Interface characteristic of friction stir welding lap joints of Ti/Al dissimilar alloys

Lap joints of TC1 Ti alloy and LF6 A1 alloy dissimilar materials were fabricated by friction stir welding and corresponding interface characteristics were investigated. Using the selected welding parameters, excellent surface appearance forms, but the interface macrograph for each lap joint cross-section is different. With the increase of welding speed or the decrease of tool rotation rate, the amount of Ti alloy particles stirred into the stir zone by the force of tool pin decreases continuously. Moreover, the failure loads of the lap joints also decrease with increasing welding speed and the largest value is achieved at welding speed of 60 mm/min and tool rotation rate of 1500 r/min, where the interracial zone can be divided into 3 kinds of layers. The microhardness of the lap joint shows an uneven distribution and the maximum hardness of HV 502 is found in the middle of the stir zone.

Influence of tool pin profile on the interface migration of friction stir lap joints＊

Friction stir lap joints of LY12 aluminum alloy plates with a thickness of 3 mm were fabricated using several tools with different pin profiles. The effects of tool pin profile on the interface migration of friction stir lap joints were investigated with the comparison of weld morphologies. The results show that the screw thread of the pin plays an important role in the migration of weld interface in the thickness direction. The interface between the sheets will move upwards to the top of the plate when the pin with left hand thread was used. Conversely, the interface will move downwards to the tip of the pin when the pin with right hand thread was used： As for a stir pin with smooth surface was used, the upward or downward migration of the weld interface was largely reduced, but the extension of weld interface to the weld center line from the retreating side becomes more serious. By analyzing the force on the pin according to the sucking-extruding theory for the weld formation, the obtained results have been well explained.

Mechanical properties and friction-wear characteristics of VN/Ag multilayer coatings with heterogeneous and transition interfaces

The heterogeneous multilayer interface of VN/Ag coatings and transition multilayer interface of VN/Ag coatings were prepared on Inconel 781 and Si(100),and the microstructures,mechanical and tribological properties were investigated from 25 to 700℃.The results showed that the surface roughness and average grain size of VN/Ag coatings with transition multilayer interface are obviously larger than those of VN/Ag coatings with heterogeneous multilayer interface.The coatings with transition multilayer interface have higher adhesion force and hardness than the coatings with heterogeneous multilayer interface,and both coatings can effectively restrict the initiation and propagation of microcracks.Both coatings have excellent self-adaptive lubricating properties with a decrease of friction coefficient as the temperature increases,but their wear rates reveal a drastic increase.The phase composition of the worn area of both coatings was investigated,which indicates that a smooth Ag,Magnéli phase(V2O5)and bimetallic oxides(Ag3VO4 and AgVO3)can be responsible to the excellent lubricity of both coatings.To sum up,the coatings with transition multilayer interface have excellent adaptive lubricating properties and can properly control the diffusion rate and release rate of the lubricating phase,indicating that they have great potential in solving the problem of friction and wear of mechanical parts.

Application of response surface methodology to maximize tensile strength and minimize interface hardness of friction welded dissimilar joints of austenitic stainless steel and copper alloy

An attempt was made to optimize friction welding parameters to attain a minimum hardness at the interface and a maximum tensile strength of the dissimilar joints of AISI 304 austenitic stainless steel （ASS） and copper （Cu） alloy using response surface methodology （RSM）. Three-factor, five-level central composite design matrix was used to specify experimental conditions. Twenty joints were fabricated using ASS and Cu alloy. Tensile strength and interface hardness were measured experimentally. Analysis of variance （ANOVA） method was used to find out significant main and interaction parameters and empirical relationships were developed using regression analysis. The friction welding parameters were optimized by constructing response graphs and contour plots using design expert software. The developed empirical relationships can be effectively used to predict tensile strength and interface hardness of friction welded ASS-Cu joints at 95% confidence level. The developed contour plots can be used to attain required level of optimum conditions to join ASS-Cu alloy by friction welding process.

Interface repairing for AA5083/T2 copper explosive composite plate by friction stir processing

Multi-pass friction stir processing(M-FSP)was performed to repair the interface defects of AA5083/T2 copper explosive composite plates.The interface morphology and its bonding mechanism were explored.The results show that higher rotation speed and lower transverse speed produce more heat generated during FSP.The defect-free and good mechanical properties of the AA5083/T2 copper composite plate can be obtained under the condition of the rotation speed of 1200 r/min,the transverse speed of 30 mm/min and the overlap of 2/24.Moreover,M-FSP changes the interface bonding mechanism from metallurgical bonding to vortex connection,improving the bonding strength of composite plate,which can guarantee the repairing quality of composite plates.

Change of the mode of failure by interface friction and width-to-height ratio of coal specimens

Bumps in coal mines have been recognized as a major hazard for many years. These sudden and violent failures around mine openings have compromised safety, ventilation and access to mine workings.Previous studies showed that the violence of coal specimen failure depends on both the interface friction and width-to-height（W/H） ratio of coal specimen. The mode of failure for a uniaxially loaded coal specimen or a coal pillar is a combination of both shear failure along the interface and compressive failure in the coal. The shear failure along the interface triggered the compressive failure in coal. The compressive failure of a coal specimen or a coal pillar can be controlled by changing its W/H ratio. As the W/H ratio increases, the ultimate strength increases. Hence, with a proper combination of interface friction and the W/H ratio of pillar or coal specimen, the mode of failure will change from sudden violent failure which is brittle failure to non-violent failure which is ductile failure. The main objective of this paper is to determine at what W/H ratio and interface friction the mode of failure changes from violent to non-violent. In this research, coal specimens of W/H ratio ranging from 1 to 10 were uniaxially tested under two interface frictions of 0.1 and 0.25, and the results are presented and discussed.

Bonding interface morphology of keyholeless friction stir spot welded joint of AZ31B Mg alloy and DP600 galvanized steel

Because the bonding interface of dissimilar metal joint between AZ31 B Mg alloy and DP600 galvanized steel by keyholeless friction stir spot welding(KFSSW)is permanent bonding,the interface morphology cannot be directly observed.If the joint is separated by external force,the original features of bonding interface of joint will be destroyed,which has influence on the accuracy for observation and analysis of the result.In this paper,the coordinates of the key point at the interface of every cross-section at intervals of 0.2 mm were measured and connected into an outline.The outline of all interfaces makes up the three-dimensional morphologies of bonding interface between AZ31 B Mg alloy and DP600 steel by KFSSW,which was constructed by Solidworks software to restore the real mechanical bonding state of joint.Combined with the microhardness analysis of cross-section and results of in-situ tensile test,the unique bonding state and morphology of Mg and steel in the welded joint were confirmed.

Study on Interface Friction Model for Engineering Materials Testing on Split Hopkinson Pressure Bar Tests

Split Hopkinson pressure bar (SHPB) has become a frequently used technique to measure the uniaxial compressive stress-strain relation of various engineering materials at high strain-rates. The accuracy of an SHPB test is based on the assumption of uniaxial and uniform stress distribution within the specimen, which, however, is not always satisfied in an actual SHPB test due to the existence of some unavoidable negative factors, e.g., interface friction constrains. Kinetic interface friction tests based on a simple device for engineering materials testing on SHPB tests are performed. A kinetic interface friction model is proposed and validated by implementing it into a numerical model. It shows that the proposed simple device is sufficient to obtain kinetic interface friction results for common SHPB tests. The kinetic friction model should be used instead of the frequently used constant friction model for more accurate numerical simulation of SHPB tests.

Friction Characteristics Between Marine Clay and Construction Materials

Structure-soil interface friction characteristics is of importance to investigate the interaction between engineering structures and soils,especially for offshore structures.The interface friction behavior between marine clay and structural materials with different roughness was studied in this paper by using 3D optical scanning tests,a modified direct shear device and numerical simulation.Relationships between the surface roughness of structures,water content and interface friction angle were presented by model tests.The increase of water contents decreased the interface friction angles.For interfaces with different roughness,the interface friction angles will be smaller than that of the soil when the water content exceeds a certain value.The roughness of the interface and the water content of the soil are mutually coupled to influence the coefficient of friction(COF).This paper proposed a Finite Element Method(FEM)to simulate the interface direct shear tests of structures with different roughness.The surface models with different roughness are established based on the structure data obtained by 3D scanning.The Coupled Eulerian-Lagrangian(CEL)approach was employed to analyse soils sheared by irregular surfaces.The interface behavior for interfaces with different roughness under cyclic shear stresses was analyzed by FEM.

Prediction of corrosion rate for friction stir processed WE43 alloy by combining PSO-based virtual sample generation and machine learning

The corrosion rate is a crucial factor that impacts the longevity of materials in different applications.After undergoing friction stir processing(FSP),the refined grain structure leads to a notable decrease in corrosion rate.However,a better understanding of the correlation between the FSP process parameters and the corrosion rate is still lacking.The current study used machine learning to establish the relationship between the corrosion rate and FSP process parameters(rotational speed,traverse speed,and shoulder diameter)for WE43 alloy.The Taguchi L27 design of experiments was used for the experimental analysis.In addition,synthetic data was generated using particle swarm optimization for virtual sample generation(VSG).The application of VSG has led to an increase in the prediction accuracy of machine learning models.A sensitivity analysis was performed using Shapley Additive Explanations to determine the key factors affecting the corrosion rate.The shoulder diameter had a significant impact in comparison to the traverse speed.A graphical user interface(GUI)has been created to predict the corrosion rate using the identified factors.This study focuses on the WE43 alloy,but its findings can also be used to predict the corrosion rate of other magnesium alloys.

Mechanical Characterisation of Interface for Steel/Polymer Composite Using Pull-out Test: Shear-Lag and Frictional Analysis

Fibre-matrix interface is known to have contribution to the mechanical performance of fibre-reinforced composite by its potential for load transfer between the fibre and the matrix. Such load transfer is of great importance in dentistry when a post is used for fixing a ceramic crown on the tooth. In this study, a pull-out test was carried out to analyse the interfacial properties of a steel fibre embedded in a polyester and epoxy matrices. It was found that the fibre-matrix interface is debonded on the whole embedded length when the fibre stress reached the debonding stress. Then, the fibre stress fell down to the initial extraction stress required to pulling out the debonded fibre from the matrix. Both debonding stress and initial extraction stress initiated a linear increase with the implantation length after the debonding stress reached horizontal asymptotes. To analyse the fibre-matrix load transfer before debonding, an analytical shear-lag model was adopted to in this test conditions. Fitting the experimental results with the analytical model provided the interfacial shear strength. By considering the Coulomb friction at the fibre-matrix interface during the fibre extraction process, an analytical model which considers Poisson＇s effects on both fibre and matrix, was developed. In this model, knowledge of the initial extraction stress of the fibre provides the residual normal stress at the fibre-matrix interface.

Friction Characteristics at the Pipe-Soil Interface

-In order to analyze the stability of pipelines on the sea bed, the friction characteristics at the pipe-soil interface were examined by means of special direct shear tests. High density polythene was used as the surface of the pipe, which is a widely-utilized material for the outer cover of the pipe to prevent sea water corrosion. Sands of different gradings were tested. The reconstituted soft clay taken from the Bohai area was consolidated to different degrees of consolidation by the vacuum preloading technique, and tested.

The Effects of Contact Interface on the Friction Characteristics of Self-assembly Monolayers

The effects of different contact interfaces on the friction characteristics of OTS self-assembled monolayers were investigated by a universal micro-tribometer in different sliding velocities. The results indicate that there exist lower friction coefficients between OTS SAMs and Ti, Ni and Cu films deposited on GCr15 steel balls than those between OTS SAMs and GCr15 steel ball. The friction coefficient between OTS SAMs and Ti film is the largest, and the friction coefficient between OTS SAMs and Cu film is the least in these three films, which depends on the intrinsic characteristics of the materials. The friction coefficients between OTS SAMs and GCr15 steel ball and three nanometer films increase with the sliding velocity increasing, which can be explained by the relaxation characteristics of OTS molecules.

Influence of Friction Interface Contact on Ultrasonic Motor Efficiency Under Static Conditions

The friction interface matching plays a deterministic role in the motor efficiency,and the microcosmic contact status of friction interface should be investigated to improve the ultrasonic motor performance.The main purpose is to improve the effective output power of ultrasonic motor.Hence,one studies the contact condition of the friction interface of the ultrasonic motor,analyzes the micro condition of contact interface through finite element analysis,optimizes unreasonable structures,and compares the two different-structure ultrasonic motors through experiments.The results reflect the necessity of optimization.After optimization,the stator and rotor deform after pre-pressure and the contact interface of them full contact theoretically.When reaching heat balance the effective output of the motor is 37%,and the average effective output efficiency is 2.384 times higher than that of the unoptimized.It can be seen that the total consumption of the ultrasonic motor system decreases significantly.Therefore,when using in certain system the consumption taken from the system will decreases largely,especially in the system with a strict consumption control.

CONTACT FRICTION ANALYSIS AND STRESS OSCILLATION SUPPRESSION WITH A SIMPLE INTERFACE ELEMENT

A simple interface element for analyzing contact friction problems is developed. Taking nodal displacements and contact stresses as unknowns, this element can simulate frictional slippage, decoupling and re-bonding of two bodies initially mating or having gaps at a common interface. The method is based on the Finite Element Method and load incremental theory. The geometric and static constraint conditions on contact surfaces are treated as additional conditions and are included in stiffness equations. This simple element has the advantages of easy implementation into standard finite element programs and fast speed for convergence as well as high accuracy for stress distribution in interface. Undesirable stress oscillations are also investigated whenever large stress gradients exist over the contact surfaces. Exact integration or the conventional Gauss integration scheme used to evaluate the interpolation function matrix of the interface element is found to be the source of the oscillations. Eigenmode analysis demonstrates that the stress behavior of an interface element can be improved by using the Newton-Cotes integration scheme. Finally, the test example of a strip footing problem is presented.

Analysis of composite material interface crack face contact and friction effects using a new node-pairs contact algorithm

A new node-pairs contact algorithm is proposed to deal with a composite material or bi-material interface crack face contact and friction problem （e.g., resistant coating and thermal barrier coatings） subjected to complicated load conditions. To decrease the calculation scale and calculation errors, the local Lagrange multipliers are solved only on a pair of contact nodes using the Jacobi iteration method, and the constraint modification of the tangential multipliers are required. After the calculation of the present node-pairs Lagrange multiplier, it is turned to next contact node-pairs until all node-pairs have finished. Compared with an ordinary contact algorithm, the new local node-pairs contact algorithm is allowed a more precise element on the contact face without the stiffness matrix singularity. The stress intensity factors （SIFs） and the contact region of an infinite plate central crack are calculated and show good agreement with those in the literature. The contact zone near the crack tip as well as its influence on singularity of stress fields are studied. Furthermore, the frictional contacts are also considered and found to have a significant influence on the SIFs. The normalized mode-II stress intensity factors KII for the friction coefficient decrease by 16% when f changes from 1 to 0.

System-size effect on the friction at liquid-solid interfaces

The friction at the liquid-solid interfaces is widely involved in various phenomena ranging from nanometer to micrometer scales. By the molecular dynamic(MD)simulation, the friction properties of liquid-solid interfaces at the molecular level are calculated via the Green-Kubo relation. It is found that the system size will influence the value of the friction coefficient, especially for the solid surfaces with the larger polar charge. The value of the friction coefficient decreases with the increase in the system size and converges at large system sizes. The large polar charge will lead to a significant friction coefficient. However, the diffusion of water molecules on this surface is almost a constant, indicating that the diffusion coefficient seems to be independent of the system size and polar charge. This work provides insights for the selection of the system size in modeling the frictional properties of hydrophobic/hydrophilic surfaces.

Decohesion of graphene from a uniaxially-stretched substrate:Failure analysis of a frictional adhesive interface

Composite structures consisting of two-dimensional(2D)materials deposited on elastic substrates have a wide range of potential applications in flexible electronics.For such devices,robust 2D film/substrate interfacial adhesion is essential for their reliable performance when subjected to external thermal and mechanical loads.To better understand the strength and failure behavior of the 2D film/substrate interfaces,two types of graphene/polymer samples with distinct interfacial adhesion properties are fabricated and tested by uniaxially stretching the substrates.Depending on the interfacial adhesion,two drastically different debonding rates are observed,i.e.,rapid snap-through debonding and more progressive crack propagation.Motivated by the experimental observation,we propose an improved shear-lag model with a trapezoidal-shaped cohesive zone to derive an analytical solution for the decohesion behavior.The theoretical model reveals that the decohesion behavior of the frictional adhesive interface is governed by three dimensionless parameters.Particularly,the dimensionless length of the film essentially determines the decohesion rate;while the other two parameters affect the critical substrate strain to initiate debonding.By fitting the experimental data with the theoretical model,the intrinsic adhesion properties of the two samples are obtained with physically meaningful values.This work offers an analytical solution to describing the decohesion behavior of general thin film/substrate systems with a frictional adhesive interface,which is beneficial for characterizing and optimizing the mechanical properties of various thin film/polymer devices.

A simplified approach for negative skin friction calculation of special-shaped pile considering pile-soil interaction under surcharge

A simplified approach was proposed to analyze the negative skin friction calculation of special-shaped pile considering pile-soil interaction under surcharge. Based on the concentric cylinder shearing theory, considering the changes of pile shape(such as, taper angle and diameters of pile base, etc.), the load-transfer of special-shaped pile was built. The accuracy of the developed simplified approach was verified by numerical simulation model with the same condition. Then, the influence factors, such as, taper angles, the diameter of pile base, surcharge, and pile-soil interface parameters were analyzed and discussed. The results show that the developed simplified approach can calculate NSF of special-shaped pile under surcharge effectively. A limited parametric study indicates that in many practical situations special-shaped piles(such as belled wedge pile shown in this work) offer a design option that is more economical than traditional uniform cross-section piles.

INTERFACE DEFORMATION CHARACTERISTICS OF BIMETAL FORMING

ＩＮＴＥＲＦＡＣＥＤＥＦＯＲＭＡＴＩＯＮＣＨＡＲＡＣＴＥＲＩＳＴＩＣＳＯＦＢＩＭＥＴＡＬＦＯＲＭＩＮＧ①ＰｅｎｇＹｉｎｇｈｏｎｇａｎｄＲｕａｎＸｕｅｙｕＮａｔｉｏｎａｌＤｉｅ＆ＭｏｌｄＣＡＤＥｎｇｉｎｅｒｉｎｇＲｅｓｅａｒｃｈＣｅｎｔｅｒ，Ｓｈａｎｇ...