Academic literature on the topic 'Friction bit joining'
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Journal articles on the topic "Friction bit joining"
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Lim, Yong, Hoonmo Park, Junho Jang, Jake McMurray, Bradly Lokitz, Jong Keum, Zhenggang Wu, and Zhili Feng. "Dissimilar Materials Joining of Carbon Fiber Polymer to Dual Phase 980 by Friction Bit Joining, Adhesive Bonding, and Weldbonding." Metals 8, no. 11 (October 24, 2018): 865. http://dx.doi.org/10.3390/met8110865.
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In the present work, joining of a carbon fiber-reinforced polymer and dual phase 980 steel was studied using the friction bit joining, adhesive bonding, and weldbonding processes. The friction bit joining process was optimized for the maximum joint strength by varying the process parameters. Then, the adhesive bonding and weld bonding (friction bit joining plus adhesive bonding) processes were further developed. Lap shear tensile and cross-tension testing were used to assess the joint integrity of each process. Fractured specimens were compared for the individual processes. The microstructures in the joining bit ranged from tempered martensite to fully martensite in the cross-section view of friction bit-joined specimens. Additionally, the thermal decomposition temperature of the as-received carbon fiber composite was studied by thermogravimetric analysis. Fourier-transform infrared–attenuated total reflectance spectroscopy and X-ray diffraction measurements showed minimal variations in the absorption peak and diffraction peak patterns, indicating insignificant thermal degradation of the carbon fiber matrix due to friction bit joining.
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Huang, T., Y. S. Sato, H. Kokawa, M. P. Miles, K. Kohkonen, B. Siemssen, R. J. Steel, and S. Packer. "Microstructural Evolution of DP980 Steel during Friction Bit Joining." Metallurgical and Materials Transactions A 40, no. 12 (October 14, 2009): 2994–3000. http://dx.doi.org/10.1007/s11661-009-0016-x.
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Miles, Michael, Sung-Tae Hong, Coulter Woodward, and Yong-Ha Jeong. "Spot welding of aluminum and cast iron by friction bit joining." International Journal of Precision Engineering and Manufacturing 14, no. 6 (June 2013): 1003–6. http://dx.doi.org/10.1007/s12541-013-0133-8.
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Lim, Yong Chae, Lile Squires, Tsung-Yu Pan, Michael Miles, Guang-Ling Song, Yanli Wang, and Zhili Feng. "Study of mechanical joint strength of aluminum alloy 7075-T6 and dual phase steel 980 welded by friction bit joining and weld-bonding under corrosion medium." Materials & Design 69 (March 2015): 37–43. http://dx.doi.org/10.1016/j.matdes.2014.12.043.
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"Research on Friction Stirs Welding of Aluminum Alloy and Copper Dissimilar Metals." International Journal of Innovative Technology and Exploring Engineering 8, no. 12S2 (December 31, 2019): 325–28. http://dx.doi.org/10.35940/ijitee.l1060.10812s219.
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Unique joining of Aluminum Alloys and Copperaluminum plate thickness 5mm resolved through erosion mix welding (FSW) system. The perfect manner parameter that gets to the joint use factual methodologies. Five diverse personnel shape has been used to break up the effect of move-pace shaft speed and nature of microstructures and bending. In the FSW technique, the road to the welding of the base cloth, well under the dissolving temperature, has unfolded new patterns in creating divergent joint talented. Impact on micro welding pace, violent robbery and docile nature of welded joints examined. By changing the parameters of the method, freed from imperfections and excessive effectiveness of the welded joints are created. The share among the dimension device and stick shoulder distance is the maximum dominant issue. From examination of the microstructure is obvious that the set substances to hand pushing a bit of district policies. HAZ violence in 6061 is seen as
Dissertations / Theses on the topic "Friction bit joining"
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Peterson, Rebecca Hilary. "Friction Bit Joining of Dissimilar Combinations of DP 980 Steel and AA 7075." BYU ScholarsArchive, 2015. https://scholarsarchive.byu.edu/etd/6030.
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Friction Bit Joining (FBJ) is a new technology that allows lightweight metals to be joined to advanced high-strength steels (AHSS). Joining of dissimilar metals is especially beneficial to the automotive industry because of the desire to use materials such as aluminum and AHSS in order to reduce weight and increase fuel efficiency. In this study, FBJ was used to join 7075 aluminum and DP980 ultra-high-strength steel. FBJ is a two-stage process using a consumable bit. In the first stage, the bit cuts through the top material (aluminum), and in the second stage the bit is friction welded to the base material (steel). The purpose of the research was to examine the impact a solid head bit design would have on joint strength, manufacturability, and ease of automation. The solid head design was driven externally. This design was compared to a previous internally driven head design. Joint strength was assessed according to an automotive standard established by Honda. Joints were mechanically tested in lap-shear tension, cross-tension, and peel configurations. Joints were also fatigue tested, cycling between loads of 100 N and 750 N. The failure modes that joints could experience during testing include: head, nugget, material, or interfacial failure. All tested specimens in this research experienced interfacial failure. Welds were also created and examined under a microscope in order to validate a simulation model of the FBJ process. The simulation model predicted a similar weld shape and bond length with 5 percent accuracy. Joints made with external bits demonstrated comparable joint strength to internal bits in lap-shear tension and cross-tension testing. Only external bits were tested after lap-shear tension, because it was determined that external bits would perform comparably to internal bits. Joints made with external bits also exceeded the standard for failure during fatigue testing. Peel tested specimens did not meet the required strength for the automotive standard. Examining specimens under a microscope revealed micro-cracks in the weld. These defects have been shown to decrease joint strength. Joint strength, especially during peel testing, could be increased by reducing the presence of micro-cracks. The external bit design is an improvement from the internal bits for manufacturability and ability to be automated, because of the less-expensive processes used to form the bit heads and the design that lends to ease of alignment.
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Okazaki, Matthew R. "Friction Bit Joining of Similar Alloy Sheets of High-Strength Aluminum Alloy 7085." BYU ScholarsArchive, 2018. https://scholarsarchive.byu.edu/etd/6866.
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Friction Bit Joining (FBJ) is a new technology used primarily in joining dissimilar metals. Its primary use has been focused in the automotive industry to provide an alternative joining process to welding. As automotive manufacturing has continually pushed toward using dissimilar materials, new joining processes have been needed to replace traditional welding practices that do not perform well when materials are not weld compatible. FBJ meets these needs perfectly as it provides strength as well as the ability to join materials of almost any kind.The purpose of this research was to explore different applications of the FBJ process. Traditionally FBJ has used a steel bit to drill through a thin piece of aluminum and weld to a piece of steel behind the aluminum. This research explored a different application of FBJ by using a steel bit to drill through multiple pieces of aluminum and weld to a small steel bit on the backside of the aluminum. The primary goal of this research was to answer two questions. (1) How does drilling impact peak weld strength and (2) Does an optimal shank diameter exist in terms of peak weld strength? As in other research, no universal parameters were found for optimization of lap shear, cross tension and t-peel tests. Drilling was found to be an important factor in peak weld strength. Number of flutes on the consumable steel bit was varied to see the impact of better and worse chip clearance ability. Increasing number of flutes was found to positively impact peak weld strength to a point. Optimal number of flutes was found to be different for each type of testing. It was found that there was an optimal bit head to bit shank diameter ratio that optimized peak weld strength. Again the optimal diameter was different for each test. Bits of different diameters were created and then tested to measure the impact of varying shank diameters on peak weld strength. It was found that there was a strength tradeoff between two localized joint areas in diameter testing. Decreasing the shank diameter increased the amount of overlap formed by the bit head over the top coupon. This shifted strength to the bit head region. While this strengthened the bit head region of the joint, strength was sacrificed in the bit-nut intersection. This tradeoff was consistently found in all test types.
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Squires, Lile P. "Friction Bit Joining of Dissimilar Combinations of Advanced High-Strength Steel and Aluminum Alloys." BYU ScholarsArchive, 2014. https://scholarsarchive.byu.edu/etd/4104.
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Friction bit joining (FBJ) is a new method that enables lightweight metal to be joined to advanced high-strength steels. Weight reduction through the use of advanced high-strength materials is necessary in the automotive industry, as well as other markets, where weight savings are increasingly emphasized in pursuit of fuel efficiency. The purpose of this research is twofold: (1) to understand the influence that process parameters such as bit design, material type and machine commands have on the consistency and strength of friction bit joints in dissimilar metal alloys; and (2) to pioneer machine and bit configurations that would aid commercial, automated application of the system. Rotary broaching was established as an effective bit production method, pointing towards cold heading and other forming methods in commercial production. Bit hardness equal to the base material was found to be highly critical for strong welds. Bit geometry was found to contribute significantly as well, with weld strength increasing with larger bit shaft diameter. Solid bit heads are also desirable from both a metallurgical and industry standpoint. Cutting features are necessary for flat welds and allow multiple material types to be joined to advanced high-strength steel. Parameters for driving the bit were established and relationships identified. Greater surface area of contact between the bit and the driver was shown to aid in weld consistency. Microstructure changes resulting from the weld process were characterized and showed a transition zone between the bit head and the bit shaft where bit hardness was significantly increased. This zone is frequently the location of fracture modes. Fatigue testing showed the ability of FBJ to resist constant stress cycles, with the joined aluminum failing prior to the FBJ fusion bond in all cases. Corrosion testing established the use of adhesive to be an effective method for reducing galvanic corrosion and also for protecting the weld from oxidation reactions.
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Siemssen, Brandon Raymond. "Development and Characterization of Friction Bit Joining: A New Solid State Spot Joining Technology Applied to Dissimilar Al/Steel Joints." Diss., CLICK HERE for online access, 2008. http://contentdm.lib.byu.edu/ETD/image/etd2425.pdf.
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Weickum, Britney. "Friction Bit Joining of 5754 Aluminum to DP980 Ultra-High Strength Steel: A Feasibility Study." BYU ScholarsArchive, 2011. https://scholarsarchive.byu.edu/etd/2789.
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In this study, the dissimilar metals 5754 aluminum and DP980 ultra-high strength steel were joined using the friction bit joining (FBJ) process. The friction bits were made using one of three steels: 4140, 4340, or H13. Experiments were performed in lap shear, T-peel, and cross tension configurations, with the 0.070" thick 5754 aluminum alloy as the top layer through which the friction bit cut, and the 0.065" thick DP980 as the bottom layer to which the friction bit welded. All experiments were performed using a computer controlled welding machine that was purpose-built and provided by MegaStir Technologies. Through a series of designed experiments (DOE), weld processing parameters were varied and controlled to determine which parameters had a significant effect on weld strength at a 95% confidence level. The parameters that were varied included spindle rotational speeds, Z-command depths, Z-velocity plunge rates, dwell times, and friction bit geometry. Maximum lap shear weld strengths were calculated to be 1425.4lbf and were to be obtained using a bit tip length at 0.175", tip diameter at 0.245", neck diameter at 0.198", cutting and welding z-velocities at 2.6"/min, cutting and welding RPMs at 550 and 2160 respectively, cutting and welding z-commands at -0.07" and -0.12" respectively, cooling dwell at 500 ms, and welding dwell at 1133.8 ms. These parameters were further refined to reduce the weld creation time to 1.66 seconds. These parameters also worked well in conjunction with an adhesive to form weld bonded samples. The uncured adhesive had no effect on the lap shear strengths of the samples. Using the parameters described above, it was discovered that cross tension and T-peel samples suffered from shearing within the bit that caused the samples to break underneath the flange of the bit during testing. Visual inspection of sectioned welds indicated the presence of cracking and void zones within the bit.
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Atwood, Lorne Steele. "Friction Bit Joining of Dissimilar Combinations of GADP 1180 Steel and AA 7085 – T76 Aluminum." BYU ScholarsArchive, 2016. https://scholarsarchive.byu.edu/etd/6400.
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Friction Bit Joining (FBJ) is a method used to join lightweight metals to advanced high-strength steels (AHSS). The automotive industry is experiencing pressure to improve fuel efficiency in their vehicles. The use of AHSS and aluminum will reduce vehicle weight which will assist in reducing fuel consumption. Previous research achieved joint strengths well above that which was required in three out of the four standard joint strength tests using DP980 AHSS and 7075 aluminum. The joints were mechanically tested and passed the lap-shear tension, cross-tension, and fatigue cycling tests. The t-peel test configuration never passed the minimum requirements. The purpose of continuing research was to increase the joint strength using FBJ to join the aluminum and AHSS the automotive industry desires to use specifically in the t-peel test. In this study FBJ was used to join 7085 aluminum and GADP1180 AHSS. The galvanic coating on the AHSS and its increased strength with the different aluminum alloy required that all the tests be re-evaluated and proven to pass the standard tests. FBJ is a two-step process that uses a consumable bit. In the first step the welding machine spins the bit to cut through the aluminum, and the second step applies pressure to the bit as it comes in contact with the AHSS to create a friction weld.
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Gardner, Rebecca. "An Experimental Investigation of Friction Bit Joining in AZ31 Magnesium and Advanced High-Strength Automotive Sheet Steel." BYU ScholarsArchive, 2010. https://scholarsarchive.byu.edu/etd/2159.
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Friction Bit Joining (FBJ) is a recently developed spot joining technology capable of joining dissimilar metals. A consumable bit cuts through the upper layer of metal to be joined, then friction welds to the lower layer. The bit then snaps off, leaving a flange. This research focuses on FBJ using DP980 or DP590 steel as the lower layer, AZ31 magnesium alloy as the top layer, and 4140 or 4130 steel as the bit material. In order to determine optimal settings for the magnesium/steel joints, experimentation was performed using a purpose-built computer controlled welding machine, varying factors such as rotational speeds, plunge speed, cutting and welding depths, and dwell times. It was determined that, when using 1.6 mm thick coupons, maximum joint strengths would be obtained at a 2.03 mm cutting depth, 3.30 mm welding depth, and 2500 RPM welding speed. At these levels, the weld is stronger than the magnesium alloy, resulting in failure in the AZ31 rather than in the FBJ joint in lap shear testing.
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Wood, Shane Forrest. "Manipulation and Automation of FBJ Short-Axis Fasteners." BYU ScholarsArchive, 2018. https://scholarsarchive.byu.edu/etd/7311.
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Legislative and market pressures are pushing automakers to achieve new fuel economy requirements in the coming years. To help achieve these goals automakers are reducing the overall weight of the vehicle by increasing the use of high-strength aluminum and advanced high-strength steels, and with this increased use comes the desire to quickly, and securely, join these materials within the vehicle. Friction bit joining is a process that lends itself well to joining these materials. This process uses consumable fasteners that need to be used in an automated production line. The geometry of these fasteners causes two main problems: the bits have a short longitudinal axis, which makes them difficult to orient, and the welding platform may be used at different angles; requiring a robust reloading system that is indifferent to its orientation.Our research explored ways that these short axis FBJ fasteners could be handled and transported using various automated methods. We tested the use of small mechanical carriages and magnetic tracks to test their viability for transporting FBJ fasteners. The two different types of fasteners that were used in the project are described. Blow feed tubes ended up being a reliable method of transportation given that the fastener has suitable geometry. The superior bit and feed system design were bench tested using a manually controlled feed system. The system was tested in various orientations to test the robustness of the system since the system was designed to be part of the end effector on a production line robot. The testing revealed that the feed tube is a reliable method of bit transportation and mechanical jaws are a suitable solution for FBJ fastener manipulation. These jaws have several key design features that dramatically increase their effectiveness. Suggestions for future work would be an optimized feed tube cross section, improved material properties in the bit jaw, and more air flow at a higher pressure through the feed tube.
Conference papers on the topic "Friction bit joining"
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Miles, M. P., Kent E. Kohkonen, B. Weickum, and Z. Feng. "Friction Bit Joining of Dissimilar Material Combinations of High Strength Steel DP 980 and Al Alloy AA 5754." In SAE World Congress & Exhibition. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 2009. http://dx.doi.org/10.4271/2009-01-0031.
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Kruger, Grant H., Scott F. Miller, Albert J. Shih, and Theo I. van Niekerk. "Robustness of 802.15 Wireless Interface for Real-Time Thermal Feedback Control of the Friction Stir Welding Process." In ASME 2015 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2015. http://dx.doi.org/10.1115/msec2015-9431.
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Friction Stir Welding (FSW) is a modern, solid-state joining processes, involving frictional heating and mechanical forging. High quality joints can be created using a control system that compensates for external disturbances by regulating the state of the weld zone (WZ) surrounding the tool. However, in this situation direct monitoring is complex since the rotating tool is embedded in plasticized material. This research discusses the development of a Bluetooth-based Wireless Rotating Process Monitoring (WRPM) system to overcome limitations in inductive/capacitive telemetry systems. Communication channel performance was assessed to determine the suitability of Bluetooth for use in the feedback control loop for in-process FSW WZ temperature control. Peak round-trip communications latencies of 300–650 ms for 20–200 byte payloads were observed. Additionally, electrical noise from the machine tool reduced the receive signal strength measured on the Bluetooth module. The bit error rate (BER) also increased from 0 to 0.001 % as spindle speed increased from 0 to 1400 rpm. Due to the communication latency, the signal strength and BER effects were not observed to affect throughput. The results support the use of the WRPM system for feedback control of FSW. However, deterministic communication latency must be achieved to enable the design of a stable control system.
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Li, YongBing, ZeYu Wei, YaTing Li, ZhaoZhao Wang, and Xiaobo Zhu. "Friction Self-Piercing Riveting (F-SPR) of AA6061-T6 to AZ31B." In ASME 2013 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/imece2013-64212.
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Implementation of lightweight low-ductility materials such as aluminum alloys, magnesium alloys and composite materials has become urgently needed for automotive manufacturers to improve the competitiveness of their products. However, the hybrid use of these materials poses big challenges to joining processes. Self-piercing riveting (SPR) is currently the most popular technique for joining dissimilar materials and has been widely used in joining all-aluminum and multi-material vehicle bodies. However, in riveting magnesium alloys, cracks always occur for its low ductility. In this paper, a hybrid joining process named friction self-piercing riveting (F-SPR), which combines mechanical joining mechanism of SPR with solid-state joining mechanism of friction stir spot welding (FSSW) by making rivet rotating at high speed in riveting process, was proposed aiming at joining the low ductility materials. 1-mm-thick AA6061-T6 and 2-mm-thick AZ31B were used to validate the effectiveness of the F-SPR process. The results showed that the F-SPR process could significantly improve the rivetability of magnesium alloys, and greatly increase the joint strength, comparing with traditional SPR process.
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Liu, Xun, Sheng Zhao, and Jun Ni. "Material Flow Visualization of Dissimilar Friction Stir Welding Process Using Nano-CT." In ASME 2018 13th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/msec2018-6363.
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In this study, Friction stir welding (FSW) of aluminum alloy 6061-T6511 to TRIP 780 steel are analyzed under various process conditions. Two FSW tools with different sizes are used. To understand the underlying joining mechanisms and material flow behavior, nano-CT is applied for a 3D visualization of material distribution in the weld. With insufficient heat input, steel fragments are generally scattered in the weld zone in large pieces. This is observed in a combined condition of big tool, small tool offset and low rotating speed or a small tool with low rotating speed. Higher heat input improves the material flowability and generates a continuous strip of steel. The remaining steel fragments are much finer. When the volume fraction of steel involved in the stirring nugget is small, this steel strip can be in a flat shape near the bottom, which generally corresponds to a better joint quality and the joint would fracture in the base aluminum side. Otherwise, a hook structure is formed and reduces the joint strength. The joint would fail with a combined brittle behavior on the steel hook and a ductile behavior in the surrounding aluminum matrix.