• Journal of Powder Materials
• /
• v.31 no.1
• /
• pp.37-42
• /
• 2024

Friction stir spot welding (FSSW) is a solid-state joining process and a rapidly growing dissimilar material welding technology for joining metallic alloys in the automotive industry. Welding tool shape and process conditions must be appropriately controlled to obtain high bonding characteristics. In this study, FSSW is performed on dissimilar materials AA5052-H32 aluminum alloy sheet and SPRC440 steel sheet, and the influence of the shape of joining tool and tool insertion depth during joining is investigated. A new intermetallic compound is produced at the aluminum and steel sheets joint. When the insertion depth of the tool is insufficient, the intermetallic compound between the two sheets did not form uniformly. As the insertion depth increased, the intermetallic compound layer become uniform and continuous. The joint specimen shows higher values of tensile shear load as the diameter and insertion depth of the tool increase. This shows that the uniform formation of the intermetallic compound strengthens the bonding force between the joining specimens and increases the tensile shear load.

• Journal of Surface Science and Engineering
• /
• v.42 no.5
• /
• pp.240-245
• /
• 2009

The Friction Stir Welding (FSW) has mainly been used for making butt joints in Al alloys. Development of FSW would expand the number of applications. The FSW is a relatively solid-state joining process. This study possibility of a welding between C1020 and Al6063 by means of FSW has fundamentally clarified. The primary process parameters, such as a rotating speed, rotating direction of tool and off-set of pin periphery from materials interface were optimize, respectively.

• Journal of Welding and Joining
• /
• v.34 no.3
• /
• pp.6-11
• /
• 2016

Joining Al/Fe dissimilar metals is becoming a subject of special interest in the assembly of automotive parts as a trade-off between the weight lightening and the cost reduction. Although various studies have been introduced to join Al alloy with the steel sheet by fusion welding, weak joint strength and galvanic corrosion still remained as problems to be solved. As a solid state welding, friction stir welding has been preferred to fusion welding processes in the dissimilar metal joints. This study investigated friction stir spot welding (FSSW) of Al alloy to the thin steel sheet with a thickness of 0.65 mm. The conventional FSSW is a stationary spot welding process but new approach adopted an additional circumferential movement in company with high speed tool rotation. A full factorial experimental design was implemented, and the main and interaction effects of parameters were analysed on the failure load in the tensile shear test. The direction and radius of rotation were statistically significant parameters and these two parameters affected the joint width and the shape of the hook.

• Journal of Welding and Joining
• /
• v.26 no.6
• /
• pp.67-73
• /
• 2008

Three-dimensional transient simulation of laser-GMA hybrid welding involving multiple physical phenomena is conducted neglecting the interaction effect of laser and arc heat sources. To reproduce the bubble and pore formations in welding process, a new bubble model is suggested and added to the established laser and arc welding models comprehending VOF, Gaussian laser and arc heat source, recoil pressure, arc pressure, electromagnetic force, surface tension, multiple reflection and Fresnel reflection models. Based on the models mentioned above, simulations of laser-GMA hybrid butt welding are carried out and besides the molten pool flow, top and back bead formations could be observed. In addition, the laser induced keyhole formation and bubble generation duo to keyhole collapse are investigated. The bubbles are ejected from the molten pool through its top and bottom regions. However, some of those are entrapped by solid-liquid interface and remained as pores. Those bubbles and pores are intensively generated when the absorption of laser power is largely reduced and consequently the full penetration changes to the partial penetration.

• Journal of the Korean Society for Precision Engineering
• /
• v.33 no.4
• /
• pp.257-264
• /
• 2016

Solid state joining techniques are increasingly applied in a wide range of industrial applications. Friction welding is a solid state welding technique that is used to join similar or dissimilar materials. In this study, friction welding was applied to rotor shaft composed of a disk and a shaft. The disk and shaft were manufactured by hot forging and rolling, respectively. The aim of the study was to predict the structural characteristics during hot forging and friction welding process for rotor shaft of turbo charger. The structural characteristics were determined by heat input and heat affected zone (HAZ) during a short cycle time. Thus, transient FE analysis for hot forging and friction welding was based on heat transfer. The results were used to predict structural characteristics during hot forging and friction welding processes. The prototype of rotor shaft was manufactured by the result-based process parameters.

• Journal of Welding and Joining
• /
• v.15 no.3
• /
• pp.99-108
• /
• 1997

For the conventional welding method, the high heat transfer makes the crystallization of the work material unavoidable. Whereas the laser is able to weld the amorphous metal without a crystallized zone, because heat transfer is limited withn a very small restricted volume. In this paper, the possibilities and the limits of the laser welding in a deep frozen environment by liquid nitrogen were studied to utilize the advantageous properties of amorphous metal foils. The author investigated, after laser welding in a deep frozen environment with a solid state laser (Nd:YAG-laser), the achievable strengths and the influences of the laser beam parameters on the strengths.

• Journal of Welding and Joining
• /
• v.25 no.3
• /
• pp.28-36
• /
• 2007

A bulk amorphous NiTiZrSiSn powder produced using an inert gas atomization was sprayed by kinetic spraying process that is basically a solid-state deposition process onto a mild steel substrate. They were successfully overlaid onto the mild steel substrate. In order to evaluate the tribological behavior of the kinetic sprayed NiTiZrSiSn BMG (Bulk Metallic Glass) coatings, a partially crystallized coating and a fully crystallized coating were prepared by the isothermal heat treatments. Tribological behaviors were investigated in view of friction coefficient, hardness and amorphous phase fraction of coating layer. Surface morphologies and depth in the wear tracks were observed and measured by scanning electron microscope and alpha-step. From the examination of the scratch wear track microstructure, transition from the ductile like deformation (micro cutting) to the brittle deformation (micro fracturing) in the scratch groove was observed with the increase of the crystallinity.

• International Journal of Korean Welding Society
• /
• v.3 no.1
• /
• pp.34-38
• /
• 2003

It has been used many kinds of horizontal butt-welding methods at block-to-block erection stage in shipbuilding companies. For examples, some companies use conventional FCAW process with one side or both sides groove joint welding, others use carriage with torch holder type mechanized welding method. Although lots of efforts were done until now, some problems in quality and productivity still remain in ship's hull welding. In this study, we have attempted to raise productivity and quality on horizontal position of welding with following 3 items. 1) Prepare groove condition with no root gap for making easy fit-up work. 2) Develop improved MAG (100% $CO_2$ gas shielding) welding process with solid wire for making sound root bead from one side. 3) Develop and apply quite new automatic welding carriage. The stability of new welding process was confirmed by conducting mechanical tests of weldments to verify the soundness of weldments.

• Proceedings of the KWS Conference
• /
• 2005.06a
• /
• pp.393-395
• /
• 2005

The bonding for Aluminum and Copper in the air is investigated in this study. This bonding method does not include the special process of removing aluminum oxide films. In case of this bending, each metal Is heated at bonding temperature where is above eutectic temperature of Al-Cu system and below melting point of Aluminum. The liquefaction around the bonding surface occurs after the diffusion at solid state of each metal. This phenomenon is predicted by the temperature range above eutectic temperature of Al-Cu equilibrium phase diagram.

• Journal of the Korean Society for Heat Treatment
• /
• v.32 no.3
• /
• pp.124-130
• /
• 2019

Friction stir welding is one of the interesting welding methods for titanium and its alloy which proceeds with plastic flow due to thermo-mechanical stirring and friction heat. Solid-state welding can solve severe problems such as high-temperature oxidation, interstitial oxygen diffusion and grain coarsening by liquid-state welding. Dynamic recrystallization and grain refinement can vary significantly with the plunging load and rotational speed of tool during friction stir welding, and suitable process conditions must be optimized to obtain microstructure and better mechanical characteristics. Suitable FSW conditions were 1000 kg of plunging load and 200 rpm of rotational speed and it showed YS 270 MPa, UTS 332.1 MPa, and El 17.3%, which were very similar to those of wrought titanium sheet.