Abstract
The manufacturing process is inevitably accompanied with the production of scraps, which leads to resource waste and environmental pollution. Recycling and remanufacturing are the most commonly used approaches for metal scraps due to their well-established advantages from economic and environmental perspectives. In this study, spinning experiments with 2195 Al-Li alloy tailor welded blanks produced by friction stir welding from metal scraps were conducted under different process parameter designs. And then the effects of various process parameters on spinning of thin-walled curved surface parts were systematically studied. The results of the corresponding experimental groups show that the roller attack angle, the spinning clearance, and the installation method of tailor welded blanks have the most significant effect on the weld torsion angle. In addition, it was found that along the longitude direction of spun parts, the surface roughnesses of the weld of spun parts were greatly improved under the roller nose radius of 10 mm, the spinning clearance of 1.0 mm, the constant linear velocity, and the installation method of tailor welded blanks (the lower surface of tailor welded blanks is spun by rollers), while the process parameters have little significant effect on the surface roughness along the latitude direction of spun parts. Furthermore, it can be concluded that the forming profiles of spun parts fitted the mandrel well under the roller nose radius of 6 mm, double rollers, the roller attack angle of 30° and 45°, spinning clearance of 1.5 mm, and the installation method of tailor welded blanks (the upper surface of tailor welded blanks is spun by rollers). The research results will provide guidance for the precise spinning of thin-walled curved surface parts with tailor welded blanks. Thereby, it is also beneficial for green manufacturing involving recycling and remanufacturing of metal scraps.
Highlights
Al-Li alloy thin-walled curved surface parts have been widely used in aeronautical and astronautical engineering fields in recent years because of their high performance, light weight, and high reliability (Huang et al, 2018; Meng et al, 2018; Zhan et al, 2018; Xie et al, 2021)
Tailor welded blanks from metal scraps by welding to manufacturing products has become a popular trend for many industrial fields, which is considered to provide an effective approach to minimizing process scraps and enabling material re-use prior to destructive re-cycling
Spinning using tailor welded blanks, which is prepared through metal scraps and friction stir welding (FSW), has become an eco-friendly and no-waste manufacturing approach to the thin-walled curved surface parts
Summary
Al-Li alloy thin-walled curved surface parts have been widely used in aeronautical and astronautical engineering fields in recent years because of their high performance, light weight, and high reliability (Huang et al, 2018; Meng et al, 2018; Zhan et al, 2018; Xie et al, 2021). Tailor welded blanks from metal scraps by welding to manufacturing products has become a popular trend for many industrial fields, which is considered to provide an effective approach to minimizing process scraps and enabling material re-use prior to destructive re-cycling. Spinning using tailor welded blanks, which is prepared through metal scraps and FSW, has become an eco-friendly and no-waste manufacturing approach to the thin-walled curved surface parts. In this study, spinning experiments with 2195 Al-Li alloy tailor welded blanks produced by FSW were carried out for thin-walled curved surface parts. The research results will give a basis and guidance for forming the process design and optimization in precision spinning of thinwalled curved surface parts using tailor welded blanks
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