7075-T6 aluminum alloy/low carbon steel joint was carried out via a novel friction plug−riveting spot welding process.This process utilized uniquely designed steel rivets with a tip and groove shape.The macro-morpholo...7075-T6 aluminum alloy/low carbon steel joint was carried out via a novel friction plug−riveting spot welding process.This process utilized uniquely designed steel rivets with a tip and groove shape.The macro-morphology formation,microstructure,microhardness and lap shear performance of joints were investigated.As the spindle down distance increased,the rivet tip was friction welded with the lower steel sheet,resulting in the formation of a solid phase welding zone exhibiting metallurgical bonding.Additionally,a hook was formed in the joint,providing the mechanical locking.The results showed that under optimal parameters of spindle down distance of 3.4 mm,rotation speed of 4000 r/min,and spindle down speed of 2.4 mm/s,the lap shear load of the joints reached a maximum of 14.36 kN.Failure occurred at the aluminum alloy base metal.展开更多
Friction stir keyholeless spot welding（FSKSW） using a retractable pin for 1.0 mm thick galvanized mild steel and 3 mm thick AZ31 B magnesium alloy in a lap configuration was investigated.The process variables were o...Friction stir keyholeless spot welding（FSKSW） using a retractable pin for 1.0 mm thick galvanized mild steel and 3 mm thick AZ31 B magnesium alloy in a lap configuration was investigated.The process variables were optimized in terms of the joint strength.The effects of the stacking sequence on joint formation and the joining mechanism of FSKSW AZ31B-to-mild steel joints were also analyzed.It shows that the process window and joint strength are strongly influenced by the stacking sequence of the workpieces.While the process window is narrow and unstable for FSKSW of a magnesium-to-steel stack-up,a desirable process was established for the steel-to-magnesium stacking sequence,a desirable process and higher strength joint can be got when the steel-to-magnesium stacking sequence.XRD phase and EPMA analyses of the FSKSW joint showed that the intermetallic compounds are formed at the steel-to-magnesium interface,and the element diffusion between the mild steel and AZ31 B magnesium alloy revealed that the joining methods for FSKSW joints is the main mechanical joining along with certain metallurgical bonding.展开更多
The fatigue behavior of friction stir spot welded （FSSW） AZ31 magnesium alloy sheet joints was investigated by tension- compression of fatigue test. The results suggest that all the fatigue failures occur at the sti...The fatigue behavior of friction stir spot welded （FSSW） AZ31 magnesium alloy sheet joints was investigated by tension- compression of fatigue test. The results suggest that all the fatigue failures occur at the stir zone of the FSSW AZ31 sheet joints, and all cracks initiate at the stir zone outer edge between the upper and lower sheet. When the cycle force equals 1 kN, the crack propagates along the interface of heat-affected zone and thermo-mechanical zone, simultaneously across the direction of force; while the cycle force equals 3 kN, the crack propagates along the diameter of stir zone and shear failure occurs finally. Moreover, the transverse microsections indicate that there is a tongue-like region at the outer edge of stir zone between the two AZ31 sheets, and the direction of tongue-like region is toward outside of the stirred zone and all fatigue cracks initiate at the tongue-like region.展开更多
A point to? point positioning control of systems with highly nonlinear frictions is studied. In view of variable frictions caused by the changes of load torque, an experimental comparison was made between the valve?...A point to? point positioning control of systems with highly nonlinear frictions is studied. In view of variable frictions caused by the changes of load torque, an experimental comparison was made between the valve? controlled hydraulic motor servo system with PID control and that with friction compensation control. Experimental results show that the gross steady errors are caused by frictions when the system is controlled by the conventional proportional control algorithm. Although the errors can be reduced by introducing the integral control, the limit cycle oscillation and the long setting time are caused. The positioning error for a constant load torque can be eliminated by using fixed friction compensation, but poor positioning accuracy is caused by the same fixed friction compensation when the load torques varies greatly. The dynamic friction compensation based on the error and change in error measurements can significantly improve the position precision in a broad range of the changes of load torque.展开更多
Friction stir spot welding technique was employed to join pure copper （C11000） and pure aluminium （AA1060） sheets. The evolving properties of the welds produced were characterized. The spot welds were produced by ...Friction stir spot welding technique was employed to join pure copper （C11000） and pure aluminium （AA1060） sheets. The evolving properties of the welds produced were characterized. The spot welds were produced by varying the rotational speed, shoulder plunge depth using different tool geometries. The presence of a copper ring of different lengths was observed on both sides of the welds indicating that Cu extruded upward into the Al sheet which contributed to obtaining strong welds. The microstructure showed the presence of copper particles in the aluminium matrix which led to the presence of various intermetallics observed by the energy dispersive spectroscopy and X-ray diffraction. The maximum tensile failure load increases with an increase in the shoulder plunge depth, except for the weld produced at 800 r/min using a conical pin and a concave shoulder. A nugget pull-out failure mode occurred in all the friction stir spot welds under the lap-shear loading conditions. High peaks of Vickers microhardness values were obtained in the vicinity of the keyhole of most of the samples which correlated to the presence of intermetallics in the stir zone of the welds.展开更多
The microstructure and mechanical properties of dissimilar pinless friction stir spot welded joint of2A12aluminum alloy and TC4titanium alloy were evaluated.The results show that the joint of Al/Ti dissimilar alloys c...The microstructure and mechanical properties of dissimilar pinless friction stir spot welded joint of2A12aluminum alloy and TC4titanium alloy were evaluated.The results show that the joint of Al/Ti dissimilar alloys can be successfully attained through pinless friction stir spot welding(FSSW).The joint can be divided into three zones(SZ,TMAZ and HAZ).The microstructure of joint in Al alloy side changes significantly but it basically has no change in Ti alloy side.At the same rotation speed,the maximum load of welded joints gradually rises with the increase in dwell time.At the same dwell time,the maximum load of the welded joint increases with the increase of the rotational speed.In addition,optimal parameters were obtained in this work,and they are rotation speed of1500r/min,plunge speed of30mm/min,plunge depth of0.3mm and dwell time of15s.The fracture mode of welded joints is interfacial shear fracture.The microhardness of the joint on the Al side distributes in a typical“W”type and is symmetry along the weld center,but the distribution of the microhardness on the Ti side has no obvious change.展开更多
The AZ31 magnesium alloy with a thickness of 1.8 mm was welded by the probeless friction stir spot welding process without Zn interlayer.The influence of process parameters on joint microstructure and mechanical prope...The AZ31 magnesium alloy with a thickness of 1.8 mm was welded by the probeless friction stir spot welding process without Zn interlayer.The influence of process parameters on joint microstructure and mechanical properties was investigated by using different rotating speeds and dwell time.Microstructure of joints is divided into three regions:stir zone,thermomechanically-affected zone and heat-affected zone.With the increase of rotation speed and dwell time,the depth of stir zone gradually increases,and hook defects extend from the interface of two plates to the surface of the upper plate.The tensile shear strength of joints and two fracture modes(shear fracture and plug fracture)are closely related to hook defects.The maximum tensile shear strength of the joint is 4.22 kN when rotation speed and dwell time are 1180 r/min and 9 s,respectively.Microhardness value and its fluctuation in upper sheet are evidently higher than those of the lower sheet.展开更多
基金supported by the National Natural Science Foundation of China(No.51875037).
文摘7075-T6 aluminum alloy/low carbon steel joint was carried out via a novel friction plug−riveting spot welding process.This process utilized uniquely designed steel rivets with a tip and groove shape.The macro-morphology formation,microstructure,microhardness and lap shear performance of joints were investigated.As the spindle down distance increased,the rivet tip was friction welded with the lower steel sheet,resulting in the formation of a solid phase welding zone exhibiting metallurgical bonding.Additionally,a hook was formed in the joint,providing the mechanical locking.The results showed that under optimal parameters of spindle down distance of 3.4 mm,rotation speed of 4000 r/min,and spindle down speed of 2.4 mm/s,the lap shear load of the joints reached a maximum of 14.36 kN.Failure occurred at the aluminum alloy base metal.
基金Project (10902047,51265030) supported by the National Natural Science Foundation of China
文摘Friction stir keyholeless spot welding（FSKSW） using a retractable pin for 1.0 mm thick galvanized mild steel and 3 mm thick AZ31 B magnesium alloy in a lap configuration was investigated.The process variables were optimized in terms of the joint strength.The effects of the stacking sequence on joint formation and the joining mechanism of FSKSW AZ31B-to-mild steel joints were also analyzed.It shows that the process window and joint strength are strongly influenced by the stacking sequence of the workpieces.While the process window is narrow and unstable for FSKSW of a magnesium-to-steel stack-up,a desirable process was established for the steel-to-magnesium stacking sequence,a desirable process and higher strength joint can be got when the steel-to-magnesium stacking sequence.XRD phase and EPMA analyses of the FSKSW joint showed that the intermetallic compounds are formed at the steel-to-magnesium interface,and the element diffusion between the mild steel and AZ31 B magnesium alloy revealed that the joining methods for FSKSW joints is the main mechanical joining along with certain metallurgical bonding.
基金Project(2007CB613705)supported by the National Key Technologies R&D Program of ChinaProject(2011DFA50902)supported by the International S&T Cooperation Program of China
文摘The fatigue behavior of friction stir spot welded （FSSW） AZ31 magnesium alloy sheet joints was investigated by tension- compression of fatigue test. The results suggest that all the fatigue failures occur at the stir zone of the FSSW AZ31 sheet joints, and all cracks initiate at the stir zone outer edge between the upper and lower sheet. When the cycle force equals 1 kN, the crack propagates along the interface of heat-affected zone and thermo-mechanical zone, simultaneously across the direction of force; while the cycle force equals 3 kN, the crack propagates along the diameter of stir zone and shear failure occurs finally. Moreover, the transverse microsections indicate that there is a tongue-like region at the outer edge of stir zone between the two AZ31 sheets, and the direction of tongue-like region is toward outside of the stirred zone and all fatigue cracks initiate at the tongue-like region.
文摘A point to? point positioning control of systems with highly nonlinear frictions is studied. In view of variable frictions caused by the changes of load torque, an experimental comparison was made between the valve? controlled hydraulic motor servo system with PID control and that with friction compensation control. Experimental results show that the gross steady errors are caused by frictions when the system is controlled by the conventional proportional control algorithm. Although the errors can be reduced by introducing the integral control, the limit cycle oscillation and the long setting time are caused. The positioning error for a constant load torque can be eliminated by using fixed friction compensation, but poor positioning accuracy is caused by the same fixed friction compensation when the load torques varies greatly. The dynamic friction compensation based on the error and change in error measurements can significantly improve the position precision in a broad range of the changes of load torque.
基金financial support of the University of Johannesburg and the assistance from Mr Riaan Brown (Nelson Mandela Metropolitan University) for operating the MTS PDS I-Stir machine are acknowledged
文摘Friction stir spot welding technique was employed to join pure copper （C11000） and pure aluminium （AA1060） sheets. The evolving properties of the welds produced were characterized. The spot welds were produced by varying the rotational speed, shoulder plunge depth using different tool geometries. The presence of a copper ring of different lengths was observed on both sides of the welds indicating that Cu extruded upward into the Al sheet which contributed to obtaining strong welds. The microstructure showed the presence of copper particles in the aluminium matrix which led to the presence of various intermetallics observed by the energy dispersive spectroscopy and X-ray diffraction. The maximum tensile failure load increases with an increase in the shoulder plunge depth, except for the weld produced at 800 r/min using a conical pin and a concave shoulder. A nugget pull-out failure mode occurred in all the friction stir spot welds under the lap-shear loading conditions. High peaks of Vickers microhardness values were obtained in the vicinity of the keyhole of most of the samples which correlated to the presence of intermetallics in the stir zone of the welds.
基金Projects(51405389,51675435)supported by the National Natural Science Foundation of ChinaProject(3102017ZY005)supported by the Fundamental Research Funds for the Central Universities,China+3 种基金Project(SAST2016043)supported by the Fund of SAST,ChinaProject(20161125002)supported by the Aeronautical Science Foundation of ChinaProject(B08040)supported by the 111 Project,ChinaProjects(2016YFB0701203,2016YFB1100104)supported by the National Key Research and Development Program of China
文摘The microstructure and mechanical properties of dissimilar pinless friction stir spot welded joint of2A12aluminum alloy and TC4titanium alloy were evaluated.The results show that the joint of Al/Ti dissimilar alloys can be successfully attained through pinless friction stir spot welding(FSSW).The joint can be divided into three zones(SZ,TMAZ and HAZ).The microstructure of joint in Al alloy side changes significantly but it basically has no change in Ti alloy side.At the same rotation speed,the maximum load of welded joints gradually rises with the increase in dwell time.At the same dwell time,the maximum load of the welded joint increases with the increase of the rotational speed.In addition,optimal parameters were obtained in this work,and they are rotation speed of1500r/min,plunge speed of30mm/min,plunge depth of0.3mm and dwell time of15s.The fracture mode of welded joints is interfacial shear fracture.The microhardness of the joint on the Al side distributes in a typical“W”type and is symmetry along the weld center,but the distribution of the microhardness on the Ti side has no obvious change.
基金Projects(51875470,51405389) supported by the National Natural Science Foundation of ChinaProject(2018JM5159) supported by the Natural Science Foundation of Shaanxi Province,ChinaProject(2016YFB1100104) supported by the National Key Research and Development Program of China
文摘The AZ31 magnesium alloy with a thickness of 1.8 mm was welded by the probeless friction stir spot welding process without Zn interlayer.The influence of process parameters on joint microstructure and mechanical properties was investigated by using different rotating speeds and dwell time.Microstructure of joints is divided into three regions:stir zone,thermomechanically-affected zone and heat-affected zone.With the increase of rotation speed and dwell time,the depth of stir zone gradually increases,and hook defects extend from the interface of two plates to the surface of the upper plate.The tensile shear strength of joints and two fracture modes(shear fracture and plug fracture)are closely related to hook defects.The maximum tensile shear strength of the joint is 4.22 kN when rotation speed and dwell time are 1180 r/min and 9 s,respectively.Microhardness value and its fluctuation in upper sheet are evidently higher than those of the lower sheet.
