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FSW of lightweight aluminum structures: lap joint development

Buffa G., Fratini L.

Computer Methods in Materials Science

2009

Vol. 9, No. 1

123-129

In the last decade, the employ of Aluminum alloys in the automotive and aircraft industries appears to be the best technical solution as well as great challenge for the engineers; such materials present several advantages and a few shortcomings which have to be properly overcome. In particular, through a proper design to market, it is possible to improve at least three main aspects of the products requirements, namely active and passive safety increase, fuel costs reduction and environmental impact reduction. In turn, such materials present lower ductility with respect to steels, anisotropy phenomena and, what is more, they are often difficult to be welded or even non-weldable. For this last reason, in the last years, some alternative joining technologies have been proposed with the aim to take rid of the above reported shortcomings. Among these adhesive bonding, self-piercing mechanical fasteners, clinching and friction stir welding are probably the most interesting. All the cited techniques avoid the melting of the base material. In order to obtain a continuum joint the friction stir welding process (FSW) can be developed. Such process is a solid state welding technique in which a specially designed rotating pin is first inserted into the adjoining edges of the sheets to be welded with a proper nuting angle and then moved all along the joint. Such pin produces frictional and plastic deformation heating in the welding zone, and, as the tool moves, material is forced to flow around it in a quite complex flow pattern. In the paper, a wide experimental and numerical investigation on the lap joining of 2xxx aluminum alloys blanks by FSW is presented. In particular, self-piercing riveting, clinching and friction stir welding were taken into account. The influence of some relevant parameters is investigated with the aim to maximize the joint strength, just starting from the joint configuration. An accurate analysis on the obtained parts was carried out and the reached results gave important information on the investigated joining technique.

Tematem niniejszej pracy są badania laboratoryjne oraz analiza numeryczna procesu spawania zakładkowego metodą Friction Stir Welding (FSW) stopów aluminium serii 2xxx. Analizie poddany został wpływ parametrów geometrycznych oraz technologicznych na wytrzymałość uzyskiwanych spoin. W pracy omówiono uzyskane wyniki oraz wynikające z nich wnioski.

The analysis of closed-die forging process with the help of computer simulation

Bilik J., Kapustowa M.

Hutnik, Wiadomości Hutnicze

2008

Vol. 75, nr 8

462-465

The paper is focused on analysis of materials behaviour at die filling during closed die forging. The analysis was done for forging of part for transmission gear with simulation software SuperForge. The analysis enabled to optimize forging process especially from the point of view of elimination of the flash creation. The analysis allowed the verification of forging tools design for production of the part made of STN 416220 steel.

W artykule skupiono się na analizie wypełniania matrycy w trakcie kucia matrycowego. Analiza przeprowadzona była dla procesu wytwarzania elementu skrzyni biegów z zastosowaniem oprogramowania SuperForge. Analiza umożliwiła optymalizację procesu kucia z punktu widzenia minimalizacji wypływki. Analiza pozwoliła na weryfikacją projektu narządzi stosowanych podczas procesu kucia elementu ze stali STN 416220.