• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.3 s.174
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• pp.752-760
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• 2000

Mechanical press joining has been used in sheet metal joining processes because of its simple process and possibility of joining dissimilar metals, such as steel and aluminum. The strength of mechanical press joining varies with joining conditions. The optimum joining conditions considering tensile-shear and peel-tension strength have to be established to assure the reliability in the joining strength. Therefore, optimization of joining conditions has been investigated for improving joining strength of sheet metal. It is possible to obtain optimum strength from improvement on the joining strength of peel-tension mechanical press joint under multiaxial stress states.

• Journal of Welding and Joining
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• v.15 no.2
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• pp.43-53
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• 1997

The complete joining method for dissimilar press punch materials and its real-time evaluation method is not available at present. Brazing method has been used for joining them, but it is known that the welded joint by the brazing has the lower bonding efficiency and reliability than the diffusion welding. The friction welding with a diffusion mechanism in bonding was applied in this study. This work was carried out to determine the proper friction welding conditions and to analyze mechanical properties of friction welded joints of sintered carbide tool materials (SKNM50 for the blade part of press punch) to alloy steel (SCM440 for the shank part of press punch) using aluminum (A6061 for the interlayer material) as an insert material between the sintered carbide tool materials and the alloy steel. In addition, acoustic emission test was carried out during friction welding to evaluate the weld quality.

• International Journal of Advanced Culture Technology
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• v.3 no.1
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• pp.161-168
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• 2015

This article aims to apply a friction stir spot welding for producing a lap joint of AA1100 aluminum alloy and SGACD zinc coated steel. The experiment was designed by MINITAB and then investigated the relation among the friction spot joint parameters. The experimental results are as follows. The friction spot joining could successively produce the lap joint of AA1100 aluminum alloy and SGACD zinc coated steel. Interaction between the rotate speed, the hold time and the tool insert speed affected to vary the tensile shear strength of the lap joint. The prediction of the optimized welding parameters that indicated the tensile shear strength of 1966 N was the rotated speed of 4000 rpm, the pin hold time of 6 sec, the pin insert rate of 6 mm/min with the S/N ratio of 66.56 that was higher than that of the total mean S/N ratio. The practical experiment of the predicted welding parameters indicated the tensile shear strength of 2165 N and had the S/N ratio of 66.70 that was higher than the predicted tensile shear strength.

• Journal of Welding and Joining
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• v.22 no.5
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• pp.46-52
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• 2004

AlSi-Al$_2$O$_3$ composite layer was prepared by plasma spray on steel substrate. The composite powder for plasma spray was prepared by simple mechanical blending. The wear resistance of the composite layers and matrix aluminum alloy were performed in terms of size distribution of ceramic particles. Friction coefficients of AlSi were decreased with incorporation of $Al_2$O$_3$. The tribological properties of coated layers were affected by the size of incorporated $Al_2$O$_3$ particle. The reinforcement of $Al_2$O$_3$ particle into aluminum alloy matrix decreased the friction coefficient as well as wear loss.

• Journal of Korea Foundry Society
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• v.14 no.5
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• pp.455-463
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• 1994

Aluminum matrix composites reinforced by fine steel wires were fabricated by squeeze casting process. Preforms made of fine steel wires were prepared with different surface conditions, namely uncoated(TN), carbo-nitriding treated(TT), and brass coated(TA). Squeeze casting were performed under the pressure of $1500kg/cm^2$ for 3min. during solidification, and pouring temp. of the melt being $750^{\circ}C$ and the steel mold being preheated at $250^{\circ}C$. Microstructural characteristics were evaluated, particularly concerned with the effect of the surface conditions of the preforms. The results obtained from this study are like these. TN specimens show partially non-wetted regions, due to easy formation of oxides on the surface of the fine steel wires. TT specimens show no interfacial reaction between the steel wires and the aluminum alloy matrix, possibly due to the formation of carbo-nitrided zone on the surface of the steel wires. TA specimens show excellent wettabillity between the reinforced steel wires and the aluminum alloy matrix and very thin interfacial zone is formed between them. During the solution hardening treatment of TA specimens, thickness of the interfacial reaction zones were increased with the solution treating time. TA specimens show typical ductile fracture in tensile test, but TT specimens show brittle fracture possibly due to the formation of the brittle hard surface on the steel wires during carbo-nitriding treatments. TA specimens which were reinforced with 40 vol.% of the fine steel wires exhibit high tensile strength of $77.1kgf/mm^2$ and impact value of $8.1kgf-m/cm^2$.

• International Journal of Automotive Technology
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• v.6 no.6
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• pp.657-663
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• 2005

Recently, weight reduction of vehicles has been of great interest, and consequently the use of composite materials in the automotive industry is increasing every year. Composite sandwich panels which consist of two skins and core materials are replacing steels in automotive floor and door. The substitution of one material for another is accompanied by change of joining method, so that adhesive bonding has been popularly used for joining method of composite materials. In the case of adhesive bonding of composite materials, there could be loss in the joint strength by delamination of two faceplates or cracking on faceplate. Thus, it is necessary to prevent loss in the joint strength by designing the joint geometry. In the present paper, adhesive bonding of aluminum sandwich sheet was tried. For understanding joint behavior, studies on stresses in the single lap joint were reviewed and failure modes of composite material were analyzed. Strength tests on the single lap joint consisting of aluminum sandwich sheet and steel were performed and variation of the joint strength with the joint configuration was shown. Based on these results, design guide of adhesive bonding in aluminum sandwich sheet was suggested.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.10
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• pp.1204-1209
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• 2011

In this study, fatigue life is evaluated by comparing with lighter car body through the experiment on SPR joints. An experimental activity on sheet metal samples of Aluminum 5J32 and Steel SPRC440 has been conducted to achieve better understanding of the process. In addition, SPR joint used less than the existing Spot Welding improves joint strength and fatigue life is evaluated by using SPR and adhesive joining Hybrid. Joining(bonding) strength and fatigue life on SPR and Hybrid (SPR + adhesive) are evaluated throughout the experiment. With joining strength than 20 % of the aluminum material, dissimilar materials has improved over 2 times as large as the strength In case of dissimilar materials, the fatigue life of aluminum is increased by 1.6 to 2.5 times as large as the life.

• Journal of Welding and Joining
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• v.8 no.2
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• pp.1-12
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• 1990

본 고에서는 알루미늄 점용접시의 용접품질 및 용접봉 수명에 미치는 요소와 점용접부 설계방법에 대하여 간략히 설명하였다. 점 용접방법은 알루미늄 뿐만 아니라 steel의 박판용접에도 많이 사용되고 있으며, 특히 최근 공정자동화에 맞추어 가장 쉽게 자동화할 수 있는 용접 방법 중의 하나이다. 그러나 아직까지는 용접품질을 보증할 수 있는 비파괴 검사방법이 없기 때문에 새로운 비파괴 검사방법 개발 혹은 컴퓨터를 이용한 용접품질 추적방법에 대한 많은 연구가 요청된다. 한편 용접부 설계 관점에서는 조그만 단순 시편이 아닌 설계구조물을 이용한 용접강도 해석방법에 대한 연구가 미약하므로 이에 대한 많은 연구도 요청되고 있다.

• Journal of Welding and Joining
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• v.33 no.3
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• pp.75-80
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• 2015

Self-piercing riveting is an joining method of advanced high strength steels (AHSS) and other dissimilar materials. It has attracted considerable interest from the automotive industry. The SPR has become an interesting alternative joining technique for difficult to weld materials such as steels and aluminium alloys. In this paper, self-piercing rivet and anvil for SPR were designed for the joining conditions with AHSS and aluminium alloy. Various conditions of SPR were simulated for the design of rivets and anvils. The simulated results were in good agreement with experimental ones. As a result, over HV500 rivet is desirable to joint SPFC780 AHSS and aluminum alloy.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.401-404
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• 2009

The purpose of this study is investigating the joint characteristics of advanced high strength steel DP780 and Al5052 alloy sheet in the clinching process. It is difficult to join the advanced high strength steel with light-weight materials like aluminum alloy, because of low formability of DP780. The defects of clinching joint such as necking of the upper sheet, cracks of the lower sheet and no interlocking were occurred by different ductility between advanced high strength steel and aluminum alloy. The clinching conditions should be optimized to interlock without any defects. In this study, the effect of process parameters of clinching process on joinability of advanced high strength steel with Al5052 alloy was investigated by using FE-analysis. From the result of FE-analysis, the clearance between clinching punch and die, die depth and the shape of die cavity mainly affected the joinability of advanced high strength steel with Al5052 alloy.