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Tailor welded blanks for advanced manufacturing

Edited by B Kinsey, University of New Hampshire and X Wu, Wayne State University, USA

Woodhead Publishing Series in Welding and Other Joining Technologies No. 75

 - examines the manufacturing of tailor welded blanks and explores their current and potential future applications
 - investigates processing and quality issues in tailor welded blank manufacturing including weld integrity and deformation
 - reviews both current and potential future applications of tailor welded blanks as well as specific applications in the automotive and aerospace industries

Tailor welded blanks are metallic sheets made from different strengths, materials, and/or thicknesses pre-welded together before forming into the final component geometry. By combining various sheets into a welded blank, engineers are able to ‘tailor’ the blank so that the properties are located precisely where they are needed and cost-effective, low weight components are produced. Tailor welded blanks for advanced manufacturing examines the manufacturing of tailor welded blanks and explores their current and potential future applications.

Part one investigates processing and modelling issues in tailor welded blank manufacturing. Chapters discuss weld integrity, deformation during forming and the analytical and numerical simulation modelling of tailor welded blanks for advanced manufacturing. Part two looks at the current and potential future applications of tailor welded blanks. Chapters review tailor welded blanks of lightweight metals and of advanced high-strength steel and finally discuss the uses of tailor-welded blanks in the automotive and aerospace industries.

With its distinguished editors and international team of expert contributors, Tailor welded blanks for advanced manufacturing proves an invaluable resource for metal fabricators, product designers, welders, welding companies, suppliers of welding machinery and anyone working in industries that use advanced materials such as in automotive and aerospace engineering. Engineers and academics involved in manufacturing and metallurgy may also find this book a useful reference.

ISBN 1 84569 704 9
ISBN-13: 978 1 84569 704 4
July 2011
240 pages  234 x 156mm  hardback  
£125.00 / US$210.00 / €150.00

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About the editors

Professor Brad. L. Kinsey is Associate Professor in the Mechanical Engineering Department at the University of New Hampshire, USA.

Professor Xin Wu is Associate Professor in the Department of Mechanical Engineering at Wayne State University, USA. Both editors are widely regarded for their research expertise in sheet metal and tailor welded blank forming, behaviour, processing and manufacturing.

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Contents

PART 1 PROCESSING AND MODELING
PART 2 APPLICATIONS

PART 1 PROCESSING AND MODELING

Weld integrity of tailor welded blanks
M M Li, TWB Company, USA
Introduction
 - Typical weld imperfections
 - Testing methods
 - Quality control in production
 - Conclusions
 - References

Deformation of tailor welded blanks during forming
K Narasimhan, IIT Bombay and R G Narayanan, Indian Institute of Technology, India
 - Introduction
 - Estimation of the constitutive behaviour of the weld region
 - Methods to evaluate the weld width (or cross-sectional area) in tailor welded blanks (TWBs)
 - Forming limits of tailor welded blanks TWBs: Influence of weld orientation
 - Weld line movement
 - Design considerations for TWB forming
 - Simulation of TWB forming behaviour
 - Conclusions
 - Acknowledgement
 - References

Mechanics based modelling of tailor welded blank forming
B L Kinsey, University of New Hampshire, USA
 - Introduction
 - Thickness and strength ratio analysis
 - Determination of weld line movement and forming height
 - Determination of material draw-in ratios
 - Determination of non-uniform binder force
 - Conclusions
 - References

Numerical simulation modelling of tailor welded blank forming
A A Zadpoor, Materials Innovation Institute (M2i) and Delft University of Technology, J Sinke, and R Benedictus, Delft University of Technology, The Netherlands
 - Introduction
 - Finite element modelling (FEM) of the welded zones
 - Material models
 - Theoretical failure prediction of tailor welded blanks (TWBs)
 - Some topics in design and optimization of TWBs
 - Conclusions
 - Future trends
 - Sources of further information and advice
 - Acknowledgements
 - References

PART 2 APPLICATIONS

Light weight metal alloy tailor welded blanks
R Padmanabhan, University of Coimbra, Portugal and VIT University, India, M C Oliveira and L F Menezes, University of Coimbra, Portugal
 - Introduction
 - Light weight metal alloy tailor welded blanks (LWMA TWB)
 - LWMA TWB formability
 - LWMA TWB benefits, recycling
 - References

Advanced high-strength steel, tailor-welded blanks (AHSS-TWBs)
X Wu, Wayne State University and W Hou, ArcelorMittal USA Inc., USA
 - Introduction to advanced high-strength steel (AHSS)
 - Types of advanced high-strength steels and their characteristics
 - Fabrication of advanced high strength steels for tailor welded blanks (AHSS-TWBs)
 - Properties and formability of AHSS-TWBs
 - Understanding evolution of microstructure and its impact on properties of TWB-AHSS
 - Other manufacturing processes related to AHSS-TWBs
 - Conclusions
 - References

Tailor-welded blanks for the automotive industry
B L Kinsey, University of New Hampshire, USA
 - Introduction
 - Door inner example
 - Historical perspective
 - Adavantages of tailor welded blanks (TWBs)
 - Disadvantages of TWBs
 - Research efforts for TWBs
 - TWB forming methods
 - Welding processes for TWBs
 - Materials used to produce TWBs
 - Conclusions
 - References

Tailor-made blanks for the aerospace industry
J Sinke, Delft University of Technology, A A Zadpoor Materials Innovation Institute (M2i) and Delft University of Technology and R Benedictus, Delft University of Technology, The Netherlands
 - Introduction
 - The tailor made blanks (TMB) concept and the aircraft industry
 - Future trends
 - Conclusions
 - Acknowledgements
 - References