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EN
Composite materials based on aluminum alloys are widely used in the automotive, aviation, and shipbuilding industries. The presence of the ceramic reinforcing phase significantly changes the mechanical properties of aluminum alloys. By appropriate selection of the components that make up the composite materials, it is possible to create mechanical properties that are not possible with unreinforced alloys. Structural elements made of these types of materials often require joining in welding processes. This article presents a general description of methods of joining composites based on aluminum alloys reinforced with ceramic particles, which have been divided into three groups: fusion welding method, solid state welding, and different methods. The individual methods highlighted how the presence of a reinforcing phase affects the welding process. Difficulties mainly arise from the disintegration of the ceramic phase by the concentrated heat source during welding processes, the formation of harmful surface products, and the lack of wettability of the ceramic particles through the metal matrix. The joints obtained vary in terms of structure, ceramic particle distribution, and mechanical properties with respect to the values characterizing the native material. From an analysis of the individual methods, it appears that solid-phase methods have the smallest effect on the degradation of ceramic particles, but have limitations in terms of the shape and size of the materials to be joined. In fusion welding methods, the degradation of the reinforcement phase by the concentrate heat source is greatest. To a certain extent, this can be compensated for by the choice of an additive material, which consists of elements that improve the wettability of the reinforcement phase through the metal matrix and form strengthening separations.
EN
In this article, electric vehicles (EVs) are generally introduced, and the benefits of shifting from conventional automobiles toward EVs are discussed. Batteries, as the core technology of EVs, are then addressed, and various battery types are reviewed. Next, the critical role of copper as one of the primary materials essential for various EV components, as well as the expected growth in its demand in the near future, are discussed. Following that, the significance of using advanced high-strength steels (AHSSs) in the body structure of EVs to reduce weight while maintaining safety requirements is emphasized, and different types of AHSSs are generally mentioned. Subsequently, common metal forming and joining methods for manufacturing and assembling EV components are reviewed. After that, the importance of proper EV constructional design is highlighted, and the strategic battery pack placement for safety and effective weight distribution is highlighted. The importance of using lightweight materials that offer high strength-to-weight ratios in the body structure of EVs and their benefits for improving the efficiency of EVs through increasing the driving range are also outlined. In addition, the importance of responsible end-of-life actions, including recycling or responsible disposal of EV components after their functional lifespan, is also overviewed. Finally, useful strategies for facilitating wider adoption of EVs are discussed, and alternative options for addressing air pollution and global warming are mentioned.
EN
Car trailers are quite a popular means of transport and are offered in many versions, from single axle light trailers with a maximum permissible weight of 750 kg, through two- or more-axle specialized trailers. The issues of research car trailers focus on two directions: testing the driving properties and analysing the strength of the supporting frame system. Issues related to the construction of light trailers are often common to trailers used in agriculture or general transport. In this article, based on a mass-produced car trailer, an analysis was carried out regarding the choice in the technology of making the supporting structure consisting of a lower frame and an upper frame. The term upper frame should be understood as the structure on which the lifted load box rests. The costs of materials, assembly and technological possibilities of small-scale production were taken into account. In addition, strength analyses of the numerical models were carried out for critical areas of the frame during operation. After considering the unit costs for each of the analysed assembly technologies, it was shown that riveting would be the cheapest. However, the most suitable method of assembly is welding, as it allows the use of standard profiles.
PL
Rusztowania są konstrukcjami inżynierskimi i tak jak inne konstrukcje inżynierskie, w celu zapewnienia niezawodności, powinny być sprawdzone za pomocą analiz statyczno-wytrzymałościowych. Wykonanie takiej analizy wymaga stworzenia wiarygodnego schematu statycznego, który obecnie jest jednocześnie modelem numerycznym konstrukcji. W tym artykule jest opisany proces opracowywania takiego modelu numerycznego rusztowania, a w szczególności proces zdobywania informacji, niezbędnych do opracowania tego modelu. W przypadku rusztowań zaleca się, aby parametry schematu statycznego były przyjmowane na podstawie badań laboratoryjnych pojedynczych elementów (itp. podstawki, stojaki, stężenia,), wybranych zestawów elementów (sztywność pozioma pomostów) i połączeń. Na podstawie pomiarów wyznacza się sztywności (lub podatności) i nośności elementów. Na tej podstawie należy opracować model numeryczny, który w kolejnym kroku należy zweryfikować. Ta część procedury polega na porównaniu wyników obliczeń z wynikami pomiarów laboratoryjnych odpowiedzi reprezentatywnej sekcji konfiguracji rusztowania. Parametry zastosowane w zweryfikowanym modelu należy stosować podczas projektowania typowych (konfiguracje w dokumentacji producenta) i nietypowych rusztowań.
EN
Scaffoldings are engineering structures and, like other engineering structures, in order to ensure reliability, they should be checked using static-strength analyses. Performing such an analysis requires to create a reliable static scheme, which is currently also a numerical model of the structure. This paper describes the process of developing such a numerical model of scaffolding, and in particular the process of obtaining information necessary to develop this model. In the case of scaffolding, it is recommended that the parameters of the static scheme be adopted on the basis of laboratory tests of individual elements (e.g. base jacks, stands, bracings), selected sets of elements (horizontal stiffness of platforms) and joints. Based on the measurements, the stiffness (or flexibility) and load-bearing capacity of the elements are determined. On this basis, a numerical model should be developed and verified in the next step. This part of the procedure involves comparing the calculation results with laboratory measurement results of the response of a representative section of a system configuration. The parameters used in the verified model should be used to designe typical (configurations in the manufacturer’s documentation) and non-typical scaffoldings.
EN
This work aims to join sheets of carbon steel to aluminum alloy AA6061. A lap joint arrangement was used with a joint lap area of dimensions *25 25 mm . The joining procedure was carried out using a rotating tool of 10 mm shoulder diameter. Three process parameters, with three levels for each parameter, were selected to investigate their effects on joints quality. The parameter’s levels for each experiment were designed using the design of the experiment method (DOE). The results indicated that the two materials were joined by a mechanical interlock at an interface line, without formation of intermetallic compounds. The shear force of the joint reached an ultimate value of .4 82kN . The shear force of the joint improved by increasing plunging depth of the tool. Samples of minimum shear force value failed by a pull-outing aluminum metal from the carbon steel specimen. Samples of higher shear force value exhibited a shear mode of fracture. Increasing the rotating speed and decreasing pre-heating increased the process temperature.
EN
A novel dieless clinching process free of blank holder was proposed in this study. This novel clinching process applied to joining Al5052 sheets under the forming forces from 24 to 54 kN was investigated experimentally. The joint geometrical characteristics, static mechanical strength, energy absorption and failure modes were revealed. From the results, the sound joints can be produced under various forming forces from 24 to 54 kN. With the forming force increasing, the neck thickness was increased continually while the interlock value remained almost constant. On the other hand, the protrusion height of clinched joint was reduced continually with the forming force increasing. Both the tensile strength and shear strength were enhanced with the forming force increasing. Under the forming force of 54 kN, the tensile strength and the shear strength were 1249 and 1107 kN, respectively. In general, a larger joining force leads to a better clinched joint with lower protrusion height and higher mechanical strength.
8
Content available remote Hybrid welding of metal-polymer composites with a non-conducting polymer layer
EN
Metal-polymer composites (MPCs) are becoming increasingly popular primarily because of their high strength-to-weight ratio. Metal-polymer composites consist of three layers, i.e. two external metallic sheets (linings) and the core made of plastic. The presence of the internal plastic layer makes MPCs impossible to join using conventional welding processes, which significantly limits their usability. One of the solutions to the problem involves the use of hybrid methods, e.g. ultrasonic method-aided resistance welding. The research work discussed in the article involved the development of a prototype test rig and a technology enabling the joining of the Litecor® composite with steel DP600. The joining process consisted of two stages. The first stage involved the removal of the non-conducting layer of polymer from the welding area and the making of an appropriate electric contact for resistance welding. The second stage was the classical resistance spot welding process. The development of the concept posed a challenge as it was necessary to develop an appropriate acoustic waveguide for high-power ultrasonic waves which, at the same time, could transfer loads in the form of electrode force as well as provide appropriate electric and thermal conductivity without compromising acoustic parameters during the welding process. The development of the test rig was followed by the performance of numerous tests aimed to identify the appropriate window of process parameters. Test joints were subjected to macrographic, strength, ultrasonic and topographic tests.
PL
Kompozyty metalowo-polimerowe (MPC) zyskują na znaczeniu głównie ze względu na wysoki stosunek wytrzymałości do masy. Składają się one z trzech warstw, tj. dwóch zewnętrznych metalowych arkuszy (okładzin) i rdzenia z tworzywa sztucznego. Obecność wewnętrznej warstwy tworzywa sztucznego sprawia, że nie można ich łączyć za pomocą konwencjonalnych procesów zgrzewania, co znacznie ogranicza zakres ich stosowania. Jednym ze sposobów rozwiązania tego problemu jest zastosowanie metod hybrydowych, np. zgrzewania rezystancyjnego wspomaganego metoda ultradźwiękową. W ramach podjętych badań opracowano prototypowe stanowisko badawcze oraz technologię łączenia kompozytu Litecor® ze stalą DP600. Proces łączenia opierał się na dwóch etapach. W pierwszym istotne jest usunięcie nieprzewodzącej warstwy polimeru ze strefy zgrzewania i stworzenie odpowiedniego styku elektrycznego do zgrzewania oporowego. Etap drugi to klasyczne zgrzewanie rezystancyjne punktowe. Opracowanie tej koncepcji było wyzwaniem ze względu na konieczność zaprojektowania odpowiedniego falowodu akustycznego dla fali ultradźwiękowej dużej mocy, który jednocześnie przeniesie obciążenia w postaci siły docisku elektrod, zapewni odpowiedną przewodność elektryczną i cieplną, a przede wszystkim zachowa swoje parametry akustyczne w trakcie procesu zgrzewania. Po opracowaniu stanowiska badawczego dokonano licznych badań w celu opracowania odpowiednego okna parametrów procesowych. Ponadto wykonane złącza były poddawane niezbędnym badaniom, w tym makrograficznym, wytrzymałościowym, ultradźwiękowym oraz topograficznym
PL
Metoda wykorzystująca wiertło tarciowe Flowdrill (flowdrill joining, FDJ) umożliwia łączenie metalu z kompozytami termoplastycznymi wzmocnionymi włóknami ciągłymi (FRTP) bez udziału pomocniczych elementów łączących. W metodzie tej włókna w kompozycie nie są przecinane jak w klasycznym sposobie łączenia, ale rozszerzane, co sprawia, że połączenie cechuje się dużą wytrzymałością. Technika FDJ potencjalnie może być stosowana do konstrukcji lekkich. Ważną cechą wymaganą od wykorzystywanych w przemyśle samochodowym elementów wykonanych wg tej technologii łączenia jest odporność na obciążenia temperaturowe i chemiczne towarzyszące procesom produkcyjnym, takim jak lakierowanie katodowe (CDP). Stwierdzono, że obróbka CDP nie wpływa niekorzystnie na właściwości quasi-statyczne badanych połączeń FDJ, wytrzymują one obciążenia sił ścinających do 2900 N i krzyżowych do ok. 1100 N zarówno przed, jak i po procesie lakierowania.
EN
The flow drill joining concept (FDJ) allows the load adjusted joining of continuous fiber reinforced thermoplastics (FRTP) and metallic sheets without auxiliary joining elements. As there is no scathe done to the fiber reinforcement, a radial realignment of the fibers leads to high-strength joints with high lightweight potential. In terms of their use in automotive lightweight construction, an important requirement for joining technologies is the resistance to temperature loads and chemicals, applied in the production processes, e.g., in vehicle lacquering. Therefore, force flux aligned FDJ-joints were investigated in cross tension and shear testings, after passing through a serial cathodic dip painting (CDP) process. The results show that the CDP-treatment does not adversely affect the quasi-static properties of the tested FDJ-joints, as they resist shear loads up to 2900 N and cross tension loads of about 1100 N, both, before and after the lacquering process.
EN
This paper describes a study of explosively welded, commercially pure titanium-stainless steel 316L plates. Following welding, the plates were heat-treated at the temperature of 600°C for 90 minutes. Examinations of the bond structure were carried out before and after heat treatment to investigate the processes taking place during explosive welding of materials. Observations were performed using light, scanning electron (SEM) and transmission electron microscopy (TEM). The mechanical properties were examined applying three-point bending tests with cyclic loads. Fractographic examination and hardness measurements were also performed. It has been found that the bonding zones are characterized by a specific microstructure, chemical composition and microhardness. The heat treatment used in the study increases the relative volume of brittle intermetallic phases, causing a reduction in fatigue strength of the joint.
EN
Self-piercing riveting (SPR) is a method used for joining sheet materials by creating a mechanical interlock between the sheets. SPR is of increasing interest in automobile industries due to its suitability for joining lightweight, high strength and dissimilar materials. The quality of an SPR joint from cross-sectional perspective is primarily characterized by the amount of mechanical interlock known as rivet flaring. Other parameters, such as rivet head height, bottom thickness and effective length of the rivet in the bottom sheet are also considered as quality parameters. However, the many factors that determine the quality of an SPR joint are poorly described in the literature and, as a consequence, the opportunities to develop new product and optimize the process are limited. In this paper, several of the key parameters that affect the quality of an SPR joint are described and some assistive technologies that have the potential of improving the quality of a joint are discussed. This is a zone in the field of SPR joining which has plenty of research opportunities. Innovative progress will be achieved by a combination of techniques, together with industrial trials and laboratory simulations.
PL
Badania nieniszczące i testy funkcjonalne stanowią integralną część procesu produkcyjnego podzespołów i komponentów wykorzystywanych w przemyśle motoryzacyjnym. Półosie i wały napędowe zgrzewane łukiem wirującym (MIAB), będące elementami przeniesienia napędu są częściami, które podlegając ciągłym obciążeniom dynamicznym, muszą spełniać szczególnie wysokie kryteria jakościowe. Obecnie badania te polegają na kontroli parametrów procesu i badaniach niszczących (w tym badaniach metalograficznych i testach funkcjonalnych – zgniatanie, skręcanie, test płatkowy). W artykule przedstawiono nowatorską i innowacyjną w branży motoryzacyjnej, obejmującej producentów półosi i wałów napędowych nieniszczącą, ultradźwiękową metodę kontroli jakości połączeń zgrzewanych łukiem wirującym. Omówiono podstawowe rodzaje prezentacji sygnałów ultradźwiękowych oraz sposoby ich interpretacji. Szczególny nacisk położono na przedstawienie możliwości i funkcjonalności opracowanej autorskiej aplikacji, umożliwiającej wizualizację i akwizycję sygnałów ultradźwiękowych rejestrowanych podczas zautomatyzowanego badania zgrzein wykonanych metodą MIAB.
EN
Non-destructive testing and functional tests are an integral part of the manufacturing process of components and constructions used in the automotive industry. The drive and transmission shafts joined by Magnetically Impelled Arc Butt (MIAB) welding process, continuously work under constant dynamic loads and must meet particularly high quality criteria. Currently, these tests involve the control of process parameters and destructive tests (including metallographic and functional tests – crushing, twisting, petal test). The article presents an innovative in the automotive industry, including transmission driveshaft manufacturers, non-destructive, ultrasonic quality control methods of MIAB joints. The basic types of presentation of ultrasonic signals are discussed as well as how they are interpreted. Particular emphasis has been placed on the presentation of the capabilities and functionality of the developed application, which enables the visualization and acquisition of ultrasonic signals recorded during automated MIAB weld tests.
PL
Określono nośność obliczeniową belek metalowych przed zespoleniem i po zespoleniu z płytą betonową, korzystając zarówno z procedur normowych, jak i z symulacji komputerowej. Omówiono wyniki analiz obliczeniowych.
EN
The load bearing capacity and stiffness of metal beams before and after of the joining with the concrete slab were evaluated using standards and a numerical simulation. The results of analysis were discussed.
EN
This paper discusses the joining of AZ91 magnesium alloy with AlSi17 aluminium alloy by compound casting. Molten AZ91 was cast at 650oC onto a solid AlSi17 insert placed in a steel mould under normal atmospheric conditions. Before casting, the mould with the insert inside was heated up to about 370oC. The bonding zone forming between the two alloys as a result of diffusion had a multiphase structure and a thickness of about 200 μm. The microstructure and composition of the bonding zone were analysed using optical microscopy, scanning electron microscopy and energy dispersive X-ray spectroscopy. The results indicate that the bonding zone adjacent to the AlSi17 alloy was composed of an Al3Mg2 intermetallic phase with not fully consumed primary Si particles, surrounded by a rim of an Mg2Si intermetallic phase and fine Mg2Si particles. The bonding zone near the AZ91 alloy was composed of a eutectic (an Mg17Al12 intermetallic phase and a solid solution of Al and Si in Mg). It was also found that the compound casting process slightly affected the AZ91alloy microstructure; a thin layer adjacent to the bonding zone of the alloy was enriched with aluminium.
EN
The aim of this paper was to present preliminary results of researches conducted in PZL Mielec within the FAST_FSW project (INNOLOT program) on the influence of tool eccentricity on microstructure and mechanical properties of 1.6 mm and 0.8 mm thick Al 7075 T6 sheets joints. Samples were performed using CNC milling machine. The range of tool eccentricity was 0–0.3 mm, rotational speed and feed rate were variable. The influence of the applied welding parameters on microstructure and mechanical properties of joints was assessed on the basis of metallographic inspections and tensile tests. Microstructural observations have shown that the change of FSW tool eccentricity affects the weld geometry: the mixing zone depth, the weld width, or the shape of the contact line.
PL
W pracy przedstawiono technologie łączenia pasów zębatych poliuretanowych. Przeprowadzono badania wytrzymałości o zmiennej długości połączeń ze względu na rozciąganie pasów zębatych poliuretanowych łączonych oraz łączonych wzmocnionych kołkami.
EN
The article presents the joining technology od polyurethane timing belts. Strength testing was performed on the variable-length joining area due to the stretching of timing belts of polyurethane combined and joining reinforced by steel pins.
17
Content available remote Rozwój technik łączenia materiałów – spawanie tworzyw polimerowych
PL
W artykule przedstawiono dynamicznie rozwijające się metody i techniki łączenia elementów z tworzyw polimerowych. Zgrzewanie i spawanie to podstawowe techniki łączenie tworzyw termoplastycznych. Bardzo interesującymi cechami charakteryzuje się zwłaszcza zgrzewanie laserowe.
EN
The article presents a dynamically developing methods and techniques of plastic elements joining. Welding is the basic technique of thermoplastics junction. Laser welding is characterized by very interesting features.
EN
Several well established procedures are used for butt fusion welding of PE pipes globally. The most widely used are the European Single Pressure, UK Dual Pressure, and the USA High Pressure procedures. In the future it may be possible to rationalise these procedures. Materials and machinery developments are resulting in an increasing size range of pipe. Confirmation of the appropriate test methods is required to assure weld quality, to fully understand the properties of the welds, and to confirm the suitability of the fusion procedure used for such pipes. The PE 100+ Association established a project to evaluate welds in large diameter thick walled pipe. The results of this programme are discussed and final conclusions made.
PL
W skali globalnej, do zgrzewania doczołowego rur polietylenowych stosuje się szereg sprawdzonych technologii. Najbardziej rozpowszechnione z nich to europejska technologia jednociśnieniowa, brytyjska technologia dwuciśnieniowa oraz amerykańska technologia wysokociśnieniowa. Być może w przyszłości pojawi się możliwość racjonalizacji tych technologii. Rozwój w zakresie materiałów i maszyn skutkuje coraz większym zakresem rozmiarów rur. W celu zapewnienia dobrej jakości zgrzewów, dokładnego zrozumienia właściwości zgrzewów, oraz potwierdzenia przydatności technologii zgrzewania stosowanej w odniesieniu do takich rur, wymagane jest potwierdzenie odnośnych metod testowych. Stowarzyszenie PE 100+ wprowadziło projekt mający na celu dokonanie oceny zgrzewów w rurach grubościennych o dużych średnicach. Wyniki tego programu zostały omówione, po czym wyciągnięto ostateczne wnioski.
EN
The green body and dense substrate of indium tin oxide was joined by uniaxially pressing at 0.3 MPa at 1300°C to test the restoring of the eroded part of transparent conducting oxide target. The green body was sintered to 98% of theoretical density under the suppression of shrinkage along the boundary below 5%. The boundary between two parts was free of pore but could be recognized from the difference in grain sizes. The joined part had the virtually same density with the substrate, but the grain size was less than one fifth compared with that of substrate.
20
Content available Preliminary studies of riveted joints at feed force
EN
The aim of the study was to determine the feasibility of riveted joints in composites materials. Static tensile test method was used. In the test one type of glass fabric was used (Interglas 92140) from which two types of composite samples were prepared. In each sample the same type of fiber with the same fiber orientation – 3 layers - was used. The samples had dimensions of 100×100 mm and thickness of approximately 1 mm. The composite probes were located in a metal frame with a screw connection which was made of screws with nominal thread pitch M5. Screws were tightened with constant torque. It was to provide an axial force to the sample during the tensile test. The frame was placed between cross-bars of tensile machine INSTRON 8516. The samples were stretched at a speed of 0.05 mm/s at a distance up to 15 mm. During the tensile test displacement of the samples and pull force were registered. Depending on the fibre orientations and the value of feed force, damage models were described. On the basis of the results the possibility of usage of aluminium rivet nuts connections in composite materials was determined.
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