Search results for: metallurgy of friction welding

Authors: Farzad Vakili-Farahani, Joern Lungershausen, Kilian Wasmer

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Wobbled laser beam welding, fast oscillations of a tiny laser beam within a designed path (weld geometry) during the laser pulse illumination, opens new possibilities to improve the marco-to micro-manufacturing process. The present work introduces the wobbled laser beam welding as a robust welding strategy for improving macro-to micro-fabrication process, e.g., the laser processing for gap-bridging and packaging industry. The typical requisites and relevant equipment for the development of a wobbled laser processing unit are addressed, including a suitable laser source, light delivery system, optics, proper beam deflection system and the design geometry. In addition, experiments have been carried out on titanium plate to compare the results of wobbled laser welding with conventional pulsed laser welding. As compared to the pulsed laser welding, the wobbled laser welding offers a much greater fusion area (i.e. additional molten material) while minimizing the HAZ and provides a better confinement of the material microstructural changes.

Keywords: wobbled laser beam welding, wobbling function, beam oscillation, micro welding

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Authors: K. Digheche, K. Saadi, Z. Boumerzoug

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Welding is one of the most important technological processes used in many branches of industry such as industrial engineering, shipbuilding, pipeline fabrication among others. Generally, welding is the preferred joining method and most common steels are weldable. This investigation is a contribution to scientific work of welding of low carbon steel. This work presents the results of the isothermal heat treatment effect at 200, 400 and 600 °C on microstructural evolution in weld region of X70 pipeline steel. The welding process has been realized in three passes by industrial arc welding. We have found that the heat treatments cause grain growth reaction.

Keywords: heat treatments, low carbon steel, microstructures, welding

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Authors: Hyun-Seok Hong, In-Gun Kim, Ye-Jun Oh, Ju Lee

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This paper deals with the effects of welding performed for the manufacture of laminations in a stator in the case of prototype motors that are manufactured in small quantity. As a result of performing the no-load test for an IPM (interior permanent magnet)-type BLDC (blushless direct current) motor manufactured by welding both inside and outside of the stator, it was found that more DC input than expected was provided. To verify the effects of welding, a stator was re-manufactured by bonding, and DC inputs provided during the no-load test were compared.

Keywords: welding, stator, Eddy current, BLDC

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Authors: Ziad. Sh. Al Sarraf

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Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.

Keywords: ultrasonic welding, vibration amplitude, welding force, weld strength

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Authors: Rukiye Ertan

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In this study, a brake friction material composition was investigated experimentally related to the effects of the friction modifiers and abrasive proportions on the tribological properties. The investigation was based on a simple experimental formulation, consisting of seven friction materials with different proportions of abrasives (ZrSiO4 and Fe2O3) and friction modifiers (cashew dust). The friction materials were evaluated using a Chase friction tester. The tribological properties, such as the wear resistance and friction stability, depending on the test temperature and the number of braking were obtained related to the friction material ingredient proportions. The results showed that the tribological properties of the brake pad were greatly affected by the abrasive and then cashew dust proportion.

Keywords: brake pad, friction, wear, abrasives

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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: Sheetal Kumar Parwar, J. Deb Barma, A. Majumder

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Submerged arc welding is a very complex process. It is a very efficient and high performance welding process. In this present study an attempt have been done to reduce the welding distortion by increased amount of oxide flux through TiO2 in submerged arc welding process. Care has been taken to avoid the excessiveness of the adding agent for attainment of significant results. Data Envelopment Analysis (DEA) based BAT algorithm is used for the parametric optimization purpose in which DEA Data Envelopment Analysis is used to convert multi response parameters into a single response parameter. The present study also helps to know the effectiveness of the addition of TiO2 in active flux during submerged arc welding process.

Keywords: BAT algorithm, design of experiment, optimization, submerged arc welding

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Authors: Szymon Kowieski, Zygmunt Mikno

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

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

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Authors: 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: V. M. Levshakov, N. A. Steshenkova, N. A. Nosyrev

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Application of hulls processing technologies, based on high-concentrated energy sources (laser and plasma technologies), allow improve shipbuilding production. It is typical for high-speed vessels construction using steel and aluminum alloys with high precision hulls required. Report describes high-performance technologies for plasma welding (using direct current of reversed polarity), laser, and hybrid laser-arc welding of hulls structures developed by JSC “SSTC”.

Keywords: flat sections, hybrid laser-arc welding, plasma welding, plasmatron

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Authors: Eyob Messele Sefene, Atinkut Atinafu Yilma

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

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

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Authors: Aleksandr Kalinenko, Igor Vysotskiy, Sergey Malopheyev, Sergey Mironov, Rustam Kaibyshev

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From a thermo-mechanical standpoint, friction-stir welding (FSW) represents a unique combination of very large strains, high temperature and relatively high strain rate. The material behavior under such extreme deformation conditions is not studied well and thus, the microstructural examinations of the friction-stir welded materials represent an essential academic interest. Moreover, a clear understanding of the microstructural mechanisms operating during FSW should improve our understanding of the microstructure-properties relationship in the FSWed materials and thus enables us to optimize their service characteristics. Despite extensive research in this field, the microstructural behavior of some important structural materials remains not completely clear. In order to contribute to this important work, the present study was undertaken to examine the grain structure evolution during the FSW of 6061-T6 aluminum alloy. To provide an in-depth insight into this process, the electron backscatter diffraction (EBSD) technique was employed for this purpose. Microstructural observations were conducted by using an FEI Quanta 450 Nova field-emission-gun scanning electron microscope equipped with TSL OIMTM software. A suitable surface finish for EBSD was obtained by electro-polishing in a solution of 25% nitric acid in methanol. A 15° criterion was employed to differentiate low-angle boundaries (LABs) from high-angle boundaries (HABs). In the entire range of the studied FSW regimes, the grain structure evolved in the stir zone was found to be dominated by nearly-equiaxed grains with a relatively high fraction of low-angle boundaries and the moderate-strength B/-B {112}<110> simple-shear texture. In all cases, the grain-structure development was found to be dictated by an extensive formation of deformation-induced boundaries, their gradual transformation to the high-angle grain boundaries. Accordingly, the grain subdivision was concluded to the key microstructural mechanism. Remarkably, a gradual suppression of this mechanism has been observed at relatively high welding temperatures. This surprising result has been attributed to the reduction of dislocation density due to the annihilation phenomena.

Keywords: electron backscatter diffraction, friction-stir welding, heat-treatable aluminum alloys, microstructure

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Authors: Anthony Okechukwu Ifediniru, Austin Ikechukwu Gbasouzor, Isidore Uche Uju

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This article is centered on the design, analysis, construction, and test of a locally made arc welding machine that operates on 250vac with 8 amp output taps ranging from 60vac to 250vac at a fixed frequency, which is of benefit to urban areas; while considering its cost-effectiveness, strength, portability, and mobility. The welding machine uses a power supply to create an electric arc between an electrode and the metal at the welding point. A current selector coil needed for current selection is connected to the primary winding. Electric power is supplied to the primary winding of its transformer and is transferred to the secondary winding by induction. The voltage and current output of the secondary winding are connected to the output terminal, which is used to carry out welding work. The output current of the machine ranges from 110amps for low current welding to 250amps for high current welding. The machine uses a step-down transformer configuration for stepping down the voltage in order to obtain a high current level for effective welding. The welder can adjust the output current within a certain range. This allows the welder to properly set the output current for the type of welding that is being performed. The constructed arc welding machine was tested by connecting the work piece to it. Since there was no shock or spark from the transformer’s laminated core and was successfully used to join metals, it confirmed and validated the design.

Keywords: AC current, arc welding machine, DC current, transformer, welds

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Authors: Jasvinder Singh, Manjinder Singh

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Welding of dissimilar materials is a complicated process due to the difference in melting point of two materials. Thermal conductivity and coefficient of thermal expansion of dissimilar materials also different; therefore, residual stresses produced in the weldment and base metal are the most critical problem associated with the joining of dissimilar materials. Tensile strength and impact toughness also reduced due to the residual stresses. In the present research work, an attempt has been made to weld SS304 and MS1018 dissimilar materials by submerged arc welding (SAW). By conducting trail, runs most effective parameters welding current, Arc voltage, welding speed and nozzle to plate distance were selected to weld these materials. The fractional factorial technique was used to optimize the welding parameters. Effect on tensile strength (TS), fracture toughness (FT) and microhardness of weldment were studied. It was concluded that by optimizing welding current, voltage and welding speed the properties of weldment can be enhanced.

Keywords: SAW, Tensile Strength (TS), fracture toughness, micro hardness

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Authors: Ryu Wonjin, Choi Hyeok, Park Joonhong

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Overlay welding for improving surface properties is a method of the surface treatments which improve surface properties of material by welding materials of alloy having corrosion resistance on the basic material surface. Overlay welding affects contents of chemical components and weld hardness from different parts by dilution of the lamination layer thickness, and it determines surface properties. Therefore, overlay welding has to take into account thickness of the lamination layers with the process. As a result in this study examined contents of Fe, weldability of the base metal and monel materials, hardness and surface flatness from different parts according to each the lamination layer parameters by overlay welding monel materials with corrosion resources to the base material of carbon steel. Through this, evaluated effect by the lamination layer parameters of welding and presented decision methods of the lamination layer parameters of the overlay welding by the purpose of use.

Keywords: clad pipe, lamination layer parameters, monel, overlay welding

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Authors: Masoud Mohammadpour, Nima Yazdian, Radovan Kovacevic

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The Oil and Gas industries are vigorously looking for new ways to increase the efficiency of their pipeline constructions. Besides the other approaches, implementing of new welding methods for joining pipes can be the best candidate on this regard. Hybrid Laser Arc Welding (HLAW) with the capabilities of high welding speed, deep penetration, and excellent gap bridging ability can be a possible alternative method in pipeline girth welding. This paper investigates the feasibility of applying the HLAW to join ASTM A106-B as the mostly used piping material for transporting high-temperature and high-pressure fluids and gases. The experiments were carried out on six-inch diameter pipes with the wall thickness of 10mm. AWS ER 70 S6 filler wire with diameter of 1.2mm was employed. Relating to this welding procedure, characterization of welded samples such as hardness, tensile testing and Charpy V-notch testing were performed and the results will be reported in this paper. In order to have better understanding about the thermal history and the microstructural alterations caused by the welding heat cycle, a comprehensive Finite Element (FE) model was also conducted. The obtained results have shown that the Gas Metal Arc Welding (GMAW) procedure with the minimum number of 5 passes to complete the wall thickness, was reduced to only single pass by using the HLAW process with the welding time less than 15s.

Keywords: finite element modeling, high-temperature service, hybrid laser/arc welding, welding pipes

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Authors: Mahdi Amne Elahi, Marcus Koch, Peter Plapper

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

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

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Authors: 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

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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: Marcus Walter, Norbert Nitzsche, Dirk Odenthal, Steffen Müller

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This contribution presents a friction estimator for industrial purposes which identifies Coulomb friction in a steering system. The estimator only needs a few, usually known, steering system parameters. Friction occurs on almost every mechanical system and has a negative influence on high-precision position control. This is demonstrated on a steering angle controller for highly automated driving. In this steering system the friction induces limit cycles which cause oscillating vehicle movement when the vehicle follows a given reference trajectory. When compensating the friction with the introduced estimator, limit cycles can be suppressed. This is demonstrated by measurements in a series vehicle.

Keywords: friction estimation, friction compensation, steering system, lateral vehicle guidance

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Authors: In-Gun Kim, Hyun-Seok Hong, Dong-Woo Kang, Ju Lee

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An Inverter type arc-welding machine is inclined to be designed for higher frequency in order to reduce the size and cost. The need of the core material reconsideration for high frequency pulse transformer is more important since core loss grows as the frequency rises. An arc welding machine’s pulse transformer is designed using an Area Product (Ap) method and is considered margin air gap core design in order to prevent the burning of the IGBT by the inrush current. Finally, the reduction of the core weight and the core size are compared according to different materials for 30kW inverter type arc welding machine.

Keywords: pulse transformers, welding, inrush current, air gaps

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Authors: Seyed Hamid Mirmohammad Sadeghi, Raffaella Sesana, Daniela Maffiodo

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This study presents a procedure for friction calculation of column electric power steering (C-EPS) system which affects handling and comfort in driving. The friction losses estimation is obtained from experimental tests and mathematical calculation. Parts in C-EPS mainly involved in friction losses are bearings and worm gear. In the theoretical approach, the gear geometry and Hertz law were employed to measure the normal load and the sliding velocity and contact areas from the worm gears driving conditions. The viscous friction generated in the worm gear was obtained with a theoretical approach and the result was applied to model the friction in the steering system. Finally, by viscous friction coefficient and Coulomb friction coefficient, values of friction in worm gear were calculated. According to the Bearing Company and the characteristics of each bearing, the friction torques due to load and due to speed were calculated. A MATLAB Simulink model for calculating the friction in bearings and worm gear in C-EPS were done and the total friction value was estimated.

Keywords: friction, worm gear, column electric power steering system, simulink, bearing, EPS

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Authors: Martin Goubej, Tomas Popule, Alois Krejci

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This paper deals with experimental identification of mechanical systems with nonlinear friction characteristics. Dynamic LuGre friction model is adopted and a systematic approach to parameter identification of both linear and nonlinear subsystems is given. The identification procedure consists of three subsequent experiments which deal with the individual parts of plant dynamics. The proposed method is experimentally verified on an industrial-grade robotic manipulator. Model fidelity is compared with the results achieved with a static friction model.

Keywords: mechanical friction, LuGre model, friction identification, motion control

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Authors: Carlos Alberto Carvalho Castro, Nancy Del Ducca Barbedo, Edmilsom Otoni Côrrea

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With increase the production oil and lines transmission gases that are in ample expansion, the industries medium and great transport they had to adapt itself to supply the demand manufacture in this fabrication segment. In this context, two welding processes have been more extensively used: the GMAW (Gas Metal Arc Welding) and the FCAW (Flux Cored Arc Welding). In this work, welds using these processes were carried out in flat position on ASTM A-36 carbon steel plates in order to make a comparative evaluation between them concerning to mechanical and metallurgical properties. A statistical tool based on technical analysis and design of experiments, DOE, from the Minitab software was adopted. For these analyses, the voltage, current, and welding speed, in both processes, were varied. As a result, it was observed that the welds in both processes have different characteristics in relation to the metallurgical properties and performance, but they present good weldability, satisfactory mechanical strength e developed mathematical models.

Keywords: Flux Cored Arc Welding (FCAW), Gas Metal Arc Welding (GMAW), Design of Experiments (DOE), mathematical models

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Authors: P. M. Keshtiban, M. Zadshakoyan

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One of the important factors that alter different process and geometrical parameters on metal forming processes is friction between contacting surfaces. Some important factors that effected directly by friction are: stress, strain, required load, wear of surfaces and then geometrical parameters. In order to control friction effects permanent lubrication is necessary. In this article, the friction coefficient is elicited by the most effective method, ring compression tests. The tests were done by both finite element method and practical tests. Different friction curves that extracted by finite element simulations and has good conformity with published results, used for obtaining final friction coefficient. In this study Mos2 is used as the lubricant and Al5754 alloy used as the specimens material.

Keywords: experiment, FEM, friction coefficient, ring compression

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Authors: A. Nait Salah, M. Kaddami

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

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

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Authors: Rehan Waheed, Abdul Shakoor

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Distortion produced during welding of thin metal plates is a problem in many industries. The purpose of this research was to study distortion produced during welding in 2mm Mild Steel plate by simulating the welding process using Finite Element Analysis. Simulation of welding process requires a couple field transient analyses. At first a transient thermal analysis is performed and the temperature obtained from thermal analysis is used as input in structural analysis to find distortion. An actual weld sample is prepared and the weld distortion produced is measured. The simulated and actual results were in quite agreement with each other and it has been found that there is profound deflection at center of plate. Temperature dependent material properties play significant role in prediction of weld distortion. The results of this research can be used for prediction and control of weld distortion in large steel structures by changing different weld parameters.

Keywords: welding simulation, FEA, welding distortion, temperature dependent mechanical properties

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Authors: Emmanuel Ogundimu, Esther Akinlabi, Mutiu Erinosho

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

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

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Authors: Milan Uhríčik, Andrea Soviarová, Zuzana Dresslerová, Peter Palček, Alan Vaško

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The article is focused on the analysis changes dependence on the temperature on the magnesium alloy with 5,48% Al, 0,813% Zn and 0,398% Mn by internal friction. Internal friction is a property of the material is measured on the ultrasonic resonant aparature at a frequency about f = 20470 Hz. The measured temperature range was from 30 °C up to 420 °C. Precisely measurement of the internal friction can be monitored ongoing structural changes and various mechanisms that prevent these changes.

Keywords: internal friction, magnesium alloy, temperature, resonant frequency

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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

Procedia PDF Downloads 81