Article
Materials Science, Multidisciplinary
Shengwei Zhang, Kun Gao, Sung-Tae Hong, Hyunuk Ahn, Yoongil Choi, Siwhan Lee, Heung Nam Han
Summary: The lap joining of dissimilar steel and aluminum alloy sheets in the solid state using electrically assisted pressure joining (EAPJ) method was successful, with joint strength increasing with higher electric current density and holding time at elevated temperature. Microstructural analysis and quasi-static lap shear tensile testing were conducted to confirm the solid-state joining and joint strength enhancement.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Materials Science, Coatings & Films
Peter Totaro, Boris Khusid
Summary: This study demonstrated the overall advantages of multistep anodization for heat-treated wrought aluminum alloy AA7075-T6, showing that multistep processes can improve coating properties and morphology, increase abrasion resistance and hardness of the coatings.
SURFACE & COATINGS TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Kambiz Moradi, Seyyed Ehsan Mirsalehi
Summary: In this study, lap joints between AA6061-T6 aluminum alloy sheets and St14 low-carbon steel sheets were achieved using the friction stir spot welding-brazing method with a pinless tool and a zinc interlayer. The effects of rotating speed and dwell time on the microstructure and mechanical properties were investigated. The joints exhibited sound shapes and the maximum tensile-shear failure load (TSFL) was observed to be over 4.2 kN for all the joints.
METALS AND MATERIALS INTERNATIONAL
(2023)
Article
Engineering, Mechanical
Xiushuo Zhang, Yu' e Ma, Meng Yang, Wei Huang, Yilin Peng, Zhenhai Wang
Summary: Residual stress significantly affects fatigue performance in friction stir weld (FSW) joints. This study investigates the effect of biaxial residual stress components on mixed-mode crack propagation behavior in FSWed 7075-T6 fuselage panel through experiments and numerical simulations.
THEORETICAL AND APPLIED FRACTURE MECHANICS
(2022)
Article
Materials Science, Characterization & Testing
Miguel Delgado, R. Flores, C. Santana, Luis Reyes-Osorio
Summary: This study investigates the evaluation of tunnel defects in Al-7075 T6 sheets processed by friction stir welding (FSW) using computed tomography (CT) and the finite element method (FEM). The effects of axial force and temperature generated during FSW were assessed using different rotational and welding speeds. CT-scanned joints were reconstructed to show the forms, places, and levels of detected defects. The combination of CT and numerical results provides an in-depth understanding of material flow and defect formation during the friction process.
NONDESTRUCTIVE TESTING AND EVALUATION
(2023)
Article
Engineering, Civil
Xinhang Zhi, Yuanqing Wang, Ying Zhang, Beibei Li, Yuanwen Ouyang
Summary: This paper investigates the local buckling performance of 7075-T6 high-strength aluminium alloy extruded H-section stub columns. Experimental tests and finite element analysis are conducted to evaluate the accuracy of current design standards for different cross-section shapes of stub columns and propose an improved design approach.
THIN-WALLED STRUCTURES
(2022)
Article
Automation & Control Systems
Tinu P. Saju, R. Ganesh Narayanan, Barnik Saha Roy
Summary: The study investigated the use of dieless friction stir riveting on dissimilar grades of aluminum alloy sheets, finding that single-hole configurations perform better than multi-hole configurations in terms of mechanical properties. The research also examined the fracture modes and microstructural changes related to this difference in performance.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Nanoscience & Nanotechnology
Pengliang Niu, Wenya Li, Chenggang Yang, Yuhua Chen, Daolun Chen
Summary: Low cycle fatigue tests were conducted on friction stir welded dissimilar aluminum alloy joints with different strain amplitudes, revealing that the positioning of base materials during FSW affected the fatigue resistance of joints. When 7075 aluminum alloy was placed on the advancing side, longer fatigue life was achieved. Fracture of fatigued specimens always occurred at the softer heat-affected zone on the 2024 side, with crack initiation from the specimen surface and crack propagation characterized by typical fatigue striations.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Chemistry, Physical
Hao Wu, Mark Porter, Richard Ward, Justin Quinn, Cormac McGarrigle, Shaun McFadden
Summary: Friction drilling is a non-conventional hole-making process suitable for thin-section, ductile metals. In this study, threaded holes were created using friction drilling and thread forming. The mechanical properties of the threaded holes were compared under different rotation speeds, and it was found that the optimum range of rotation rate for achieving higher load-bearing capacities is 3000-3500 rpm.
Article
Engineering, Mechanical
Xiushuo Zhang, Yu'e. Ma, Zhenhai Wang, Yanning Guo
Summary: Residual stress has a considerable effect on mixed-mode crack propagation behavior under biaxial loading conditions, especially influencing crack deviation in the early stage of propagation. The variation of crack path is strongly linked with residual stress and biaxial loading ratio.
FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES
(2021)
Article
Materials Science, Multidisciplinary
Mukesh Kumar, Ashish Das, Raj Ballav
Summary: In order to reduce the weight of structures in the transportation industry, it is necessary to join dissimilar aluminum (Al) and magnesium (Mg) alloys. However, joining dissimilar materials is more challenging due to their different properties. This study introduces a novel strategy using Zn interlayers to improve the mechanical properties, microstructure, and corrosion behaviors of Al/Mg alloy joints. The addition of Zn resulted in the formation of finer and better-distributed Mg-Zn intermetallic compounds (IMCs) and significantly improved the tensile strength of the joints. Furthermore, the Al/Mg joints with Zn interlayers exhibited better corrosion resistance compared to those without Zn.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Materials Science, Coatings & Films
P. Vieth, M. -A. Garthe, D. Voswinkel, M. Schaper, G. Grundmeier
Summary: This study combined laser surface melting and molecular adhesion to improve the corrosion resistance and wet-adhesion strength of aluminum alloy. The correlation between surface morphology, chemical state, and electrochemical properties was analyzed, and the results showed promising outcomes.
SURFACE & COATINGS TECHNOLOGY
(2022)
Article
Chemistry, Physical
Jan Slota, Andrzej Kubit, Tomasz Trzepiecinski, Bogdan Krasowski, Jan Varga
Summary: This study proposed a novel method for manufacturing rib-stiffened panels using single point incremental forming, and investigated the deformation characteristics of panels through axial compression tests. The results revealed two distinct buckling modes in the panels, which can be attributed to the interaction of the rotating tool on the surface of the formed ribs causing different transverse and longitudinal springback behaviors.
Article
Mechanics
Yan Li, Xiaoyang Bi, Mengjia Xu, Zhengchao Xie, Zhenmin Wang
Summary: The study investigates the influence of welding parameters on the stability of friction lap joining hybrid joints between CFRPA6 and 6061. By optimizing the welding parameters, a high-strength hybrid joint is achieved. Experimental and computational results reveal the mechanism of interface connection between CFRPA6 and 6061.
COMPOSITE STRUCTURES
(2023)
Article
Materials Science, Multidisciplinary
Yue Zhao, Zhou Gong, Wei Liu, Xinghuo Wang, Zhenmin Wang, Zhengchao Xie, Yukun Chen
Summary: This paper introduces a method to improve the interface performance between PP/EPDM TPV and aluminium alloy 6061-T6 (A6061) by introducing zinc sorbate (ZDS). The results show that the polymerization of ZDS can enhance the interface compatibility, melt strength and surface energy of PP/EPDM/ZDS TPV while reducing the linear expansion coefficient of TPV. By optimizing the heat input, the PP/EPDM/ZDS TPV was directly connected to A6061, achieving a high joint strength.
MATERIALS CHEMISTRY AND PHYSICS
(2023)
Article
Materials Science, Multidisciplinary
Wei Zhang, Yanfei Gao, Zhili Feng, Xin Wang, Siyu Zhang, Lan Huang, Zaiwang Huang, Liang Jiang
Article
Materials Science, Multidisciplinary
Jian Chen, Yong Chae Lim, Donovan Leonard, Hui Huang, Zhili Feng, Xin Sun
Article
Engineering, Manufacturing
Yong Chae Lim, Jian Chen, Jiheon Jun, Donovan N. Leonard, Michael P. Brady, Charles David Warren, Zhili Feng
Summary: In this study, thermoset carbon fiber-reinforced polymer (CFRP) was spot joined to magnesium alloy AZ31B using a friction self-piercing riveting (F-SPR) process, showing good mechanical interlocking between the steel rivet and AZ31B, with AZ31B being the most active in terms of corrosion potential, CFRP being the most noble, and the steel rivet falling between the two. Salt fog corrosion testing revealed good corrosion resistance with extensive corrosion observed on AZ31B while steel rivet was minimally affected due to sacrificial anode effect.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2021)
Article
Materials Science, Multidisciplinary
Xue Wang, Yanfei Gao, Xun Liu, Martin McDonnell, Zhili Feng
Summary: Friction stir welding is widely used in automotive and aerospace industries for its solid-state bonding and versatility. However, the lack of mechanistic understanding of tool-workpiece frictional behavior hinders the study of the relationship among processing parameters, material properties, and bonding extent.
Article
Chemistry, Physical
Jiheon Jun, Yong Chae Lim, Yuan Li, Charles David Warren, Zhili Feng
Summary: The study shows that the use of polymer insulation can effectively mitigate galvanic corrosion at bolted joints between magnesium alloy and carbon fiber-reinforced composite, resulting in reduced corrosion depth and volume. In the polymer-insulated group, the reduction in joint strength post-corrosion was relatively small, while in the non-insulated group it was significantly greater.
Article
Metallurgy & Metallurgical Engineering
Yong Chae Lim, Jiheon Jun, Donovan N. Leonard, Yuan Li, Jian Chen, Michael P. Brady, Zhili Feng
Summary: A new testing methodology was developed to study galvanic corrosion of AZ31B and thermoset carbon-fiber-reinforced polymer. The results showed that massive galvanic corrosion of AZ31B occurred over time, with the corrosion current significantly higher than that of AZ31B without galvanic coupling. The mechanical joint integrity of the corroded joints was retained to a certain extent, but decreased due to the massive volume loss of AZ31B.
JOURNAL OF MAGNESIUM AND ALLOYS
(2022)
Article
Metallurgy & Metallurgical Engineering
Yuan Li, Yong Chae Lim, Jian Chen, Jiheon Jun, Zhili Feng
Summary: This study investigates the effects of different steel rivet shank sizes on the performance of carbon fiber reinforced polymer (CFRP) and AZ31B Mg alloy joints joined by friction self-piercing riveting (F-SPR). The results show that the lap shear fracture load and mechanical interlock distance increase with the increase of rivet shank size. Ultrafine grains are formed at the joint in AZ31B, resulting in higher hardness. In terms of fatigue life, the CFRP-AZ31B joint performs better at higher peak loads (>2 kN) and is comparable to resistance spot welding of AZ31B to AZ31B at lower peak loads (<1 kN).
JOURNAL OF MAGNESIUM AND ALLOYS
(2022)
Article
Polymer Science
Demetrios A. A. Tzelepis, Jorge Suzuki, Yi Feng Su, Yiyu Wang, Yong Chae Lim, Mohsen Zayernouri, Valeriy V. V. Ginzburg
Summary: In this study, we synthesized, characterized, and modeled IPDI-DETDA-PO PUa with different hard segment contents. Through various analysis techniques, we observed the microphase separation between the hard and soft nano-domains and studied the linear viscoelastic response of the PUa. We also developed a new micro-mechanical model that accurately described the DMA results and the relationship between the percolated hard phase and the hard segment weight-fraction.
JOURNAL OF APPLIED POLYMER SCIENCE
(2023)
Article
Engineering, Manufacturing
Wei Zhang, Dali Wang, Jian Chen, Hassan Ghassemi-Armaki, Blair Carlson, Zhili Feng
Summary: The root cause of post-weld baking on the mechanical performance of Al-steel dissimilar resistance spot welds has been identified using machine learning and finite element modeling. A deep neural network model correlated spot weld performance with joint attributes, stacking materials, and other conditions. It was found that post-weld baking reduces joint performance, with the extent of degradation depending on the stacking materials' thickness. Finite element modeling revealed that high thermal stresses during baking, caused by thermal expansion mismatch, lead to damage and cracking of the brittle intermetallic compound formed at the weld nugget interface during welding.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Materials Science, Multidisciplinary
Zhili Feng, S. A. David, V. K. Manchiraju, D. A. Frederick, W. Thomas
Summary: Friction extrusion is a solid-state process that utilizes frictional heating and plastic deformation to synthesize and recycle metals and alloys into highly engineered materials. It is an energy-efficient, zero-emission, and economically competitive technology that eliminates the need for energy-intensive melting and solidification steps. This work introduces the concept and configuration of friction extrusion, analyzes its energy-saving advantage, demonstrates its feasibility with synthesizing Al alloys, and presents the results of metallographic and mechanical properties studies. The future prospects of friction extrusion technology are outlined.
Article
Chemistry, Analytical
Shenghan Guo, Dali Wang, Zhili Feng, Jian Chen, Weihong Guo
Summary: In this study, manufacturing domain knowledge was leveraged to enhance the accuracy and interpretability of convolutional neural networks (CNNs) in quality prediction. A novel CNN model called Di-CNN was developed, which learned from design-stage information and real-time sensor data and adaptively weighted these data sources during training. By using domain knowledge to guide model training, the proposed model achieved superior performance in quality prediction.
Article
Metallurgy & Metallurgical Engineering
Jiheon Jun, Vineet V. Joshi, Alasdair Crawford, Vilayanur Viswanathan, Donovan N. Leonard, Jian Chen, Piyush Updadhyay, Yong Chae Lim, Zhili Feng
Summary: Quantitative study was conducted on the galvanic corrosion of AZ31B joined with bare or Zn-coated DP590 steel by ultrasonic spot welding or linear friction stir welding. The corrosion volume and depth were analyzed based on cathode surface type and welding method. Experimental results showed that Zn-coated cathode surface significantly reduced Mg galvanic corrosion, while COMSOL modeling provided reasonable simulation but underestimated the corrosion volume.
JOURNAL OF MAGNESIUM AND ALLOYS
(2023)
Article
Engineering, Manufacturing
Hui Huang, Yiyu Wang, Jian Chen, Zhili Feng
Summary: Thermal distortion and residual stresses are important factors affecting the quality and reliability of steel parts manufactured by LPBF. A cost-effective model is needed to evaluate these heat effects to optimize the manufacturing process. The study compared the computational accuracy and efficiency of layer heating and track-layer scanning methods for simulating the thermo-mechanical response of IN625 tube parts built by LPBF. The layer heating method efficiently captured stress distribution patterns with reasonable accuracy, while the grouped track-layer scanning method predicted residual stresses and strains more accurately at a higher cost.
INTEGRATING MATERIALS AND MANUFACTURING INNOVATION
(2021)