Advanced Welding and Deforming

Front-matter_2021_Advanced-Welding-and-Deforming
Copyright_2021_Advanced-Welding-and-Deforming
Contributors_2021_Advanced-Welding-and-Deforming
Series-Foreword_2021_Advanced-Welding-and-Deforming
Preface_2021_Advanced-Welding-and-Deforming
Chapter-1---Ultrasonic-welding-a-modern-welding-tech_2021_Advanced-Welding-a
Chapter 1 - Ultrasonic welding—a modern welding technology for metals and plastics
1 - Introduction
2 - Ultrasonic welding system and process variation
2.1 - Spot welding
2.2 - Line welding
2.3 - Continuous seam weld
2.4 - Torsion/ring weld
3 - Ultrasonic welding process mechanism and working
4 - Ultrasonic welding process parameters
4.1 - Frequency
4.2 - Amplitude
4.3 - Static clamping force
4.4 - Welding power, time, and energy
4.5 - Material
4.6 - Tooling
5 - Ultrasonic welding of metals and alloys
5.1 - Welding of similar metals and alloys
5.2 - Welding of dissimilar metals and alloys
5.3 - Welding of plastic: similar material
5.4 - Welding of plastic: dissimilar material/hybrid welding
6 - Ultrasonic welding applications
6.1 - Automotive industries
6.2 - Packaging industries
6.3 - Plastic industries
6.4 - Electronic industries
6.5 - Miscellaneous application
7 - Ultrasonic welding: advantages and limitations
7.1 - Advantages
7.2 - Limitations
8 - Summary
9 - Ultrasonic welding: future trends
References
Chapter-2---Fiber-laser-welding-of-Ti-6Al-4V_2021_Advanced-Welding-and-Defor
Chapter 2 - Fiber laser welding of Ti-6Al-4V alloy
1 - Material processing with the laser beam
1.1 - Laser beam generation
1.2 - Optical absorption
2 - Welding process
2.1 - Laser beam welding
2.1.1 - Advantages of LBW
2.1.2 - Limitations of LBW
2.2 - Laser welding modes
2.2.1 - Conduction mode
2.2.2 - Keyhole mode
2.3 - Classification of laser heat sources
2.4 - Fiber laser
2.4.1 - Fiber laser construction
2.4.2 - Laser beam quality
2.4.3 - Advantages of fiber laser
2.5 - LBW process parameters
3 - Weldability of Ti-6Al-4V Alloy
4 - Experimental setup
4.1 - Workpiece fixture
4.2 - Joint configuration
4.3 - Measurement methodology
4.3.1 - Macro and microstructural analysis
4.3.2 - Vickers micro-hardness test
4.3.3 - Tensile test
4.3.4 - Measurement of cooling rate in fusion-zone
4.3.5 - Grain size measurement
5 - Study of different bead features
5.1 - Bead shape
5.2 - Bead surface appearance
5.3 - Penetration depth and fusion zone width
5.4 - Focal position
6 - Microstructural analysis
6.1 - Mechanism of phase transformation
6.2 - HAZ and FZ microstructure
7 - Weld defects and minimization techniques
7.1 - Porosity
8 - Study of mechanical properties
8.1 - Weld bead hardness
8.2 - Tensile properties and fractography
9 - Summary
References
Chapter-3---Advances-in-gas-metal-arc-welding-process--_2021_Advanced-Weldin
Chapter 3 - Advances in gas metal arc welding process: modifications in short-circuiting transfer mode
1 - Introduction to welding process
2 - Gas metal arc welding (GMAW) process
2.1 - Polarities in GMAW
2.2 - Types of metal transferral in gas metal arc welding
2.2.1 - Short-circuit transfer
2.2.2 - Globular transfer
2.2.3 - Spray arc transfer
2.3 - Advantages of GMAW
2.4 - Disadvantages of GMAW
3 - The need for modifications in the shortcircuiting mode of metal transfer
4 - WiseRoot process
5 - Surface Tension Transfer process
6 - Regulated metal deposition process
7 - Cold Arc process
8 - ColdMIG process
9 - Intelligent arc control process
10 - Super-imposition process
11 - Controlled bridge transfer process
12 - Cold metal transfer process
13 - MicroMIG process
14 - Summary
References
Chapter-4---Comprehensive-analysis-of-gas-tungsten-arc_2021_Advanced-Welding
Chapter 4 - Comprehensive analysis of gas tungsten arc welding technique for Ni-base weld overlay
1 - Introduction
2 - GTAW process description
3 - Experimental details and procedure for weld overlay
4 - Results and discussion
4.1 - Heat flow analysis
4.2 - Interfacial weld chemistry analysis
4.3 - Weldment microstructure and micro-hardness
4.4 - X-ray diffraction analysis
5 - Summary and future research directions
References
Chapter-5---Developments-in-laser-welding-of-al_2021_Advanced-Welding-and-De
Chapter 5 - Developments in laser welding of aluminum alloys
1 - Introduction
2 - Aluminum alloys for industrial applications
3 - Basics of laser welding of aluminum alloys
4 - Challenges in laser welding of aluminum alloys
5 - Microstructural and mechanical properties of welded parts
6 - Welding imperfections and their prevention
7 - Conclusions and future prospects
Acknowledgments
References
Chapter-6---Evolution-and-current-practices-in-fric_2021_Advanced-Welding-an
Chapter 6 - Evolution and current practices in friction stir welding tool design
1 - Introduction
2 - FSW process parameters
3 - FSW tool geometry and material
3.1 - Tool shoulder
3.2 - Tool pin profile
3.3 - FSW tool configuration
3.4 - Tool material
4 - Approaches for tool design
5 - Tool design and material mixing
6 - Special purpose FSW tools
6.1 - Friction stir spot welding
6.2 - Retractable pin tool
6.3 - Stationary shoulder tool
6.4 - Cylindrical FSW tool
6.5 - Heat assisted FSW tool
6.6 - Reverse dual rotation FSW tool
7 - Conclusions
References
Chapter-7---Magnetic-pulse-welding_2021_Advanced-Welding-and-Deforming
Chapter 7 - Magnetic pulse welding
1 - Introduction
2 - Comparison of magnetic pulse welding with other welding processes
2.1 - Advantages of MPW over conventional welding processes
2.2 - Comparison with explosive welding
2.3 - Comparison with brazing
2.4 - Comparison of ultrasonic welding with MPW
3 - Process parameters in magnetic pulse welding
4 - Interface structure and joint formation mechanism
5 - Destructive and non-destructive testing of magnetic pulse welded components
6 - Summary
References
Chapter-8---Laser-welding-of-nickel-titanium--NiTi_2021_Advanced-Welding-and
Chapter 8 - Laser welding of nickel-titanium (NiTi) shape memory alloys
1 - Introduction
2 - NiTi shape memory alloys
3 - Laser welding of NiTi alloys
3.1 - Similar laser welding
3.2 - Dissimilar laser welding
4 - Microstructural and metallurgical investigation
5 - Mechanical investigation
6 - Conclusion
References
Chapter-9---Hybrid-welding-technologies_2021_Advanced-Welding-and-Deforming
Chapter 9 - Hybrid welding technologies
Abbreviations
1 - Introduction
2 - Laser-based hybrid welding
2.1 - Laser-TIG hybrid welding
2.1.1 - Relative location of laser beam and TIG arc
2.1.2 - Laser power and arc energy
2.1.3 - Pulsed laser-TIG hybrid welding
2.1.4 - Laser-TIG welding with filler wire
2.2 - Laser-MIG hybrid welding
2.2.1 - Double GMA or twin arc hybrid laser welding process
2.2.2 - Magnetic field assisted laser MIG hybrid welding
2.2.3 - Ultrasonic assisted laser-MIG hybrid welding
2.2.4 - Laser-MIG arc hybrid brazing-fusion welding
2.2.5 - Double sided laser-MIG hybrid welding
2.3 - Laser-assisted plasma arc hybrid welding
2.4 - Laser beam submerged arc hybrid welding
3 - Arc-based hybrid welding
3.1 - TIG-MIG hybrid welding
3.2 - Plasma-MIG hybrid welding
3.3 - Submerged arc welding-GMAW
3.4 - Hot wire arc welding
3.5 - Hybrid multipass arc welding
4 - Solid state hybrid welding
4.1 - Laser friction stir welding (FSW) hybrid welding
4.2 - Ultrasonically assisted FSW/FSSW
4.3 - Electrically assisted FW/FSW
4.4 - Arc assisted FSW/ultrasonic welding
5 - Summary
References
Chapter-10---Modern-optimization-techniques-for-perf_2021_Advanced-Welding-a
Chapter 10 - Modern optimization techniques for performance enhancement in welding
1 - Introduction
2 - Overview of soft computing techniques
2.1 - Fuzzy logic
2.2 - Artificial neural networks
2.3 - Evolutionary computing
2.3.1 - Evolutionary algorithms
2.3.2 - Physics-based algorithms
2.3.3 - Swarm intelligence-based algorithms
2.3.4 - Other bio-inspired algorithms
3 - Performance enhancement in welding
3.1 - Mechanical properties of welds
3.2 - Weld bead geometry
3.3 - Weld microstructure
3.4 - Residual stresses, distortion, and weld defects
3.5 - Arc stability and process monitoring
4 - Conclusions
References
Chapter-11---Laser-cladding-a-modern-joining-t_2021_Advanced-Welding-and-Def
Chapter 11 - Laser cladding—a modern joining technique
1 - Introduction
2 - Laser cladding process and materials
2.1 - Laser cladding/alloying technique
2.2 - Material selection
2.3 - Drawbacks related to laser cladding
3 - Types of laser cladding techniques and their application areas
4 - Alloy production by laser cladding
4.1 - Novel material development
4.2 - Micro-nano laser cladding
4.3 - Engineering microstructures obtained by cladding
4.4 - Modeling, simulation, database, and application-oriented challenge
5 - Laser welding
5.1 - Laser beam features
5.2 - Process control
5.3 - Practical considerations
5.3.1 - Joint constellation and precision
5.3.2 - Safety
5.4 - Developments
6 - Conclusions
References
Chapter-12---A-comprehensive-detail-of-friction-stir-pr_2021_Advanced-Weldin
Chapter 12 - A comprehensive detail of friction stir processing—with a case of fabrication of nanocomposites
1 - Introduction
2 - Friction stir processing working principle and mechanism
2.1 - Microstructure modification during FSP
2.2 - Friction-stir processing (FSP) parameters
2.2.1 - Significance of parameters
2.2.2 - Rotational and traveling speed
2.2.3 - Axial-force of the tool
2.2.4 - Tilt-angle
2.3 - Effects of tool geometry
3 - Techniques for adding reinforcement
3.1 - Smearing
3.2 - Holes
3.3 - Groove
3.4 - Selective laser melting
3.5 - Cold spraying
4 - Manufacturing of nanocomposites by FSP
5 - Summary and scope for future research
References
Chapter-13---Microwave-processing-of-polymer-c_2021_Advanced-Welding-and-Def
Chapter 13 - Microwave processing of polymer composites
1 - Introduction
2 - Microwave-assisted composite fabrication techniques
2.1 - Microwave material processing technology
2.2 - Microwave material interaction
2.2.1 - Microwave transparent materials
2.2.2 - Microwave reflecting materials
2.2.3 - Microwave absorbing materials
2.2.4 - Mixed absorber materials
2.3 - Fabrication of PMC through microwave-assisted heating
2.3.1 - Synthetic fiber-reinforced composites
2.3.2 - Natural fiber-reinforced composites
2.3.3 - CNT reinforced composites
2.3.4 - HA reinforced PCL and PLLA composites
2.3.5 - HA reinforced UHMWPE composites
3 - Properties of various microwave processed composites
4 - Summary and future scope
References
Chapter-14---Equal-channel-angular-processing-a-modern_2021_Advanced-Welding
Chapter 14 - Equal channel angular processing—a modern deforming technique for quality products
1 - Introduction
2 - Working principle and mechanism of ECAP
2.1 - Strain imposed in ECAP
2.2 - Processing routes and their associated slip systems in ECAP
2.3 - Modification of the ECAP process
3 - Variables in ECAP
3.1 - Die design
3.1.1 - Die materials
3.1.2 - Effect of channel angles Ψ and Φ
3.1.3 - Pressing speed
3.2 - ECAP processing temperature
3.3 - ECAP load
4 - Processing routes in ECAP
5 - Temperature measurement during ECAP
6 - Shearing characteristics during ECAP
6.1 - Strain imposed in ECAP
6.2 - Homogeneity in deformation
7 - Microstructural evolution during ECAP
7.1 - Single crystals
7.2 - Polycrystalline materials
7.2.1 - Aluminum (Al) and its alloys
7.2.2 - Magnesium (Mg) and its alloys
7.2.3 - Titanium and its alloys
7.2.4 - Cu and its alloys
7.2.5 - ECAP of steels
8 - Texture behavior
9 - Effect of ECAP on mechanical properties
9.1 - Hardness
9.2 - Tensile behavior
9.2.1 - Stress-strain behavior
9.2.2 - Strain hardening/strain softening
9.2.3 - Superplastic behavior
9.2.4 - Fractography
9.3 - Compression
9.4 - Wear
9.5 - Corrosion behavior
9.6 - Thermal stability of the ECAPed material
10 - Use of finite element methods (FEM) in ECAP
11 - Conclusions
References
Chapter-15---Fundamentals-and-advancements-in-lon_2021_Advanced-Welding-and-
Chapter 15 - Fundamentals and advancements in longitudinal rolling
1 - Introduction to rolling
2 - Working principle and mechanism of rolling
2.1 - Deformation zone and its geometric characteristics
2.1.1 - Strain indicators and their relationship
2.1.2 - Formulas for the deformation zone parameter calculation
2.1.3 - Actual deformation zone during rolling
2.2 - Conditions of metal biting by rolls
2.2.1 - Free biting in a simple rolling process
2.2.2 - Forced biting
2.2.3 - Dynamic biting
2.2.4 - Biting conditions in steady-state rolling process
2.2.5 - Ways to increase the biting ability of the rolls
2.3 - Kinematic conditions of rolling
2.3.1 - Stage of the rolling process
2.3.2 - Ratio of the speed of metal and rolls in the deformation zone
2.3.3 - Advance and lag of strip ends
2.3.4 - Continuous rolling strip speed
2.3.5 - Determination of the average strain rate
2.4 - Stress-strain state and strip deformation
2.4.1 - General description of the metal stress and strain state
2.4.2 - Deformation distribution along the strip height
2.4.3 - Factors affecting broadening
2.4.4 - Determination of the broadening value
2.5 - External friction during rolling
2.5.1 - Physical basics of contact friction
2.5.2 - Determination of the friction factor during rolling
2.5.3 - Influence of rolling factors on the friction factor
2.6 - Rolling process force parameters
2.6.1 - Metal deformation resistance
2.6.2 - Effect of rolling factors on average contact pressure
2.6.3 - Modern methods for calculating the average contact pressure
2.6.4 - Rolling force calculation
2.7 - Rolling torques, work, and power
2.7.1 - Determination of rolling torque by rolling force
2.7.2 - Determination of torque for rolling with tension
2.7.3 - Determination of rolling work and power
2.7.4 - Rolling mill engine power
3 - Advances in longitudinal rolling
4 - Summary
References
Chapter-16---Energy-assisted-forming--theory-an_2021_Advanced-Welding-and-De
Chapter 16 - Energy-assisted forming: theory and applications
1 - Introduction
1.1 - Formability
1.2 - Formability improvement during manufacturing process
1.3 - Fundamentals of plastic deformation
2 - Servo press
2.1 - Mechanism of ductility enhancement due to stress relaxation
3 - Electrical-assisted forming
3.1 - Mechanism for electro-plasticity
3.1.1 - Influence on microstructure and mechanical behavior
4 - Ultrasonic-assisted forming
4.1 - Mechanism
4.1.1 - Stress superposition
4.1.2 - Friction effects
4.1.3 - Acoustic softening
5 - Modeling energy-assisted forming
5.1 - Empirical models
5.2 - Physically based constitutive models
5.2.1 - Extension of dislocation density model for energy-assisted forming
6 - Conclusions and future research
References
Chapter-17---Multi-directional-forging--an-advanced-def_2021_Advanced-Weldin
Chapter 17 - Multi directional forging: an advanced deforming technique for severe plastic deformation
1 - Introduction
2 - Severe plastic deformation
2.1 - Multi directional forging
2.2 - Process parameters of MDF process
2.2.1 - Strain imposed
2.2.2 - Strain rate
2.2.3 - Pressing temperature
2.2.4 - Friction and lubrication
2.3 - Advantages and limitations of MDF
2.3.1 - Advantages of MDF
2.3.2 - Limitations of MDF
3 - Multidirectional forging of different materials
3.1 - Multi directional forging of Al and its alloys
3.2 - Multi directional forging of Mg and its alloy
3.3 - Multi directional forging of Ti and its alloy
3.4 - Multi directional forging of Cu and its alloy
3.5 - MDF/MAF processing of Zn, Ni-Fe, and steel materials
4 - Conclusions
Acknowledgments
References
Chapter-18---Superplastic-forming-analysis-te_2021_Advanced-Welding-and-Defo
Chapter 18 - Superplastic forming analysis techniques
1 - Introduction to superplastic forming (SPF)
2 - Biaxial tests
2.1 - Material selection
2.2 - Clamping and sealing
2.3 - Heat application
2.4 - Height measurement
3 - Theoretical framework
3.1 - Analysis theories in the literature
4 - FEM based analysis
4.1 - Space model
4.2 - Sheet modeling
4.3 - Contact model
5 - Dimensional analysis
5.1 - Normalization
5.2 - Pi-Buckingham
6 - Conclusions
References
Further readings
Chapter-19---Current-technologies-for-aluminum-cast_2021_Advanced-Welding-an
Chapter 19 - Current technologies for aluminum castings and their machinability
1 - Introduction
2 - Importance of casting
3 - Aluminum casting methods and applications
3.1 - Sand casting
3.2 - Permanent mold casting (gravity die casting)
3.3 - Die casting
3.4 - Squeeze casting
4 - Aluminum-based castings alloys and machinability
4.1 - Al-Si alloys
4.2 - Al-Si-Cu and Al-Cu alloys
4.3 - Al-Si-Mg alloys
4.4 - Al-Si-Zn alloys
4.5 - Al-Zn alloys
5 - Conclusions
References
Chapter-20---Processing-and-applications-of-cera_2021_Advanced-Welding-and-D
Chapter 20 - Processing and applications of ceramic microspheres
Nomenclature
1 - Introduction
2 - Processing of ceramic microspheres
2.1 - Hard templating processes
2.2 - Solvothermal process
2.3 - Hydrothermal process
2.4 - Sol-gel process
2.5 - Emulsion process
2.6 - Spray-drying process
2.7 - Self-quenching technology
2.8 - Replication
2.9 - Self-formation phenomenon
2.10 - Post-treatment
2.11 - Zeolitization
2.12 - Selective leaching
2.13 - Breath figures
2.14 - Supercritical fluids
2.15 - Phase separation
2.16 - Bioinspiring process
3 - Conclusion
References
Index_2021_Advanced-Welding-and-Deforming