Search results for: Welding speed and Tensile strength.

Authors: A. B. Chehreh, M. Grätzel, M. Klein, J. P. Bergmann, F. Walther

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Friction stir welding (FSW) is an advantageous method in the thermal joining processes, featuring the welding of various dissimilar and similar material combinations, joining temperatures below the melting point which prevents irregularities such as pores and hot cracks as well as high strengths mechanical joints near the base material. The FSW process consists of a rotating tool which is made of a shoulder and a probe. The welding process is based on a rotating tool which plunges in the workpiece under axial pressure. As a result, the material is plasticized by frictional heat which leads to a decrease in the flow stress. During the welding procedure, the material is continuously displaced by the tool, creating a firmly bonded weld seam behind the tool. However, the mechanical properties of the weld seam are affected by the design and geometry of the tool. These include in particular microstructural and surface properties which can favor crack initiation. Following investigation compares the dynamic properties of FSW weld seams with conventional and stationary shoulder geometry based on load increase test (LIT). Compared to classical Woehler tests, it is possible to determine the fatigue strength of the specimens after a short amount of time. The investigations were carried out on a robotized welding setup on 2 mm thick EN AW 5754 aluminum alloy sheets. It was shown that an increased tensile and fatigue strength can be achieved by using the stationary shoulder concept. Furthermore, it could be demonstrated that the LIT is a valid method to describe the fatigue behavior of FSW weld seams.

Keywords: Aluminum alloy, fatigue performance, fracture, friction stir welding.

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Authors: Adnan Mazari, Engin Akcagun, Antonin Havelka, Funda Buyuk Mazari, Pavel Kejzlar

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This article experimentally investigates various physical properties of special fire retardant sewing threads under different sewing speeds. The aramid threads are common for sewing the fire-fighter clothing due to high strength and high melting temperature. 3 types of aramid threads with different linear densities are used for sewing at different speed of 2000 to 4000 r/min. The needle temperature is measured at different speeds of sewing and tensile properties of threads are measured before and after the sewing process respectively. The results shows that the friction and abrasion during the sewing process causes a significant loss to the tensile properties of the threads and needle temperature rises to nearly 300^oC at 4000 r/min of machine speed. The Scanning electron microscope images are taken before and after the sewing process and shows no melting spots but significant damage to the yarn. It is also found that machine speed of 2000r/min is ideal for sewing firefighter clothing for higher tensile properties and production.

Keywords: Kevlar, needle temperature, Nomex, sewing.

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Authors: A. Khalina, K. Shaharuddin, M. S. Wahab, M. P. Saiman, H. A. Aisyah

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This paper investigates the effect of alkali treatment and mechanical properties of kenaf (Hibiscus cannabinus) fibre for the development of yarn. Two different fibre sources are used for the yarn production. Kenaf fibres were treated with sodium hydroxide (NaOH) in the concentration of 3, 6, 9, and 12% prior to fibre opening process and tested for their tensile strength and Young’s modulus. Then, the selected fibres were introduced to fibre opener at three different opening processing parameters; namely, speed of roller feeder, small drum, and big drum. The diameter size, surface morphology, and fibre durability towards machine of the fibres were characterized. The results show that concentrations of NaOH used have greater effects on fibre mechanical properties. From this study, the tensile and modulus properties of the treated fibres for both types have improved significantly as compared to untreated fibres, especially at the optimum level of 6% NaOH. It is also interesting to highlight that 6% NaOH is the optimum concentration for the alkaline treatment. The untreated and treated fibres at 6% NaOH were then introduced to fibre opener, and it was found that the treated fibre produced higher fibre diameter with better surface morphology compared to the untreated fibre. Higher speed parameter during opening was found to produce higher yield of opened-kenaf fibres.

Keywords: Alkaline treatment, Kenaf fibre, Tensile strength, Yarn production.

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Authors: H. A. Alguhi, W. A. Elsaigh

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This paper provides a tensile stress-strain (σ-ε) relationship for High-Strength Steel Fiber Reinforced Concrete (HSFRC). Load-deflection (P-δ) behavior of HSFRC beams tested under four-point flexural load were used with inverse analysis to calculate the tensile σ-ε relationship for various tested concrete grades (70 and 90MPa) containing 60 kg/m³ (0.76 %) of hook-end steel fibers. A first estimate of the tensile (σ-ε) relationship is obtained using RILEM TC 162-TDF and other methods available in literature, frequently used for determining tensile σ-ε relationship of Normal-Strength Concrete (NSC) Non-Linear Finite Element Analysis (NLFEA) package ABAQUS^® is used to model the beam’s P-δ behavior. The results have shown that an element-size dependent tensile σ-ε relationship for HSFRC can be successfully generated and adopted for further analyses involving HSFRC structures.

Keywords: Tensile stress-strain, flexural response, high strength concrete, steel fibers, non-linear finite element analysis.

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Authors: K. Kalaiselvan, A. Elango

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Laser beam welding of dissimilar sheet metal combinations such as Ti/Al, SS/Al and Cu/Al are increasingly demanded due to high energy densities with less fusion and heat affected zones. A good weld joint strength involves combinations of dissimilar metals and the formation of solid solution in the weld pool. Many metal pairs suffer from significant intermetallic phase formation during welding which greatly reduces their strength. The three different sheet metal mentioned above is critically reviewed and phase diagram for the combinations are given. The aim of this study is to develop an efficient metal combinations and the influence on their interfacial characteristics. For that the following parameters such as weld geometry, residual distortion, micro hardness, microstructure and mechanical properties are analyzed systematically.

Keywords: Laser Beam Welding (LBW), dissimilar metals, Ti/Al, SS/Al and Cu/Al sheets.

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Authors: Kimia Khoshdel Vajari, Saber Saffar

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

Keywords: Residual stress, X750 superalloy, finite element, welding, thermal analysis.

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Authors: A. Ito, S. Okamoto

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We constructed an atomic structure model for a PAN-based carbon fiber containing amorphous structures using molecular dynamics methods. It was found that basic physical properties such as crystallinity, Young’s modulus, and thermal conductivity of our model were nearly identical to those of real carbon fibers. We then obtained the tensile strength of a carbon fiber, which has no macro defects. We finally determined that the limitation of the tensile strength was 19 GPa.

Keywords: Amorphous, carbon fiber, molecular dynamics, tensile strength.

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Authors: T.S.Balasubramanian, V.Balasubramanian, M.A.Muthumanikkam

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This paper reports the fatigue crack growth behaviour of gas tungsten arc, electron beam and laser beam welded Ti-6Al-4V titanium alloy. Centre cracked tensile specimens were prepared to evaluate the fatigue crack growth behaviour. A 100kN servo hydraulic controlled fatigue testing machine was used under constant amplitude uniaxial tensile load (stress ratio of 0.1 and frequency of 10 Hz). Crack growth curves were plotted and crack growth parameters (exponent and intercept) were evaluated. Critical and threshold stress intensity factor ranges were also evaluated. Fatigue crack growth behaviour of welds was correlated with mechanical properties and microstructural characteristics of welds. Of the three joints, the joint fabricated by laser beam welding exhibited higher fatigue crack growth resistance due to the presence of fine lamellar microstructure in the weld metal.

Keywords: Fatigue, Non ferrous metals and alloys, welding

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Authors: Mukuna P. Mubiayi, Esther T. Akinlabi

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Friction Stir Welding is a solid state welding technique which can be used to produce sound welds between similar and dissimilar materials. Dissimilar welds which include welds between the different series of aluminium alloys, aluminium to magnesium, steel and titanium has been successfully produced by many researchers. This review covers the work conducted in the above mentioned materials and further concludes by showing the need to fully understand the FSW process in order to expand the latter industrially.

Keywords: aluminium, dissimilar materials, FSW, hardness, magnesium, microstructure, steel, tensile test, titanium

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Authors: Juyi Park, Sang-Bum Lee, Jin-Wook Kim, Ji-Yoon Kim, Jung-Min Kim, Hee-Hwan Park, Jae-Won Seo, Gye-Hyung Kang, Soo-Ho Kim

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This paper presents a portable robot that is to use for welding process in shipbuilding yard. It has six degree of freedom and 3kg payload capability. Its weight is 21.5kg so that human workers can carry it to the work place. Its body mainly made of magnesium alloy and aluminum alloy for few parts that require high strength. Since the distance between robot and controller should be 50m at most, the robot controller controls the robot through EtherCAT. RTX and KPA are used for real time EtherCAT control on Windows XP. The performance of the developed robot was satisfactory, in welding of U type cell in shipbuilding yard.

Keywords: Portable welding robot, Shipbuilding, EtherCAT

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Authors: K. Kalaiselvan, A. Elango, N.M. Nagarajan, N. Mathiazhagan

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Dissimilar joining of Titanium and Aluminum thin sheets has potential applications in aerospace and automobile industry which can reduce weight and cost and improve strength, corrosion resistance and high temperature properties. However successful welding of Titanium/Aluminium sheets is of challenge due to differences in physical, chemical and metallurgical properties between the two. This paper describes research results of Laser Beam Welding (LBW) of Ti/Al thin sheets in which many researchers have recently performed and critically reviewed from different perspectives. Also some of notable works in the field of laser welding with changes in mechanical properties, crack propagation, diffusion behavior, chemical potential, interfacial reaction and the microstructure are reported.

Keywords: Laser Beam Welding (LBW), Mechanical properties, Titanium and Aluminium thin sheets.

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Authors: Ross Jeffry, Muhammad N. S. Hadi

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High strength concrete (HSC) provides high strength but lower ductility than normal strength concrete. This low ductility limits the benefit of using HSC in building safe structures. On the other hand, when designing reinforced concrete beams, designers have to limit the amount of tensile reinforcement to prevent the brittle failure of concrete. Therefore the full potential of the use of steel reinforcement can not be achieved. This paper presents the idea of confining concrete in the compression zone so that the HSC will be in a state of triaxial compression, which leads to improvements in strength and ductility. Five beams made of HSC were cast and tested. The cross section of the beams was 200×300 mm, with a length of 4 m and a clear span of 3.6 m subjected to four-point loading, with emphasis placed on the midspan deflection. The first beam served as a reference beam. The remaining beams had different tensile reinforcement and the confinement shapes were changed to gauge their effectiveness in improving the strength and ductility of the beams. The compressive strength of the concrete was 85 MPa and the tensile strength of the steel was 500 MPa and for the stirrups and helixes was 250 MPa. Results of testing the five beams proved that placing helixes with different diameters as a variable parameter in the compression zone of reinforced concrete beams improve their strength and ductility.

Keywords: Confinement, ductility, high strength concrete, reinforced concrete beam.

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Authors: P. Sawitri, S. Cdr. Sittha, T. Kritsana

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Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.

Keywords: Flow forming, Pressure vessel, four rollers, feed rate, spindle speed, cold work.

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Authors: R. Dangtungee, A. Rattanapan, S. Siengchin

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Waste silicon carbide (waste SiC) filled high-density polyethylene (HDPE) with and without surface modifiers were studied. Two types of surface modifiers namely; high-density polyethylene-grafted-maleic anhydride (HDPE-g-MA) and 3-aminopropyltriethoxysilane have been used in this study. The composites were produced using a two roll mill, extruder and shaped in a hydraulic compression molding machine. The mechanical properties of polymer composites such as flexural strength and modulus, impact strength, tensile strength, stiffness and hardness were investigated over a range of compositions. It was found that, flexural strength and modulus, tensile modulus and hardness increased, whereas impact strength and tensile strength decreased with the increasing in filler contents, compared to the neat HDPE. At similar filler content, the effect of both surface modifiers increased flexural modulus, impact strength, tensile strength and stiffness but reduced the flexural strength. Morphological investigation using SEM revealed that the improvement in mechanical properties was due to enhancement of the interfacial adhesion between waste SiC and HDPE.

Keywords: High-density polyethylene, HDPE-g-MA, mechanical properties, morphological properties, silicon carbide, waste silicon carbide.

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Authors: H. Katkhuda, B. Hanayneh, N. Shatarat

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The main objective of this paper is to determine the isolated effect of silica fume on tensile, compressive and flexure strengths on high strength lightweight concrete. Many experiments were carried out by replacing cement with different percentages of silica fume at different constant water-binder ratio keeping other mix design variables constant. The silica fume was replaced by 0%, 5%, 10%, 15%, 20% and 25% for a water-binder ratios ranging from 0.26 to 0.42. For all mixes, split tensile, compressive and flexure strengths were determined at 28 days. The results showed that the tensile, compressive and flexure strengths increased with silica fume incorporation but the optimum replacement percentage is not constant because it depends on the water–cementitious material (w/cm) ratio of the mix. Based on the results, a relationship between split tensile, compressive and flexure strengths of silica fume concrete was developed using statistical methods.

Keywords: Silica fume, Lightweight, High strength concrete, and Strength.

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Authors: N. Karunakaran, V. Balasubramanian

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This paper presents the results of a study aimed at establishing the temperature distribution during the welding of aluminum alloy plates by Pulsed Current Gas Tungsten Arc Welding (PCGTAW) and Constant Current Gas Tungsten Arc Welding (CCGTAW) processes. Pulsing of the GTA welding current influences the dimensions and solidification rate of the fused zone, it also reduces the weld pool volume hence a narrower bead. In this investigation, the base material considered was aluminum alloy AA 6351 T6, which is finding use in aircraft, automobile and high-speed train components. A finite element analysis was carried out using ANSYS, and the results of the FEA were compared with the experimental results. It is evident from the study that the finite element analysis using ANSYS can be effectively used to model PCGTAW process for finding temperature distribution.

Keywords: Gas tungsten arc welding, pulsed current, finite element analysis, thermal analysis, aluminum alloy.

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Authors: Wasiu O. Ajagbe, Habeeb O. Hamzat, Waris A. Adebisi

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Structural failures occur due to a number of reasons. These may include under design, poor workmanship, substandard materials, misleading laboratory tests and lots more. Reinforcing steel bar is an important construction material, hence its properties must be accurately known before being utilized in construction. Understanding this property involves carrying out mechanical tests prior to design and during construction to ascertain correlation using steel testing machine which is usually not readily available due to the location of project. This study was conducted to determine the reliability of reinforcing steel testing machines. Reconnaissance survey was conducted to identify laboratories where yield and ultimate tensile strengths tests can be carried out. Six laboratories were identified within Ibadan and environs. However, only four were functional at the time of the study. Three steel samples were tested for yield and tensile strengths, using a steel testing machine, at each of the four laboratories (LM, LO, LP and LS). The yield and tensile strength results obtained from the laboratories were compared with the manufacturer’s specification using a reliability analysis programme. Structured questionnaire was administered to the operators in each laboratory to consider their impact on the test results. The average value of manufacturers’ tensile strength and yield strength are 673.7 N/mm² and 559.7 N/mm² respectively. The tensile strength obtained from the four laboratories LM, LO, LP and LS are given as 579.4, 652.7, 646.0 and 649.9 N/mm² respectively while their yield strengths respectively are 453.3, 597.0, 550.7 and 564.7 N/mm². Minimum tensile to yield strength ratio is 1.08 for BS 4449: 2005 and 1.15 for ASTM A615. Tensile to yield strength ratio from the four laboratories are 1.28, 1.09, 1.17 and 1.15 for LM, LO, LP and LS respectively. The tensile to yield strength ratio shows that the result obtained from all the laboratories meet the code requirements used for the test. The result of the reliability test shows varying level of reliability between the manufacturers’ specification and the result obtained from the laboratories. Three of the laboratories; LO, LS and LP have high value of reliability with the manufacturer i.e. 0.798, 0.866 and 0.712 respectively. The fourth laboratory, LM has a reliability value of 0.100. Steel test should be carried out in a laboratory using the same code in which the structural design was carried out. More emphasis should be laid on the importance of code provisions.

Keywords: Reinforcing steel bars, reliability analysis, tensile strength, universal testing machine, yield strength.

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Authors: C. A. C. Castro, D. C. Urashima, E. P. Silva, P. M. L.Silva

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Since 1920, the industry has almost completely changed the rivets production techniques for the manufacture of permanent welding join production of structures and manufacture of other products. The welding arc is the process more widely used in industries. This is accomplished by the heat of an electric arc which melts the base metal while the molten metal droplets are transferred through the arc to the welding pool, protected from the atmosphere by a gas curtain. The GMAW (Gas metal arc welding) process is influenced by variables such as: current, polarity, welding speed, electrode: extension, position, moving direction; type of joint, welder's ability, among others. It is remarkable that the knowledge and control of these variables are essential for obtaining satisfactory quality welds, knowing that are interconnected so that changes in one of them requiring changes in one or more of the other to produce the desired results. The optimum values are affected by the type of base metal, the electrode composition, the welding position and the quality requirements. Thus, this paper proposes a new methodology, adding the variable vibration through a mechanism developed for GMAW welding, in order to improve the mechanical and metallurgical properties which does not affect the ability of the welder and enables repeatability of the welds made. For confirmation metallographic analysis and mechanical tests were made.

Keywords: HAZ, GMAW, vibration, welding.

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Authors: N.Karunakaran, V.Balasubramanian

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This paper presents the results of a study aimed at establishing the temperature distribution during the welding of magnesium alloy sheets by Pulsed Current Gas Tungsten Arc Welding (PCGTAW) and Constant Current Gas Tungsten Arc Welding (CCGTAW) processes. Pulsing of the GTAW welding current influences the dimensions and solidification rate of the fused zone, it also reduces the weld pool volume hence a narrower bead. In this investigation, the base material considered was 2mm thin AZ 31 B magnesium alloy, which is finding use in aircraft, automobile and high-speed train components. A finite element analysis was carried out using ANSYS, and the results of the FEA were compared with the experimental results. It is evident from this study that the finite element analysis using ANSYS can be effectively used to model PCGTAW process for finding temperature distribution.

Keywords: gas tungsten arc welding, pulsed current, finiteelement analysis, thermal analysis, magnesium alloy.

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Authors: K. Kalaiselvan, K. Sekar, S. Elavarasi

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The use of laser beam welding for joining titanium and aluminum offers more advantages compared with conventional joining processes. Dissimilar metal combination is very much needed for aircraft structural industries and research activities. The quality of a weld joint is directly influenced by the welding input parameters. The common problem that is faced by the manufactures is the control of the process parameters to obtain a good weld joint with minimal detrimental. To overcome this issue, various parameters can be preferred to obtain quality of weld joint. In this present study an overall literature review on processing parameters such as offset distance, welding speed, laser power, shielding gas and filler metals are discussed with the effects on quality weldment. Additionally, mechanical properties of welds joint are discussed. The aim of the report is to review the recent progress in the welding of dissimilar titanium (Ti) and aluminum (Al) alloys to provide a basis for follow up research.

Keywords: Laser beam welding, titanium, aluminum, process parameters.

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Authors: Ayman M. Othman, Hassan Y. Ahmed

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This paper discusses the effect of using blast furnace iron slag as a part of fine aggregate on the mechanical performance of hot mix asphalt (HMA). The mechanical performance was evaluated based on various mechanical properties that include; Marshall/stiffness, indirect tensile strength and unconfined compressive strength. The effect of iron slag content on the mechanical properties of the mixtures was also investigated. Four HMA with various iron slag contents, namely; 0%, 5%, 10% and 15% by weight of total mixture were studied. Laboratory testing has revealed an enhancement in the compressive strength of HMA when iron slag was used. Within the tested range of iron slag content, a considerable increase in the compressive strength of the mixtures was observed with the increase of slag content. No significant improvement on Marshall/stiffness and indirect tensile strength of the mixtures was observed when slag was used. Even so, blast furnace iron slag can still be used in asphalt paving for environmental advantages.

Keywords: Blast furnace iron slag, HMA, Marshall/stiffness, indirect tensile strength, compressive strength.

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Authors: Md R. Islam, Rafiqul A. Tarefder

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This study investigates the effect of moisture conditioning on the Indirect Tensile Strength (ITS) of asphalt concrete. As a first step, cylindrical samples of 100 mm diameter and 50 mm thick were prepared using a Superpave gyratory compactor. Next, the samples were conditioned using Moisture Induced Susceptibility Test (MIST) device at different numbers of moisture conditioning cycles. In the MIST device, samples are subjected water pressure through the sample pores cyclically. The MIST conditioned samples were tested for ITS. Results show that the ITS does not change significantly with MIST conditioning at the specific pressure and cycles adopted in this study.

Keywords: Asphalt concrete, tensile strength, moisture, laboratory test.

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Authors: Sefiu A. Bello, Nasirudeen K. Raji, Jeleel A. Adebisi, Sadiq A. Raji

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Pure metals are not used in most cases for structural applications because of their limited properties. Presently, high entropy alloys (HEAs) are emerging by mixing comparative proportions of metals with the aim of maximizing the entropy leading to enhancement in structural and mechanical properties. Aluminum Silicon Nickel Iron Vanadium (AlSiNiFeV) alloy was developed using stir cast technique and analysed. Results obtained show that the alloy grade G0 contains 44 percentage by weight (wt%) Al, 32 wt% Si, 9 wt% Ni, 4 wt% Fe, 3 wt% V and 8 wt% for minor elements with tensile strength and elongation of 106 Nmm^-2 and 2.68%, respectively. X-ray diffraction confirmed intermetallic compounds having hexagonal closed packed (HCP), orthorhombic and cubic structures in cubic dendritic matrix. This affirmed transformation from the cubic structures of elemental constituents of the HEAs to the precipitated structures of the intermetallic compounds. A maximum tensile strength of 188 Nmm^-2 with 4% elongation was noticed at 10wt% of silica addition to the G0. An increase in tensile strength with an increment in silica content could be attributed to different phases and crystal geometries characterizing each HEA.

Keywords: High entropy alloys, phases, model, tensile strength.

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Authors: Ahmed A. D. Sarhan, Chong Feng Duan, Mum Wai Yip, M. Sayuti

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Rapid Prototyping (RP) technologies enable physical parts to be produced from various materials without depending on the conventional tooling. Fused Deposition Modeling (FDM) is one of the famous RP processes used at present. Tensile strength and compressive strength resistance will be identified for different sample structures and different layer orientations of ABS rapid prototype solid models. The samples will be fabricated by a FDM rapid prototyping machine in different layer orientations with variations in internal geometrical structure. The 0° orientation where layers were deposited along the length of the samples displayed superior strength and impact resistance over all the other orientations. The anisotropic properties were probably caused by weak interlayer bonding and interlayer porosity.

Keywords: Building orientation, compression strength, rapid prototyping, tensile strength.

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Authors: Dhananjayulu Avula, Ratnesh Kumar Raj Singh, D.K.Dwivedi, N.K.Mehta

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This study demonstrates the feasibility of joining the commercial pure copper plates by friction stir welding (FSW). Microstructure, microhardness and tensile properties in terms of the joint efficiency were found 94.03 % compare to as receive base material (BM). The average hardness at the top was higher than bottom. Hardness of weld zone was higher than the base material. Different microstructure zones were revealed by optical microscopy and scanning electron microscopy. The stirred zone (SZ) exhibited primary two phases namely, recrystallized grains and fine precipitates in matrix of copper.

Keywords: Welding; FSW, Commercial Copper, Mechanical properties

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Authors: N. Siva Shanmugam, G. Buvanashekaran, K. Sankaranarayanasamy

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In this research work, investigations are carried out on Continuous Wave (CW) Nd:YAG laser welding system after preliminary experimentation to understand the influencing parameters associated with laser welding of AISI 304. The experimental procedure involves a series of laser welding trials on AISI 304 stainless steel sheets with various combinations of process parameters like beam power, beam incident angle and beam incident angle. An industrial 2 kW CW Nd:YAG laser system, available at Welding Research Institute (WRI), BHEL Tiruchirappalli, is used for conducting the welding trials for this research. After proper tuning of laser beam, laser welding experiments are conducted on AISI 304 grade sheets to evaluate the influence of various input parameters on weld bead geometry i.e. bead width (BW) and depth of penetration (DOP). From the laser welding results, it is noticed that the beam power and welding speed are the two influencing parameters on depth and width of the bead. Three dimensional finite element simulation of high density heat source have been performed for laser welding technique using finite element code ANSYS for predicting the temperature profile of laser beam heat source on AISI 304 stainless steel sheets. The temperature dependent material properties for AISI 304 stainless steel are taken into account in the simulation, which has a great influence in computing the temperature profiles. The latent heat of fusion is considered by the thermal enthalpy of material for calculation of phase transition problem. A Gaussian distribution of heat flux using a moving heat source with a conical shape is used for analyzing the temperature profiles. Experimental and simulated values for weld bead profiles are analyzed for stainless steel material for different beam power, welding speed and beam incident angle. The results obtained from the simulation are compared with those from the experimental data and it is observed that the results of numerical analysis (FEM) are in good agreement with experimental results, with an overall percentage of error estimated to be within ±6%.

Keywords: Laser welding, Butt weld, 304 SS, FEM.

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Authors: Richard E. Miller

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12.7-mm thick plates of 6061-T6511 aluminum alloy and high hardness steel (528 HV) were successfully joined by a friction stir bonding process using a tungsten-rhenium stir tool. Process parameter variation experiments, which included tool design geometry, plunge and traverse rates, tool offset, spindle tilt, and rotation speed, were conducted to develop a parameter set which yielded a defect free joint. Laboratory tensile tests exhibited yield stresses which exceed the strengths of comparable AA6061-to-AA6061 fusion and friction stir weld joints. Scanning electron microscopy and energy dispersive X-ray spectroscopy analysis also show atomic diffusion at the material interface region.

Keywords: Dissimilar materials, friction stir, welding.

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Authors: M. T. Z. Butt, T. Ahmad, N. A. Siddiqui

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Commercially SA 516 Grade 70 is frequently used for the manufacturing of pressure vessels, boilers and storage tanks etc. in fabrication industry. Heat input is the major parameter during welding that may bring significant changes in the microstructure as well as the mechanical properties. Different welding technique has different heat input rate per unit surface area. Materials with large thickness are dealt with different combination of welding techniques to achieve required mechanical properties. In the present research two schemes: Scheme 1: SMAW (Shielded Metal Arc Welding) & GTAW (Gas Tungsten Arc Welding) and Scheme 2: SMAW & SAW (Submerged Arc Welding) of hybrid welding techniques have been studied. The purpose of these schemes was to study hybrid welding effect on the microstructure and mechanical properties of the weldment, heat affected zone and base metal area. It is significant to note that the thickness of base plate was 12 mm, also welding conditions and parameters were set according to ASME Section IX. It was observed that two different hybrid welding techniques performed on two different plates demonstrated that the mechanical properties of both schemes are more or less similar. It means that the heat input, welding techniques and varying welding operating conditions & temperatures did not make any detrimental effect on the mechanical properties. Hence, the hybrid welding techniques mentioned in the present study are favorable to implicate for the industry using the plate thickness around 12 mm thick.

Keywords: Grade 70, GTAW, hybrid welding, SAW, SMAW.

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Authors: S.Rajanna, H.K.Shivanand, Akash Deep B.N

Abstract:

Thermite welding is mainly used in world. The reasons why the thermite welding method is widely used are that the equipment has good mobility and total working time of that is shorter than that of the enclosed arc welding method on site. Moreover, the operating skill, which required for thermite welding, is less than that of for enclosed arc welding. In the present research work, heat treatment and combined 'expulsion and heat treatment' techniques were used improve the mechanical properties and weldment structure. The specimens were cut in the transverse direction from expulsion with Heat treated and heat treated Thermite Welded rails. Specimens were prepared according to AWS standard and subjected to tensile test, Impact test and hardness and their results were tabulated. Microstructural analysis was carried out with the help of SEM. Then analyze to effect of heat treated and 'expulsion with heat treated' with the properties of their thermite welded rails. Compare the mechanical and microstructural properties of thermite welded rails between heat expulsion with heat treated and heat treated. Mechanical and microstructural response expulsion with heat treated thermite welded rail is higher value as compared to heat treatment.

Keywords: Expulsion, Heat treatment, Mechanical, Weldment.

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Authors: S. S. Panda, Arkesh Chouhan, Yogesh Deshpande

Abstract:

The present paper deals with designing and fabricating an apparatus for the speedy and accurate manufacturing of fiber reinforced composite lamina of different orientation, thickness and stacking sequences for testing. Properties derived through an analytical approach are verified through measuring the elastic modulus, ultimate tensile strength, flexural modulus and flexural strength of the samples. The 0⁰ orientation ply looks stiffer compared to the 90⁰ ply. Similarly, the flexural strength of 0⁰ ply is higher than to the 90⁰ ply. Sample machinability has been studied by conducting numbers of drilling based on Taguchi Design experiments. Multi Responses (Delamination and Damage grading) is obtained using the desirability approach and optimum cutting condition (spindle speed, feed and drill diameter), at which responses are minimized is obtained thereafter. Delamination increases nonlinearly with the increase in spindle speed. Similarly, the influence of the drill diameter on delamination is higher than the spindle speed and feed rate.

Keywords: Delamination, FRP composite, multi response optimization, Taguchi design.

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