Development and process verification of a linear friction welding platform for small Ti6AI4V coupons
- Mohlala, Narishe Taetso Arnold
- Authors: Mohlala, Narishe Taetso Arnold
- Date: 2020
- Subjects: Friction welding , Pressure welding
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46196 , vital:39513
- Description: This thesis reports on a study conducted to establish the feasibility of implementing linear friction welding as a joining technique for small Ti6AI4V coupons. The main of this project is to facilitate the manufacturing of high-integrity near-net-shape components for aerospace, automotive and medical appliances. LFW is a solid-state welding technique that uses frictional heat generated by the rubbing of surfaces under an axially applied load, thereby forming a weld at temperature below beta tranus. This technique is advantageous as it has the potential to reduce defeats normally associated with conventional welding of this material. The first part of the study will describe the development of an experimental platform to facilitate the evaluation of the influence of selected process parameters on joint integrity.
- Full Text:
- Date Issued: 2020
Development and process verification of a linear friction welding platform for small Ti6AI4V coupons
- Authors: Mohlala, Narishe Taetso Arnold
- Date: 2020
- Subjects: Friction welding , Pressure welding
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46196 , vital:39513
- Description: This thesis reports on a study conducted to establish the feasibility of implementing linear friction welding as a joining technique for small Ti6AI4V coupons. The main of this project is to facilitate the manufacturing of high-integrity near-net-shape components for aerospace, automotive and medical appliances. LFW is a solid-state welding technique that uses frictional heat generated by the rubbing of surfaces under an axially applied load, thereby forming a weld at temperature below beta tranus. This technique is advantageous as it has the potential to reduce defeats normally associated with conventional welding of this material. The first part of the study will describe the development of an experimental platform to facilitate the evaluation of the influence of selected process parameters on joint integrity.
- Full Text:
- Date Issued: 2020
Friction stir welding of thin section aluminium extrusions for marine applications
- Authors: Chikamhi, Prince Philhelene
- Date: 2020
- Subjects: Friction welding , Welding
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46030 , vital:39410
- Description: This dissertation focuses on the development of a welding extrusion feeder, tool and schedule for implementation of defect-free butt welds on long, thin and complex-shape aluminium extrusions, as used by the marine industry. Viability of employing Friction Stir Welding (FSW) as a welding technology for joining long extrusions with a short-bed and bolt-on feeder to facilitate onsite fabrication of flat structures in shipbuilding is evaluated. An FSW feeder, tool and process control unit were designed, developed and integrated with an existing FSW platform, to facilitate implementation of continuous welds. Weld data acquired from literature review, experimentation, mechanical testing and metallographic analysis was used in design considerations for the development of a feeder. Subsequently, butt welds were implemented successfully on long 3 mm AA6082-T6 extrusions, during continuous FSW on the feeder. A specially adapted tool, the Floating Bobbin Tool, used with the feeder to implement butt welds was designed and developed from literature tool heuristics and weld trials. The tool eliminated the need for a backing bar and enabled tool-workpiece auto-alignment, beneficial with thin-section extrusions. Effect of rotational and weld speed and tool geometry of two tools (Tool 1 and 2), on weld forces and quality was tested, to establish optimum parameters for attaining high quality welds. Tool geometry had a profound effect on weld forces and integrity; Tool 2 welds exhibited superior and consistent weld quality, meeting maritime rules and standards and proving the adequacy of using FSW for joining long thin extrusions. Feeder process control, automation and optimisation, was implemented by process control unit devices, in addition to force and position control provided by the existing FSW platform. Owing to process control, automation and optimisation during continuous FSW of thin long and complex-shape aluminium extrusions, welding setup times and process variations are minimised and chances for defect-free welds increased, boosting production and cost savings in large panel fabrication in shipbuilding.
- Full Text:
- Date Issued: 2020
- Authors: Chikamhi, Prince Philhelene
- Date: 2020
- Subjects: Friction welding , Welding
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46030 , vital:39410
- Description: This dissertation focuses on the development of a welding extrusion feeder, tool and schedule for implementation of defect-free butt welds on long, thin and complex-shape aluminium extrusions, as used by the marine industry. Viability of employing Friction Stir Welding (FSW) as a welding technology for joining long extrusions with a short-bed and bolt-on feeder to facilitate onsite fabrication of flat structures in shipbuilding is evaluated. An FSW feeder, tool and process control unit were designed, developed and integrated with an existing FSW platform, to facilitate implementation of continuous welds. Weld data acquired from literature review, experimentation, mechanical testing and metallographic analysis was used in design considerations for the development of a feeder. Subsequently, butt welds were implemented successfully on long 3 mm AA6082-T6 extrusions, during continuous FSW on the feeder. A specially adapted tool, the Floating Bobbin Tool, used with the feeder to implement butt welds was designed and developed from literature tool heuristics and weld trials. The tool eliminated the need for a backing bar and enabled tool-workpiece auto-alignment, beneficial with thin-section extrusions. Effect of rotational and weld speed and tool geometry of two tools (Tool 1 and 2), on weld forces and quality was tested, to establish optimum parameters for attaining high quality welds. Tool geometry had a profound effect on weld forces and integrity; Tool 2 welds exhibited superior and consistent weld quality, meeting maritime rules and standards and proving the adequacy of using FSW for joining long thin extrusions. Feeder process control, automation and optimisation, was implemented by process control unit devices, in addition to force and position control provided by the existing FSW platform. Owing to process control, automation and optimisation during continuous FSW of thin long and complex-shape aluminium extrusions, welding setup times and process variations are minimised and chances for defect-free welds increased, boosting production and cost savings in large panel fabrication in shipbuilding.
- Full Text:
- Date Issued: 2020
Influence of process energy on stress corrosion susceptibility of a friction hydro pillar repaired steam turbine rotor disc blade locating hole
- Authors: Pentz, Willem Gerhard
- Date: 2020
- Subjects: Friction welding , Mechanical engineering
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/47106 , vital:39810
- Description: Currently the power generation industry is struggling to keep older coal power plants running efficiently. One of the major hurdles is to keep repair and service cost low. Over time stress corrosion cracking (SCC) occurs in the locating pinholes of tier type rotors which locate the turbine blades. This is where this research aims to assist with an alternative repair technique, Friction Hydro Pillar Processing (FHPP) welding, to have longer service intervals thus saving cost and time. The same material can be used for welding and a new aligned hole can be drilled. FHPP welding is a solid state friction welding process. Four different FHPP axial forces were selected to compare their respective performance in subsequent tensile testing, impact testing and SCC testing. All the tensile samples extracted from preheated welds and post weld heat treated welds fracture in the parent material, which indicates good weld efficiency. The impact crack route from the weld nugget towards the parent material was identified in the energy and force graph. Axial force which promote impact toughness can be selected with this curve. SCC occurs when a tensile stress is applied to a susceptible material when in a conducive environment for cracking. A new SCC W-shape was designed and performed well during initial testing. With the SCC W-shape two specimens can be extracted opposite each other and tested. Both the preheated weld samples and the post weld heat treatment (PWHT) weld samples had improved SCC performance over their respective parent material samples. A high axial force, low process energy, and high process energy rate (low process energy and low weld time) produced a weld with improved SCC resistance. FHPP (with PWHT) is a promising repair technique as it improved on the SCC resistance and impact toughness as well as having 100% bond efficiency. More research is still required to identify the SCC mechanism of the FHPP weld.
- Full Text:
- Date Issued: 2020
- Authors: Pentz, Willem Gerhard
- Date: 2020
- Subjects: Friction welding , Mechanical engineering
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/47106 , vital:39810
- Description: Currently the power generation industry is struggling to keep older coal power plants running efficiently. One of the major hurdles is to keep repair and service cost low. Over time stress corrosion cracking (SCC) occurs in the locating pinholes of tier type rotors which locate the turbine blades. This is where this research aims to assist with an alternative repair technique, Friction Hydro Pillar Processing (FHPP) welding, to have longer service intervals thus saving cost and time. The same material can be used for welding and a new aligned hole can be drilled. FHPP welding is a solid state friction welding process. Four different FHPP axial forces were selected to compare their respective performance in subsequent tensile testing, impact testing and SCC testing. All the tensile samples extracted from preheated welds and post weld heat treated welds fracture in the parent material, which indicates good weld efficiency. The impact crack route from the weld nugget towards the parent material was identified in the energy and force graph. Axial force which promote impact toughness can be selected with this curve. SCC occurs when a tensile stress is applied to a susceptible material when in a conducive environment for cracking. A new SCC W-shape was designed and performed well during initial testing. With the SCC W-shape two specimens can be extracted opposite each other and tested. Both the preheated weld samples and the post weld heat treatment (PWHT) weld samples had improved SCC performance over their respective parent material samples. A high axial force, low process energy, and high process energy rate (low process energy and low weld time) produced a weld with improved SCC resistance. FHPP (with PWHT) is a promising repair technique as it improved on the SCC resistance and impact toughness as well as having 100% bond efficiency. More research is still required to identify the SCC mechanism of the FHPP weld.
- Full Text:
- Date Issued: 2020
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