Search results for: weld repair rate in joint and linear basis

Authors: Suraya Mohamad Nadzir, Badrol Ahmad, Norlia Berahim

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T91 steel has been used as construction material for superheater tubes in sub-critical and super critical boiler. This steel was developed with higher creep strength property as compared to conventional low alloy steel. However, this steel is also susceptible to materials degradation due to its sensitivity to heat treatment especially Post Weld Heat Treatment (PWHT) after weld repair process. Review of PWHT process shows that the holding temperature may different from one batch to other batch of samples depending on the material composition. This issue was reviewed by many researchers and one of the potential solutions is the development of weld repair process without PWHT. This process is possible with the use of temper bead welding technique. However, study has shown the hardness value across the weld joint with exception of PWHT is much higher compare to recommended hardness value. Based on the above findings, a study to evaluate the microstructure and hardness changes of T91 weld joint after heating at 560°C at varying duration was carried out. This study was carried out to evaluate the possibility of self-tempering process during in-service period. In this study, the T91 weld joint was heat-up in air furnace at 560°C for duration of 50 and 150 hours. The heating process was controlled with heating rate of 200°C/hours, and cooling rate about 100°C/hours. Following this process, samples were prepared for the microstructure examination and hardness evaluation. Results have shown full tempered martensite structure and acceptance hardness value was achieved after 50 hours heating. This result shows that the thin component such as T91 superheater tubes is able to self-tempering during service hour.

Keywords: T91, weld-joint, tempered martensite, self-tempering

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Authors: Abdalaziz M. Alsalhabi, Loai M. Alowa

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This paper investigates Weld Rejection Rate (WRR) limits and tracer effects in construction projects, with a specific focus on a Gas Plant Project, a mega-project held by Saudi Aramco (SA) in Saudi Arabia. The study included a comprehensive examination of various factors impacting WRR limits. It commenced by comparing the Company practices with ASME standards, followed by an in-depth analysis of both weekly and cumulative projects' historical WRR data, evaluation of Radiographic Testing (RT) reports for rejected welds, and proposal of mitigation methods to eliminate future rejections. Additionally, the study revealed the causes of fluctuation in WRR data and benchmarked with the industry practices. Furthermore, a case study was conducted to explore the impact of tracers on WRR, providing insights into their influence on the welding process. This paper aims to achieve three primary objectives. Firstly, it seeks to validate the existing practices of WRR limits and advocate for their inclusion within relevant International Industry Standards. Secondly, it aims to validate the effectiveness of the WRR formula that incorporates tracer effects, ensuring its reliability in assessing weld quality. Lastly, this study aims to identify opportunities for process improvement in WRR control, with the ultimate goal of enhancing project processes and ensuring the integrity, safety, and efficiency of constructed assets.

Keywords: weld rejection rate, weld repair rate in joint and linear basis, tracers effects, construction projects

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Authors: Amruta Rout, Golak Bihari Mahanta, Gunji Bala Murali, Bibhuti Bhusan Biswal, B. B. V. L. Deepak

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The use of industrial robots for performing welding operation is one of the chief sign of contemporary welding in these days. The weld joint parameter and weld process parameter modeling is one of the most crucial aspects of robotic welding. As weld process parameters affect the weld joint parameters differently, a multi-objective optimization technique has to be utilized to obtain optimal setting of weld process parameter. In this paper, a hybrid optimization technique, i.e., Principal Component Analysis (PCA) combined with fuzzy logic has been proposed to get optimal setting of weld process parameters like wire feed rate, welding current. Gas flow rate, welding speed and nozzle tip to plate distance. The weld joint parameters considered for optimization are the depth of penetration, yield strength, and ultimate strength. PCA is a very efficient multi-objective technique for converting the correlated and dependent parameters into uncorrelated and independent variables like the weld joint parameters. Also in this approach, no need for checking the correlation among responses as no individual weight has been assigned to responses. Fuzzy Inference Engine can efficiently consider these aspects into an internal hierarchy of it thereby overcoming various limitations of existing optimization approaches. At last Taguchi method is used to get the optimal setting of weld process parameters. Therefore, it has been concluded the hybrid technique has its own advantages which can be used for quality improvement in industrial applications.

Keywords: robotic arc welding, weld process parameters, weld joint parameters, principal component analysis, fuzzy logic, Taguchi method

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Authors: Sagar Pandit

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The present work focuses on the effect of various process parameters on the mechanical properties and microstructure of joints produced by continuous drive friction welding and linear friction welding. An attempt is made to investigate the feasibility of obtaining an acceptable weld joint between similar as well as dissimilar components and the microstructural changes have also been assessed once the good weld joints were considered (using Optical Microscopy and Scanning Electron Microscopy techniques). The impact of forging pressure in the microstructure of the weld joint has been studied and the variation in joint strength with varying forge pressure is analyzed. The weld joints were obtained two pair of dissimilar materials and one pair of similar materials, which are listed respectively as: Al-AA5083 & Cu-C101 (dissimilar), Aluminium alloy-3000 series & Mild Steel (dissimilar) and High Nitrogen Austenitic Stainless Steel pair (similar). Intermetallic phase formation was observed at the weld joints in the Al-Cu joint, which consequently harmed the properties of the joint (less tensile strength). It was also concluded that the increase in forging pressure led to both increment and decrement in the tensile strength of the joint depending on the similarity or dissimilarity of the components. The hardness was also observed to possess maximum as well as minimum values at the weld joint depending on the similarity or dissimilarity of workpieces. It was also suggested that a higher forging pressure is needed to obtain complete joining for the formation of the weld joint.

Keywords: forging pressure, friction welding, mechanical properties, microstructure

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Authors: Pavel Zlabek, Vaclav Mentl

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The fatigue crack growth rate evaluation is a basic experimental characteristic when assessment o f the remaining lifetime is needed. Within the repair welding technology project, the crack growth rate at cyclic loading was measured in base and weld metals and in the situation when cracks were initiated in base metal and grew into the weld metal through heat-affected zone and back to the base metal. Two welding technologies were applied and specimens in as-welded state and after heat treatment were tested. Fatigue crack growth rate measurement was performed on CrMoV pressure vessel steel and the tests were performed at room temperature. The crack growth rate was measured on CCT test specimens (see figure) for both the base and weld metals and also in the case of crack subsequent transition through all the weld zones. A 500 kN MTS controlled electro-hydraulic testing machine and Model 632.13C-20 MTS extensometer were used to perform the tests.

Keywords: cracks, fatigue, steels, weldments

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Authors: A. Sharma, S. S. Sandhu, A. Shahi, A. Kumar

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The aim of present investigation was to carry out Finite element modeling of distortion in the case of butt weld. 12mm thick AISI 304L plates were butt welded using three different combinations of groove design namely Double U, Double V and Composite. A full simulation of shielded metal arc welding (SMAW) of nonlinear heat transfer is carried out. Aspects like, temperature-dependent thermal properties of AISI stainless steel above liquid phase, the effect of thermal boundary conditions, were included in the model. Since welding heat dissipation characteristics changed due to variable groove design significant changes in the microhardness tensile strength and impact toughness of the joints were observed. The cumulative distortion was found to be least in double V joint followed by the Composite and Double U-joints. All the joints have joint efficiency more than 100%. CVN value of the Double V-groove weld metal was highest. The experimental results and the FEM results were compared and reveal a very good correlation for distortion and weld groove design for a multipass joint with a standard analogy of 83%.

Keywords: AISI 304 L, Butt joint, distortion, FEM, groove design, SMAW

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Authors: Dongho Kim, Sung Choi, Kyowoong Pee, Youngsik Cho, Seungwoo Jeong, Soo-Ho Kim

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This study is about the orbital TIG welding robot system which travels on the guide rail installed on the pipe, and welds and tracks the pipe seam using the LVS (Laser Vision Sensor) joint profile data. The orbital welding robot system consists of the robot, welder, controller, and LVS. Moreover we can define the relationship between welding travel speed and wire feed speed, and we can make the linear equation using the maximum and minimum amount of weld metal. Using the linear equation we can determine the welding travel speed and the wire feed speed accurately corresponding to the area of weld captured by LVS. We applied this orbital TIG welding robot system to the stainless steel or duplex pipe on DSME (Daewoo Shipbuilding and Marine Engineering Co. Ltd.,) shipyard and the result of radiographic test is almost perfect. (Defect rate: 0.033%).

Keywords: adaptive welding, automatic welding, pipe welding, orbital welding, laser vision sensor, LVS, welding D/B

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Authors: Abdulmagid A. Khattabi, Abdul Fatah M. Emhamed

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The steel alloy Introduced after becoming carbon-steel does not meet the requirements of engineering industry; and it cannot be obtained tensile strength from carbon-steel higher than (700MPa), the low alloy steel enters in a lot of heavy engineering equipment parts, molds, agricultural equipment and other industry. In addition, that may be exposed to in-service failure, which may require returned to work, to do the repairs or maintenance by one of the welding methods available. The ability of steel weld determined through palpation of the cracks, which can reduce by many ways. These ways are often expensive and difficult to implement, perhaps the control to choose the type of electrode welding user is one of the easiest and least expensive applications. It has been welding the steel low alloys high resistance by manual metal arc (MMA), and by using a set of welding electrodes which varying in chemical composition and in their prices as well and test their effect on tensile strength. Results showed that using the poles of welding, which have a high proportion of iron powder and low hydrogen. The Tensile resistance is (484MPa) and the weld joint efficiency was (56.9%), but when (OK 47.04) electrode was used the tensile strength increased to (720MPa) and the weld joint efficiency to (84.7%). Using the cheapest electrode (OK 45.00) the weld joint efficiency did not exceed (24.2%), but when using the most expensive electrode (OK 91.28) the weld joint efficiency is (38.1%).

Keywords: steel low alloys high resistance, electrodes welding, tensile test

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Authors: H. Pasternak, A. Chwastek

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The paper describes the results from a research project about repair of welds. The repair was carried out by grinding the flawed seams and re-welding them. The main task was to determine the FAT classes of original state and after repair of seams according to the assessment procedures, such as nominal, structural and effective notch stress approach. The first part shows the results of the tests, the second part encloses numerical analysis and evaluation of results to determine the fatigue strength classes according to three assessment procedures.

Keywords: cyclic loading, fatigue crack, post-weld treatment, seams’ repair

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Authors: Sarakorn Sukaviriya

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This paper describes the inspection procedure, root cause analysis, the rectification of crack, and how to apply the procedure with other similar plants. During the operation of the steam turbine (620MW), instruments such as speed sensor of steam turbine, the servo valve of main stop valve and electrical wires were malfunction caused by leakage steam from main steam governing valve. Therefore, the power plant decided to shutdown steam turbines for figuring out the cause of leakage steam. Inspection techniques to be applied in this problem were microstructure testing (SEM), pipe stress analysis (FEM) and non-destructive testing. The crack was initially found on main governing valve’s weldment by visual inspection. To analyze more precisely, pipe stress analysis and microstructure testing were applied and results indicated that the crack was intergranular and originated from the weld defect. This weld defect caused the notch with high-stress concentration which created crack and then propagated to steam leakage. The major root cause of this problem was an inappropriate welding process, which created a weld defect. To repair this joint from damage, we used a welding technique by producing refinement of coarse grain HAZ and eliminating stress concentration. After the weldment was completely repaired, other adjacent weldments still had risk. Hence, to prevent any future cracks, non-destructive testing (NDT) shall be applied to all joints in order to ensure that there will be no indication of crack.

Keywords: steam-pipe leakage, steam leakage, weld crack analysis, weld defect

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Authors: A. Nait Salah, M. Kaddami

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This work describes an investigation on the effect of filler metals diameter to weld joint, and low alloy carbon steel A516 Grade 70 is the base metal. Commercially SA516 Grade70 is frequently used for the manufacturing of pressure vessels, boilers and storage tank, etc. In fabrication industry, the hardness of the weld joint is between the important parameters to check, after heat treatment of the weld. Submerged arc welding (SAW) is used with two filler metal diameters, and this solid wire electrode is used for SAW non-alloy and for fine grain steels (SFA 5.17). The different diameters were selected (Ø = 2.4 mm and Ø = 4 mm) to weld two specimens. Both specimens were subjected to the same preparation conditions, heat treatment, macrograph, metallurgy micrograph, and micro-hardness test. Samples show almost similar structure with highest hardness. It is important to indicate that the thickness used in the base metal is 22 mm, and all specifications, preparation and controls were according to the ASME section IX. It was observed that two different filler metal diameters performed on two similar specimens demonstrated that the mechanical property (hardness) increases with decreasing diameter. It means that even the heat treatment has the same effect with the same conditions, the filler metal diameter insures a depth weld penetration and better homogenization. Hence, the SAW welding technique mentioned in the present study is favorable to implicate for the industry using the small filler metal diameter.

Keywords: ASME, base metal, micro-hardness test, submerged arc welding

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Authors: S. Ramesh, A. S. Sasiraaju, K. Sidhaarth, N. Sudhan Rajkumar, V. Manivel Muralidaran

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This work presents the result of investigations aimed at determining the hardness of the welded Chromoly (A 4130) steel plate of 2” thickness. Multi pass welding for the thick sections was carried out and analyzed for the Chromoly alloy steel plates. The study of hardness at the weld metal reveals that there is the presence of different micro structure products which yields diverse properties. The welding carried out using GMAW with ER70s-2 electrode. Single V groove design was selected for the butt joint configuration. The presence of hydrogen has been suppressed by selecting low hydrogen electrode. Preheating of the plate prior to welding reduces the cooling rate which also affects the weld metal microstructure. The shielding gas composition used in this analysis is 80% Ar-20% CO2. The experimental analysis gives the detailed study of the hardness of the material.

Keywords: chromoly, gas metal arc weld (GMAW), hardness, multi pass weld, shielding gas composition

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Authors: Guoqing Wang, Yanhua Zhao, Lina Zhang, Jingbin Bai, Ruican Zhu

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Friction stir welding with bobbin tool is a simple technique compared to conventional FSW since the backing fixture is no longer needed and assembling labor is reduced. It gets adopted more and more in the aerospace industry as a result. However, a post-weld problem, the left keyhole, has to be fixed by forced repair welding. To close the keyhole, the conventional fusion repair could be an option if the joint properties are not deteriorated; friction push plug welding, a forced repair, could be another except that a rigid support unit is demanded at the back of the weldment. Therefore, neither of the above ways is satisfaction in welding a large enclosed structure, like rocket propellant tank. Although friction pulls plug welding does not need a backing plate, the wide applications are still held back because of the disadvantages in respects of unappropriated tensile stress, (i.e. excessive stress causing neck shrinkage of plug that will bring about back defects while insufficient stress causing lack of heat input that will bring about face defects), complicated welding parameters (including rotation speed, transverse speed, friction force, welding pressure and upset)，short welding time (approx. 0.5 sec.), narrow windows and poor stability of process. In this research, an updated technique called inertia friction pull plug welding, and its equipment was developed. The influencing rules of technological parameters on joint properties of inertia friction pull plug welding were observed. The microstructure characteristics were analyzed. Based on the elementary performance data acquired, the conclusion is made that the uniform energy provided by an inertia flywheel will be a guarantee to a stable welding process. Meanwhile, due to the abandon of backing plate, the inertia friction pull plug welding is considered as a promising technique in repairing keyhole of bobbin tool FSW and point type defects of aluminium base material.

Keywords: defect repairing, equipment, inertia friction pull plug welding, technological parameters

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Authors: Emmanuel Ogundimu, Esther Akinlabi, Mutiu Erinosho

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Welding is described as the process of joining metals so that bonding can be created as a result of inter-atomic penetration. This study investigated the influence of heat input on the efficiency of the welded joints of 304 stainless steel. Three welds joint were made from two similar 304 stainless steel plates of thickness 6 mm. The tensile results obtained showed that the maximum average tensile strength of 672 MPa is possessed by the sample A1 with low heat input. It was discovered that the tensile strength, % elongation and weld joint efficiency decreased with the increase in heat input into the weld. The average % elongation for the entire samples ranged from 28.4% to 36.5%. Sample A1 had the highest joint efficiency of 94.5%. However, the optimum welding current of 190 for TIG- MIG hybrid welding of type-304 austenite stainless steel can be recommended for advanced technological applications such as aircraft manufacturing, nuclear industry, automobile industry, and processing industry.

Keywords: microhardness, microstructure, tensile, MIG welding, process, tensile, shear stress TIG welding, TIG-MIG welding

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Authors: S. H. Park, D. W. You

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This study is about to the field survey and repair works in a marine approach-bride. In order to evaluate the stability of the ground and the structure, field surveys such as exterior inspection, non-destructive inspection, measurement, and geophysical exploration are carried out. Numerical analysis is conducted to investigate the cause of the abutment displacement at the same time. In addition, repair works are practiced to the region damaged with intent to sustain long-term safety.

Keywords: field survey, expansion joint, repair, maintenance

Procedia PDF Downloads 280

Authors: A. Sharma, S. S. Sandhu, A.Shahi, A. Kumar

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In this study, the effects of geometric configurations of butt joints i.e. double V groove, double U groove and UV groove of AISI 304L of thickness 12 mm by using Gas Tungsten Arc Welding (GTAW) are investigated. The magnitude of transverse shrinkage stress and distortion generated during welding under the unrestrained conditions of butt joints is the main objective of the study. The effect of groove design on impact strength and metallurgical properties are also studied. The Finite element analysis for the groove design is done and compared the actual experimentation. The experimental results and the FEM results were compared and reveal a very good correlation for distortion and weld groove design for multipass joint with a standard analogy of 80%. In the case of VV groove design it was found that the transverse stress and cumulative deflection have the lowest value. It was found that the UV groove design had the maximum ultimate and yield tensile strength, VV groove had the highest impact strength. Vicker’s hardness value of all the groove design was measured. Micro structural studies were carried out using conventional microscopic tools which revealed a lot of useful information for correlating the microstructure with mechanical properties.

Keywords: weld groove design, distortion, AISI 304 L, butt joint, FEM, GTAW

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Authors: Ajay Sidana, Kulbir Singh Sandhu, Balwinder Singh Sidhu

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Joining of dissimilar non-ferrous alloys like aluminium and magnesium alloys becomes important in various automobile and aerospace applications due to their low density and good corrosion resistance. Friction Stir Welding (FSW), a solid state joining process, successfully welds difficult to weld similar and dissimilar aluminum and magnesium alloys. Two tool rotation speeds were selected by keeping the transverse speed constant to weld similar and dissimilar alloys. Similar(Al to Al) and Dissimilar(Al to Mg) weld joints were obtained by FSW. SEM scans revealed that higher tool rotation fragments the coarse grains of base material into fine grains in the weld zone. Also, there are less welding defects in weld joints obtained with higher tool rotation speed. The material of dissimilar alloys was mixed with each other forming recrystallised new intermetallics. There was decrease in hardness of similar weld joint however there is significant increase in hardness of weld zone in case of dissimilar weld joints due to stirring action of tool and formation of inter metallics. Tensile tests revealed that there was decrease in percentage elongation in both similar and dissimilar weld joints.

Keywords: aluminum alloys, magnesium alloys, friction stir welding, microstructure, mechanical properties

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Authors: Emmanuel Ogundimu, Esther Akinlabi, Mutiu Erinosho

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The aim of this paper is to study the effect of welding current on the microstructure and the mechanical properties. Material characterizations were conducted on a 6 mm thick plates of type-304 austenite stainless steel, welded by TIG welding process at two different welding currents of 150 A (Sample F3) and 170 A (Sample F4). The tensile strength and the elongation obtained from sample F4 weld were approximately 584 MPa and 19.3 %; which were higher than sample F3 weld. The average microhardness value of sample F4 weld was found to be 235.7 HV, while that of sample F3 weld was 233.4 HV respectively. Homogenous distribution of iron (Fe), chromium (Cr) and nickel (Ni) were observed at the welded joint of the two samples. The energy dispersive spectroscopy (EDS) analysis revealed that Fe, Cr, and Ni made up the composition formed in the weld zone. The optimum welding current of 170 A for TIG welding of type-304 austenite stainless steel can be recommended for high-tech industrial applications.

Keywords: microhardness, microstructure, tensile, MIG welding, process, tensile, shear stress TIG welding, TIG-MIG welding

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Authors: Eyob Messele Sefene, Atinkut Atinafu Yilma

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The highest strength-to-weight ratio criterion has fascinated increasing curiosity in virtually all areas where weight reduction is indispensable. One of the recent advances in manufacturing to achieve this intention endears friction stir welding (FSW). The process is widely used for joining similar and dissimilar non-ferrous materials. In FSW, the mechanical properties of the weld joints are impelled by property-selected process parameters. This paper presents verdicts of optimum process parameters in attempting to attain enhanced mechanical properties of the weld joint. The experiment was conducted on a 5 mm 6061 aluminum alloy sheet. A butt joint configuration was employed. Process parameters, rotational speed, traverse speed or feed rate, axial force, dwell time, tool material and tool profiles were utilized. Process parameters were also optimized, making use of a mixed L18 orthogonal array and the Grey relation analysis method with larger is better quality characteristics. The mechanical properties of the weld joint are examined through the tensile test, hardness test and liquid penetrant test at ambient temperature. ANOVA was conducted in order to investigate the significant process parameters. This research shows that dwell time, rotational speed, tool shape, and traverse speed have become significant, with a joint efficiency of about 82.58%. Nine confirmatory tests are conducted, and the results indicate that the average values of the grey relational grade fall within the 99% confidence interval. Hence the experiment is proven reliable.

Keywords: friction stir welding, optimization, 6061 AA, Taguchi

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Authors: Juzar Vohra, Ravish Malhotra, Tim Pasang, Mana Azizi, Yuan Tao, Masami Mizutani

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In this paper, dissimilar welding of titanium to stainless steels is reported. Laser Beam Welding (LBW) and Gas Tungsten Arc Welding (GTAW) were employed to join CPTi to SS304. The welds were examined using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). FeTi, Ti2Cr and Fe2Ti dendrites are formed along with beta phase titanium matrix. The hardness values of these phases are high which makes them brittle and leading to cracking along the weld pool. However, it is believed that cracking, hence, fracturing of this weld joint is largely due to the difference in thermal properties of the two alloys.

Keywords: dissimilar metals, fusion welding, intermetallics, brittle

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Authors: Mahdi Amne Elahi, Marcus Koch, Peter Plapper

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Due to the demand of miniaturizing in automotive industry, the application of laser welding is quite promising. The current study focused on laser micro-welding of CuSn6 bronze and nickel wire for a miniature electromechanical hybrid component. Due to the advantages of laser welding, the welding can be tailored specifically for the requirements of the part. Scanning electron and optical microscopy were implemented to study the microstructure and tensile-shear test was selected to represent the mechanical properties. Different welding sides, beam oscillations, and speeds have been investigated to optimize the tensile-shear load and microstructure. The results show that the mechanical properties and microstructure of the joint is highly under the influence of the mentioned parameters. Due to the lack of intermetallic compounds, the soundness of the joint is achievable by manipulating the geometry of the weld seam and minimize weld defects.

Keywords: bronze, laser micro-welding, microstructure, nickel, tensile shear test

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Authors: T. Nakkeran, C. Dhamodharan, Win Myint Soe , Ramasamy Deverajan, M. Ganesh Babu

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This manuscript presents the results of an experimental investigation performed to study the material and mechanical properties of two weld joints fabricated within close proximity. The experiment was designed using welded S355 D Z35 with distances between two parallel adjacent weld toes at 8 mm. These distances were less than the distance that has normally been recommended in standards, codes, and specifications. The main idea of the analysis is to determine any significant effects when welding the joints with the close proximity of 8mm using the SAW welding process of the one joint with high heat put and one joint welded with the FCAW welding process and evaluating the destructing and nondestructive testing between the welded joints. Further, we have evaluated the joints with Mechanical Testing for evaluating by performing Tensile test, bend testing, Macrostructure, Microstructure, Hardness test, and Impact testing. After evaluating the final outcome of the result, no significant changes were observed for welding the close proximity of weld of 8mm distance between the joints as compared to the specification minimum distance between the weldments of any design should be 50mm.

Keywords: S355 carbon steel, weld proximity, SAW process, FCAW process, heat input, bend test, tensile test, hardness test, impact test, macro and microscopic examinations

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Authors: Helen Bartsch, Markus Feldmann

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The dimensioning of steel structures subject to fatigue loads, such as wind turbines, bridges, masts and towers, crane runways and weirs or components in crane construction, is often dominated by fatigue verification. The fatigue details defined by the welded connections, such as butt or cruciform joints, longitudinal welds, welded-on or welded-in stiffeners, etc., are decisive. In Europe, the verification is usually carried out according to EN 1993-1-9 on a nominal stress basis. The basis is the detailed catalog, which specifies the fatigue strength of the various weld and construction details according to fatigue classes. Until now, a relation between fatigue classes and weld imperfection sizes is not included. Quality levels for imperfections in fusion-welded joints in steel, nickel, titanium and their alloys are regulated in EN ISO 5817, which, however, doesn’t contain direct correlations to fatigue resistances. The question arises whether some imperfections might be tolerable to a certain extent since they may be present in the test data used for detail classifications dating back decades ago. Although current standardization requires proof of satisfying limits of imperfection sizes, it would also be possible to tolerate welds with certain irregularities if these can be reliably quantified by non-destructive testing. Fabricators would be prepared to undertake carefully and sustained weld inspection in view of the significant economic consequences of such unfavorable fatigue classes. This paper presents investigations on the fatigue behavior of common welded details containing imperfections. In contrast to the common nominal stress concept, local fatigue concepts were used to consider the true stress increase, i.e., local stresses at the weld toe and root. The actual shape of a weld comprising imperfections, e.g., gaps or undercuts, can be incorporated into the fatigue evaluation, usually on a numerical basis. With the help of the effective notch stress concept, the fatigue resistance of detailed local weld shapes is assessed. Validated numerical models serve to investigate notch factors of fatigue details with different geometries. By utilizing parametrized ABAQUS routines, detailed numerical studies have been performed. Depending on the shape and size of different weld irregularities, fatigue classes can be defined. As well load-carrying welded details, such as the cruciform joint, as non-load carrying welded details, e.g., welded-on or welded-in stiffeners, are regarded. The investigated imperfections include, among others, undercuts, excessive convexity, incorrect weld toe, excessive asymmetry and insufficient or excessive throat thickness. Comparisons of the impact of different imperfections on the different types of fatigue details are made. Moreover, the influence of a combination of crucial weld imperfections on the fatigue resistance is analyzed. With regard to the trend of increasing efficiency in steel construction, the overall aim of the investigations is to include a more economical differentiation of fatigue details with regard to tolerance sizes. In the long term, the harmonization of design standards, execution standards and regulations of weld imperfections is intended.

Keywords: effective notch stress, fatigue, fatigue design, weld imperfections

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Authors: D. S. Nagesh, G. L. Datta

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In the field of welding, various studies had been made by some of the previous investigators to predict as well as optimize weld bead geometric descriptors. Modeling of weld bead shape is important for predicting the quality of welds. In most of the cases, design of experiments technique to postulate multiple linear regression equations have been used. Nowadays, Genetic Algorithm (GA) an intelligent information treatment system with the characteristics of treating complex relationships as seen in welding processes used as a tool for inverse mapping/optimization of the process is attempted.

Keywords: smaw, genetic algorithm, bead geometry, optimization/inverse mapping

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Authors: D. S. Nagesh, G. L. Datta

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In the field of welding, various studies had been made by some of the previous investigators to predict as well as optimize weld bead geometric descriptors. Modeling of weld bead shape is important for predicting the quality of welds. In most of the cases design of experiments technique to postulate multiple linear regression equations have been used. Nowadays Genetic Algorithm (GA) an intelligent information treatment system with the characteristics of treating complex relationships as seen in welding processes used as a tool for inverse mapping/optimization of the process is attempted.

Keywords: SMAW, genetic algorithm, bead geometry, optimization/inverse mapping

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Authors: Emmanuel Ogundimu, Esther Akinlabi, Mutiu Erinosho

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In this research, studies were done on the material characterization of type 304 austenitic stainless steel weld produced by TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) welding processes. This research is aimed to establish optimized process parameters that will result in a defect-free weld joint, homogenous distribution of the iron (Fe), chromium (Cr) and nickel (Ni) was observed at the welded joint of all the six samples. The welded sample produced at the current of 170 A by TIG welding process had the highest ultimate tensile strength (UTS) value of 621 MPa at the welds zone, and the welded sample produced by MIG process at the welding current of 150 A had the lowest UTS value of 568 MPa. However, it was established that TIG welding process is more appropriate for the welding of type 304 austenitic stainless steel compared to the MIG welding process.

Keywords: microhardness, microstructure, tensile, MIG welding, process, tensile, shear stress TIG welding, TIG-MIG welding

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Authors: Szymon Kowieski, Zygmunt Mikno

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The study involved the optimization of process parameters during resistance spot welding of Al-coated martensitic boron steel 22MnB5, applied in hot stamping, performed using a programme with a multiple current impulse mode and a programme with variable pressure force. The aim of this research work was to determine the possibilities of a growth in welded joint strength and to identify the expansion of a welding lobe. The process parameters were adjusted on the basis of welding process simulation and confronted with experimental data. 22MnB5 steel is known for its tendency to obtain high hardness values in weld nuggets, often leading to interfacial failures (observed in the study-related tests). In addition, during resistance spot welding, many production-related factors can affect process stability, e.g. welding lobe narrowing, and lead to the deterioration of quality. Resistance spot welding performed using the above-named welding programme featuring 3 levels of force made it possible to achieve 82% of welding lobe extension. Joints made using the multiple current impulse program, where the total welding time was below 1.4s, revealed a change in a peeling mode (to full plug) and an increase in weld tensile shear strength of 10%.

Keywords: 22MnB5, hot stamping, interfacial fracture, resistance spot welding, simulation, single lap joint, welding lobe

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Authors: Ahmad K. Jassim, Raheem Kh. Al-Subar

Abstract:

Friction stir welding is a modern and an environmentally friendly solid state joining process used to joint relatively lighter family of materials. Recently, friction stir spot welding has been used instead of resistance spot welding which has received considerable attention from the automotive industry. It is environmentally friendly process that eliminated heat and pollution. In this research, friction stir spot welding has been used to study the possibility to weld AA1100 aluminum alloy sheet with 3 mm thickness by overlapping the edges of sheet as lap joint. The process was done using a drilling machine instead of milling machine. Different tool rotational speeds of 760, 1065, 1445, and 2000 RPM have been applied with manual and automatic compression to study their effect on the quality of welded joints. Heat generation, pressure applied, and depth of tool penetration have been measured during the welding process. The result shows that there is a possibility to weld AA1100 sheets; however, there is some surface defect that happened due to insufficient condition of welding. Moreover, the relationship between rotational speed, pressure, heat generation and tool depth penetration was created.

Keywords: friction, spot, stir, environmental, sustainable, AA1100 aluminum alloy

Procedia PDF Downloads 183

Authors: Chukwuemeka Daniel Ezeliora, Chukwuebuka Lawrence Ezeliora

Abstract:

The research focused on the appraisal of impact strength on mild steel cladding weld metal geometry. Over the years, poor welding has resulted in failures in engineering components, poor material quality, the collapse of welded materials, and failures in material strength. This is as a result of poor selection and combination of welding input process parameters. The application of the Tungsten Inert Gas (TIG) welding method with weld specimen of length 60; width 40, and thickness of 10 was used for the experiment. A butt joint method was prepared for the welding, and tungsten inert gas welding process was used to perform the twenty (20) experimental runs. A response surface methodology was used to model and to analyze the system. For an adequate polynomial approximation, the experimental design was used to collect the data. The key parameters considered in this work are welding current, gas flow rate, welding speed, and voltage. The range of the input process parameters was selected from the literature and the design. The steps followed to achieve the experimental design and results is the use of response surface method (RSM) implemented in central composite design (CCD) to generate the design matrix, to obtain quadratic model, and evaluate the interactions in the factors as well as optimizing the factors and the response. The result expresses that the best impact strength of the mild steel cladding weld metal geometry is 115.419 Joules. However, it was observed that the result of the input factors is; current 180.4 amp, voltage 23.99 volt, welding speed 142.7 mm.s and gas flow rate 10.8 lit/min as the optimum of the input process parameters. The optimal solution gives a guide for optimal impact strength of the weldment when welding with tungsten inert gas (TIG) under study.

Keywords: mild steel, impact strength, response surface, bead geometry, welding

Procedia PDF Downloads 108

Authors: Abdullah Kaymakci, Daniel M. Madyira, Hilda Moseme

Abstract:

Repairing railway wheels by weld build-up is one of the technological solutions that have been applied in the past. However, the effects of this process on the material properties are not well established. The effects of the weld build-up on the mechanical properties of the wheel material in comparison to the required mechanical properties for proper service performance were investigated in this study. A turning process was used to remove the worn surface from the railway wheel. During this process 5mm thickness was removed to ensure that, if there was any weld build-up done in the previous years, it was removed. This was followed by welding a round bar on the sides of the wheel to provide build-up guide. There were two welding processes performed, namely submerged arc welding (SAW) and gas metal arc welding (GMAW). Submerged arc welding (SAW) was used to build up weld on one rim while the other rim was just left with metal arc welding of the round bar at the edges. Both processes produced hardness values that were lower than that of the parent material of 195 HV as the GMAW welds had an average of 184 HV and SAW had an average of 194 HV. Whilst a number of defects were noted on the GMAW welds at both macro and micro levels, SAW welds had less defects and they were all micro defects. All the microstructures were ferritic but with differences in grain sizes. Furthermore, in the SAW weld build up, the grains of the weld build-up appeared to be elongated which was a result of the cooling rate. Using GMAW instead of SAW would result in improved wear and fatigue performance.

Keywords: submerged arc welding, gas metal arc welding, railway wheel, microstructure, micro hardness

Procedia PDF Downloads 290