Dissimilar Materials Research Articles

Design of in-vessel mirror of ITER poloidal polarimeter

Diagnostics in-vessel mirrors receive high neutron heating loads and high radiation heat loads because it directly faces the plasma. The in-vessel mirror of this study consists of three layers; tungsten mirror, copper-alloy heatsink and stainless-steel mirror mount. The copper-alloy heatsink is actively cooled by cooling-water pipe. The tungsten mirror is attached to the heatsink with contact pressure of 3.5 MPa and is cooled by thermal conduction to the heatsink. The mirror is not rigidly fixed to the heatsink but is able to slide on the surface of the heatsink because thermal stress in the dissimilar materials during baking needs to be avoided. The structural integrity was evaluated according to RCC-MRx code. The highest primary load to the mirror was the acceleration load during plasma disruption, and the highest secondary load was the baking temperature (240 °C). All design criteria specified in RCC-MRx code are satisfied. In addition, the design of the in-vessel mirrors was developed to facilitate adjustment of mirror angle with accuracy of 0.1° A prototype mirror was made to confirm the surface deformation owing to the assembly load. Surface deformation was 6.3 μm and was sufficiently small compared to the laser wavelength.

Underwater dissimilar friction stir lap welding of aluminum alloy and CFRTP

With the rapid development of the transportation and electronic equipment industries, the demand for robust joining technology for metal/polymer has become imperative, especially in the pursuit of lightweight solutions. Underwater welding is one of the methods to reduce the formation of holes and other welding defects, which is conducive to improve the quality and strength of joints. In this study, the underwater friction stir lap welding (UFSLW) of 6061-T6 Al alloy and carbon fiber reinforced thermoplastic (CFRTP) joints is investigated. The welds are evaluated by optical microscope (OM) image, scanning electron microscope (SEM), and energy dispersive X-ray spectrometer (EDS) of the fracture, tensile, and hardness analysis. Research reveals that the presence of cracks and tunnel defects similar to those in air FSLW (AFSLW) is reduced in the underwater welding process. From the microscopic result analysis, the rapid dissipation of frictional heat and substrate viscosity in the cooling medium of circulating water in the stirring zone reduces the interaction between Al alloy and molten CFRTP, which leads to the rapid transformation of the plasticized material into a solid state and reduces the formation of thick stacked layer. In addition, finer Al alloy fragments are obtained in the welding zone due to the fast cooling rate. Ultimately, the maximum tensile strength of 32.12 MPa is achieved, which is 10.76% higher than that of the same welding parameters in air. Based on UFSLW technology, the joint strength of this study is 69% higher than that of Al alloy and polymer joints, which demonstrates enormous application potential and opens up new prospects for the joining technology of dissimilar materials.

Compositional, Structural, and Biomechanical Properties of Three Different Soft Tissue-Hard Tissue Insertions: A Comparative Review.

Connective tissue attaches to bone across an insertion with spatial gradients in components, microstructure, and biomechanics. Due to regional stress concentrations between two mechanically dissimilar materials, the insertion is vulnerable to mechanical damage during joint movements and difficult to repair completely, which remains a significant clinical challenge. Despite interface stress concentrations, the native insertion physiologically functions as the effective load-transfer device between soft tissue and bone. This review summarizes tendon, ligament, and meniscus insertions cross-sectionally, which is novel in this field. Herein, the similarities and differences between the three kinds of insertions in terms of components, microstructure, and biomechanics are compared in great detail. This review begins with describing the basic components existing in the four zones (original soft tissue, uncalcified fibrocartilage, calcified fibrocartilage, and bone) of each kind of insertion, respectively. It then discusses the microstructure constructed from collagen, glycosaminoglycans (GAGs), minerals and others, which provides key support for the biomechanical properties and affects its physiological functions. Finally, the review continues by describing variations in mechanical properties at the millimeter, micrometer, and nanometer scale, which minimize stress concentrations and control stretch at the insertion. In summary, investigating the contrasts between the three has enlightening significance for future directions of repair strategies of insertion diseases and for bioinspired approaches to effective soft-hard interfaces and other tough and robust materials in medicine and engineering.

Quantitative study of solid-state mechanical mixing by high-pressure torsion based on image processing

Mechanical alloying through the process of severe plastic deformation can significantly enhance the mechanical properties of dissimilar metals. However, uneven mixing of these materials can adversely affect their mechanical performance and may even lead to material failure. To quantitatively assess the degree of mixing between dissimilar materials, a mechanical mixing efficiency index (η) has been introduced. This index is calculated accurately by combining an improved Non-dominated Sorting Genetic Algorithm II (NSGA-II) with computer image processing techniques. The study focuses on the Al-Zn mechanical mixture, establishing a parametric correlation between the mechanical mixing efficiency index and the microstructural evolution of mechanical mixing. The findings indicate that when the η value falls below 0.27865, the material transitions from the mechanical mixing stage to the chemical fusion stage. This research facilitates the controllable preparation of mechanical alloying, providing theoretical support and practical evidence for the process.

Morphological and plastic deformation study on impact strength of AA7075 and 316LSS in friction stir welding

The Impact of Friction stir Welding (FSW) in two dissimilar materials particularly in 316L Stainless Steel (SS) and AA7075 is very challenging due to its inherent properties when exposed to elevated temperature environment. The 316L SS is the grade generally used for deep drawing process of various SS applications. The Aluminum which generally provides the oxide formation when subjected to friction stir welding and develops the proper patter of stir zone in the heat affected environment. General preheating is required for SS before exposing it to the FSW process. The temperature might be of around 350˚ C is required for SS, so that the developmental of thermal gradient and weld quality between the two metals will achieve in proper pattern. As the Impact study will provides the aluminum and Stainless steels in the welded zone or Heat Affected Zone (HAZ) with different cracking and nucleation behavior. This phenomenon enhances the mechanical property in the Aluminum zone. After the various literature study, the FSW welded region of the metal provides improper pattern due to same start of welding at the mid of the dissimilar joints. In this phenomenon the FSW can start its process from the steel side of the joint and completing it to the Aluminum joint will reduces the growth of void and nucleate the agglomeration of oxides fromAA7075 to 316LSS.

Characterization of the spin arc welding technique for dissimilar materials Hastelloy C-2000 and C-276

Hastelloy C-2000 and C-276 are primarily employed in the petrochemical and pharmaceutical industries. Finding an effective way to combine these alloys is still a complex task in industry. The main focus of this study is to investigate the potential efficacy of the spin arc welding process on Hastelloy C-2000 and C-276. The welding process was carried out under various conditions, such as weld current, spinning speed, and spin diameter. ERNiCrMo-4, with a diameter of 1.2 mm, was employed as a filler. Optical microscopy, XRD and FESEM were used for microstructural examination. The mechanical properties of the welded samples were critically analyzed. The results of the ultimate tensile strength (UTS), hardness value (HV), and impact tests of spin arc welding were compared with those of the multipass pulsed current gas tungsten arc welding process (MPCGTAW). In spin arc welding, Hastelloy C-2000 and C-276 exhibited higher UTS, HV, and toughness compared to MPCGTAW because there was no secondary TCP phase formation in the weld centre and hot cracking in spin arc weldments. Additionally, compared to MPCGTAW, the elongation with spin arc welding was noted to be lower. Moreover, microstructural analysis revealed no evidence of grain segregation, which may have contributed to the improved UTS and HV of the materials during spin arc welding. Thus, spin arc welding proves to be superior for dissimilar Hastelloy joints of C-2000 and C-276.

Friction Welding Processes: A Review

Friction welding is a sort of solid-state welding process that does not use flux, shielding gases, or filler metal; instead, the heat needed to fuse the materials is produced by the friction between two or more objects moving relative to one another. This kind of welding is an alternative to the traditional fusion and adhesive-based welding procedures. The method is reliable, capable of joining materials that would seem hard to join with traditional welding, and suitable for joining both similar and dissimilar materials including wood, steel, aluminum, copper, masurium, nickel, zinc and carbon steel. Friction welding can be carried out by using several techniques including linear, rotary, friction stir, direct drive and inertia welding. Each of these welding techniques is distinct and are named according to the relative motion involved. Although the process varies slightly subject to the type of motion, the procedure is consistent and the resultant joint is comparable with those obtained through conventional welding technique. This study reviews the distinct friction welding processes and specific techniques involved in the process.

Texture Analysis of Hot Rolled Martensitic and Bainitic Steels by Electron Backscatter Diffraction to Quantify Parent Austenite States

To measure textures of hot rolled martensitic and bainitic steels, electron backscatter diffraction (EBSD) is applied to large areas, each covering about a thousand of prior grains. A scanning step is selected to keep reasonable time of the data acquisition still providing in any grain a significant number of analyzed points. Contributions to the transformation texture appearing from deformation and recrystallization components of the parent texture are estimated with the Bain relationship. To assess the parent austenite state, their proportion is then expressed by a scalar parameter. The results are verified by independent metallographic data. Avoiding the reconstruction of prior grains, this statistical approach will facilitate evaluation of complex austenite structures with comparable fractions of dissimilar material states.

Advancements in Friction Stir Welding Techniques for Enhanced Performance in Aluminum Alloy Structures

Abstract: Friction Stir Welding (FSW) is a solid- state welding method that can be utilized on both comparable and dissimilar materials. The technology is frequently utilized because it generates quality welds and avoids common issues like solidification and liquefaction cracks that are connected with fusion welding processes. The FSW of Aluminum 5086 andits alloys has been commercialized, and there is renewed interest in connecting dissimilar materials. However, before the process can be commercialized, research studies must be conducted to describe and set process windows. In particular, FSW has prompted researchers to try combining incompatible materials with different characteristics, such as Aluminum 5086, and sound welds with no or few intermetallic compounds have been formed.

Development of Hot-Wire Laser Additive Manufacturing for Dissimilar Materials of Stainless Steel/Aluminum Alloys

The formation of brittle intermetallic compounds (IMCs) at the interface between dissimilar materials causes considerable problems. In this study, a multi-material additive manufacturing technique that employs a diode laser and the hot-wire method was developed for stainless steel/aluminum alloys. An Al-Mg aluminum alloy filler wire (JIS 5183-WY) was fed on an austenitic stainless-steel plate (JIS SUS304) while varying the laser power and process speed and using paste-type flux and flux-cored wire. The effects of laser power and process speed on phenomena during manufacturing and IMC formation were investigated. Finally, the wall-type multilayer specimens were fabricated under optimized conditions. The suppression of IMC formation to a thickness of less than 2 μm was achieved in the specimens, along with a high interfacial strength of over 120 MPa on average.

Effect of Friction Pressure on the Mechanical Properties of CDFW Dissimilar Aluminium 6061-T6 and Stainless steel 304 Welding Joints

Welding technology has significantly developed in the industrial sector along with advances in manufacturing technology. The demand for joining methods combining dissimilar metals is increasing in the industrial sector. However, joining dissimilar metals is challenging because of differences in physical and mechanical properties. Continuous drive friction welding is a solid-state joining method widely used to join dissimilar metals. The research aimed to determine the effect of variations in friction pressure on the mechanical properties of continuous drive friction welding joints with dissimilar materials, Aluminum 6061 T6 and Stainless Steel 304. The process parameters used in this welding were the friction pressures used were 30 MPa, 35 MPa, and 45 MPa. The friction time is 2 seconds, the rotation speed is 1000 rpm, and the upset pressure is 50 MPa. Then, welded joints were evaluated for Vickers microhardness and microstructure observations. Based on the research results, it shows that the temperature distribution and microstructure results show that there is a change in the hardness value of the aluminum material. In contrast, the 304 stainless steel material experiences an insignificant change in the hardness value.

Deposition of Functionally Graded Material Fabricated by Robot Plasma Arc Welding

Functionally graded materials is a new type of composite materials capable of facilitating the dependable bonding of dissimilar materials. A double‐wire plasma welding process is used to manufacture SS316L/Inconel625 FGM. Subsequently, two thin‐walled structures with 5% gradient and non‐gradient are fabricated to investigate the morphology, microstructure, and properties in different gradients, focusing on the 67% SS316L region. The findings indicate that two depositions exhibit well‐formed structures with varying gradients and no macroscopic defects. The composition experiences an abrupt transition at the interface between deposition with a non‐gradient, whereas deposition with a 5% gradient does not exhibit this issue and demonstrates a higher effective deposition rate. The analysis of the energy dispersive spectrum indicates the presence of Nb elements at the grain boundary in the 67% SS316L region, with no observed cracks. This suggests resistance to cracking and impediment to the segregation of Nb. Additionally, the hardness and tensile strength in various regions exhibit a gradual increase with a 5% gradient of Inconel625 content, while the tensile anisotropy is not noticeable. Consequently, the 5% gradient transition demonstrates a more favorable performance in comparison to the non‐gradient sample, resulting in the avoidance of the 75% SS316L region due to its poor performance.This article is protected by copyright. All rights reserved.

Experimental analysis and optimization of friction welding parameters for joining dissimilar materials through design of experiments

Experimental analysis and optimization of friction welding parameters for joining dissimilar materials through design of experiments

Influence of Metal Surface Structures on Composite Formation during Polymer–Metal Joining Based on Reactive Al/Ni Multilayer Foil

Progressive developments in the field of lightweight construction and engineering demand continuous substitution of metals with suitable polymers. However, the combination of dissimilar materials results in a multitude of challenges based on different chemical and physical material properties. Reactive multilayer systems offer a promising joining method for flexible and low‐distortion joining of dissimilar joining partners with an energy source introduced directly into the joining zone. Within this publication, hybrid lap joints between semicrystalline polyamide 6 and surface‐structured austenitic steel X5CrNi18–10 (EN 1.4301) are joined using reactive Al/Ni multilayer foils of the type Indium–NanoFoil. The main objective is to examine possibilities of influencing crack initiation in the foil plane by variation of joining pressure and different metal surface structures with regard to geometry, density, and orientation. Thus, the position of foil cracks is superimposed onto the metal structure and associated filling with molten plastic is improved. Consequently, characterization of occurring crack positions as a function of joining pressure and metal structure, analysis of the composite in terms of structural filling and joint strength, as well as possible causes of crack initiation are evaluated.

Strengthening sandwich composites by laminating ultra-thin oriented carbon nanotube sheets at the skin/core interface

Strong, tough, and lightweight composites are increasingly needed for diverse applications, from wind turbines to cars and aircraft. These composites typically contain sheets of strong and high-modulus fibers in a matrix that are joined with other materials to resist fracture. Coupling these dissimilar materials together is challenging to enhance delamination properties at their interface. We herein investigate using a trace amount of carbon nanotube sheets to improve the coupling between composite skins and core in a composite sandwich. Ultra-thin (∼100 nm) forest-drawn multi-walled carbon nanotube (MWNT) sheets are interleaved within the skin/core interphase, with MWNTs aligned in the longitudinal direction. The mechanical behavior is characterized by end-notched flexural testing (ENF). With two MWNT sheets placed in the skin/core interphase, the following performance enhancements are achieved: 36.8 % increase in flexural strength; 127.3 % and 125.7 % increases in mode I & II fracture toughness values, respectively; and 152.8 % increase in interfacial shear strength (IFSS). These are achieved with negligible weight gain of the composite sandwich (0.084 wt% increase over the baseline sandwich without MWNT sheets). The finite element simulation results show that MWNT sheets enhance the skin/core coupling by reducing stress concentration, enabling the transition from catastrophic brittle failure to a stable ductile failure mode. The MWNT sheets interleaved sandwich composites are thus demonstrated to be stronger and tougher while providing electrical conductivity (4.3 × 104S/m) at the skin/core interface for potential de-icing, electromagnetic interference shielding, and structural health monitoring.

The effect of Sn interlayer on weld structure, intermetallic compounds, and joint properties of Al/Mg friction stir welding with ultrasonic assistance

ABSTRACT: The formation of intermetallic compounds (IMCs) is a primary factor that affects the welding joint between dissimilar materials. In this study, experiments were performed using Al/Mg friction stir welding (FSW) and ultrasonic vibration enhanced FSW (UVeFSW) with varying thicknesses of Sn interlayer. Detailed characterization and tests were conducted to explore the effect of Sn interlayer with or without ultrasonic vibration on weld surface morphology, macro-micro structure, generation of IMCs, and joint tensile strength. The study discusses the effect of ultrasonic vibration coupled with Sn interlayer and provides ideas for IMCs regulation when joining dissimilar materials. The study showed that adding a Sn interlayer cannot eliminate the generation of Al-Mg IMCs, but it can significantly reduce their thickness. Applying ultrasonic vibration with Sn interlayer can further reduce the thickness of Al-Mg IMCs and improve the interface microstructure from ‘IMC + matrix +IMC + matrix’ multilayer structures to simple IMCs structures. Furthermore, the highest joint strength was achieved when the Sn interlayer thickness was 0.1 mm during FSW. UVeFSW’s joint strength can be further improved with 0.05 mm and 0.1 mm Sn interlayer.

Advancing 4D printing through designing interlocking blocks: enhancing deformation uniformity in active composite structures

Interlocking assemblies have been explored to address large assembly and complex parts and are now integral to additive manufacturing (AM) for creating objects with dissimilar materials and multiple properties. 4D printing technology, which combines smart materials (SMs) with AM, aligns with this approach by enabling the creation of objects that can change shape or properties when exposed to external stimuli. As 4D printing trends towards strategically arranging active and passive materials for improved control and performance, challenges arise due to the limited compatibility of existing 3D printers with the required SM properties. To address this issue, interlocking blocks of dissimilar materials can be printed and then assembled into a desired shape. This work aims to generalize the applicability of the interlocking block assembly approach. This will be achieved by improving the deformation uniformity in a 4D multi-material interlocked assembly. This paper also addresses limitations that can occur due to the interfaces between interlocking blocks, such as lack of deformation and contact continuity. Thus, it will be a question of customizing the shapes of the blocks in the early stages of assembly generation, considering SMs and their potential transformations. Finally, this approach is illustrated with an example, shedding light on the practical implications.

Extrinsic-Riveting Friction Stir Lap Welding of Al/Steel Dissimilar Materials.

To obtain high-quality joints of Al/steel dissimilar materials, a new extrinsic-riveting friction stir lap welding (ERFSLW) method was proposed combining the synthesis advantages of mechanical riveting and metallurgical bonding. SiC-reinforced Al matrix composite bars were placed in the prefabricated holes in Al sheets and steel sheets, arranged in a zigzag array. The bars were stirred and mixed with Al sheets under severe plastic deformation (SPD), forming composite rivets to strengthen the mechanical joining. SiC particles were uniformly dispersed in the lower part of the welding nugget zone (WNZ). The smooth transition between the SiC mixed zone and extrinsic-riveting zone (ERZ) ensured the metallurgical bonding. The maximum tensile shear load of the joints reached 7.8 kN and the maximum load of the weld per unit length was 497 N/mm. The fracture occurred at the interface between the rivets and steel sheets rather than the conventional Al/steel joining interface. Moreover, ERFSLW can prolong the service life of joints due to three fracture stages. This method can be further extended to the welding of other dissimilar materials that conform to the model of "soft/hard".

Magnet-in-ferroelectric crystals exhibiting photomultiferroicity

Growing crystallographically incommensurate and dissimilar organic materials is fundamentally intriguing but challenging for the prominent cross-correlation phenomenon enabling unique magnetic, electronic, and optical functionalities. Here, we report the growth of molecular layered magnet-in-ferroelectric crystals, demonstrating photomanipulation of interfacial ferroic coupling. The heterocrystals exhibit striking photomagnetization and magnetoelectricity, resulting in photomultiferroic coupling and complete change of their color while inheriting ferroelectricity and magnetism from the parent phases. Under a light illumination, ferromagnetic resonance shifts of 910 Oe are observed in heterocrystals while showing a magnetization change of 0.015 emu/g. In addition, a noticeable magnetization change (8% of magnetization at a 1,000 Oe external field) in the vicinity of ferro-to-paraelectric transition is observed. The mechanistic electric-field-dependent studies suggest the photoinduced ferroelectric field effect responsible for the tailoring of photo-piezo-magnetism. The crystallographic analyses further evidence the lattice coupling of a magnet-in-ferroelectric heterocrystal system.

Friction Welding of ETP-Cu Plate to SS304L Round Bar: An Experimental Study on Asymmetrical Dissimilar Metal Joints

This article outlines the development and examination of the properties of an asymmetrical dissimilar metal joint produced using friction welding (FW). Friction welding involving dissimilar materials, specifically a 50 mm (length) × 45 mm (width) × 20-mm (thickness) electrolytic tough pitch copper (ETP-Cu) plate and a 12.5-mm-diameter SS304L rod, was carried out. The assessment of the asymmetrically welded components encompassed ultrasonic testing, high-pressure helium gas testing, leak testing, tensile testing, scanning electron microscopy, optical microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction analysis, hardness measurements, and elemental mapping via X-ray. Significantly, there was an observed increase in tensile strength, resulting in a joint efficiency of 86.50% compared to the ETP-Cu base material, following FW between an asymmetric ETP-Cu plate and SS304L rod. The study unveiled notable variations in the microstructure near the joint interface on the ETP-Cu material side. Intermetallic compounds, such as FeCu4 and Cu9Si phases, were detected within the reaction layer at the interface between ETP-Cu and SS304L, exhibiting a variable thickness ranging from 30 to 50 μm.