QUARTERLY JOURNAL OF THE JAPAN WELDING SOCIETY
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PRINT ISSN: 0288-4771

QUARTERLY JOURNAL OF THE JAPAN WELDING SOCIETY Vol. 32 (2014), No. 1

  • Novel Dissimilar Spot Welding of Aluminum Alloy and Steel Sheets by Friction Stirring

    pp. 1-7

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    DOI:10.2207/qjjws.32.1

    Friction Stir Spot Welding (FSSW) has been applied to a dissimilar metal lap joint of an aluminum alloy and steel by stirring only the upper aluminum alloy sheet. Therefore, FSSW cannot be used to weld a lap joint composed of three or more sheets and a lap joint with an adhesive interlayer. In the present work, we propose a novel spot welding process for dissimilar metal lap joints using a new tool with the tip made of spherical ceramics. When this process is applied to the lap joint of the aluminum alloy and steel, the tool can be plunged into the lower steel sheet, then a steel projection is formed in the aluminum alloy sheet. The height of this steel projection increases with the plunge depth, and accordingly, the weld strength increases; the tensile shear strength and the cross tensile strength reached about 3.6 kN/point and 2.3 kN/point, respectively.
  • Development of Manufacturing Technology of Radial Plate in Superconducting Coil for Fusion Reactor by Diffusion Bonding by Hot Isostatic Pressing (HIP)

    pp. 8-14

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    DOI:10.2207/qjjws.32.8

    The radial plates (RPs), which is used in Toroidal field (TF) coil in ITER, are quite large, such as 13 m tall and 9 m wide, but thin, such as 10 cm thick, and are made of stainless steel. Even though they are very large structures, they require very high manufacturing tolerances and high mechanical strength at 4 K. The similar requirements will be required in the next generation fusion reactor. Therefore, the authors intend to develop efficient manufacturing methods in parallel with ITER TF coil RP manufacture. The authors therefore performed trial manufacture of the RP segments using a diffusion bonding method, namely Hot Isostatic Pressing (HIP). As a result of trials, it was clarified that even when HIPping is applied, the mechanical characteristic of base metal is not deteriorated. The machining period can be reduced by about 1/3 compared with the traditional manufacturing method. On the other hand, mechanical strength at 4 K is degraded due to weak bonding, that is no grain growth through joint, by HIPping. However, additional test indicates promising possibility of much better joint by higher temperature and joint surface treated HIPpings. These results justified that RP segment manufacturing is not only possible, but it is a technically valid manufacturing method that satisfies all requirements.
  • Clarification of Defect Formation Mechanism in Friction Stir Welding by X-ray Radiography

    pp. 31-37

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    DOI:10.2207/qjjws.32.31

    Defect formation mechanism during friction stir welding (FSW) was investigated by three-dimensional visualization of material flow around a tool. The three-dimensional flow patterns in various FSW conditions were obtained using two pairs of x-ray transmission real-time imaging systems. It revealed that the tilt of the horizontal material flow around the tool and the stagnation of the material flow at retreating side of the tool were tightly connected with the defect formation mechanism. Additionally, the material flow rates during FSW were directly calculated by the results of the three-dimensional visualization. The material flow rate at advancing side was obviously decreased in the defect formation process conditions.
  • Laser Brazing of Dissimilar Joint of Austenitic Stainless Steel and Pure Copper

    pp. 38-46

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    DOI:10.2207/qjjws.32.38

    In many industries, there are applications that require the joining of stainless steel and copper components; therefore, the welding of dissimilar stainless steel/copper joints is a common process. For this investigation, the optimal brazing conditions and suitable filler metals for laser brazing of stainless steel/copper lap joints were studied. Tensile shear force increases with increases in the laser spot diameter or in the laser irradiation angle, which is associated with increased bonding width; however, as bonding width approaches 2 mm, tensile shear force reaches a saturated value due to fracturing at the HAZ of the Cu base plate. In order to obtain joints with high tensile shear strength, laser brazing was optimized by using Cu-Si-based filler metal under the following conditions: laser power: 4 kW; spot diameter: 3mm; laser irradiation angle: 80 degrees; irradiation position shift: 0.6 mm; brazing speed: 0.30 m/min; and filler metal feed speed: 0.30 min. Concerning filler metals, it was found that the Ni-Cu type showed relatively large tensile shear force even at high welding speeds in comparison with those of the Cu-Si, Cu, Cu-Ni, Ni-Cu and Ni types, respectively.
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