Study on Joining for Thin-Walled Aluminum Alloy/Steel Tubes by Electromagnetic Flanging Process
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials Preparation
2.2. Experiments of Joining by Electromagnetic Flanging
2.3. Test Methods
3. Numerical Simulation
3.1. Numerical Model
3.2. Verification of Model
4. Results and Discussion
4.1. Formation Process of the Joint
4.2. Mechanical Properties of the Joint
4.3. Morphology of the Joint
5. Conclusions
- The electromagnetic flanging process could obtain effective joints between the aluminum alloy tube and the steel tube, which was a manufacturing process with application prospects for thin-walled structural tube components of vehicles.
- The formation process of the joint was analyzed through numerical simulation. Because of the uneven distribution of the induced current density and Lorentz force, the deformation of flanges of the prefabricated holes on the outer tubes at the axial ends was greater than that at other positions. Therefore, their projection shape on the longitudinal section was oval.
- It was found by tensile tests and morphology observation that the maximum tensile load of the joint increased with the discharge energy. There were two failure modes of the joint. When the discharge energy was below 19 kJ, the failure mode of the joints was pull-out. When the discharge energy reached 19 kJ, the failure mode of the joints was a fracture.
- When the failure mode of the joint transited from pull-out (18 kJ) to fracture (19 kJ), the maximum tensile load just increased from 8771.70 N to 8894.77 N, while the inner tube fractured brittlely, which was not suitable for service. Hence, the comprehensive performance of the joints was better when the discharge energy was 18 kJ.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Material | Si | Cr | Cu | Mn | C | Zn | V | P | Ti | Mo | Mg | Co | Al | Fe |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
T6061-T6 | 0.4~0.8 | 0.04~0.35 | 0.15~0.4 | <0.15 | - | <0.25 | - | 0.04~0.35 | <0.15 | - | 0.5~1.2 | - | Bal. | <0.7 |
Q195 | <0.05 | <0.3 | - | 0.3~0.5 | 0.12~0.2 | - | <0.03 | <0.05 | <0.03 | <0.03 | - | <0.03 | Bal. |
Material | Young’s Modulus (GPa) | Yield Strength (MPa) | Tensile Strength (MPa) | Density (kg/m3) | Poisson Ratio |
---|---|---|---|---|---|
T6061-T6 | 69 | 240 | 290 | 2700 | 0.330 |
Q195 | 212 | 195 | 390 | 7690 | 0.286 |
Part | Number of Elements | Number of Nodes |
---|---|---|
Coil | 21,224 | 28,050 |
Field shaper | 3672 | 4654 |
Outer tube | 40,196 | 60,534 |
Inner tube | 3559 | 7296 |
Material | A (MPa) | B (MPa) | n | C |
---|---|---|---|---|
T6061-T6 | 205.78 | 130.59 | 0.357 | 0.015 |
Q195 | 294 | 818.72 | 0.3792 | −0.06441 |
Part | Material | Density (kg/m3) | Young’s Modulus (GPa) | Poisson Ratio | Material Model | Electrical Conductivity (S/m) |
---|---|---|---|---|---|---|
Coil | 6061T6 | 2700 | 69 | 0.330 | Rigid | 2.46 × 107 |
Field shaper | Copper | 8900 | 97 | 0.330 | Rigid | 5.71 × 107 |
Outer tube | 6061T6 | 2700 | 69 | 0.330 | Plastic | 2.46 × 107 |
Inner tube | Q195 | 7690 | 212 | 0.286 | Plastic | 0.65 × 107 |
Discharge Energy (kJ) | Average Maximum Tensile Load (N) | Failure Mode |
---|---|---|
14 | 5726.90 | Pull-out |
15 | 5861.79 | Pull-out |
16 | 6475.27 | Pull-out |
17 | 7422.24 | Pull-out |
18 | 8771.70 | Pull-out |
19 | 8894.77 | Fracture |
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Chen, C.; Zhao, Y.; Wang, D.; Cui, J.; Li, G.; Jiang, H. Study on Joining for Thin-Walled Aluminum Alloy/Steel Tubes by Electromagnetic Flanging Process. Metals 2023, 13, 1529. https://doi.org/10.3390/met13091529
Chen C, Zhao Y, Wang D, Cui J, Li G, Jiang H. Study on Joining for Thin-Walled Aluminum Alloy/Steel Tubes by Electromagnetic Flanging Process. Metals. 2023; 13(9):1529. https://doi.org/10.3390/met13091529
Chicago/Turabian StyleChen, Chang, Yujia Zhao, Dayong Wang, Junjia Cui, Guangyao Li, and Hao Jiang. 2023. "Study on Joining for Thin-Walled Aluminum Alloy/Steel Tubes by Electromagnetic Flanging Process" Metals 13, no. 9: 1529. https://doi.org/10.3390/met13091529