Browse Topic: Welding

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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
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
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
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
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
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.
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
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.
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
The Study of Local Stress Intensity Factors for Kinked (and Branched) Cracks in Commonly Used Spot Weld Specimens05-12-03-00158/26/2019
Local stress intensity factors (LSIFs) for kinked (and branched) cracks of spot welds in lap-shear (LS), cross-tension (CT), U-shaped (US), and coach-peel (CP) specimens were investigated by three-dimensional (3D) finite element analyses (FEA). Models of spot welds without and with kinked (and branched) cracks were developed to derive global SIF (GSIF) and LSIF, respectively. Kinked (and branched) cracks with semielliptical shapes were assumed. Two dominant cracking modes were considered for each specimen. Note that fine mesh size and reasonable mesh design for crack tip regions were adopted to improve the computation accuracy. GSIFs for main crack were obtained to derive local SIFs for infinitesimal kinked cracks. LSIFs for finite kinked (and branched) cracks were then obtained. The computational results show that the LSIF solutions of the four specimens have similar general trends. As kinked (and branched) crack length increases, mode I LSIF solutions gradually increase and then decrease, while mode II LSIF solutions show inverse trends. Finally, applications of local SIFs for fatigue life estimations of spot welds were discussed.
Lin, Zhi-Long, Wang, Dung-An, Chee, Ching-Ying, Lin, Pai-Chen
Effect of Welding Parameters on the Microstructure and Tensile Properties of Friction Stir-Welded DP600 Steel05-12-03-00137/2/2019
The aim of this study was to investigate the effect of friction stir welding (FSW) parameters on the microstructure and tensile properties of dual-phase (DP) steels. In this regard, DP600 steel sheets were joined using FSW under different tool rotational (ω) and transverse speeds (v). Optical microstructure of the stir zone exhibited a mixture of bainite, Widmanstatten ferrite, grain boundary ferrite, and ferrite-carbide (FC) aggregate, which resulted in a hardness increase compared to the base metal (BM). The fraction of bainite and Widmanstatten ferrite in the stir zone increased with increasing the welding heat input. Formation of a softened zone in the subcritical area of the heat-affected zone (HAZ) resulted in the reduction of ultimate tensile strength and total elongation compared to those for the BM, while the yield strength was only marginally affected. Based on the experimental results, it was found that the joint efficiency of friction stir (FS)-welded DP600 steel decreased in a parabolic trend with increasing ω/v value.
Ashrafi, Hamid, Shamanian, M., Emadi, R., Ahl Sarmadi, M.
Titanium Alloy, Extrusions and Flash Welded Rings 6Al - 4V Solution Heat Treated and AgedAMS4934H (Historical)6/3/2019
This specification covers a titanium alloy in the form of extruded bars, and shapes, flash welded rings up through 3.000 inches (76.20 mm) inclusive, in nominal diameter or least distance between parallel sides, and stock for flash welded rings of any size.
AMS G Titanium and Refractory Metals Committee
Joining Gun Bonds Metal and Plastic in SecondsTBMG-346126/1/2019
The connection of plastics and metals poses a challenge due to the different physical properties of the two materials. All conventional joining options, such as bonds using adhesives or rivets, have their disadvantages — adhesives need time to harden, which delays further processing, and plastics can be easily damaged during riveting. Furthermore, both adhesive bonding and riveting require additional materials that increase production costs.
Aluminum Alloy, Extrusions and Rings 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr - (6061-T6) Solution and Precipitation Heat TreatedAMS4150N (Historical)5/14/2019
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing, flash welded rings fabricated from extruded stock, and stock for flash welded rings.
AMS D Nonferrous Alloys Committee
Optimized Requirements Verification for Flexible Drive ShaftsF-0075-2019-145455/13/2019
An optimized design, fabrication and testing solution is presented for flexible drive systems. A single piece welded drive shaft as well as a system consisting of sub and supercritical shafts, couplings and bearing hangers (for Tail Drive System in Helicopters and Interconnect Drive Systems in Tiltrotors) are included. This solution facilitates the qualification for flight of the drive shaft in airframes with reduced iron bird and expensive flight testing on the airframe. This solution also provides opportunities for improvements during the prototype phase such that potential deficiencies are identified and corrected before the drive shaft is put into service. An important part of the testing is accelerated testing, not in terms of operational life, but in terms of reliability. Theoretical Life of a flexible drive shaft is 'infinite' by design. 2.0
King, Michael, Schaefer, Joyel, Iyer, Raghu
Analysis and Comparison between Different Joining Technology of Aircraft Structures including Innovative FSW and RFSSW ProcessesF-0075-2019-146325/13/2019
One of the alternative method for welding method is a friction stir welding (FSW), which was developed in 1991 at TWI Ltd. (The Welding Institute) in the United Kingdom, initially especially for joining aluminum and its alloys [1]. This process consists in joining of materials in solid state, which eliminates the problems resulting from melting the material and its re-solidifying, such as, hot cracking, residual stresses and distortion created during conventional welding.
Luty, Grzegorz, Wronska, Agata, Andres, Jacek, Login, Waldemar, Gałaczynski, Tomasz
Why Reel-to-Reel Molding Might Be Right for Medical ComponentsTBMG-344485/1/2019
Reel-to-reel insert molding can prove a more efficient process for design engineers when it comes to lowering assembly costs. The process is best suited for products that require dimensional stability and need to function in harsh environments, such as drug-delivery device parts and components.
Three-Dimensional Finite Element Analyses of Local Stress Intensity Factor Solutions for Kinked Cracks of Spot Welds in Commonly Used Specimens2019-01-11104/2/2019
Local stress intensity factors (LSIFs) for kinked cracks of spot welds in four specimens, lap-shear, cross-tension, U-shaped, and coach-peel, were studied by three-dimensional finite element analyses. Finite element models for spot welds without and with kinked cracks were developed. Semi-elliptical cracks with various kinked crack lengths were assumed. Two dominant cracking modes for each specimen were considered. The global stress intensity factor (GSIF) solutions for spot welds without kinked cracks were first obtained to determine the analytical LSIF solutions for spot welds with infinitesimal kinked cracks. The LSIF solutions for spot welds with finite kinked cracks were then obtained. The LSIF solutions of the four specimens show similar general trends. As kinked crack length increases, the mode I LSIF solutions gradually increase and then decrease, while the mode II LSIF solutions show inverse trends. Finally, the applications of LSIFs for fatigue life estimations of various types of spot welds or spot joints are discussed.
Lin, Pai-Chen, Lin, Zhi-Long, Wang, Dung-an
MELD exploits plastic deformation of metals with non-melt AM process19TOFHP04_074/1/2019
Additive manufacturing (AM) has been a catalyst in improving speed and efficiency during the product development process. However, the technology has been limited in the size and materials available to be produced. MELD Manufacturing believes it has the remedy for these limitations, and it has garnered numerous accolades for its patented MELD process, including the 2018 “Create the Future” award in the Robotics/Automation/Manufacturing category. The design contest is produced by Tech Briefs Media Group. While additive manufacturing has thus far relied on melting materials to produce custom components, the MELD process does not require taking metals up to their melting points. Instead, materials are brought to their plastic deformation state and then formed into the desired shape. By not melting the materials, MELD believes it is taking additive manufacturing beyond just an evolutionary step.
Borst, Matthew
Research Explores Internal Flow Behavior in Additive Manufacturing, Welding of MetalsTBMG-340273/1/2019
Arc welding and additive manufacturing are hugely important for creating large metal components relatively inexpensively and quickly. New research by a team at the University of Leicester, Delft University of Technology, Diamond Light Source, University College Dublin, and TATA Steel Research UK has shown how to optimize this process to improve efficiency and cost. A paper detailing the findings was recently published in Nature Communications. The research explores the internal flow behavior in additive manufacturing of metals and arc welding — the most widely used welding process in modern manufacturing. It focused on examining the melt pools that are created during the welding process.
Electrocutting and Mechanical Cutting for Endoscopic ApplicationsTBMG-340253/1/2019
Even the simplest medical cable assembly projects contain numerous engineering considerations. And among the most complex applications, the quantity of requirements can skyrocket. Factors such as diameter, construction, material, coating, length, and tolerance are only a few of the often-mountainous specifications medical device engineers must consider. Regardless of the complexities of a medical cable assembly, the decision as to how to cut the cable is built in to virtually any medical device cable project, big or small, intricate or straightforward.
Study of Temperature Distribution and Parametric Optimization during FSW of AA6082 Using Statistical Approaches05-12-01-00052/1/2019
In this article, Al-Mg-Si-Mn alloy (AA6082) is butt joined by employing friction stir welding (FSW). The mechanical and metallurgical properties of joints are analyzed by conducting tensile and microhardness testing, respectively. To measure the temperature at different locations, eight thermocouples (L-shaped k-type) are placed at equal distance from the centerline. Least square method attempts to calculate the temperature at the centerline of joints. The process parameters are also optimized using Taguchi’s five-level experimental design. The optimum process parameters are determined, employing ultimate tensile strength (UTS) as a response parameter. A statistical test “analysis of variance” is used to check the adequacy of the model. It has been observed that rotational speed and feed rate are the predominant factors for UTS and microhardness. Optical microscopic and electron backscatter diffraction analyses are carried out to obtain the macrostructure and microstructure of joints.
Verma, Shubham, Misra, Joy Prakash, Gupta, Meenu
Parameter Sensitivity and Process Time Reduction for Friction Element Welding of 6061-T6 Aluminum to 1500 MPa Press-Hardened Steel05-12-01-000412/14/2018
Conventional fusion joining techniques pervasive in the automotive industry are unable to effectively join aluminum and steel. To solve this problem, a technique termed friction element welding (FEW) has been developed, which is able to join any nonferrous top sheet material to a base steel layer, independent of the base layer strength. FEW works on the same principles as friction welding, as a steel element is pushed and rotated against a nonferrous top sheet to create frictional energy which softens and flows the material around the fastener shaft and under the fastener head, exposing the steel below. The element then contacts the steel and bonds through traditional friction welding. FEW is a four-step process (penetration, cleaning, welding, compression), with two to four parameters (endload, spindle speed, displacement transition, time transition) controlling each step. This research examines the parameter sensitivity of the FEW process in the cleaning, welding, and compression steps with an emphasis on reducing process time while maintaining joint strength. Joint strength is evaluated through transverse shear, cross tension, and fatigue transverse shear. It is found that process time can be reduced by up to 39% with only a nominal reduction in strength. Dominant parameters are identified for controlling peak torque, process time, and joint strength.
Absar, Saheem, Choi, Hongseok, Zhao, Xin
Evaluation of Weldability and Mechanical Properties in Resistance Spot Welding of Ultrahigh-Strength TRIP1100 Steel05-12-01-000112/14/2018
To use steel in the automotive industry, it is essential to characterize its weldability and weldable current range. The resistance spot welding of ultrahigh-strength transformation-induced plasticity steel (TRIP1100 steel), which is a candidate for application in an autobody, is studied here. Identifying the weld lobe and the best welding parameters and studying the microstructure and mechanical properties of the spot welds of TRIP steel were done using metallurgical techniques, tensile-shear and cross-tension tests, and fractography and microhardness testing. A partial fracture analysis (stepwise tensile test) showed a crack initiated at the tip of the notch. The best range for welding current was found to be 10-12 kA. The diameter of the weld nugget increased up to 5√t; however, it was found that at least 15% increase in the diameter of the weld nugget can result in a more favorable failure. The ductility ratio was found to be less than 0.5 for ultrahigh-strength steel. At the welding currents of 11 and 12 kA, the desired ductility ratio was achieved.
Hajiannia, Iman, Shamanian, Morteza, Atapour, Masoud
Metal Tubing Offers Flexibility for Disposable DevicesTBMG-3325811/1/2018
Traditional handheld surgical tools continue to provide benefits where surgeons need instruments to be more rigid and have strong holding power to withstand complex procedures. The majority of these small handheld devices include tubing technology. Those made with metal can be formed to meet specific needs. Base tubing can be created from drawn tubing or from flat sheets of metal in a patented technique known as rolled-tube technology, which is ideal for creating high volume disposable devices.
Tailoring Plastics Joining Methods to DIVERSE Medical Device NeedsTBMG-3308410/1/2018
The European Commission defines personalized medicine as, “a medical approach tailored to the patient or a group of patients for prevention, prediction and treatment . . . that moves away from the ‘one size fits all’ medical model.”
Using Direct Current with Inverter Technology Reduces Costs and Improves ControlTBMG-3308610/1/2018
Resistance welding with direct current (DC) using inverter technology reduces costs by improving quality, reducing maintenance, and increasing productivity. Switching from traditional alternative current (AC) to DC with inverters also reduces a range of facilities costs and improves the process. Finally, it provides the ability to weld new materials, so it can add to a company's capability or product scope.
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