Non-monotonic behaviour of tool life function as explained by fuzzy set theory

Abstract

This article attempts to show how the theory of fuzzy sets may be used in explaining non-monotonic behaviour of the tool life function. Results obtained in orthogonal turning of Stellite cobalt alloys served as a basis for presenting rules underlying the so called areas of undetermined chip formation and for determining local extremes of the function. Fuzzy set theory is presented to the extent that it is capable of explaining the observed bifurcation between two branches of the function.     

Effect of Non-conductive Film on the Reliability of Multi-chip Package Bonded Using Ultrasonic Energy

As silicon semiconductor technologies need to achieve smaller dimensions, the development of System-onChip (SOC) devices with a large variety of functional blocks becomes very difficult to realize. A 3-D stacked package is a promising alternative to improve the performance and density of devices beyond traditional package scaling limits. However, there are many issues related to process integration, thermal management, and reliability of 3-D stacked packages. In this study, the printed circuit board (PCB), silicon carrier and silicon chip are integrated with the ultrasonic bonding method. Die shear tests on the joints were carried out with increasing bonding time and input power to optimize the bonding conditions. The integrated chips were successfully bonded with and without non-conductive film (NCF) using ultrasonic energy. The measured electrical resistance of multi-chip package bonded with NCF was lower than that of multi-chip package bonded without NCF. Thermal cycle and high temperature storage tests were carried out to see if the interface was vulnerable. Cross-sectional features of the bonded interface were inspected using a scanning electron microscope.     

Adhesion strength of sodium dodecyl sulfate-modified soy protein to fiberboard

Thermal and rheological properties of sodium dodecyl sulfate (SDS)-modified soy protein isolate (SPI) adhesives were studied using differential scanning calorimetry (DSC) and rheometry. The ordered structure of native SPI was denatured as SDS concentration increased, and thermal stability of native SPI decreased at high SDS concentration. The enthalpy of SPI denaturation decreased significantly with increasing SDS concentration. Apparent viscosity of the SPI adhesives increased as SDS concentration increased. The SPI adhesives modified by high concentrations of SDS exhibited characteristics of a Newtonian-type flow. The SDS-modified SPI adhesives were applied to fiberboard, and effects of SDS concentration, press conditions, and assembly time on bond strength were investigated. Shear strength of the SPI adhesives increased with SDS concentration, reaching its maximum value at 3 wt% of SDS, and then decreased significantly. The shear strength increased as press time and/or press temperature increased. High press temperature (100 °C) and long press time (5 min) are needed to achieve relatively good adhesion properties. The shear strength also increased as assembly time increased. The shear strength of the SDS-modified SPI adhesives decreased after soaking in water for 24 h.     

Failure mode transition and mechanical properties of similar and dissimilar resistance spot welds of DP600 and low carbon steels

Abstract

The present work addresses the microstructure and mechanical properties of similar and dissimilar resistance spot welds of low carbon steel (LCS) and dual phase steel (DP600). Correlations between the critical fusion zone size required to ensure pullout failure mode, the weld microstructure and the weld hardness characteristics were developed. Dissimilar DP600/LCS spot welds exhibit the lowest tendency to fail in interfacial failure mode. Effects of weld physical attributes and weld microstructure on the peak load and energy absorption of similar and dissimilar DP600/LCS resistance spot welds are analysed.     

Expulsion monitoring in spot welded advanced high strength automotive steels

Abstract

Although there have been a number of investigations on monitoring and controlling the resistance spot welding (RSW) of low carbon galvanised steels, those of advanced high strength steels (AHSS) are limited. A data acquisition system was designed for monitoring weld expulsion via the measurement of voltage, current, electrode force and displacement and the calculation of resistance. The dynamic resistance, electrode force and tip displacement were characterised and correlated with the phenomenon of expulsion during RSW of dual phase (DP) steel using an ac welder. Two control strategies for DP600 spot welding were proposed on the basis of the rate of change in the dynamic resistance and the electrode force.     

Influence of welding current shape on expulsion and weld strength of resistance spot welds

Abstract

The present paper presents the influence of welding current shape on weld strength of resistance spot welds of zinc coated mild steel sheets. The influence is analysed at different levels of the electrode wear. Welding currents with different peak values and different RMS (root mean square) values were used in the experiment. The results show that welding current with high peak values implies higher weld strength.     

Effect of weld nugget size on overload failure mode of resistance spot welds

Abstract

In the present paper, effects of welding current, welding time, electrode pressure and holding time on the weld nugget size were studied. A failure mechanism was proposed to describe both interfacial and pullout failure modes. This mechanism was confirmed by SEM investigations. In the light of this mechanism, the effect of welding parameters on static weld strength and failure mode was studied. Then, an analytical model was proposed to predict failure mode and to estimate minimum nugget diameter (critical diameter) to ensure pullout failure mode in shear tensile test. On the contrary to existing industrial standards, in this model, critical nugget diameter is attributed to metallurgical characterisation of material (weld nugget hardness to failure location hardness ratio), in addition to sheet thickness. For a given sheet thickness, decreasing H_WN/H_FL increases interfacial failure mode tendency. The results of this model were compared with experimental data and also with the literature.     

Online quality inspection of resistance spot welded joint based on electrode indentation using servo gun

Abstract

Resistance spot welding is one of the major joining techniques widely used for car body assembly. Weld quality may significantly influence the durability and reliability of the automobile body. Automotive manufacturers often rely on destructive testing and monitoring variables which indirectly reflected weld quality to assess the weld quality and control the welding process. However, these approaches have inherent limitations and are difficult to be implemented in plant environments. Therefore, it is imperative to develop an online inspection method to evaluate weld quality. In the present study, a method of producing a series of substantially uniform spot welds between two metal parts using a servomotor driven movable electrode and an axially opposing fixed electrode is proposed. The indentation in the workpiece surface is suitably measured by the displacement of the movable electrode as it applies an electrode force and welding current is passed through the weld site of the workpiece. The optimal indentation range is determined by peel test and metallographic examinations with respect to various sheet gages and grades. Consequently, online weld quality inspection results are achieved based on developed optimal indentation range.     

Resistance welding of thin stainless steel sandwich sheets with fibrous metallic cores: experimental and numerical studies

Abstract

This paper concerns resistance spot welding (RSW) of two types of thin stainless steel sandwich sheet. The cores of these materials, made of stainless steel fibres, are highly porous (> around 85 vol.-%) and have low thermal and electrical conductivities. However, these conductivities change during the compression and heating associated with RSW. A sequentially coupled finite element model has been developed, in which the crushed core is treated as a continuum, with properties which vary throughout the process. It is shown that a constitutive relationship of the type commonly used for crushable foams can be successfully employed to simulate the deformation of the sandwich sheets. The thermoelectrical part of the model incorporates the effects of the associated phase transformations and changes in interfacial conductance. It is shown that the predictions are broadly consistent with data obtained during welding experiments. The model is used to explore the effects of welding parameters on weld characteristics (weld pool formation and weld nugget shape).