Advanced Joining Processes: Welding, Plastic Deformation, and Adhesion

Front-Matter_2021_Advanced-Joining-Processes
	Advanced Joining Processes
Copyright_2021_Advanced-Joining-Processes
	Copyright
Contributors_2021_Advanced-Joining-Processes
	Contributors
Preface_2021_Advanced-Joining-Processes
	Preface
Chapter-1---Laser-joining_2021_Advanced-Joining-Processes
	1. Laser joining
		1. Introduction
		2. Laser heat conduction welding
		3. Laser keyhole welding
		4. Laser hybrid welding
		5. Laser beam micro welding
			5.1 Spot welding
			5.2 Overlap spot welding
			5.3 Continuous laser micro welding
			5.4 Laser soldering
			5.5 Laser welding of thermoplastic polymers
			5.6 Laser joining of polymer-metal hybrid components
			5.7 Laser sources for laser joining processes
		6. Summary
		References
Chapter-2---Electron-beam-welding_2021_Advanced-Joining-Processes
	2. Electron beam welding
		1. Introduction
		2. State of research on electron beam welding
			2.1 Publications related to materials
		3. Publications related to simulation
			3.1 Transmissivity of the vapor channel
			3.2 Melt pool dynamics and kinetics of the vapor capillary
			3.3 Equivalent heat source and residual stress simulation
		4. Process-related publications
		5. Process diagnostic – online monitoring
			5.1 Secondary effects
			5.2 Backscatter electron signal
			5.3 Ion current
			5.4 X-ray braking radiation
			5.5 Magnetic field
			5.6 Secondary signals on the underside of the weld seam
			5.7 Goniometry
			5.8 Beam measurement
				5.8.1 Diabeam-system – combination of slotted ring aperture and pinhole
				5.8.2 Slit apertures and beam on circular path
				5.8.3 TechScan - rotating disk scanner
					5.8.3.1 Optical beam measurement
			5.9 Beam quality
				5.9.1 Influence of mounting position
				5.9.2 Influence of cathode wear
			5.10 Plasma cathode
			5.11 Non-vacuum electron beam welding technology (NV-EBW)
			5.12 Additive Manufacturing
			5.13 Differentiation of AM manufacturing processes
			5.14 Distortion simulation EBAM
		6. Conclusion
		References
Chapter-3---Computational-weld-analysis-and-fatigue-_2021_Advanced-Joining-P
	3. Computational weld analysis and fatigue of welded structures
		1. Introduction
		2. Computational weld mechanics
		3. Various stress definitions used in weld fatigue analysis
			3.1 Stress state at a weld toe
		4. The nominal (S-N) stress method
		5. The local (ε-N) elastic-plastic strain-stress method
		6. The fracture mechanics (da/dN-ΔK) method
		7. The GY2 method for shell mesh weld modeling
			7.1 The nominal and the hot spot stress in a welded joint structure
			7.2 Various stress quantities in weldments and stress field invariants
			7.3 The nominal stress in welded structures
			7.4 Definition of the local nominal stress or the local hot spot stress
			7.5 The composed stress concentration factors for weldments
			7.6 Determination of the shell hot spot stresses σhsm and σhsb
			7.7 Stress concentration factors for welds
				7.7.1 Stress concentration factors for butt welded joints
				7.7.2 Stress concentration factors for asymmetric fillet welds (T-welded joint)
				7.7.3 Stress concentration factors for symmetric fillet welds (cruciform joint)
			7.8 Example – Illustration of GY2 weld model
			7.9 Conclusions – GY2 weld model
		8. The GR3 method for solid mesh weld modeling
			8.1 Stress quantities obtained from various finite element analyses
			8.2 Determination of hot spot stresses from coarse mesh 3D FE data
			8.3 The link between the membrane and bending hot spot stresses and the 3D FE stress data
			8.4 The GR3 method for determination of the local hot spot stresses
			8.5 Example– Illustration of GR3 weld model
			8.6 Conclusions – GR3 weld model
		References
Chapter-4---Deformation-assisted-joining_2021_Advanced-Joining-Processes
	4. Deformation assisted joining
		1. Introduction
		2. Mechanical joining
			2.1 Form-fit joints
			2.2 Interference-fit joints
			2.3 Resistance heated interference joining of micro fork and wire
		3. Joining by solid-phase welding
			3.1 Cold pressure welding of Al-Steel slide bearing
			3.2 Cold pressure welding of a valve floater
		4. Joining by combined fusion and solid-state welding
			4.1 Resistance welding of a thermostat valve
			4.2 Resistance spot welding of three sheets
			4.3 Joining of two perpendicular sheets by resistance projection welding
			4.4 Joining of a new lightweight sandwich material by spot welding
		5. Conclusions
		Acknowledgments
		References
Chapter-5---Friction-stir-welding_2021_Advanced-Joining-Processes
	5. Friction stir welding
		1. Introduction
		2. FSW of aluminum alloys
		3. Harder metal alloys FSW
		4. Polymers and composites FSW
			4.1 Friction stir spot welding (FFSW)
			4.2 Friction stir welding (FSW)
			4.3 Stationary shoulder friction stir welding (SSFSW)
		5. FSW hybridization
		6. Conclusions
		References
Chapter-6---Explosive-welding_2021_Advanced-Joining-Processes
	6. Explosive welding
		1. Introduction
		2. The explosive welding process
			2.1 The mechanism of explosive welding
			2.2 Characteristics of the interface and wave formation
			2.3 Parameter selection: the weldability window
			2.4 Advantages and limitations
			2.5 Applications of explosive welded joints
				2.5.1 Applications of aluminum to copper and aluminum to steel joints
		3. Explosive welding of aluminum to copper
			3.1 Remarks
			3.2 Recent developments
		4. Explosive welding of aluminum to steel
			4.1 Explosive welding of aluminum to carbon/low-alloy steel
			4.2 Explosive welding of aluminum to stainless steel
			4.3 Remarks
			4.4 Recent developments
		5. Conclusions
		Acknowledgments
		References
Chapter-7---Ultrasonic-welding_2021_Advanced-Joining-Processes
	7. Ultrasonic welding
		1. Introduction
		2. Fundamentals of ultrasonic
			2.1 Principle of ultrasonics
			2.2 Components of a metal ultrasonic device
			2.3 Ultrasonic metal welding
				2.3.1 Welding principles
				2.3.2 Joint and material configurations
				2.3.3 Joint formation mechanism
		3. Applications and challenges during ultrasonic metal welding
			3.1 Process properties
			3.2 An overview over ultrasonic welding of hybrid joints
			3.3 Ultrasonic welding of Al/Cu
			3.4 Ultrasonic welding of aluminum wire to copper sheets
				3.4.1 Compaction in ultrasonic welding of wire and sheets
			3.5 Simulation and modeling approaches in ultrasonic metal welding
		4. Conclusion
		References
Chapter-8---Manufacture-and-testing_2021_Advanced-Joining-Processes
	8. Manufacture and testing
		1. Introduction
		2. Structural adhesives
			2.1 Types of adhesives
			2.2 Adhesive characterization
				2.2.1 Tensile tests
				2.2.2 Compressive tests
				2.2.3 Shear tests
				2.2.4 Fracture tests
		3. Joint design
			3.1 Adhesive joints configurations
				3.1.1 Butt joints
				3.1.2 Lap joints
				3.1.3 Strap joints
				3.1.4 Cylindrical joints
				3.1.5 T joints
				3.1.6 Corner joints
				3.1.7 Reinforcements
			3.2 Joint strength prediction
				3.2.1 Analytical models for stress analysis
				3.2.2 Failure modes
				3.2.3 Factors that influence joint strength
		4. Surface treatment
			4.1 Mechanical treatments
			4.2 Chemical treatments
			4.3 Physical treatments
		5. Manufacture
			5.1 Storage
				5.1.1 Storage time
				5.1.2 Storage temperature
				5.1.3 Humidity
				5.1.4 Radiation
				5.1.5 Contamination
			5.2 Metering and mixing
			5.3 Adhesive dispensing
				5.3.1 Paste
				5.3.2 Liquid
				5.3.3 Film
				5.3.4 Tape
			5.4 Fixturing
				5.4.1 Pressure application methods
				5.4.2 Molds and jigs
				5.4.3 Techniques for controlling adhesive thickness
			5.5 Hardening and curing
				5.5.1 Cure by chemical reaction
				5.5.2 UV curing
				5.5.3 Moisture curing
				5.5.4 Anaerobic curing
				5.5.5 Loss of solvent or water
				5.5.6 Hardening from a melted state
		6. Quality control
			6.1 Destructive tests
				6.1.1 Quasi-static tests
				6.1.2 High rate and impact tests
				6.1.3 Fatigue tests
				6.1.4 Creep tests
			6.2 Non-destructive tests
				6.2.1 Visual inspection
				6.2.2 Tap method
				6.2.3 Ultrasonic methods
				6.2.4 Thermal methods
				6.2.5 Post fracture analysis
		7. Conclusions
		Acknowledgments
		References
Chapter-9---Simulation_2021_Advanced-Joining-Processes
	9. Simulation
		1. Introduction
		2. Numerical simulation of adhesive joints using CZM and XFEM techniques
			2.1 CZM
			2.2 XFEM
		3. Fatigue life analysis of adhesives and adhesive joints
		4. Numerical simulation of adhesive joints at different strain rate and impact conditions
		5. Numerical analysis of adhesive joints under different environmental conditions
		Acknowledgments
		References
Chapter-10---Hybrid-joining-techniques_2021_Advanced-Joining-Processes
	10. Hybrid joining techniques
		1. Introduction
		2. Bolted-bond hybrid joints for structural steel applications
		3. Bolted-bond hybrid joints for G-FRP
			3.1 Illustration on lap shear tests
			3.2 Illustration on tubular lap shear tests
		4. Hybrid joints in timber engineering
			4.1 Experimental investigations
			4.2 Results
			4.3 Discussion
			4.4 Conclusions
		5. Hybrid mechanical/adhesive joints for the automotive industry
		6. Welded bond hybrid joints
		7. Concluding remarks
		References
Index_2021_Advanced-Joining-Processes
	Index
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