The area of research dealing with joining of dissimilar metals has been active in recent time. Although fusion and non-fusion techniques of joining have been effectively used for manufacturing components, a comprehensive scientific understanding of the process is lacking. This void exists both in fusion and non-fusion welding methods. The present investigation addresses some of these aspects. The investigation consists of two sections - Part A and Part B. Part A is on Friction welding and Part B deals with Fusion welding using laser. Each section has two chapters each. Following an introductory chapter, basic aspects of friction welding is presented in chapter 2. Chapter 3 deals with the work on friction welding of Fe-Cu couple. Fe-Cu couple is a system with positive heat of mixing. After a brief introduction on various non-equilibrium processes that can occur in this system, experimental details and results are presented. Using the results an attempt is made to understand the flash formation, formation of pores at the interface and the formation of chemically altered zone. It is observed that a chemically altered layer forms predominantly on the Cu side of the interface. It consists of Fe entrapped as fragments/fine crystals and as solid solution in Cu matrix. This zone has higher thickness at the edges than at the center. The mechanism of formation of this interfacial layer which is central to the joining process is related to the fracture and transport of fragments during plastic deformation. Fe forms solid solution in copper under non-equilibrium conditions promoted by shear energy. Using the concept of ballistic mixing, the formation of solid solution is explored. Using nano-indentation experiments mechanical properties of the weldment is estimated and an attempt is made to correlate mechanical properties with the amount of second element present in that location. The chapter 4 in part A deals with the friction welding of Ni-Ti couple. Ni-Ti system has negative heat of mixing and it forms a number of intermetallics. After a brief introduction to the chapter, various experimental techniques and strategies followed to carry out the experiments are explained. Following these, the results are presented. It is observed that TiNi3 formed at initial stage. Theories based on effective heat of formation and surface energy also predict the nucleation of TiNi3. With the continuation of frictional processes, the formation of TiNi and Ti2Ni phases were also observed. Formation of Ti2Ni was shown to greatly accelerate due to shear process. In this system two complementary processes like ballistic mixing and thermal assisted diffusion accelerate Ti2Ni formation. From mechanical tests it is found that Ti2Ni layer in the weldment is weak and hence formation of Ti2Ni in the weldment is detrimental. In chapter 5 an introduction to fusion welding of dissimilar metals is presented as background materials for the subsequent chapters. Chapter 6 deals with nature of segregation of Ag during laser welding of Fe-Ni couple. Ag is used as a tracer to probe fluid flow in the Fe-Ni couple during laser welding. Ag is immiscible both in Fe and Ni whereas Fe and Ni form a complete solution at an elevated temperature and in liquid state. Besides the experimental work, numerical simulation of the weld pool were carried out using homogeneous mixture model using SIMPLER algorithm. Experiments and simulations indicate that fluid flow is asymmetrical and in the deep penetration welding strong convection in the pool drives the tracer to the top of the pool. Overall distribution of the tracer is due to the combined effect of convection and diffusion. In shallow welding there exists a boundary region where tracer does not penetrate. In chapter 7 the results of instrumented indentation experiments on laser welded Fe-Cu weldment has been presented. It was earlier reported that during laser welding of Fe-Cu couple, a variety of microstructures evolves at various locations in the weldment and hardness of the weldment were found to be very high. Here an attempt has been made to explore in details the origin of such a high hardness. The chapter starts with a description of various microstructures that are observed in this weldment followed by the various procedures used for extracting data from instrumented indentation tests. It is followed by the presentation of the experimental results. It is found that rule of mixture along with Hall-Petch strengthening explains the observed increase in hardness of the weldment. The fine scale microstructure consisting of alternate Fe rich and Cu rich layers increases the hardness of the weldment. On copper side of the weldment, composition and scale of microstructure fluctuates and so also the hardness. Finally in chapter 8 overall conclusions of the various chapters in the thesis have been summarised.

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1982. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING / Includes bibliographical references. / by Miriam Zacksenhouse. / M.S.

Thesis (Ph. D.)--Ohio State University, 2006. / Title from first page of PDF file. Includes bibliographical references (p. 146-149).

This Master Thesis was performed in terms of robotic three dimensional friction stir welding with T-butt joint. Friction stir welding (FSW) is a solid state welding method that achieves the weld temperature by friction of a rotating non-consumable tool with the workpiece. Science and technology fast developing requires for higher seam quality and more complex welding joint geometry like 3D welds. In order to acquire high productivity, capacity and flexibility with acceptable cost, robotic FSW solution have been proposed. Instead of the standard FSW machine, using a robot to perform complicated welds such as, three-dimensional. In this report, a solution for weld a 3D T-butt joint, which located in an aluminium cylinder with 1.5 mm thickness using a robot, was developed. Moreover, two new paths were investigated in order to avoid the use of two welds to perform this type of joint. The paths were tested on 2D and on 3D (with a 5050 curvature radius) geometries. Both paths had good results. What is more, the parameter developing methods of FSW process, which is composed of necessary parameter setting, positional compensation was introduced. Specially,the study demonstrates how complicate geometry can be welded using a robot. Also,it shows that TWT temperature control is able to acquire high quality 3D welds. In addition, an analysis of the 2D welding and 3D welding was performed, which exposed that, keeping exactly the same welding conditions, higher lateral forces on the tool were found during 3D welding. Basis on the special case in this paper, when the tool goes like "climbing" the sample, the suffering force of tool decreasing with increasing the height(Z position); nevertheless, when the tool goes like "downhill", the suffering force of tool decreasing with decreasing the height (Z position). What is more, in 2D weld, increasing the downforce (Fz) results increasing the lateral forces which can be Fx and/or Fy. Finally, the future works suggestions were presented in terms of (1) performing the new paths into a real cylinder, (2) performing tensile test on the paths and comparing it with conventional path which weld twice, (3) researching how the downforce (Fz) influence the Fx and Fy during welding of different 3D geometries, (4) how the cooling rate of backing bar influence the seam quality when it is use the same welding parameters and (5) the effect of performing welds in the same welding temperature achieved with different combination of the tool rotational speed and downforce on the material properties

No description available.

The purpose of the present study is to obtain insight into the formation, behaviour and magnitude of welding-induced residual stresses and distortions resulting from welding nozzles onto cylindrical pressure vessels. A hybrid methodology that comprises numerical analysis, experimental measurements and empirical calculations is used in the present study. The welding process induces a high thermal gradient on the material due to non-uniform temperature distribution; thereby causing the portion of the material that is exposed to high temperatures to expand. However, the relatively cooler material portion that is away from the weld pool resists such expansion, thereby subjecting the structure to stresses and distortions around the fusion zone (FZ) and the heat-affected zone (HAZ). Over the last two decades a number of studies have been done in an effort to predict the effect of welding-induced residual stresses on the integrity of welded structures. However, to this end, such studies have focussed on analysing residual stresses on bead-on-plate, plate-to-plate and [to a less extent] on pipe-to-pipe weld joints. Fewer studies have looked at nozzle-cylinder joints of pressure vessels as is the case in this study. The second chapter gives a detailed review of applicable literature. The constitutive model described in the third chapter includes a two-phase sequentially-coupled thermo-mechanical analysis, which incorporates metallurgical effects. The non-linear transient problem is solved using an axisymmetric 2D model with ‘element birth’ technique, developed on ABAQUS. The first phase comprises the thermal analysis based on Goldak’s moving heat source model that is used to determine temperature histories. The second phase is a sequel stress/strain analysis wherein the temperature fields are used as input loads. The results discussed in chapters three and four show that there is a high concentration of residual stresses close to the weld centre-line, and these die down as distance away from centre-line increases. It is also shown that the inside surface is under tensile stresses, while the outer surface is under compressive stress, whose magnitude approaches yield strength of the material. Axial deflections of up to 0.384mm and radial shrinkage of 0.0237mm are observed. Distortion decreases as distance away from weld centre-line increases. Minimum axial shrinkage, which is close to zero, is observed at the restrained end. The analytical results show adequate corroboration and agreement with the experimental measurements. A number of mitigation techniques are suggested in order to alleviate the impact of residual stress and distortions on fatigue performance of welded structures. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2012.

Thesis (M.Comp.Sc.(Hons.))--University of Wollongong, 2003. / Typescript. Includes bibliographical references: leaf 49-55.

Thesis (Ph.D.)--University of Wollongong, 2004. / Typescript. Includes bibliographical references: leaf 305-322.

Thesis (M.S.)--Brigham Young University. School of Technology, 2007. / Includes bibliographical references (p. 73-75).

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