The requirement of increased fuel economy standards has forced automakers to incorporate multi-materials into their current steel dominant vehicles in order to lightweight their fleets. Technologies such as Self Piercing Rivets and Flow Drill Screws are currently implemented for joining aluminum to high-strength steels but only one-technology is viable for joining aluminum to ultra-high-strength steels without pre-holes, namely Friction Element Welding. This study is aimed at investigating how variations in the cleaning and welding steps of the Friction Element Welding process influence joint quality. A design of experiment was conducted to understand the influence of key process parameters (endload, spindle RPM, and relative distance) during these steps on the pre-defined joint quality metrics of head height, weld zone diameter, under-head fill area, temperature, and microhardness. It is found that cleaning step parameters have the greatest influence on process time and energy consumption, while welding step parameters greatly influence maximum torque on the element, head height, and underhead fill, with both cleaning force and weld force influencing weld diameter, all parameters influence temperature.
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ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing
June 4–8, 2017
Los Angeles, California, USA
Conference Sponsors:
- Manufacturing Engineering Division
ISBN:
978-0-7918-5072-5
PROCEEDINGS PAPER
Investigation of the Cleaning and Welding Steps From the Friction Element Welding Process
Jamie D. Skovron,
Jamie D. Skovron
Clemson University, Greenville, SC
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Brandt J. Ruszkiewicz,
Brandt J. Ruszkiewicz
Clemson University, Greenville, SC
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Laine Mears,
Laine Mears
Clemson University, Greenville, SC
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Hongseok Choi,
Hongseok Choi
Clemson University, Clemson, SC
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Xin Zhao
Xin Zhao
Clemson University, Clemson, SC
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Jamie D. Skovron
Clemson University, Greenville, SC
Brandt J. Ruszkiewicz
Clemson University, Greenville, SC
Laine Mears
Clemson University, Greenville, SC
Tim Abke
Honda R&D Americas, Raymond, OH
Ankit Varma
Clemson University, Clemson, SC
Yuxin Li
Clemson University, Clemson, SC
Hongseok Choi
Clemson University, Clemson, SC
Xin Zhao
Clemson University, Clemson, SC
Paper No:
MSEC2017-2786, V001T02A004; 14 pages
Published Online:
July 24, 2017
Citation
Skovron, JD, Ruszkiewicz, BJ, Mears, L, Abke, T, Varma, A, Li, Y, Choi, H, & Zhao, X. "Investigation of the Cleaning and Welding Steps From the Friction Element Welding Process." Proceedings of the ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. Volume 1: Processes. Los Angeles, California, USA. June 4–8, 2017. V001T02A004. ASME. https://doi.org/10.1115/MSEC2017-2786
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