An innovative joint interface design for reducing intermetallic compounds and improving joint strength of thick plate friction stir welded Al/Mg joints

Friction stir welding of dissimilar Al/Mg thick plates still faces severe challenges, such as poor formability, formation of thick intermetallic compounds, and low joint strength. In this work, two joint configurations, namely inclined butt(conventional butt) and serrated interlocking(innovative butt), are proposed for improving weld formation and joint quality. The results show that a continuous and straight intermetallic compound layer appears at the Mg side interface in conventional butt joint, and the maximum average thickness reaches about 60.1 μm.Additionally, the Mg side interface also partially melts, forming a eutectic structure composed of Mg solid solution and Al_(12)Mg_(17) phase.For the innovative butt joint, the Mg side interface presents the curved interlocking feature, and intermetallic compounds can be reduced to less than 10 μm. The joint strength of innovative butt joint is more than three times that of conventional butt joint. This is due to the interlocking effect and thin intermetallic compounds in the innovative joint.

Electron-Beam Welding Joint Strength of Dissimilar Materials

This paper provides an in-depth discussion of the joint strength of electron beam welding of dissimilar materials.The effect of welding parameters and material properties on the joint strength was analyzed,and an argument for the optimal parameter combination is presented.Electron-beam welding technology offers several advantages,including high energy density and the ability to create fine weld seams.However,it also presents certain challenges,such as the complexity of welding parameters and the potential generation of brittle phases.The analysis conducted in this paper holds significant importance in enhancing the quality and efficiency of dissimilar material welding processes.

Characteristics of structural loess strength and preliminary framework for joint strength formula

The strength of structural loess consists of the shear strength and tensile strength. In this study, the stress path, the failure envelope of principal stress （ Kf line）, and the strength failure envelope of structurally intact loess and remolded loess were analyzed through three kinds of tests： the tensile strength test, the uniaxial compressive strength test, and the conventional triaxial shear strength test. Then, in order to describe the tensile strength and shear strength of structural loess comprehensively and reasonably, a joint strength formula for structural loess was established. This formula comprehensively considers tensile and shear properties. Studies have shown that the tensile strength exhibits a decreasing trend with increasing water content. When the water content is constant, the tensile strength of the structurally intact soil is greater than that ofremolded soil. In the studies, no loss of the originally cured cohesion in the structurally intact soil samples was observed, given that the soil samples did not experience loading disturbance during the uniaxial compressive strength test, meaning there is a high initial structural strength. The results of the conventional triaxial shear strength test show that the water content is correlated with the strength of the structural loess. When the water content is low, the structural properties are strong, and when the water content is high, the structural properties are weak, which means that the water content and the ambient pressure have significant effects on the stress-strain relationship of structural loess. The established joint strength formula of structural loess effectively avoids overestimating the role of soil tensile strength in the traditional theory of Mohr-Coulomb strength.

Effect of Metallurgical Behaviour at the Interface between Ceramic and Interlayer on the Si_3N_4/1.25Cr-0.5Mo Steel Joint Strength

By using newly developed CuNi5~25Ti16~28 B rapldly solidifled brazing filler the joining of Si3 N4/1.25Cr-0.5Mo steel has been carried out with interlayer method. If employing the interlayer structure of steel (0.2 mm)/W (2.0 mm)/Ni(0.2 mm), the joint strength can be increased greatly compared with employing that of Ni/W/Ni, and the three point bend strength of the Joint shows the value of 261 MPa. The metallurgical behaviour at the interface between Si3N4 and the interlayer has been studied. It is found that Fe participated in the interfacial reactions between Si3N4 and the brazing filler at the Si3N4/steel (0.2 mm) interface and the compound Fe5Si3 was produced. However, since the reactions of Fe with the active Ti are weaker than those of Ni with Ti, the normal inter facial reactions were still assured at the interface of Si3N4/steel (0.2 mm) instead of Si3N4/Ni (0.2 mm), resulting in the improvement of the joint strength. The mechanism of the formation of Fe5Si3 is also discussed. Finally, some ideas to further ameliorate and simplify the interlayer structure are put forward.

Influence of electroless Sn/Bi on Sn/Pb soldered joint strength

The solder joint strength of Pb/Sn soldering aluminum with electroless layer Sn/Bi and Cu was studied. The results show that the joint shear strength of electroless Sn/Bi on aluminum surface is lower than that of Cu. A Pb-riched region with porosity is formed in region of soldering fillet with electroless Sn/Bi. Both the electroless Sn/Bi layer and Pb-riched layer become thicker, which are the reasons why the shear strength of the solder joint with electroless Sn/Bi on aluminum surface is lower than that of electroless Cu, and the higher the thickness of the electroless Sn/Bi layer is, the lower the shear strength of solder joint is.

Prediction of Cross-Tension Strength of Self-Piercing Riveted Joints Using Finite Element Simulation and XGBoost Algorithm

Self-piercing riveting(SPR)has been widely used in automobile industry,and the strength prediction of SPR joints always attracts the attention of researchers.In this work,a prediction method of the cross-tension strength of SPR joints was proposed on the basis of finite element(FE)simulation and extreme gradient boosting decision tree(XGBoost)algorithm.An FE model of SPR process was established to simulate the plastic deformations of rivet and substrate materials and verified in terms of cross-sectional dimensions of SPR joints.The residual mechanical field from SPR process simulation was imported into a 2D FE model for the cross-tension testing simulation of SPR joints,and cross-tension strengths from FE simulation show a good consistence with the experiment result.Based on the verified FE model,the mechanical properties and thickness of substrate materials were varied and then used for FE simulation to obtain cross-tension strengths of a number of SPR joints,which were used to train the regression model based on the XGBoost algorithm in order to achieve prediction for cross-tension strength of SPR joints.Results show that the cross-tension strengths of SPR steel/aluminum joints could be successfully predicted by the XGBoost regression model with a respective error less than 7.6%compared to experimental values.

Strength and interfacial microstructure of Si3N4 joint brazed with amorphous Ti-Zr-Ni-Cu filler metal

In this paper, the vacuum brazing of Si3N4 ceramic was carried out with Ti40Zr25Ni15Cu20 amorphous filler metal. The interfacial microstructure was investigated by scanning electron microscopy （ SEM ）, energy dispersive spectroscopy （EDS） etc. According to the analysis, the interface reaction layer was mode up of TiN abut on the ceramic and the Ti-Si, Zr-Si compounds. The influence of brazing temperature and holding time on the joint strength was also studied. The results shows that the joint strength first increased and then decreased with the increasing of holding time and brazing temperature. The joint strength was significantly affected by the thickness of the reaction layer. Under the same experimental conditions, the joint brazed with amorphous filler metal exhibits much higher strength compared with the one brazed with crystalline filler metal with the same composition. To achieve higher joint strength at relatively low temperature, it is favorable to use the amorphous filler metal than the crystalline filler metal.

Recent advances in joining of SiC-based materials(monolithic SiC and SiC_f/SiC composites):Joining processes,joint strength, and interfacial behavior

Silicon carbide(SiC) has been widely concerned for its excellent overall mechanical and physical properties, such as low density, good thermal-shock behavior, high temperature oxidation resistance, and radiation resistance; as a result, the SiC-based materials have been or are being widely used in most advanced fields involving aerospace, aviation, military, and nuclear power. Joining of SiC-based materials(monolithic SiC and SiCf/SiC composites) can resolve the problems on poor processing performance and difficulty of fabrication of large-sized and complex-shaped components to a certain extent, which are originated from their high inherent brittleness and low impact toughness.Starting from the introduction to SiC-based materials, joining of ceramics, and joint strength characterization, the joining of SiC-based materials is reviewed by classifying the as-received interlayer materials, involving no interlayer, metallic, glass-ceramic, and organic interlayers. In particular, joining processes(involving joining techniques and parameter conditions), joint strength,interfacial microstructures, and/or reaction products are highlighted for understanding interfacial behavior and for supporting development of application-oriented joining techniques.

Shear strength criteria for rock,rock joints,rockfill and rock masses:Problems and some solutions

Although many intact rock types can be very strong,a critical confining pressure can eventually be reached in triaxial testing,such that the Mohr shear strength envelope becomes horizontal.This critical state has recently been better defined,and correct curvature or correct deviation from linear Mohr-Coulomb（MC） has finally been found.Standard shear testing procedures for rock joints,using multiple testing of the same sample,in case of insufficient samples,can be shown to exaggerate apparent cohesion.Even rough joints do not have any cohesion,but instead have very high friction angles at low stress,due to strong dilation.Rock masses,implying problems of large-scale interaction with engineering structures,may have both cohesive and frictional strength components.However,it is not correct to add these,following linear M-C or nonlinear Hoek-Brown（H-B） standard routines.Cohesion is broken at small strain,while friction is mobilized at larger strain and remains to the end of the shear deformation.The criterion ＇c then σn tan φ＇ should replace ＇c plus σn tan φ＇ for improved fit to reality.Transformation of principal stresses to a shear plane seems to ignore mobilized dilation,and caused great experimental difficulties until understood.There seems to be plenty of room for continued research,so that errors of judgement of the last 50 years can be corrected.

Strength behaviour of a model rock intersected by non-persistent joint

Several constructions in the field of civil engineering quite often need to deal with rocks.Strength behaviour of rock intersected by a discontinuity or a set of discontinuities has been a topic of keen interest for engineering community.The popular attributes of discontinuities that have been given due importance are their frequency,orientation and surface characteristics.Non-persistency,however,has been given little attention.This article presents an experimental study wherein focus has been made on the effect of non-persistency of the joint on the uniaxial compressive strength(UCS)of a model rock for various geometries such as orientation,discontinuity length ratio and number of joint segments.The applicability of single plane of weakness theory(SPWT)to assess the strength of jointed specimens has also been evaluated.It has been noticed that SPWT captures the strength behaviour only for a narrow range of discontinuity orientations.As an improvement,an approach is suggested by extending concepts of degree of persistence and joint factor to have a better understanding towards strength behaviour of rocks intersected by non-persistent joints.

Prediction of Static Strength of Tubular T and X Joints Subjected to Axial Compression

-The formulation of ring analogy method for the prediction of static strength (ductile collapse) of tubular T, X joints under axial compression based on the limit analysis of the ring with some assumptions is presented in this papaer. The regression formula for the effective length of the chord based on test results is established by means of the least square method. The results computed by the present semi-analytic formula are compared with previous results and test data. They are quite close to each other. The accuracy of the present formula depends on the reasonable selection of the effective length of the chord, which requires numerous test data.

Investigation on jointed rock strength based on fractal theory

Strength of discontinuities with complex structure is an important topic in rock engineering.A large number of studies have shown that fractal is applicable in the description of this discontinuity.Using fractal interpolation method for the generation of rock joints,numerical experiments of shear tests of the jointed rock mass model were carried out using FLAC^(3D).The test results show that the real rock joints can be simulated by fractal curves obtained by fractal interpolation.The fractal dimension is an important factor for the characterization of jointed rock mass;test results show that the fractal dimension of rock joints can be related to the equivalent cohesion strength and shear strength of the rock mass.When the fractal dimension of the joint surface is less than critical dimension Dc 1.404,the cohesion strength and shear strength of the rock mass increase as the fractal dimension increases;for larger fractal dimensions,all mechanical parameters decrease as the fractal dimension increases.Joint surfaces with different degrees of roughness were obtained by the fractal interpolation method.Three types of failure modes were observed in the tests:climbing slip failure,climbing gnawing fracture,and non-climbing gnawing fracture.

New Developed Welding Electrode for Improving the Fatigue Strength of Welded Joints

A new welding electrode, low transformation temperature electrode (LTTE), was introduced in this paper. It was described in design principle, mechanics, chemical compositions of their deposited metal and manufacturing methods. It was proved that the best transformation starting temperature from austenite to martensite of the deposited metal of LTTE was at about 191℃ and it was obtained by adding alloying elements such as Cr, Ni, Mn and Mo. The microstructure of the weld metal of the LTTE was low carbon martensite and residual austenite. The compressive residual stress was induced around the weld of the LTTE and the -145 MPa in compression could be obtained in middle of weld metal. The fatigue tests showed that the fatigue strength of the longitudinal welded joints welded with the LTTE at 2×106 cycles was improved by 59% compared with that of the same type of welded joints welded with conventional E5015 and the fatigue life was increased by 47 times at 162 MPa. It is a very valuable method to improve the fatigue performance of welded joints.

Determination of geological strength index of jointed rock mass based on image processing

The geological strength index(GSI) system,widely used for the design and practice of mining process,is a unique rock mass classification system related to the rock mass strength and deformation parameters based on the generalized Hoek-Brown and Mohr-Coulomb failure criteria.The GSI can be estimated using standard chart and field observations of rock mass blockiness and discontinuity surface conditions.The GSI value gives a numerical representation of the overall geotechnical quality of the rock mass.In this study,we propose a method to determine the GSI quantitatively using photographic images of in situ jointed rock mass with image processing technology,fractal theory and artificial neural network(ANN).We employ the GSI system to characterize the jointed rock mass around the working in a coal mine.The relative error between the proposed value and the given value in the GSI chart is less than 3.6%.

Direct Comparison between Tensile Strength and Flexural Strength of Ceramic/Metal Brazing Joint

A design of the sandwich joint,steel/ ceramic/steel,was made for direct comparison be- tween tensile and flexural strength of ceramic/metal joint.The flexural strength is about twice as high as the tensile strength for the same joint.The results also showed that the flexural test is more excellent than tensile test for joint with a high interracial bond strength.

Experimental investigation on tensile strength of butt welded joint post high temperatures

In order to investigate the laws of variation on tensile strength of butt welded joint post high temperatures, the wide plate tension tests for butt welded joint were conducted after cooling down from different high temperatures. The tests indicate that specimens appear ductile fracture at the steel plate during the tension tests after cooling down. The maximum temperatures undergone and the cooling pattern are major factors influencing tensile strength of butt welded joint post high temperatures. The tensile strength mostly reduces by 8% within 900℃. Based on the experimental results, the paper proposes the calculation formulas of tensile strength of butt welded joint post high temperatures. The conclusions of the paper supply references for evaluation damage and reinforcement of steel structure post fire.

Interfacial intermetallic compound growth and shear strength of low-silver SnAgCuBiNi/Cu lead-free solder joints

The growth rule of the interfacial intermetallic compound （IMC） and the degradation of shear strength of Sn-0.SAg-0.5Cu-2.0Bi-0.05Ni （SACBN）/Cu solder joints were investigated in comparison with Sn-3.0Ag-0.5Cu （SAC305）/ Cu solder joints aging at 373, 403, and 438 K. The results show that （Cul-x,Nix）6Sn5 phase forms between the SACBN solder and Cu substrate during soldering. The interracial IMC thickens constantly with the aging time increasing, and the higher the aging temperature, the faster the IMC layer grows. Compared with the SAC305/Cu couple, the SACBN/Cu couple exhibits a lower layer growth coefficient. The activation energies of IMC growth for SACBN/Cu and SAC305/Cu couples are 111.70 and 82.35 kJ/mol, respectively. In general, the shear strength of aged solder joints declines continuously. However, SACBN/Cu solder joints exhibit a better shear strength than SAC305/Cu solder joints.

An Average Failure Index Method for the Tensile Strength Prediction of Composite Adhesive-bonded π Joints

An average failure index method based on accurate FEA was proposed for the tensile strength prediction of composite out-of-plane adhesive-bonded π joints. Based on the simple and independent maximum stress failure criterion, the failure index was introduced to characterize the degree of stress components close to their corresponding material strength. With a brief load transfer analysis, the weak fillers were prominent and further detailed discussion was performed. The maximum value among the average failure indices which were related with different stress components was filtrated to represent the failure strength of the critical surface, which is either the two curved upside surfaces or the bottom plane of the fillers for composite π joints. The tensile strength of three kinds of π joints with different material systems, configurations and lay-ups was predicted by the proposed method and corresponding experiments were conducted. Good agreements between the numerical and experimental results give evidence of the effectiveness of the proposed method. In contrast to the existed time-consuming strength prediction methods, the proposed method provides a capability of quickly assessing the failure of complex out-of-plane joints and is easy and convenient to be widely utilized in engineering.

Calculation of the Strengths of Jointswith Fillet Welds in Welded Structure

In the paper, the finite element method (FEM) , engineering calculationmethod (ECM) and empirical fromular method (EFM) were used to calculatethe strengths of fillet joints in an Al-alloy vehicle. The results obtained withdifferent calculation methods were analysed, and then each method wasreviewed and assessed. FEM is accurate, but complicated, and its results haveno strength reserve; ECM and EFM are simple and convenient, butconservative.

Ultimate Strength of Completely Overlapped Joint for Fixed Offshore Wind Turbine Jacket Substructures

This paper presents an innovative eccentric jacket substructure for offshore wind turbines to better withstand intense environmental forces and to replace conventional X-braced jackets in seismically active areas. The proposed eccentric jacket comprises of completely overlapped joint at every joint connection. The joint consists of a chord and two braces in a single plane. The two braces are fully overlapped with a short segment of the diagonal brace welded directly onto the chord. The characteristic feature of this joint configuration is that the short segment member can be designed to absorb and dissipate energy under cyclic load excitation. The experimental and numerical study revealed that the completely overlapped joint performed better in terms of strength resistance, stiffness, ductility, and energy absorption capacity than the conventional gap joints commonly found in typical X-braced jacket framings. The eccentric jacket could also be designed to becoming less stiff, with an inelastic yielding and local buckling of short segment member, so as to better resist the cyclic load generated from intense environmental forces and earthquake. From the design economics, the eccentric jacket provided a more straightforward fabrication with reduced number of welded joints and shorter thicker wall cans than the conventional X-braced jacket. It can therefore be concluded based on the results presented in the study that by designing the short segment member in accordance with strength and ductility requirement,the eccentric jacket substructure supporting the wind turbine could be made to remain stable under gravity loads and to sustain a significantly large amount of motion in the event of rare and intense earthquake or environmental forces, without collapsing.