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Friction-Assisted Dissimilar Solid State Lap Joining of Aluminum and Copper Pipes
Ji-Won Kang,Shengwei Zhang,Tu-Anh Bui Thi,Sung-Tae Hong,Siwhan Lee,Heung Nam Han 한국정밀공학회 2023 International Journal of Precision Engineering and Vol.24 No.2
The friction-assisted solid state lap joining process of dissimilar metal pipes is proposed by joining copper (Cu) and aluminum (Al) pipes. The joining process is designed to have two successive stages. In the first stage, the Cu pipe rotating with a mandrel rotates against the inner surface of the Al pipe. In the first stage, the relative rotation between the Cu and Al pipes breaks the oxide layers on the contacting surfaces and increases the temperature at the interface. In the second stage, as the area of the contact surface between the Cu and Al pipes increases due to the linear motion of the mandrel; as the mandrel begins to rotate alone against the Cu pipe, which now becomes stationary to induce diffusion bonding between the Cu and Al pipes. The results of microstructural analysis and mechanical testing show that solid state lap joining between the Cu and Al pipes for a light-weight heat exchanging component is successfully achieved. The microstructure evolution suggests that grain refinement by recrystallization occurs in the joining region for both the Cu and Al sides.
소형선박용 5000계/6000계 알루미늄합금제의 마찰교반접합 특성 연구
조제형,김명현,최준웅,Cho, Je-Hyoung,Kim, Myung-Hyun,Choi, Jun-Woong 대한용접접합학회 2014 대한용접·접합학회지 Vol.32 No.1
There are so many difficulties of melt bonding mainly applied for hull construction of a aluminum alloy small boat. For resolving this problem, Friction stir welding(FSW) in non-melting solid state welding Process generally is applied in the transport industry. This paper is studied the joining strength characteristics and macrostructure according to dissimilar aluminium 5000/6000 alloy joining for a small boat applied for this FSW technology. It is reported that difference of joining strength in accordance with the direction of rotation in case of friction stir welding between dissimilar metals(Al/Cu, Al/Fe) is also highly large. In this study, Test is carried out by making the specimen according to the direction of rotation of dissimilar aluminium alloy joining.
서보모터방식 마찰용접을 이용한 TiAl 합금과 SCM440의 접합에 미치는 용접조건의 영향
박종문 ( Jong Moon Park ),김기영 ( Ki Young Kim ),김경균 ( Kyoung Kyun Kim ),오명훈 ( Myung Hoon Oh ) 한국열처리공학회 2016 熱處理工學會誌 Vol.29 No.2
In this study, characteristics of TiAl alloy and SCM440 (Cr-Mo steel) have been investigated with the various joining condition by servo motor type friction welder. The experimental factors of friction welder used in this study are spindle revolution, friction speed, and distance, upset speed and distance, respectively. Servo motor type friction welder could be controlled by the level of oil pressure, and it could be performed by position control dependence of electrical energy. Mechanical properties and morphology of welded interface were characterized by various joining condition. This aroused due to the bond strength dependence on friction heat and size of the heat affected zone. Therefore, it is necessary to have enough friction heat and decreased heat affected zone for good friction welding between dissimilar metals. An optimum bond was obtained between TiAl alloy and SCM440 by controlling friction speed and distance. At the spindle revolution 4,000 rpm, friction speed 120 mm/ min, friction distance 15 mm, the bond strength was found to be 312 MPa. (Received February 11, 2016; Revised February 17, 2016; Accepted February 25, 2016)
마찰교반용접(FSW)을 이용한 순 티타늄 판재의 용접부 특성 대한 연구
이종식(Jong-Sik Lee),안현모(Hyun-Mo Ann) 산업기술교육훈련학회 2012 산업기술연구논문지 (JITR) Vol.17 No.4
Titanium and titanium alloy is widely used in heat exchangers due to its unique character of corrosion resistance from the sea water and big in specific strength. Especially the pure titanium is optimum to make heat exchange panels, as pure titanium is good for mold-ability. However there is a potential risk of a flaw in welding when using titanium, due to its strong chemical attraction with oxygen, nitrogen and hydrogen and the characteristic of welded part which is weaker and lighter compared to the deposited metal zone and the parent metal. As a consequence, instead of typical connection methods of fusion welding such as MIG (metal inert gas), TIG (tungsten inert gas) welding, GMAW(gas metal arc welding), laser welding or electron beam welding, the friction stir welding is perceived as more eco friendly, and economic connection method since it is unnecessary to use additional heat source, welding rod and filler metal, as well as there is no spatter, harmful ray or material while connecting. Friction stir welding is when materials near the tool area becomes soften by the friction heat occurred from the friction between the tool and binder, while the materials on the sides of the composite plane are forced to blend by the plastic deformation and flow from the rotary motion of the tool, and the binder joints after cool down. There are 4 major types of titanium – pure titanium, α alloy, α+β alloy and β alloy. Pure titanium Grade 2, one of the most popularly used types of titanium also has been used in this study. Angle butt joint and lap joint of 2mm thick pure titanium panels will be executed using friction stir welding, and then a macroscopic observation will be undertaken about each welding method’s micro Vickers hardness test, maximum load resistance test, the ultimate strength, stress-strain diagram, of the welded part using the produced specimen. The examination results of the tension test, hardness test and modified structure after the execution of butt joint and lap joint friction stir welding using the pure titanium panels are as follow: ⑴ The result demonstrated that the tension and hardness under lap joint welding measured lower than butt joint welding, as the tension force decreased due to the welded part highly affected by the friction heat which lead to weaken of it. ⑵ Having checked on the fractured part after the tension test, butt joint welding method showed typical dimple type refined structure due to ductile fracture while lap joint welding method showed cleavage type microstructural feature due to brittle fracture. ⑶Having observed on the microscopic organization after friction stir welding, it has been revealed that it transforms into a different structure from the parent metal. The structure on the stir zone becomes more fineness structural than the parent metal, and such incident happened more on the lap joint welding which has a higher revolution speed of welding roll. ⑷ When executing friction stir welding using 2mm thick pure titanium panel, butt joint welding seems to be more ideal than lap joint welding in terms of mechanical characterization and microstructural characterization.
박정수(Jung-Soo Park),신형섭(Hyung-Seop Shin),Y. Yokoyama,A. Inoue 대한기계학회 2007 대한기계학회 춘추학술대회 Vol.2007 No.10
In this study, using a devised friction welding apparatus which incorporates a pneumatic actuator and gripper to give a precise control of the friction time and pressure, the friction welding of Zr-based bulk metallic glasses (BMG) to crystalline metals has been tried. The shape and volume of the protrusion formed at the weld interface were investigated. As crystalline metals, Ti-alloys, Al-alloys and a Zr-metal were adopted. In order to characterize the friction welded interface, micrographic observation and X-ray diffraction analysis on the weld cross-section were carried out. A successful joining of the Zr-based bulk metallic glasses(BMG) to crystalline metals could be obtained certain pairs of materials combination used and through the precise control of friction conditions. The residual strength after welding bulk metallic glasses(BMG) to crystalline was evaluated by the four-point bending test and compared with the cases of friction welding to similar materials.
마찰교반 점용접(FSJ)을 이용한 자동차용 Al 합금의 접합성 평가
조현진,김흥주,천창근,장웅성,방국수,Cho, Hyeon-Jin,Kim, Heung-Ju,Cheon, Chang-Keun,Chang, Woong-Seong,Bang, Kook-Soo 대한용접접합학회 2006 대한용접·접합학회지 Vol.24 No.1
In an attempt to optimize friction spot joining process of Al alloys for automobiles, effects of joining parameters such as tool rotating speed, plunging depth, and joining time on the joints properties were investigated. A wide range of joining conditions could be applied to join Al alloys for automobile without defects in the weld zone except for certain welding conditions with a lower heat input. For sound joints without defects, tensile shear strength of joints was higher than acceptable criteria of tensile shear strength of resistance spot welded joints for aluminum.
마그네슘합금(AZ31B) 판재의 마찰교반 점용접시 접합특성에 미치는 툴 속도의 영향
신형섭,정윤철,최광,Shin, Hyung-Seop,Jung, Yoon-Chul,Choi, Kwang 대한용접접합학회 2011 대한용접·접합학회지 Vol.29 No.2
In this study, the friction stir spot welding (FSSW) of Mg alloy sheets has been tried using an apparatus devised with a CNC milling machine to give the precise control of joining condition including tool speed. The probe tool used is made of hard metal and composed of cylindrical shoulder and pin parts. The variation of morphologies formed after the friction stir spot welding depending on the plunge speed of the tool were investigated at each rpm of tool. The history of the temperature distribution and the vertical load induced during the spot welding with friction time were measured by using an Infrared Thermal Imager (THERMA CAMTM SC2000) and a loadcell located below the specimen fixture, respectively. Tensile-shear tests were also performed to evaluate the fracture load of welded specimens. In order to characterize the friction stir spot welding of Mg alloy sheets, the variation of the fracture load was discussed on micrographic observations, temperature distribution during the FSSW according to the plunge speeds of tool.
황빛나(B.N. Hwang),이찬주(C.J. Lee),김재영(J.Y. Kim),이상곤(S.K. Lee),고대철(D.C. Ko),김병민(B.M. Kim) 대한기계학회 2009 대한기계학회 춘추학술대회 Vol.2009 No.5
Hybrid clinching is a combination of adhesive bonding and clinching joining method to attach similar or dissimilar materials. During the hybrid clinching process, the adhesive applied on each adherend and reduce d the friction between adherends as lubricant. In this study, the effect of frictional characteristics of adhesive on deformation of adherend in clinching process was investigated by using the FE-analysis. From the result of FE-analysis, the neck thickness was increased and undercut was decreased with increasing of frictional coefficient. The flat friction test was performed to evaluate the frictional coefficient of adhesive. And hybrid clinching experiment was performed and compared its cross section with FE-analysis result with the frictional coefficient of adhesive. It had good agreement between experiment and FE-analysis.
김영표(Young-Pyo Kim),김철희(Cheol-Hee Kim),김영곤(Young-Gon Kim),주성민(Sung-Min Joo) 대한용접·접합학회 2016 대한용접·접합학회지 Vol.34 No.3
At present, FSW(friction stir welding) process is being considered as an actual way for production of various industrial products. However FSW process involves high temperature and load on the tool during welding. These are make a difference between FSW machine and general machine tools. From this reason, development of FSW machine needs very careful consideration on stiffness of machine structure, spindle and moving axis including machine control system. In this study authors investigate on the trends of technology development of FSW machine in order to share the information for more extension of FSW technology with related researchers and engineers.