Search results for: Flux Cored Arc Welding (FCAW)

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

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Joining of 1 mm thick aluminum 6061 to titanium TC4 was conducted using Bypass-current MIG welding-brazed, and stable welding process and good bead appearance were obtained. The Joint profile and microstructure of Ti/Al joints were observed by optical microscopy and SEM and then the structure of the interfacial reaction layers were analyzed in details. It was found that the intermetallic compound layer at the interfacial top is in the form of columnar crystal, which is in short and dense state. A mount of AlTi were observed at the interfacial layer near the Ti base metal while intermetallic compound like Al3Ti、TiSi3 were formed near the Al base metal, and the Al11Ti5 transition phase was found in the center of the interface layer due to the uneven distribution inside the weld pool during the welding process. Tensile test results show that the average tensile strength of joints is up to 182.6 MPa, which reaches about 97.6% of aluminum base metal. Fracture is prone to occur in the base metal with a certain amount of necking.

Keywords: bypass-current MIG welding-brazed, Al alloy, Ti alloy, joint characteristics, mechanical properties

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Authors: Manish Chand, Subhrojit Bagchi, R. Kumar

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A new dry tube (DT) has been installed in the tank of KAMINI research reactor, Kalpakkam India. This tube will be used for neutron activation analysis of small to large samples and testing of neutron detectors. DT tube is 375 cm height and 7.5 cm in diameter, located 35 cm away from the core centre. The experimental thermal flux at various axial positions inside the tube has been measured by irradiating the flux monitor (¹⁹⁷Au) at 20kW reactor power. The measured activity of ¹⁹⁸Au and the thermal cross section of ¹⁹⁷Au (n,γ) ¹⁹⁸Au reaction were used for experimental thermal flux measurement. The flux inside the tube varies from 10⁹ to 10¹⁰ and maximum flux was (1.02 ± 0.023) x10¹⁰ n cm⁻²s⁻¹ at 36 cm from the bottom of the tube. The Au and Zr foils without and with cadmium cover of 1-mm thickness were irradiated at the maximum flux position in the DT to find out the irradiation specific input parameters like sub-cadmium to epithermal neutron flux ratio (f) and the epithermal neutron flux shape factor (α). The f value was 143 ± 5, indicates about 99.3% thermal neutron component and α value was -0.2886 ± 0.0125, indicates hard epithermal neutron spectrum due to insufficient moderation. The measured flux profile has been validated using theoretical model of KAMINI reactor through Monte Carlo N-Particle Code (MCNP). In MCNP, the complex geometry of the entire reactor is modelled in 3D, ensuring minimum approximations for all the components. Continuous energy cross-section data from ENDF-B/VII.1 as well as S (α, β) thermal neutron scattering functions are considered. The neutron flux has been estimated at the corresponding axial locations of the DT using mesh tally. The thermal flux obtained from the experiment shows good agreement with the theoretically predicted values by MCNP, it was within ± 10%. It can be concluded that this MCNP model can be utilized for calculating other important parameters like neutron spectra, dose rate, etc. and multi elemental analysis can be carried out by irradiating the sample at maximum flux position using measured f and α parameters by k₀-NAA standardization.

Keywords: neutron flux, neutron activation analysis, neutron flux shape factor, MCNP, Monte Carlo N-Particle Code

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Authors: Ola Jon Mork, Lars Andre Giske, Emil Bjørlykhaug

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Stabilization of critical processes in order to have the right quality of the products, more efficient production and smoother flow is a key issue in lean production. This paper presents how simulation of key welding processes can stabilize complicated welding processes in small scale production, and how simulation can impact the entire production concept seen from the perspective of lean production. First, a field study was made to learn the production processes in the factory, and subsequently the field study was transformed into a value stream map to get insight into each operation, the quality issues, operation times, lead times and flow of materials. Valuable practical knowledge of how the welding operations were done by operators, appropriate tools and jigs, and type of robots that could be used, was collected. All available information was then implemented into a simulation environment for further elaboration and development. Three researchers, the management of the company and skilled operators at the work floor where working on the project over a period of eight months, and a detailed description of the process was made by the researchers. The simulation showed that simulation could solve a number of technical challenges, the robot program can be tuned in off line mode, and the design and testing of the robot cell could be made in the simulator. Further on the design of the product could be optimized for robot welding and the jigs could be designed and tested in simulation environment. This means that a key issue of lean production can be solved; the welding operation will work with almost 100% performance when it is put into real production. Stabilizing of one key process is critical to gain control of the entire value chain, then a Takt Time can be established and the focus can be directed towards the next process in the production which should be stabilized. Results show that industrial parameters like welding time, welding cost and welding quality can be defined on the simulation stage. Further on, this gives valuable information for calculation of the factories business performance, like manufacturing volume and manufacturing efficiency. Industrial impact from simulation is more efficient implementation of lean manufacturing, since the welding process can be stabilized. More research should be done to gain more knowledge about simulation as a tool for implementation of lean, especially where there complex processes.

Keywords: simulation, lean, stabilization, welding process

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Authors: Seyedmilad Kazemisangdehi, Seyedmehdi Kazemisangdehi

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Flux switching permanent magnet machines are considered for wide range of applications because of their outstanding merits including high torque/power densities, high efficiency, simple and robust rotor structure. Therefore, several topologies have been proposed like the PM exited flux switching machine, hybrid excited flux switching type, and so on. Recently, a novel laminated segmented rotor flux switching permanent magnet machine was introduced. It features flux barriers on rotor structure to enhance the performances of machine including torque ripple reduction and also torque and efficiency improvements at the same time. This is while, the design of barriers was not optimized by the authors. Therefore, in this paper three coefficients regarding the position of the barriers are considered for optimization. The effect of each coefficient on the performance of this machine is investigated by finite element method and finally an optimized design of flux barriers based on these three coefficients is proposed from different points of view including electromagnetic torque maximization and cogging torque/torque ripple minimization. At optimum design from maximum developed torque aspect, this machine generates 0.65 Nm torque higher than that of the not-optimized design with an almost 0.4 % improvement in efficiency.

Keywords: finite element analysis, FSPM, laminated segmented rotor flux switching permanent magnet machine, optimization

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Authors: Fadi Al-Badour, Nesar Merah, Abdelrahman Shuaib, Abdelaziz Bazoune

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In the current work, a Coupled Eulerian Lagrangian (CEL) model is developed to simulate the friction stir welding (FSW) process of dissimilar Aluminum alloys (Al 6061-T6 with Al 5083-O). The model predicts volumetric defects, material flow, developed temperatures, and stresses in addition to tool reaction loads. Simulation of welding phase is performed by employing a control volume approach, whereas the welding speed is defined as inflow and outflow over Eulerian domain boundaries. Only material softening due to inelastic heat generation is considered and material behavior is assumed to obey Johnson-Cook’s Model. The model was validated using published experimentally measured temperatures, at similar welding conditions, and by qualitative comparison of dissimilar weld microstructure. The FE results showed that most of developed temperatures were below melting and that the bulk of the deformed material in solid state. The temperature gradient on AL6061-T6 side was found to be less than that of Al 5083-O. Changing the position Al 6061-T6 from retreating (Ret.) side to advancing (Adv.) side led to a decrease in maximum process temperature and strain rate. This could be due to the higher resistance of Al 6061-T6 to flow as compared to Al 5083-O.

Keywords: friction stir welding, dissimilar metals, finite element modeling, coupled Eulerian Lagrangian Analysis

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Authors: A. Al-Sayyad, P. Lama, J. Bardon, P. Hirchenhahn, L. Houssiau, P. Plapper

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Composite metal–polymer materials, in particular titanium alloy (Ti-6Al-4V) to polyamide (PA6.6), fabricated by laser joining, have gained cogent interest among industries and researchers concerned with aerospace and biomedical applications. This work adopts infrared (IR) thermography technique to investigate effects of laser parameters used in the welding process on the three-dimensional temperature profile at the rear-side of titanium, at the region to be welded with polyamide. Cross sectional analysis of welded joints showed correlations between the morphology of titanium and polyamide at the weld zone with the corresponding temperature profile. In particular, spatial temperature profile was found to be correlated with the laser beam energy density, titanium molten pool width and depth, and polyamide heat affected zone depth.

Keywords: laser welding, metals to polymers joining, process monitoring, temperature profile, thermography

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Authors: Seyedeh Fatemeh Nabavi, Hamid Dalir, Anooshiravan Farshidianfar

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Laser welding is pivotal in modern manufacturing, offering unmatched precision, speed, and efficiency. Its versatility in minimizing heat-affected zones, seamlessly joining dissimilar materials, and working with various metals makes it indispensable for crafting intricate automotive components. Integration into automated systems ensures consistent delivery of high-quality welds, thereby enhancing overall production efficiency. Noteworthy are the safety benefits of laser welding, including reduced fumes and consumable materials, which align with industry standards and environmental sustainability goals. As the automotive sector increasingly demands advanced materials and stringent safety and quality standards, laser welding emerges as a cornerstone technology. A comprehensive model encompassing thermal dynamic and characteristics models accurately predicts geometrical, metallurgical, and mechanical aspects of the laser beam welding process. Notably, Model 2 showcases exceptional accuracy, achieving remarkably low error rates in predicting primary and secondary dendrite arm spacing (PDAS and SDAS). These findings underscore the model's reliability and effectiveness, providing invaluable insights and predictive capabilities crucial for optimizing welding processes and ensuring superior productivity, efficiency, and quality in the automotive industry.

Keywords: laser welding process, geometrical characteristics, mechanical characteristics, metallurgical characteristics, comprehensive model, thermal dynamic

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Authors: Thammarak Srimarut, Witthaya Mekhum

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This study analysed and developed a model for monk’s food bowl production on occupational health safety and environment at work for the encouragement of Rattanakosin local wisdom at Banbart Community. The process of blowpipe welding was necessary to produce the bowl which was very dangerous or 93.59% risk. After the employment of new sitting posture, the work risk was lower 48.41% or moderate risk. When considering in details, it was found that: 1) the traditional sitting posture could create work risk at 88.89% while the new sitting posture could create the work risk at 58.86%. 2) About the environmental pollution, with the traditional sitting posture, workers exposed to the polluted fume from welding at 61.11% while with the new sitting posture workers exposed to the polluted fume from welding at 40.47%. 3) On accidental risk, with the traditional sitting posture, workers exposed to the accident from welding at 94.44% while with the new sitting posture workers exposed to the accident from welding at 62.54%.

Keywords: occupational health safety, environment at work, Monk’s food bowl, machine intelligence

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Authors: Ahbdelfattah M. Khourshid, T. Elabeidi

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Friction Stir Welding (FSW), a solid state joining technique, is widely being used for joining Al alloys for aerospace, marine automotive and many other applications of commercial importance. FSW were carried out using a vertical milling machine on Al 5083 alloy pipe. These pipe sections are relatively small in diameter, 5mm, and relatively thin walled, 2mm. In this study, 5083 aluminum alloy pipe were welded as similar alloy joints using (FSW) process in order to investigate mechanical and microstructural properties .rotation speed 1400 r.p.m and weld speed 10,40,70 mm/min. In order to investigate the effect of welding speeds on mechanical properties, metallographic and mechanical tests were carried out on the welded areas. Vickers hardness profile and tensile tests of the joints as a metallurgical investigation, Optic Microscopy and Scanning Electron Microscopy (SEM) were used for base and weld zones.

Keywords: friction stir welding (FSW), Al alloys, mechanical properties, microstructure

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Authors: Harish K. Arya, Kulwant Singh, R. K. Saxena

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The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on penetration and bead width. The penetration reduces with increase in plate thickness due to heat loss in thickness direction for same heat input, while bead width increases for thicker plate due to faster cooling.

Keywords: submerged arc welding, plate thickness, bead geometry, cooling rate

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Authors: Harish Kumar Arya, Kulwant Singh, R. K Saxena, Deepti Jaiswal

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The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on bead geometry and dilution. The penetration reduces with increase in plate thickness due to heat loss in thickness direction, while bead width and reinforcement increases for thicker plate due to faster cooling.

Keywords: submerged arc welding, plate thickness, bead geometry, cooling rate

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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: S. Holly, R. Schnitzer, P. Haslberger, D. Zügner

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The development of new filler consumables necessitates a high effort regarding samples and experiments to achieve the required mechanical properties and chemistry. In the scope of the development of a metal-cored wire with the target tensile strength of 1150 MPa and acceptable impact toughness, thermodynamic and kinetic calculations via MatCalc were used to reduce the experimental work and the resources required. Micro alloying elements were used to reach the high strength as an alternative approach compared to the conventional solid solution hardening. In order to understand the influence of different micro alloying elements in more detail, the influence of different elements on the precipitation behavior in the weld metal was evaluated. Investigations of the microstructure were made via atom probe and EBSD to understand the effect of micro alloying elements. The calculated results are in accordance with the results obtained by experiments and can be explained by the microstructural investigations. On the example of aluminium, the approach is exemplified and clarifies the efficient way of development.

Keywords: alloy development, high strength steel, MatCalc, metal-cored wire

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Authors: Ehsan Motamedian

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Finding all optimal flux distributions of a metabolic model is an important challenge in systems biology. In this paper, a new algorithm is introduced to identify all alternate optimal solutions of a large scale metabolic network. The algorithm reduces the model to decrease computations for finding optimal solutions. The algorithm was implemented on the Escherichia coli metabolic model to find all optimal solutions for lactate and acetate production. There were more optimal flux distributions when acetate production was optimized. The model was reduced from 1076 to 80 variable fluxes for lactate while it was reduced to 91 variable fluxes for acetate. These 11 more variable fluxes resulted in about three times more optimal flux distributions. Variable fluxes were from 12 various metabolic pathways and most of them belonged to nucleotide salvage and extra cellular transport pathways.

Keywords: flux variability, metabolic network, mixed-integer linear programming, multiple optimal solutions

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Authors: Philip Baillie, Stuart W. Campbell, Alexander M. Galloway, Stephen R. Cater, Norman A. McPherson

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This study compared the mechanical and microstructural properties produced during friction stir welding(FSW) of S275 structural steel in air and underwater. Post weld tests assessed the tensile strength, micro-hardness, distortion, Charpy impact toughness and fatigue performance in each case. The study showed that there was no significant difference in the strength, hardness or fatigue life of the air and underwater specimens. However, Charpy impact toughness was shown to decrease for the underwater specimens and was attributed to a lower degree of recrystallization caused by the higher rate of heat loss experienced when welding underwater. Reduced angular and longitudinal distortion was observed in the underwater welded plate compared to the plate welded in air.

Keywords: Charpy impact toughness, distortion, fatigue, friction stir welding(FSW), micro-hardness, underwater

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Authors: Jia-Jia He, Lin Jiang, Jin-Hua Sun

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Rigid polyurethane foam (RPU) has been extensively applied in building insulation system, yet with high flammability for being easily ignited by high temperature spark or radiative heat flux from other flaming materials or surrounding building facade. Using a cone calorimeter by Fire Testing Technology and thermal couple tree, this study systematically investigated the effect of radiative heat flux on the ignition time and characteristic temperature distribution during RPU combustion under different heat fluxes gradient (12, 15, 20, 25, 30, 35, 40, 45, and 50 kW/m²) with spark ignition/ignition by radiation. The ignition time decreases proportionally with increase of external heat flux, meanwhile increasing the external heat flux raises the peak heat release rate and impresses on the vertical temperature distribution greatly. The critical ignition heat flux is found to be 15 and 25 kW/m² for spark ignition and radiative ignition, respectively. Based on previous experienced ignition formula, a methodology to predict ignition times in both modes has been developed theoretically. By analyzing the heat transfer mechanism around the sample surroundings, both radiation from cone calorimeter and convection flow are considered and calculated theoretically. The experimental ignition times agree well with the theoretical ones in both radiative and convective conditions; however, the observed critical ignition heat flux is higher than the calculated one under piloted-ignition mode because the heat loss process, especially in lower heat flux radiation, is not considered in this developed methodology.

Keywords: rigid polyurethane foam, cone calorimeter, ignition time, external heat flux

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Authors: Stuart W. Campbell, Alexander M. Galloway, Norman A. McPherson, Duncan Camilleri, Daniel Micallef

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Gas tungsten arc welding requires a gas shield to be present in order to protect the arc area from contamination by atmospheric gases. As a result of each gas having its own unique thermophysical properties, the shielding gas selected can have a major influence on the arc stability, welding speed, weld appearance and geometry, mechanical properties and fume generation. Alternating shielding gases is a relatively new method of discreetly supplying two different shielding gases to the welding region in order to take advantage of the beneficial properties of each gas, as well as the inherent pulsing effects generated. As part of an ongoing process to fully evaluate the effects of this novel supply method, a computational fluid dynamics model has been generated to include the gas dependent thermodynamic and transport properties in order to evaluate the effects that an alternating gas supply has on the arc plasma. Experimental trials have also been conducted to validate the model arc profile predictions.

Keywords: Alternating shielding gases, ANSYS CFX, Gas tungsten arc welding(GTAW), magnetohydrodynamics(MHD)

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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: Natheer Alatawneh

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The finite element analysis of magnetic fields in electromagnetic devices shows that the machine cores experience different flux patterns including alternating and rotating fields. The rotating fields are generated in different configurations range between circular and elliptical with different ratios between the major and minor axis of the flux locus. Experimental measurements on electrical steel exposed to different flux patterns disclose different magnetic losses in the samples under test. Consequently, electric machines require special attention during the cores loss calculation process to consider the flux patterns. In this study, a circular rotational single sheet tester is employed to measure the core losses in electric steel sample of M36G29. The sample was exposed to alternating field, circular field, and elliptical fields with axis ratios of 0.2, 0.4, 0.6 and 0.8. The measured data was implemented on 6-4 switched reluctance motor at three different frequencies of interest to the industry as 60 Hz, 400 Hz, and 1 kHz. The results disclose a high margin of error that may occur during the loss calculations if the flux patterns issue is neglected. The error in different parts of the machine associated with considering the flux patterns can be around 50%, 10%, and 2% at 60Hz, 400Hz, and 1 kHz, respectively. The future work will focus on the optimization of machine geometrical shape which has a primary effect on the flux pattern in order to minimize the magnetic losses in machine cores.

Keywords: alternating core losses, electric machines, finite element analysis, rotational core losses

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Authors: Qian You, Ibrahim Hassan, Lyes Kadem

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An experiment is conducted to fundamentally investigate flow oscillation characteristics in different sizes of single microtubes in vertical upward flow direction. Three microtubes have 0.889 mm, 0.533 mm, and 0.305 mm hydraulic diameters with 100 mm identical heated length. The mass flux of the working fluid FC-72 varies from 700 kg/m2•s to 1400 kg/m2•s, and the heat flux is uniformly applied on the tube surface up to 9.4 W/cm2. The subcooled inlet temperature is maintained around 24°C during the experiment. The effect of hydraulic diameter and mass flux are studied. The results showed that they have interactions on the flow oscillations occurrence and behaviors. The onset of flow instability (OFI), which is a threshold of unstable flow, usually appears in large microtube with diversified and sustained flow oscillations, while the transient point, which is the point when the flow turns from one stable state to another suddenly, is more observed in small microtube without characterized flow oscillations due to the bubble confinement. The OFI/transient point occurs early as hydraulic diameter reduces at a given mass flux. The increased mass flux can delay the OFI/transient point occurrence in large hydraulic diameter, but no significant effect in small size. Although the only transient point is observed in the smallest tube, it appears at small heat flux and is not sensitive to mass flux; hence, the smallest microtube is not recommended since increasing heat flux may cause local dryout.

Keywords: flow boiling instability, hydraulic diameter effect, a single microtube, vertical upward flow

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Authors: Mohammed A. Tashkandi, Jawdat A. Al-Jarrah, Masoud Ibrahim

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This paper investigates the shear strength of the joints produced by friction stir spot welding process (FSSW). FSSW parameters such as tool rotational speed, plunge depth, shoulder diameter of the welding tool and dwell time play the major role in determining the shear strength of the joints. The effect of these four parameters on FSSW process as well as the shear strength of the welded joints was studied via five levels of each parameter. Taguchi method was used to minimize the number of experiments required to determine the fracture load of the friction stir spot-welded joints by incorporating independently controllable FSSW parameters. Taguchi analysis was applied to optimize the FSSW parameters to attain the maximum shear strength of the spot weld for this type of aluminum alloy.

Keywords: Friction Stir Spot Welding, Al6061 alloy, Shear Strength, FSSW process parameters

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Authors: Egoitz Aldanondo, Ekaitz Arruti, Amaia Iturrioz, Ivan Huarte, Fidel Zubiri

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Manufacturing aeronautic structures joining extruded profiles or stringers to sheets or skins of aluminium is a typical manufacturing procedure in aeronautic structures. Although riveting is the conventional manufacturing technology to produce such joints, the Friction Stir Welding (FSW) and Laser Beam Welding (LBW) technologies have also demonstrated their potential for this kind of applications. Therefore, FSW and LBW technologies have the potential to continue their development as manufacturing processes for aeronautic structures showing benefits such as time-saving, light-weighting and overall cost reduction. In addition to that, new aluminium-lithium based alloy developments represent great opportunities for advanced aeronautic structure manufacturing with potential benefits such as lightweight construction or improved corrosion resistance. This work presents the main approaches by FSW and LBW to develop those technologies to produce stiffened panel structures such as fuselage by stringer-skin joints and using innovative aluminium-lithium alloys. Initial welding tests were performed in AA2198-T3S aluminium alloys for LBW technology and with AA2198-T851 for FSW. Later tests for both FSW and LBW have been carried out using AA2099-T83 alloy extrusions as stringers and AA2060-T8E30 as skin materials. The weld quality and properties have been examined by metallographic analysis and mechanical testing, including shear tensile tests and pull-out tests. The analysis of the results have shown the relationships between processing conditions, micro-macrostructural properties and the mechanical strength of the welded joints. The effects produced in the different alloys investigated have been observed and particular weld formation mechanics have been studied for each material and welding technology. Therefore, relationships between welding conditions and the obtained weld properties for each material combination and welding technology will be discussed in this presentation.

Keywords: AA2060-T8E30, AA2099-T83, AA2198-T3S, AA2198-T851, friction stir welding, laser beam welding

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Authors: R. G. Ramírez-Chavarría, C. Sánchez-Pérez, V. Argueta-Díaz

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In this paper we present the design of an optical device based on a Herriott multi-pass cell fabricated on a small sized acrylic slab for heat flux measurements using the deflection of a laser beam propagating inside the cell. The beam deflection is produced by the heat flux conducted to the acrylic slab due to a gradient in the refractive index. The use of a long path cell as the sensitive element in this measurement device, gives the possibility of high sensitivity within a small size device. We present the optical design as well as some experimental results in order to validate the device’s operation principle.

Keywords: heat flux, Herriott cell, optical beam deflection, thermal conductivity

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Authors: Mohamed Moustafa Mahmoud Sedky

Abstract:

The double-fed induction generator wind turbine has recently received a great attention. The steady state performance and response of double fed induction generator (DFIG) based wind turbine are now well understood. This paper presents the analysis of stator and rotor flux linkage dq models operation of DFIG under different faults and at different locations.

Keywords: double fed induction motor, wind energy, flux linkage, short circuit

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Authors: Blanca A. Pichardo, Victor H. Lopez, Melchor Salazar, Rafael Garcia, Alberto Ruiz

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Clad pipes in comparison to plain carbon steel pipes offer the oil and gas industry high corrosion resistance, reduction in economic losses due to pipeline failures and maintenance, lower labor risk, prevent pollution and environmental damage due to hydrocarbons spills caused by deteriorated pipelines. In this context, it is paramount to establish reliable welding procedures to join bimetallic plates or pipes. Thus, the aim of this work is to study the microstructure and mechanical behavior of clad plates welded by the gas metal arc welding (GMAW) process. A clad of 316L stainless steel was deposited onto API 5L X-60 plates by overlay welding with the GMAW process. Welding parameters were, 22.5 V, 271 A, heat input 1,25 kJ/mm, shielding gas 98% Ar + 2% O₂, reverse polarity, torch displacement speed 3.6 mm/s, feed rate 120 mm/s, electrode diameter 1.2 mm and application of an electromagnetic field of 3.5 mT. The overlay welds were subjected to macro-structural and microstructural characterization. After manufacturing the clad plates, a single V groove joint was machined with a 60° bevel and 1 mm root face. GMA welding of the bimetallic plates was performed in four passes with ER316L-Si filler for the root pass and an ER70s-6 electrode for the subsequent welding passes. For joining the clad plates, an electromagnetic field was applied with 2 purposes; to improve the microstructural characteristics and to assist the stability of the electric arc during welding in order to avoid magnetic arc blow. The welds were macro and microstructurally characterized and the mechanical properties were also evaluated. Vickers microhardness (100 g load for 10 s) measurements were made across the welded joints at three levels. The first profile, at the 316L stainless steel cladding, was quite even with a value of approximately 230 HV. The second microhardness profile showed high values in the weld metal, ~400 HV, this was due to the formation of a martensitic microstructure by dilution of the first welding pass with the second. The third profile crossed the third and fourth welding passes and an average value of 240 HV was measured. In the tensile tests, yield strength was between 400 to 450 MPa with a tensile strength of ~512 MPa. In the Charpy impact tests, the results were 86 and 96 J for specimens with the notch in the face and in the root of the weld bead, respectively. The results of the mechanical properties were in the range of the API 5L X-60 base material. The overlap welding process used for cladding is not suitable for large components, however, it guarantees a metallurgical bond, unlike the most commonly used processes such as thermal expansion. For welding bimetallic plates, control of the temperature gradients is key to avoid distortions. Besides, the dissimilar nature of the bimetallic plates gives rise to the formation of a martensitic microstructure during welding.

Keywords: clad pipe, dissimilar welding, gas metal arc welding, magnetic fields

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Authors: Joon-Suk Kim, Hae-Woo Lee

Abstract:

This study discusses the effect of welding heat input on intergranular corrosion of the weld metal of Inconel 625 alloy. A specimen of Inconel 625 with a weld metal that controlled welding heat input was manufactured, and aging heat treatment was conducted to investigate sensitization by chromium carbides. The electrochemical SL and DL EPR experiments, together with the chemical ferric sulfate-sulfuric acid and nitric acid tests, were conducted to determine intergranular corrosion susceptibility between the specimens. In the SL and DL EPR experiments, specimens were stabilized in the weld metal, and therefore intergranular corrosion susceptibility could not be determined. However, in the ferric sulfate-sulfuric acid and nitric acid tests, the corrosion speed increased as heat input increased. This was because the amount of diluted Fe increased as the welding heat input increased, leading to microsegregation between the dendrites, which had a negative effect on the corrosion resistance.

Keywords: Inconel 625, weling, overlay, heat input, intergranular corrosion

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Authors: Mohamed Moustafa Mahmoud Sedky

Abstract:

The double-fed induction generator wind turbine has recently received a great attention. The steady state performance and response of double fed induction generator (DFIG) based wind turbine are now well understood. This paper presents the analysis of stator and rotor flux linkage dq models operation of DFIG under different faults and at different locations.

Keywords: double fed induction motor, wind energy, flux linkage, short circuit

Procedia PDF Downloads 565

Authors: Abdullah Kaymakci, Daniel M. Madyira, Ntokozo Nkwanyana

Abstract:

The effect of metal transfer modes on mechanical properties of welded 3CR12 stainless steel were investigated. This was achieved by butt welding 10 mm thick plates of 3CR12 in different positions while varying the welding positions for different metal transfer modes. The ASME IX: 2010 (Welding and Brazing Qualifications) code was used as a basis for welding variables. The material and the thickness of the base metal were kept constant together with the filler metal, shielding gas and joint types. The effect of the metal transfer modes on the microstructure and the mechanical properties of the 3CR12 steel was then investigated as it was hypothesized that the change in welding positions will affect the transfer modes partly due to the effect of gravity. The microscopic examination revealed that the substrate was characterized by dual phase microstructure, that is, alpha phase and beta phase grain structures. Using the spectroscopic examination results and the ferritic factor calculation had shown that the microstructure was expected to be ferritic-martensitic during air cooling process. The tested tensile strength and Charpy impact energy were measured to be 498 MPa and 102 J which were in line with mechanical properties given in the material certificate. The heat input in the material was observed to be greater than 1 kJ/mm which is the limiting factor for grain growth during the welding process. Grain growths were observed in the heat affected zone of the welded materials. Ferritic-martensitic microstructure was observed in the microstructure during the microscopic examination. The grain growth altered the mechanical properties of the test material. Globular down hand had higher mechanical properties than spray down hand. Globular vertical up had better mechanical properties than globular vertical down.

Keywords: welding, metal transfer modes, stainless steel, microstructure, hardness, tensile strength

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

Abstract:

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

Procedia PDF Downloads 287

Authors: O. S. Pradeep, S. Vigneshwaran, K. Praveen Kumar, K. Jeyendran, V. R. Sanal Kumar

Abstract:

The influence of injector attitude on wall heat flux plays an important role in predicting the start-up transient and also determining the combustion chamber wall durability of liquid rockets. In this paper comprehensive numerical studies have been carried out on an idealized liquid rocket combustion chamber to examine the transient wall heat flux during its start-up transient at different injector attitude. Numerical simulations have been carried out with the help of a validated 2d axisymmetric, double precision, pressure-based, transient, species transport, SST k-omega model with laminar finite rate model for governing turbulent-chemistry interaction for four cases with different jet intersection angles, viz., 0^o, 30^o, 45^o, and 60^o. We concluded that the jets intersection angle is having a bearing on the time and location of the maximum wall-heat flux zone of the liquid rocket combustion chamber during the start-up transient. We also concluded that the wall heat flux mapping in liquid rocket combustion chamber during the start-up transient is a meaningful objective for the chamber wall material selection and the lucrative design optimization of the combustion chamber for improving the payload capability of the rocket.  

Keywords: combustion chamber, injector, liquid rocket, rocket engine wall heat flux

Procedia PDF Downloads 458