Search Results (4)

Wire and arc additive manufacturing (WAAM) is a promising method of producing medium- and large-sized aluminum alloy structures, though it faces challenges such as porosity, residual stresses and inconsistent mechanical properties. This study investigates the effect of current type (AC and DC MIG welding) and polarity balance (influencing the duration of the positive/negative period of the cycle) on the mechanical and microstructural properties of 6063 aluminum alloy walls produced by WAAM. A TiB₂-refined Al–Mg–Si (6063) filler wire, specifically developed for arc-based processing, was used. Tensile tests, Vickers hardness measurements (HV5), optical microscopy and X-ray diffraction based on cosα method were used to evaluate performance in terms of strength, ductility, hardness, grain structure, porosity and residual stress. The results showed that the balance of AC polarity significantly affects wall geometry, porosity and grain structure. Increasing the negative polarity period resulted in taller and narrower walls, while the widest walls were produced with increased positive polarity. Residual stress measurements revealed a tensile–compressive–tensile distribution, with the DC-MIG samples showing the highest surface stress values. The highest tensile strength (172 MPa) was measured in the lower region of the DC-MIG sample, suggesting that areas near the substrate benefit from faster cooling. Full article

In this paper, a portable residual stress tester and synchrotron radiation diffraction technique were used to measure the residual stress distribution of thick 2A14 aluminum alloy plates under different aging conditions after solution treatment. The stress changes after solution and aging were analyzed using metallographic structure observation, electron backscattered diffraction (EBSD), X-ray diffraction (XRD), and other characterization methods. The results show that after solution treatment at 500 °C and aging at 170 °C, the second phase precipitates, lattice distortion is released, and the stress level gradually decreases with aging time. The residual stress of the plate comprises compressive stress; there is stress concentration in the central area. The stress distribution obtained by the two residual stress calculation methods, cosα and sin²ψ, under different process conditions was consistent. Full article

Friction-spinning as an innovative incremental forming process enables high degrees of deformation in the field of tube and sheet metal forming due to self-induced heat generation in the forming area. The complex thermomechanical conditions generate non-uniform residual stress distributions. In order to specifically adjust these residual stress distributions, the influence of different process parameters on residual stress distributions in flanges formed by the friction-spinning of tubes is investigated using the design of experiments (DoE) method. The feed rate with an effect of −156 MPa/mm is the dominating control parameter for residual stress depth distribution in steel flange forming, whereas the rotation speed of the workpiece with an effect of 18 MPa/mm dominates the gradient of residual stress generation in the aluminium flange-forming process. A run-to-run predictive control system for the specific adjustment of residual stress distributions is proposed and validated. The predictive model provides an initial solution in the form of a parameter set, and the controlled feedback iteratively approaches the target value with new parameter sets recalculated on the basis of the deviation of the previous run. Residual stress measurements are carried out using the hole-drilling method and X-ray diffraction by the cosα-method. Full article

In order to reduce the vibration of mountain self-propelled electric monorail transporters (MSEMT) caused by the impact of the meshing of roller gear with toothed rail (MRGTR), and to improve the stability and safety of monorail transporters, this paper theoretically analyzed the MRGTR mechanism of toothed monorail transporters as well as established the MSEMT displacement model and its instantaneous velocity model. The vibration signals of MSEMT with four different parameters of toothed rail were collected by the acceleration sensor and signal acquisition system. The signals were analyzed by the Hilbert envelope demodulation method to investigate the influence of toothed rail parameters on meshing impact vibration. Moreover, taking the vibration acceleration amplitude of MSEMT and the vibration attenuation time of meshing impact as evaluation indexes, a test based on the three-factor and two-level orthogonal test was engaged with factors of toothed rail pressure angle, the ratio of L—the chord length of two adjacent roller centers of a roller gear—and rack pitch p (wheel-tooth ratio) and the load mass of the MSEMT. It showed that the impact of MRGTR was the main excitation source of the vibration of MSEMT. The pressure angle and wheel-tooth ratio both have a significant impact on the smooth operation of MSEMT, the latter to a greater extent. So did the interaction between wheel-tooth ratio and load mass. The amplitude of the characteristic frequency of the MSEMT decreased with the growth of the pressure angle. When the wheel-tooth ratio was cosα, the number of the characteristic frequency was less than that when it was 1, and the amplitude became smaller too. When the pressure angle was 15, the amplitude of vibration acceleration characteristic frequency decreased as a consequence of load mass increasing. At the pressure angle of 25, the amplitude of characteristic frequency decreased with the increase of load mass if the wheel-tooth ratio was 1, and the opposite result occurs in the case when the wheel-tooth ratio was cosα. This paper provides a theoretical basis and reference for improving the impact vibration of MRGTR and optimizing the design of the toothed rail. Full article