. On the other hand, the accuracy tends to be worse by high speed processing for increasing production efficiency. Therefore, we investigated relationship between gear honing machine vibration and the accuracy. The vibration acceleration of the honing machine was measured at various conditions, and the gear accuracy was measured after processing. As results, the accuracy was observed to be affected by both the original gear accuracy before honing processing and the gear secondary rotational vibration of the machine in operation. Subsequently, we applied transfer path analysis (TPA) to investigate which directional force in operation increased the vibration. As the results, the contribution from the input force at gear processing point along normal direction was the main contributor. Then, vibration transmission characteristics of the machine

Hanioka, Hiroaki, Ogawa, Yunosuke, Yoshida, Junji, Onishi, Yoichi, Kurokawa, Yasuhiro

Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions

2024-32-003804/18/2025

The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to

Hada, Yusuke, Sugita, Hisayuki

Development of Higher Clarity Injection Molded Windscreen for Motorcycles

2024-32-004004/18/2025

The windscreen is one of the key elements to enhance passenger comfort of touring motorcycle. The clarity through the windscreen should not discomfort the rider. The discomfort we discuss here mainly refers to three factors: the “distortion,” the “blur,” and the “transparency.” Introduced in this paper is the technical measures to achieve sufficient clarity by the injection molding method. Firstly, with respect to the “distortion,” we determined the main cause was local unevenness of plate thickness. As the uneven thickness were related to the accuracy of the die, we clarified the tolerable zone and carried out higher precision machining of the die to satisfy the requirements. Regarding the “blur,” we analyzed the refractive power of the windscreen and found the main cause of blur is the microscopic roughness on the surface. As the microscopic roughness were attributable to the die surface, we clarified the tolerable zone and established the polishing conditions satisfactory for the

Yamada, Atsushi, Endo, Sakae

Mechanical Property Analysis of Triply Periodic Minimal Surface Structure with a Novel Hybrid Structure

2025-01-8215

04/03/2025

Abstract Triply periodic minimal surface (TPMS) structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with

Tang, Haiyuan, Xu, Dexing, Sun, Xiaowang, Wang, Xianhui, Wang, Liangmo, Wang, Tao

IAQG-03282025-1

IAQG-03282025-1 (Current)04/02/2025

IAQG-03282025-1

IAQG-1 Standards Committee

A review of warm forming for steels: History, Methodology and Emerging trends

2025-01-881404/01/2025

Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of

Kella, Caroline, Wormald, Tom, Gatts, Joshua

Characterization and Aluminum Recovery from Chemical Milling Sludge in Aerospace Industry

2025-01-501603/21/2025

The chemical milling process used in the aerospace industry generates substantial metallic residue in the etching bath, referred to as chemical milling sludge (CMS). The direct disposal of CMS into the environment leads to ecological deterioration and economic losses. This study focused on the recovery of aluminum from the aerospace industry CMS, aiming to mitigate environmental harm and enhance resource efficiency. The energy-dispersive X-ray (EDX) analysis revealed that the aluminum content in extracted CMS increased significantly to 95.86%, compared to 28.98% in non-extracted sludge. The XRD analysis of the CMS extracted samples also revealed the presence of increased Al2O3. The surface morphology study suggested the irregularly shaped particles with large chunks, and fine granules were observed on CMS. The yield of Al2O3 was observed to be 35.9% (wt) prior to the calcination process followed by 12.1% (wt) after calcination. The phytotoxicity study indicated that the CMS inhibited

Prasad, Jag, Sonwani, Ravi Kumar

How Will TSN Ethernet Impact the Future of Embedded Computing for Aerospace and Defense Applications?

25AERP03_0603/01/2025

Time Sensitive Networking (TSN) Ethernet is a real-time networking capability that is being developed by a growing number of embedded computing companies for the earliest stages of adoption by aerospace and defense manufacturers and their suppliers. According to the Institute of Electrical and Electronics Engineers (IEEE) TSN working group, it is a set of standards that provides deterministic connectivity within IEEE 802-aligned networks. Nigel Forrester is the Director of Product Strategy for Concurrent Technologies, a UK-based provider of high performance embedded computing solutions for aerospace, defense and many other industries. Check out our interview with Forrester about the potential impact of TSN Ethernet on new and legacy aerospace and defense applications, and how it is being adopted by manufacturers and system integrators below.

test rejection

SAE-PP-0945901/27/2025

test

Rickard, Christopher

Revolutionizing the Traffic Light

21AVEP01_0501/27/2025

Two start-ups are using cameras, sensors and AI to enable more efficient vehicle flow through intersections. Every motorist has experienced the frustration of waiting at a red light when there is no traffic in sight. These days, countless household devices use sensors, cameras and connectivity to understand and respond to the world - so why do most traffic lights languish in the analog age, causing our vehicles to unnecessarily stop and idle? In a spring 2019 report, Guidehouse Insights forecast that just 7% of North America's signalized intersections would use so-called adaptive traffic-control technology in 2020. On a global level, that number was 2.3%.

Berman, Bradley

EDITORIAL: Farewell and thanks, Mr. Birch

21AUTP06_0401/27/2025

“We pay close attention to the SAE magazines because your guy in Europe writes interesting articles,” a BMW engineering executive told me one year at the Frankfurt Motor Show. He was referring to Stuart Birch, our veteran European Editor, who has recently decided - after nearly 37 years of outstanding reporting for SAE International - to hang up his keyboard and spend more time with his wife, Kim, their family and friends in the British countryside, and his classic Porsche 911. Our staff had been dreading the day that Stuart would announce his retirement, foremost because he's been a great friend as well as a colleague. And because journalists with his qualities - professionalism, perspective, a powerful work ethic and great wit - are increasingly rare in the mobility-technology space. As SAE's global audience knew, Stuart Birch delivered compelling technical and business information. He covered product, processes and people with equal poise. And he thrived on the R&D beat: Virtual

Brooke, Lindsay

German OEMs flex 3D manufacturing muscle

21AUTP03_0801/27/2025

A chief impediment for wider adoption of additive manufacturing long has been its limited potential for application in high-volume and high-throughput production. But continuing process and technique developments from automakers and suppliers are moving additive manufacturing, also known as 3D printing, closer to high-volume Valhalla, while also enabling production of increasingly complex and substantial components. BMW has sporadically fitted specialized 3D-printed parts - both metal and polymer - in series-production models for more than a decade. Recently it has used its Rolls-Royce brand as a platform for introducing 3D-printing innovations in a low-volume but high-expectation environment. And in mid-2020, BMW invested some 15 million euros to establish its Additive Manufacturing Campus near Munich to research and develop new 3D printing processes and other innovations that might accelerate the potential for 3D-printed components at large scale. The company said the facility

Visnic, Bill

Bosch consolidates computing talent in new mobility division

21AUTP03_1101/27/2025

Bosch announced on January 7 during its CES 2021 conference event that it has created a new division labeled Cross-Domain Computing Solutions (CDCC). The CDCC division pools 17,000 of Bosch's automotive software and electronics associates to create a single source for software-intensive systems for future vehicle architectures. According to Bosch, the market for such systems is expected to grow 15% annually between now and 2030, and the organizational move is designed to extend the supplier's market-leading position. Bosch has assigned software, electrical and electronics engineers from the areas of driver assistance, automated driving, car multimedia, powertrain and body electronics to the new unit. “Bosch is an automotive electronics pioneer. Moreover, for quite some time now, it has also been a software company,” said Dr. Stefan Hartung, chairman of Bosch's Mobility Solutions business sector. “Only a company with wide-ranging electronics and software expertise will be in a position

Seredynski, Paul

ZF builds ‘middleware’ to address vehicle software escalation

21AUTP03_0901/27/2025

Acknowledging the emergence of the “software-defined” vehicle, ZF announced that it is in the process of developing a “middleware” platform designed to facilitate communication between a typical new vehicle's ballooning number of software-controlled components and systems. Company engineers and executives said the first vehicles leveraging the new middleware will be on the road in 2024, but the platform is being created because the industry has to grasp “what the car will look like in the 2030s,” said Dirk Walliser, senior VP - corporate R&D, Innovation & Technology for ZF Friedrichshafen AG. Coinciding with the undertaking to create its middleware platform, ZF also announced it is establishing a Global Software Center to, according to a release, prepare for “new challenges in the triad of software, functions and smart systems” and to proactively pursue “numerous development processes.” Opening in 2021, the Global Software Center will be headed by Nico Hartmann, VP, Software Solutions

Visnic, Bill

Arinc Automation Document - Standard Characteristic - PageCount less than 45

KJH003 (Current)12/19/2024

Arinc Automation Document - Standard Characteristic - PageCount less than 45

Aviation Maintenance Committee

NASA’s Inspection Technology for Spacecraft Tests Quality of Seacraft Hulls

TBMG-5222312/05/2024

Shipbuilders didn’t have the option of fiberglass when the nonprofit American Bureau of Shipping (ABS) was established 160 years ago to help safeguard life and property on the seas. Fortunately, technology to help better ensure the safety of ocean vessels has also come a long way in that time, in part because people have become a spacefaring species.

These Speedy Cold Spray Machines Can 3D Print Vehicle Parts in War Zones

TBMG-5212212/01/2024

Advancing Implantable Medical Device Reliability with Enhanced Laser Joining Technology

TBMG-5217712/01/2024

Revolutionizing Seafood Production with Adaptive Robots

TBMG-5217812/01/2024

Robotic automation technology is reshaping food manufacturing, packaging, and handling by driving significant improvements in efficiency, quality, and flexibility. By integrating advanced artificial intelligence, computer vision, and proprietary force-sensing technology, Flexiv has introduced cutting-edge automation to the food processing sector.

Contract Manufacturing: Accelerating Product Development

TBMG-5217212/01/2024

Design and material choices can have a long-term impact on an original equipment manufacturer’s (OEM) production costs and product quality. When an OEM works together with an experienced contract design manufacturer (CDM) from the start of a project, many negative impacts to cost and quality can be avoided.

Dormant Capacity Reserve in Lithium-Ion Batteries Detected

TBMG-5214312/01/2024

Lithium iron phosphate is one of the most important materials for batteries in electric cars, stationary energy storage systems, and tools. It has a long service life, is comparatively inexpensive and does not tend to spontaneously combust. Energy density is also making progress. However, experts are still puzzled as to why lithium iron phosphate batteries undercut their theoretical electricity storage capacity by up to 25 percent in practice. To utilize this dormant capacity reserve, it would be crucial to know exactly where and how lithium ions are stored in and released from the battery material during the charging and discharging cycles. Researchers at Graz University of Technology (TU Graz) have now taken a significant step in this direction. Using transmission electron microscopes, they were able to systematically track the lithium ions as they traveled through the battery material, map their arrangement in the crystal lattice of an iron phosphate cathode with unprecedented

Maximizing the Potential of TPU Extrusion in Medical Tubing Applications

TBMG-5216412/01/2024

Whether for vascular catheters or implantable devices, medical tubing must meet tough standards for flexibility, strength, and biocompatibility. That’s why more manufacturers are turning to thermoplastic polyurethanes (TPUs) that strike the ideal balance between these key properties, making them an excellent choice for high-performance medical tubing. Unlocking the best that TPUs have to offer means optimizing the extrusion process. This article looks at why TPUs are a top pick, the common obstacles in extrusion, and the ways manufacturers can fine-tune their process to get the most out of different grades.

3D-Printed Reactor Core Makes Solar Fuel Production More Efficient

TBMG-5219312/01/2024

In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.

4D Printing of Shape Memory Polymers

TBMG-5219112/01/2024

Researchers have successfully demonstrated the four-dimensional (4D) printing of shape memory polymers in submicron dimensions that are comparable to the wavelength of visible light. 4D printing enables 3D-printed structures to change their configurations over time and is used in a variety of fields such as soft robotics, flexible electronics, and medical devices.

Where Do EV Batteries Go When They Die?

TBMG-5213812/01/2024

At Cox Automotive’s EV Battery Solutions center in Oklahoma City, the conglomerate most famous for its KBB, Autotrader, and Manheim auction brands, has become a go-to for EV battery research, repair, remanufacturing, and recycling.

Scientists Fuse Simulations and Machine Learning to Accelerate Novel Additively Manufactured Materials

TBMG-5212712/01/2024

Researchers at the Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, have demonstrated a novel approach for applying machine learning to predict microstructures produced by a widely used additive manufacturing technique. Their approach promises to dramatically reduce the time and cost of developing materials with tailored physical properties and will soon be implemented on a NASA-funded effort focused on creation of a digital twin.

Solvent-Free 3D Printing Material Could Enable Biodegradable Implants

TBMG-5216712/01/2024

Duke University Durham, NC

Bio-Ink for 3D Printing

TBMG-5218912/01/2024

Biomedical engineers have developed a “bio-ink” for 3D-printed materials that could serve as scaffolds for growing human tissues to repair or replace damaged ones in the body. Bioengineered tissues show promise in regenerative, precision, and personalized medicine; product development; and basic research, especially with the advent of 3D printing of biomaterials that could serve as scaffolds or temporary structures to grow tissues.

OMNI-DIRECTIONAL AUTONOMOUS GUIDED VEHICLE (AGV) WITH WIRELESS NAVIGATION

2024-01-343611/15/2024

ABSTRACT Automatic guided vehicles (AGV) have made big inroads in the automation of assembly plants and warehouse operations. There are thousands of AGV units in operation at OEM supplier and service facilities worldwide in virtually every major manufacturing and distribution sector. Although today’s AGV systems can be reconfigured and adapted to meet changes in operation and need, their adaptability is often limited because of inadequacies in current systems. This paper describes a wireless navigated (WN) omni-directional (OD) autonomous guided vehicle (AGV) that incorporates three technical innovations that address the shortfalls. The AGV features consist of: 1) A newly developed integrated wireless navigation technology to allow rapid rerouting of navigation pathways; 2) Omnidirectional wheels to move independently in different directions; 3) Modular space frame construction to conveniently resize and reshape the AGV platform. It includes an overview of the AGVs technical features

Cheok, Ka C, Radovnikovich, Micho, Fleck, Paul, Hallenbeck, Kevin, Grzebyk, Steve, Vanneste, Jerry, Ludwig, Wolfgang, Garner, Robert

3D-PRINTING IMPACTS ON SYSTEMS ENGINEERING IN DEFENSE INDUSTRY

2024-01-352711/15/2024

ABSTRACT Today’s combat vehicle designs are largely constrained by traditional manufacturing processes, such as machining, welding, casting, and forging. Recent advancements in 3D-Printing technology offer tremendous potential to provide economical, optimized components by eliminating fundamental process limitations. The ability to re-design suitable components for 3D-printing has potential to significantly reduce cost, weight, and lead-time in a variety of Defense & Aerospace applications. 3D-printing will not completely replace traditional processes, but instead represents a new tool in our toolbox - from both a design and a manufacturing standpoint.

Deters, Jason

asdg

jmsaldkfgjalkerjtw (Current)08/29/2024

asdg

Airlines Electronic Engineering Committee

Automation Title for Group Code D22

PC-Auto-1713447343633 (Current)04/18/2024

Automation Abstract for Group Code D22

Airlines Electronic Engineering Committee

Automation Title for Group Code D21

PC-CUR-1232 (Current)04/18/2024

Automation Abstract for Group Code D21

Airlines Electronic Engineering Committee

Automation Title for Group Code D23

PC-Auto-1713447365379 (Current)04/18/2024

Automation Abstract for Group Code D23

Flight Simulator Engineering and Maintenance Committee

Automation Title for Group Code D21

PC-Auto-1713447321320 (Current)04/18/2024

Automation Abstract for Group Code D21

Airlines Electronic Engineering Committee

Additive Manufacturing in the Mobility Industry: Vol. 2

EPRCOMPV022023-TEST-REC04/15/2024

Additive Manufacturing in the Mobility Industry: Vol. 1

EPRCOMPV012023

04/15/2024

Additive Manufacturing in the Mobility Industry: Vol. 2

EPRCOMPV022023

04/15/2024

Additive Manufacturing in the Mobility Industry: Vol. 1

EPRCOMPV012023-TEST-REC04/15/2024

An eleventh one for CUR-1174

PC11-CUR-1174 (Current)04/02/2024

Italic

Flight Simulator Engineering and Maintenance Committee

Liquid Runway Deicing/Anti-icing Product

AMS1435E (Current)

03/12/2024

This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.

G-12RDP Runway Deicing Product Committee

Liquid Runway Deicing/Anti-icing Product

AMS1435E-TEST-REC (Current)03/12/2024

This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.

G-12RDP Runway Deicing Product Committee

Casting Equipment Engineering Guide

B-ASM-05603/01/2024

Casting Equipment Engineering Guide is an essential resource covering engineering details of casting equipment, their design features, applications, capabilities, and selection guidelines. This book is written for mechanical engineers, practicing engineers, engineering students, and metallurgists specializing in casting technology.

Schey’s Tribology in Metalworking: Friction, Lubrication, and Wear

B-ASM-05702/28/2024

Schey’s Tribology in Metalworking—Friction, Lubrication, and Wear is an update to the seminal text Tribology in Metalworking by John Schey, originally published by ASM International in 1983. The 1983 first edition served as a recognized essential resource for researchers in the fields of manufacturing tribology and metal forming for many decades. This 2023 update preserves the essential information in that first edition but provides a thorough update, including a description of the significant advances in tribological research and detailed information for every metal forming process.

Enhancing Microstructural Characteristics and Mechanical Properties in Friction Stir Welding of Thick Magnesium Alloy Plates through Optimization

2024-01-501402/06/2024

This research explores friction stir welding (FSW) to examine the mechanical characteristics and microstructure of thick plates manufactured from the Mg-8Al-0.5Zn alloy. Applying the FSW procedure to warm-form an Mg-8Al-0.5Zn alloy for the differential case covering the gears in the car’s automotive technology. Weld quality was significantly improved after using response surface methodology (RSM) to examine various welding parameters and find the best configurations. Improved grain refinement and phase distribution in the weld zone were found in the microstructural study of 11.5 mm thick magnesium alloy plates using RSM-optimized parameters. By dynamic recrystallization, the grain size was reduced to 16 μm, which is fifteen times smaller than the original material, thanks to the good results of single-pass FSW welding. Welding results showing high-quality characteristics such as tensile strength (161.8 MPa), elongation (27.83%), and joint efficiency (98.96%) were achieved using the

Sabari, K., Muniappan, A., Singh, Mandeep

Pre-print testing CSP-6572

SAE-PP-0915102/01/2024

Regression pre-print submission

Atash, Ganira

Methodical Design of a Subframe for a Novel Modular Chassis Concept without Knowledge of Final Vehicle Parameters

02-17-01-0006

01/22/2024

Abstract This article presents the methodical development of a subframe for a novel on-the-road-modular vehicle concept, which was developed for the U-Shift project. The subframe serves as the basis for a modular chassis. This chassis offers the possibility to exchange chassis components by the operator, which means after completion by the manufacturer, and thus to adapt the vehicle to different purposes. According to the applied methodology, the relevant wheel loads are determined and a geometric reference model is created. By defining the relevant load cases, the forces acting on the subframe, and thus the physical boundary conditions, can be determined from the wheel loads. In addition to the wheel loads and the geometric boundary conditions, no other vehicle parameters are required for the development of the subframe. The results of the topology optimization are used to identify areas of the geometric reference model that are not exposed to high loads. Based on the results of the

Weitz, Fabian, Frey, Michael, Gauterin, Frank

A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack

2024-26-010901/16/2024

EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of

Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar

A review and modelling of PMSM drive technology for Electric vehicle application

2024-26-012701/16/2024

The increased pollution and environmental damage caused by rapid consumption of fossil fuel as the increased number of vehicles on road given a strong impetus to the growth and development of fuel-efﬁcient vehicles. INDIA has already adopted the stringent CAFÉ II norms in 2022 which penalizes the CO2 levels above the corporate average target. This will give a push to automotive manufacturer to reduce their carbon footprint. Considering all the above-mentioned factors, Electric Vehicles are proving to be a promising solution to curb the Carbon footprint and limit the dependence on the fossil fuel which will dampen the effect of increased fuel prices on customers as well. The main advantage to EVs is that the motor and battery configuration allows the vehicle to operate more efficiently. The main components of Electric vehicles are HV battery, E-Drive (Motor), Inverter, On board charger, Power distribution Unit. The performance of EVs greatly depends on these components and its

Sharma, Prashant, V, Suryanarayanan, Redii, Ashok, Raut, Sandip, Hareesh, Sangaraju

Evaluation of interface microstructure and bonding strength for dissimilar rotary friction welding of E46 and AA6061-T6

2024-26-019501/16/2024

Nowadays, friction welding is recognised as a highly productive and economic joining process for similar as well as dissimilar welding of automobile and aerospace components. Friction welding is the viable solution to offset the challenges of dissimilar fusion welding due to varying thermal and physical properties as well as limited mutual solubility. The main objective of this study is to evaluate the interface microstructure and interface bonding strength for dissimilar rotary friction welding of 3.15 mm E46 disc and 45 mm AA6061-T6 bar at different friction time and forging pressure. The direct drive rotary friction welding of E46 and AA6061-T6 is performed at combinations of two different friction time (4 sec and 7 sec) and forging pressure (108 MPa and 125 MPa). Mechanical bonding strength at the interface is evaluated based on the push-off and multi-step shear strength. Further, fractography of failed samples is carried out to understand the failure mechanism of welded joints

Chudasama, Gautam, Kalyankar PhD, Vivek, Chauhan, Shiv

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