A review on ultrasonic spot welding of copper alloys

As a solid state joining process, ultrasonic spot welding has been proven to be a promising technique for joining copper alloys. However, challenges still remain in employing ultrasonic spot welding to join copper alloys. This article comprehensively reviews the current state of ultrasonic spot welding of copper alloys with a number of critical issues including materials flow, plastic deformation, temperature distribution, vibration, relative motion, vertical displacement, interface friction coefficient, online monitoring technique, coupled with the macrostructure and microstructure, the mechanical properties and electrical conductivity. In addition, the future trends in this field are provided.     

FE simulation of the curing behavior of the epoxy adhesive Hysol EA-9321

Cold-curing adhesives, characterized by an unsteady curing degree, present various advantages for assembling large scale structures set up under outdoor conditions. Thus various applications can be found in aerospace and automotive industries where structures are affected by thermal and mechanical loads. Hence, the curing state of the adhesive must be known to evaluate the lifetime of such bonded structures. The evolution of the polymerization of the adhesive Hysol EA-9321 during the curing process was examined in this paper. To that end, the curing degree of the adhesive was experimentally and analytically investigated for different curing cycles with a view to a potential application in the aerospace domain, where structures are assembled at low temperatures. Existing dynamic and isothermal curing models were applied to simulate the curing behavior of the adhesive. Then, an FEM model was developed to simulate the process of adhesive curing by taking into account a thermo-kinetic coupling.     

An approach to measure infill matric suction of irregular infilled rock joints under constant normal stiffness shearing

Rock joints infilled with sediments can strongly influence the strength of rock mass. As infilled joints often exist under unsaturated condition, this study investigated the influence of matric suction of infill on the overall joint shear strength. A novel technique that allows direct measurement of matric suction of infill using high capacity tensiometers (HCTs) during direct shear of infilled joints under constant normal stiffness (CNS) is described. The CNS apparatus was modified to accommodate the HCT and the procedure is explained in detail. Joint specimens were simulated by gypsum plaster using three-dimensional (3D) printed surface moulds, and filled with kaolin and sand mixture prepared at different water contents. Shear behaviours of both planar infilled joints and rough joints having joint roughness coefficients (JRCs) of 8–10 and 18–20 with the ratios of infill thickness to asperity height (t/a) equal to 0.5 were investigated. Matric suction shows predominantly unimodal behaviour during shearing of both planar and rough joints, which is closely associated with the variation of unloading rate and volumetric changes of the infill material. As expected, two-peak behaviour was observed for the rough joints and both peaks increased with the increase of infill matric suction. The results suggest that the contribution of matric suction of infill on the joint peak normalised shear stress is relatively independent of the joint roughness.     

古建筑木结构透榫节点力学模型研究

为研究古建筑木结构透榫节点的M-θ力学模型，在分析透榫节点构造特征与受力机理的基础上，建立其数值模型，用透榫节点的试验数据验证了该数值模型的正确性，并分析了节点缝隙、木材横纹弹性模量和大榫头长度对透榫节点受弯承载力的影响。根据受力分析结果，建立以弹性点、屈服点与极限点为特征点的三折线多参数M-θ力学模型，其结果与多数的试验结果基本吻合，并将该力学模型应用于木构架的受力分析。研究结果表明：透榫节点的滞回耗能能力强，节点的变形主要集中在榫头处。当榫头与卯口之间的缝隙增大时，节点的受弯承载力降低。随木材横纹弹性模量的提高和大榫头长度的增加，节点的受弯承载力有一定提高。文章建立的M-θ力学模型能较好反映透榫节点的受力过程，适用于木构架的受力分析，其荷载 位移骨架曲线与试验结果基本吻合。研究成果可为古建筑木结构的维修与保护提供参考。     

Bearing Failure Optimization of Composite Double-Lap Bolted Joints Based on a Three-Step Strategy Marked By Feasible Region Reduction and Model Decoupling

To minimize the mass and increase the bearing failure load of composite doublelap bolted joints, a three-step optimization strategy including feasible region reduction, optimization model decoupling and optimization was presented. In feasible region reduction, the dimensions of the feasible design region were reduced by selecting dominant design variables from numerous multilevel parameters by sensitivity analyses, and the feasible regions of variables were reduced by influence mechanism analyses. In model decoupling, the optimization model with a large number of variables was divided into various sub-models with fewer variables by variance analysis. In the third step, the optimization sub-models were solved one by one using a genetic algorithm, and the modified characteristic curve method was adopted as the failure prediction method. Based on the proposed optimization method, optimization of a double-lap single-bolt joint was performed using the ANSYS^® code. The results show that the bearing failure load increased by 13.5% and that the mass decreased by 8.7% compared with those of the initial design of the joint, which validated the effectiveness of the three-step optimization strategy.     

Solid state reactions between SiC and Ir

Reactivity between SiC and Ir as a function of SiC-crystallinity was investigated by diffusion bonding technique under a vacuum and over the temperature range of 1200–1450 °C. As reaction products, various Ir-silicides and free unreacted-C were detected. Reactivity is strongly affected by the temperature and SiC-crystallinity involving a series of interactions, from “no reaction” to “massive exothermic reactions”. In particular, interfacial phenomena are more pronounced by the presence of defects and grain boundaries.Solid state reactions result in formation of fine C-precipitates rearranged in a quasi-periodic microstructure. On the contrary, clustering of highly ordered C-precipitates (C-graphitized) occurs after “massive reactions” take place.A relationship between the degree of graphitization (from 1 to multi-layers of graphene), temperature and SiC crystallinity was found by Raman spectroscopy. 2D-layering phenomenon is enhanced in polycrystalline SiC at high temperature.     

Fatigue performance of Friction Stir Welded titanium structural joints

The Friction Stir Welding process for producing corner and T-joints out of 6 mm Ti–6Al–4V was developed in this effort using previous work on butt weld joints as a starting point. A limited number of corner joints were also subjected to a bending fatigue test to preliminarily assess the applicability of the process in producing fatigue critical structures. These results were also compared to predictions made by applying stress concentration factors to previously generated uniaxial butt joint test data. While additional testing is still required to obtain a higher degree of confidence in the conclusions of this study, it was found that the performance of these corner joints in fatigue could be compared to butt joint data when a geometrically based stress concentration factor is applied. Furthermore, these welded joints possessed equivalent fatigue performance relative to identical test specimens machined from wrought product forms, both bar and extrusion. Thus, from the perspective of fatigue design, this study has shown that Friction Stir Welding is able to produce structures with the same performance as currently made from wrought materials.     

Effects of Seismically Induced Pounding at Expansion Joints of Concrete Bridges

This paper presents the result of a study on the effect of pounding at expansion joints on concrete bridge response to earthquake ground motions. An engineering approach, rather than continuum mechanics approach, is emphasized. First, the dynamic behavior of a damped multidegree-of-freedom bridge system separated by an expansion joint involving an impact is examined by means of the finite element method. Second, the sensitivity analysis of the stiffness in gap elements is performed. Third, usefulness of the analysis method for simulation of pounding phenomena is demonstrated and the effect of pounding on the ductility demands measured in terms of the rotation of column ends is investigated. Two-dimensional finite element analysis using a bilinear hysterestic model for bridge substructure joints and a nonlinear gap element for the expansion joint is performed on a realistic bridge with an expansion joint. The effects of the primary factors on the ductility demand such as gap sizes and characteristics of earthquake ground motion are investigated through a parametric study. The major conclusions are (1) the effect of impact most directly depends on the size of momentum (or pounding magnitude); and (2) the pounding effect is generally found to be negligible on the ductility demand for wide practical ranges of gap size and peak ground acceleration, but is potentially significant at the locations of impact.     

Limit load analysis of strength undermatched welded T-joints under bending

An increasing amount of laser beam welded T‐joints (e.g. skin‐stringer) of aluminium alloys are now in use in advanced fuselage applications designed as ‘integral structures’ for weight and cost savings. It is known that weld joints generally show lower strength (undermatching) than base metal in both laser beam and friction stir welded joints of 6xxx series Al‐alloys. Damage tolerance considerations in terms of the residual strength of such joints require limit load solutions to be used in engineering fitness‐for‐service (FFS) analysis. The paper, therefore, provides an upper bound limit load solution in closed form for welded T‐joints (idealized) with strength undermatching and subject to a bending moment. In addition to the necessary requirements of the upper bound theorem, the kinematically admissible velocity field chosen leads to a stress field, which satisfies the equilibrium equations and some stress boundary conditions in the plastic zone. This is an advantage of the solution and, therefore, it is expected that the upper bound obtained is close to the exact limit load of such joints.     

Practical Equivalent Continuum Model for Simulation of Jointed Rock Mass Using FLAC3D

A simple practical equivalent continuum numerical model for simulating the behavior of jointed rock mass has been extended to three-dimensional using FLAC3D. This model estimates the properties of jointed rock mass from the properties of intact rock and a joint factor (Jf), which is the integration of the properties of joints to take care of the effects of frequency, orientation, and strength of joint. A new FISH function has been written in FLAC3D specifically for modeling jointed rocks using the Duncan and Chang hyperbolic model. This model has been validated first with simple element tests at different confining pressures for different rocks with different joint configurations. Explicit modeling of the joints has also been done in element tests and results obtained compare well with the results of equivalent continuum model and also with experimental results. Further, this has been applied for a case study of a large underground power house cavern in the Himalayas. The analysis has been done under various stages of excavation, assigning a null model available in FLAC3D for simulating the excavation.