Browse Topic: Welding

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Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Technical Paper
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
Technical Paper
A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack2024-26-010901/16/2024
EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of
Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar
Technical Paper
Evaluation of interface microstructure and bonding strength for dissimilar rotary friction welding of E46 and AA6061-T62024-26-019501/16/2024
Nowadays, friction welding is recognised as a highly productive and economic joining process for similar as well as dissimilar welding of automobile and aerospace components. Friction welding is the viable solution to offset the challenges of dissimilar fusion welding due to varying thermal and physical properties as well as limited mutual solubility. The main objective of this study is to evaluate the interface microstructure and interface bonding strength for dissimilar rotary friction welding of 3.15 mm E46 disc and 45 mm AA6061-T6 bar at different friction time and forging pressure. The direct drive rotary friction welding of E46 and AA6061-T6 is performed at combinations of two different friction time (4 sec and 7 sec) and forging pressure (108 MPa and 125 MPa). Mechanical bonding strength at the interface is evaluated based on the push-off and multi-step shear strength. Further, fractography of failed samples is carried out to understand the failure mechanism of welded joints
Chudasama, Gautam, Kalyankar PhD, Vivek, Chauhan, Shiv
Technical Paper
Review on Laser welding of High Strength Aluminium alloy for Automotive Applications2024-26-019301/16/2024
High strength aluminium alloys are an ideal material in the automotive sector leading to a significant weight reduction and enhancement in product safety. In recent past extensive development in the field of high strength steel and aluminium was undertaken. This development has been propelled due to demand for light weight automotive parts. The high strength to weight ratio possessed by Al alloy helps in reducing the total weight of the vehicle without effecting the overall performance, thereby increasing the fuel economy and reducing the carbon emission level. Joining of high strength aluminium alloy is critical to develop durable automotive products. Joining of high strength aluminium alloy for mass production in automobile industry is a challenging task. Laser welding is recognized as an advanced process to join materials with a laser beam of high-power, high-energy density. In the present study efforts are made to summarise the influence of important process parameters of laser
Sahu, Hemant, Dave, Rajeev, Chauhan, Shiv, Dwivedi, Ravi
Technical Paper
Damage Tolerant Fracture Assessment of Cracks in Non-Standard Geometries Under Static and Fatigue Loading2024-26-027601/16/2024
Cracks on metallic components may appear due to manufacturing, handling, installation, repair, welding etc. and are controlled by quality documents. However, if cracks violate the limit defined in quality document, then either parts will be scraped or will need additional evaluation through detailed and specialized Linear Elastic Fracture Mechanics (LEFM) approach. The initial size, orientation and shape of crack, part geometry and loading highly impacts the behavior of crack growth and remaining useful life. Study has been performed to understand the effect of crack aspect ratio on stress intensity factor under different stress gradient scenario. This paper also provides the simplified methodology to address the multiple cracks in complex geometries under static and fatigue loading.
Puranik, Shashank Suresh, Pathan, Irfan, Shinde, Swapnil, Soni, Nitesh, Kindleysides, Andrew
Technical Paper
Lightweight potential and crash performance of friction stir welded Tailored Blanks2023-01-122006/26/2023
In former papers methods to join different aluminium or different steel sheets having same thicknesses are presented using the friction stir welding process with flat tools. In order to increase the lightweight potential, the Materials Testing Institute of the University of Stuttgart, developed a novel variant of the friction stir welding process, enabling the joining of aluminium and steel sheets of different thicknesses. Compared to the conventional welding method, the difference relates to the stir welding tool used, which consists of a stepped welding pin and allows combined lap-and-butt joints to be produced. Potential applications for this innovative joining technology include lightweight components for car bodies. In this context, this paper aims to demonstrate the lightweight potential and the crash performance of Tailor Welded Blanks (TWBs) made from DX54(1 mm) and AL6016 - T4 (2 mm). For this purpose, possible parts of a car body that can be replaced with these TWBs were
Bachmann, Maximilian
Technical Paper
Why Cleanroom Assembly of Plastic Medical and Electronic Devices Requires Ultrasonic Welding TechnologyTBMG-4646409/01/2022
For years, ultrasonic welding has been used in cleanrooms where plastic components are assembled to complete medical and electronic devices. That is unlikely to change. What is changing, however —rapidly — is the sophistication and complexity of these products and the level of precision and quality required to complete their assembly.
Magazine Article
3D Welding Additive Manufacturing Humanoid for Spacecraft2022-26-119305/26/2022
Space exploration is truly the most adventurous journey in the history of mankind. Satellites, space flights, and stations are deeper into the infinite expanse of the universe and these are susceptible to impact by orbital debris and meteoroids. In order to protect these machines from failures of their components and build new parts in space, we need an effective method to build 3D durable components in space. This paper discusses the usage of a LEMUR Robot for Additive Manufacturing using 3D Laser Welding. 3D laser welding uses a high concentration of energy to fuse the metal wires into a precise part that can withstand harsh conditions in the space environment. It offers high geometrical accuracy and material strengths. 3D welding uses laser metal fusion to build products layer by layer using the robotic arm attached to the Limbed Excursion Mechanical Utility Robot (LEMUR) which was originally designed to do repairs on the ISS. LEMUR has two legs and two arms which helps it to
Bhurat, Shryas, Yadav, Aashish, Shetty, Naman
Technical Paper
Development of an electric vehicle battery module laser welding process using SYSWELD and validation by test data2022-01-037603/29/2022
With lightweight design in modern electric vehicles to achieve high energy efficiency, high strength and thin materials are widely adopted. For battery modules, 5000 and 6000 aluminum are typically utilized as a structural material with a thickness range between 1 to 5 mm. Laser welding is one of the most optimum welding tools for joining such a thin material due to its unique advantages, e.g., high welding speed, high accuracy, high energy yet the smallest heat affect zone, etc. This paper aims to develop an FE modeling procedure using SYSWELD to simulate the laser welding process used in electric vehicle battery module manufacturing. A sequentially-coupled thermo-mechanical analysis procedure is developed based on the welding processes for 6063 T6 aluminum alloys and the dissimilar joint between 6063 T6 and 5083 aluminum alloys. Different heat source models for laser welding are studies and compared. The effectiveness of the developed modeling procedure is confirmed by a large number
Song, Shaopin, JIANG, Weiran, Ding, Peiran
Technical Paper
Evolution and Redistribution of Residual Stress in Welded Plates During Fatigue Loading2022-01-029803/29/2022
The presence of residual stresses affect the fatigue response of welded components. In the present study of a thick welded cantilever specimen, residual stresses were measured in an as-welded A36 steel sample and in a sample subjected to a short history of bending loads where substantial local plasticity is expected at the fatigue hot-spot weld toe. Extensive XRD measurements describe the residual stress state in a large region in front of the weld toe both in an untested as-welded sample and in a sample subjected to a short load history that generated an estimated 0.01 strain amplitude at the stress concentration zone at the weld toe. The results show that such a test will significantly alter the welding induced residual stresses. Fatigue life prediction methods need to be aware that such alterations are possible and incorporate the effects of such cyclic stress relaxation in life computations.
Pineault, James, Gales, Casey, Conle, Al
Technical Paper
Sensitivity of Solid Element Spot Weld Modeling Methodology to Nugget Diameter2022-01-094103/29/2022
A vehicle’s structure has more than 4000 spot welds, which can be considered as one of the main design criterion that affects the general stiffness as well as the durability of an automobile. Considering the essential role of finite element based simulations of the spot welded structures on the design phases of vehicle development, accuracy of analyses can be considered as one of the main concerns to meet the design objectives. This study examines the sensitivity of solid element spot weld modeling technology to nugget diameter. Comparative stress and multi-axial low cycle fatigue analyses are conducted for the inspection of the effect of weld diameter on solid element spot weld simulations. Displacement contours as well as local stress profiles at the vicinity of the spot welds are examined to evaluate the effect of nugget diameter on general stiffness and safety. Multi-axial low cycle fatigue analyses are conducted for the specimens composed of U-profiles, and different thickness
Duran, Ertuğrul Tolga
Technical Paper
Prediction of Crash Performance of Adhesively Bonded Vehicle Front Rails2022-01-105103/29/2022
Adhesive bonding provides a versatile strategy for joining metallic as well as non-metallic substrates, and also offers the functionality for joining dissimilar materials. For problems of elastic behavior and small strains in vehicle unibody structures such as designing for NVH (Noise, Vibration and Harshness), adhesive bonding of sheet metal parts along flanges provides enhanced stiffening of body and improved acoustics due to sealing of openings between flanges. However, due to the brittle nature of adhesives, they remain susceptible to failure under impact loading conditions which can cause crumpling of sheet metal parts resulting in plasticity and large strains. The viability of structural adhesives as a sole or predominant mode of joining stamped sheet metal panels into closed hollow sections such as hat sections thus remains suspect and requires further investigation. The mechanical behavior of adhesives tends to be significantly different as compared to ductile and isotropic
Ramachandra, Sanketh, Deb, Dr. Anindya, Chou, Clifford
Technical Paper
Impact of weld fixture clamp force variation on dimensional integrity in low volume Body-in-White build2021-28-021610/01/2021
Body in White (BIW) is an assembly of multiple sheet metal components. The BIW is the major contributor to the dimensional and structural integrity of an automobile. The accuracy and precision of the BIW is influenced by multiple factors involved in the manufacturing lifecycle of the BIW. Weld fixtures are the tools used for accurately locating and holding sheet metal components during joining. The primary motive of the locating and holding strategy is to arrest all degrees of freedom of a component. Geometric repeatability of the components is also of high importance. Component location is universally achieved by standardized locator pins and mylars that maintain the Principal Location Points (PLP) and Master Control Patches (MCP). In Low volume BIW build employs non-automated clamping methodologies in general, using manual clamps or toggle clamps. This paper studied the dimensional variation of sheet metal assemblies with variation in clamping forces in manual non-automated clamping
voppuru, Naga Sheshank Reddy, Selvam, Ganesan, Kannan, Muniya Gounder, Baskaran, V, Thiruppathi, R
Technical Paper
Parametric Optimization of Friction Stir Welded AA2024 using Regression Methods2021-28-022310/01/2021
In this study, a model to optimize the friction stir welding parameters which were rotational speed, welding speed, axial force, tool pin profile, and tool material was established. The target of any design is to maximize the welded properties either to get the base metal properties or higher than that. The model constructed is the result of various regression methods which are quantified for adequacy. In this model, we have taken three levels of varying shoulder diameters, rotation speed, welding speed, tilting angles. A mathematical model is developed for the effect of four process parameters at three levels using response surface methodology (RSM). Analysis of variance (ANOVA) technique is used to check the adequacy of the developed mathematical model. The experimental and predicted values of the mechanical properties are correlated.
Ramasamy, Madesh, Kesavan, Gokul Kumar, Settu, Nandhakumar, Subramanian, Arun Prakash, Naiju, CD
Technical Paper
An alternate CED process for low volume BIW manufacturing with single stage vertical dipping2021-28-022710/01/2021
Body in White (BIW) is a major assembly in an automobile. It is made of sheet metal components that are welded together by Resistance spot welding. Assembled BIWs are put through an anti-corrosion process called Cathodic Electrodeposition (CED) and baked to set the CED coat. CED process has an elaborate sequence of rinse cycles and coat cycles. Single stage dipping stations are used for coating large volumes of smaller components. The high-cost multi-stage setup is a commonly used process in large scale BIW manufacturing systems. In the context of small-scale batch production or prototype builds, the extensive setup is not viable. This paper studied the feasibility of CED coating large BIWs in a single stage setup. Multiple process modifications explored to establish single stage setup for BIW coating. Process capability and effectiveness of utilization was studied. The results were analyzed, and the comprehensive process chain was concluded and discussed for implementation.
B, Sivasankar, Selvam, Ganesan, Kannan, Muniya Gounder, voppuru, Naga Sheshank Reddy, Thiruppathi, R
Technical Paper
An experimental investigation on hot cracking and properties of TIG welded AA2014 alloy using continuous current and pulsed current2021-28-026210/01/2021
AA2014 Aluminum alloys are most widely used for automobile and aerospace structures where specific strength is important. Hot cracking is a major problem while welding these alloys. In the present investigation, the metallurgical studies, viz, hot cracking sensitivity, microstructure and the mechanical properties, viz, hardness and tensile strength of the 4 mm thickness AA2014 aluminum alloy were studied using two different methods. The first method involves TIG (Tungsten Inert Gas) welding with continuous current process and the second method involves TIG welding with pulsed current process. In the both the process commercial argon pure gas was used as a shielding gas. The results showed that hot cracking sensitivity was decreased when the specimen was welded using pulsed current process compared to continuous current process. Similarly, the specimen was welded with pulsed current process showed improved mechanical properties compared to continuous current process because of low heat
Kaliyaperumal, Balasubramanian, R, Soundararajan, Rengaraj, Jeyakumar, Rangasamy, Ramamoorthi
Technical Paper
Mechanical and microstructural behaviour of friction stir welded Al6061/Cr2O3 metal matrix composite.2021-28-022410/01/2021
Aluminium metal matrix composite are widely used in various field like aerospace, marine and automobile application. The application of composites necessitates joining process and its difficult due to different materials. To address the considering difficulties the present study is, Cr2O3 was reinforced in Al 6061 matrix in 2% to 6% in the incremental step of 2%. The stir casting technique was used to fabricate the composites with 300rpm stirring speed and the stirring time duration was 3min throughout the fabrication process. The PCBN tool is used for prepared friction stir welded (FSW) joints and tool having 6.7mm pin diameter and 6mm pin height. The fabrication process is conducted by 1000rpm tool rotational speed and 25mm/min welding speed. The atmospheric and underwater environmental conditions was preferred to perform friction stir welding. The mechanical properties of the joint, such as tensile strength (ASTM E8), hardness (ASTM E18) and impact strength (ASTM E23) are
K, Senthilraj, Govindasamy, Rajamurugan, Krishnasamy, Prabu, Uday, KN
Technical Paper
Characterization of Laser brazed joints Vis a Vis conventional BIW joining methods2021-26-044709/22/2021
In recent years, there has been a rapid growing demand for laser brazing in the transportation industry for automotive-Body in White (BIW) steel sheet assembly. Implementation of laser brazing is aimed primarily to improve productivity, quality of joints and cost. Laser brazing works by filling the opening amongst two substrates by melting the filler wire with the help of laser beam (used as a heat source), whereas in conventional resistance spot welding, contacting metal surface points are joined by the heat obtained from resistance to electric current. Body in White (BIW) is essentially a welded metal structure which is meant to provide durability and crashworthiness to the vehicle and is conventionally assembled using resistance spot welding process. The BIW structure comprises of various steel grades having varying thicknesses, composition, microstructure and mechanical properties. Laser brazing as a joining method was introduced as an alternative to resistance spot welding for
Kumar, Animesh, Hatwalne, Mrunal, Ponkshe, Shripadraj, Misal, Swapnali
Technical Paper
Strength Evaluation and Validation of Structural Joints.2021-26-031509/22/2021
Many methods have been developed to evaluate the fatigue life of structures when the its joints are as per ideal case. But if the joints are loosening, it leads to increase in loading on the other members which causes failures. Most commonly in commercial vehicle segment welding joint & Bolting joints are most popular ones. It is very easy to find out bolts strength & loosening effect in static conditions. But when vehicle is moving (i.e. dynamic condition), same method cannot be used. For this we have developed methodology to predict the bolts loosening in dynamic condition using vibration data. Similarly, loading may differ on the structural members if the welds are failing in dynamic conditions. To overcome this problem, in our organization we have a solution. Of course to simulate welding failures fatigue analysis is mandatory. We are using notch-stress approach for evaluating the welding strength of the joint. This method does not need weld material data instead it increases the
Desai, Ankit Desai, Telukala, Haricharan, Jadhav, Santosh, Kurna, Srinivas
Technical Paper
Effect of Welding Consumables on Static and Dynamic Properties of Representative Welded Joints for Chassis Structure2021-26-025909/22/2021
Automotive suspension system forms the basis for the design of vehicle with durability, reliability and NVH requirements. The automotive suspension systems are exposed to dynamic and static loads which in turn demands the highest integrity and performance against fatigue based metallic degradation. The current focus in automotive industry is to reduce the weight of the automotive parts and components without compromising with its static and dynamic mechanical properties. This weight reduction imparts fuel efficiency with added advantages. High-strength low alloy steel (HSLA) offers optimum combination of mechanical properties. Furthermore, welding processes offer design flexibility to achieve robust and lightweight designs with high strength steels. However, welding process has to be established to get optimum benefits of high strength steels with minimal adverse effects and deterioration of the static and dynamic mechanical properties of the weldments. In current work, effect of
Chauhan, Shiv, Varatharajan, Senthilkumaran, Shende, Deodatta
Technical Paper
Steel, Welding Wire 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620) Vacuum Melted, Environment Controlled PackagingAMS6375E (Current)04/06/2021
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
Material Specification
Steel, Welding Wire 0.65Si - 1.25Cr - 0.50Mo - 0.30V (0.28 - 0.33C) Vacuum Melted, Environment Controlled PackagingAMS6458K (Current)02/03/2021
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
Material Specification
Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130)AMS6370R-TEST-REC (Historical)07/07/2020
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
Material Specification
Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130)AMS6370R (Current)07/07/2020
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
Material Specification
Experimental Study on Static and Fatigue Performance of Self-Piercing Riveted Joints and Adhesively Bonded Self-Piercing Riveted Joints Connecting Steel and Aluminum Components2020-01-017704/14/2020
This paper describes an experimental study on the performance of self-piercing riveted (SPR) joints and adhesively bonded SPR joints connecting steel and aluminum components under both quasi-static and cyclic loading. The joint configurations cover a wide range of material gauges, types and grades. Two and three thickness joints, with and without adhesive are also part of this study. Load versus deflection behavior, load carrying capacity, fatigue life and the failure modes for each type of joint are discussed. This study focuses on the influence of dissimilar material and adhesives to the joint performance. In addition, comparison of load carrying capacity and fatigue strength between SPR and resistance spot welded joints is also discussed.
Guo, Mingchao, El-Tawil, Ghassan
Technical Paper
Spot Weld Fatigue Correlation Improvement in Automotive Structures Using Stress Based Approach with Contact Modelling2020-01-018204/14/2020
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
Kadakuntla, Srikesh, Mohapatra, Durga Prasad, Kangde, Suhas
Technical Paper
Full Body Car Analysis in the Time and Frequency Domains - Sheet, Spot and Seam Weld Fatigue Benchmark Studies2020-01-019504/14/2020
The fatigue analysis of a full car body requires the sheet metal (sheet fatigue), spot welds (spot weld fatigue) and seam welds (seam weld fatigue) to be thoroughly evaluated for durability. Traditionally this has always been done (via separate processes) in the time domain but recently new techniques have been implemented to perform all of these tasks in the frequency domain with numerous advantages. This paper will summarize the frequency domain process and then compare the results (and performance) against the more usual time base result
Meehan, Trenton, Bishop, Neil, Kerr, Stuart, Woodward, Andy
Technical Paper
Coupled Weld-Rupture Analysis of Automotive Assemblies2020-01-107604/14/2020
Lightweight driven design in the automotive industry and the push for Electric Vehicles mandate the use of innovative materials such as Steel (HSS, UHSS, AHSS) and Aluminum alloys. For steel suppliers to meet the strength requirements of high strength steels, they often alloy the steel chemistry (depending on mill capability, rolling capacity, quenching capacity, etc.). When used in welded assembly constructions, these steels, as compared to traditional steels, behave differently. Depending on the welding heat input, the material chemistry and thickness, they either harden or soften in the heat affected zone. Similar behavior is observed with the most commonly used aluminum alloys (5000 and 6000 series) in the automotive sector. For both alloy types, different strengthening mechanism are used to meet their initial strength requirements (by work hardening and by heat treating respectively) but they both undergo softening in the heat affected zone during welding. Regardless of the alloys
Gooroochurn, Yogendra, Jiang, Weiran, Dwarampudi, Ramesh, Tunga, Vijay, Seshadri, Megha, Raveendra, Ravi
Technical Paper
Spatially Optimized Diffusion Alloys: A Novel Multi-Layered Steel Material for Exhaust Applications2020-01-105104/14/2020
A novel Spatially Optimized Diffusion Alloy (SODA) material has been developed and applied to exhaust systems, a very aggressive environment with high temperatures and loads, as well as excessive corrosion. Traditional stainless steels disperse chromium homogeneously throughout the material, with varying amounts ranging from 11% to 18% dependent upon its grade (e.g. 409, 436, 439, and 441). SODA steels, however, offer layered concentrations of chromium, enabling an increased amount along the outer surface for much needed corrosion resistance and aesthetics. This outer layer, approximately 70µm thick, exceeds 20% of chromium concentration locally, but is only 3% in bulk, offering selective placement of the chromium to minimize its overall usage. And, since this layer is metallurgically bonded, it cannot delaminate or separate from its core, enabling durable protection throughout manufacturing processes and full useful life. The core material may be of various grades, however, so this
Kotrba, Adam, Quan, Tony, Wei, Winston, Detweiler, Zachary, Keifer, David, Bullard, Daniel
Journal Article
Development of Laser Welding Pressed-frame for Small Scooters Considering High Production Efficiency2019-32-054401/24/2020
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
Kawano, Sunao, Kobayashi, Takeru
Technical Paper
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
Recommended Practice
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
Information Report
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
Singh, Adarsh, Rajamurugan, Govindasamy, Krishnasamy, Prabu, Dhanabalan, Dinesh
Technical Paper
Investigation of Setting Input Process Parameters for Getting Better Product Quality in Machining of AM60 Magnesium Alloy - TOPSIS and ANOVA Approach2019-28-013610/11/2019
This investigation shows the improvement of Machining parameters on AM-60 Mg alloy made with the help of Gravity Die Casting and with reactions upheld symmetrical cluster with “Technique for Order Preference by Similarity to Ideal Solution” (TOPSIS). Which Focuses on the streamlining of Machining parameters utilizing the system to get least surface Roughness (Ra), Minimum Tool Wear, minimum Cutting Time, Power Requirement and Torque and Maximize MRR. A good amount of Machining tests was directed in view of the L9 Orthogonal array on CNC machine. The trials were performed on AM60 utilizing cutting device of grade-ISO 460.1-1140-034A0-XM GC3 of 12,16 and 25 mm width with cutting point of 140 degrees, all throughout the test work under various cutting conditions. TOPSIS and ANOVA were utilized to work out the major vital parameters like Cutting speed, feed rate, Depth of Cut and Tool Diameter which influence the Response. The normal qualities and estimated esteems are genuinely close. The
Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Rajendran, Raj, Sivam Sundarlingam Paramasivam, Sundar Singh, Kumaran, Durai, Sriram, Harish
Technical Paper
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
S, Deepankumar
Technical Paper
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
Loganathan, Ganesh Babu, Kumaran, Durai, Sivam Sundarlingam Paramasivam, Sundar Singh, Saravanan, Krishnaswamy, Rajendran, Raj
Technical Paper
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
Technical Paper
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
Rajamurugan, Govindasamy, Deepankumar, Sadhasivam, Ramakrishnan, Anbalagan, Krishnasamy, Prabu, Dhanabalan, Dinesh
Technical Paper
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
Technical Paper
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
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Kumaran, Durai, Saravanan, Krishnaswamy, Rajendran, Raj, Sriram, Harish
Technical Paper
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
Kannan, Vetri Velmurugan, Kannan, Venkatesan, Sundararajan, Devendiran, Uday Kumar, Budireddy, Anvesh, Dhulipalla, Akhil, Varupula
Technical Paper
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
Sivam Sundarlingam Paramasivam, Sundar Singh, Banerjee, Aishik, Kulkarni, Avanti
Technical Paper
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
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Kumaran, Durai, Rajendran, Raj, Sriram, Harish
Technical Paper
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
Loganathan, Ganesh Babu, Sivam Sundarlingam Paramasivam, Sundar Singh, Kumaran, Durai, Saravanan, Krishnaswamy, Rajendran, Raj
Technical Paper
A Study on Mechanical Properties and Multi Response Optimization of Process Parameters for Showing Signs of Improvement Product Quality in Drilling AlSi 7 Cu 4 Utilizing GRA in Taguchi Method2019-28-005810/11/2019
Showing and streamlining of cutting parameters are a champion among the most essential components in drilling processes. This examination displays the change of drilling procedures parameters on AlSi7Cu4 made by Gravity Die Casting and with replies in light of OA with Taughi GRA and ANOVA. The effects of alloying parts were bear on the Chemical Composition, microstructures, mechanical property, Hardness, X-Ray and S Das response is particularly analyzed. Motivations on the progression of Drilling parameters using the Taguchi strategy to obtain slightest surface Roughness (Ra), Circularity Error, Burr size and Thrust Force. Different Drilling Trails were coordinated using the L9 OA on CNC Milling machine. The examinations were accomplished on AlSi7Cu4 composite piece cutting tool of an ISO 460.1-1140-034A0-XM GC3 of 12 mm measurement with Tool 140 degrees, used all through the preliminary work under dry cutting conditions. The central and participation effect of the data factors on the
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Kumaran, Durai, Rajendran, Raj
Technical Paper
NIST Research Sparks New Insights on Laser WeldingTBMG-3537310/01/2019
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.
Magazine Article
The Study of Local Stress Intensity Factors for Kinked (and Branched) Cracks in Commonly Used Spot Weld Specimens05-12-03-001508/26/2019
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
Lin, Zhi-Long, Wang, Dung-An, Chee, Ching-Ying, Lin, Pai-Chen
Journal Article
Effect of Welding Parameters on the Microstructure and Tensile Properties of Friction Stir-Welded DP600 Steel05-12-03-001307/02/2019
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
Ashrafi, Hamid, Shamanian, M., Emadi, R., Ahl Sarmadi, M.
Journal Article
Titanium Alloy, Extrusions and Flash Welded Rings 6Al - 4V Solution Heat Treated and AgedAMS4934H (Historical)06/03/2019
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
Material Specification
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