Project 1 : Flatbed welding

Brief
Working with a Canadian Flatbed manufacturer to compare the strength and durability of riveted and FCRW welded construction

Status

• Riveted samples and material for FCRW have been received from the customer
• Rivet samples are being tested for tensile and fatigue (durability) properties
• Weld tool design has been completed
• Two weld designs are being tested to ensure that weld strength and durability exceed that of the riveted joints
• Collaborative work with the Edison Welding Institute is being attempted
• Joint geometry ideally suited for FCRW

Project 2 : FCRW using a CD welder

Brief
Cooperative work with Process Equipment Company (PECo) in Tipp City, Ohio is being planned to carry out FCRW using a CD welder

Status

• Aluminum alloys 6061 T6, 5182-O and 7075 are planned to be welded using the above process
• Joint efficiencies of 90% are proposed to be obtained in all above alloy combinations, while including the heat-affected zone (HAZ) in the joint strength testing samples
• Demonstration of high quality welds with no defects of aerospace alloy 7075 that is conventionally considered  “difficult-to-weld” is planned

Project 3 : FCRW on Multi-Layered Sheets

Brief
Attempts are being made to obtaine multilayered aluminum alloy material from Novelis through the help of Dr. Mariana Forrest for weld trials

Status

• FCRW weld trials are proposed to be done, while maintaining the unique properties of the various layers of the aluminum alloy layers using both FCRW-CD  and FCRW in a resistance welder
• Weld metal strength, microstructures and hardness traverse profiles are proposed to be investigated

Project 4 : Robotic Manufacturing FCRW Cell

Brief
Cooperative Work is being planned with Comau Inc. in Southfield, MI to set up a robotic manufacturing cell to carry out FCRW

Status

• Size transformer, load bearing ability, conductors, shunts and all other components for parameters relevant to FCRW of aluminum alloy structures such as a car body structural welds
• Assemble and test such a robotic cell at Comau, Inc, in the next few months while evaluating weld quality