Search results for: dissimilar welded joint

Authors: Daniel N. L. Alves, Marcelo C. Rodrigues, Jose G. de Almeida

Abstract:

The search for structural efficiency in mechanical systems has been strongly exerted with aim of economic optimization and structural safety. As soon, to understand the response of materials when submitted to adverse conditions is essential to design a safety project. This work investigates the presence of cracks in dissimilar welded joints (DWJ). Its fracture toughness responses depend upon the heterogeneity present in these joints. Thus, this work aim analyzing the behavior of the crack tip zone located in a buttery dissimilar welded joint (ASTM A-36, Inconel, and AISI 8630 M) used in the union of pipes present in the offshore oil production lines. The crack was placed 1 mm from fusion line (FL) Inconel-AISI 8630 M toward the AISI 8630 M. Finite Element Method (FEM) was used to analyze stress and strain fields generated during the loading imposed on the specimen. It was possible observing critical stress area by the numerical tool as well as a preferential plastic flow was also observed in the sample of dissimilar welded joint, which can be considered a harbinger of the crack growth path. The results obtained through numerical analysis showed a convergent behavior in relation to the plastic flow, qualitatively and quantitatively, in agreement with previous performed.

Keywords: crack, dissimilar welded joint, numerical analysis, strain field, the stress field

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Authors: Ezzeddin Anawa, Abdol-Ghane Olabi

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The dissimilar joint between aluminum /titanium alloys (Al 6082 and Ti G2) alloys were successfully achieved by CO2 laser welding with a single pass and without filler material using the overlap joint design. Laser welding parameters ranges combinations were experimentally determined using Taguchi approach with the objective of producing welded joint with acceptable welding profile and high quality of mechanical properties. In this study a joining of dissimilar Al 6082 / Ti G2 was result in three distinct regions fusion area (FA), heat-affected zone (HAZ), and the unaffected base metal (BM) in the weldment. These regions are studied in terms of its microstructural characteristics and microhardness which are directly affecting the welding quality. The weld metal was mainly composed of martensite alpha prime. In two different metals in the two different sides of joint HAZ, grain growth was detected. The microhardness of the joint distribution also has shown microhardness increasing in the HAZ of two base metals and a varying microhardness in fusion zone.

Keywords: microharness , microstructure, laser welding and dissimilar jointed materials.

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Authors: Rehan Waheed, Hasan Aftab Saeed, Wasim Tarar, Khalid Mahmood, Sajid Ullah Butt

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Electromagnetic Interference (EMI) shielded doors made from brass extruded channels need to be welded with shielded enclosures to attain optimum shielding performance. Control of welding induced distortion is a problem in welding dissimilar metals like steel and brass. In this research, soldering of the steel-brass joint has been proposed to avoid weld distortion. The material used for brass channel is UNS C36000. The thickness of brass is defined by the manufacturing process, i.e. extrusion. The thickness of shielded enclosure material (ASTM A36) can be varied to produce joint between the dissimilar metals. Steel sections of different gauges are soldered using (91% tin, 9% zinc) solder to the brass, and strength of joint is measured by standard test procedures. It is observed that thin steel sheets produce a stronger bond with brass. The steel sections further require to be welded with shielded enclosure steel sheets through TIG welding process. Stresses and deformation in the vicinity of soldered portion is calculated through FE simulation. Crack formation in soldered area is also studied through experimental work. It has been found that in thin sheets deformation produced due to applied force is localized and has no effect on soldered joint area whereas in thick sheets profound cracks have been observed in soldered joint. The shielding effectiveness of EMI shielded door is compromised due to these cracks. The shielding effectiveness of the specimens is tested and results are compared.

Keywords: dissimilar metal, EMI shielding, joint strength, soldering

Procedia PDF Downloads 139

Authors: Sagar Pandit

Abstract:

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

Procedia PDF Downloads 77

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

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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

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Authors: Aboozar Aghaei

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In the present work, the dissimilar Monel400 and SS316 were joined by friction stir welding (FSW). The applied rotating speed was 400 rpm, whereas the traverse speed varied between 50 and 150 mm/min. At a constant rotating speed, the sound welds were obtained at the welding speeds of 50 and 100 mm/min. However, a groove-like defect was formed when the welding speed exceeded 100 mm/min. The mechanical properties of the joints were evaluated using tensile and fatigue tests. The fatigue strength of dissimilar FSWed specimen was higher than that of both Monel400 and SS316. To study the failure behavior of FSWed specimens, the fracture surfaces were analyzed using scanning electron microscope (SEM). The failure analysis indicates that different mechanisms may contribute to the fracture of welds. This was attributed to the dissimilar characteristics of dissimilar materials exhibiting different failure behaviors.

Keywords: mechanical properties, stainless steel, frictions, monel

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Authors: Prashant S. Humnabad

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The objective of this work is to carry out a thermal heat transfer analysis to obtain the time dependent temperature field in welding process friction stir welded dissimilar materials with different preheating temperature. A series of joints were made on four mm thick aluminum and steel plates. The temperature used was 100ºC, 150ºC and 200ºC. The welding operation was performed with different rotational speeds and traverse speed (1000, 1400 and 2000 rmp and 16, 20 and 25 mm/min..). In numerical model, the welded plate was modeled as the weld line is the symmetric line. The work-piece has dimensions of 100x100x4 mm. The obtained result was compared with experimental result, which shows good agreement and within the acceptable limit. The peak temperature at the weld zone increases significantly with respect to increase in process time.

Keywords: FEA, thermal analysis, preheating, friction stir welding

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Authors: Aboozar Aghaei

Abstract:

In the present work, the dissimilar Monel400 and SS316 were joined by friction stir welding (FSW). The applied rotating speed was 400 rpm, whereas the traverse speed varied between 50 and 150 mm/min. At a constant rotating speed, the sound welds were obtained at the welding speeds of 50 and 100 mm/min. However, a groove-like defect was formed when the welding speed exceeded 100 mm/min. The mechanical properties of the joints were evaluated using tensile and fatigue tests. The fatigue strength of dissimilar FSWed specimens was higher than that of both Monel400 and SS316. To study the failure behavior of FSWed specimens, the fracture surfaces were analyzed using a scanning electron microscope (SEM). The failure analysis indicates that different mechanisms may contribute to the fracture of welds. This was attributed to the dissimilar characteristics of dissimilar materials exhibiting different failure behaviors.

Keywords: frictions stir welding (FSW), stainless steel, mechanical properties, Monel400

Procedia PDF Downloads 54

Authors: Aboozar Aghaei, Kamran Dehghani

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In the present work, the dissimilar Monel400 and SS316 were joined by friction stir welding (FSW). The applied rotating speed was 400 rpm, whereas the traverse speed varied between 50 and 150 mm/min. At a constant rotating speed, the sound welds were obtained at the welding speeds of 50 and 100 mm/min. However, a groove-like defect was formed when the welding speed exceeded 100 mm/min. The mechanical properties of the joints were evaluated using tensile and fatigue tests. The fatigue strength of dissimilar FSWed specimens was higher than that of both Monel400 and SS316. To study the failure behavior of FSWed specimens, the fracture surfaces were analyzed using a scanning electron microscope (SEM). The failure analysis indicates that different mechanisms may contribute to the fracture of welds. This was attributed to the dissimilar characteristics of dissimilar materials exhibiting different failure behaviors.

Keywords: frictions stir welding, stainless steel, Monel400, mechanical properties

Procedia PDF Downloads 56

Authors: A. Elrefaei

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The possibility of having sheets with different thicknesses and materials in one assembly facilitates the optimal material distribution within the final product and reduces the weight of the structure. Ability of joining process to assembly these different material combinations is always a challenge to the designer. In this study, 0.6 mm thick 6061-T6 and 2 mm thick 5182-O were robot CMT welded using ER5356 and ER4043 filler metals. The thermal effect of welding resulted in a loss of hardness in the 6061 HAZ. Joints welded by ER5356 filler metal were much higher in fracture load than joints welded by ER4043 and the elongation of joints welded by ER5356 was almost double its corresponding joints welded by ER4043 filler. Owing to the big difference in formability and thickness of base metals, the fracture in forming test occurred in the softened 6061 HAZ out from the weld centerline.

Keywords: aluminum, CMT, mechanical, welding

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Authors: Sanjay Patil, Shakil A. Kagzi, Harit K. Raval

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Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.

Keywords: ANOVA, deep drawing, Tailor Welded Blank (TWB), weld line movement

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Authors: Muna Khethier Abbass, Khairia Salman Hussan, Huda Mohummed AbdudAlaziz

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This work aims to study the effect of shot peening on the mechanical properties of welded joints which performed by two different welding processes: Tungsten inert gas (TIG) welding and friction stir welding (FSW) processes of aluminum alloy 6061 T6. Arc welding process (TIG) was carried out on the sheet with dimensions of (100x50x6 mm) to obtain many welded joints with using electrode type ER4043 (AlSi5) as a filler metal and argon as shielding gas. While the friction stir welding process was carried out using CNC milling machine with a tool of rotational speed (1000 rpm) and welding speed of (20 mm/min) to obtain the same butt welded joints. The welded pieces were tested by X-ray radiography to detect the internal defects and faulty welded pieces were excluded. Tensile test specimens were prepared from welded joints and base alloy in the dimensions according to ASTM17500 and then subjected to shot peening process using steel ball of diameter 0.9 mm and for 15 min. All specimens were subjected to Vickers hardness test and micro structure examination to study the effect of welding process (TIG and FSW) on the micro structure of the weld zones. Results showed that a general decay of mechanical properties of TIG and FSW welded joints comparing with base alloy while the FSW welded joint gives better mechanical properties than that of TIG welded joint. This is due to the micro structure changes during the welding process. It has been found that the surface hardening by shot peening improved the mechanical properties of both welded joints, this is due to the compressive residual stress generation in the weld zones which was measured using X-Ray diffraction (XRD) inspection.

Keywords: friction stir welding, TIG welding, mechanical properties, shot peening

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Authors: S. D. El Wakil

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The research work reported here was aimed at investigating the feasibility of joining high-porosity stainless steel discs and wrought iron bars by friction welding. The sound friction-welded joints were then subjected to a metallurgical investigation and an analysis of failure resulting from tensile loading. Discs having 50 mm diameter and 10 mm thickness were produced by loose sintering of stainless steel powder at a temperature of 1350 ^oC in an argon atmosphere for one hour. Minor machining was then carried out to control the dimensions of the discs, and the density of each disc could then be determined. The level of porosity was calculated and was found to be about 40% in all of those discs. Solid wrought iron bars were also machined to facilitate tensile testing of the joints produced by friction welding. Using our previously gained experience, the porous stainless steel disc and the wrought iron tube were successfully friction welded. SEM was employed to examine the fracture surface after a tensile test of the joint in order to determine the type of failure. It revealed that the failure did not occur in the joint, but rather in the in the porous metal in the area adjacent to the joint. The load carrying capacity was actually determined by the strength of the porous metal and not by that of the welded joint. Macroscopic and microscopic metallographic examinations were also performed and showed that the welded joint involved a dense heat-affected zone where the porous metal underwent densification at elevated temperature, explaining and supporting the findings of the SEM study.

Keywords: fracture of friction-welded joints, metallurgy of friction welding, solid-porous structures, strength of joints

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Authors: Gurpreet Singh, Hazoor Singh, Kulbir Singh Sandhu

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Friction Stir Welding Process emerged as promising solid-state welding and eliminates various welding defects like cracks and porosity in joining of dissimilar aluminum alloys. In the present research, Friction Stir Welding (FSW) is carried out on dissimilar aluminum alloys 2000 series and 6000 series this combination of alloys are highly used in automobile and aerospace industry due to their good strength to weight ratio, mechanical, and corrosion properties. The joints characterized by applying various destructive and non-destructive tests. Three critical welding parameters were considered i.e. Tool Rotation speed, Transverse speed, and Tool Geometry. The effective range of tool rotation speed from 1200-1800 rpm and transverse speed from 60-240 mm/min and tool geometry was studied. The two-different difficult to weld alloys were successfully welded. All the samples showed different microstructure with different set of welding parameters. It has been revealed with microstructure scans that grain refinement plays a crucial role in mechanical properties.

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

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Authors: Arvind Mittal, Rajesh Gupta

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Influence of heat input on the micro structure and mechanical properties of shield metal arc welded of duplex stainless steel UNSNO.S-31803 has been investigated. Three heat input combinations designated as low heat (0.675 KJ/mm), medium heat (0.860 KJ/mm) and high heat (1.094 KJ/mm) and weld joints made using these combinations were subjected to micro structural evaluations and tensile and impact testing so as to analyze the effect of thermal arc energy on the micro structure and mechanical properties of these joints. The result of this investigation shows that the joints made using low heat input exhibited higher tensile strength than those welded with medium and high heat input. Heat affected zone of welded joint made with medium heat input has austenitic ferritic grain structure with some patchy austenite provide high toughness. Significant grain coarsening was observed in the heat affected zone (HAZ) of medium and high heat input welded joints, whereas low heat input welded joint shows the fine grain structure in the heat affected zone with small amount of dendritic formation and equiaxed grain structure where inner zone indicates slowly cooled grains in the direction of heat dissipation. This is the main reason for the observable changes of tensile properties of weld joints welded with different arc energy inputs.

Keywords: microstructure, mechanical properties, shield metal arc welded, duplex stainless steel

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Authors: K. Subbaiah, C. V. Jeyakumar, S. R. Koteswara Rao

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Cast Aluminum-Magnesium-Scandium alloy was Gas Tungsten Arc (GTA) welded, and the microstructure and mechanical properties of the joint and its component parts were examined and analyzed. The global joint fractured in the base metal, and thus possessed slightly greater tensile strength than the base metal. These results clearly show that Gas Tungsten Arc welding is an optimum / suitable welding process for cast Aluminum-Magnesium-Scandium alloys.

Keywords: cast Al-Mg-Sc alloy, GTAW, microstructure, mechanical properties

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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: 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: Sang Hwan Bak, Min Jung Kim, Dong Bok Lee

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Fe-2%Mn-0.5%Si-0.2C steel was welded and corroded at 600, 700 and 800oC for 20 h in 1 atm of N2/H2S/H2O-mixed gas in order to characterize the high-temperature corrosion behavior of the welded joint. Corrosion proceeded fast and almost linearly. It increased with an increase in the corrosion temperature. H2S formed FeS owing to sulfur released from H2S. The scales were fragile and nonadherent.

Keywords: Fe-Mn-Si steel, corrosion, welding, sulfidation, H2S gas

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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: 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: B. Paygozar, S.A. Dizaji

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Adhesive bonding is a highly valued type of fastening mechanical parts in complex structures, where joining some simple components is always needed. This method is of several merits, such as uniform stress distribution, appropriate bonding strength, and fatigue performance, and lightness, thereby outweighing other sorts of bonding methods. This study is to investigate the failure load of adhesive single-strap joints, including adherends of different sizes and materials. This kind of adhesive joint is very practical in different industries, especially when repairing the existing joints or attaching substrates of dissimilar materials. In this research, experimentally validated numerical analyses carried out in a commercial finite element package, ABAQUS, are utilized to extract the failure loads of the joints, based on the cohesive zone model. In addition, the stress analyses of the substrates are performed in order to acquire the effects of lowering the thickness of the substrates on the stress distribution inside them to avoid designs suffering from the necking or failure of the adherends. It was found out that this method of bonding is really feasible in joining dissimilar materials which can be utilized in a variety of applications. Moreover, the stress analyses indicated the minimum thickness for the adherends so as to avoid the failure of them.

Keywords: cohesive zone model, dissimilar materials, failure load, single strap joint

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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: Aashutosh A. Tadse, Kush Mehta, Hardik Vyas

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Friction Stir Welding is a process in which an FSW tool produces friction heat and thus penetrates through the junction and upon rotation carries out the weld by exchange of material within the 2 metals being welded. It involves holding the workpieces stiff enough to bear the force of the tool moving across the junction to carry out a successful weld. The weld that has flat plates as workpieces, has a quite simpler geometry in terms of fixture holding them. In the case of FSW of pipes, the pipes need to be held firm with the chucks and jaws according to the diameter of the pipes being welded; the FSW tool is then revolved around the pipes to carry out the weld. Machine requires a larger area and it becomes more costly because of such a setup. To carry out the weld on the Milling machine, the newly designed fixture must be set-up on the table of milling machine and must facilitate rotation of pipes by the motor being shafted to one end of the fixture, and the other end automatically rotated because of the rotating jaws held tight enough with the pipes. The set-up has tapered cones as the jaws that would go in the pipes thus holding it with the help of its knurled surface providing the required grip. The process has rotation of pipes with the stationary rotating tool penetrating into the junction. The FSW on pipes in this process requires a very low RPM of pipes to carry out a fine weld and the speed shall change with every combination of material and diameter of pipes, so a variable speed setting motor shall serve the purpose. To withstand the force of the tool, an attachment to the shaft is provided which will be diameter specific that will resist flow of material towards the center during the weld. The welded joint thus carried out will be proper to required standards and specifications. Current industrial requirements state the need of space efficient, cost-friendly and more generalized form of fixtures and set-ups of machines to be put up. The proposed design considers every mentioned factor and thus proves to be positive in the same.

Keywords: force of tool, friction stir welding, milling machine, rotation of pipes, tapered cones

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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

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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: Daniel Osorio, Andreas Klenk, Stefan Weihe, Andreas Kopp, Frank Rödiger

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Future power plants currently face high design requirements due to worsening climate change and environmental restrictions, which demand high operational flexibility, superior thermal performance, minimal emissions, and higher cyclic capability. The aim of the paper is, therefore, to investigate the creep and thermo-mechanical material behavior of improved materials experimentally and welded joints at component scale under near-to-service operating conditions, which are promising for application in highly efficient and flexible future power plants. These materials promise an increase in flexibility and a reduction in manufacturing costs by providing enhanced creep strength and, therefore, the possibility for wall thickness reduction. At the temperature range between 550°C and 625°C, the investigation focuses on the in-phase thermo-mechanical fatigue behavior of dissimilar welded joints of conventional materials (ferritic and martensitic material T24 and T92) to nickel-based alloys (A617B and HR6W) by means of membrane test panels. The temperature and external load are varied in phase during the test, while the internal pressure remains constant. At the temperature range between 650°C and 750°C, it focuses on the creep behavior under multiaxial stress loading of similar and dissimilar welded joints of high temperature resistant nickel-based alloys (A740H, A617B, and HR6W) by means of a thick-walled-component test. In this case, the temperature, the external axial load, and the internal pressure remain constant during testing. Numerical simulations are used for the estimation of the axial component load in order to induce a meaningful damage evolution without causing a total component failure. Metallographic investigations after testing will provide support for understanding the damage mechanism and the influence of the thermo-mechanical load and multiaxiality on the microstructure change and on the creep and TMF- strength.

Keywords: creep, creep-fatigue, component behaviour, weld joints, high temperature material behaviour, nickel-alloys, high temperature resistant steels

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Authors: S. H. Bae, D. W. Cho, W. B. Jeong, J. R. Cho

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Fatigue fracture of an aluminum welded structure is a phenomenon frequently occurring from pores in a weld. In order to grasp the state of the welded structure in operation in real time, the acceleration signal of the structure is measured. At this time, the vibration characteristic of the signal according to the fatigue load is an important parameter of the state diagnosis. This paper was an experimental study on the variation of vibration characteristics of welded beams with vibration aging (especially bending vibration). First simple beams were produced according to welding conditions. Each beam was vibrated and measured beam's PSD (power spectral density) according to the degree of aging. Also, modal testing was conducted to compare the transfer functions of welded beams. Testing result shows that the natural frequencies of the beam changed with the vibration aging due to the change of stiffness in welding part and its stiffness was estimated by the finite element method.

Keywords: modal testing, natural frequency, vibration aging, welded structure

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

Abstract:

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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