This article showcases details on enumerative information of dissimilar aluminum (Al) to steel welds manufactured using different friction-based welding processes with an emphasis on the description of the manufacturing process, influence of parameters, microstructural variations, formation of intermetallic compounds (IMCs), and variations in mechanical properties. Friction-based welding processes such as friction welding, friction stir welding, hybrid friction stir welding, friction stir spot welding, friction stir spot fusion welding, friction stir scribe welding, friction stir brazing, friction melt bonding, friction stir dovetailing, friction bit joining, friction stir extrusion, and friction stir assisted diffusion welding are analyzed for the formation of dissimilar Al–steel joints. It can be summarized that friction-based joining processes have great potential to obtain sound Al–steel joints. The amount of frictional heat applied decides the type and volume fraction of IMCs that subsequently affects mechanical joint properties. Process variations and novel process parameters can enhance joint properties.

/pdf/a-review-on-friction-based-joining-of-dissimilar-aluminum-33ex2zbqwr.pdf

A review on friction-based joining of dissimilar aluminum–steel joints

Microstructure and mechanical properties of resistance-spot-welded joints for A5052 aluminum alloy and DP 600 steel

In this study, we proposed a novel approach to improve centrifugal pump performance with regard to the pump head, pump efficiency, and power. Firstly, to establish constraints, an optimal numerical model that accounted for factors such as pump efficiency and the head was considered. The pump was designed, and an artificial intelligence algorithmic approach was applied to the pump before performing experiments. We considered a set of models by selecting the parameters of the centrifugal pump casing section area, the interference of the impeller, the volute tongue length, and the volute tongue angle. The weights of the factors of safety and displacement on the optimization indices were estimated. The matrix of the weights for the optimal process was less than 38% or greater than 62%. This approach guarantees a complicated multi-objective optimization problem. The results show that the centrifugal pump performances were improved.

/pdf/cfd-analysis-and-optimum-design-for-a-centrifugal-pump-using-2hj7s9ta.pdf

CFD Analysis and Optimum Design for a Centrifugal Pump Using an Effectively Artificial Intelligent Algorithm

Effect of beam oscillation on porosity and intermetallics of electron beam welded DP600-steel to Al 5754-alloy

The proper implementation of sustainable manufacturing processes is an effective step towards a clean environment. The modern cooling strategies applied in the manufacturing sector have presented promising solutions that enable economic growth and ecological environment. In machining operations, cryogenic cooling and minimum quantity lubrication (MQL) have been extensively utilized to replace conventional cooling techniques. Thus, this work offers a detailed review of major works focused on manufacturing processes that use some of these sustainable cooling/lubrication modes (i.e., MQL, nanocutting fluids, nanofluid-based MQL strategy, and other miscellaneous MQL upgrades). The main driver of this study is to create a bridge between the past and present studies related to MQL and MQL upgrades. In this way, a new guideline can be established to offer clear directions for a better economic vision and a cleaner manufacturing process. Thus, this review has mainly focused on the machining of the most commonly used materials under MQL-related methods in conventional operations including turning, milling, drilling, and grinding. Current work provides a detailed insight into the major benefits, limitations, as well as mechanisms of cooling strategies that directly affects the machinability performance from a sustainable point of view. In summary, further potential upgrades are indicated so that it will help to drive more sustainable approaches in terms of cooling and lubrication environment during machining processes.

Progress for sustainability in the mist assisted cooling techniques: a critical review

Compliant mechanisms' design aims to create a larger workspace and simple structural shapes because these mechanical systems usually have small dimensions, reduced friction, and less bending. From that request, we designed optimal bridge-type compliant mechanism flexure hinges with a high magnification ratio, low stress by using a flexure joint, and especially no friction and no bending. This joint was designed with optimal dimensions for the studied mechanism by using the method of grey relational analysis (GRA), which is based on the Taguchi method (TM), and finite element analysis (FEA). Grey relational grade (GRG) has been estimated by an artificial neural network (ANN). The optimal values were in good agreement with the predicted value of the Taguchi method and regression analysis. The finite element analysis, signal-to-noise analysis, surface plot, and analysis of variance demonstrated that the design dimensions significantly affected the equivalent stress and displacement. The optimal values of displacement were also verified by the experiment. The outcomes were in good agreement with a deviation lower than 6%. Specifically, the displacement amplification ratio was obtained as 65.36 times compared with initial design.

Optimal Design for Compliant Mechanism Flexure Hinges: Bridge-Type.

Butt joints of A5052 aluminum alloy and SS400 steel, with a new type of chamfered edge, are welded by means of metal inert gas welding and ER4043 Al-Si filler metal. The microhardness and microstructure of the joint are investigated. An intermetallic layer is found on the surface of the welding seam and SS400 steel sheet. The hardness of the intermetallic layer is examined using the Vickers hardness test. The average hardness values at the Intermetallic (IMC) layer zone and without the IMC layer zone were higher than that of the welding wire ER4043. The tensile strength test showed a fracture at the intermetallic layer when the tensile strength is 225.9 MPa. The tensile value test indicated the average of welds was equivalent to the 85% tensile strength of the A5052 aluminum alloy. The thickness of the intermetallic layers is non-uniform at different positions with the ranges from 1.95 to 5 μm. The quality of the butt joint is better if the intermetallic layer is minimized. The Si crystals which appeared at the welding seam, indicating that this element participated actively during the welding process, also contributed to the IMC layer's formation.

An Investigation of the Microstructure of an Intermetallic Layer in Welding Aluminum Alloys to Steel by MIG Process

Minimizing Warpage for Macro-Size Fused Deposition Modeling Parts

The tungsten inert gas (TIG) welding method most commonly used to weld ferrous metals, nonferrous metals, and other metals since it is simple, easily implemented, and achieves consistent high-quality welds. In this study, butt joints produced between aluminum alloy A6061-T6 and stainless steel SUS304L have been achieved by using TIG welding with ER4047 filler metal. The macrostructure and microstructure of the resulting specimens were analyzed by means of an optical microscope (OM), a scanning electron microscope (SEM), and an energy dispersive X-ray spectrometer (EDS). A uniform intermetallic layer was found at the interface between the stainless steel and the weld seam having a thickness of 2 µm, and the intermetallic compound (IMC) includes Fe4Al13, Fe2Al5, and FeAl3 phases. The micro-hardness and tensile strength of the weld joints were also investigated. Due to Si content in the compensating metal, there was a prevention of iron diffusion into the aluminum, thus hindering the development of the IMC layer and reducing its thickness in such a way that the weld joint strength increases. The analyzed results show that the average micro-hardness of the stainless steel, weld seam, aluminum alloys, and IMC layer were 218 HV, 88.3 HV, 63.3 HV, and 411 HV, respectively. The fracture occurred at the brazed interface, and the ultimate tensile strength value reached 225 MPa.

Microstructure and Mechanical Properties of Butt Joints between Stainless Steel SUS304L and Aluminum Alloy A6061-T6 by TIG Welding.

In metal machining, the selection of cutting parameters and cooling conditions affects the quality of the cutting process as surface roughness. For this purpose, the effect of cutting fluids (dry, MQL, and Nanofluid based MQL) and cutting parameters (cutting speed, depth-of-cut, and feed rate) on surface roughness was investigated during hard milling of AISI H13 steel. The experiments were carried out by using the Taguchi method and the optimal values were introduced based on an analysis of the signal-to-noise response and ANOVA. The results of the present study indicated that the cooling condition and the feed rate are the factors holding the most influence on surface roughness.

Quoc Manh Nguyen

Papers

Optimal Design for Compliant Mechanism Flexure Hinges: Bridge-Type.

An Investigation of the Microstructure of an Intermetallic Layer in Welding Aluminum Alloys to Steel by MIG Process

Minimizing Warpage for Macro-Size Fused Deposition Modeling Parts

Microstructure and Mechanical Properties of Butt Joints between Stainless Steel SUS304L and Aluminum Alloy A6061-T6 by TIG Welding.

Optimization of cooling conditions and cutting parameters during hard milling of AISI H13 steel by using Taguchi method