Composite Materials
Resistance Welding Lesson Objectives When you finish this lesson you will understand: Learning Activities 1.View Slides; 2.Read Notes, 3.Listen to lecture 4.Do on-line workbook Keywords
Matrix Materials Magnesium Lowest density (37% lighter than aluminum) Aerospace applications Creeps at low temp Relatively low strength Prone to variety of corrosion problems Aluminum Easy to process, inexpensive Density only 35% of Steel Can be alloyed to fairly high strengths 57% stiffer than Magnesium Excellent corrosion resistance Most widely used material
Matrix Materials Titanium Twice as strong as aerospace aluminum 65% heavier than aluminum, but 65% stiffer Temp & corrosion resistant = use in demanding environments Copper, Iron, Nickel, Tungsten Special use alloys Electronic Circuits Metal forming dies Jet engines Military applications
Reinforcements Ceramics Silicon Carbide (SiC) Aluminum Oxide (Al 2 O 3 ) Titanium Carbide (TiC) Boron Carbide (B 4 C) Other Graphite (C) Titanium Diboride (TiB 2 ) Metal Filaments Boron Steel Tungsten Choice of matrix and reinforcement depends on: Desired properties of composite Compatibility between matrix and reinforcement MMC Processing route
Rule of Mixtures
Designation for MMC Matrix + Reinforcement / Volume % Form Matrix = metal or alloy designation of matrix Reinforcement = chemical formula of reinforcement Volume % = Volume percent without the % sign Form = Form of the reinforcement f, fiber or filament c, chopped fiber w, whisker p, particulate Example: SiC/20w
Welding Handbook, AWS
Particulate Composite Short-Fiber Composite Long-Fiber Composite Laminated Composite Manufacturing Processes Welding Handbook, AWS
Processing Methods Solid State Semi-solid Liquid
Solid State Processing Bonding of continuous fibers between metal foils to make panels Aerospace Applications Ti/Sic; Al/B Laminated Composite Powder Metallurgy Mix particles of matrix with reinforcement Vacuum hot press (near solidus) Extrude or roll Al/B 4 C; Al/SiC
Semi-Solid Processing Spray Deposition Chilled Plate MMC Build Up Flame Spray Matrix Flame Spray Reinforcement ……….. Rheocasting Mix reinforcement into matrix held between solidus and liquidus x
Liquid Processing Infiltration Interfacial reactions can be a problem
Applications - From Ukraine Krivov, Optimization of design-production…, Welding in the World, Nov-Dec 1994
Applications Krivov, Optimization of design-production…, Welding in the World, Nov-Dec 1994
Krivov, Optimization of design-production…, Welding in the World, Nov-Dec 1994
Welding Handbook, AWS
Detrimental Weld Pool Chemical Reactions [l] indicates liquid phase [s] indicates solid phase [Al l ] indicates in solution with liquid aluminum
Resistance Welding Arc Welding Time-Temp Effect of Chem Reaction Welding Handbook, AWS
Capacitor Discharge Stud Welding Solid State Fusion Weld Brazing
Capacitor Discharge Stud Welding MMC Materials Welded 6061, 2024, 6061/SiC/40p, 6061/SiC/48f, 6061/B 4 C/30p, AZ61/B 4 C/40p Studs = 0.25 in; Sheet=0.13 in Time = 0.4 ms Solidification rate = 10 6 C/s
Welding Handbook, AWS Stud Welding
Welding Handbook, AWS
Capacitor Discharge - Solid State Welding Ti-6Al-4V/SiC Sheets Ti-6Al-4V/SCS-6 Diffusion (solid state) Bond No Melting Failure Occurred Upon Loading Remote from Weld Interface Baeslack & Froes, Joining Similar & Dissimilar……, JOM March 1995 SCS-6 is a complex fiber with SiC vapor deposited onto a graphite carbon core
Increase in Welding Current (Voltage) Causes Change From Solid State to Fusion Weld Cox et al, Capacitor Discharge RSW of SiC Fiber… Welding Journal, Oct 1993
Capacitor Discharge Solid State Weld No liquid - Weld Strength 80% of Monolithic SCS-6 Fiber Cox et al, Capacitor Discharge RSW of SiC Fiber… Welding Journal, Oct 1993
Solid State Weld with no Fiber degradation Cox et al, Capacitor Discharge RSW of SiC Fiber… Welding Journal, Oct 1993
Capacitor Discharge - Fusion Welding
Partial Melting Fusion Weld Cox et al, Capacitor Discharge RSW of SiC Fiber… Welding Journal, Oct 1993
Solidified Liquid around fiber, Property degradation Cox et al, Capacitor Discharge RSW of SiC Fiber… Welding Journal, Oct 1993
Al-7Zn/C BAlSi-4 Brazing Foil Low force = expulsion > 400 lb = fiber packing at weld center (see next slide) Spot Brazing Continuous C Fiber MMC
Welding Handbook, AWS Brazing
Spot Brazing Continuous SiC Fiber MMC Ti-22Al-23Nb/SiC Ti-Cu-Ni Braze Foil Baeslack & Froes, Joining Similar & Dissimilar……, JOM March 1995
Baeslack & Froes, Joining Similar & Dissimilar……, JOM March 1995
Resistance Welding Arc Welding Time-Temp Effect of Chem Reaction Welding Handbook, AWS
Resistance Spot Welding Solid State With Melting/Solidification
Spot Welding Welding Handbook, AWS
Adjusting Welding Force Welding Time To Avoid Fiber Crushing in Al/B MMC Welding Handbook, AWS (Continuous Fiber)
Aluminum/Boron Continuous Fiber Hersh, Resistance Spot Weld MMC, Welding Journal, June 1970
Aluminum/Boron Continuous Fiber Hersh, Resistance Spot Weld MMC, Welding Journal, June 1970
Aluminum/Boron Continuous Fiber Hersh, Resistance Spot Weld MMC, Welding Journal, June 1970
Aluminum/Boron Continuous Fiber Hersh, Resistance Spot Weld MMC, Welding Journal, June 1970
Aluminum/Boron Continuous Fiber Hersh, Resistance Spot Weld MMC, Welding Journal, June 1970
Spot Welding Discontinuous Fibers Segregation of reinforcement (see next slide)
Welding Handbook, AWS