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Keywords = friction stud welding

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26 pages, 8400 KiB  
Article
Conceptual Design of a Hybrid Composite to Metal Joint for Naval Vessels Applications
by Man Chi Cheung, Nenad Djordjevic, Chris Worrall, Rade Vignjevic, Mihalis Kazilas and Kevin Hughes
Materials 2025, 18(15), 3512; https://doi.org/10.3390/ma18153512 - 26 Jul 2025
Viewed by 329
Abstract
This paper describes the development of a new hybrid composite for the metal joints of aluminium and glass fibre composite adherents. The aluminium adherend is manufactured using friction stir-formed studs that are inserted into the composite adherend in the through-thickness direction during the [...] Read more.
This paper describes the development of a new hybrid composite for the metal joints of aluminium and glass fibre composite adherents. The aluminium adherend is manufactured using friction stir-formed studs that are inserted into the composite adherend in the through-thickness direction during the composite manufacturing process, where the dry fibres are displaced to accommodate the studs before the resin infusion process. The materials used were AA6082-T6 aluminium and plain-woven E-glass fabric reinforced epoxy, with primary applications in naval vessels. This joining approach offers a cost-effective solution that does not require complicated onsite welding. The joint design was developed based on a simulation test program with finite element analysis, followed by experimental characterisation and validation. The design solution was analysed in terms of the force displacement response, sequence of load transfer, and characterisation of the joint failure modes. Full article
(This article belongs to the Section Advanced Composites)
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16 pages, 7134 KiB  
Article
Erosion–Corrosion Behavior of Friction Stud Welded Joints of X65 Pipelines in Simulated Seawater under Different Flow Rates
by Jie Zhao, Yuqi Feng, Hui Gao, Lei Wang, Xiaoyu Yang and Yanhong Gu
Materials 2023, 16(12), 4326; https://doi.org/10.3390/ma16124326 - 12 Jun 2023
Viewed by 2028
Abstract
In order to study the complex erosion–corrosion mechanism of friction stud welded joints in seawater, experiments were carried out in the mixed solution of 3 wt% sea sand and 3.5% NaCl at flow rates of 0 m/s, 0.2 m/s, 0.4 m/s, and 0.6 [...] Read more.
In order to study the complex erosion–corrosion mechanism of friction stud welded joints in seawater, experiments were carried out in the mixed solution of 3 wt% sea sand and 3.5% NaCl at flow rates of 0 m/s, 0.2 m/s, 0.4 m/s, and 0.6 m/s. The effects of corrosion and erosion–corrosion at different flow rates on materials were compared. The corrosion resistance of X65 friction stud welded joint was studied by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) curves. The corrosion morphology was observed by a scanning electron microscope (SEM), and the corrosion products were analyzed by energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The results showed that the corrosion current density decreased first and then increased with the increase in the simulated seawater flow rate, which indicated that the corrosion resistance of the friction stud welded joint increased first and then decreased. The corrosion products are FeOOH (α-FeOOH and γ-FeOOH), and Fe3O4. According to the experimental results, the erosion–corrosion mechanism of friction stud welded joints in seawater environment was predicted. Full article
(This article belongs to the Special Issue Advances in Surface Corrosion Science)
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17 pages, 4180 KiB  
Article
Investigation on Impact Strength of Friction Stud Welded AA6061-B4C Composite/AISI 1030 Steel Joints in Inert Gas Atmosphere
by Navasingh Rajesh Jesudoss Hynes, Selvaraj Raja, Ramakrishnan Tharmaraj, Michael Brykov and Antoaneta Ene
Processes 2022, 10(10), 2052; https://doi.org/10.3390/pr10102052 - 11 Oct 2022
Cited by 4 | Viewed by 1988
Abstract
A more contemporary variation of the friction welding procedure, friction stud welding, is promising for military, space, automotive and naval applications. The joining of steel/aluminium matrix composite joints has been crucial in many of these contemporary applications. In all of these applications, the [...] Read more.
A more contemporary variation of the friction welding procedure, friction stud welding, is promising for military, space, automotive and naval applications. The joining of steel/aluminium matrix composite joints has been crucial in many of these contemporary applications. In all of these applications, the strength of the dissimilar joint is a critical consideration. Heat-affected zones arise because of the heterogeneous temperature distribution and change in thermal characteristics, which weaken the strength of the joints between different materials. The presence of oxygen in the weld interfacial region of the dissimilar joint is detrimental to its strength and integrity. Hence, a new method that can strengthen the dissimilar joint is adopted in the current work. In the friction stud-welding machine, an additional set up is integrated for providing an inert atmospheric condition during the welding process. Microstructural analysis shows that an inert atmosphere is helpful to get rid of oxygen at the interface and it increases joint efficiency. The results show that the impact strength of AA6061-B4C composite/AISI 1030 steel joints tends to increase in the argon inert atmosphere from 14% to 28%. Full article
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