Sharif Digital Repository

Composite production is an important method for increasing abrasion resistance in materials. Friction stir processing (FSP) is a solid composite production method which has eliminated the problems of liquid composite production. This research used FSP to study the possibility of in situ production of 1050 aluminum composite with a mixture of copper and iron powder with micrometer sizes of 25-14 and 10 μm, respectively, as reinforcing particles. The following weight percentages of reinforcing powder was added to the sample: 75% iron-25% copper, 50% iron-50% copper and 25% iron-75% copper. In addition, 3 and 5 process passes were considered as another variable in this study. Afterward, the... 

Martensitic stainless steels with high strength, good corrosion resistance and formability in the annealed condition are good choices for automotive applications, but they suffer from low weldability due to high hardenability and formation of brittle martensite without tempered structure in the weld metal and heat affected zone (HAZ). In other word, martensitic stainless steels have the worst weldability among all kinds of stainless steels. On the other hand, resistance spot welding is the main method for joining sheets in the automotive industry. Therefore, in the present work, microstructure and mechanical properties of the resistance spot welds of AISI 420 martensitic stainless steel in... 

Upset Resistance Welding (URW) is a solid-state joining process which can be used to join a variety of parts and profiles including railways, wheel rims and pipes used in oil and petrochemical industries. This process has three primary parameters, welding current, current passage time and mechanical pressure. Martensitic Stainless Steels (MSSs) due to high strength and wear resistance, good atmospheric corrosion resistance and relatively low price and Duplex Stainless Steels (DSSs) because of higher strength and better corrosion resistance in chlorine environments, are widely used in different industries. Dissimilar MSS/DSS joints are of great importance for piping, specially in oil and... 

Friction stir spot welding (FSSW) as a solid-state process is able to tackle some problems of fusion welding. On the contrary, FSSW has some drawbacks such as the low area of connection and weakness in fatigue behavior. In this study, an innovative method called friction stir spot welding via consumable pin (CP-FSSW) was used, which was able to eliminate the exit-hole. In this process, at the first stage, a hole is created in the center of the overlap area of the sheets; such that the hole is complete in the upper sheet and up to the half thickness of the lower sheet. Then, the rotating tool composed of a consumable pin with diameter length as much as the created hole and same type of the... 

Magnesium alloys as the lightest structural alloys, have a strong potential for improving the energy efficiency of different transportation systems such as automobiles, aerospace and electronics due to their high strength to weight ratio. Welding plays a crucial role as a foundational manufacturing technology. Hence, the extensive utilization of materials is greatly impacted by their ability to be welded.These alloys are highly susceptible to hot cracking such as liquation cracking during the fusion welding processes.Various mechanisms play a role in the occurrence of hot cracking, but the constitutional liquation of the coarse eutectic mg17al12 intermetallic phase is accountable for the... 

Today because of increasing use of fuel, environmental problems and problems due to heavy structures in different industries it is important to use structures with high specific strength. Using different materials in structures like polymers accompanying aluminum could be useful. Polymers are light, heat insulating and have a high corrosion resistance. Polypropylene is one of the useful polymers which can have high impact energy and strength via adding Elastomer and Talc powder, relatively. One of the common ways in joining metal to polymer uses adhesive. It has variety of benefits such as low distortion in joining, different materials joints and having joints with complex geometry. Welding... 

Joining metal and alloy is a continuous and inevitable effort in oil and gas and automotive industry, and a considerable number of these joints are dissimilar joints. Steels and aluminum alloys are two of the most utilized engineering material and bi-metallic steel-aluminum parts have a lot of applications due to having the combined properties of both alloys (for example the high tensile strength and wear resistance of steels along with good thermal and electrical conductivity and corrosion resistance of aluminum alloys). However, fusion welding of aluminum to steel possesses great challenges due to the difference in melting point, coefficient of thermal expansion, thermal conductivity and... 

Friction Stir Spot Welding as a solid state process is able to solve some of the disadvantages of fusion welding processes. On the other hand, this welding method has disadvantages such as low connection surface due to the hole left by the pin and poor resistance to fatigue loading. In this study, a method called friction stir spot welding via consumable pin was used so that the hole caused by the pin no longer remains at the welding site. The process is done in such a way that first a hole is made in the center of the overlap of the sheets. The rotating tool, in which the consumable pin is made of 6061 aluminum alloy with a diameter equal to the diameter of the hole is lowered at a... 

The use of tin-lead solder alloys (Pb-Sn) has been limited due to environmental problems in recent years, and several types of research are being carried out on lead-free solder alloys. However, these solders have weaker physical and thermal properties than Pb-Sn solders. In recent years, researchers have been trying to improve these solders' physical and mechanical properties by adding reinforcing particles to the solder and using a magnetic field during melting and solidifying the solder. On the other hand, with the growth path of miniaturization and, simultaneously, compaction and integration of electronic equipment, electronic circuits should have higher current density, better... 

Considering the unique characteristics of aluminum alloys in the 5XXX series, such as high strength-to-weight ratio and corrosion resistance, as well as the absence of precipitation hardening, composite fabrication using these alloys has garnered attention. Consequently, friction stir additive manufacturing (FSAM), a novel solid-state layering technique, has been proposed for manufacturing components from these alloys, avoiding the drawbacks associated with traditional melt-based additive manufacture methods. The objective of this research is to produce a five-layer 20mm composite wall in the aluminum 5754 substrate using iron powder via FSAM to achieve desirable mechanical properties. To... 

Due to the growing trends in application of aluminum alloys for automotive body production, the need for development of successful dissimilar joints between steels and aluminum alloys is growing too. The main process for joining these metals in automotive industry is resistance spot welding (RSW). However, there are some challenges in RSW of the aluminum to steel such as different physical properties of two metals, formation of brittle Al/Fe intermetallic compounds (IMCs) and presence of porosities at the weld interface which adversely affect the weld properties. In order to overcome these limitations, several methods have been proposed. Al interlayer is one of these methods. The use of the... 

Use of materials with both high strength and good formability in car structure is a serious approach in the automotive industry to reduce weight as well as maintain the security of occupants. Stainless steels such as duplex steels are one of the most attractive candidates. Thus, metallurgical and mechanical behavior during resistance spot is important. The aim of this work is to study the microstructure-property relationships in resistance spot welding of duplex stainless steel. Austenite-ferrite phase balance and weld nugget size are two key factors determining the mechanical properties of these steels. High cooling rate of resistance spot welding can have a significant impact on the... 

Fusion welding of Duplex Stainless Steel (DSS) and dissimilar welding of This alloy and other steels have a lot of problems such as losing phase balance and formation of secondary phases i.e. Sigma Phase. Therefore, Friction Stir Welding (FSW) was used as a substitute for traditional fusion welding techniques of DSS. The present study investigates the relationship between the process variables and microstructural and the mechanical properties of frictional welding of similar and dissimiliar FSW of DSS to carbon steel in order to obtain the joint with the highest mechanical strength. In this study, similar welding of S2304 DSSs and dissimilar welding of S2304 and St12 using FSW were... 

Nowadays, metal-polymer dissimilar joints have attracted the attention of many industries, and the aplication of these joints in various industries such as automotive and aerospace is increasing. However, due to considerable differences in physical properties of metals and polymers, proper bonding between these materials is not easily possible, and metal-polymer joining remains one of the major challenges in the development of advanced composite structures. The adhesive/friction stir joining hybrid process is a relatively new idea that has been proposed to achieve longer lasting bonds and more safe structures. Using this process for metal-polymer joining can take advantage of both methods;... 

High-strength aluminum alloys are widely used in various industries; however, their usage is limited to solid-state welding or mechanical joints due to their low weldability. The main metallurgical challenge of alloy 7075 welding is hot cracking. Thus, the mentioned alloy is introduced as a "non-weldable alloys" category. In this study, the PMZ was investigated, and it was shown that precipitations play an essential role in intensifying the phenomenon of partial melting. On the other hand, the result of the mechanisms activated in the PMZ, called the "L" region, occurs in the grain boundaries during welding. Welded plate with FM1050 causes liquation cracking, while Welded plate with FM4043... 

In this research, the strength and wear resistance of aluminum 5083 was improved by using composites with magnesium oxide nanoparticles (MgO-20nm) and friction stir processing. The effect of the number of process passes and rotational speed variables, considering the number of one, three, and five passes at rotational speeds of 700, 1000, 1300, 1600, and 1900 rpm, was investigated on the mechanical properties and wear behavior of the composite. To determine the appropriate weight percentage of MgO powder, the longitudinal tensile strength of three composites with different weight percentages of 3, 4.7, and 6 were compared. The linear movement speed of the tool was selected as a constant... 

Wire-arc additive manufacturing is one of the types of additive manufacturing methods that creates the desired part through layer-by-layer deposition. Heat input and interlayer temperature have an important role in this process. Duplex stainless steels have a wide range of applications due to their high corrosion resistance in chloride environments and higher strength than austenitic stainless steels. In this study, the effect of heat input (0.3 kJ/mm and 0.8 kJ/mm) and interlayer temperature (250 ºC and 40 ºC) was investigated on the macrostructure, microstructure and mechanical properties of 2209 duplex stainless steel walls that produced by gas metal arc welding based wire-arc additive... 

Resistance spot welding is one of the types of sheet metal joining processes used in many industries, such as automotive, home appliances, and aviation. In the direct welding of aluminum to steel, brittle intermetallic compounds are formed, which is necessary to control the thickness of these intermetallic compounds to improve welding properties. Using an aluminum-clad layer can effectively reduce the thickness of intermetallic compounds by reducing the heat generation at the steel-aluminum interface. This research aims to investigate experimentally and theoretically the welding of aluminum-clad steel sheet to Al-Mg aluminum sheet by resistance spot welding process with finite element method... 

All humanare subject to a physiligical phenomenon known as tremor, which introduces unintended, relatively high frequency movments into various limbs. This involuntary movment is main reason of human disability in doing of precision tasks. Precision surgery like eye surgery is among them that surgeons must have very ittle tremor to enable them to oprate on the small anatomy of the eye. In this reaearch by emphasizing on reduction of muscle fatigue in precision surgery, weight balancing mechanism designed and analyzed. Fatigue is most important cause of tremor, thus we expected tremor amplitude reduce by reduction of muscle fatigue. Purpose mechanism is passive mechanism that balances the... 

In this study, Butt resistance welding of copper to aluminum wires was studied. In this regard, the effect of current, pressure, post weld heat treatment and using intermediate layer of tin on the microstructure, strength and special electrical resistance of welds were examined. Based on a series of initial tests to establish the connection with the appropriate strength, the diameter of the aluminum and copper wires respectively 3 and 3.5 mm and their length 9 and 3.5 cm were selected. In order to weld samples, currents 4.4 to 4.7 KA and pressures 0.3 and 0.5 MPa were used. Then post weld heat treatment at currents 0.5, 1 and 1.5 KA on the welded sample in the pressure 0.3 MPa and the...