Please use this identifier to cite or link to this item:
|Title:||DEVELOPMENT OF FATIGUE AND FRACTURE RESISTANT WELD BOND OF ALUMINIUM ALLOYS|
|Keywords:||MECHANICAL INDUSTRIAL ENGINEERING|
FATIGUE AND FRACTURE RESISTANT WELD BOND
|Abstract:||This report contains of experimental investigations to develop the fracture resistant weld bonds of aluminum alloys. The weld bonds were characterized in respect of mechanical and metallurgical properties. Mechanical properties include shear-tensile testing, fatigue testing and micro hardness studies in Weld nugget and HAZ and metallurgical properties includes microstructural studies. Joining of metals by employing spot welding in combination with adhesive bonding has drawn considerable attention of numerous scientists and industrialists as this combined technology has greater advantages over the individual techniques as spot welding or adhesive bonding alone. This report presents a systematic experimental study of weld bonding which was conducted in three phases- phase 1: pilot experiments, phase 2: main experiments and phase 3: confirmation experiments. Initially pilot experiments were conducted to identify the Optimum values of surface roughness and overlap length for maximisation of USTL of adhesive bonds as these two parameters majorly affect the performance of adhesive bonds. Some weld bonds were also developed to identify the range of resistance welding parameters so as to develop the sound weld bonds. Optimised values of surface roughness and overlap length during pilot experiments were used during main experimentation in development of weld bonds and were kept constant. During main experiments, the effect of input process parameters namely curing temperature, curing time, welding pressure, welding time and welding current on the characteristics of the weld bonds such as bondline thickness, equivalent nugget diameter, corona size and ultimate shear tensile strength according to the Box-Behnken design (BBD) and response 'surface methodology (RSM). Using the results of main experiments, regression models were developed. The development of regression models and their statistical analysis including ANOVA, for the four responses were done with the help of Design-Expert 8.1 software. Study of the main effects and interaction effects of the variable process parameters on the responses characteristics of weld bonds was done. Using model, the optimal combination of weld bonding process parameters for maximum shear tensile strength of the weld bond was obtained. Further, efforts were made to relate the bond-line thickness, equivalent nugget diameter and corona size with ultimate shear tensile strength of weld bonds. The regression models were validated by conducting confirmation experiments.|
|Appears in Collections:||MASTERS' DISSERTATIONS (MIED)|
Items in DSpace are protected by copyright, with all rights reserved, unless otherwise indicated.