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Joint-site structure friction welding method as a tool for drive pinion light weighting in heavy-duty trucks
Affiliation:1. Technology Management Daimler Trucks (TG/MFT), Daimler AG, 001/E200, 70546 Stuttgart, Germany;2. Production and Materials Technology (PWT/VEP), Daimler AG, H152, 70546 Stuttgart, Germany;3. Head of Division 9.3 – Welding Technology, BAM Bundesanstalt für Materialforschung und -prüfung, Unter den Eichen 87, 12205 Berlin, Germany;1. Centre for Infectious Diseases and Microbiology, University of Sydney, Westmead Hospital, Sydney, NSW, Australia;2. Centre for Research Excellence in Critical Infection and Marie Bashir Institute for Infectious Diseases and Biosecurity, University of Sydney, Sydney, NSW, Australia;3. Westmead Millennium Institute, Westmead, NSW, Australia;4. Department of Infectious Diseases, West China Hospital, Sichuan University, Chengdu, China;5. Department of Laboratory Medicine, National University Health System, Singapore;6. Department of Microbiology and Department of Pathology, National University of Singapore, Singapore;7. Department of Medicine, National University of Singapore, Singapore;8. University Medical Cluster, National University Health System, Singapore;9. Department of Pathology and Laboratory Medicine, NorthShore University HealthSystem, IL, USA;10. Department of Medicine, NorthShore University HealthSystem, IL, USA;11. University of Chicago, Pritzker School of Medicine, Chicago, IL, USA;1. Dpt. Mechanical Engineering UPV/EHU, Almeda de Urkijo s/n, 48013 Bilbao, Spain;2. TEMPO EA 4542 Laboratory, UVHC Carnot Arts Institute, 59300 Valenciennes, France;1. State Key Laboratory of Metastable Materials Science and Technology, Yanshan University, Qinhuangdao 066004, China;2. Department of Mechanical and Nuclear Engineering, The Pennsylvania State University, University Park, PA 16802, USA;1. Jiangxi Key Laboratory of Advanced Copper and Tungsten Materials, Jiangxi Academy of Sciences, Nanchang 330029, China;2. Institute of Applied Physics of Jiangxi Academy of Sciences, Nanchang 330029, China;3. State Key Laboratory of Heavy Oil Processing and Department of Materials Science and engineering, China University of Petroleum, Beijing 102249, China;4. School of Mechanical and Chemical Engineering, The University of Western Australia, WA 6009, Australia;5. X-ray Science Division, Argonne National Laboratory, Argonne, IL 60439, USA
Abstract:To satisfy the applied compressive stresses of friction welded drive pinion fabricated by using the joint-site structure (JSS) method, three different variants were followed: (A) the initial design with two joints was carried out. Two different burn-off lengths were examined for this variant. (B) The optimum burn-off length was considered for only one weld zone. (C) The weld zone was moved radially from the initial location and two different gap sizes were compared. The smallest gap size for the third variant led to the largest weld length. The lack of structural welding defects for this variant was assessed by ultrasonic testing. Hardness of the material after friction welding (FW) was correlated to the Continuous Cooling Transformation (CCT) diagram of the used materials and revealed the phase/microstructure transformation of the material. The simulated applied stresses on the optimized friction welded design of the drive pinion showed suitable results. The new drive pinion friction welded by the JSS method reduced the weight of the component by approx. 14%.
Keywords:Friction welding  Joint-site structure  Drive pinion  Lightweight design
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