Search results for: welded medium-walled I-shaped sections

Authors: Qian Zhu, Shidong Nie, Bo Yang, Gang Xiong, Guoxin Dai

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GJ steel is a new type of high-performance structural steel which has been increasingly adopted in practical engineering. Q460GJ structural steel has a nominal yield strength of 460 MPa, which does not decrease significantly with the increase of steel plate thickness like normal structural steel. Thus, Q460GJ structural steel is normally used in medium-walled welded sections. However, research works on the residual stress in GJ steel members are few though it is one of the vital factors that can affect the member and structural behavior. This article aims to investigate the residual stresses in welded I-shaped sections fabricated from Q460GJ structural steel plates by experimental tests. A total of four full scale welded medium-walled I-shaped sections were tested by sectioning method. Both circular curve correction method and straightening measurement method were adopted in this study to obtain the final magnitude and distribution of the longitudinal residual stresses. In addition, this paper also explores the interaction between flanges and webs. And based on the statistical evaluation of the experimental data, a multilayer residual stress model is proposed.

Keywords: Q460GJ structural steel, residual stresses, sectioning method, welded medium-walled I-shaped sections

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Authors: Hannachi Med Tahar, H. Djebaili, B. Daheche

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In this approach, we have tried to describe the flattening of welded tubes, and its experimental application. The test is carried out at the (National product processing company dishes and tubes production). Usually, the final products (tubes) undergo a series of non-destructive inspection online and offline welding, and obviously destructive mechanical testing (bending, flattening, flaring, etc.). For this and for the purpose of implementing the flattening test, which applies to the processing of round tubes in other forms, it took four sections of welded tubes draft (before stretching hot) and welded tubes finished (after drawing hot and annealing), it was also noted the report 'health' flattened tubes must not show or crack or tear. The test is considered poor if it reveals a lack of ductility of the metal.

Keywords: flattening, destructive testing, tube drafts, finished tube, Castem 2001

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Authors: P. Leo, E. Cerri, L. Fratini, G. Buffa

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The Friction Stir Welding process uses an inert rotating mandrel and a force on the mandrel normal to the plane of the sheets to generate the frictional heat. The heat and the stirring action of the mandrel create a bond between the two sheets without melting the base metal. As matter of fact, the use of a solid state welding process limits the insurgence of defects, due to the presence of gas in melting bath, and avoids the negative effects of materials metallurgical transformation strictly connected with the change of phase. The industrial importance of Ti-6Al-4V alloy is well known. It provides an exceptional good balance of strength, ductility, fatigue and fracture properties together with good corrosion resistance and good metallurgical stability. In this paper, the authors analyze the microstructure of friction stir welded joints of Ti-6Al-4V processed at the same travel speed (35 mm/min) but at different rotation speeds (300-500 rpm). The microstructure of base material (BM), as result from both optical microscope and scanning electron microscope analysis is not homogenous. It is characterized by distorted α/β lamellar microstructure together with smashed zone of fragmented β layer and β retained grain boundary phase. The BM has been welded in the-as received state, without any previous heat treatment. Even the microstructure of the transverse and longitudinal sections of joints is not homogeneous. Close to the top of weld cross sections a much finer microstructure than the initial condition has been observed, while in the center of the joints the microstructure is less refined. Along longitudinal sections, the microstructure is characterized by equiaxed grains and lamellae. Both the length and area fraction of lamellas increases with distance from longitudinal axis. The hardness of joints is higher than that of BM. As the process temperature increases the average microhardness slightly decreases.

Keywords: friction stir welding, microhardness, microstructure, Ti-6Al-4V

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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: 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: 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: 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: 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: Getachew Demeissie Ayalew, Yongtao Sun, Yang Yang

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The spiral welded pipe manufacturing industry requires strict production standards for automated grinders for welding seams. However, traditional grinding machines in this sector are insufficient due to a lack of quality control protocols and inconsistent performance. This research aims to improve the quality of spiral welded pipes by developing intelligent automated abrasive belt grinding equipment. The system has equipped with six degrees of freedom (6 DOF) KUKA KR360 industrial robots, enabling concurrent grinding operations on both internal and external welds. The grinding robot control system is designed with a PLC, and a human-machine interface (HMI) system is employed for operations. The system includes an electric speed controller, data connection card, DC driver, analog amplifier, and HMI for input data. This control system enables the grinding of spiral welded pipe. It ensures consistent production quality and cost-effectiveness by reducing the product life cycle and minimizing risks in the working environment.

Keywords: Intelligent Systems, Spiral Welded Pipe, Grinding, Industrial Robot, End-Effector, PLC Controller System, 3D Laser Sensor, HMI.

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Authors: Gurmeet Singh Cheema, Navjotinder Singh, Gurjinder Singh, Amardeep Singh

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Aluminium and its alloys play have excellent corrosion resistant properties, ease of fabrication and high specific strength to weight ratio. In this investigation an attempt has been made to study the effect of different post weld heat treatment methods on the mechanical and metallurgical properties of TIG welded joints of the commercial aluminium alloy. Three different methods of post weld heat treatments are, solution heat treatment, artificial aged and combination of solution heat treatment and artificial aging are given to TIG welded aluminium joints. Mechanical and metallurgical properties of as welded and post weld treated joints of the aluminium alloys was examined.

Keywords: aluminium alloys, TIG welding, post weld heat treatment

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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

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Authors: A. Kouadri-Henni, L. Barrallier

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The objective of the study was to characterize the properties of a magnesium alloy welded by friction stir welding (FSW). The results led to a better understanding of the relationship between this process, the microstructure and anisotropic properties of alloy materials. Welding principally leads to a large reduction in grain size in welded zones due to the phenomenon of dynamic recrystallization. The most remarkable observation was that crystallographic textures changed from a base metal with one texture in two zones: the thermo-mechanically affected and stir welded zones. The latter zone has the peculiarity of possessing a marked texture with two components on the basal plane and the pyramidal plane. These characteristics disappeared in the TMAZ, which had only one component following the basal plane. These modifications have been explained by the nature of the plastic deformation in these zones, which occurs at a moderate temperature in the TMAZ and high temperature in the SWZ. In the same time, we compared this evolution with the nature and the level of the residual stresses obtained by X-ray diffraction.

Keywords: texture christallography, residual stresses, FSW process

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

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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: M. N. Zelenin, V. S. Mikhailov, R. P. Zhivotovsky

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It is known that residual welding deformations give negative effect to processability and operational quality of welded structures, complicating their assembly and reducing strength. Therefore, selection of optimal technology, ensuring minimum welding deformations, is one of the main goals in developing a technology for manufacturing of welded structures. Through years, JSC SSTC has been developing a theory for estimation of welding deformations and practical activities for reducing and compensating such deformations during welding process. During long time a methodology was used, based on analytic dependence. This methodology allowed defining volumetric changes of metal due to welding heating and subsequent cooling. However, dependences for definition of structures deformations, arising as a result of volumetric changes of metal in the weld area, allowed performing calculations only for simple structures, such as units, flat sections and sections with small curvature. In case of complex 3D structures, estimations on the base of analytic dependences gave significant errors. To eliminate this shortage, it was suggested to use finite elements method for resolving of deformation problem. Here, one shall first calculate volumes of longitudinal and transversal shortenings of welding joints using method of analytic dependences and further, with obtained shortenings, calculate forces, which action is equivalent to the action of active welding stresses. Further, a finite-elements model of the structure is developed and equivalent forces are added to this model. Having results of calculations, an optimal sequence of assembly and welding is selected and special measures to reduce and compensate welding deformations are developed and taken.

Keywords: residual welding deformations, longitudinal and transverse shortenings of welding joints, method of analytic dependences, finite elements method

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Authors: Yue Zhang, Bo Yang, Gang Xiong, Mohamed Elchalakanic, Shidong Nie

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This study aims to investigate the lateral torsional buckling of I-shaped cross-section beams fabricated from Q460GJ structural steel plates. Both experimental and numerical simulation results are presented in this paper. A total of eight specimens were tested under a three-point bending, and the corresponding numerical models were established to conduct parametric studies. The effects of some key parameters such as the non-dimensional member slenderness and the height-to-width ratio, were investigated based on the verified numerical models. Also, the results obtained from the parametric studies were compared with the predictions calculated by different design codes including the Chinese design code (GB50017-2003, 2003), the new draft version of Chinese design code (GB50017-201X, 2012), Eurocode 3 (EC3, 2005) and the North America design code (ANSI/AISC360-10, 2010). These comparisons indicated that the sectional height-to-width ratio does not play an important role to influence the overall stability load-carrying capacity of Q460GJ structural steel beams with welded I-shaped cross-sections. It was also found that the design methods in GB50017-2003 and ANSI/AISC360-10 overestimate the overall stability and load-carrying capacity of Q460GJ welded I-shaped cross-section beams.

Keywords: experimental study, finite element analysis, global stability, lateral torsional buckling, Q460GJ structural steel

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Authors: Tugrul Tulunay, Iyas Devran Celik

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When the materials used in structural steel industry are evaluated, box beam profiles are considerably preferred. As a result of the cross-sectional properties that these profiles possess, the connection of these profiles to each other and to profiles having different types of cross sections is becoming viable by means of additional measures. An important point to note in such combinations is continuous transfer of internal forces from element to element. At the beginning to ensure this continuity, header plate is needed to use. The connection of the plates to the elements works mainly through welds. In this study, it is aimed to determine the ideal welding thickness in box beam under bending effect and the joints exposed to local buckles that will form in the column. The connection with box column and box beam designed in this context was made by means of corner and circular filler welds. Corner welds of different thickness and analysis by types with different lengths depending on plate dimensions in numerical models were made with the help of ANSYS Workbench program and examined behaviours.

Keywords: welding thickness, box beam-column joints, design of steel structures, calculation and construction principles 2016, welded joints under local buckling

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Authors: Bilge Demir, Ahmet Durgutlu, Mustafa Acarer

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In this study, the butt welding of the commercial AZ31 magnesium alloy sheets have been carried out by using Tungsten Inert Gas (TIG) welding process with alternative and pulsed current. Welded samples were examined with regards to hardness and microstructure. Despite some recent developments in welding of magnesium alloys, they have some problems such as porosity, hot cracking, oxide formation and so on. Samples of the welded parts have undergone metallographic and mechanical examination. Porosities and homogeneous micron grain oxides were rarely observed. Orientations of the weld microstructure in terms of heat transfer also were rarely observed and equiaxed grain morphology was dominant grain structure as in the base metal. As results, fusion zone and few locations of the HAZ of the welded samples have shown twin’s grains. Hot cracking was not observed for any samples. Weld bead geometry of the welded samples were evaluated as normal according to welding parameters. In the results, conditions of alternative and pulsed current and the samples were compared to each other with regards to microstructure and hardness.

Keywords: AZ31 magnesium alloy, microstructures, micro hardness TIG welding

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Authors: Lakhya Jyoti Basumatary, M. J. Davidson

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Tailor Welded Blanks (TWBs) have established themselves to be a revolutionary and foremost integral part of the automotive and aerospace industries. Metals sheets with varied thickness, strength and coatings are welded together to form TWBs through friction stir welding and laser welding prior to stamping operations. The formability of the TWBs completely varies from those of conventional blanks due to the diverse strength levels of individual sheets which are made to deform under the same forming load uniformly throughout causing unequal and unsatisfactory deformation in the blank. Limiting Dome Height(LDH) test helps predicting the formability of each blanks and assists in determining the appropriate TWB. Finite Element Simulation of LDH test for both base material and TWBs was performed and analysed for both before and after the solution heat treatment. The comparison and validation of simulation results are done with the experimental data and correlated accordingly. The formability of solution heat treated TWBs had enhanced than those of blanks made from non-heat treated TWBs.

Keywords: tailor welded blanks, friction stir welding, limiting dome height test, finite element simulation

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Authors: Suk Woo Hong, Chang Sung Seok, Jae Mean Koo

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Recently, the welding is widely used in modern industry for joining the structures. However, the waterworks pipes are exposed to the fatigue load by cars, earthquake and etc because of being buried underground. Moreover, the residual stress exists in weld zone by welding process and it is well known that the fatigue life of welded structures is degraded by residual stress. Due to such reasons, the crack can occur in the weld zone of pipeline. In this case, The ground subsidence or sinkhole can occur, if the soil and sand are washed down by fluid leaked from the crack of water pipe. These problems can lead to property damage and endangering lives. For these reasons, the estimation of fatigue characteristics for water pipeline weld zone is needed. Therefore, in this study, for fatigue characteristics estimation of spiral welded waterworks pipe, ASTM standard specimens and Curved Plate specimens were collected from the spiral welded waterworks pipe and the fatigue tests were performed. The S-N curves of each specimen were estimated, and then the fatigue life of weldment Curved Plate specimen was predicted by theoretical and analytical methods. After that, the weldment Curved Plate specimens were collected from the pipe and verification fatigue tests were performed. Finally, it was verified that the predicted S-N curve of weldment Curved Plate specimen was good agreement with fatigue test data.

Keywords: spiral welded pipe, prediction fatigue life, endurance limit modifying factors, residual stress

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Authors: H. Zedira, M. T. Hannachi, H. Djebaili, B. Daheche

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The rapid pace of technology development and strong competition in the market, prompted us to consider the field of manufacturing of steel pipes by a process complies fully with the requirements of industrial induction welding is high frequency (HF), this technique is better known today in Algeria, more precisely for the manufacture of tubes diameters Single Annabib TG Tebessa. The aim of our study is based on the characterization of processes controlling the mechanical behavior of steel pipes (type E24-2), welded by high frequency induction, considering the different tests and among the most destructive known test internal pressure. The internal pressure test is performed according to the application area of welded pipes, or as leak test, either as a test of strength (bursting). All tubes are subjected to a hydraulic test pressure of 50 bar kept at room temperature for a period of 6 seconds. This study provides information that helps optimize the design and implementation to predict the behavior of the tubes during operation.

Keywords: castem, pressure, stress, tubes, thickness

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Authors: Hadi Farhadian, Homayoon Katibeh

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In this paper, groundwater seepage into Amirkabir tunnel has been estimated using analytical and numerical methods for 14 different sections of the tunnel. Site Groundwater Rating (SGR) method also has been performed for qualitative and quantitative classification of the tunnel sections. The obtained results of above-mentioned methods were compared together. The study shows reasonable accordance with results of the all methods unless for two sections of tunnel. In these two sections there are some significant discrepancies between numerical and analytical results mainly originated from model geometry and high overburden. SGR and the analytical and numerical calculations, confirm the high concentration of seepage inflow in fault zones. Maximum seepage flow into tunnel has been estimated 0.425 lit/sec/m using analytical method and 0.628 lit/sec/m using numerical method occurred in crashed zone. Based on SGR method, six sections of 14 sections in Amirkabir tunnel axis are found to be in "No Risk" class that is supported by the analytical and numerical seepage value of less than 0.04 lit/sec/m.

Keywords: water Seepage, Amirkabir Tunnel, analytical method, DEM, SGR

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Authors: Guang Zou, Kian Banisoleiman, Arturo González

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Crack initiation and propagation threatens structural integrity of welded joints and normally inspections are assigned based on crack propagation models. However, the approach based on crack propagation models may not be applicable for some high-quality welded joints, because the initial flaws in them may be so small that it may take long time for the flaws to develop into a detectable size. This raises a concern regarding the inspection planning of high-quality welded joins, as there is no generally acceptable approach for modeling the whole fatigue process that includes the crack initiation period. In order to address the issue, this paper reviews treatment methods for crack initiation period and initial crack size in crack propagation models applied to inspection planning. Generally, there are four approaches, by: 1) Neglecting the crack initiation period and fitting a probabilistic distribution for initial crack size based on statistical data; 2) Extrapolating the crack propagation stage to a very small fictitious initial crack size, so that the whole fatigue process can be modeled by crack propagation models; 3) Assuming a fixed detectable initial crack size and fitting a probabilistic distribution for crack initiation time based on specimen tests; and, 4) Modeling the crack initiation and propagation stage separately using small crack growth theories and Paris law or similar models. The conclusion is that in view of trade-off between accuracy and computation efforts, calibration of a small fictitious initial crack size to S-N curves is the most efficient approach.

Keywords: crack initiation, fatigue reliability, inspection planning, welded joints

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Authors: S. D. El Wakil

Abstract:

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: Yahaya Taiwo, Adedayo M. Segun

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This study investigated the effect of postweld soaking temperature on mechanical properties of AISI 1018 steel plate welded in aqueous environment. Pairs of 90 x 70 x 12 mm, AISI 1018 steel plates were welded with weld zone beyond distance 10 mm from weld centerline immersed in a water jacket at 25°C. The welded specimens were tempered at temperature of 200, 300, 400, 500 and 600°C for 1.5 hours. Tensile, hardness and toughness tests at distances 15, 30, 45 and 60 mm from the weld centreline with micro structural evaluation were carried out. The results show that the aqueous environment as-weld sample exhibited higher hardness and tensile strength values of 45.3 HV and 448.12 N/mm2 respectively while the hardness and tensile strength of aqueous environment postweld heat treated samples were 44.9 HV and 378.98 N/mm2. This revealed 0.82% and 15.4% reduction in hardness and strength respectively. The metallographic tests showed that the postweld heat treated AISI 1018 steel micro structure contained tempered martensite with ferritic structure and precipitation of carbides. Postweld heat treatment produced materials of lower hardness and improved toughness.

Keywords: air weld samples, aqueous environment weld samples, soaking temperature, water jacket

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Authors: I. M. B. Omiogbemi, D. S. Yawas, I. M. Dagwa, F. G. Okibe

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This work present the effects of some gas metal arc welding parameters on the corrosion behavior of austenitic stainless steel, exposed to 0.5M sodium hydroxide at ambient temperatures (298K) using conventional weight loss determination, together with surface morphology evaluation by scanning electron microscopy and the application of factorial design of experiment to determine welding conditions which enhance the integrity of the welded stainless steel. The welding variables evaluated include speed, voltage and current. Different samples of the welded stainless steels were immersed in the corrosion environment for 8, 16, 24, 32 and 40 days and weight loss determined. From the results, it was found that increase in welding current and speed at constant voltage gave the optimum performance of the austenitic stainless steel in the environment. At a of speed 40cm/min, 110Amp current and voltage of 230 volt the welded stainless steel showed only a 0.0015mg loss in weight after 40 days. Pit-like openings were observed on the surface of the metals indicating corrosion but were minimal at the optimum conditions. It was concluded from the research that relatively high welding speed and current at a constant voltage gives a good welded austenitic stainless steel with better integrity.

Keywords: welding, current, speed, austenitic stainless steel, sodium hydroxide

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Authors: A. M. Khourshid, I. Sabry

Abstract:

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, 2 mm. 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 feasibility of friction stir welding for joining Al 6061 aluminum alloy welding was performed on pipe with different thickness 2, 3 and 4 mm,five rotational speeds (485,710,910,1120 and 1400) rpm and a traverse speed (4, 8 and 10)mm/min was applied. This work focuses on two methods such as artificial neural networks using software (pythia) and response surface methodology (RSM) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminum alloy. An artificial neural network (ANN) model was developed for the analysis of the friction stir welding parameters of 6061 pipe. The tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters Tool rotation speed, material thickness and travel speed as a function. A comparison was made between measured and predicted data. Response surface methodology (RSM) also developed and the values obtained for the response Tensile strengths, the percentage of elongation and hardness are compared with measured values. The effect of FSW process parameter on mechanical properties of 6061 aluminum alloy has been analyzed in detail.

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

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Authors: B. Daheche, M. T. Hannachi, H. Djebaili

Abstract:

In this approach, we tried to describe the flare test tubes welded by high frequency induction HF, and its experimental application. The test is carried out ENTTPP (National company of pipe mill and processing of flat products). Usually, the final products (tube) undergo a series of destructive testing (CD) in order to see the efficiency of welding. This test performed on sections of pipe with a length defined in the notice is made under a determined effort (pressure), which depends on its share of other parameters namely mechanical (fracture resistance) and geometry (thickness tube, outside diameter), the variation of this effort is well researched and recorded.

Keywords: flare, destructive testing, pressure, drafts tube, tube finished

Procedia PDF Downloads 278

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

Abstract:

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

Procedia PDF Downloads 374

Authors: Saliha Gachi, Mouloud Aissani, Fouad Boubenider

Abstract:

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

Procedia PDF Downloads 244