Sharif Digital Repository

Joining feasibility of aluminium alloy to polypropylene sheets via friction stir lap joining was examined. Effects of heat-input on microstructure and mechanical behaviour of the joints were investigated. A covering plate was used to confine flow of molten polymer. The results showed a distinctive interaction layer at polymer/aluminium interface, consisted mainly of C, O and Al. Shear strength of the joints decreased by enhancement of the heat-input due to increase in the thickness of the interaction layer as well as the gap width between this layer and both aluminium and polymer matrices. Maximum shear-tensile strength of 5.1MPa (∼20% of polymer shear strength) was obtained, which was... 

Electric arc welding is a routine operation in the construction of metallic structures, but the fumes generated during the welding process can threaten the health of welders. Fumes are undesirable products of the majority of welding operations and may have various detrimental effects on health. The purpose of this study was to investigate the effect of operational parameters of the shielded metal arc welding SMAW process on the emission of fumes. A dust monitor was used to measure the number and mass concentration of fumes generated by SMAW. Measurements were made at the distances of 23 cm hood inlet and 41 cm welder’s breathing zone from the weld point, with different values assigned to... 

In the present study, a thermo-elastic-plastic model was developed in order to evaluate the residual stresses in dissimilar automatic tungsten inert gas (TIG) welds between plain carbon steel CK4 and a ferritic stainless steel AISI409. The effect of welding heat input on the magnitude and the distribution of residual stresses was investigated and the results of simulation were validated by X-ray diffraction measurements. It is shown that the calculated residual stresses are in good agreement with the residual stresses determined experimentally. It was found that the magnitudes of stresses at the weld center line increases with increasing the welding speed  

In this study, friction stir soldering (FSS) as an emerging joining process with the aid of a preliminary electroplating process was utilized for the first time to fabricate graphite-copper lap joints aimed at investigation of rotational speed influence on joint interface microstructure and mechanical behaviour. To do so, an Sn-37Pb solder foil was placed between a copper sheet and a copper-coated graphite substrate after which a rotating pin-free tool was plunged into the copper sheet and allowed to travel along the joint. Results indicated that adhesive strength between the electroplated copper coating and graphite substrate was strongly affected by surface roughness and plating current... 

The heat affected zone (HAZ) softening behavior of strain-hardened Al-6.7Mg alloy welded by gas tungsten arc welding (GTAW) process was investigated. Increasing the heat input during welding led to formation of a wider HAZ. Moreover, the size of the precipitates was increased at higher heat inputs. Consequently, by increasing the heat input, lower strength was obtained for the welding joints. At the second stage of the study, pulsed-GTAW (PGTAW) process was employed to improve the strength of the joints. It was observed that the overall strength of the welding joints was improved and the fracture during tensile test was moved from the HAZ to the fusion zone. Moreover, the effect of duration... 

In this study, AA 1050 aluminum alloy and commercially pure copper in annealed and severely plastic deformed conditions were used. The technique used for imposing the severe strain to the sheets was constrained groove pressing (CGP) process. The annealed and severely plastic deformed sheets were subjected to friction stir welding (FSW) at different rotation and traverse speeds. Cu was placed in advancing side. Constant offset of approximately 1 mm was used toward Al side for all welds. A range of welding parameters which can lead to acceptable welds with appropriate mechanical properties was found. For the FSWed CGPed samples, it was observed that the welding heat input caused grain growth... 

In this study, a novel Magnetically Variable Conductance Thermosyphon Heat Pipe (MVCTHP) was investigated experimentally. The possibility of deactivating a portion of evaporator length and subsequently altering heat pipe resistance by positioning a steel ball inside the evaporator and moving it by an external magnet was studied. The effect of various ball positions in the evaporator and inclination angles on heat pipe performance was studied at 30, 60, 90 and 120 W. The results indicated that at a given heat input, moving the ball away from the beginning of the evaporator of heat pipe increases its thermal resistance. Furthermore, by increasing heat input, MVCTHP performance for various ball... 

The effect of working fluid inventory and heat input on the performance of thermosyphon is investigated in this paper. First, a thermosyphon with diameter of 16 mm made of steel with toluene as working fluid and the length of the evaporator, adiabatic and condenser section 10, 23 and 17 cm was considered, respectively. The working fluid inventory was considered 0.1, 0.14, 0.18 and 0.24 of total volume of thermosyphon and in each case 54–235 W of heat input applied to the evaporator area also. In order to evaluate the transient behavior of the thermosyphon, in any amount of working fluid, 28 W of heat input was considered and temperature of the evaporator area were recorded at different... 

This research investigates the relationship between the microstructures of thermomechanically affected zone (TMAZ) and heat input in friction stir welding (FSW) of 5086 aluminum alloy. First, welding heat input has been predicted using a three-dimensional finite element analysis; then, welding experiments have been carried out on annealed and work-hardened conditions to study the developed microstructures and the mechanical properties of the welded metal. The results show that the temperature field in the FSW process is asymmetrically distributed with respect to the welding line. Also, both experimental and predicted data illustrates that peak temperatures are higher on the advancing side... 

Al-Mg aluminum alloy was lap joined to aluminum clad steel sheet using pulsed gas tungsten arc welding process and Al-Si filler metal. The effects of the welding heat-input were investigated on the joint microstructure and mechanical properties. Weld metal microstructure, formation of intermetallic compounds (IMCs) at the joint interface and the fracture locations were studied using stereo, optical and scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS). The joint strength of the welds was evaluated by shear-tensile test. The results showed that presence of a thin aluminum clad layer with 350 μm thickness drastically decreased the Al-Fe intermetallic... 

Tungsten Inert Gas (TIG) process and titanium cored wires filled with micro size TiC particles were employed to produce surface composite coatings on commercial pure Ti substrate for wear resistance improvement. Wire drawing process was utilized to produce several cored wires from titanium strips and titanium carbide powders. Subsequently, these cored wires were melted and coated on commercial pure Ti using TIG process. This procedure was repeated at different current intensities and welding travel speeds. Composite coating tracks were found to be affected by TIG heat input. The microstructural studies using optical and scanning electron microscopy supported by X-ray diffraction showed that... 

The present work investigates the thermal performance of a five turn Open Loop Pulsating Heat Pipe (OLPHP). The effects of working fluid namely water and ferrofluid, heat input, ferrofluid concentration, charging ratio, and orientation will be considered. Experimental results show that using ferrofluids can enhance the thermal performance in comparison with the case of distilled water. In addition, applying a magnetic field on the OLPHP charged with ferrofluid reduces its thermal resistance. Variation of the ferrofluid concentration results in different thermal performance of the OLPHP. Best charging ratio for the distilled water and ferrofluid without magnetic field is 60 % in most of the... 

There has been great demand for shape memory alloy (SMA) wires as actuators for shape control of flexible structures. The experimental setup of this study consists of a flexible beam actuated by two active SMA actuators. The input applied to the SMA actuator in this setup is electrical current while the output is the strain or position. To control strain of the actuator, the SMA wire is heated resistively in order to reach the desired temperature calculated by inverse of the phenomenological model. In heating the SMA wire resistively, the controllable quantity is the heat input to the wire via an applied current. In controller design, changes of physical properties of SMA wires and the... 

It is proposed to employ melting rate, heat input, and detaching droplet diameter as controlled variables to control heat and mass transfer to work piece in a gas metal arc welding process. A two-layer architecture with cascade configuration of PI and MPC controllers is implemented to incorporate existing constraints on the process variables, improve transient behavior of the closed-loop responses and reduce interaction level. Computer simulation results are presented to indicate usefulness of the proposed controlled variables selection and applying two-layer control architecture to control heat and mass transfer to work piece  

In the present research, different weld layers were deposited on a 1.2714 steel die by gas tungsten arc (GTA) welding with the weld wire of Udimet 520, and effects of welding parameters on microstructure and mechanical properties of Udimet 520 superalloy were investigated. The results showed Udimet 520 weld with cellular-dendritic and rarely dendritic structure including γ matrix rich of Cr, Mo and W, low percentage associated with order morphology and relative uniform distribution of MC type carbides. Udimet 520 alloy showed high resistance against hot cracking during welding and hot cracking occurred only at high input heat values. Also, cracking during welding occurred at the places that... 

In this work, a four-turn pulsating heat pipe (PHP) is fabricated and tested experimentally. The novelty of the present PHP is the capability to obtain various thermal performances at a specific heat input by changing the magnetic field. The effects of working fluid (water and ferrofluid), charging ratio (40% and 70%), heat input (35, 45, 55, 65, 75, and 85 W), orientation (horizontal and vertical heat mode), ferrofluid volumetric concentration (2.5% and 7%), and magnetic field on the thermal performance of PHPs are investigated. The results showed that applying the magnetic field on the water-based ferrofluid reduced the thermal resistance of PHP in all orientations. In the presence of a... 

The aim of this investigation is to study the effect of geometric tool parameters on mechanical and microstructural behaviours during dissimilar friction stir welding of 5 mm thick plates of AA 5086- O and AA 6061-T6. Three tool geometries were used, including a tool with a concave shoulder and a conical probe with three grooves, flat shoulder and threadless cylindrical probe, and a tool with a flat shoulder and a threaded cylindrical probe. It was found that the tool with a concave shoulder and a conical probe with three grooves produces higher heat input and temperatures that provides more homogeneous stir zones than the other tools. In addition, the grain sizes of the stir zone in the AA...