Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars
This paper presents a joining by plastic deformation process for fabricating hybrid electrical busbars made from copper and aluminum sheets. The process comprises the innovative use of wire-arc additive manufacturing to deposit copper rivets at specific locations on the copper sheets, the machining...
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| Format: | Article |
| Language: | English |
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Elsevier
2024-11-01
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| Series: | Journal of Advanced Joining Processes |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666330924000888 |
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| author | Pedro M.S. Rosado Rui F.V. Sampaio João P.M. Pragana Ivo M.F. Bragança Carlos M.A. Silva Paulo A.F. Martins |
| author_facet | Pedro M.S. Rosado Rui F.V. Sampaio João P.M. Pragana Ivo M.F. Bragança Carlos M.A. Silva Paulo A.F. Martins |
| author_sort | Pedro M.S. Rosado |
| collection | DOAJ |
| description | This paper presents a joining by plastic deformation process for fabricating hybrid electrical busbars made from copper and aluminum sheets. The process comprises the innovative use of wire-arc additive manufacturing to deposit copper rivets at specific locations on the copper sheets, the machining of slots with the required geometry in the aluminum sheets, and the compression of the copper sheets to force the rivets into the pre-machined slots of the aluminum sheets, creating form-closed mechanical interlocks. The work combines experimentation and finite element modeling to analyze the influence of the most significant process parameters, and the electrical performance of the hybrid busbar joints is evaluated and compared to that of conventional fastened joints at different service temperatures. Results demonstrate the effectiveness and potential advantages of the new joining by plastic deformation process for fabricating hybrid electrical busbars. |
| format | Article |
| id | doaj-art-ff3a45ca333a4410b6db6d29824b896e |
| institution | Kabale University |
| issn | 2666-3309 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Advanced Joining Processes |
| spelling | doaj-art-ff3a45ca333a4410b6db6d29824b896e2024-12-13T11:04:55ZengElsevierJournal of Advanced Joining Processes2666-33092024-11-0110100272Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbarsPedro M.S. Rosado0Rui F.V. Sampaio1João P.M. Pragana2Ivo M.F. Bragança3Carlos M.A. Silva4Paulo A.F. Martins5IDMEC, Instituto Superior Técnico, Universidade de Lisboa, PortugalIDMEC, Instituto Superior Técnico, Universidade de Lisboa, PortugalIDMEC, Instituto Superior Técnico, Universidade de Lisboa, PortugalCIMOSM, Instituto Superior de Engenharia de Lisboa, Instituto Politécnico de Lisboa, PortugalIDMEC, Instituto Superior Técnico, Universidade de Lisboa, PortugalIDMEC, Instituto Superior Técnico, Universidade de Lisboa, Portugal; Corresponding author.This paper presents a joining by plastic deformation process for fabricating hybrid electrical busbars made from copper and aluminum sheets. The process comprises the innovative use of wire-arc additive manufacturing to deposit copper rivets at specific locations on the copper sheets, the machining of slots with the required geometry in the aluminum sheets, and the compression of the copper sheets to force the rivets into the pre-machined slots of the aluminum sheets, creating form-closed mechanical interlocks. The work combines experimentation and finite element modeling to analyze the influence of the most significant process parameters, and the electrical performance of the hybrid busbar joints is evaluated and compared to that of conventional fastened joints at different service temperatures. Results demonstrate the effectiveness and potential advantages of the new joining by plastic deformation process for fabricating hybrid electrical busbars.http://www.sciencedirect.com/science/article/pii/S2666330924000888Joining by plastic deformationAdditive manufacturingHybrid electrical busbarsExperimentationFinite element modelling |
| spellingShingle | Pedro M.S. Rosado Rui F.V. Sampaio João P.M. Pragana Ivo M.F. Bragança Carlos M.A. Silva Paulo A.F. Martins Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars Journal of Advanced Joining Processes Joining by plastic deformation Additive manufacturing Hybrid electrical busbars Experimentation Finite element modelling |
| title | Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars |
| title_full | Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars |
| title_fullStr | Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars |
| title_full_unstemmed | Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars |
| title_short | Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars |
| title_sort | exploring wire arc additive manufactured rivets for joining hybrid electrical busbars |
| topic | Joining by plastic deformation Additive manufacturing Hybrid electrical busbars Experimentation Finite element modelling |
| url | http://www.sciencedirect.com/science/article/pii/S2666330924000888 |
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