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All Journal Mechanical Engineering for Society and Industry Automotive Experiences
Triyono Triyono
Universitas Sebelas Maret, Indonesia
Aerospace Engineering Automotive Engineering Chemical Engineering, Chemistry & Bioengineering Control & Systems Engineering Electrical & Electronics Engineering Energy Engineering Industrial & Manufacturing Engineering Materials Science & Nanotechnology Mechanical Engineering Transportation

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Mitigation of Porosity and Residual Stress on Car Body Aluminum Alloy Vibration Welding: A Systematic Literature Review Saifudin Saifudin; Nurul Muhayat; Eko Surojo; Yupiter HP Manurung; Triyono Triyono
Automotive Experiences Vol 5 No 3 (2022)
Publisher : Automotive Laboratory of Universitas Muhammadiyah Magelang in collaboration with Association of Indonesian Vocational Educators (AIVE)

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/ae.7965

Abstract

Fatigue resistance is influenced by porosity and residual stress in welded joints. Fatigue failure in some means of transportation is caused by the inability to withstand the load received from the car body and passengers while operating. This study uses a systematic literature review (SLR) method to identify the effect of vibration welding on porosity and residual stress. Vibration can reduce the empty cavity (porosity) and increase the density of the weld. The ultrasonic vibration spot resistance (UVSR) method with 20 kHz on AA6082 is able to reduce residual stress up to 53% and is effective for homogenization of concentrated residual stress up to 57%.
Tensile shear load in resistance spot welding of dissimilar metals: An optimization study using response surface methodology Sukarman Sukarman; Triyono Triyono; Budi Kristiawan; Amir Amir; Nazar Fazrin; Ade Suhara; Renata Lintang Azizah; Fajar Mucharom
Mechanical Engineering for Society and Industry Vol 3 No 2 (2023)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.9606

Abstract

Resistance spot welding (RSW) is being applied extensively in different industries, specifically the automotive sector. Therefore, this study was conducted to optimize the tensile strength load (TSL) in RSW by investigating the application of dissimilar materials as input parameters. The optimization process involved the combination of different galvanized and non-galvanized steel materials. The production of car bodies using galvanized steel with approximately 13.0 microns thick zinc (Zn) coating was found to be a standard practice, but this zinc layer usually presents challenges due to the poor weldability. This study prepared 27 units of TSL samples using a spot-welding machine and a pressure force system (PFS) for the electrode tip. The aim was to determine the optimal TSL through the exploration of specified RSW parameters. The process focused on using the response surface methodology (RSM) to achieve the desired outcome while the Box-Behnken design was applied to determine the input parameters. The optimal TSL obtained was 5265.15 N by setting the squeeze time to 21.0 cycles at a welding current of 24.5 kA, a welding time of 0.5 s, and a holding time of 15.0 cycles. The highest TSL value recorded was 5937.94 N at 21.0 cycles, 27.0 kA, 0.6 s, and 15.0 cycles respectively. These findings were considered significant to the enhancement of productivity across industries, specifically in the RSW process. However, further study was required to investigate additional response variables such as the changes in hardness and microstructure.
Temperature and material flow in one-step double-acting friction stir welding process of aluminum alloy: Modeling and experimental Eko Prasetya Budiana; Sekar Gading Happy Hapsari; Essam R. I. Mahmoud; Triyono Triyono
Mechanical Engineering for Society and Industry Vol 5 No 1 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.12987

Abstract

Aluminum, known for its lower density compared to steel, is widely used in various applications. Welding is often required to form aluminum into technical structures. However, when fusion welding is used, it can lead to porosity in the weld. This occurs due to the significant difference in hydrogen gas solubility between liquid and solid aluminum, which traps hydrogen gas within the weld metal. Friction Stir Welding (FSW), a solid-state welding technique, has been proven to minimize porosity. However, for thick structures, FSW poses challenges, as welding must be done on both sides, increasing the welding time. To overcome this limitation, FSW has been modified into a one-step double-side FSW process, where two tools simultaneously work on both surfaces of the workpiece. This creates a unique condition with two heat sources and two stirring motion sources. To understand the temperature distribution and material flow in this process, modeling was conducted using Computational Fluid Dynamics (CFD). The upper and lower tools in the one-step double-side FSW process operate under identical conditions: a rotation speed of 1500 rpm, a welding speed of 30 mm/min, and a tilt angle of 0 degrees. The aluminum plate is treated as fluid, while the tools are considered solid in the model. The results of the temperature distribution modeling were validated against published studies, and the material flow was verified through macro- and microstructural observations of the cross-section. The validation showed that the model is accurate, with an error of only 4.07%.
Co-Authors Ade Suhara Amir Amir Budi Kristiawan Eko Prasetya Budiana Eko Surojo Essam R. I. Mahmoud Fajar Mucharom Nazar Fazrin Nurul Muhayat Renata Lintang Azizah Saifudin Saifudin Sekar Gading Happy Hapsari Sukarman Sukarman Yupiter HP Manurung