Hybrid Bulk Metal Components

In recent years, the requirements for technical components have steadily been increasing. This development is intensified by the desire for products with a lower weight, smaller size, and extended functionality, but also with a higher resistance against specific stresses. Mono-material components, which are produced by established processes, feature limited properties according to their respective material characteristics. Thus, a significant increase in production quality and efficiency can only be reached by combining different materials in a hybrid metal component. In this way, components with tailored properties can be manufactured that meet the locally varying requirements. Through the local use of different materials within a component, for example, the weight or the use of expensive alloying elements can be reduced. The aim of this Special Issue is to cover the recent progress and new developments regarding all aspects of hybrid bulk metal components. This includes fundamental questions regarding the joining, forming, finishing, simulation, and testing of hybrid metal parts

Mission oriented R and D and the advancement of technology: The impact of NASA contributions, volume 2

NASA contributions to the advancement of major developments in twelve selected fields of technology are presented. The twelve fields of technology discussed are: (1) cryogenics, (2) electrochemical energy conversion and storage, (3) high-temperature ceramics, (4) high-temperature metals (5) integrated circuits, (6) internal gas dynamics (7) materials machining and forming, (8) materials joining, (9) microwave systems, (10) nondestructive testing, (11) simulation, and (12) telemetry. These field were selected on the basis of both NASA and nonaerospace interest and activity

Friction stir welding of thin section aluminium extrusions for marine applications

This dissertation focuses on the development of a welding extrusion feeder, tool and schedule for implementation of defect-free butt welds on long, thin and complex-shape aluminium extrusions, as used by the marine industry. Viability of employing Friction Stir Welding (FSW) as a welding technology for joining long extrusions with a short-bed and bolt-on feeder to facilitate onsite fabrication of flat structures in shipbuilding is evaluated. An FSW feeder, tool and process control unit were designed, developed and integrated with an existing FSW platform, to facilitate implementation of continuous welds. Weld data acquired from literature review, experimentation, mechanical testing and metallographic analysis was used in design considerations for the development of a feeder. Subsequently, butt welds were implemented successfully on long 3 mm AA6082-T6 extrusions, during continuous FSW on the feeder. A specially adapted tool, the Floating Bobbin Tool, used with the feeder to implement butt welds was designed and developed from literature tool heuristics and weld trials. The tool eliminated the need for a backing bar and enabled tool-workpiece auto-alignment, beneficial with thin-section extrusions. Effect of rotational and weld speed and tool geometry of two tools (Tool 1 and 2), on weld forces and quality was tested, to establish optimum parameters for attaining high quality welds. Tool geometry had a profound effect on weld forces and integrity; Tool 2 welds exhibited superior and consistent weld quality, meeting maritime rules and standards and proving the adequacy of using FSW for joining long thin extrusions. Feeder process control, automation and optimisation, was implemented by process control unit devices, in addition to force and position control provided by the existing FSW platform. Owing to process control, automation and optimisation during continuous FSW of thin long and complex-shape aluminium extrusions, welding setup times and process variations are minimised and chances for defect-free welds increased, boosting production and cost savings in large panel fabrication in shipbuilding

Friction stir welding of thin section aluminium extrusions for marine applications

This dissertation focuses on the development of a welding extrusion feeder, tool and schedule for implementation of defect-free butt welds on long, thin and complex-shape aluminium extrusions, as used by the marine industry. Viability of employing Friction Stir Welding (FSW) as a welding technology for joining long extrusions with a short-bed and bolt-on feeder to facilitate onsite fabrication of flat structures in shipbuilding is evaluated. An FSW feeder, tool and process control unit were designed, developed and integrated with an existing FSW platform, to facilitate implementation of continuous welds. Weld data acquired from literature review, experimentation, mechanical testing and metallographic analysis was used in design considerations for the development of a feeder. Subsequently, butt welds were implemented successfully on long 3 mm AA6082-T6 extrusions, during continuous FSW on the feeder. A specially adapted tool, the Floating Bobbin Tool, used with the feeder to implement butt welds was designed and developed from literature tool heuristics and weld trials. The tool eliminated the need for a backing bar and enabled tool-workpiece auto-alignment, beneficial with thin-section extrusions. Effect of rotational and weld speed and tool geometry of two tools (Tool 1 and 2), on weld forces and quality was tested, to establish optimum parameters for attaining high quality welds. Tool geometry had a profound effect on weld forces and integrity; Tool 2 welds exhibited superior and consistent weld quality, meeting maritime rules and standards and proving the adequacy of using FSW for joining long thin extrusions. Feeder process control, automation and optimisation, was implemented by process control unit devices, in addition to force and position control provided by the existing FSW platform. Owing to process control, automation and optimisation during continuous FSW of thin long and complex-shape aluminium extrusions, welding setup times and process variations are minimised and chances for defect-free welds increased, boosting production and cost savings in large panel fabrication in shipbuilding

Fast algorithms for material specific process chain design and analysis in metal forming - final report DFG Priority Programme SPP 1204

The book summarises the results of the DFG-funded coordinated priority programme \"Fast Algorithms for Material Specific Process Chain Design and Analysis in Metal Forming\". In the first part it includes articles which provide a general introduction and overview on the field of process modeling in metal forming. The second part collates the reports from all projects included in the priority programme

Manufacturing Distinction: Gaining access to Mass Customization in the Production of Architecture

Contemporary architecture often finds itself challenging the physical constraints of the previous era and typically aims to be one of a kind. This thesis views architecture as the accumulation of design and construction and considers both from the view of constructibility. The design of architecture relies upon the formal desire, its materiality, function, direction of which parts are needed and how they can be constructed. The construction of architecture focuses on the coordination, fabrication and assembly of these parts. The industry of construction has three primary constraints: time, cost, and labour. To ease the construction process ideals have been borrowed and implemented from manufacturing to allow streamlining and moved away from the world of bespoke construction. We sit in a system of construction based upon the manufactured part. Manufacturing operations follow one essential formula, the transformation of raw material through the addition of machinery, tools, energy, and labour, to provide the desired product with greater function and value. All consumer items are created through these methods individually or in some combination, having to navigate the complex order of procedures which transform simple materials into everyday objects. The constraints of material play a significant role in the manufacturing operation available to produce any given object and its subsequent performance in an architectural application. Architecture is much more than the manufacturing of a single object. Similar to the production of bikes, cars and other consumer products, architecture utilizes what is known as a system of production. With increased product demand the system of production has naturally transformed as well. Improvements can be seen in areas of logical flow (the division of labour and interchangeable parts), physical flow (the assembly line, mechanization, and digitalization), and controls (tolerances and standards). The constraints of a product play a large role in the appropriateness of a system of production for that object, subsequently impacting the feasibility of any object being economically produced. Manufacturing processes are moving towards digital management and flow as a way of offering unique options within the production of manufactured parts. Overall, architecture strives for a way to be unique within the boundaries of manufactured elements, achieving this through different means such as distilling the function of a space to the elements that construct it, constructing with modular elements, and componentized customization. The transition towards digital design of objects within the industry allows a physically ‘free’ environment to create within; additive manufacturing offers the processing counterpart by digitally shaping physical objects from ‘nothing’. Moving architecture into the digital realm shifts it into a place to easily integrate digital design data into the manufacturing process. Having the ability to bypass the challenges of how we make items, why we choose specific materials, why we produce at specific volume runs, and ties into existing digital production processes. The potentials stand out in the area of producing objects with unique physical constraints or meeting the demands of small product runs

Technological Adaptation on the Frontier: An Examination of Blacksmithing at Fort Michilimackinac, 1715-1781

This research examines the blacksmith and his work within the 18th century fur trade community at Fort Michilimackinac (1715-1781). Located at the northern tip of the Lower Peninsula of Michigan, this fortified trading post was important to the French (1715-1760) and British (1761-1781) fur trade economies in North America. Archaeological data and historic documents describing the use, trade, and demand for iron products at Fort Michilimackinac are used to understand the blacksmith and his work within the 18th century fur trade frontier and the wider socioeconomic landscape of which he was part. Blacksmiths were essential in supporting the material needs of frontier communities and the technological adaptations necessitated by frontier conditions are examined through the archaeological remains of the blacksmith workshops at Fort Michilimackinac, as well as metal artifacts found across the site. A model for identifying blacksmithing activities within workshops was applied to archaeological data from Fort Michilimackinac and three blacksmith workshops were identified. These are described in terms of the archaeological features represented and their spatial attributes. Several artifact groups were selected for analysis based on trade records and other historic documents that described their local production and/or repair at the fort. Trends in repair methods and potential technological adaptations of blacksmithing techniques exhibited by these repairs are identified. Portable x-ray fluorescence analysis was used to further examine traits of frontier metals and identify types of artifacts that were likely produced by the blacksmiths at Fort Michilimackinac. By examining the blacksmith and his work, this research contributes to a holistic understanding of the fur trade frontier and the importance of individuals and craftsmen, like the blacksmith, within the communities that aided the continued success of the fur trade and European expansion in North America

THE TRADE MANUFACTURE AND DESIGN OF ENGLISH BLACKSMITHING IN THE POST WAR PERIOD

Blacksmithing has undergone a dramatic transformation in the last twenty five years. This study examines the changes and the context within which they have taken place. The effects upon the products of the blacksmith are considered through empirical research and practical work. The working methods and philosophies of blacksmiths representative of a continuity of traditions and innovatory practice are investigated through interviews and other approaches. From its origins as a rural and industrial craft, blacksmithing has emerged in the form of art-blacksmithing. Institutional and government intervention, new technologies and markets provide the context in which the ideologies and practices are examined. It is argued that these new blacksmiths are selfconscious designer-makers who are technically innovative, and commercially aware, operating successfully between and within the cultural and commercial arenas. In combining practical and decorative functionalism, and producing site-specific art work at a competitive price, artist blacksmiths successfully inhabit the worlds of art, industry, trade and craft, often simultaneously