Hybrid components combine the contradictory characteristics of plastics and metal thus can lead to advantageous construction part properties. As a result light concomitantly stiff be produced. Therefore, need for joining these dissimilar materials is central challenge. A new approach overcome problems state-of-the-art technologies using laser radiation ablate surface in order create microstructures with undercut grooves. When above placed plastic melted or induction joining, material expands...

Abstract Changing process conditions such as distortion, varying seam preparation or gap width during welding is a major challenge in automated gas metal arc (GMAW). While human welders can adjust the (e.g. speed, torch orientation), an system needs sensors to detect and actuators process. Adjusting response changing usually referred adaptive welding. The aim of this work build robotic capable automatically adapting using some approaches welder. To enable control, built. It consists four...

Abstract Wire- and arc-based additive manufacturing (WAAM) is a promising technology for large-scale of metallic components. However, due to the high heat input by electric arc, interpass cooling time decelerates average speed. Since future applications aim production large structural steel components, speed key parameter make WAAM usable civil engineering. Within scope this paper, different process strategies are weighed up against one another with regard efficiency, impact on process, as...

Studies in the field of environmental epidemiology indicate that for adverse effect inhaled particles not only particle mass is crucial but also size is. Ultrafine with diameters below 100nm are special interest since these have high surface area to ratio and properties which differ from those larger particles. In this paper, distributions various welding joining techniques were measured close process using a fast mobility sizer (FMPS). It turned out processes emission rates (manual metal...

Abstract Friction stir welding (FSW) is a solid-state process, which has significantly disrupted technology particularly for aluminum alloy applications. Due to its high-quality welds in all alloys, comparatively low heat input with high energy efficiency and ecological friendliness, FSW used rapidly growing number of Currently, destructive non-destructive testing methods are attached as separate process step verify weld seam quality, detecting imperfections late production requiring costly...

Ultrasonic metal welding is an efficient, solid-state process that well established in the production of electrical equipment. However, isolated and untraceable failures occasionally occur industrial processes. According to state art, these are due a multitude influencing variables, such as material surface condition joining partners, tool fixture wear. This study presents quality prediction models based on measurements mechanical vibrations machine using laser triangulation sensors,...

Estimating the properties of dissimilar metal welded joints made using modern high-energy beam techniques presents significant challenges due to complex nature process. These complexities arise from different thermal and mechanical materials involved. The a joint are primarily determined by element mixing final chemical composition when two metals fused together, or filler material is used. Hence, representative model capable tracking elemental distribution temperature essential for...

Abstract The anode boundary layer in atmospheric pressure arc discharges is studied numerically on the basis of hydrodynamic (diffusion) equations for plasma components. governing are formulated a unified manner without assumptions thermal equilibrium, ionization equilibrium or quasi-neutrality. For comparison, quasi-neutral model also considered. numerical computations performed an argon at typical values current density layers (500–2000 A cm −2 ). results modelling show that common...

Ultrasonic metal welding (USMW) is a common used manufacturing technology for cell, module or pack assembly of Lithium-ion battery systems pouch type. Since every single joint can affect the efficiency and safety entire system, quality fluctuations are one greatest challenges. Despite its industrial spread in manufacturing, USMW has large number influencing variables that may bond but cannot be detected 100% failsafe with existing monitoring methods. Therefore aim this paper to investigate...

The Friction Stir Welding (FSW) process is known as a solid state welding comparably stable against external disturbances in its steady state. Therefore, the commonly applied with fixed parameters utilizing axial force control or position strategies. External and internal disturbances, introduced by workpieces, gap tolerances, tool wear machine/tool inadequacies are rarely monitored no conclusion towards weld seam quality drawn. In most applications sole monitoring feature measures often...

Wire and arc additive manufacturing (WAAM) is one of the most promising technologies for large-scale 3D printing metal parts. Besides high deposition rates, advantages WAAM possibility using in situ alloying to modify chemical composition therefore material properties fabricated workpiece. This can be achieved by feeding multiple wires different compositions into molten pool welding process generating a new alloy during itself. At present, changed stepwise keeping wire feed speeds per layer...

Abstract The level of residual stresses is great importance for many applications. In this work, the two established stress analysis methods x-ray and incremental hole-drilling combined with electronic speckle pattern interferometry are compared. Each method has its specific limitations. Furthermore, state a material influenced by processing history. To compare both methods, aluminum-based specimens (AlCu6Mn, AlZn5.5MgCu) different histories were investigated. Measurements conducted on same...

Abstract The production of electrical components for vehicles, battery systems, and power electronics using ultrasonic metal welding is now well established. industrial applications take advantage the large joining surface associated excellent thermal conduction properties. However, this also prevents weld quality from being monitored based on resistance measurements. For reason, mechanical properties are used as a substituting criterion process optimization control. type testing depends...