Today ultrasonic power technique is consider a mandatory technique which is always entered in many processes such as in metal and plastic welding to overcomes many issues,with aided of applying force(pressure)and supp...Today ultrasonic power technique is consider a mandatory technique which is always entered in many processes such as in metal and plastic welding to overcomes many issues,with aided of applying force(pressure)and supplied high frequency vibration,a solid-state weld can be generated by ultrasonic metal welding technique.That gives a technique the ability to join not only a small component,whereas also to join thicker specimens,which depends on a proper control of matching welding conditions.Therefore a welding performance can be studied and compared after designed welding horn to resonance at frequencies of 20 kHz and 40 kHz.The analyses of the designed horn are completed through use a vibration mathematical expressions,modal and harmonic analyses to ensure the weldability due to applying ultrasonic power to the working area and also to compare the performance of joint at using two resonance frequencies of 20 kHz and 40 kHz.The dimensions of the horns were determined to match the selected resonance frequencies,which the lengths were calculated as 132 mm and 66 mm respectively.The analysis of the exciting model indicates that the axial vibration modes of 19,584 Hz and 39,794 Hz are obtained in 10th mode,while the two frequency values are recorded 19,600 Hz and 39,800 Hz from the frequency response of the two horns.The weld strength between Al and Cu specimens with a thickness 0.5 mm was evaluated using a tensile test,which the analyses were obtained under using different welding pressure and varied amplitudes.The results were recorded within exciting a horn with two different resonance frequencies,show the enhancement of weld strength and quality through control of stepping amplitude,the enhancement means obtain good strength of the weld,reduce sticking horn to specimen,and lower specimen marking.展开更多
Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders p...Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds(IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar Al-Mg joining due to the inherent low heat inputs involved in the process. However, the IMCs, namely Al_(3)Mg_(2) and Al_(12)Mg_(17) phases, have also been reported to form during Al-Mg dissimilar FSW;their amount and thickness depend on the heat input involved;thus,the weld parameters used. Since the heat dissipated in the material during the welding process significantly affects the amount of IMCs,the heat input during FSW should be kept as low as possible to control and reduce the amount of IMCs. This review aims to critically discuss and evaluate the studies conducted in the dissimilar Al/Mg FSW through a scientometric analysis and also with a focus on the strategies recently applied to enhance joint quality. The scientometric analysis showed that the main research directions in Mg/Al FSW are the technological weldability of aluminum and magnesium during FSW, structural morphology, and mechanical properties of dissimilar welded joints. Considering the scope of application of the aforementioned joints, the low share of articles dealing with environmental degradation and operational cracking is surprising. This might be attributed to the need for well-developed strategies for obtaining high-quality and sustainable joints for applications. Thus, the second part of this review is conventional, focusing mainly on the new strategies for obtaining high-quality Mg/Al joints. It can be concluded that in addition to the necessity to optimum welding parameters to suppress the excessive heat to limit the amount and thickness of IMC formed and improve the overall joint quality, strategies such as using Zn interlayer, electric current assisted FSW(EAFSW), ultrasonic vibration FSW(UVa FSW), are considered effective in the elimination, reduction, and fragmentation of the brittle IMCs.展开更多
文摘Today ultrasonic power technique is consider a mandatory technique which is always entered in many processes such as in metal and plastic welding to overcomes many issues,with aided of applying force(pressure)and supplied high frequency vibration,a solid-state weld can be generated by ultrasonic metal welding technique.That gives a technique the ability to join not only a small component,whereas also to join thicker specimens,which depends on a proper control of matching welding conditions.Therefore a welding performance can be studied and compared after designed welding horn to resonance at frequencies of 20 kHz and 40 kHz.The analyses of the designed horn are completed through use a vibration mathematical expressions,modal and harmonic analyses to ensure the weldability due to applying ultrasonic power to the working area and also to compare the performance of joint at using two resonance frequencies of 20 kHz and 40 kHz.The dimensions of the horns were determined to match the selected resonance frequencies,which the lengths were calculated as 132 mm and 66 mm respectively.The analysis of the exciting model indicates that the axial vibration modes of 19,584 Hz and 39,794 Hz are obtained in 10th mode,while the two frequency values are recorded 19,600 Hz and 39,800 Hz from the frequency response of the two horns.The weld strength between Al and Cu specimens with a thickness 0.5 mm was evaluated using a tensile test,which the analyses were obtained under using different welding pressure and varied amplitudes.The results were recorded within exciting a horn with two different resonance frequencies,show the enhancement of weld strength and quality through control of stepping amplitude,the enhancement means obtain good strength of the weld,reduce sticking horn to specimen,and lower specimen marking.
基金sponsored by the Prince Sattam bin Abdulaziz University via project number 2023/RV/018。
文摘Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds(IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar Al-Mg joining due to the inherent low heat inputs involved in the process. However, the IMCs, namely Al_(3)Mg_(2) and Al_(12)Mg_(17) phases, have also been reported to form during Al-Mg dissimilar FSW;their amount and thickness depend on the heat input involved;thus,the weld parameters used. Since the heat dissipated in the material during the welding process significantly affects the amount of IMCs,the heat input during FSW should be kept as low as possible to control and reduce the amount of IMCs. This review aims to critically discuss and evaluate the studies conducted in the dissimilar Al/Mg FSW through a scientometric analysis and also with a focus on the strategies recently applied to enhance joint quality. The scientometric analysis showed that the main research directions in Mg/Al FSW are the technological weldability of aluminum and magnesium during FSW, structural morphology, and mechanical properties of dissimilar welded joints. Considering the scope of application of the aforementioned joints, the low share of articles dealing with environmental degradation and operational cracking is surprising. This might be attributed to the need for well-developed strategies for obtaining high-quality and sustainable joints for applications. Thus, the second part of this review is conventional, focusing mainly on the new strategies for obtaining high-quality Mg/Al joints. It can be concluded that in addition to the necessity to optimum welding parameters to suppress the excessive heat to limit the amount and thickness of IMC formed and improve the overall joint quality, strategies such as using Zn interlayer, electric current assisted FSW(EAFSW), ultrasonic vibration FSW(UVa FSW), are considered effective in the elimination, reduction, and fragmentation of the brittle IMCs.
