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.

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.

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.

DEVELOPMENT OF EFFECTIVE TECHNOLOGICAL PROCESSES OF HIGH-STRENGTH STEEL WELDING

Composition and service properties of high - strength low-alloyed steels with 590-980 MPa yield strength,which find an application in Russia, Belorus,Ukraine and other countries of the former USSR in manufacture of welded structures of a powerful mining and transport machinery, are given. Electrodes and wires for main processes of arc welding of these steels have been devel- oped on the basis of a rational use of different systems of alloying (08KhN2GM,08KhNG2M, and also economical systems of type 10G25, ect. ). Main approaches to the technological provess- es of manufacture of structures of high - strength steels are formulated.They are mainly directed to the weakening of de offect of the factors which contribute to a delayed fracture of joints (diffusive hydrogen,unfavourable rates of cooling,level of residual stresses). When there are no stress concentrators (and at a low level of residual stresses) the welded joints of these steels have a good resistance to fatigue and brittle fractures.As a rule, they are prevented with the help of the known approaches.It is shown that in addition to them and due to a proper selection of conditions of welding the life of welded joints of the high - strength steels can be 1. 2 - 1. 4 times in- creased.

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.

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.

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.

Study on vacuum induction brazing of SiC_p/LY12 composite using Al-Cu-Si-Mg filler metal

The vacuum induction brazing of SiC particulate reinforced LY12 alloy matrix composite using Al-28Cu-5Si-2Mg filler metal has been carried out. The micrograph of the joint interface was observed by scanning electron microscopy. The joint strength was determined by shear tests. The results show that brazing temperature, holding time, SiC particle volume percentage and post heat treatment influence joint strength. SiC particles happen in the brazing seam and the distribution of SiC particles in the joint is not uniform. Particle-poor zones in the joint exist near the base metal, and particle concentrate zones exist in the center of the brazing seam. In addition, the failure of the composite is predominantly initiated by the rooting of SiC particle in the brazing seam and the micro-crack expanded along the brazing seam with low energy.

Experimental study and stress analysis of rock bolt anchorage performance

A new method was developed to apply pull-and-shear loads to the bolt specimen in order to evaluate theanchorage performance of the rebar bolt and the D-Bolt. In the tests, five displacing angles （0°, 20°, 40°,60°, and 90°）, two joint gaps （0 mm and 30 mm）, and three kinds of host rock materials （weak concrete,strong concrete, and concrete-granite） were considered, and stressestrain measurements were conducted.Results show that the ultimate loads of both the D-Bolt and the rebar bolt remained constantwith any displacing angles. The ultimate displacement of the D-Bolt changed from 140 mm at the0 displacing angle （pure pull） to approximately 70 mm at a displacing angle greater than 40. Thedisplacement capacity of the D-Bolt is approximately 3.5 times that of the rebar bolt under pure pull and50% higher than that of the rebar bolt under pure shear. The compressive stress exists at 50 mm from thebolt head, and the maximum bending moment value rises with the increasing displacing angle. The rebarbolt mobilises greater applied load than the D-Bolt when subjected to the maximum bending. Theyielding length （at 0） of the D-Bolt is longer than that of the rebar bolt. The displacement capacity of thebolts increased with the joint gap. The bolt subjected to joint gap effect yields more quickly with greaterbending moment and smaller applied load. The displacement capacities of the D-Bolt and the rebar boltare greater in the weak host rock than that in the hard host rock. In pure shear condition, the ultimateload of the bolts slightly decreases in the hard rock. The yielding speed in the hard rock is higher thanthat in the weak rock. 2014 Institute of Rock and Soil Mechanics, Chinese Academy of Sciences. Production and hosting byElsevier B.V. All rights reserved.

Study of galvanic corrosion and mechanical joint properties of AZ31B and carbon-fiber–reinforced polymer joined by friction self-piercing riveting

A new testing methodology was developed to quantitively study galvanic corrosion of AZ31B and thermoset carbon-fiber–reinforced polymer spot-joined by a friction self-piercing riveting process.Pre-defined areas of AZ31B in the joint were exposed in 0.1 M NaCl solution over time.Massive galvanic corrosion of AZ31B was observed as exposure time increased.The measured volume loss was converted into corrosion current that was at least 48 times greater than the corrosion current of AZ31B without galvanic coupling.Ninety percent of the mechanical joint integrity was retained for corroded F-SPR joints to 200 h and then decreased because of the massive volume loss of AZ31B。

Study on ASTM Shear-loaded Adhesive Lap Joints

Finite element analyses and experiments are conducted to analyze the mechanical behavior of ASTM shear-loaded adhesive lap joints. Adhesive is characterized for the stress-strain relation by comparing the apparent shear-strain relations obtained from finite element analysis and experiments following ASTM D 5656 Standard. With the established stress-strain relation, two failure criteria using equivalent plastic strain and J-integral are adopted to predict the failure loads for joint specimens following ASTM D 5656 and ASTM D 3165 Standard, respectively. Good correlation is found between the finite element results and the experimental results. The strength of ASTM D 3165 specimens with debonding defects is also studied. Calculation results shows that experiment data following the standards provide only relative material constants, such as apparent shear modulus and strengths. Further investigation is required to find out the engineering properties needed for actual joint design. For the specimens with debonding defects, the locations of defects have great effects on their load bearing ability.

Key technologies and risk management of deep tunnel construction at Jinping Ⅱ hydropower station

Tunneling in complex rock mass conditions is a challenging task, especially in the Himalayan terrain, where a number of unpredicted conditions are reported. Rock joint parameters such as persistence, spacing and shear strength are the factors which significantly modify the working environments in the vicinity of the openings. Therefore, a detailed tunnel stability assessment is critically important based on the field data collection on the excavated tunnel＇s face. In this context, intact as well as rock mass strength and deformation modulus is obtained from laboratory tests for each rock type encountered in the study area. Finite element method（FEM） is used for stability analysis purpose by parametrically varying rock joint persistence, spacing and shear strength parameters, until the condition of overbreak is reached. Another case of marginally stable condition is also obtained based on the same parameters. The results show that stability of tunnels is highly influenced by these parameters and the size of overbreak is controlled by joint persistence and spacing. Garnetiferous schist and slate characterized using high persistence show the development of large plastic zones but small block size, depending upon joint spacing; whereas low persistence, low spacing and low shear strength in marble and quartzite create rock block fall condition.

Interfacial structure and mechanical property of Mg/Al alloy joint diffusion bonded with Zn interlayer metal

The characteristics of microstructure and mechanical strength of the Mg/Al alloy joint diffusion bonded with a Zn interlayer were studied by means of metalloscopy,X-ray diffraction(XRD),electron probe microanalysis(EPMA) and mechanical property test.Investigations showed that the Mg/Al alloy joint diffusion bonded with Zn interlayer consists of a multilayer sandwich structure,including the transition zone on Al side,Zn and Zn-Mg transition zone,as well as the transition zone on Mg side.The transition zone on Al side is very thin and composed mainly of a solid solution structure,while the Zn-Mg transition zone has a relative larger dimension after a rapid eutectic reaction.The addition of zinc interlayer inhibits the inter-diffusion of Mg and Al alloy efficiently.The Zn-Mg transition zone constitutes the main part of the joint and consists of Mg crystals and the new phase formed is MgZn intermetallic compound.The mechanical strength of Mg/Al alloy joints diffusion bonded with Zn interlayer reached 42 MPa.According to the phase constitution analyses executed on each side of the fracture face,it was deduced that the fracture of Mg/Al alloy joint located around the interface of Zn and Zn-Mg transition zone.

TiC Particle Reinforced Silicon Nitride Composite Joined With Y_2O_3-Al_2O_3-SiO_2 Mixture

Silicon nitride composite is joined to itself by heating interlayer of Y2 O3 -AL2O3 -SiO2 mixtures above their liquidus temperatures in flowing nitrogen. The joined specimens are tested in four point flexure from room temperature to 1373 K. The interface microstruclure and fractured surfaces after testing are observed and analyzed by SEM, EPMA and XRD respectively. The results show that F2 O3 -A12 O3 -SiO2 glass reacts with Si3 N4 at interface, forming the Si3 N4/Si2 N2 O( Y-AlrSi-O-N glass/ Y-Al- Si-O glass gradient interface. With the increase of bonding temperature and holding time, the joint strength first increases, reaching a peak, and then decreases . According to interfacial analyses , the bonding strength depends on joint thickness .

Bonding of Al_2O_3 to Cu with Ti foil

Bonding ofAl_2O_3 to Cu is performed directly using Ti foil at temperature of 1273K. The microstructure of the joint interface is investigated through scanning electron microscope ( SEM), electron probe microanalysis ( EPMA) and X-ray diffraction (XRD). The effect of the initial Ti foil thickness on the reaction layer thickness and the joint strength are investigated.

Numerical studies on the stress distribution in weldbonded joints with different adhesives

The Effect of elastic modulus and thickness of the adhesives on the stress distribution in weldbonded joints has been studied with three-dimensional elastoplastic finite element method ( FEM). Stress distribution curves have been obtained at the edges of the spot welds and the lap zones in weldbonded joints, which were made with adhesives of different elastic modulus or different thickness. Results show that there exists larger stress concentration at the edge of the spot welds, though the shear stresses in the adhesive layers are smaller for weldbonded joints with low elastic modulus or thick adhesive layers. The stress concentration decreases and the shear stresses in adhesive layers increase with the increase of the elastic modulus or the decrease of the adhesive thickness. It is concluded that the thiner adhesive layers with higher elastic modulius are preferable in weldbonded joints to cut down the stress concentration.

New filler metal systems for the brazing of titanium alloys

It＇ s well known welding takes the leading role in development of titanium structures. However, in number of cases technological processes of brazing are more appropriate and, sometimes, being the single possible, in particular, during production of multilayer thin-wall structures. It should be noted that brazing filler metals of Ti-Cu-Ni, Ti-Zr-Cu-Ni, Zr-Ti-Ni and Cu-Zr-Ti systems in a form of plastic foils, as well as in powder form are mainly used in world practice for brazing of titanium alloys. Present work provides the results of complex investigations of brazing filler metals of Ti-Zr-Fe, Ti-Zr-Mn and Ti-Zr-Co systems using differential thermal analysis, light and scanning microscopy, X-ray microspectrum analysis. Data on melting ranges of pilot alloys were obtained, and liquidas su^Caces of given systems using simplex-lattice method were build. Brazing filler metals covering brazing temperature range of current structural titanium materials based on solid solutions as well as intermetallics were proposed. Structure, chemical inhomogeniety and strength characteristics of brazed joints were studied. It is determined that brazing of solid solution based alloys （OT4, VT6 ） using indicated brazing fiUer metals ensures strength characteristics of joints, which are not inferior to that obtained with application of known brazing filler metals even if they are received at lower brazing temperature.