Friction hydro pillar riveting process of Ti-6AI-4V titanium sheet
- Authors: Tsikayi, Davies Shamiso
- Date: 2015
- Subjects: Friction welding , Titanium alloys -- Welding , Sheet-metal
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: http://hdl.handle.net/10948/6357 , vital:21078
- Description: Mechanical fasteners are used extensively in the joining of two or more metal plates or sheets. Riveted joints have been the joints of choice mainly for the Aerospace Industry. However for this research, Friction Hydro Pillar Processing has been used to develop and characterise a new riveting technique termed Friction Hydro Pillar Riveting (FHPR). Two overlapping 3.17 mm Ti-6Al-4V sheets were joined together using Ø6 mm rivet which was friction processed. This research has focussed on the initial development of Friction Hydro Pillar Riveting thereby establishing a basic understanding of the influences of main process parameters, rotational speed and axial force - and also joint configurations. The results showed that with a decrease in the bottom hole chamfer angle, there was resulting overall increase in the rivet joint pull off strength. From the best performing joint configuration in pull off tests, shear tests were conducted whilst a blind hole FHPR joint was also done and tested in pull off and shear strength. The shear test fracture surfaces exhibited ductile failure. The microstructure of the joints was thus evaluated. From parent material, heat affected zone and to weld zone there was a variation in the microstructure analysed. The hardness profiles showed increased hardness in the weld zone which partly explained the shear results. The hardness increase was mainly due to grain refinement in the weld zone by the Friction Hydro Pillar Riveting process.
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- Date Issued: 2015
Development of thick section friction stir welding using a sliding tool shoulder
- Authors: Chetty, Shamalin
- Date: 2013
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9633 , http://hdl.handle.net/10948/d1015081
- Description: Sliding shoulder friction stir welding (SSFSW) is an alternative joining technique to the conventional friction stir welding process. The welding mechanism comprises of a rotating probe and a non-rotating shoulder. The shoulder therefore does not contribute to any heat generation or plastic deformation. When welding thicker section material, the contribution of heat generation from the shoulder becomes less significant and most of the heat and plastic deformation must be generated by the tool probe. For this reason it was decided to develop the process for thick section AA6082-T6. Due to the stationary (non-rotating) shoulder the weld track is smooth and there is no reduction in cross-sectional area. This research is based on the development of a sliding shoulder friction stir welding tool with the ability to create joints of up to 25mm thick on aluminium alloy 6082-T6 plate as well as the associated process development. The sliding shoulder friction stir welding tool was designed, manufactured and tested by initially performing partial penetration welds with various size tool probes and then finally by performing a sliding shoulder friction stir butt weld on 25mm thick plate. As welds were performed and more knowledge gained about the process, design modifications were made. These included varying the clearance between the tool probe and stationary shoulder; the profile of the shoulder which contributes to material flow during the process; and supporting the tool probe to prevent deflection when welding thicker sections at high forge forces. From the sliding shoulder friction stir welds performed, an understanding of material flow during the process was gained when analysing the macro-sections and exit holes of the welds. Typical process forces and torques associated with the process were measured to assist with future head unit and tool designs with regard to sliding shoulder friction stir welding.
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- Date Issued: 2013
Analysis and modelling of the temperature distribution during the friction taper stud welding of 10CrMo910
- Authors: Van Zyl, Carlo Angelo Antonio
- Date: 2008
- Subjects: Friction welding , Pressure welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9630 , http://hdl.handle.net/10948/720 , http://hdl.handle.net/10948/d1012898 , Friction welding , Pressure welding
- Description: Heat generation during the FTSW process plays and important role in determining the characteristics of the weld. In order to obtain temperature fields, a transient temperature heat analysis is required. An area is the maximum temperatures reached within the base material during the FTSW process. These temperatures will be measured during experimentation, and compared to the welding simulation done using FEA. From the literature search it appeared that no heat transfer analysis had been done using finite element methods.
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- Date Issued: 2008
A fuzzy logic control system for a friction stir welding process
- Authors: Majara, Khotso Ernest
- Date: 2006
- Subjects: Friction welding , Fuzzy logic , Automatic control , Fuzzy systems
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9594 , http://hdl.handle.net/10948/405 , Friction welding , Fuzzy logic , Automatic control , Fuzzy systems
- Description: FSW is a welding technique invented and patented by The Welding Institute in 1991. This welding technique utilises the benefits of solid-state welding to materials regarded as difficult to weld by fusion processes. The productivity of the process was not optimised as the real-time dynamics of the material and tool changes were not considered. Furthermore, the process has a plastic weld region where no traditional modelling describing the interaction between the tool and work piece is available. Fuzzy logic technology is one of the artificial intelligent strategies used to improve the control of the dynamics of industrial processes. Fuzzy control was proposed as a viable solution to improve the productivity of the FSW process. The simulations indicated that FLC can use feed rate and welding speed to adaptively regulate the feed force and tool temperature respectively, irrespective of varying tool and material change. The simulations presented fuzzy logic technology to be robust enough to regulate FSW process in the absence of accurate mathematical models.
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- Date Issued: 2006
Development and analysis of a friction stir spot welding process for aluminium
- Authors: Stephen, Michael George
- Date: 2005
- Subjects: Friction welding , Electric welding , Aluminum alloys -- Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9631 , http://hdl.handle.net/10948/1351 , Friction welding , Electric welding , Aluminum alloys -- Welding
- Description: Friction Stir Spot Welding (FSSW) has been developed from the conventional Friction Stir Welding (FSW) process, developed at The Welding Institute (TWI). FSSWs have been done without the keyhole being eliminated. Elimination of the keyhole would result in the process being more commercially viable. This dissertation focuses on an attempt of eliminating the keyhole using a retractable pin tool as well as a comparison of the weld integrity of a FSSW to that of a conventional Resistance Spot Weld (RSW). Welds were conducted on aluminium alloy 6063 T4. Comparisons between different weld procedures were done. Further analysis of the weld integrity between FSSW and RSW were conducted, comparing tensile strengths, microstructure and hardness. For the above welding procedure to take place, the current retractable pin tool, patented by PE Technikon, was redesigned. Problems associated during the welding process and the results obtained are documented. Reasons for the keyhole not being eliminated as well as recommendations for future work in the attempt to remove the keyhole are discussed.
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- Date Issued: 2005