Browse Topic: Joining

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Nickel Alloy, Corrosion and Heat-Resistant, Bars, Forgings, and Rings, 60Ni - 22Cr - 2.0Mo - 14W - 0.35Al - 0.03La, Solution Heat TreatedAMS5891D (Historical)11/25/2025
This specification covers a corrosion and heat-resistant nickel alloy in the form of bars, forgings, flash welded rings, and stock for forging, flash welded rings, or heading.
AMS F Corrosion Heat Resistant Alloys Committee
Nickel Alloy, Corrosion and Heat-Resistant, Bars, Wire, Forgings, and Rings 61Ni - 20.5Cr - 8.5Mo - 3.4Cb(Nb) - 1.3Ti - 5.0Fe Consumable Electrode or Vacuum Induction Melted Solution Heat Treated AMS5854D (Current)11/25/2025
This specification covers a corrosion and heat-resistant nickel alloy in the form of bars, wire, forgings, flash welded rings, and extrusions 4 inches (102 mm) and under in nominal diameter or least distance between parallel sides, and stock for forging or flash welded rings.
AMS F Corrosion Heat Resistant Alloys Committee
Iron Alloy, Corrosion and Heat-Resistant, Welding Wire, 31Fe - 21Cr - 20Ni - 20Co - 3.0Mo - 2.5W - 1.0Cb - 0.15N, AnnealedAMS5794G (Current)11/25/2025
This specification covers a corrosion and heat-resistant iron alloy in the form of welding wire.
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion and Heat-Resistant, Welding Wire 19Cr - 12.5Ni - 2.5Mo AMS5696F (Current)11/25/2025
This specification covers a corrosion and heat-resistant steel in the form of welding wire.
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb - 4.0Cu Solution Heat Treated, Precipitation Hardenable Consumable Electrode Remelted AMS5622H (Current)11/25/2025
This specification covers a premium aircraft-quality corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, flash welded rings up to 8.0 inches (203 mm) in diameter or least distance between parallel sides in the solution heat treated condition (see 8.4), and stock of any size for forging, flash welded rings, or heading (see 8.8).
AMS F Corrosion Heat Resistant Alloys Committee
Electron-Beam Welding For Fatigue Critical ApplicationsAMS2680D (Current)9/30/2025
This specification defines the procedures and requirements for joining metals and alloys using the electron beam welding process.
AMS B Finishes Processes and Fluids Committee
3D-PRINTING IMPACTS ON SYSTEMS ENGINEERING IN DEFENSE INDUSTRY2024-01-352711/15/2024
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
Flux, Aluminum Brazing For Torch or Furnace BrazingAMS3412F (Current)8/9/2021
This specification covers the requirements for an aluminum brazing flux in the form of powder or paste.
AMS B Finishes Processes and Fluids Committee
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D (Current)7/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Steel, Welding Wire 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620) Vacuum Melted, Environment Controlled PackagingAMS6375E (Current)4/6/2021
This specification covers a low-alloy steel in the form of welding wire. Type 2 - copper coated wire was removed from this document (see 8.5).
AMS E Carbon and Low Alloy Steels Committee
Numerical Simulation of Aircraft Assembly Process with Presence of Sealant2021-01-00013/2/2021
Sealant is applied between joined aircraft parts in the final stage of the assembly, before installation of permanent fasteners. In this paper a novel approach for aircraft assembly simulation is suggested, which allows to resolve the transient interaction between parts and sealant in the course of airframe assembly process. The simulation incorporates such phenomena as compliance of parts, contact interaction between them and fluidity of sealant with presence of free surface. The approach based on fluid-structure interaction techniques consists of two basic steps: at the first one the pressure of sealant is found after corresponding fluid dynamics problem is solved and at the second the displacements of parts and sealant are calculated through the solving of contact problem. Iterations between structural and fluid dynamics solvers are performed to achieve convergence. The developed approach is demonstrated on example of joining of two test aircraft panels. The viscosity of sealant was selected based on available experimental data. The results of simulations show how such parameters as fastening force and sealant layer thickness affect the assembly process.
Eliseev, Artem, Lupuleac, Sergey, Grigor'ev, Boris, Shinder, Julia, Bouriquet, Jacques
Steel, Welding Wire 0.65Si - 1.25Cr - 0.50Mo - 0.30V (0.28 - 0.33C) Vacuum Melted, Environment Controlled PackagingAMS6458K (Current)2/3/2021
This specification covers a low-alloy steel in the form of bare welding wire. Type 2 - copper coated wire was removed from this document (see 8.5).
AMS E Carbon and Low Alloy Steels Committee
Overlap Shear Test for Automotive Type Sealant for Stationary Glass BondingJ1529_202101 (Current)1/7/2021
This SAE Recommended Practice defines a procedure for the construction and testing of glass to metal lap shears for determining shear strength of sealant adhesives for automotive stationary glass bonding. This procedure can also be used for fiber reinforced plastic (FRP) when used in place of metal.
Materials, Processes and Parts Council
Lap Shear Test for Automotive-Type Adhesives for Fiber Reinforced Plastic (FRP) BondingJ1525_202101 (Current)1/7/2021
This SAE Recommended Practice describes a lap shear test method for use in measuring the bonding characteristics of automotive-type adhesives for joining fiber reinforced plastics (FRPs) to themselves and to metals.
Materials, Processes and Parts Council
Coach Joint Fracture TestJ1863_202101 (Current)1/7/2021
This SAE Recommended Practice defines a procedure for determining the cleavage strength of an adhesive used for bonding automotive oily metal substrates.
Materials, Processes and Parts Council
Surface Match Verification Method for Pressure Sensitive Adhesively Attached ComponentsJ2215_202101 (Current)1/7/2021
This SAE Recommended Practice applies to evaluation of the conformance match condition existing between two surfaces. Evaluation of this conformance may be especially useful in bonded applications although it may also have relevance to bolted adjacent surface joint conditions. Since good bonding surface conformity is necessary for providing optimal bond performance with pressure sensitive adhesives, the purpose of this document is to provide a method of evaluating the conformance match of the mating surfaces. This document is intended as a guide toward standard practice but may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering the use of this document. Tool types, materials, application tools, and component contact area evaluation methods are included as part of this document. In most cases a visual evaluation of contact performance may be satisfactory; however, for greater accuracy a measurement tool may be used. When reporting a contact value the mode of evaluation (e.g., visual, measurement tool) should be indicated.
Materials, Processes and Parts Council
LEAD-FREE SOLDER VALIDATION TEST PLANUSCAR40-2 (Current)11/19/2020
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
USCAR
Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130)AMS6370R (Historical)7/7/2020
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, flash welded rings, and stock for forging or flash welded rings.
AMS E Carbon and Low Alloy Steels Committee
Hybrid Forming - A Novel Manufacturing Technique for Metal-LFT Structural Parts2020-01-02354/14/2020
Hybrid structural parts combining aluminum or steel sheets with long glass fiber reinforced thermoplastics (LFT) offer a great opportunity to reduce component weight for automotive applications. But due to high manufacturing cost, metal-LFT hybrid components are still scarcely used in automotive large-scale production. Thus in this work a novel cost- and time efficient manufacturing process for simultaneous metal sheet forming and compression molding of long fiber reinforced thermoplastics to manufacture automotive lightweight components is presented. In this manufacturing process, which is referred to as “Hybrid forming”, a fiber reinforced thermoplastic melt is used as a forming medium in the manner of well-known hydroforming processes. After forming the metal sheet by polymer melt in combination with the rigid die, the melt solidifies and forms a local reinforcement structure in the hybrid component. Since the metal sheet is pre-coated with a bonding agent prior to the forming process, a firmly bonded connection between metal and LFT can be achieved. For proof of concept a longitudinal control arm in a multi-link rear axle is chosen. By utilizing Hybrid forming a hybrid steel-LFT control arm is manufactured with weight savings of 20 % with regard to the metal reference component. Weight savings are derived by reducing the metal thickness and compensate stiffness and strength with local load-conforming LFT ribs. The metal part of the hybrid control arm guaranties the same positive fail-safe behavior of a metal component in contrast to the brittle failure mechanics of pure CFRP/GFRP components. To verify the resilience of the hybrid component and especially the bonding surface between steel and LFT quasi-static tests and fatigue tests were conducted. The results are compared with the FE-simulations to validate the simulation technique, which can be used to design metal-LFT structural parts manufactured by hybrid forming for future applications.
Heidrich, Daniel, Kloska, Tobias, Fang, Xiangfan
Process Development of Dissimilar Clinch Joints in Cross-Tension Specimens of AA5052 and TP-CFRP Sheets2020-01-02254/14/2020
This paper studied the process development of dissimilar clinch joints in cross-tension specimens of aluminum alloy 5052-H32 (AA5052-H32)/thermoplastic carbon fiber reinforced plastic (TP-CFRP) sheets. The AA5052-H32 and TP-CFRP sheets with a thickness of 1.6 mm were used. The important processing parameters for AA5052/TP-CFRP clinch joints, such as the punching load, heating mode, heating temperature, and die depth, were considered. The failure loads, failure modes, and metallographic micrographs of AA5052/TP-CFRP clinch joints were analyzed to determine an available processing parameter set for fatigue tests. Finally, the fatigue performance and failure mode of AA5052/TP-CFRP clinch joints were obtained.
Lin, Pai-Chen, Fang, Gavin, Lin, Chia-Wei, Ching, Yern Chee
A Crack Detection Method for Self-Piercing Riveting Button Images through Machine Learning2020-01-02214/14/2020
Self-piercing rivet (SPR) joints are a key joining technology for lightweight materials, and they have been widely used in automobile manufacturing. Manual visual crack inspection of SPR joints could be time-consuming and relies on high-level training for engineers to distinguish features subjectively. This paper presents a novel machine learning-based crack detection method for SPR joint button images. Firstly, sub-images are cropped from the button images and preprocessed into three categories (i.e., cracks, edges and smooth regions) as training samples. Then, the Artificial Neural Network (ANN) is chosen as the classification algorithm for sub-images. In the training of ANN, three pattern descriptors are proposed as feature extractors of sub-images, and compared with validation samples. Lastly, a search algorithm is developed to extend the application of the learned model from sub-images into the original button images. The preliminary results on non-cracked and cracked button images show that the proposed crack detection method is an effective approach to identify a potential defect.
Jiang, Ling, Huang, Li, Wang, Xuyang, Zhan, Zhenfei, Huang, Shiyao, Huff, Garret, Freis, Amanda
Spot Weld Fatigue Correlation Improvement in Automotive Structures Using Stress Based Approach with Contact Modelling2020-01-01824/14/2020
In automotive Body-In-White (BIW) structures, stiffness and the fatigue behavior is greatly influenced by the properties of its joints. Spot welding is one of the most widely used process for joining of sheet metals in BIW. Spot weld fatigue life under Accelerated Durability Test (ADT) is crucial for durability performance of BIW structures. Experience of BIW validations highlighted more number of spot weld failures in CAE when compared to actual tests. Hence, lot of iterations in the form of design modifications are required to be carried out to make these spot welds meet the targets which increases design & development time as well as cost. Current practice uses force-based approach for predicting spot weld fatigue life in CAE. To improve the spot weld fatigue life correlation, extensive study has been carried out on the approaches used for calculating spot weld fatigue life, namely force & stress-based approaches. This study highlights the limitations of force based approach and addresses the advantages of stress based approach. Standard Double Cup (DC) spot weld specimen has been used for correlation of test fatigue life with the force based and stress-based approaches. Good correlation improvement has been observed with stress-based approach with contact definitions between the panels. Deployment of stress-based approach with contact definition on BIW showed significant reduction in the CAE predicted failed spot welds. Overall activity will help in ensuring first time right design and faster design convergence.
Kadakuntla, Srikesh, Mohapatra, Durga Prasad, Kangde, Suhas
A Communication-Free Human-Robot-Collaboration Approach for Aircraft Riveting Process Using AI Probabilistic Planning2020-01-00133/10/2020
In large scale industries attempts are continuously being made to automate assembly processes to not only increase productivity but also alleviate non-ergonomic tasks. However this is not always technologically possible due to specific joining challenges and the high number of special-purpose parts. For the riveting process, for example, semi-automated approaches represent an alternative to optimizing aircraft assembly and to reduce the exposure of workers to non-ergonomic conditions entailed by performing repetitive tasks. In [1], a semi-automated solution is proposed for the riveting process of assembling the section barrel of the aft section to its pressure bulkhead. The method introduced a dynamic task sharing strategy between human and robot that implements interaction possibilities to establish a communication between a human and a robot in Human-Robot-collaboration fashion. Although intuitive, interacting with the robot constantly is still not natural for the worker as in the manual process no explicit communication between both workers is needed. In this work a communication-free Human-Robot-collaboration solution is presented. The method developed not only enables sharing assembly missions by dividing tasks based on skills, but also offers the possibility of decision making to the robot. In this context, off-the-shelf Artificial Intelligence planning tools are used to model the work-flow of the human as well as the task of the robot handling alongside possible uncertainties yielding while perceiving the environment or the activity of the human.
Rekik, Khansa, Müller, Rainer, Hoffmann, Jörg, Vette, Matthias
Laser Welding ‘Clear-on-Clear’ Plastics for Medical ApplicationsTBMG-362723/1/2020
Through a new process, it is now possible to laser-weld two optically clear plastic parts made of a wide range of polymer materials for medical applications. This innovation combines patented Branson Simultaneous Through-Transmission Infrared® (STTIr®) laser welding technology from Emerson with precision ultrasonic spray deposition technology from Sono-Tek to open up new design possibilities for the makers of medical devices, drug-delivery systems, and in-vitro testing products.
Marubeni Citizen-Cincom Opens New Technical CenterTBMG-362733/1/2020
Marubeni Citizen-Cincom Inc. (MCC) has opened a new technical center in Agawam, MA. The company is holding a ribbon cutting and grand opening celebration March 9. An open house will follow to introduce the company’s new L12 Type X and the new 12 mm laser cutting and welding machine. A variety of Cincom sliding headstock and Miyano fixed headstock lathes will be on display as well. The event will also include technical seminars presented by Sandvik, Esprit, and Gen Swiss.
Leading Women in Engineering & Science: Dr. Annette Teng, CEO; Lisa Wen, Process EngineerTBMG-362633/1/2020
Using Plasma Treatments to Improve, Enhance Medical DevicesTBMG-360142/1/2020
Whether attempting to improve adhesion of dissimilar materials, depositing coatings, cleaning surfaces, applying a protective coating that repels water for example or biological fluids or enhancing surface wettability or functional coating, plasma treatments often add significant value to medical devices.
‘Hyper Glue’ Could Be Used for Medical ImplantsTBMG-360152/1/2020
Researchers hope to make everything from protective clothing to medical implants stronger and more corrosion resistant thanks to a newly developed hyper glue formula. The team of chemists and composite materials researchers discovered a broadly applicable method of bonding plastics and synthetic fibers at the molecular level in a procedure called cross-linking. The cross-linking takes effect when the adhesive is exposed to heat or long-wave UV light making strong connections that are both impact-resistant and corrosion-resistant. Even with a minimal amount of cross linking, the materials are tightly bonded.
Soft, Skin-Like Structures for Robotic Locomotion and TransportationTBMG-359992/1/2020
Stretchable, skin-like robots that can be rolled up and put in your pocket have been developed using a new way of embedding artificial muscles and electrical adhesion into soft materials. This new advance could create new thin and light robots for environmental monitoring and deployment in hazardous environments, robot grippers for delicate objects, and new wearable technologies.
Development of Laser Welding Pressed-frame for Small Scooters Considering High Production Efficiency2019-32-05441/24/2020
The laser-welded pressed-steel frame made of the high-tensile-strength steel sheet and suitable for high efficiency production has been developed for small scooters. In majority of the conventional designs, the frame of small scooters is composed of a large number of steel pipes and stamped parts complexly welded together, requiring a number of welded joints. As a result, since the welding length increase and the dimensional error of the frame body after welding tends to be large, a correction operation in a post process is required. This has been one of the factors preventing further enhancement of production efficiency. In an attempt to cope with this issue, we have chosen to apply the pressed-steel frame construction using the high-tensile-strength steel sheet, which has been applied to small motorcycles, to small scooters. In addition, we replaced the spot welding with more efficient laser welding to further enhance productivity. The optimum cross section design taking advantages of the pressed-steel frame construction permits more gradual changes of cross sectional area than the conventional steel pipe frame, allowing dispersing of stresses in the frame. Consequently, the frame reinforcement members are reduced while maintaining the same or higher strength as the steel pipe frame, realizing a 39% reduction of number of parts and 10.7 kg reduction of frame weight. The torsional stiffness is also increased by 4% from the conventional design, contributing to the riding comfort and the steering stability. The production time per frame is reduced by 43% from the conventional steel pipe frame.
Kawano, Sunao, Kobayashi, Takeru
Double-Sided Tape for Tissues Could Replace Surgical SuturesTBMG-357811/1/2020
Inspired by a sticky substance that spiders use to catch their prey, MIT engineers have designed a double-sided tape that can rapidly seal tissues together.
2019 'Create the Future' Manufacturing/Robotics/Automation Category Winner: The HPCI® Joining GunTBMG-3544011/1/2019
STRSW (Squeeze Type Resistance Spot Welding) Equipment Acceptance Criteria for the Collision Repair IndustryJ2667_201910 (Current)10/28/2019
This SAE Recommended Practice provides a minimum standard for evaluating squeeze-type resistance spot welding (STRSW) equipment and minimum weld performance criteria for two-sided automotive collision repair welding. This document contains several standardized test methods that are designed for evaluating equipment performance in a laboratory environment.
Motor Vehicle Council
Metallic WhiskersAIR4129A (Current)10/17/2019
This AIR presents an abbreviated review of the metallurgical phenomena known as whiskers. It is not all encompassing; rather, it is intended to introduce the design engineer to the technical issues of metallic whiskers, their formation, and the potentially dangerous problems they can cause.
AMS B Finishes Processes and Fluids Committee
Experimental Investigation of Mechanical and Corrosion Characteristics of Friction Stir Welded Aluminum Alloy 7075-T62019-28-017510/11/2019
Friction Stir Welding (FSW) is a quite new solid-state joining process. This joining technique is energy efficient, environment friendly, and adaptable. In particular, it can be used to join high- strength Aluminium alloys and other metallic alloys that are difficult to weld by conventional fusion welding. Friction Stir Welding heats metal to the temperature below re crystallization. FSW avoids welding defects like porosity and hot cracking which are frequently in conventional welding techniques due to alloy’s very low re- crystallization temperature and higher heat dissipating nature. This process combining deformation heating and mechanical work to obtain high defect free joints. Aluminum alloy 7075-T6 is generally used in various industrial applications such as automobile, ship building and aerospace due to their light weight, good mechanical properties and high corrosion resistance. In the present study, aluminum alloy 7075-T6 was successfully made by friction stir welding technique. The Corrosion, micro structure analysis and mechanical behavior of the welded joints were investigated at different welding parameters.
S, Deepankumar
Investigation on Microstructure and Mechanical Properties of Corrosion Resistance Alloy C-2000 Fabricated by Conventional Arc Welding Technique2019-28-017710/11/2019
In the current work the metallurgical and tensile properties of the weld joints of alloy C-2000 were investigated. Welding technique employed in this study is Tungsten Inert Gas Welding (TIG) and Pulsed Current Tungsten Inert Gas (PC-TIG) welding with autogenous mode and Ni-Cr-Mo rich ERNiCrMo-10 filler wire. The results show that PC-TIG weldment obtained the refined microstructure compared to the TIG weldment. Energy dispersive spectroscopy (EDS) showed the extent of Cr segregation was observed in all the weldments. PC-TIG welding shows reduced segregation compared to the corresponding TIG. X-ray diffraction (XRD) corroborated the existence of Ni3Cr2 phases in the weld fusion zone. Tensile test results show the PC-TIG weldment obtained marginally higher tensile properties comparing over the corresponding TIG weldment. The strength of the weldments is inferior in all cases in comparison to base metal.
John, Aashish, Jacob Johny, Kiran, Arulmurugan, Balasubramanian, Rajkumar, Sivan, Arivazhagan, Natarajan, Naiju, Chooriyaparambil Damodaran, Manikandan, Manoharan
Optimization of Machining Process Parameters for Minimizing the Waste Stream Response through Multi-Objective Optimization2019-28-006210/11/2019
During the delivering of an item, any material created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a notable conservation worry for creators. The shape and condition of waste streams created, and their transportation components divergence with the strategy utilized and also shift among the technique. The effect in view of each waste stream differs as well. This examination reports a machining strategy includes the procedure of material to give a completed or a semi-completed item. This is frequently done by misapplication tools, totaling, machines and distinctive data sources that are appropriate to the strategy. The procedures thought of for the point of this work includes machining of material manipulation devices to give parts and items. The yield of the technique incorporates the item and increase the waste streams. The waste streams will be in the form of Chips, Energy usage, and Worn cutting tools and Operating time. TOPSIS and ANOVA was acclimated gauge the chief essential Cutting speed, Feed rate, Depth of Cut and Tool Nose Radius conditions that influencing the Minimum Response. The most support effect of the info factors on the normal reactions is researched. The normal esteems and estimated esteems are genuinely close. The given model may be acclimated pick the measure of machining process parameters.
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Kumaran, Durai, Rajendran, Raj, Sriram, Harish
Corrosion Characteristics on Friction Stir Welding of Dissimilar AA2014/AA6061 Alloy for Automobile Application2019-28-006310/11/2019
Friction Stir Welding (FSW) is a widely used solid state welding process in which its heats metal to the below recrystallization temperature due to frictional force. FSW mostly avoids welding defects like hot cracking and porosity which are mainly occur in conventional welding techniques. In this process the combination of frictional force and the mechanical work provide heating the base metal to get defect free weld joints. Aluminium Alloys 2014 and 6061 are generally used in a wide range of automobile applications like Engine valves and tie rod, shipbuilding, and aerospace due to their high corrosion resistance, lightweight, and good mechanical properties. In the present work, aluminium alloys of AA6061 and AA2014 were effectively welded by friction stir welding technique. The tool rotational speed, travel speed, and tool profile are the important parameters in FSW process. High Speed Steel (HSS) tool with Hexagonal profile is used for this joining. The tool rotational speed is varied form 700, 1000 and 1400 rpm and the travel speed is varied from 25, 30 and 50 mm/min. From the experimental results the open circuit potential is drastically reduced at 1400 rpm tool rotational speed and the TAFEL plot is also decreased with the same rotational speed and 50 mm/min travel speed.
Rajamurugan, Govindasamy, Deepankumar, Sadhasivam, Ramakrishnan, Anbalagan, Krishnasamy, Prabu, Dhanabalan, Dinesh
Multi Characteristics Optimization of Treated Drill Tool in Drilling Operation Key Process Parameter Using TOPSIS and ANOVA Technique2019-28-005510/11/2019
To survive in the present global competitive world, the manufacturing sectors have been making use of various tools to achieve the high quality products at a comparatively cheaper price. Appropriate cutting set up must be used to further better the machinability of a work piece material. A longer life of the tools and equipment’s are important factors in any industry. Since the inception of the machine tool industry, cutting tool life and tool wear remain a subject of deep interest to study its failure and improvement. The present study finds out the optimum cutting results in drilling of AM60 magnesium alloy using different cryogenically treated cutting inserts. The Utility concept coupled with Taguchi with Multi response approach (TOPSIS) was employed. According to Analysis of variance (ANOVA) results, the feed was the major dominating factor followed by the cutting speed. This work deals with optimization approaches for the determination of the optimum process parameters by cryogenically treated drill HSS tools which minimizes surface roughness, torque, tool life, entry burr and tool cost, and maximizes material removal rate in a drilling operation of high-speed steel. Spindle speed, feed, and three different combinations of treated drill bits are taken as the input process parameters for this study. The experimental results obtained from design of experiment are optimized using TOPSIS and ANOVA technique to determine the optimized values.
Sivam Sundarlingam Paramasivam, Sundar Singh, Banerjee, Aishik, Kulkarni, Avanti
Improvement of Mechanical Properties, and Optimization of Process Parameters of AISI 1050 Spheriodized Annealed Steel by Ranking Algorithm2019-28-014310/11/2019
AISI 1050 is used in the production of landing gear, actuators and other aerospace components but their application is limited due to machinability of the material. In any metal cutting operation the features of tools, input work materials, machine parameter settings will influence the process efficiency and output quality characteristics. A significant improvement in process efficiency may be obtained by process parameter optimization that identifies and determines the regions of critical process control factors leading to desired outputs or responses with acceptable variations ensuring a lower cost of manufacturing. This experimental study elucidates the problems and machinability issues like failure of tools and accuracy are found while machining and less output in machining. In the present study of spherodizing heat treatment of AISI 1050 was investigated during the turning operation in CNC lathe, under the consideration of several turning process parameters. The microstructures of the as-received, and heated specimens were investigated by Optical Microscopy (OM). A correlation between various process parameters on the desired response namely surface finish, roundness Material Removal Rate (MRR), power consumption and tool wear were ranked and analyzed by ANOVA method for finding the optimized settings. The predicted results were found to be in good agreement with the experimental values.
Loganathan, Ganesh Babu, Kumaran, Durai, Sivam Sundarlingam Paramasivam, Sundar Singh, Saravanan, Krishnaswamy, Rajendran, Raj
Experimental Investigation on Turning Characteristics of TiC/MoS 2 Nanoparticles Reinforced Al7075 Using TiN Coated Cutting Tool2019-28-016510/11/2019
In recent years, aluminum metal matrix composites (Al-MMC) are found as a potential material for numerous applications owing to its excellent tribological and mechanical properties. In this work, the machining characteristics of aluminum alloy (Al7075) reinforced with TiC/MoS2 having nanoparticle has been studied. The samples of aluminum metal matrix composites by varying TiC in 0, 2 and 4 and MoS2 in 0 and 2 of the percentage weight of aluminum alloy (Composite 1(Al7075), Composite 2 (Al7075/2TiC/2MoS2) and composite 3 (Al7075/4TiC/2MoS2), respectively) are fabricated by the stir-casing method. The turning characteristics of the developed metal matrix composites are studied at various parameters such as cutting velocity (30 m/min, 60 m/min and 90 m/min), cutting depth (0.5 mm, 1.0 mm and 1.5 mm) and composites (1, 2 and 3) using TiN coated cutting tool by dry turning at 0.05 mm/rev feed rate. The turning characteristics of the prepared samples are compared each other under L20 orthogonal array on CNC turning machine. The significant findings in the present study are: hardness of base aluminum alloy is found to increase with the addition of TiC/MoS2 in Al7075; surface roughness and flank wear are found to grow with the addition of nanoparticles of TiC/MoS2 in Al7075, evidence of built-up edge is observed for addition of nanoparticles in Al7075; cracks are originated from the edges of the chip and are propagated to the inner side along shear planes on examining the chip shape..
Kannan, Vetri Velmurugan, Kannan, Venkatesan, Sundararajan, Devendiran, Uday Kumar, Budireddy, Anvesh, Dhulipalla, Akhil, Varupula
Surface Modification of Aluminium Alloy 5083 Reinforced with Cr 2 O 3 /TiO 2 by Friction Stir Process2019-28-017910/11/2019
The surface properties have a vital role in the overall performance of the parts like brake shoe pad and other frame system. The mechanical and residual stress measurements of aluminium alloy 5083 were investigated on friction stir processed plates using the reinforcements of chromium oxide (Cr2O3) and titanium dioxide (TiO2) separately as well as combination of these powders. A comparative study was made to analyze the effects of reinforcements, tool type (cylindrical and threaded), parameters and the volume fraction of the reinforcements. The mechanical properties such as surface hardness and residual stress of the friction stir processed specimens were investigated. The experimental results shows that there was a significant increase in surface hardness (118 HRC) as well as a decrease in residual stress compare to the base metal. This study also reveals that the threaded tool with a reinforcement of Cr2O3 and TiO2 reflected better mechanical properties than the cylindrical tool. The SEM images show that the uniform distribution of reinforcement in the processed zone. The surface-hardened plates can be used in brake shoe pad in automobile brake equipment.
Singh, Adarsh, Rajamurugan, Govindasamy, Krishnasamy, Prabu, Dhanabalan, Dinesh
Function of Taguchi Grey Relation Analysis for Influencing the Process Parameter for Getting Better Product Quality and Minimize the Industrial Pollution by Coolants in Turning of Ti-6Al-4V Alloy2019-28-006510/11/2019
Cutting liquids are important for cutting titanium. In spite of the fact that ventures are discovering routes that to cut titanium dry, the properties of this material reason imperative deterrents for doing this. It is sticky, has low Thermal conductivity, and highlights a low flash point. Thus, the chips don't divert the warmth, and the work will get sufficiently hot to touch off and consume. Cutting Fluids thwart the issue by greasing up the sting, flushing the chips away and cooling the work piece. To guarantee that the cutting liquid plays out these capacities well, titanium combinations lean toward cutting liquids conveyed at a high weight, generally inside the scope of 4,000 psi. to 7,000 psi. This thinks about reports the aftereffects of a Turning test led on the Ti- 6Al- 4V compound of the symmetrical exhibit with Grey relational analysis by Taguchi Method. Spotlights on the improvement of Turning process parameters utilizing the system to get least surface Roughness (Ra), Maximum MRR, Min Tool Wear and Thrust Force with Minimum Industrial pollutants like coolant. Various Turning tests were led abuse the L9 symmetrical cluster on CNC Turning focus. The tests were performed on Ti- 6Al- 4V composite square of cutting apparatus of a CNMP120408-SM TN8025of 12 mm diameter across with cutting point 140 degrees, utilized all through the exploratory work underneath various cutting conditions. Grey relational Analysis & ANOVA was utilized to work out the principal imperative Cutting velocity, feed rate, Depth of Cut, and Different greases conditions which influencing the reaction. The fundamental and collaboration impact of the information factors on the normal reactions are researched. The normal qualities and estimated esteems are genuinely close. The given model could be utilized to choose the level of turning process parameters.
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Kumaran, Durai, Saravanan, Krishnaswamy, Rajendran, Raj, Sriram, Harish
Development and Influence of Setting Process Variables in Single Point Incremental Sheet Metal Forming of AA 8011 Using Complex Proportional Assessment and ANOVA2019-28-006410/11/2019
Single point Incremental forming (SPIF) is a metal forming process that has achieved impeccable quality since the early 1990s. ISF is a very limited twisting process in which an improved device that must be used after a particular direction travels on a metal sheet to form the desired shape. Process parameters such as axial feed (mm), feed (mm / min), tool diameter (mm) and depth (mm) at the interface between samples during SPIF greatly affect the quality of the cone. Maximum thinning (mm), cone height (mm), wall angle (mm), formation time (minutes), etc. The purpose of this study was to study these parameters by improving the cone mass formed by VMC. For a detailed study of these parameters, experiments were performed using the orthogonal array L9. Output parameters such as mechanical quality effects were analysed using COPRAS (Complex Proportional Assessment of alternatives) and ANOVA.
Sivam Sundarlingam Paramasivam, Sundar Singh, Kumaran, Durai, Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Rajendran, Raj, Sriram, Harish
Experimental Study on Verification of Alloy ASTM A510 High-Speed Micro Turning by Parameters Validation through Ranking Algorithm2019-28-007110/11/2019
In the details and assembly, in the range of less than 1 mm, the number of functions increases, and the demand for industrial products in which the size and characteristics of components are decreasing is increasing. Micromachining is the most basic technology for producing these small parts and components. In this study, a series of turning operations, micromachining parameters, were performed under microscopic conditions to obtain the best response for the benefit of the industry. The needle is very high. Speed (3000, 3500, 4000 rpm), pre- (20, 40, 80 μm / sec), depth of cut (0.2.0.4.0.8 μm), tool radius (0.4.08, 1, 2 mm). Surface quality, material removal rates, energy consumption, and tool wear differences for various input process variables were investigated. Once the experiment is complete, we will develop an optimization strategy for this set of input parameters to improve responsiveness using the Grey Relational Analysis (GRA) and ANOVA. Therefore, the model can create micro-process parameters to achieve the highest product accuracy and improved performance.
Loganathan, Ganesh Babu, Sivam Sundarlingam Paramasivam, Sundar Singh, Kumaran, Durai, Saravanan, Krishnaswamy, Rajendran, Raj
Clean Design: Reducing Patient Infections Starts with Design for CleanabilityTBMG-3532810/1/2019
Although the Food and Drug Administration (FDA) has reported progress on reducing overall infection rates with enhanced safety measures and better disinfection methods, the risks associated with reusable medical devices are an ongoing challenge, with drug-resistant microbes and other organisms continuing to survive the cleaning process at an unacceptable rate.1
NIST Research Sparks New Insights on Laser WeldingTBMG-3537310/1/2019
On its surface, the work is deceptively simple: Shoot a high-power laser beam onto a piece of metal for a fraction of a second and see what happens. But researchers say the physics of laser welding is surprisingly complex. A better understanding of the interaction between laser and metal could give industry more control over laser welding, a technology that is becoming increasingly popular in manufacturing.
Advanced Assembly Solutions for the Airbus RACER Joined-Wing Configuration2019-01-18849/16/2019
The Rapid And Cost Effective Rotorcraft (RACER) is being developed by Airbus Helicopters (AH) to demonstrate a new Vertical Take-Off and Landing configuration to fill the mobility gap between conventional helicopters and aeroplanes. RACER is a compound rotorcraft featuring wings and multiple rotors. The wing arrangement suggested by AH is defined as a staggered bi-plane joined configuration with an upper and a lower straight wing, either side of the fuselage, connected at their outboard extent to form a triangular structure. The ASTRAL consortium, consisting of the University of Nottingham and GE Aviation Systems, are responsible for the design, manufacture, assembly and testing of the wings. Producing an optimised strategy to assemble a joined-wing configuration for a passenger carrying rotorcraft is challenging and novel. The objective of this work concerns all aspects of assembling the joined-wing structure. The joined-wing and fuselage structures will be produced independently and mated together during the final RACER assembly. A multi-stage process will deliver the joined-wing assembly and ensure it will fit to the fuselage. Producing the individual wing structures requires a novel build philosophy driven by the innovative, one-piece composite moulding that forms the leading edge (LE) and upper aerodynamic surface of each wing. Using the Flap sub-assembly as the tool to set interfacing wing-box items provides a cost effective solution to assembly jig design. The independent wing structures must be joined at the outboard hinge line, whilst meeting the fuselage interchangeability definition. Matched tooling, replicating the fuselage interface, will be employed to overcome this hurdle. Successfully joining the wing structures also requires the innovative application of 3D tolerance analysis methods to size bush diameters within the interface. The overall build philosophy is summarised in this work, including assembly sequencing; definition of datum frames; assembly tooling; design tolerances and the analysis required to deliver assembly key characteristics.
Bainbridge, David, Bacharoudis, Konstantinos, Cini, Andrea, Turner, Alison, Popov, Atanas, Ratchev, Svetan
The Right Stuff for Aging Electronics/Intermittence/No Fault Found2019-01-18899/16/2019
For those in the avionics repair and maintenance business, the acronyms NFF (No Fault Found), NTF (No Trouble Found), and CND (Cannot Duplicate) are, unfortunately, all too familiar terms. After several decades of frustration with this illusive phenomenon, it continues to consume an enormous amount of test and diagnostic effort and is the source of considerable cost and discomfort within the multi-level avionics repair model. There are undoubtedly many causes of NFF and all of them should be addressed. The question is: Where do you start and which solution will be the most beneficial? Our particular efforts have focused on the literal or statistical analysis of NFF, recognizing that if the system’s MTBF (Mean Time Between Failure) has decreased, or if the device's NFF rate has increased with age and deterioration, a physical fault is most likely present. However, if it isn’t found during conventional testing then it probably only fails intermittently. Similarly, having an intermittent failure mode, it in all probability cannot be detected or diagnosed at testing time because of known and demonstrated limitations in the conventional measurement equipment used to perform the tests. In this paper we will outline the problem of intermittence and its testing difficulties. More importantly, we will describe the unique equipment and process which has produced overwhelming success in Intermittence / NFF resolution and MTBF extension. Our team-developed overhaul system called IFDIS 2.0 (Intermittent Fault Detection and Isolation System 2.0) incorporates all the necessary testing procedures and technological capabilities that are proving to be critical to the resolution of the chronic intermittent / NFF problem.
Knudsen, Hector I.
Low Cost Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Rotorcraft Wing Assembly2019-01-18779/16/2019
Reconfigurable tooling frames consisting of steel box sections and bolted friction clamps offer an opportunity to replace traditional expensive welded steel tooling. This well publicized reconfigurable reusable jig tooling has been investigated for use in the assembly of a prototype compound helicopter wing. Due to the aircraft configuration, the wing design is pinned at both ends and therefore requires a higher degree of end to end accuracy, over the 4m length, than conventional wings. During the investigation some fundamental issues are approached, including: Potential cost savings and variables which effect the business case. Achievable Jig accuracy. Potential sources of instability that may affect accuracy over time. Repeatability of measurements with various features and methods. Typical jig stability over 24hrs including effects of small temperature fluctuations. Deflections that occur due to loading. The cost benefit of reusable tooling in a low volume prototype scenario is examined followed by the design of the jig and location features to enable the accurate build and certification documentation to be completed. A prototype 4m test jig comprising of commercially available components and bespoke machined ‘pick-ups’ is presented. Hardware and measurement process cost modelling is documented along with results for the positional and center-line concentricity setting accuracy that was achieved using a Leica AT901 laser tracking system. Subsequent measurements over a 24hr period are also discussed along with potential sources of deviation in jig accuracy over time and with an applied load.
Crossley, Richard J., Ratchev, Svetan
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