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Underwater Robotic Welding of Lap Joints with Sandwiched Reactive Multilayers: Thermal, Mechanical and Material Analysis

Published online by Cambridge University Press:  22 March 2018

Aseel Hussein ,
Ayesha Alkhoori ,
Abdelaziz Al Zaabi ,
Cesare Stefanini ,
Federico Renda ,
Syed Jaffar ,
Ibrahim Emre Gunduz ,
Kyriaki Polychronopoulou ,
Claus Georg Rebholz  and
Charalabos Constantinos Doumanidis
Aseel Hussein
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Ayesha Alkhoori
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Abdelaziz Al Zaabi
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Cesare Stefanini
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Federico Renda
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Syed Jaffar
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Ibrahim Emre Gunduz
Affiliation:
Department of Mechanical Engineering, Purdue University, West Lafayette, IN47907, U.S.A.
Kyriaki Polychronopoulou
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
Claus Georg Rebholz
Affiliation:
Department of Mechanical-Manufacturing Engineering, University of Cyprus, Nicosia, Cyprus
Charalabos Constantinos Doumanidis*
Affiliation:
Department of Mechanical Engineering, Khalifa University, P.O.127788, Abu Dhabi, U.A.E.
*
*(Email: haris.doumanidis@kustar.ac.ae)
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Abstract

Underwater welding using reactive materials pre-deposited at the junction surfaces as a self-contained, in-situ ignitable heat source mitigates external power and gas supply requirements. Consequently, lending itself to robotic implementation eliminating the cost along with health and safety hazards of human welder-divers. This project reports on lap joining of aluminum sheets with sandwiched commercial reactive Ni-Al multilayers that are perforated to allow for melt fusion under compression upon ignition, in saline and deionized water as well as air for comparison. Finite-element thermal simulations are employed to study the resulting welding temperature field and melt conditions. Infrared pyrometry and thermocouple measurements during welding were used to validate the computational simulations. The lap joints are subjected to standard shear testing, and comparable compliance, strength and toughness values of the welds are assessed for underwater and dry joints. Scanning electron (SEM) of the weld sections reveal rapidly melting and solidifying microstructures of the parent metal, with minimal melt flow and perfusion of nickel aluminide aggregates from the reacted multilayers, and no signs of cavitation.

Keywords

scanning electron microscopy (SEM)weldingnanoscale
Type
Articles
Information
MRS Advances , Volume 3 , Issue 17: Processing and Manufacturing , 2018 , pp. 911 - 920
Copyright
Copyright © Materials Research Society 2018 

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References

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