Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will...
-
Upload
manuel-masengale -
Category
Documents
-
view
215 -
download
0
Transcript of Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will...
![Page 1: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/1.jpg)
Composite Materials
![Page 2: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/2.jpg)
Resistance Welding
Lesson ObjectivesWhen you finish this lesson you will understand:•
Learning Activities1. View Slides; 2. Read Notes, 3. Listen to lecture4. Do on-line workbook
Keywords
![Page 3: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/3.jpg)
Matrix Materials
Magnesium• Lowest density (37% lighter than aluminum) • Aerospace applications• Creeps at low temp• Relatively low strength• Prone to variety of corrosion problems
Aluminum• Easy to process, inexpensive• Density only 35% of Steel• Can be alloyed to fairly high strengths• 57% stiffer than Magnesium• Excellent corrosion resistance• Most widely used material
![Page 4: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/4.jpg)
Matrix Materials
Titanium• Twice as strong as aerospace aluminum• 65% heavier than aluminum, but 65% stiffer• Temp & corrosion resistant = use in demanding environments
Copper, Iron, Nickel, Tungsten• Special use alloys
• Electronic Circuits• Metal forming dies• Jet engines• Military applications
![Page 5: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/5.jpg)
Reinforcements
Ceramics• Silicon Carbide (SiC)• Aluminum Oxide (Al2O3)• Titanium Carbide (TiC)• Boron Carbide (B4C)
Other• Graphite (C)• Titanium Diboride (TiB2)
Metal Filaments• Boron• Steel• Tungsten
Choice of matrix and reinforcement depends on:• Desired properties of composite• Compatibility between matrix and reinforcement• MMC Processing route
![Page 6: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/6.jpg)
orcementinfrer
matrixm
compositec
fractionvolumeV
consideredpropertyX
Where
VXVXX rrmmc
Rule of Mixtures
![Page 7: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/7.jpg)
Designation for MMC
Matrix + Reinforcement / Volume % Form
Matrix = metal or alloy designation of matrixReinforcement = chemical formula of reinforcementVolume % = Volume percent without the % signForm = Form of the reinforcement
• f, fiber or filament• c, chopped fiber• w, whisker• p, particulate
Example: 6061 + SiC/20w
![Page 8: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/8.jpg)
Welding Handbook, AWS
![Page 9: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/9.jpg)
Particulate Composite
Short-Fiber Composite
Long-Fiber Composite Laminated Composite
Manufacturing ProcessesWelding Handbook, AWS
![Page 10: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/10.jpg)
Processing Methods
Solid StateSemi-solidLiquid
![Page 11: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/11.jpg)
Solid State Processing
Bonding of continuous fibers between metal foils to make panels• Aerospace Applications• Ti/Sic; Al/B
Laminated Composite
Powder Metallurgy• Mix particles of matrix with reinforcement• Vacuum hot press (near solidus)• Extrude or roll• Al/B4C; Al/SiC
![Page 12: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/12.jpg)
Semi-Solid Processing
Spray Deposition
Chilled Plate
MMC Build UpMMC Build Up
Flame Spray MatrixFlame Spray Matrix
Flame Spray Reinforcement
………..
Rheocasting• Mix reinforcement into matrix held between solidus and liquidus
TEMP
COMP
x
![Page 13: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/13.jpg)
Liquid Processing
Infiltration• Interfacial reactions can be a problem
![Page 14: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/14.jpg)
Applications - From Ukraine
Krivov, Optimization of design-production…,Welding in the World, Nov-Dec 1994
![Page 15: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/15.jpg)
Applications
Krivov, Optimization of design-production…,Welding in the World, Nov-Dec 1994
![Page 16: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/16.jpg)
Krivov, Optimization of design-production…,Welding in the World, Nov-Dec 1994
![Page 17: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/17.jpg)
Welding Handbook, AWS
![Page 18: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/18.jpg)
Detrimental Weld Pool Chemical Reactions
]l[Al2]s[OMgAl3]s[OAl4]Al[Mg3
)TiAlAlTi](l[Al]Al[Si]s[TiC]s[SiC]l[Al3]Al[Ti5
]Al[Si3]s[CAl]s[SiC3]l[Al4
4232l
3ll
l34
[l] indicates liquid phase[s] indicates solid phase[All] indicates in solution with liquid aluminum
![Page 19: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/19.jpg)
ResistanceWelding
ArcWelding
Time-Temp Effect of Chem Reaction
Welding Handbook, AWS
![Page 20: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/20.jpg)
Capacitor Discharge• Stud Welding• Solid State• Fusion Weld• Brazing
![Page 21: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/21.jpg)
Capacitor Discharge Stud Welding
MMC Materials Welded• 6061, 2024, 6061/SiC/40p, 6061/SiC/48f, 6061/B4C/30p,
AZ61/B4C/40p• Studs = 0.25 in; Sheet=0.13 in• Time = 0.4 ms• Solidification rate = 106 C/s
![Page 22: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/22.jpg)
Welding Handbook, AWS
Stud Welding
![Page 23: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/23.jpg)
Welding Handbook, AWS
![Page 24: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/24.jpg)
Welding Handbook, AWS
![Page 25: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/25.jpg)
Capacitor Discharge - Solid State Welding• Ti-6Al-4V/SiC Sheets• Ti-6Al-4V/SCS-6
Diffusion (solid state) BondNo Melting
Failure Occurred Upon Loading Remote from Weld Interface
Baeslack & Froes, Joining Similar & Dissimilar……,JOM March 1995
SCS-6 is a complex fiber with SiC vapor deposited onto a graphite carbon core
![Page 26: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/26.jpg)
Increase in Welding Current (Voltage) Causes ChangeFrom Solid State to Fusion Weld
Cox et al, Capacitor Discharge RSW of SiC Fiber…Welding Journal, Oct 1993
![Page 27: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/27.jpg)
Capacitor Discharge Solid State WeldNo liquid - Weld Strength 80% of Monolithic
SCS-6 Fiber
Cox et al, Capacitor Discharge RSW of SiC Fiber…Welding Journal, Oct 1993
![Page 28: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/28.jpg)
Solid State Weld with no Fiber degradation
Cox et al, Capacitor Discharge RSW of SiC Fiber…Welding Journal, Oct 1993
![Page 29: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/29.jpg)
Capacitor Discharge - Fusion Welding
![Page 30: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/30.jpg)
Partial Melting Fusion Weld
Cox et al, Capacitor Discharge RSW of SiC Fiber…Welding Journal, Oct 1993
![Page 31: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/31.jpg)
Solidified Liquid around fiber, Property degradation
Cox et al, Capacitor Discharge RSW of SiC Fiber…Welding Journal, Oct 1993
![Page 32: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/32.jpg)
Al-7Zn/CBAlSi-4BrazingFoil
Low force = expulsion> 400 lb = fiber packing at weld center (see next slide)
Spot Brazing Continuous C Fiber MMC
![Page 33: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/33.jpg)
Welding Handbook, AWSBrazing
![Page 34: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/34.jpg)
Spot Brazing Continuous SiC Fiber MMC
Ti-22Al-23Nb/SiC
Ti-Cu-NiBraze Foil
Baeslack & Froes, Joining Similar & Dissimilar……,JOM March 1995
![Page 35: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/35.jpg)
Baeslack & Froes, Joining Similar & Dissimilar……,JOM March 1995
![Page 36: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/36.jpg)
ResistanceWelding
ArcWelding
Time-Temp Effect of Chem Reaction
Welding Handbook, AWS
![Page 37: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/37.jpg)
Resistance Spot Welding• Solid State• With Melting/Solidification
![Page 38: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/38.jpg)
Spot Welding
Welding Handbook, AWS
![Page 39: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/39.jpg)
Adjusting Welding ForceWelding TimeTo Avoid FiberCrushing inAl/B MMC
Welding Handbook, AWS
(Continuous Fiber)
![Page 40: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/40.jpg)
Aluminum/Boron Continuous Fiber
Hersh, Resistance Spot Weld MMC,Welding Journal, June 1970
![Page 41: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/41.jpg)
Aluminum/Boron Continuous Fiber
Hersh, Resistance Spot Weld MMC,Welding Journal, June 1970
![Page 42: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/42.jpg)
Aluminum/Boron Continuous Fiber
Hersh, Resistance Spot Weld MMC,Welding Journal, June 1970
![Page 43: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/43.jpg)
Aluminum/Boron Continuous Fiber
Hersh, Resistance Spot Weld MMC,Welding Journal, June 1970
![Page 44: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/44.jpg)
Aluminum/Boron Continuous Fiber
Hersh, Resistance Spot Weld MMC,Welding Journal, June 1970
![Page 45: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/45.jpg)
Spot Welding Discontinuous Fibers
Segregation of reinforcement (see next slide)
![Page 46: Composite Materials. Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes,](https://reader035.fdocuments.us/reader035/viewer/2022070306/55180eb55503468c438b46d8/html5/thumbnails/46.jpg)
Welding Handbook, AWS