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Evaluating spot welds of dissimilar metals via integrated mechanical testing and finite element modeling
Authors:
Kamal Abdulkareem Mohammed1
, Ahmed Ali Farhan Ogaili1
, Abdul Wahab A. Taha1
,
Ahmed Mohsin Alsayah2
1Mechanical Engineering Department, College of Engineering, Mustansiriyah University, Baghdad 10052, Iraq
2Refrigeration & Air-condition Department, Technical Engineering College, The Islamic University, Najaf, Iraq
Received: 12 February 2025
Revised: 1 March 2025
Accepted: 18 March 2025
Published: 30 June 2025
Abstract:
This study investigates resistance spot welding of dissimilar materials, namely 37.2 carbon steel, 304 stainless steel, and commercial aluminium. The effect of welding parameters on nugget growth, tensile shear strength, and failure modes in various material combinations was investigated using a combined experimental and finite element modeling (FEM) approach. Experimental studies included a welding current range (5-15 kA) and time range (10-30 cycles), complemented by tensile testing and hardness measurements. It was observed that Carbon Steel-Stainless Steel (CS-SS) joints achieved the highest strength (9.5 kN at 9 kA), while aluminium-containing joints exhibited lower strengths but required higher optimal currents. Hardness profiles showed extensive variations across weld zones, particularly for aluminium-steel joints. Failure mode analysis showed a prevalence of pullout failures for CS-SS joints, in contrast to more interfacial failures in aluminium-steel combinations. A finite element model was developed and validated against experimental data, showing excellent predictive capability for nugget size and joint strength (R²>0.96). This study contributes to the development of dissimilar material welding by providing new insights into parameter optimization, failure mechanisms, and industrial application, particularly for automotive and aerospace industries.
Keywords:
Dissimilar Metals, Tensile shear strength, Failure modes, Finite element analysis, Welding parameters
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© 2025 by the authors. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 2
June 2025
Last Edition
Volume 10
Number 2
June 2025
How to Cite
K. Abdulkareem Mohammed, A.A.F. Ogaili, A.W. A. Taha, A.M. Alsayah, Evaluating Spot Welds of Dissimilar Metals via Integrated Mechanical Testing and Finite Element Modeling. Applied Engineering Letters, 10(2), 2025: 77-89.
https://doi.org/10.46793/aeletters.2025.10.2.2
More Citation Formats
Abdulkareem Mohammed, K., Ogaili, A.A.F., Taha, A.W. A., & Alsayah, A.M. (2025). Evaluating Spot Welds of Dissimilar Metals via Integrated Mechanical Testing and Finite Element Modeling. Applied Engineering Letters, 10(2), 77-89.
https://doi.org/10.46793/aeletters.2025.10.2.2
Abdulkareem Mohammed, Kamal, et al. “Evaluating Spot Welds of Dissimilar Metals via Integrated Mechanical Testing and Finite Element Modeling.“ Applied Engineering Letters, vol. 10, no. 2, 2025, pp. 77-89.
https://doi.org/10.46793/aeletters.2025.10.2.2
Abdulkareem Mohammed, Kamal, Ahmed Ali Farhan Ogaili, Abdul Wahab A. Taha, and Ahmed Mohsin Alsayah. 2025. “Evaluating Spot Welds of Dissimilar Metals via Integrated Mechanical Testing and Finite Element Modeling.“ Applied Engineering Letters, 10 (2): 77-89.
https://doi.org/10.46793/aeletters.2025.10.2.2
Abdulkareem Mohammed, K., Ogaili, A.A.F., Taha, A.W. A., and Alsayah, A.M. (2025). Evaluating Spot Welds of Dissimilar Metals via Integrated Mechanical Testing and Finite Element Modeling. Applied Engineering Letters, 10(2), pp. 77-89.
doi: 10.46793/aeletters.2025.10.2.2.
Using lean manufacturing to improve process efficiency in a fabrication company
Authors:
Andra Maria Popa1
, Kapil Gupta1
1University of Johannesburg, Mechanical and Industrial Engineering Technology, Johannesburg, South Africa
Received: 29 June 2024
Revised: 20 September 2024
Accepted: 26 September 2024
Published: 30 September 2024
Abstract:
This article presents a case study on improving process efficiency in a mining equipment part fabrication company. The company was facing issues concerning communication, organisation, and workflow processes. This study investigated that ineffective communication among departments was the major weakness which was responsible for the long lead or idle time. This lead time was a waste that affected the company’s productivity. A great amount of time was spent on non-value-added processes. The Kanban Centralised Communication System was implemented. Time study and value stream mapping were also used. A significant improvement in process efficiency from 34% to 85% was achieved by reducing lead time from 4200 minutes to 1680 minutes after streamlining the communication in the company using Kanban.
Keywords:
Lean manufacturing, Kanban, Optimization, Process efficiency, Production lead time, Value stream mapping
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© 2024 by the author. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 2
June 2025
Last Edition
Volume 10
Number 2
June 2025
How to Cite
V.H. Quan, Research and Optimization of Sport Utility Vehicle Aerodynamic Design. Applied Engineering Letters, 9(2), 2024: 105-115.
https://doi.org/10.46793/aeletters.2024.9.2.5
More Citation Formats
Quan, V.H. (2024). Research and Optimization of Sport Utility Vehicle Aerodynamic Design. Applied Engineering Letters, 9(2), 105-115.
https://doi.org/10.46793/aeletters.2024.9.2.5
Quan, Vu Hai, “Research and Optimization of Sport Utility Vehicle Aerodynamic Design.“ Applied Engineering Letters, vol. 9, no. 2, pp. 2024, 105-115.
https://doi.org/10.46793/aeletters.2024.9.2.5
Quan, Vu Hai, 2024. “Research and Optimization of Sport Utility Vehicle Aerodynamic Design.“ Applied Engineering Letters, 9 (2):105-115.
https://doi.org/10.46793/aeletters.2024.9.2.5
Quan, V.H. (2024). Research and Optimization of Sport Utility Vehicle Aerodynamic Design. Applied Engineering Letters, 9(2), pp. 105-115.
doi: 10.46793/aeletters.2024.9.2.5.