Comprehensive study of microstructure and mechanical properties of friction stir welded 5182-O/HC260YD+Z lap joint

The welding of aluminum(Al)and steel has attracted more and more interest due to the weight reduction trend in vehicle and aerospace manufacturing industries.5182-O/HC260YD+Z lap joint was produced by friction stir welding(FSW),and the microstructure and mechanical property of the joint were systemically characterized.The microstructure in horizontal direction of the Al and steel near interface was similar to their corresponding conventional friction stir welded joint.The joint was divided into stir zone of Al(ST-Al),stir zone of interface(ST-I),thermal-mechanically affected zone of steel(TMAZ-Fe)and base material of steel(BM-Fe)according to their distinct microstructure vertically.Three kinds of intermetallic compounds(IMCs)of FeAl_(3),FeAl and Fe_(3)Al were formed at the interface.The horizontal micro hardness distribution exhibited a hat shape and“M”shape in Al and steel,respectively.The hardest region of the joint was located at the ST-I,with a hardness of 175 HV−210 HV.The joint was fractured along the hook structure,with an average shear strength of 73.9 MPa.Fractural morphology of Al and steel indicted a cleavage fracture mode.

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.

Corrosion evaluation of friction stir welded lap joints of AA6061-T6 aluminum alloy

Corrosion behavior of friction stir lap welded AA6061-T6 aluminum alloy was investigated by immersion tests in sodium chloride + hydrogen peroxide solution. Electrochemical measurement by cyclic potentiodynamic polarization, scanning electron microscopy, and energy dispersive spectroscopy were employed to characterize corrosion morphology and to realize corrosion mechanism of weld regions as opposed to the parent alloy. The microstructure and shear strength of welded joint were fully investigated. The results indicate that, compared with the parent alloy, the weld regions are susceptible to intergranular and pitting attacks in the test solution during immersion time. The obtained results of lap shear testing disclose that tensile shear strength of the welds is 128 MPa which is more than 60% of the strength of parent alloy in lap shear testing. Electrochemical results show that the protection potentials of the WNZ and HAZ regions are more negative than the pitting potential. This means that the WNZ and HAZ regions do not show more tendencies to pitting corrosion. Corrosion resistance of parent alloy is higher than that for the weldments, and the lowest corrosion resistance is related to the heat affected zone. The pitting attacks originate from the edge of intermetallic particles as the cathode compared with the Al matrix due to their high self-corrosion potential. It is supposed that by increasing intermetallic particle distributed throughout the matrix of weld regions, the galvanic corrosion couples are increased, and hence decrease the corrosion resistance of weld regions.

EFFECT OF Z-PINS’ DIAMETER,SPACING AND OVERLAP LENGTH ON CONNECTING PERFORMANCE OF CMC SINGLE LAP JOINT

The effect of through-thickness reinforcement by composite pins （Z-pins） on the static tensile strength and failure mechanisms of the joints made from ceramic matrix composite （CMC） is investigated. Overlap length of the single lap joint is 15 mm, 20 mm, 23 mm, 37 mm, and 60 mm, respectively. The experimental results indicate that the final failure modes of the joints can be divided into two groups, （a） the bond-line stops debonding until crack encounters Z-pins; and then the adherends break at the location of Z-pins, when overlap length is more than 20 mm; （b） the bond-line detaches entirely and Z-pins are drawn from adherends, when overlap length is equal to 15 mm. A simple efficient computational approach is presented for analyzing the benefit of through-thickness pins for restricting failure in the single lap joints. Here, the mechanics problem is simplified by representing the effect of the pins by tractions acting on the fracture surfaces of the cracked bond-line. The tractions are prescribed as functions of the crack displacement, which are available in simple forms that summarize the complex deformations to a reasonable accuracy. The resulting model can be used to track the evolution of complete failure mechanisms, for example, bond-line initial delamination and ultimate failure associated with Z-pin pullout, ultimate failure of the adherends. The paper simulates connecting performance of the single lap joints with different Z-pins＇ diameter, spacing and overlap length; the numerical results agree with the experimental results; the numerical results indicate enlarging diameter and decreasing spacing of Z-pins are in favor of improving the connecting performance of the joints. By numerical analysis method, the critical overlap length that lies between two final failure modes is between 18 mm and 19 mm, when Z-pins＇ diameter and spacing are 0.4 mm, 5 mm, respectively.

Fatigue Resistance and Failure Behavior of Penetration and Non-Penetration Laser Welded Lap Joints

Penetration and non-penetration lap laser welding is the joining method for assembling side facade panels of railway passenger cars,while their fatigue performances and the difference between them are not completely understood.In this study,the fatigue resistance and failure behavior of penetration 1.5+0.8-P and non-penetration 0.8+1.5-N laser welded lap joints prepared with 0.8 mm and 1.5 mm cold-rolled 301L plates were investigated.The weld beads showed a solidification microstructure of primary ferrite with good thermal cracking resistance,and their hardness was lower than that of the plates.The 1.5+0.8-P joint exhibited better fatigue resistance to low stress amplitudes,whereas the 0.8+1.5-N joint showed greater resistance to high stress amplitudes.The failure modes of 0.8+1.5-N and 1.5+0.8-P joints were 1.5 mm and 0.8 mm lower lap plate fracture,respectively,and the primary cracks were initiated at welding fusion lines on the lap surface.There were long plastic ribs on the penetration plate fracture,but not on the non-penetration plate fracture.The fatigue resistance stresses in the crack initiation area of the penetration and non-penetration plates calculated based on the mean fatigue limits are 408 MPa and 326 MPa,respectively,which can be used as reference stress for the fatigue design of the laser welded structures.The main reason for the difference in fatigue performance between the two laser welded joints was that the asymmetrical heating in the non-penetration plate thickness resulted in higher residual stress near the welding fusion line.

Dissimilar titanium/aluminum friction stir welding lap joints by experiments and numerical simulation

Dissimilar stir welding （FSW） lap joints were produced by friction out of Ti6A14V titanium alloy and AA2024 aluminum alloy sheets. The joints, welded with varying tool rotation and feed rate, were studied by ana- lyzing the maximum shear strength, Vickers microhardness and optical observations. A dedicated numerical model, able to take into account the presence of the two different alloys, was used to highlight the effects of the process parameters on temperature distribution, strain distribution, and material flow. The combined analysis of experimental measurements and numerical predictions allowed explaining the effects of tool rotation and feed rate on the material flow. It was found that tool rotation had a larger impact on the joint effectiveness with respect to feed rate. A competition between material mixing and heat input occurs with increasing tool rotation, resulting in higher joint strength when lower values of tool rotation are used.

A novel technique for measuring 3D deformation of adhesively bonded single lap joint

An easy-to-implement yet practical single-camera microscopic stereo-digital image correlation(stereo-DIC) technique is proposed for surface three-dimensional(3D) deformation measurement of singe lap joint(SLJ) samples subjected to mechanical loads. The basic principles, optical configurations and implementation procedures of the proposed technique are described in detail. Compared with existing single-camera 2D-DIC technique, which has been regularly used for in-plane deformation measurement of a SLJ specimen, the proposed technique offers the special merit of simultaneously determining all the three displacement components by simply adding two additional optical elements to existing single-camera 2D-DIC systems. The accuracy and effectiveness of the proposed technique is demonstrated by measuring the 3D deformation of a SLJ specimen subjected to quasi-static tensile loads.

Mechanical behaviour of adhesively single lap joint under buckling conditions

Adhesive Single Lap Joints have been subjected to tensile and bending investigations by many researchers. However, the joint is also likely to experience buckling loading in some aerospace applications. The aim of this work is to investigate the joint behaviour under quasi-static buckling conditions. For this purpose, the joints with three different adherend thicknesses and 25 mm overlap length were tested using two different types of adherends and an adhesive film. They were modelled using a non-linear Finite Element Method via the ABAQUS Explicit package programme.Load to failure and stress distributions in the joints were predicted and compared with the experimental results, which were found in a good agreement. The adhesive layer in the joint was assumed to experience shear stresses under the buckling mode, similar to that in tensile loading, yet, the stress concentrations at the ends of the overlap, the main cause of the failure, resulted in different effects on the joint performance;for the buckling mode the critical stresses were in compression but for the tensile case in peeling. Unlike the latter, the former was found to prevent failure of the layer depending on the adherend thickness, causing different failure mechanisms. There were two different failure modes of the joints;a complete failure in the adhesive layer and large plastic deformation of adherends which could be a good source for crashworthiness situations. Mechanical properties of the adherends were found to play important roles on the joint performance.

Physics-informed neural networks for estimating stress transfer mechanics in single lap joints

With the explosive growth of computational resources and data generation,deep machine learning has been successfully employed in various applications.One important and emerging scientific application of deep learning involves solving differential equations.Here,physics-informed neural networks(PINNs)are developed to solve the differential equations associated with a specific scientific problem.As such,algorithms for solving the differential equations by embedding their initial and boundary conditions in the cost function of the artificial neural networks using algorithmic differentiation must also be developed.In this study,various PINNs are adopted to estimate the stresses in the tablets and the interphase of a single lap joint.The proposed model is represented by two fourth-order non-homogeneous coupled partial differential equations,with the axial stresses in the upper and lower tablets adopted as the dependent variables.The axial stresses are a function of the tablet length,which presents the independent variable.Therefore,the axial stresses in the tablets are estimated by solving the coupled partial differential equations when subjected to the boundary conditions,whereas the remaining stress components are expressed in terms of axial stresses.The results obtained using the developed methodology are validated using the results obtained via MAPLE software.

INTERLAMINAR STRESSES OF A LAMINATED COMPOSITE LAP JOINT

The energy method has been successfully applied to solving interlaminar stresses of laminated composite lap joint with an adhesive layer of a certain thickness. This method has the merit of reckoning not only the stress component σ_y, in adherents but also the variation of stresses through the thickness of the adhesive layer. Thus we have the possibility to rectify some mistakes that have long frustrated the solution to joint problems. As all the series encountered can be summed, the solutions are, as usual, neat in closed forms. Furthermore, solutions can be confirmed by the load to be taken by the joint.

Influence of welding parameters on interface evolution and mechanical properties of FSW Al/Ti lap joints

Friction stir welding(FSW)was performed to produce Al/Ti lap joints under various welding conditions.More heat was generated when rotational rate increased or traversing rate decreased.Two types of Al/Ti interfaces–mixed interface and diffusive interface–were formed under different welding conditions.The diffusive interface was formed with low heat input,and the mixed interface was formed more heat.The grains at the mixed interface were larger than those at the diffusive interface because of the higher heat input.Moreover,the microstructure of the mixed interface had a lower texture intensity compared with that of the diffusive interface,which was attributed to the enhanced continuous dynamic recrystallization(CDRX).TiAl3 was formed at the diffusive interface.When the interface varied to the mixed interface as heat input increased,TiAl was fomed within the Al/Ti mixture following the formation of TiAl3.In addition,TiAl3 precipitates were observed in the diffusion layer.The hardness value of the mixed interface was higher than 350 HV,due to the larger amount of intermetallic compounds(IMCs).The lap shear strength reached a maximum value of 147 MPa with medium heat input and an interface that exits in a critical state between diffusive and mixed interfaces.All the specimens fractured at the interface,which was attributed to the presence of IMCs.

Effect of Hygrothermal Cycle Aging on the Mechanical Behavior of Single-lap Adhesive Bonded Joints

The aging behavior of single lap joints(SLJ) in hygrothermal cycles was investigated and compared by using a shearing strength test, Fourier transform infrared spectroscopy(FTIR), thermogravimetric analysis(TG/DTG), energy dispersive spectrometry(EDS) and scanning electronic microscopy(SEM). The temperature/relative humidity was set at 80 ℃/95% and –40 ℃/30% for 20 cycles, 40 cycles, and 60 cycles(one cycle was 12 hours), respectively. The experimental results show that hygrothermal aging significantly decreases the failure strength of adhesive joints. However, the failure displacement increases as the number of aging cycles increases. In addition, hygrothermal aging changes the failure mode of the adhesive joints from a cohesive fracture in un-aged adhesive layers to an interfacial failure of aged adhesive joints.

Preparation of FRC/Steel by Lap-joint and Its Mechanical Properties

The Lap-joint configuration and the vacuum assisted forming method were put forward to meet the demands of the compression bending strength and the strong connection between the steel and FRC.The bending mechanic tests of the Lap-joint bending specimens carried out, the fabricate processing stability, limit carrying capacity and failure modes were analyzed. The experimental results show that the fabricate processing of the Lap-joint is stable; the bending stiffness is 19.5 N/mm, and the limit bending moment reaches 318 N？m. The main failure modes are the failure of core material at junction of sandwich plate and steel, and the bending failure in the position of the inner and outer surface.

铆接夹层间隙对单搭接铆接头振动疲劳性能的影响研究

为了考虑装配间隙对单搭接结构振动疲劳性能的影响,利用ABAQUS软件建立了飞机发动机进气道局部结构金属铆接头的弹塑性有限元模型,采用Johnson-Cook失效模型模拟铆钉与被连接件的渐进失效行为,得到了不同装配间隙量的铆接头应力场分布与振动疲劳寿命。对单搭接铆接头进行振动疲劳试验,试验结果与仿真结果在疲劳寿命方面吻合较好,验证了数值模型的准确性。与无间隙模型相比,含间隙铆接试件各铆钉疲劳寿命降低了4.7%~18.0%,间隙的存在也导致了压铆过程中相邻铆钉间的挤压载荷传递,整体表现为铆钉与被连接板接触界面应力激增,导致有间隙铆接头残余应力场与无间隙铆接头残余应力场之间的差异,从而影响铆接头的振动疲劳性能。

CFRP层合板单搭胶接接头胶板界面剥离强度仿真分析

基于异材界面奇异应力场理论,以CFRP层合板单搭胶接结构为对象,通过有限元和实验的方法分析了结构承载时板胶结合界面上出现的应力分布,锁定界面剥离强度关键区域,通过网格无关的有限元应力比值法提升仿真求解精度,最大限度还原板胶界面应力分布,着重探讨了多层各向异性CFRP板与传统均质材料在仿真过程和结果的差异,及搭接长度、胶层厚度、结构胶参数等对板胶界面应力分布及起裂点位置的影响,为板胶界面剥离应力的优化、胶接工艺的改进和单搭胶接接头强度的提升提供理论支撑。结果表明:各层参数不同的CFRP板胶界面承载时,剥离应力的最大处需由三个维度共同约束,其中两个维度的约束结果与均质材料相同,极值位于板胶界面垂直于拉伸方向的边缘,实际结构中失效的起始亦常见于此处,第三维度受层合板多层异性影响,该边缘上应力最大的点既不位于该边缘的中点也不位于界面角部,具体位置由材料参数和胶接结构共同影响。

城市轨道车辆地板布粘接施胶工艺优化研究

城市地铁建设呈飞速发展趋势,此交通模式更为便利人们的出行。为此,社会对地铁的美观性、个性化也提出了更高要求。以城轨车辆为对象,首先对地板布粘接结构进行分析,然后对胶粘无缝搭接工艺关键点与步骤进行论述,最后通过实验对比分析胶粘无缝搭接与对接工艺。分析可知,无缝搭接要比对接工艺在抗拉强度上表现的更为出色,前者的断裂模式为切断,这能更好规避地板布开裂问题,不仅具有较高的美观度,而且使用年限较长;并能产生降噪、减震的效果。结果表明,无缝搭接工艺在抗开裂、抗拉强度方面表现更为出色。

湿热环境下端径比对复合材料螺栓连接结构静力拉伸失效的影响

为研究湿热环境下复合材料螺栓连接结构的静力拉伸性能,通过对七种不同端径比的T300碳纤维复合材料单钉单剪螺栓连接结构进行静力拉伸试验,得到不同端径比的连接结构在25℃干态(RTD)和70℃平衡吸湿(ETW)环境下极限失效载荷和破坏强度的变化规律,揭示了接头的破坏模式;建立复合材料单钉单剪螺栓连接有限元模型,对比不同端径比的连接结构试验的极限失效载荷,得到最优端径比为3;研究了湿热环境下最优端径比的连接结构不同铺层的损伤形式。结果表明,端径比从1增大到3时,RTD和ETW环境下连接结构的极限失效载荷分别增加了1.1倍和1倍,破坏强度均增加了1倍,当端径比从3增大到4时,RTD和ETW环境下极限失效载荷分别降低了6.56%和9.08%,破坏强度分别降低了6.83%和9.35%;在最优端径比下,与RTD环境下相比,ETW环境下连接结构的极限失效载荷和破坏强度分别下降了9.25%和9.52%,并且层合板孔周的压缩损伤更严重,存在更明显的纤维束拔起及纤维碎裂。

叠合板式综合管廊侧墙连接节点面外抗震性能试验研究

叠合板式综合管廊属于半装配式结构,其接缝数量少,抗渗性能优越,应用前景广泛。为了研究采用灌浆套筒连接和浆锚搭接连接两种连接方式的叠合板式综合管廊侧墙在面外荷载作用下的抗震性能,该文开展了采用两类连接方式的足尺侧墙模型的面外低周反复试验,并与管廊现浇侧墙构件作对比。通过分析试件破坏模式、裂缝分布以及受力性能指标,初步揭示了不同连接方式对叠合板式侧墙面外抗震性能的影响。研究表明:叠合板式试件与现浇试件抗震性能基本一致,滞回曲线均较饱满,极限承载力与刚度退化规律基本一致,满足装配式结构等同现浇的抗震设计要求;两类叠合板式管廊侧墙试件延性系数分别为7.05和8.50,均具有良好的面外延性,满足我国抗震设计规范中变形能力要求;采用浆锚搭接连接的叠合板式试件与采用灌浆套筒连接的叠合板式试件相比,滞回曲线更加饱满,变形能力好,但峰值抗侧承载力低,相同侧向位移下损伤破坏严重;两种连接方式的均可有效传递钢筋应力直至构件破坏。

两种厚度的层合板单搭接胶接接头的静力与疲劳性能研究

针对两种厚度的复合材料单搭接胶接接头开展了静力与疲劳试验研究和静力数值分析。用虚拟裂纹闭合技术模拟搭接胶接界面,研究单搭接试件在轴向拉伸载荷作用下的裂纹起始和扩展原理。结果显示:损伤起始时刻,G_(Ⅲ)远远小于G_(Ⅰ),G_(Ⅱ);G_(Ⅰ)随着裂纹长度的增加而减小,G_(Ⅱ)随裂纹长度的增加而增大;界面损伤起始主要受面外剥离力的影响,裂纹扩展主要受滑移剪切力的作用。设计两种厚度的复合材料单搭接胶接接头的疲劳试验,得到了不同疲劳载荷下试件的疲劳寿命,并给出相应裂尖G_(Ⅰ)/G_(Ⅰ)C,G_(Ⅱ)/G_(Ⅱ)C的值;绘制N-G_(Ⅰ)/G_(Ⅰ)C,G_(Ⅱ)/G_(Ⅱ)C曲线发现,寿命随G_(Ⅰ)/G_(Ⅰ)C增加的递减幅度远远大于随G_(Ⅱ)/G_(Ⅱ)C变化的幅度;对比试件胶接界面破坏形式发现,与粘接层较薄试验件相比,粘接层较厚的试验件界面破坏形式较平滑,且胶层破坏面积所占比例较高;随着疲劳载荷值的增加,搭接区域胶层破坏面积所占比例减小,被粘接的复合材料纤维层撕裂面积增加。