Search results for: pulse gas metal arc welding (P-GMAW)

Authors: Hamidreza Mansouri

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In the construction industry, the lifespan of a metal structure is directly related to the quality of welding. In most metal structures, the welded area is considered critical and is one of the most important factors in design. To date, many fracture incidents caused by these types of cracks have occurred. Various methods exist to increase the lifespan of welds to prevent failure in the welded area. Among these methods, the application of ultrasonic peening, in addition to the stress relief process, can manually and more precisely adjust the geometry of the weld toe and prevent stress concentration in this part. This research examined Gas Tungsten Arc Welding (GTAW) on common structural steels and 316 stainless steel, which require precise welding, to predict the optimal condition. The GTAW method was used to create residual stress; two samples underwent ultrasonic stress relief, and for comparison, two samples underwent thermal stress relief. Also, no treatment was considered for two samples. The residual stress of all six pieces was measured by X-Ray Diffraction (XRD) method. Then, the two ultrasonically stress-relieved samples and two untreated samples were exposed to a corrosive environment to initiate cracking and determine the effectiveness of the ultrasonic stress relief method. Thus, the residual stress caused by GTAW in the samples decreased by 3.42% with thermal treatment and by 7.69% with ultrasonic peening. Furthermore, the results show that the untreated sample developed cracks after 740 hours, while the ultrasonically stress-relieved piece showed no cracks. Given the high costs of welding and post-welding zone modification processes, finding an economical, effective, and comprehensive method that has the least limitations alongside a broad spectrum of usage is of great importance. Therefore, the impact of various ultrasonic peening stress relief parameters and the selection of the best stress relief parameter to achieve the longest lifespan for the weld area is highly significant.

Keywords: GTAW welding, stress corrosion cracking(SCC), thermal method, ultrasonic peening.

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Authors: K. Subbaiah

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Friction stir welding is a solid state welding process. Friction stir welding process eliminates the defects found in fusion welding processes. It is environmentally friend process. 5000 and 6000 series aluminum alloys are widely used in the transportation industries. The Al-Mg-Mn (5000) and Al-Mg-Si (6000) alloys are preferably offer best combination of use in Marine construction. The medium strength and high corrosion resistant 5000 series alloys are the aluminum alloys, which are found maximum utility in the world. In this review, the tool pin profile, process parameters such as hardness, yield strength and tensile strength, and microstructural evolution of friction stir welding of Al-Mg alloys 5000 Series and 6000 series have been discussed.

Keywords: 5000 series and 6000 series Al alloys, friction stir welding, tool pin profile, microstructure and properties

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Authors: Shoji Matsumoto

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Friction Stir Welding (FSW) has been widely used in the automotive, aerospace, and high-tech industries due to its superior mechanical properties after welding. However, when it becomes a matter to perform a high-quality joint using FSW, it is necessary to secure an advanced tilt angle (usually 1 to 5 degrees) using a dedicated FSW machine and to use a joint structure and a restraining jig that can withstand the tool pressure applied during the jointing process using a highly rigid processing machine. One issue that has become a challenge in this process is ‘productivity and versatility’. To solve this problem, we have conducted research and development of multi-functioning machines and robotics with FSW tools, which combine cutting/milling and FSW functions as one in recent years. However, the narrow process window makes it prone to welding defects and lacks repeatability, which makes a limitation for FSW its use in the fields where precisions required. Another reason why FSW machines are not widely used in the world is because of the matter of very high cost of ownership.

Keywords: synchronized, stir, welding, friction, traveling speed, synchronized stir welding, friction stir welding

Procedia PDF Downloads 22

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

Procedia PDF Downloads 147

Authors: Rahmad Wisnu Wardana, Eakachai Warinsiriruk, Sutep Joy-A-Ka

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Selecting the most suitable welding process usually depends on experiences or common application in similar companies. However, this approach generally ignores many criteria that can be affecting the suitable welding process selection. Therefore, knowledge automation through knowledge-based systems will significantly improve the decision-making process. The aims of this research propose integrated data envelopment analysis (DEA) and fuzzy credibility constrained programming approach for identifying the best welding process for stainless steel storage tank in the food and beverage industry. The proposed approach uses fuzzy concept and credibility measure to deal with uncertain data from experts' judgment. Furthermore, 12 parameters are used to determine the most appropriate welding processes among six competitive welding processes.

Keywords: welding process selection, data envelopment analysis, fuzzy credibility constrained programming, storage tank

Procedia PDF Downloads 150

Authors: Xiangfang Xu, Bintao Wu, Yugang Miao, Duanfeng Han

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Experiments were conducted on 5A06 aluminum alloy and Q235 steel using the laser-TIG hybrid heat source welding-brazing method to realize the reliable connection of Al/Fe dissimilar metals and the welding characteristics were analyzed. It was found that the joints with uniform seam and high tensile strength could be obtained using such a method, while the welding process demanded special welding parameters. Spectrum measurements showed that the Al and Fe atoms diffused more thoroughly at the brazing interface and formed a 3μm-thick intermetallic compound layer at the Al/Fe joints brazed connection interface. Shearing tests indicated that the shearing strength of the Al/Fe welding-brazed joint was 165MPa. The fracture occurred near the melting zone of aluminum alloy, which belonged to the mixed mode with the ductile fracture as the base and the brittle fracture as the supplement.

Keywords: Al/Fe dissimilar metals, laser-TIG hybrid heat source, shearing strength, welding-brazing method

Procedia PDF Downloads 374

Authors: E. S. Manuylovich, V. A. Astapenko, P. A. Golovinsky

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The dispersion relation binding the constant of propagation and frequency is calculated for silver cone. The evolution of the electric field of ultrashort pulse during its propagation in conical structure is considered. Increasing of electric field during pulse propagation to the top of the cone is observed. Reduction of the pulse duration at a certain distance is observed. The dependence of minimum pulse duration on initial chirp and cone angle is investigated.

Keywords: ultrashort pulses, surface plasmon polariton, dispersion, silver cone

Procedia PDF Downloads 417

Authors: Yifang Gong

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Pulse diagnosis is one of the most important diagnosis methods in traditional Chinese medicine. It is also the trickiest method to learn. It is known as that it can only to be sensed not explained. This becomes a serious threat to the survival of this diagnostic method. However, there are a large amount of experiences accumulated during the several thousand years of practice of Chinese doctors. A pulse pattern called 'Slippery pulse' is one of the indications of pregnancy. A simple fluid dynamic model is proposed to simulate the effects of the existence of a placenta. The placenta is modeled as an extra plenum in an extremely simplified fluid network model. It is found that because of the existence of the extra plenum, indeed the pulse pattern shows a secondary peak in one pulse period. As for the author’s knowledge, this work is the first time to show the link between Pulse diagnoses and basic physical principle. Key parameters which might affect the pattern are also investigated.

Keywords: Chinese medicine, flow network, pregnancy, pulse

Procedia PDF Downloads 361

Authors: Peter Antwi Buah, Yingbin Zhang, Jianxian He, Chenlin Xiang, Delali Atsu Y. Bakah

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Near-fault ground motions with velocity pulses are considered to cause significant damage to structures or slopes compared to ordinary ground motions without velocity pulses. The double pulsed pulse-like ground motion is as well known to be stronger than the single pulse. This study has numerically justified this perspective by studying the dynamic response of a homogeneous rock slope subjected to four pulse-like and two non-pulse-like ground motions using the Fast Lagrangian Analysis of Continua in 3 Dimensions (FLAC3D) software. Two of the pulse-like ground motions just have a single pulse. The results show that near-fault ground motions with velocity pulses can cause a higher dynamic response than regular ground motions. The amplification of the peak ground acceleration (PGA) in horizontal direction increases with the increase of the slope elevation. The seismic response of the slope under double pulse ground motion is stronger than that of the single pulse ground motion. The PGV amplification factor under the effect of the non-pulse-like records is also smaller than those under the pulse-like records. The velocity pulse strengthens the earthquake damage to the slope, which results in producing a more strong dynamic response.

Keywords: velocity pulses, dynamic response, PGV magnification effect, elevation effect, double pulse

Procedia PDF Downloads 144

Authors: H. Karakoc, A. Uzun, G. Kırmızı, H. Çinici, R. Çitak

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The main objective of this investigation was to apply friction welding for joining of AA7039 rods produced by powder metallurgy. Friction welding joints were carried out using a rotational friction welding machine. Friction welds were obtained under different rotational speeds between (2700 and 2900 rpm). The friction pressure of 10 MPa and friction time of 30 s was kept constant. The cross sections of joints were observed by optical microscopy. The microstructures were analyzed using scanning electron microscope/energy dispersive X-ray spectroscopy. The Vickers micro hardness measurement of the interface was evaluated using a micro hardness testing machine. Finally the results obtained were compared and discussed.

Keywords: Aluminum alloy, powder metallurgy, friction welding, microstructure

Procedia PDF Downloads 349

Authors: M.St. Węglowski, D. Miara, S. Błacha, J. Dworak, J. Rykała, K. Kwieciński, J. Pikuła, G. Ziobro, A. Szafron, P. Zimierska-Nowak, M. Richert, P. Noga

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In the paper the results of welding of car’s air-conditioning elements are presented. These systems based on, mainly, the environmental unfriendly refrigerants. Thus, the producers of cars will have to stop using traditional refrigerant and to change it to carbon dioxide (R744). This refrigerant is environmental friendly. However, it should be noted that the air condition system working with R744 refrigerant operates at high temperature (up to 150 °C) and high pressure (up to 130 bar). These two parameters are much higher than for other refrigerants. Thus new materials, design as well as joining technologies are strongly needed for these systems. AISI 304 and 316L steels as well as aluminium alloys 5xxx are ranked among the prospective materials. As a joining process laser welding, plasma welding, electron beam welding as well as high rotary friction welding can be applied. In the study, the metallographic examination based on light microscopy as well as SEM was applied to estimate the quality of welded joints. The analysis of welding was supported by numerical modelling based on Sysweld software. The results indicated that using laser, plasma and electron beam welding, it is possible to obtain proper quality of welds in stainless steel. Moreover, high rotary friction welding allows to guarantee the metallic continuity in the aluminium welded area. The metallographic examination revealed that the grain growth in the heat affected zone (HAZ) in laser and electron beam welded joints were not observed. It is due to low heat input and short welding time. The grain growth and subgrains can be observed at room temperature when the solidification mode is austenitic. This caused low microstructural changes during solidification. The columnar grain structure was found in the weld metal. Meanwhile, the equiaxed grains were detected in the interface. The numerical modelling of laser welding process allowed to estimate the temperature profile in the welded joint as well as predicts the dimensions of welds. The agreement between FEM analysis and experimental data was achieved.  

Keywords: car’s air–conditioning, microstructure, numerical modelling, welding

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Authors: Nandhini Ravi, Muthukumaran Shanmugam

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Metals are being replaced by thermoplastic polymer composites in automotive industries because of their low density, easiness to fabricate, low cost and good wear resistance. Complex polymer components consist of assemblies of smaller parts which can be joined by friction stir welding. This study deals with the additive friction stir welding of 15 wt.% glass fiber reinforced polyamide 66 composite which is a modified technique of the conventional friction stir welding by the addition of a filler plate for the heating of the composite work piece through the tool during the welding process. Welding at different combinations of tool rotational speed, travel speed and tool plunge depth was done after which the tensile strength of the respective experiments was determined. The maximum tensile strength obtained was 77 MPa which was 80% of the strength of the base material. The process parameters were optimized using the L9 orthogonal array and also the effect of individual welding parameter on the tensile strength was studied. The optimum parameter combination was determined with the help of ANOVA studies. The hardness of the welded joints was studied with the help of Shore Durometer which yielded the maximum of D 75.

Keywords: additive friction stir welding, polyamide 66, process parameters, thermoplastic polymer composite

Procedia PDF Downloads 136

Authors: Khalil Aghapouramin

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The aim of the present work is to investigate the mechanical and microstructural properties of dissimilar and similar aluminum alloys welded by Friction Stir Welding (FSW). The specimens investigated by applying different welding speed and rotary speed. Typically, mechanical properties of the joints performed through tensile test fatigue test and microhardness (HV) at room temperature. Fatigue test investigated by using electromechanical testing machine under constant loading control with similar since wave loading. The Maximum stress versus minimum got the range between 0.1 to 0.3 in the research. Based upon welding parameters by optical observation and scanning electron microscopy microstructural properties fulfilled with a cross section of welds, in addition, SEM observations were made of the fracture surfaces

Keywords: friction stir welding, fatigue and tensile test, Al alloys, microstructural behavior

Procedia PDF Downloads 319

Authors: Zahra Emami, H. Reza Mesgarzade, A. Morad Ghorbami, S. Reza Motahari

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This paper presents a method for calculation of parasitic elements consisting of leakage inductance and parasitic capacitance in a high voltage pulse transformer. The parasitic elements of pulse transformers significantly influence the resulting pulse shape of a power modulator system. In order to prevent the effects on the pulse shape before constructing the transformer an electrical model is needed. The technique procedures for computing these elements are based on finite element analysis. The finite element model of pulse transformer is created using software "Ansys Maxwell 3D". Finally, the transformer parasitic elements is calculated and compared with the value obtained from the actual test and pulse modulator is simulated and results is compared with actual test of pulse modulator. The results obtained are very similar with the test values.

Keywords: pulse transformer, simulation, modeling, Maxwell 3D, modulator

Procedia PDF Downloads 441

Authors: G. Rajyalakhmi, C. Karthik, Gerson Desouza, Rimmie Duraisamy

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In this present work, metal matrix composites with combination of aluminium with (Sic/Al2O3) were fabricated using stir casting technique. The objective of the present work is to optimize the process parameters of Wire Electric Discharge Machining (WEDM) composites. Pulse ON Time, Pulse OFF Time, wire feed and sensitivity are considered as input process parameters with responses Material Removal Rate (MRR), Surface Roughness (SR) for optimization of WEDM process. Taguchi L18 Orthogonal Array (OA) is used for experimentation. Grey Relational Analysis (GRA) is coupled with Taguchi technique for multiple process parameters optimization. ANOVA (Analysis of Variance) is used for finding the impact of process parameters individually. Finally confirmation experiments were carried out to validate the predicted results.

Keywords: parametric optimization, particulate reinforced metal matrix composites, Taguchi-grey relational analysis, WEDM

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Authors: Suchi Barua, Narottam Das, Sven Nordholm, Mohammad Razaghi

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This paper presents nonlinear pulse propagation characteristics for different input optical pulse shapes with various input pulse energy levels in semiconductor optical amplifiers. For simulation of nonlinear pulse propagation, finite-difference beam propagation method is used to solve the nonlinear Schrödinger equation. In this equation, gain spectrum dynamics, gain saturation are taken into account which depends on carrier depletion, carrier heating, spectral-hole burning, group velocity dispersion, self-phase modulation and two photon absorption. From this analysis, we obtained the output waveforms and spectra for different input pulse shapes as well as for different input energies. It shows clearly that the peak position of the output waveforms are shifted toward the leading edge which due to the gain saturation of the SOA for higher input pulse energies. We also analyzed and compared the normalized difference of full-width at half maximum for different input pulse shapes in the SOA.

Keywords: finite-difference beam propagation method, pulse shape, pulse propagation, semiconductor optical amplifier

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Authors: Mustafa Kemal Bilici, Memduh Kurtulmuş, İlyas Kartal, Ahmet İrfan Yükler

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Friction stir welding is a solid-state joining process that has gained acceptable progress in recent years. This method which was first used for welding of aluminum and its alloys is now employed for welding of other materials such as polymers and composites. The aim of the present work is to investigate the mechanical properties of butt joints produced by friction stir welding (FSW) in high density polyethylene sheets of 4 mm thickness. The effects of critical welding parameters and tool design have affected on mechanical properties, weld surface and macrostructure of friction stir welded polyethylene. Experiments were performed at tool rotational speeds of 600, 900, 1200 and 1500 r/min and traverse speeds of 30, 45 and 60 mm/min, tool diameters (d) of 4, 5, 6 mm and tool shoulder diameters (D) 20, 25, 30 mm. A strength value of 80 % of the base material was achieved at the isolated optimum welding condition. According to the tool design, the welding parameters and the mechanical properties changed to a great extent. The highest tensile strength was achieved at low feed rates, high tool rotation speeds and shoulder diameters/pin diameters ratio.

Keywords: friction stir welding, mechanical properties, polyethylene, high density polyethylene, tool design

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Authors: Lingaraju Dumpala, Laxmi Mohan Kumar Chintada, Devadas Deepu, Pravin Kumar Yadav

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Friction stir welding is the new-fangled and cutting-edge technique in welding applications; it is widely used in the fields of transportation, aerospace, defense, etc. For thriving significant welding joints and properties of friction stir welded components, it is essential to carry out this advanced process in a prescribed systematic procedure. At this moment, Underwater Friction Stir Welding (UFSW) Process is the field of interest to do research work. In the continuous assessment, the study of UFSW process is to comprehend problems occurred in the past and the structure through which the mechanical properties of the welded joints can be value-added and contributes to conclude results an acceptable and resourceful joint. A meticulous criticism is given on how to modify the experimental setup from NFSW to UFSW. It can discern the influence of tool materials, feeds, spindle angle, load, rotational speeds and mechanical properties. By expending the DEFORM-3D simulation software, the achieved outcomes are validated.

Keywords: Underwater Friction Stir Welding(UFSW), Al alloys, mechanical properties, Normal Friction Stir Welding(NFSW)

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Authors: Mohamed Adel Abdallah

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A high voltage magnetic pulse is designed by applying an electrical pulse to the coil. Capacitor banks are developed to generate a pulse current. Switching circuit consisting of DPDT switches, thyristor, and triggering circuit is built and tested. The coil current is measured using a Hall-effect current sensor. The magnetic pulse created is measured and tabulated in the graph. Simulation using FEMM is done to compare the results obtained between experiment and simulation. This technology can be applied to area such as medical equipment, measuring instrument, and military equipment.

Keywords: high voltage, magnetic pulse, capacitor discharge, coil

Procedia PDF Downloads 661

Authors: Suwarsono, Ario S. Baskoro, Gandjar Kiswanto, Budiono

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Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and produces less distortion.FSW welding process for a light structure and thin materials requires small forces as possible, to avoid structure deflection. The joining process on FSW occurs because of melting temperature and compressive forces, the temperature generation of caused by material deformation and friction between the cutting tool and material. In this research, High speed rotation of spindle was expected to reduce the force required for deformation. The welding material was Aluminum A1100, with thickness of 0.4 mm. The tool was made of HSS material which was shaped by micro grinding process. Tool shoulder diameter is 4 mm, and the length of pin was 0.6 mm (with pin diameter= 1.5 mm). The parameters that varied were the plunge speed (2 mm/min, 3 mm/min, 4 mm/min). The tool speed is fixed at 33,000 rpm. Responses of FSSW parameters to analyze were Axial Force (Z-Force), Temperature and the Shear Strength of welds. Research found the optimum µFSSW parameters, it can be concluded that the most important parameters in the μFSSW process was plunge speed. lowest plunge speed (2 mm / min) causing the lowest axial force (110.40 Newton). The increases of plunge speed will increase the axial force (maximum Z-Farce= 236.03 Newton), and decrease the shear strength of welds.

Keywords: friction stir spot welding, aluminum A1100, plunge speed, axial force, shear strength

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Authors: Shuangxin Wu

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Superalloy ultra-thin-walled components occupy a considerable proportion of aero engines and play an increasingly important role in structural weight reduction and performance improvement. To solve problems such as high deformation resistance and poor formability at room temperature, the introduction of pulse current in the processing process can improve the plasticity of metal materials, but the influence mechanism of pulse current on the forming limit of superalloy ultra-thin sheet is not clear, which is of great significance for determining the material processing window and improving the micro-forming process. The effect of pulse current on the microstructure evolution of superalloy thin plates was observed by optical microscopy (OM) and X-ray diffraction topography (XRT) by applying pulse current to GH3039 with a thickness of 0.2mm under plane strain and uniaxial tensile states. Compared with the specimen without pulse current applied at the same temperature, the internal void volume fraction is significantly reduced, reflecting the non-thermal effect of pulse current on the growth of micro-pores. ED (electrically deforming) specimens have larger and deeper dimples, but the elongation is not significantly improved because the pulse current promotes the void coalescence process, resulting in material fracture. The electro-plastic phenomenon is more obvious in the plane strain state, which is closely related to the effect of stress triaxial degree on the void evolution under pulsed current.

Keywords: pulse current, superalloy, ductile fracture, void damage

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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

Procedia PDF Downloads 182

Authors: Upamanyu Majumder, Angshuman Das

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Friction Stir Welding (FSW) is a Solid-State joining process. Unlike fusion welding techniques it does not involve operation above the melting point temperature of metals, but above the re-crystallization temperature. FSW also does not involve fusion of other material. FSW of ALUMINIUM has been commercialized and recent studies on joining dissimilar metals have been studied. Friction stir welding was introduced and patented in 1991 by The Welding Institute. For this paper, a total of nine samples each of copper and ALUMINIUM(Dissimilar metals) were welded using FSW process and Vickers Hardness were conducted on each of the samples.

Keywords: friction stir welding (FSW), recrystallization temperature, dissimilar metals, aluminium-copper, Vickers hardness test

Procedia PDF Downloads 339

Authors: Saliha Gachi, Mouloud Aissani, Fouad Boubenider

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Friction Stir Welding (FSW) is a solid-state welding technique that can join material without melting the plates to be welded. In this work, we are interested to demonstrate the potentiality of FSW for joining the heat-treatable aluminum alloy 2024-T3 which is reputed as difficult to be welded by fusion techniques. Thereafter, the FSW joint is compared with another one obtained from a conventional fusion process Tungsten Inert Gas (TIG). FSW welds are made up using an FSW tool mounted on a milling machine. Single pass welding was applied to fabricated TIG joint. The comparison between the two processes has been made on the temperature evolution, mechanical and microstructure behavior. The microstructural examination revealed that FSW weld is composed of four zones: Base metal (BM), Heat affected zone (HAZ), Thermo-mechanical affected zone (THAZ) and the nugget zone (NZ). The NZ exhibits a recrystallized equiaxed refined grains that induce better mechanical properties and good ductility compared to TIG joint where the grains have a larger size in the welded region compared with the BM due to the elevated heat input. The microhardness results show that, in FSW weld, the THAZ contains the lowest microhardness values and increase in the NZ; however, in TIG process, the lowest values are localized on the NZ.

Keywords: friction stir welding, tungsten inert gaz, aluminum, microstructure

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Authors: Kimia Khoshdel Vajari, Saber Saffar

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Reducing the residual stresses caused by welding is desirable for the industry. The effect of welding sequence, as well as the effect of yield stress on the number of residual stresses generated in Inconel X750 superalloy sheets and beams, have been investigated. The finite element model used in this research is a three-dimensional thermal and mechanical model, and the type of analysis is indirect coupling. This analysis is done in two stages. First, thermal analysis is performed, and then the thermal changes of the first analysis are used as the applied load in the second analysis. ABAQUS has been used for modeling, and the Dflux subroutine has been used in the Fortran programming environment to move the arc and the molten pool. The results of this study show that the amount of tensile residual stress in symmetric, discontinuous, and symmetric-discontinuous welds is reduced to a maximum of 27%, 54%, and 37% compared to direct welding, respectively. The results also show that the amount of residual stresses created by welding increases linearly with increasing yield stress with a slope of 40%.

Keywords: residual stress, X750 superalloy, finite element, welding, thermal analysis

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Authors: Sori Won, Bosung Seo, Kwangsuk Park, Seok Hong Min, Tae Kwon Ha

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With the increased needs for lightweight materials in automobile industry, the usage of aluminum alloys becomes prevailed as components and car bodies due to their comparative specific strength. These parts composed of different aluminum alloys should be connected each other, where welding technologies are commonly applied. Among various welding methods, friction welding method as a solid state welding gets to be popular in joining aluminum alloys as it does not produce a defect such as blowhole that is often formed during typical welding processes. Once two metals are joined, corrosion would become an issue due to different electrochemical potentials. In this study, we investigated variations of corrosion properties when Duralumin and AA6063 were joined by friction welding. From the polarization test, it was found that the potential of the welded was placed between those of two original metals, which could be explained by a concept of mixed potential. Pitting is a common form as a result of the corrosion of aluminum alloys when they are exposed to 3.5 wt% NaCl solution. However, when two different aluminum alloys (Duralumin and AA6063) were joined, pitting corrosion occurred severely and uniformly in Duralumin while there were a few pits around precipitates in AA6063, indicating that AA6063 was cathodically protected.

Keywords: corrosion properties, friction welding, dissimilar Al alloys, polarization test

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Authors: Sukhdeep Singh Gill, Gurbhinder Singh Brar

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In recent years, friction stir welding (FSW) has attracted the main attention of the concerned researcher especially in case of joining of nonferrous alloys like aluminum and magnesium due to its unmatchable properties with respect to other welding techniques. Friction stir welding is a solid state welding process which is most suitable for the welding of nonferrous alloys, especially aluminum and magnesium alloys. Aluminum and magnesium alloys are widely used for structural applications of all types of automobiles due to their superior mechanical properties with their low density. This paper deals with the critical review of the different properties (like tensile strength, microhardness, impact strength, corrosion resistance, and metallurgical investigation on SEM) obtained by the FSW of aluminum and magnesium alloys. After a critical review of the existing published literature on concerned topics, all the properties of welding joins are compared in the tabulated manner to optimize the selection of materials and FSW parameters according to mechanical and tribological properties. Different tool designs used for the FSW process are also thoroughly studied, and the influence of the design of the tool used in FSW on the different properties has also been incorporated in this paper. It has been observed from the existing published literature that FSW is the most effective and practical technique for joining the non ferrous alloys especially aluminum and magnesium alloys, and among the different FSW tools, left hand threaded tri-flute (LHTTF) tool is best for the welding of non ferrous alloys like aluminum and magnesium alloys which gives the superior mechanical properties to welding joint.

Keywords: aluminum, friction stir welding, magnesium, structural applications, tool design

Procedia PDF Downloads 157

Authors: Tran Hung Tra, Hao Dinh Duong, Masakazu Okazaki

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Copper 1100 and aluminum 1050 plates with a thickness of 5.0 mm are butt-joint using friction stir welding. The tool offset is linearly varied along the welding path. Two welding regimes, using the same linear tool offset but in opposite directions, are applied for fabricating two Cu/Al plates. The material flow is dominated by both tool offset and offset history. The intermetallic compounds layer and interface morphology in each welded plate are formed in a different manner. As a result, the bonding strength and fracture behavior between two welded plates are significantly distinct. The role of interface morphology on fracture behavior is analyzed by the finite element method.

Keywords: Cu/Al dissimilar welding, offset history, interface morphology, intermetallic compounds, strength and fracture

Procedia PDF Downloads 58

Authors: Ahmet Taşan, Süha Tirkeş, Yavuz Öztürk, Zafer Bingül

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Friction stir welding (FSW) is a joining process in the solid state, which eliminates problems associated with the material melting and solidification, such as cracks, residual stresses and distortions generated during conventional welding. Among the most important advantages of FSW are; easy automation, less distortion, lower residual stress and good mechanical properties in the joining region. FSW is a recent approach to metal joining and although originally intended for aluminum alloys, it is investigated in a variety of metallic materials. The basic concept of FSW is a rotating tool, made of non-consumable material, specially designed with a geometry consisting of a pin and a recess (shoulder). This tool is inserted as spinning on its axis at the adjoining edges of two sheets or plates to be joined and then it travels along the joining path line. The tool rotation axis defines an angle of inclination with which the components to be welded. This angle is used for receiving the material to be processed at the tool base and to promote the gradual forge effect imposed by the shoulder during the passage of the tool. This prevents the material plastic flow at the tool lateral, ensuring weld closure on the back of the pin. In this study, two 4 mm Kevlar^® plates which were produced with the Kevlar^® fabrics, are analyzed with COMSOL Multiphysics in order to investigate the weldability via FSW. Thereafter, some experimental investigation is done with an appropriate workbench in order to compare them with the analysis results.

Keywords: analytical modeling, composite materials welding, friction stir welding, heat generation

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Authors: Ahmed Hammad, Yehia Abdel-Nasser, Mohamed Shamma

Abstract:

The main configuration of ship construction consists of standard and fabricated stiffening members which are commonly used in shipbuilding such as fabricated T-sections. During the welding process, the non-uniform heating and rapid cooling lead to the inevitable presence of out-of-plane distortion and welding induced residual stresses. Because of these imperfections, the fabricated structural members may not attain their design load to be carried. The removal of these imperfections will require extra man-hours. In the present work, controlling these imperfections has been investigated at both design and fabrication stages. A typical fabricated T-girder is selected to investigate the problem of these imperfections using double-side welding. A numerical simulation based on finite element (FE) modeling has been used to investigate the effect of different parameters of the selected fabricated T-girder such as geometrical properties and welding sequences on the magnitude of welding imperfections. FE results were compared with the results of experimental model of a double-side fillet weld. The present work concludes that: Firstly, in the design stage, the optimum geometry of the fabricated T- girder is determined based on minimum steel weight and out- of- plane distortion. Secondly, in the fabrication stage, the best welding sequence is determined on the basis of minimum welding out- of- plane distortion.

Keywords: fabricated T-girder, FEM, out-of-plane distortion, section modulus, welding residual stresses

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