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Introduction to Sustainable Manufacturing Processes
Published in R. Ganesh Narayanan, Jay S. Gunasekera, Sustainable Material Forming and Joining, 2019
R. Ganesh Narayanan, Jay S. Gunasekera
A novel method of joining tube to a plate by friction stir concept has been proposed by Senthil Kumaran et al. (2012). The process consumes lesser power of 0.1874 kWh as compared with TIG welding consuming 0.6755 kWh, reducing the power charge from Rs. 3.377 to Rs. 0.937 (USD 0.047 to USD 0.013). The welding time is drastically reduced from 16 MTS to 0.683 MTS in the case of new method. The joint formed is strong enough as compared with TIG welding. The application of hybrid welding, combination of a high energy CO2 laser with the metal active gas (MAG) arc welding, is demonstrated in Wieschemann et al. (2003). It combines the advantage of deeper penetration by arc welding and arc stability given by laser welding because of the presence of plasma. The synergistic interaction increases the efficiency of the process while requiring low levels of linear energy. In order to minimize the use of fusion welding processes involving harmful consumables and fluxes, many solid-state welding methods, such as friction processing technologies, including friction stir welding, friction welding, friction spot welding (Fujimoto et al., 2005; Nicholas, 2003; Sahin, 2009), magnetic pulse welding (Kapil and Sharma, 2015; Kimchi et al., 2004), mechanical joining methods like joining by plastic deformation (Alves et al., 2011), self-pierced riveting (Bouchard et al., 2008; He et al., 2008; Porcaro et al., 2006), clinching (Lee et al., 2010; Varis, 2003), etc., are proposed. These processes are described in Figure 1.11. All the process involves plastic deformation as a major component for joining.
Magnesium and Its Alloys
Published in Omar Faruk , Jimi Tjong , Mohini Sain, Lightweight and Sustainable Materials for Automotive Applications, 2017
D. Sameer Kumar, C. Tara Sasanka
Fusion welding of magnesium die castings can be challenging due to the presence of porosity and the formation of a brittle inter metallic phase (Mg17Al12) in the welds [26]. Solid-state welding techniques, such as friction-stir welding and magnetic pulse welding can be used to improve the weld quality of magnesium die castings. While these solid-state welding techniques can potentially be used to join magnesium to dissimilar materials such as aluminum, mechanical joining (self-piercing rivets, clinching, and hemming) and adhesive bonding are preferred for dissimilar material joining involving magnesium to aluminum or steel.
Experimental investigation on structure parameters of E-shaped coil in magnetic pulse welding
Published in Materials and Manufacturing Processes, 2019
Huaiqing Zhang, Zhiyuan Yang, Lianglu Ren
Newly and more environmentally friendly manufacturing technology has been used more commonly in the past decade.[1–3] Magnetic Pulse Welding (MPW) is a cold welding process which has quickly emerged owing to the rising requests in lightweight structures manufacturing.[4,5] As an advanced manufacturing technology, MPW can realize the connection between two similar or dissimilar metals, which makes up for the shortcomings of traditional welding technology. MPW technology integrates the advantages of high-speed forming and solid-phase joining to ameliorate the differences in melting point and physical performance in welding dissimilar metals, which makes it well suited to welding dissimilar metals.[6,7] It can be seen as the ideal solution assembly in many applications such as multi-material joining or tubular overlap parts.[8,9] At present, MPW can weld materials such as iron, copper, aluminum, gold, magnesium, zinc, etc.[10,11], and it has been used in the nuclear industry, the automotive industry, aerospace, weapons, packaging, consumer goods, and electrical industries.[8]
Dissimilar metal joining and structural repair of ZE41A-T5 cast magnesium by the cold spray (CS) process
Published in Materials and Manufacturing Processes, 2018
Victor Champagne, Dan Kaplowitz, Victor Kenneth Champagne, Chris Howe, Michael K. West, Baillie McNally, Michael Rokni
Magnetic pulse welding (MPW) is a solid-state welding technique comparable to explosive welding and produces a mechanically induced local weld, with a small fusion zone and no heat affected zone (HAZ). S.D. Kore et al. reported MPW was capable of eliminating the formation of IMCs and attaining a lap shear strength of 185 MPa when testing joints of AZ31-H24 having a UTS of 270 MPa and AL 3003-H14 having a UTS of 158 MPa [47].