Pan American Materials Congress: Materials for Transportation and Lightweighting: Joining
Sponsored by: Third Pan American Materials Congress Organizing Committee
Program Organizers: Mary Wells, Univ of Guelph; Rafael Colás, Universidad Autónoma de Nuevo León; Fernand Marquis, San Diego State University; Ramalinga Viswanathan Mangalaraja, University of Concepcion; Marta Lopez, University of Concepcion; Elvi Dalgaard, Pratt & Whitney Canada; Patricia Zambrano, Universidad Autonoma de Nuevo Leon

Thursday 2:00 PM
March 2, 2017
Room: Marina G
Location: Marriott Marquis Hotel

Session Chair: Elvi Dalgaard, Pratt & Whitney Canada

2:00 PM  
Joining of Sandwich Materials – Concepts for Local Force Transmission into Innovative Vehicle Structures: Carmen Scholz1; Sebastian Wagner2; Gundolf Kopp1; Horst Friedrich1; 1German Aerospace Center; 2NMI Natural and Medical Sciences Institute at the University of Tübingen
    For a significant weight reduction in vehicle structures, the use of new materials - like sandwich materials - is necessary. Applications for sandwich structures can already be found in the form of roof or floor elements of high quality caravans. But there is a lack of appropriate manufacturing technologies. Therefore alternative construction concepts have to be investigated to integrate sandwich structures in car body design. In this study, innovative joining technologies for local force transmission into various sandwich materials were developed. In the process, critical joining parameters, dimensioning process as well as simulation method were analyzed in detail. The accumulated knowledge is incorporated into a design strategy for sandwich structures across all industries.

2:20 PM  
Influence of Robotic GMAW Welding Parameters on the Mechanical Properties of Thick Structural Steel Plates: Manuel Vazquez Esteban1; Argelia Miranda Pérez1; Rolando Praga Alejo2; Gladys Pérez Medina1; 1Corporación Mexicana de Investigación en Materiales; 2Universidad Autonoma de Coahuila
    The automotive industry of heavy vehicles has increased the use of robotic Gas Metal Arc welding (GMAW) due to its high reliability, ease of use, low cost and high productivity. Particular interest is on the Metal Inert Gas robotized process parameters and the variation of the macrostructure and mechanical properties of the weld. Therefore, the main objective of this study is to estimate the influence of voltage, amperage and welding speed on the microstructure, tensile strength and hardness. For optimal process automation is necessary to meet equations than can predict the responses characteristics; for the development of such equations Response Surface Methodology (RSM) based on a Composite Central Design (CCD) is employed, in order to optimize the welding quality, productivity and minimize total operating cost of MIG welding, applied to 1018 structural steel of 15.8 mm thickness, for rear axle used in heavy vehicles.

2:40 PM  
Joining Dissimilar Materials across Varying Length Scales by Impact Welding: Anupam Vivek1; Taeseon Lee1; Glenn Daehn1; 1Ohio State University
    Impact welding is a solid state welding technique that enables dissimilar joining of light materials such as high strength steel and aluminum alloys with reduced formation of brittle intermetallics as compared to fusion welding. This work focuses on fundamental understanding of effect of process parameters on the structure and property of impact welds. Vaporizing foil actuator welding (VFAW) and laser impact welding (LIW) processes were used for welding Al 1100 with AISI 1018 steel. The thickness of aluminum flyer sheets ranged from 0.0254 mm (0.001 inch) to 2.032 mm (0.080 inch). Impact angle and velocity were measured with a multi-probe photonic Doppler velocimeter. Under the same impact conditions, thickness of the intermetallic layer as well as the amplitude and wavelength of the interfacial waves increased with increasing flyer sheet thickness. Reduction in intermetallic content of the interface also led to stronger welds that failed in parent aluminum during mechanical testing.

3:00 PM  
Evaluation of Distortion in Pulse Spray Welding Joints of Hsla A572 Steel for Heavy Agricultural Equipment: Estuardo Raymundo Rivera Sanchez1; Gladys Yerania Perez Medina1; Eduardo Hurtado Delgado1; Leonardo Carrasco Gonzalez1; Argelia Fabiola Miranda Perez1; 1COMIMSA
    The aim of this investigation is the evaluation of the distortions generated in welding unions of HSLA A572 by effect of the welding temperature and the microestructural changes. The joint design is made of two C profile components with opposite concavity, 6mm thickness. The sequences of the welding trajectories are analyzed in combination with a variation of the welding parameters. Temperature data acquisition was developed next to the welding trajectory, obtaining the measures to generate time-temperature plots. Welding process was executed by a GMAW welding robot. The input parameters of voltage, wire feed and travel speed are set constant. The distortion of the work piece was measured using a laser scanning technique for comparison between the pre and post weld condition. Parts have concentric drills next to the weld to measure the differences post weld develop. Microstructural evaluation was performed on transversal sections of the weld for correlation against distortion.

3:20 PM Break

3:40 PM  
Comparison of the Single Pulse and the Second Pulse Current on the Fusion Zone Microstructure and Mechanical Properties of the TRIP Steel Welds: Miguel Fernando Delgado Pamanes1; Sergio Rodríguez2; Victor Hugo Hernandez2; Simitrio Ignacio Ruiz2; 1IPN - UPIIZ; 2UAZ
    In the Searching for making lighter and safer cars, auto companies and steelmakers are rapidly introducing Advanced High-Strength Steels "AHSS". Within AHSS steels are called TRansformation Induced Plasticity "TRIP". This steel is especially promising in the manufacture of structural components of the car body, which requires high strength, energy absorption (crashworthiness), good ductility (formability) and weight reduction in each of its elements, which are joint by Resistance spot welding. The welding of this steel is particularly important considering its structural application. The main objective of the present study is to improve the mechanical properties of the welding by applying a second pulse at different current levels and evaluate the microstructure of the fusion zone using optical microscopy, SEM and Hardness profiles.

4:00 PM  
Vaporizing Foil Actuator Welding as a Solution for Joining Automotive Steel and Aluminum Alloys: Anupam Vivek1; Bert Liu1; Glenn Daehn1; 1Ohio State University
    Vehicle weight reduction, by creating multi-material structures consisting of high strength-to-weight ratio materials, is one the strategies of the automotive industry to meet its fuel economy targets. Multi-material assembly raises issues of joining and corrosion and, currently, the standard solution in the industry is using fasteners and adhesives. Vaporizing foil actuator welding (VFAW) is a solid state welding technique, which enables joining of dissimilar materials without a third body. It utilizes a large pulsed current to turn a thin conductor into a highly kinetic gas, which launches one sheet of metal into another and creates an impact weld. Aluminum alloys type 5052 and 6111-T4 were welded to DP 980 and Usibor 1500 steels. During mechanical testing, failure occurred in parent aluminum. Results of mechanical testing, corrosion and advanced characterization will be discussed in light of the structure-property relationships. The stages of technology development for commercial implementation will also be presented.

4:20 PM  
Study of the discontinuities generated by GMAW process applied in AISI 1018 steel using NDT phased array and their microstructural correlation.: Luis Aguilar-Pérez1; Gladys Pérez-Medina1; Argelia Miranda-Pérez1; Rolando Praga-Alejo2; 1Corporación Mexicana de Investigación en Materiales; 2Universidad Autónoma de Coahuila
    Dependence and correlation between input variables (voltage, amperage and feed rate) and the final quality generated by the union through the GMAW welding process on steel components AISI 1018 with 15.8 mm of thickness, applied in freight transportation industry operations in its road mode, were analyzed in this study. The appearance of discontinuities and microstructural changes correlate to the input parameters through a design of experiments, whose output data were obtained by evaluating the weld, using: non-destructive testing; phased array, ultrasonic testing, visual inspection and penetration testing. Microstructural characterization by OM and SEM were carried out to evaluate the phase transformation and the mechanical properties were evaluated by microhardness testing. The maximum acceptance criteria component usually given by the design code applied often with additional requirements set by the customer, the acceptance criteria are discussed according to the new technologies due to codes currently employed in automotive industries.