Microstructure,Corrosion and Mechanical Properties of Medium-Thick 6061-T6 Alloy/T2 Pure Cu Dissimilar Joints Produced by Double Side Friction Stir Z Shape Lap-Butt Welding

A novel double side friction stir Z shape lap-butt welding(DS-FSZW)process was proposed to achieve excellent mechanical properties of Al/Cu medium-thick dissimilar joints.The influence of welding parameters on weld microstructure and properties of DS-FSZW joint were systematically investigated.It indicated that defect-free medium-thick Al/Cu DS-FSZW joint could be achieved under an optimal welding parameter.DS-FSZW joint was prone to form void defects in the bottom of the second-pass weld.The recrystallization mechanisms at the top and middle of the weld nugget zone(WNZ)were continuous dynamic recrystallization(CDRX)and geometric dynamic recrystallization(GDRX).While the major recrystallization mechanism at the bottom of the WNZ was GDRX.DS-FSZW joint of the optimal welding condition with 850 r/min-400 mm/min was produced with a continuous thin and crack-free IMCs layer at the Al/Cu interface,and the maximum tensile strength of this joint is 160.57 MPa,which is equivalent to 65.54%of pure Cu base material.Moreover,the corrosion resistance of Al/Cu DS-FSZW joints also achieved its maximum value at the optimal welding parameter of 850 r/min-400 mm/min.It demonstrates that the DS-FSZW process can simultaneously produce medium-thick Al/Cu joints with excellent mechanical performance and corrosion resistance.

Shear mechanical properties and fracturing responses of layered rough jointed rock-like materials

This study aims to investigate mechanical properties and failure mechanisms of layered rock with rough joint surfaces under direct shear loading.Cubic layered samples with dimensions of 100 mm×100 mm×100 mm were casted using rock-like materials,with anisotropic angle(α)and joint roughness coefficient(JRC)ranging from 15°to 75°and 2-20,respectively.The direct shear tests were conducted under the application of initial normal stress(σ_(n)) ranging from 1-4 MPa.The test results indicate significant differences in mechanical properties,acoustic emission(AE)responses,maximum principal strain fields,and ultimate failure modes of layered samples under different test conditions.The peak stress increases with the increasingαand achieves a maximum value atα=60°or 75°.As σ_(n) increases,the peak stress shows an increasing trend,with correlation coefficients R² ranging from 0.918 to 0.995 for the linear least squares fitting.As JRC increases from 2-4 to 18-20,the cohesion increases by 86.32%whenα=15°,while the cohesion decreases by 27.93%whenα=75°.The differences in roughness characteristics of shear failure surface induced byαresult in anisotropic post-peak AE responses,which is characterized by active AE signals whenαis small and quiet AE signals for a largeα.For a given JRC=6-8 andσ_(n)=1 MPa,asαincreases,the accumulative AE counts increase by 224.31%(αincreased from 15°to 60°),and then decrease by 14.68%(αincreased from 60°to 75°).The shear failure surface is formed along the weak interlayer whenα=15°and penetrates the layered matrix whenα=60°.Whenα=15°,as σ_(n) increases,the adjacent weak interlayer induces a change in the direction of tensile cracks propagation,resulting in a stepped pattern of cracks distribution.The increase in JRC intensifies roughness characteristics of shear failure surface for a smallα,however,it is not pronounced for a largeα.The findings will contribute to a better understanding of the mechanical responses and failure mechanisms of the layered rocks subjected to shear loads.

A review of mechanical deformation and seepage mechanism of rock with filled joints

Various defects exist in natural rock masses,withfilled joints being a vital factor complicating both the mechanical characteristics and seepage mechanisms of the rock mass.Filled jointed rocks usually show mechanical properties that are weaker than those of intact rocks but stronger than those of rocks with fractures.The shape of the rock,filling material,prefabricatedfissure geometry,fissure roughness,fissure inclination angle,and other factors mainly influence the mechanical and seepage properties.This paper systematically reviews the research progress andfindings onfilled rock joints,focusing on three key aspects:mechanical properties,seepage properties,andflow properties under mechanical response.First,the study emphasizes the effects of prefabricated defects(shape,size,filling material,inclination angle,and other factors)on the mechanical properties of the rock.The fracture extension behavior of rock masses is revealed by the stress state of rocks withfilled joints under uniaxial compression,using advanced auxiliary test techniques.Second,the seepage properties of rocks withfilled joints are discussed and summarized through theoretical analysis,experi-mental research,and numerical simulations,focusing on organizing the seepage equations of these rocks.The study also considers the form of failure under stress-seepage coupling for both fullyfilled and partiallyfilledfissured rocks.Finally,the limitations in the current research on the rock withfilled joints are pointed out.It is emphasized that the specimens should more closely resemble real conditions,the analysis of mechanical indexes should be multi-parameterized,the construction of the seepage model should be refined,and the engineering coupling application should be multi-field-multiphase.

Microstructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding

The dissimilar friction stir welding of pure copper/1350 aluminum alloy sheet with a thickness of 3 mm was investigated. Most of the rotating pin was inserted into the aluminum alloy side through a pin-off technique, and sound welds were obtained at a rotation speed of 1000 r/min and a welding speed of 80 mm/min. Complicated microstructure was formed in the nugget, in which vortex-like pattern and lamella structure could be found. No intermetallic compounds were found in the nugget. The hardness distribution indicates that the hardness at the copper side of the nugget is higher than that at the aluminum alloy side, and the hardness at the bottom of the nugget is generally higher than that in other regions. The ultimate tensile strength and elongation of the dissimilar welds are 152 MPa and 6.3%, respectively. The fracture surface observation shows that the dissimilar joints fail with a ductile-brittle mixed fracture mode durin~ tensile test.

Numerical Computation of Stress Intensity Factors for Bolt-hole Corner Crack in Mechanical Joints

The three-dimensional finite element method is used to solve the problem of the quarter-elliptical comer crack of the bolt-hole in mechanical joints being subjected to remote tension. The square-root stress singularity around the corner crack front is simulated using the collapsed 20-node quarter point singular elements. The contact interaction between the bolt and the hole boundary is considered in the finite element analysis. The stress intensity factors （SIFs） along the crack front are evaluated by using the displacement correlation technique. The effects of the amount of clearance between the hole and the bolt on the SIFs are investigated. The numerical results indicate that the SIF for mode I decrease with the decreases in clearance, and in the cases of clearance being present, the corner crack is in a mix-mode, even if mode I loading is dominant.

Mechanical properties of monodirectional Gutou mortise-tenon joints of the traditional timber buildings in the Yangtze River region

The mechanical properties of the monodirectional Gutou mortise-tenon joints of the ancient Chinese traditional timber buildings in the Yangtze River region were studied using the experimental method. Three monodirectional Gutou mortise-tenon joints were designed according to the actual configurations. The failure modes,the hysteretic curves,the skeleton curves, the rotation rigidities, and the energy dissipation capacity of this type of mortise-tenon joints under the low cyclic reversed loading were obtained. The results show that the hysteretic curves of the monodirectional Gutou mortise-tenon joints appear to be Z shape and have obvious pinch effects. During the process of the test,these mortisetenon joints pass orderly through the elastic stage,the yield stage and the failure stage. The energy dissipation capacity of these mortise-tenon joints generally decreases with the increase in the rotation angle. The equivalent viscous damping coefficients of the monodirectional Gutou mortise-tenon joints are between 0. 161 and 0. 193. The results can provide the theoretical base for the computing analysis and repair design of Chinese traditional timber buildings in the Yangtze River region.

Mechanical Properties Prediction of the Mechanical Clinching Joints Based on Genetic Algorithm and BP Neural Network

For optimal design of mechanical clinching steel-aluminum joints, the back propagation （BP） neural network is used to research the mapping relationship between joining technique parameters including sheet thickness, sheet hardness, joint bottom diameter etc., and mechanical properties of shearing and peeling in order to investigate joining technology between various material plates in the steel-aluminum hybrid structure car body. Genetic algorithm （GA） is adopted to optimize the back-propagation neural network connection weights. The training and validating samples are made by the BTM Tog-L-Loc system with different technologic parameters. The training samples＇ parameters and the corresponding joints＇ mechanical properties are supplied to the artificial neural network （ANN） for training. The validating samples＇ experimental data is used for checking up the prediction outputs. The calculation results show that GA can improve the model＇s prediction precision and generalization ability of BP neural network. The comparative analysis between the experimental data and the prediction outputs shows that ANN prediction models after training can effectively predict the mechanical properties of mechanical clinching joints and prove the feasibility and reliability of the intelligent neural networks system when used in the mechanical properties prediction of mechanical clinching joints. The prediction results can be used for a reference in the design of mechanical clinching steel-aluminum joints.

The microscopic mechanical performance for nonuniform welded joint of nickel-based alloy with nanoindentation

To quantify the nonuniform micromechanical performance of welded joint,the load-displacement curves by nanoindentation test were introduced to examine different zones including base metal,coarse grained heat affected zone,partially melted zone,weld metal near the fusion boundary and weld metal center.The results showed that the strengthening effect of weld metal was more obvious than that of heat affected zone for nickel based welded joint and especially in coarse grained heat affected zone,the hardening resulted from overheating was not apparent.Nickel based weld metal with high content of alloying elements which were often segregated at interdendritic regions or precipitated in grain interior under nonequilibrium solidification contributed to the characteristics that differ from conventional low alloy steel welded joint.

Microstructure and mechanical properties of dissimilar pinless friction stir spot welded 2A12 aluminum alloy and TC4 titanium alloy joints

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.

Microstructure and high-temperature mechanical properties of laser beam welded TC4/TA15 dissimilar titanium alloy joints

The microstructure evolution and high-temperature mechanical properties of laser beam welded TC4/TA15 dissimilar titanium alloy joints under different welding parameters were studied.The results show that the weld fusion zone of TC4/TA15 dissimilar welded joints consists of coarsenedβcolumnar crystals that contain mainly acicularα’martensite.The heat affected zone is composed of the initialαphase and the transformedβstructure,and the width of heat affected zone on the TA15 side is narrower than that on the TC4 side.With increasing temperature,the yield strength and ultimate tensile strength of the TC4/TA15 dissimilar welded joints decrease and the highest plastic deformation is obtained at 800°C.The tensile strength of the dissimilar joints with different welding parameters and base material satisfies the following relation(from high to low):TA15 base material>dissimilar joints>TC4 base material.The microhardness of a cross-section of the TC4/TA15 dissimilar joints reaches a maximum at the centre of the weld and is reduced globally after heat treatment,but the microhardness distribution is not changed.An elevated temperature tensile fracture of the dissimilar joints is located on the side of the TC4 base material.Necking occurs during the tensile tests and the fracture characteristics are typical when ductility is present in the material.

Microstructure and mechanical properties of laser beam welded TC4/TA15 dissimilar joints

The microstructure and mechanical properties of laser beam welded dissimilar joints in TC4 and TA15 titanium alloyswere investigated. The results showed that the coarse columnar grains containing a large amount of acicular α and martensite α′ werepresent in the fusion zone (FZ), some residual α phases and martensite structure were formed in the heat-affected zone (HAZ) onTC4 side, and bulk equiaxed α phase of the HAZ was on TA15 side. An asymmetrical microhardness profile across the dissimilarjoint was observed with the highest microhardness in the FZ and the lowest microhardness in TA15 BM. The orders of yield strengthand ultimate tensile strength were as follows: TC4 BM > TC4/TC4 similar joint > TA15 BM > TA15/TA15 similar joint > TC4/TA15dissimilar joint, and increased while hardening capacity and strain hardening exponent decreased with increasing strain rate from1×10?4 s?1 to 1×10?2 s?1. The TC4/TA15 dissimilar joints failed in the TA15 BM, and had characteristics of ductile fracture atdifferent strain rates.

Interfacial microstructure and mechanical properties of Ti-6Al-4V/Al7050 joints fabricated using the insert molding method

Ti-6Al-4V/Al7050 joints were fabricated by a method of insert molding and corresponding interfacial microstructure and mechanical properties were investigated. The interfacial thickness was sensitive to holding temperature during the first stage, and a good metallurgical bonding interface with a thickness of about 90 μm can be obtained at 750°C. X-ray diffraction, transmission electron microscopy, and thermodynamic analyses showed that the interface mainly contained intermetallic compound TiAl_3 and Al matrix. The joints featured good mechanical properties, i.e., shear strength of 154 MPa, tensile strength of 215 MPa, and compressive strength of 283 MPa, which are superior to those of joints fabricated by other methods. Coherent boundaries between Al/TiAl_3 and TiAl_3/Ti were confirmed to contribute to outstanding interfacial mechanical properties and also explained constant fracture occurrence in the Al matrix. Follow-up studies should focus on improving mechanical properties of the Al matrix by deformation and heat treatment.

Microstructures and mechanical properties of TC4/AZ91D bimetal prepared by solid-liquid compound casting combined with Zn/Al composite interlayer

To achieve Ti/Mg bimetallic composite with high strength and metallurgical bonding interface,Al interlayer and Zn/Al composite interlayer were used to prepare TC4/AZ91D bimetal composite with metallurgical bonding interface by solid-liquid compound casting,respectively.Al interlayer was prepared on the surface of TC4 alloy by hot dipping,and Zn/Al composite interlayer was prepared by electroplating process.The results suggested that the phases across the interface were Al Ti andα(Al)+Mg_(21)(Al,Zn)_(17)when Zn/Al composite interlayer was used.When Al interlayer was used as interlayer,Al Mg Ti ternary structure and Al_(12)Mg_(17)+δ-Mg eutectic structure were the main phases at the interface.The shear strength of TC4/AZ91D bimetal with Zn/Al composite interlayer was much higher than that with pure Al interlayer,and the value of the shear strength was increased from 48.5 to 67.4 MPa.Thermodynamic models based on different compositions of the interface were established to explain the microstructure evolution of the interfacial zone.

Modeling of Mechanical Behavior of Fractal Rock Joint

The present study shows that naturally developed fracture surfaces in rocks display the properties of self-affine fractals. Surface roughness can be quantitatively characterized by fractal dimension D and the intercept A on the log-log plot of variance: the former describes the irregularity and the later is statistically analogues to the slopes of asperities. In order to confirm the effects of these fractalparameters on the properties and mechanical behavior of rock joints, which have been observed in experiments under both normal andshear loadings, a theoretic model of rock joint is proposed on the basis of contact mechanics. The shape of asperity at contact is assumed to have a sinusoidal form in its representative scale r, with fractal dimension D and the intercept A. The model considers different local contact mechanisms, such as elastic deformation, frictional sliding and tensile fracture of the asperity. The empirical evolution law of surface damage developed in experiment is implemented into the model to up-date geometry of asperity in loading history. The effects of surface roughness characterized by D, A and re on normal and shear deformation of rock joint have been elaborated.

Study on the Basic Mechanical Behaviors of High Density Polyethylene Electrofusion Welded Joints at Different Temperature

The basic mechanical behaviors of high density polyethylene electrofusion welded joint at different temperatures were studied by using differently designed specimens in this paper. The results show that the strength of weld bonding plane is higher than that of the pipe and socket materials at room temperature. In order to get the shear strength of electrofusion welded joint, the effective bond lengths were reduced by cutting artificial groove through the socket. The effective bonding length of welded joint to get the shear strength is decreased with decreasing testing temperature. The shear strength and the sensibility to sharp notch of HDPE material increased with decreasing temperature.

A review of extreme condition effects on solder joint reliability:Understanding failure mechanisms

Solder joint,crucial component in electronic systems,face significant challenges when exposed to extreme conditions during applications.The solder joint reliability involving microstructure and mechanical properties will be affected by extreme conditions.Understanding the behaviour of solder joints under extreme conditions is vital to determine the durability and reliability of solder joint.This review paper aims to comprehensively explore the underlying failure mechanism affecting solder joint reliability under extreme conditions.This study covers an in-depth analysis of effect extreme temperature,mechanical stress,and radiation conditions towards solder joint.Impact of each condition to the microstructure including solder matrix and intermetallic compound layer,and mechanical properties such as fatigue,shear strength,creep,and hardness was thoroughly discussed.The failure mechanisms were illustrated in graphical diagrams to ensure clarity and understanding.Furthermore,the paper highlighted mitigation strategies that enhancing solder joint reliability under challenging operating conditions.The findings offer valuable guidance for researchers,engineers,and practitioners involved in electronics,engineering,and related fields,fostering advancements in solder joint reliability and performance.

Microstructure and mechanical property of resistance spot welded joint of aluminum alloy to high strength steel with especial electrodes

Dissimilar material joining of 6008 aluminum alloy to H220 YD galvanized high strength steel was performed by resistance spot welding with especial electrodes that were a flat tip electrode against the steel surface and a domed tip electrode upon the aluminum alloy surface. An intermetallic compound layer composed of Fe2Al5 and FeAl3 was formed at the steel/ aluminum interface in the welded joint. The thickness of the intermetallic compound layer increased with increasing welding current and welding time, and the maximum thickness being 7. 0 μm was obtained at 25 kA and 300 ms. The weld nugget diameter and tensile shear load of the welded joint had increased tendencies first with increasing welding current （ 18 -22 kA） and welding time （ 50 - 300 ms）, then changed little with further increasing welding current （ 22 - 25 kA） and welding time （300 -400 ms）. The maximum tensile shear load reached 5.4 kN at 22 kA and 300 ms. The welded joint fractured through brittle intermetallic compound layer and aluminum alloy nugget.

Effects of dry-wet cycles on the mechanical properties of sandstone with unloading-induced damage

Sandstone is the fundamental material in various engineering and construction projects.However,the mechanical integrity of sandstone can be compromised by initial unloading damage resulting from activities such as engineering excavations.Furthermore,this degradation is further exacerbated under periodic dry-wet environmental conditions.This study investigated the effects of dry-wet cycles and unloading on the mechanical properties of jointed fine sandstone using uniaxial and triaxial compression tests.These tests were performed on rock samples subjected to varying unloading degrees and different numbers of dry-wet cycles.The results demonstrate that with an increase in the unloading degree from 0%to 70%,there is a corresponding decrease in peak stress ranging from 10%to 33%.Additionally,the cohesion exhibits a reduction of approximately 20%to 25%,while the internal friction angle experiences a decline of about 3.5%to 6%.These findings emphasize a significant unloading effect.Moreover,the degree of peak stress degradation in unloading jointed fine sandstone diminishes with an increase in confining pressure,suggesting that confining pressure mitigates the deterioration caused by dry-wet cycles.Additionally,as the number of dry-wet cycles increases,there is a notable decline in the mechanical properties of the sandstone,evidencing significant dry-wet degradation.Utilizing the Drucker Prager criterion,this study establishes a strength criterion and fracture criterion,denoted as σ_(1)(m,n) and K_(T)^(Ⅱ)(m, n), to quantify the combined impacts of dry-wet cycles and unloading on jointed fine sandstone,which provides a comprehensive understanding of its mechanical behavior under such conditions.

Mechanical Behavior of a Glass-fiber Reinforced Composite to Steel Joint for Ships

The use of a glass-fiber reinforced composite in marine structures is becoming more common, particularly due to the potential weight savings. The mechanical response of the joint between a glass-fiber reinforced polymer （GRP） superstructure and a steel hull formed is examined and subsequently modified to improve performance through a combined program of modeling and testing. A finite-element model is developed to predict the response of the joint. The model takes into account the contact at the interface between different materials, progressive damage, large deformation theory, and a non-linear stress-strain relationship. To predict the progressive failure, the analysis combines Hashin failure criteria and maximum stress failure criteria. The results show stress response has a great influence on the strength and bearing of the joint. The Balsawood-steel interface is proved to be critical to the mechanical behavior of the joint. Good agreement between experimental results and numerical predictions is observed.

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.