Search results for: Explosive Welding

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

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

Keywords: Submerged arc welding, plate thickness, bead geometry, cooling rate.

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

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

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

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Authors: M.St. Węglowski, D. Miara, S. Błacha, J. Dworak, J. Rykała, K. Kwieciński, J. Pikuła, G. Ziobro, A. Szafron, P. Zimierska-Nowak, M. Richert, P. Noga

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In the paper the results of welding of car’s air-conditioning elements are presented. These systems based on, mainly, the environmental unfriendly refrigerants. Thus, the producers of cars will have to stop using traditional refrigerant and to change it to carbon dioxide (R744). This refrigerant is environmental friendly. However, it should be noted that the air condition system working with R744 refrigerant operates at high temperature (up to 150 °C) and high pressure (up to 130 bar). These two parameters are much higher than for other refrigerants. Thus new materials, design as well as joining technologies are strongly needed for these systems. AISI 304 and 316L steels as well as aluminium alloys 5xxx are ranked among the prospective materials. As a joining process laser welding, plasma welding, electron beam welding as well as high rotary friction welding can be applied. In the study, the metallographic examination based on light microscopy as well as SEM was applied to estimate the quality of welded joints. The analysis of welding was supported by numerical modelling based on Sysweld software. The results indicated that using laser, plasma and electron beam welding, it is possible to obtain proper quality of welds in stainless steel. Moreover, high rotary friction welding allows to guarantee the metallic continuity in the aluminium welded area. The metallographic examination revealed that the grain growth in the heat affected zone (HAZ) in laser and electron beam welded joints were not observed. It is due to low heat input and short welding time. The grain growth and subgrains can be observed at room temperature when the solidification mode is austenitic. This caused low microstructural changes during solidification. The columnar grain structure was found in the weld metal. Meanwhile, the equiaxed grains were detected in the interface. The numerical modelling of laser welding process allowed to estimate the temperature profile in the welded joint as well as predicts the dimensions of welds. The agreement between FEM analysis and experimental data was achieved.  

Keywords: Car’s air–conditioning, microstructure, numerical modelling, welding.

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Authors: Pradeep M., N. S. Mahesh, Raja Hussain

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Resistance spot welding (RSW) has been used widely to join sheet metals. It has been a challenge to get required weld quality in spot welding of dissimilar thickness materials. Weld parameters are not generally available in standards for thickness beyond 4mm. This paper presents the welding process design and parameter optimization of RSW used in joining of low carbon steel sheet of thickness 0.8 mm and metal strips of cross section 10 x 5mm for electrical motor applications. Taguchi quality design was adopted for weld current and time optimization using L9 orthogonal array. Optimum process parameters (current- 3.5kA and time- 10 cycles) were obtained from the Taguchi analysis and shear test results. Confirmation experiment result revealed that the weld quality was within acceptable interval. Further, numerical simulation of RSW process was carried out with selected weld parameters to quantify the temperature at faying surface and check for formation of appropriate nugget. The nugget geometry measured after peel test and predicted from numerical validation method were similar and in accordance with the standards.

Keywords: Resistance spot welding, dissimilar thickness, weld parameters, Taguchi method, numerical modeling.

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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: Z. Večeřa, P. Mikuška, J. Kellner, J. Navrátil, A. Langerová

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The submitted paper deals with the problems of trapping and enriching the gases and aerosols of the substances to be determined in the ambient atmosphere. Further, the paper is focused on the working principle of the miniaturized portable continuous concentrator we have designed and the possibilities of its application in air sampling and accumulation of organic and inorganic substances with which the air is contaminated. The stress is laid on trapping vapours and aerosols of solid substances with the comparatively low vapour tension such as explosive compounds.

Keywords: Detectors of explosives, portable continuousconcentrator, misuse of explosive, terrorism.

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

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

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

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Authors: Chansopheak Seang, Afia David Kouadri, Eric Ragneau

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Three dimensional analysis of thermal model in laser full penetration welding, Nd:YAG, by transparent mode DP600 alloy steel 1.25mm of thickness and gap of 0.1mm. Three models studied the influence of thermal dependent temperature properties, thermal independent temperature and the effect of peak value of specific heat at phase transformation temperature, AC1, on the transient temperature. Another seven models studied the influence of discretization, meshes on the temperature distribution in weld plate. It is shown that for the effects of thermal properties, the errors less 4% of maximum temperature in FZ and HAZ have identified. The minimum value of discretization are at least one third increment per radius for temporal discretization and the spatial discretization requires two elements per radius and four elements through thickness of the assembled plate, which therefore represent the minimum requirements of modeling for the laser welding in order to get minimum errors less than 5% compared to the fine mesh.

Keywords: FEA, welding, discretization, ABAQUS user subroutine DFLUX

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Authors: G. Tanapornraweekit, W. Kulsirikasem

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This research paper presents numerical studies of the characteristics of warhead fragmentation in terms of initial velocities, spray angles of fragments and fragment mass distribution of high explosive (HE) warhead. The behavior of warhead fragmentation depends on shape and size of warhead, thickness of casing, type of explosive, number and position of detonator, and etc. This paper focuses on the effects of material properties of warhead casing, i.e. failure strain, initial yield and ultimate strength on the characteristics of warhead fragmentation. It was found that initial yield and ultimate strength of casing has minimal effects on the initial velocities and spray angles of fragments. Moreover, a brittle warhead casing with low failure strain tends to produce higher number of fragments with less average fragment mass.

Keywords: Detonation, Material Properties, Natural Fragment, Warhead

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Authors: M. P. Chakravarthy, N. Ramanaiah, B. S. K.Sundara Siva Rao

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Taguchi approach was applied to determine the most influential control factors which will yield better tensile strength of the joints of pulse TIG welded 70/30 Cu-Ni alloy. In order to evaluate the effect of process parameters such as pulse frequency, peak current, base current and welding speed on tensile strength of Pulsed current TIG welded 70/30 Cu-Ni alloy of 5 mm thickness, Taguchi parametric design and optimization approach was used. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined at 95% confidence level. The results indicate that the Pulse frequency, peak current, welding speed and base current are the significant parameters in deciding the tensile strength of the joint. The predicted optimal values of tensile strength of Pulsed current Gas tungsten arc welding (PC GTAW) of 70/30 Cu-Ni alloy welds are 368.8MPa.

Keywords: 70/30 Cu-Ni alloy, pulsed current GTAW, mechanical properties, Taguchi technique, analysis of variance.

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Authors: Mahmoud Zarrini, R. N. Pralhad

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Avalanche velocity (from start to track zone) has been estimated in the present model for an avalanche which is triggered artificially by an explosive devise. The initial development of the model has been from the concept of micro-continuum theories [1], underwater explosions [2] and from fracture mechanics [3] with appropriate changes to the present model. The model has been computed for different slab depth R, slope angle θ, snow density ¤ü, viscosity μ, eddy viscosity η*and couple stress parameter η. The applicability of the present model in the avalanche forecasting has been highlighted.

Keywords: Snow avalanche velocity, avalanche zones, shockwave, couple stress fluids.

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Authors: M. R. Daneshgar, S. E. Habibi, E. Daneshgar, A. Daneshgar

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In this paper, a two-dimensional method is developed to simulate the fillet welds in a stiffened cylindrical shell, using finite element method. The stiffener material is aluminum 2519. The thermo-elasto-plastic analysis is used to analyze the thermo-mechanical behavior. Due to the high heat flux rate of the welding process, two uncouple thermal and mechanical analysis are carried out instead of performing a single couple thermo-mechanical simulation. In order to investigate the effects of the welding procedures, two different welding techniques are examined. The resulted residual stresses and distortions due to different welding procedures are obtained. Furthermore, this study employed the technique of element birth and death to simulate the weld filler variation with time in fillet welds. The obtained results are in good agreement with the published experimental and three-dimensional numerical simulation results. Therefore, the proposed 2D modeling technique can effectively give the corresponding results of 3D models. Furthermore, by inspection of the obtained residual hoop and transverse stresses and angular distortions, proper welding procedure is suggested.

Keywords: Stiffened cylindrical shell, fillet welds, residual stress, angular distortion, finite element method.

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Authors: Muhammad Murtaza Nasir, Safdar Abbas Zaidi, Kamran Khan

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This work is carried out to evaluate the possibility of using to-be-wasted steel as reinforcement after welding together pieces of reinforcing steel bars, left over during construction activities. Tests were performed on a total of nine samples. These were made by welding pieces of reinforcing steel bars purchased from the local scrap steel market. The samples were tested in uniaxial tension using a universal testing machine (UTM). It was found that the failure of the welded bars is governed by the thickness of the weld. It is concluded that suitable design of the weld is essential for achieving the desired level of ductility/elongation of these bars, if they are to be used as conventional reinforcement in reinforced concrete members.

Keywords: Ductility/elongation, low cost housing, reinforced concrete, welding, welded reinforcement, wastage steel.

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Authors: A. H. Kheireddine, A. A. Khalil, A. H. Ammouri, G. T. Kridli, R. F. Hamade

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Solidification cracking and hydrogen cracking are some defects generated in the fusion welding of ultrahigh carbon steels. However, friction stir welding (FSW) of such steels, being a solid-state technique, has been demonstrated to alleviate such problems encountered in traditional welding. FSW include different process parameters that must be carefully defined prior processing. These parameters included but not restricted to: tool feed, tool RPM, tool geometry, tool tilt angle. These parameters form a key factor behind avoiding warm holes and voids behind the tool and in achieving a defect-free weld. More importantly, these parameters directly affect the microstructure of the weld and hence the final mechanical properties of weld. For that, 3D finite element (FE) thermo-mechanical model was developed using DEFORM 3D to simulate FSW of carbon steel. At points of interest in the joint, tracking is done for history of critical state variables such as temperature, stresses, and strain rates. Typical results found include the ability to simulate different weld zones. Simulations predictions were successfully compared to experimental FSW tests. It is believed that such a numerical model can be used to optimize FSW processing parameters to favor desirable defect free weld with better mechanical properties.

Keywords: Carbon Steels, DEFORM 3D, FEM, Friction stir welding.

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Authors: Armansyah, I. P. Almanar, M. Saiful Bahari Shaari, M. Shamil Jaffarullah, Nur’amirah Busu, M. Arif Fadzleen Zainal Abidin, M. Amlie A. Kasim

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During welding, the amount of heat present in weld zones determines the quality of weldment produced. Thus, the heat distribution characteristics and its magnitude in weld zones with respect to process variables such as tool pin-shoulder rotational and traveling speed during welding is analyzed using thermal finite element analyses method. For this purpose, transient thermal finite element analyses are performed to model the temperatures distribution and its quantities in weld-zones with respect to process variables such as rotational speed and traveling speed during welding. Commercially available software Altair HyperWork is used to model three-dimensional tool pin-shoulder vs. workpieces and to simulate the friction stir process. The results show that increasing tool rotational speed, at a constant traveling speed, will increase the amount of heat generated in weld-zones. In contrary, increasing traveling speed, at constant tool pin-shoulder rotational speeds, will reduce the amount of heat generated in weld zones.

Keywords: Frictions Stir Welding, Temperature Distribution, Finite Element Method, Altair Hyperwork.

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Authors: Djarot B. Darmadi, John Norrish, Anh Kiet Tieu

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Solutions for the temperature profile around a moving heat source are obtained using both analytic and finite element (FEM) methods. Analytic and FEM solutions are applied to study the temperature profile in welding. A moving heat source is represented using both point heat source and uniform distributed disc heat source models. Analytic solutions are obtained by solving the partial differential equation for energy conservation in a solid, and FEM results are provided by simulating welding using the ANSYS software. Comparison is made for quasi steady state conditions. The results provided by the analytic solutions are in good agreement with results obtained by FEM.

Keywords: Analytic solution, FEM, Temperature profile, HeatSource Model

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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: B. Saha Roy, T. Medhi, S. C. Saha

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To understand the friction stir welding process, it is very important to know the nature of the material flow in and around the tool. The process is a combination of both thermal as well as mechanical work i.e. it is a coupled thermo-mechanical process. Numerical simulations are very much essential in order to obtain a complete knowledge of the process as well as the physics underlying it. In the present work a model based approach is adopted in order to study material flow. A thermo-mechanical based CFD model is developed using a Finite Element package, Comsol Multiphysics. The fluid flow analysis is done. The model simultaneously predicts shear strain fields, shear strain rates and shear stress over the entire workpiece for the given conditions. The flow fields generated by the streamline plot give an idea of the material flow. The variation of dynamic viscosity, velocity field and shear strain fields with various welding parameters is studied. Finally the result obtained from the above mentioned conditions is discussed elaborately and concluded.

Keywords: AA6061-T6, friction stir welding, material flow, CFD modelling.

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Authors: T. Teruzzi, S. Antonietti, C. Mosca, C. Paglia

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This paper discusses the causes of the structural failure in a tower crane. The structural collapse occurred at the upper joints of the extension element used to increase the height of the crane. The extension element consists of a steel lattice structure made with angular profiles and plates joined to the tower element by arc welding. Macroscopic inspection of the sections showed that the break was always observed on the angular profiles at the weld bead edge. The case study shows how, using mechanical characterization, chemical analysis of the steel and macroscopic and microscopic metallographic examinations, it was possible to obtain significant evidence that identified the mechanism causing the breakage. The analyses identified the causes of the structural failure as the use of materials that were not suitable for welding and poor performance in the welding joints.

Keywords: Failure, weld, microstructure, microcracks.

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Authors: Norasiah Muhammad, Yupiter HP Manurung

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This paper investigates the development of weld zone in Resistance Spot Welding (RSW) which focuses on weld nugget and Heat Affected Zone (HAZ). The effects of four factors namely weld current, weld time, electrode force and hold time were studied using a general 24 factorial design augmented by five centre points. The results of the analysis showed that all selected factors except hold time exhibit significant effect on weld nugget radius and HAZ size. Optimization of the welding parameters (weld current, weld time and electrode force) to normalize weld nugget and to minimize HAZ size was then conducted using Central Composite Design (CCD) in Response Surface Methodology (RSM) and the optimum parameters were determined. A regression model for radius of weld nugget and HAZ size was developed and its adequacy was evaluated. The experimental results obtained under optimum operating conditions were then compared with the predicted values and were found to agree satisfactorily with each other

Keywords: Factorial design, Optimization, Resistance Spot Welding (RSW), Response Surface Methodology (RSM).

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Authors: Saliha Gachi, Mouloud Aissani, Fouad Boubenider

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Friction Stir Welding (FSW) is a solid-state welding technique that can join material without melting the plates to be welded. In this work, we are interested to demonstrate the potentiality of FSW for joining the heat-treatable aluminum alloy 2024-T3 which is reputed as difficult to be welded by fusion techniques. Thereafter, the FSW joint is compared with another one obtained from a conventional fusion process Tungsten Inert Gas (TIG). FSW welds are made up using an FSW tool mounted on a milling machine. Single pass welding was applied to fabricated TIG joint. The comparison between the two processes has been made on the temperature evolution, mechanical and microstructure behavior. The microstructural examination revealed that FSW weld is composed of four zones: Base metal (BM), Heat affected zone (HAZ), Thermo-mechanical affected zone (THAZ) and the nugget zone (NZ). The NZ exhibits a recrystallized equiaxed refined grains that induce better mechanical properties and good ductility compared to TIG joint where the grains have a larger size in the welded region compared with the BM due to the elevated heat input. The microhardness results show that, in FSW weld, the THAZ contains the lowest microhardness values and increase in the NZ; however, in TIG process, the lowest values are localized on the NZ.

Keywords: Friction stir welding, tungsten inert gaz, aluminum, microstructure.

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Authors: Ahmet Taşan, Süha Tirkeş, Yavuz Öztürk, Zafer Bingül

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Friction stir welding (FSW) is a joining process in the solid state, which eliminates problems associated with the material melting and solidification, such as cracks, residual stresses and distortions generated during conventional welding. Among the most important advantages of FSW are; easy automation, less distortion, lower residual stress and good mechanical properties in the joining region. FSW is a recent approach to metal joining and although originally intended for aluminum alloys, it is investigated in a variety of metallic materials. The basic concept of FSW is a rotating tool, made of non-consumable material, specially designed with a geometry consisting of a pin and a recess (shoulder). This tool is inserted as spinning on its axis at the adjoining edges of two sheets or plates to be joined and then it travels along the joining path line. The tool rotation axis defines an angle of inclination with which the components to be welded. This angle is used for receiving the material to be processed at the tool base and to promote the gradual forge effect imposed by the shoulder during the passage of the tool. This prevents the material plastic flow at the tool lateral, ensuring weld closure on the back of the pin. In this study, two 4 mm Kevlar^® plates which were produced with the Kevlar^® fabrics, are analyzed with COMSOL Multiphysics in order to investigate the weldability via FSW. Thereafter, some experimental investigation is done with an appropriate workbench in order to compare them with the analysis results.

Keywords: Analytical modeling, composite materials welding, friction stir welding, heat generation.

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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: A. Chandrashekar, H. N. Reddappa, B. S. Ajaykumar

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A Friction stir welding tool is a critical component to the success of the process. The tool typically consists of a rotating round shoulder and a threaded cylindrical pin that heats the work piece, mostly by friction, and moves the softened alloy around it to form the joint. In this research work, an attempt has been made to investigate the relationship between FSW variables mainly tool profile, rotating speed, welding speed and the mechanical properties (tensile strength, yield strength, percentage elongation, and micro hardness) of friction stir welded aluminum alloy 5083 joints. From the experimental details, it can be assessed that the joint produced by using Triflute profile tool has contribute superior mechanical and structural properties as compared to Tapered unthreaded & Threaded tool for 1000rpm.

Keywords: Friction stir welding, Tool profile, Rotating speed, Strength, Speed ratio.

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Authors: İres İskender, Ahmet Karaarslan

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In this study, the performance of a high-frequency arc welding machine including a two-switch inverter is analyzed. The control of the system is achieved using two different control techniques i- fuzzy logic control (FLC) ii- state space averaging based sliding control. Fuzzy logic control does not need accurate mathematical model of a plant and can be used in nonlinear applications. The second method needs the mathematical model of the system. In this method the state space equations of the system are derived for two different “on" and “off" states of the switches. The derived state equations are combined with the sliding control rule considering the duty-cycle of the converter. The performance of the system is analyzed by simulating the system using SIMULINK tool box of MATLAB. The simulation results show that fuzzy logic controller is more robust and less sensitive to parameter variations.

Keywords: Fuzzy logic, arc welding, sliding state space control, PWM, current control.

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Authors: S. Porojan, L. Sandu, F. Topalâ

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Microplasma welding is a less expensive alternative to laser welding in dental technology. The aim of the study was to highlight discontinuities present in the microplasma welded joints of dental base metal alloys by visual analysis. Five base metal alloys designated for fixed prostheses manufacture were selected for the experiments. Using these plates, preliminary tests were conducted by microplasma welding in butt joint configuration, without filler material, bilaterally and with filler material, proper for each base metal. Macroscopic visual inspection was performed to assess carefully the irregularities in the welds. Electron microscopy allowed detection of discontinuities that are not visible to the eye and revealing details regarding location, trajectory, morphology and size of discontinuities. Supplementing visual control with microscopic analysis allows to detect small discontinuities, which escapes the macroscopic control and to make a detailed study of the weld.

Keywords: base metal alloys, fixed prosthodontics, microplasmawelding, visual inspection

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Authors: Ramesh S., Sasiraaju A. S., Sidhaarth K., Sudhan Rajkumar N., Manivel Muralidaran V.

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This work presents the result of investigations aimed at determining the hardness of the welded Chromoly (A 4130) steel plate of 2” thickness. Multi pass welding for the thick sections was carried out and analyzed for the Chromoly alloy steel plates. The study of hardness at the weld metal reveals that there is the presence of different micro structure products which yields diverse properties. The welding carried out using GMAW with ER70s-2 electrode. Single V groove design was selected for the butt joint configuration. The presence of hydrogen has been suppressed by selecting low hydrogen electrode. Preheating of the plate prior to welding reduces the cooling rate which also affects the weld metal microstructure. The shielding gas composition used in this analysis is 80% Ar-20% CO2. The experimental analysis gives the detailed study of the hardness of the material.

Keywords: Chromoly, Gas Metal Arc Weld (GMAW), Hardness, Multi pass weld, Shielding gas composition.

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Authors: Bastian Hartmann, Christoph Schauer, Norbert Link

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This paper addresses the problem of recognizing and interpreting the behavior of human workers in industrial environments for the purpose of integrating humans in software controlled manufacturing environments. In this work we propose a generic concept in order to derive solutions for task-related manual production applications. Thus, we are able to use a versatile concept providing flexible components and being less restricted to a specific problem or application. We instantiate our concept in a spot welding scenario in which the behavior of a human worker is interpreted when performing a welding task with a hand welding gun. We acquire signals from inertial sensors, video cameras and triggers and recognize atomic actions by using pose data from a marker based video tracking system and movement data from inertial sensors. Recognized atomic actions are analyzed on a higher evaluation level by a finite state machine.

Keywords: activity recognition, task modeling, marker-based video-tracking, inertial sensors.

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Authors: K. Kalaiselvan, Naresh Subramania Warrier, S. Elavarasi

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Several situations arise in industrial practice which calls for joining of dissimilar metals. With increasing demand in the application requirements, dissimilar metal joining becomes inevitable in modern engineering industries. The metals employed are the structure for effective and utilization of the special properties of each metal. The purpose of this paper is to present the research and development status of titanium (Ti) and aluminium (Al) dissimilar alloys weldment by the researchers worldwide. The detailed analysis of problems faced during welding of dissimilar metal joint for Ti/Al metal combinations are discussed. Microstructural variations in heat affected zone (HAZ), fusion zone (FZ), Intermetallic compound (IMC) layer and surface fracture of weldments are analysed. Additionally, mechanical property variations and microstructural feature have been studied by the researchers. The paper provides a detailed literature review of Ti/Al dissimilar metal joint microchemistry and property variation across the weldment.

Keywords: Laser beam welding, titanium, aluminium, metallurgical properties.

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Authors: A. Nait Salah, M. Kaddami

Abstract:

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, filler metal, micro-hardness test, submerged arc welding.

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