M. Belbasi, M. Rezae,
Volume 5, Issue 2 (1-2020)
Abstract
Today in addition to Join by friction stir welding, the composite fabrication process is also performed simultaneously. The main purpose of the present research is to investigate the effect of pin geometry on the property of Aluminum 6061- alumina nanocomposite created by friction stir welding. For this purpose friction stir welding was carried out by selecting five types of pin geometries on Aluminum 6061 in which Al2O3 particles were deposited and the samples were examined by tensile and hardness tests, optical and electron microscope. Samples were investigated by tensile and hardness test, optical and electronic microscopy. Regular hexagonal pins due to having six smooth face and impulsive movement during rotation, caused a good perturbation which resulted in maximum tensile strength and elongation percentage of 198 MPa and 10.25 and minimum grain size of 13.3 micron, respectively. In the sample welded by a threaded cylindrical pin due to non-impact during rotation, inappropriate flow of reinforcing particles and its accumulation at perturbation the lowest tensile strength and elongation percentage of 133.5 MPa and 1.95%, respectively, were observed.
Ramin Delir Nazarlou, Dr Faraz Omidbakhsh, Dr Javad Mollaei Milani,
Volume 6, Issue 1 (8-2020)
Abstract
Friction stir welding (FSW) is an economic and high quality technique at aluminum welding and joining methods. The most important factor in the soundness of this type of welding, is the mechanism of material transfer in each tool rotation. The materials transfer during the welding process involves horizontal and vertical movement that caused by extrusion process and forging force (the tilt angle due to forging force and on the other hand, shape of pin due to the extrusion process). One of the most important parameters in FSW process is the effect of rotational speed in the welded zone. In this study, the effect of rotational speed at constant welding speed, in the butt joint of pure commercial aluminum, was investigated. The results of the study showed that, increasing the rotational speed due to increases the amount of material transfer in the weld zone. The welded zone was investigated by appearance weld zone experiments and using radiography tests. Also weld zone was investigated in macro and microstructure by using cross section. Then the micro hardness testing has been used by cross section at welded zone. In order to investigate the mechanism of materials transfer during the process, the electrical resistivity test has been used to analyses the amount of materials transfer in the weld zone. Results shows that, increasing rotational speed due to increasing the amount of materials transfer in the weld zone and decreasing the amount of defects in the weld zone.
M. Hajizadeh, S. Emami, T. Saeid,
Volume 6, Issue 1 (8-2020)
Abstract
Friction stir welding was conducted on AISI 304 austenitic stainless steel sheet with dimensions of
100 mm × 100 mm × 2 mm. The FSW was performed at a welding speed of 150 mm/min and rotational speeds of 400 and 800 rpm. The results showed that high frequency of low angle grain boundaries (LAGBs) were formed through dynamic recovery in the thermo-mechanically affected zone (TMAZ). Higher amount of LAGBs were developed in the TMAZ of welded sample with 800 rpm due to the higher amount of strain and heat generated. High fraction of high angle grain boundaries were formed in the stir zone (SZ) of the welded samples through the occurrence of continuous dynamic recrystallization (CDRX). A very fine microstructure developed in the sampled welded with lower rotational speed. Analysis of texture using {111} Pole figures showed the formation of shear texture components in the SZ of both welded samples. The intensity of the obtained texture for the sample welded with 800 rpm was greater. The formation of shear texture components in the SZ of both samples implied the occurrence of CDRX mechanism
Hamed Tirband, Davood Akbari, Mohammad Golzar,
Volume 7, Issue 1 (8-2021)
Abstract
In this research, tensile strength of ultrasonic welded parts made of thermoset polymer-reinforced glass fiber with surface preparation has been investiagted. In order to elevate the adhesion of two surfaces laser grooving method has been applied. Two type of thermoplastic materials including Plymethyl methacrylate (PMMA) and polypropylene (PP) have been used as interlayers. Influences of main welding parameters were investigated. The results show that the force and compression parameters in these joints have been ineffective parameters and in higher weld welds, the thermosetting resin has started thermal degradation. The pressure considered constant and set at 2 bar, welding time set at 1.6 seconds and holding time considered 3 seconds. The results showed that the minimum tensile strength of welded samples with laser surface preparation method is 1286 N, which is much more than maximum tensile strength of welded samples without any surface preapration. This indicates that laser beam surface preparation is an effective method in improving of the adhesion strength of thermoset polymeric parts.
Mehdi Safari, Amir Hossein Rabiee, Jalal Joudaki,
Volume 7, Issue 1 (8-2021)
Abstract
Resistance Spot Welding (RSW) is one of the effective manufacturing processes used widely for joining sheet metals. Prediction of weld strength of welded samples has great importance in manufacturing and different methods are used by researchers to find the fracture force. In this article, the Adaptive Neuro-Fuzzy Inference System (ANFIS) is utilized for prediction of joint strength in welded samples by RSW. A design of experiments (DOE) is prepared according to effective process parameters includes welding current, welding cycle, cooling cycle and electrode force. The sheet metal samples prepared from AISI 1075 carbon steel. Tensile test specimens are prepared and the tensile-shear strength of welded samples are measured. A model is developed according to ANFIS and trained according to teaching-learning based optimization algorithm. 70 % of test data used for network train and the remained 30 % used for access the accuracy of trained network. The accuracy of the trained network was assessed and the results show that the trained network can predict the joint strength with high accuracy. The determination factor (R2) and mean absolute percentage error (MAPE) are 0.99 and 0.48 % for trained data and 0.95 and 6.2% for test data.
Dr. Mohammad Yousefieh,
Volume 7, Issue 1 (8-2021)
Abstract
In this paper, using the Taguchi method, the parameters affecting the toughness of super duplex stainless steels in friction stir welding were optimized. In order to achieve optimal conditions, maximum toughness, the quality characteristic was used as the higher the better. Analysis of Taguchi results showed that in order to achieve optimal conditions in super duplex stainless steel weldments must have a tool rotational speed of 500 rpm, a welding speed of 60 mm / min, an initial pressure of 70 MPa and a tool tilt angle with the workpiece is equal to 3 degrees. Under optimal conditions, the toughness obtained from the confirmation test was 61 J, which was very close to the predicted toughness (58 J). Analysis of variance was also performed on the results of signal to noise (S/N) ratio. According to the results of analysis of variance, the tool rotational speed parameter with an influence percentage of 64% was the most effective parameter on toughness in friction stir welding of super duplex stainless steels. On the other hand, the parameters of welding speed (with an influence percentage of 17 %), initial 2 pressure (with an influence percentage of 16%) and tool tilt angle to the workpiece (with an influence percentage of 3%) were in the next ranks. Also, SEM micrographs from fracture surface of the samples in the impact test proved that the sample that had the least toughness in the impact test had a cleavage morphology and as a result, brittle fracture. This was while the morphology of the fracture surface of the tested sample under optimal conditions (with the highest toughness in this study = 61 J) had a large amount of fine and deep dimples. The presence of these dimples in large quantities indicated ductile fracture and eventually reaching the highest toughness.
Majid Aslani, Mahdi Rafiei,
Volume 7, Issue 2 (1-2022)
Abstract
In this study, in order to modify the weld structure obtained from repair welding of AZ91C magnesium alloy and improvement of tensile strength, input parameters such as current intensity and preheating temperature were optimized for this alloy. T6 heat treatment was separately done befor and after the welding to homogenize the microstructure and improvement of the mentioned properties. Using variance analysis, the accuracy of the models was checked and analyzed. Optical microscopy, scanning electron microscopy (SEM), Energy dispersive X-ray spectroscopy (EDS) and tensile tests were used to characterize the microstructure and mechanical properties of the repaired parts. The results of microstructural studies showed that the samples 2 (samples that were subjected to T6 heat treatment before and after welding) had continuous precipitates which these precipitates affected the strength due to the interruption of more slip planes and creating stronger barriers in the path of dislocations, resulting the better mechanical properties as compared with samples 1 (samples that were subjected to heat treatment only after welding). Also, by plotting response surface graphs and level diagrams, the highest tensile strength for samples 1 was observed at preheating temperatures of 493 to 513 K and current intensities of 80 to 90 A, and for samples 2 at temperatures of 513 to 553 K and current intensities of 100 to 110 A.
H. Sabet, R. Tahavori, A. Alimoradi,
Volume 7, Issue 2 (1-2022)
Abstract
Effect of Interlayer Composition on the Microstructure and Mechanical Properties of 1050 Aluminium to St14 Carbon Steel Joint Via Resistance Spot Welding Method.
Behrooz Beidokhti, Amin Ghorbani,
Volume 7, Issue 2 (1-2022)
Abstract
The present study investigated the effect of electrode composition and buffer layer on the microstructure and mechanical properties of H13 tool steel repair welds. Three specimens were welded applying two conditions; i.e. with and without stainless steel underlay. The microstructure of all weld metals contained the martensitic matrix with distributed chromium carbide precipitations. The microstructure of the underlay was a mixture of austenite and layers of ferrite with the skeletal morphology. The results showed that hardness of the welded substrates with underlay was higher than that of the specimens without underlay. This difference could be more than 240 HV. However, the highest hardness values were obtained in the heat affected zone of welds. The application of tough underlay improved the weld toughness and bending properties of the welded specimens. Also, it encouraged the ductile fracture mode in weldments. Also, the higher hardness of weld metal could be resulted from the application of buffer layer.
Dr Homam Naffakh-Moosavy, Eng. Ali Rasouli,
Volume 7, Issue 2 (1-2022)
Abstract
In this research similar joining of NiTi shape memory alloy was studied. For this purpose, NiTi alloy in the form of wires with circular cross section possessing martensitic phase structure at room temperature was used. By utilizing Nd:YAG pulsed laser welding method followed by optimizing its technical parameters, a defectless joint in terms of appearance and metallurgical properties was obtained. In the next step, the effect of various pulsed laser duration time on properties of the obtained similar joint of NiTi was investigated. Moreover, the resultant microstructures were studied using optical microscope (OP) and Scanning Electron Microscope (SEM) equipped with chemical analysis of EDS. Furthermore, the samples prepared under different pulsed laser duration time conditions were characterized by using tensile and micro-hardness tests. Investigating the results of the performed evaluations revealed that higher levels of heat input has resulted in grain growth, dissolution of precipitations as well as reduction in hardness and ultimate tensile strength of the samples in the joint zone.
Hosseinn Soleimani, Kamran Amini, Farhad Gharavi,
Volume 7, Issue 2 (1-2022)
Abstract
In this research, butt joining of Al2024 and Al7075 plates were performed by Friction Stir Welding (FSW) and the effect of tool position on microstructural and mechanical properties in about 1 mm from center line of joint towards the advancing side (AS) and the retreating side (RS) was investigated at three positions of +1, 0, -1 mm. In this regard, the plates of Al2024 and Al7075 were selected as the AS and the RS, respectively. In this joining method, transvers speed of 200 mm/min and tool rotation speed of 600 rpm were chosen. Macro- and Micro- structures of various welding areas and fractography of samples were evaluated by optical and scanning electron microscopies. In addition, mechanical properties were investigated using micro-hardness and tension tests. From the obtained macro-structures, it was observed that in all three joints, the surface of weld was without any defects (i.e., porosity, lack of penetration…). With varying tool offset position, welding micro-structure morphology was changed from homogeneous mode to layer or onion ring- shaped mode. Moreover, with varying tool position into the AS-side, tensile strength increased about 17.5% as opposed to the zero-tool position, but there was a decreasing about in tensile strength with changing tool position towards the RS-side as compared with the zero-tool position. Value of micro-hardness was approximately similar in all welded samples, but the highest value of hardness was observed at the weld zone (WZ). Thus, the obtained results showed that with varying tool position into the AS-side, mechanical properties were improved as opposed to the zero-tool position and tool position towards the RS-side.
M.h. Zakeri, A.r. Nasresfahani, S.m. Barekat,
Volume 7, Issue 2 (1-2022)
Abstract
In this research, the microstructure of Inconel 625 cladded layer on ASTM A575 steel has been investigated. By examining different parameters, the optimal single-pass sample with the least amount of dilution, porosity and fusion and suitable wetting angle was determined. Then cladding process with the optimal parameter was performed. The microstructure of the cladding layer was evaluated from the base metal to the top. Due to different cooling rates, dendritic morphologies were observed at different distances. Also, the cladding layer was free of any cavities, porosity and cracks and its thickness was 0.9 mm (900 micrometers). The results of (XRD) and (EDS) analyzes indicate thatthe γphase is formed and there is a relatively uniform distribution of elements in the cladding layer. These results also indicate that no change in the chemical composition of the substrate surface was achieved near the interface.The hardness test results also show that the hardness starts from 450 VHN at the top surface and reaches to 135 VHN in the base metal with a gentle slope. This slope of hardness can be attributed to the cooling or heating rates of the substrate.
Homan Nikbakht1, Mohammadreza Khanzadeh, Hamid Bakhtiari,
Volume 7, Issue 2 (1-2022)
Abstract
In the present study, the corrosion behavior and microstructural changes of 5000 series aluminum and copper sheets after the explosive welding process have been investigated. Explosive welding is performed with a fixed stop interval and change of explosive load. Dynamic potential polarization tests and electrochemical impedance spectroscopy, light microscopy, and scanning electron microscopy were used. The results of TOEFL polarization curves show that the lowest corrosion velocity was related to the sample with an explosive load of 1.5 and the highest corrosion velocity was related to the sample with an explosive load of 2.5. The corrosion resistance of a sample with an explosive load of 2.5 is less than that of a sample with an explosive load of 1.5 due to more severe plastic deformation at the joint. The metallographic results show a wave-vortexing of the joint due to the increase in the explosive charge. The results of the impedance test in welded samples showed that the value of n (experimental power parameter) decreased with wave-vortexing of the joint and the sample with 2.5 explosive load had the highest corrosion rate. Based on the results of scanning electron microscopy, it was observed that with an increasing explosive charge, the thickness of the local melting layer gradually increases.
Mr. N. Taheri Moghaddam, Dr. A. Rabiezadeh, Dr. A. Khosravifard, Dr. L. Ghalandari,
Volume 7, Issue 2 (1-2022)
Abstract
Conventional fusion welding of aluminum alloys results in coarse-grained structure, inevitable defects, and significant softening in the welding region. Friction stir welding with bobbin tool is a technique of friction stir welding method that has a great potential for developing applications of friction stir welding method in marine, aerospace, and automotive industries due to having an extra shoulder. Sheets of 5083 aluminum alloy with a thickness of 3 mm were welded using the bobbin tool friction stir welding method to assess the feasibility of similar joining. The effect of different process variables such as shoulder pinching gap, transverse speed and tool rotation speed was investigated. The results showed that a sound joint is achieved at a transverse speed of 13 mm / min and a tool rotation speed of 1350 rpm. The results of tensile test showed that the obtained joint efficiency is 94.5%, which is higher than the joint efficiency of fusion methods and comparable to the joint efficiency of conventional friction stir welding. Microscopic evaluation of the fracture surface of welded specimens showed that for similar joints, the dominant fracture mechanism is ductile fracture.
Dr Seyed Mahdi Rafiaei, Eng. Gholamhosein Eslami,
Volume 7, Issue 2 (1-2022)
Abstract
In this research, Ti-6Al-4V alloy sheet with a thickness of one millimeter with butt joint design was welded by tungsten-gas arc welding process using pulse current (PCGTAW) and using AMS 4954G filler metal. In this study, the effect of pulse system frequency on microstructure and mechanical properties was investigated by optical microscopy, Vickers hardness and tensile strength tests. In the non-frequency welding sample, due to the lack of pulse current and lower cooling rate of the molten pool, the formation of large amounts of soft phases of the Weidmann-Statten layer in the weld metal region is possible. Finally, in this method, the lowest average hardness of 341 Vickers was obtained. The experimental results showed that using pulsed current and increasing the pulse frequency up to 450 Hz increased the cooling rate of the molten pool, followed by increasing the amount of martensitic phase α 'in the form of a basket in the weld metal region and finally increasing the average microhardness in this region. In other words, using the maximum frequency led to a significant increase in hardness up to 367 Vickers in the weld zone. Finally, using the tensile strength test, it was shown that in all the samples, failure occurred from the base metal area, which was a very good phenomenon due to the proper welding quality of the samples.
Dr Behzad Binesh, Dr Sima Mirzaei, Mr Amin Taghi-Ahari,
Volume 7, Issue 2 (1-2022)
Abstract
Transient liquid phase (TLP) bonding of AISI 304L stainless steel was carried out using BNi-2 amorphous interlayer. The microstructure of the joint area was studied by using optical and scanning electron microscopes and energy dispersive spectroscopy. The effect of bonding temperature (1030-1110 °C) was studied on the microstructure and corrosion behavior of the TLP bonded samples. Electrochemical corrosion resistance of the bonded samples was evaluated in 3.5% NaCl solution at room temperature. The mechanism of the microstructure formation and the solidification sequence at the joint area were discussed. Ni- and Cr-rich borides, Ni-Si-B compound and fine Ni3Si particles were identified in the γ-Ni matrix at the joint centerline. The microstructural investigations revealed that the solidification sequence of these phases is: L→ γ + L → γ + Ni boride + Cr boride + L → γ + Ni boride + Cr boride + Ni-Si-B Compound. The highest corrosion resistance was observed in the sample bonded at 1070 °C for 30 min, which is comparable to that of the as-received AISI 304L stainless steel. It was attributed to the bond region microstructure with a negligible amount of eutectic constituents formed in the athermally solidified zone.
Dr. Seyedeh Zahra Anvari, Eng. Meysam Khandozi,
Volume 7, Issue 2 (1-2022)
Abstract
In the present study, to resolve the problems in fusion welding methods as well as to increase the strength, FSW method was used to join aluminum alloy sheets 6061 and 2024. Moreover, optimal parameters for joining of these two alloys were also taken into consideration. Various tool rotation speeds of 565, 950 and 1500 rpm were selected. For each tool rotation speed, two traverse speed variables, two penetration depth variables, and two tool angle variables were specified. The analysis of mechanical properties of welded samples was conducted through tensile and micro-hardness tests. Furthermore, microstructure of welding zone was investigated using optical and electron microscopes. The ratio of shoulder diameter to pin diameter is among the most significant and practical factors for welding tools. So, a shoulder diameter three times larger than that of pin diameter was selected. In the present study, alloy 2024 was placed at the precursor as the harder alloy. Tensile strength and indentation hardness of optimal specimen 300 MPa and 85 HV were achieved. Moreover, hardness behavior and tensile strength of heat-affected zone (HAZ) was evaluated to be lower in alloy 6061 compared to other zones.
M. Karbasian, N. Adabavazeh, M. Nikbakht,
Volume 7, Issue 2 (1-2022)
Abstract
One of the most dangerous industries is welding and inspection. Risk assessment is a rational procedure for determining the probable repercussions of prospective incidents on people, materials, equipment, and the environment. The risk assessment identifies the efficacy of selected control mechanisms and offers essential data for risk reduction, risk management, control system enhancement, and risk response planning. The current study identified 13 dangerous parts of the "hot crack" and "cold crack." The discovered dangers were then ranked by expert academics in the welding and inspection industries using the best worst fuzzy method. A fuzzy method has been developed to address risk uncertainty and minimize decision inconsistencies. The findings indicate that the primary risk factors for weld metal hot cracking in order of importance are "frozen structure, separation, high tensile stresses in the weld metal, material composition, bonding, preheating, high flow intensity, high-thickness workpiece, and weld pollen form." And "the quantity of hydrogen in the weld metal, high tensile stresses, a vulnerable structure, and a relatively low temperature" are all factors in cold welding of weld metal. The study's results may be used to guide the selection of solutions, remove the primary dangers, and establish security policies in the welding and inspection industries.
S.e. Moosavi, M. Movahedi, M. Kazeminezhad,
Volume 8, Issue 1 (8-2022)
Abstract
In this study, thermo-mechanical stability of two-pass constrained groove pressing (CGP) AA1050 sheets towards friction stir welding (FSW) employing hybrid powder (%50vol. micrometric graphite powder+%50vol. α-Al2O3 nanoparticles) was investigated by examining its microstructural evolutions and mechanical properties. FSW was carried out via different process variables in order to reach the highest ultimate mechanical properties of joints. The welding variables employed in this study were single-pass and multi-pass FSW, and different rotation speed to traverse speed ratios (ω/v) were. In order to appraise the powder effect on mechanical properties in the fabricated hybrid metal matrix composite (HMMC), some CGPed sheets were also welded with no powder. Besides optical microscopy and field emission scanning electron microscopy (FESEM) observations, Vickers microhardness and transverse tensile tests were conducted to examine mechanical properties of the weld zone. It was revealed that the effect of graphite powder as a solid lubricant was substantially influenced by the welding variables. More precisely, by employing graphite powder during the FSW, the peak temperature decreased to 224 ℃, while the peak temperature of 489 ℃ was resulted by welding without any powder. Thus, the thermo-mechanical stability of CGPed aluminum and their mechanical properties were enhanced. On the other hand, graphite powder can be responsible for mechanical properties drop due to deteriorating material flow. In addition, different strengthening mechanisms, including grain boundary Zener-pinning and particulate stimulated nucleation (PSN) mechanism, were provided and governed by both powders. However, increasing the ω/v ratio was a practical approach to obtain uniform powder distribution, and consequently, to attain ultimate mechanical properties. Moreover, weld soundness was perceived to be achievable by increasing the number of FSW passes due to eliminating the cavities and improved material flow, resulting in an ultimate tensile strength of 101 MPa, as an optimum efficiency of ~ %80, in three-pass FSW at ω/v=70.
S. Azghandirad, M. Movahedi, A. Kokabi, M. Tamizi,
Volume 8, Issue 1 (8-2022)
Abstract
Development of electronic industries, compression of electronic equipment, and removing lead from electronic circuits for environmental issues, resulted in a significant challenge in design and development of tin-based lead-free solders with physical and mechanical properties similar to old tin-lead alloys. In this regard, the set of Sn-Ag-Cu alloys with eutectic and near eutectic compositions have been proposed to replace Sn-Pb solders. As a lead-free solder alloy, low melting point, high reliability, and compatibility with various fluxes are among the properties of this category of alloys. In order to improve the properties of the joint, these solders are sometimes reinforced with different nanoparticles. In this study, Sn0.3Ag0.7Cu compound reinforced with graphene nanosheets with different weight percentages (0, 0.05, 0.1, and 0.2) was studied. Microstructure of the alloys was investigated by scanning electron microscopy(SEM) and optical microscopy. Melting temperature, wetting behavior and electrical resistivity of the solders were evaluated. According to the results, by adding graphene nanosheets, the wetting angle of the solder first decreased and then increased. This parameter showed the optimal amount for sample containing %0.1 graphene nanosheets with a %10 reduction. The melting point and electrical resistance of the solder alloy did not change significantly with compositing. With the addition of graphene nanosheets, the thickness of the intermetallic compounds Cu6Sn5 present at the interface between copper and solder was reduced up to %30.
