Search results for: Spot Welded

Authors: Jawad Saleem, Abdul Majid, Kent Bertilsson, Torbjörn Carlberg, Nazar Ul Islam

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Resistance spot welding process comprises of electric, thermal and mechanical phenomenon, which makes this process complex and highly non-linear and thus, it becomes difficult to model it. In order to obtain good weld nugget during spot welding, hit and trial welds are usually done which is very costly. Therefore the numerical simulation research has been conducted to understand the whole process. In this paper three different cases were analyzed by varying the tip contact area and it was observed that, with the variation of tip contact area the nugget formation at the faying surface is affected. The tip contact area of the welding electrode becomes large with long welding cycles. Therefore in order to maintain consistency of nugget formation during the welding process, the current compensation in control feedback is required. If the contact area of the welding electrode tip is reduced, a large amount of current flows through the faying surface, as a result of which sputtering occurs.

Keywords: Resistance spot welding, Finite element modeling, Nugget formation, Welding electrode, Numerical method simulation,

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Authors: Li-Wei Liu, Cheng-Yu Tsai, Ming-Tsang Wu

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The study investigated the 2011 TPGA Ever Rich Championship – North Bay Open spectators- on-the-site spectating motivations, experiences, and satisfactions. The research was conducted on a convenience sample of the on-the-spot spectators at the North Bay Golf and Country Club. A total of 200 questionnaires were distributed, of which 185 valid questionnaires were collected, approaching a 92.5% response rate. The data obtained was analyzed with statistical techniques. First, the data showed significant differences in motivations, experiences, and satisfactions relative to demographic variables among the on-the-spot spectators. Second, spectating motivation, experience, and satisfaction were significantly related to one another.

Keywords: Spectating motivation, spectating experience, spectating satisfaction.

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Authors: Mustafa Salman, Nurcan Cetinkaya, Zehra Selcuk, Bugra Genc

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The objectives of the present study were to estimate the microbial-N flow to the small intestine and to predict the digestible organic matter intake (DOMI) in grazing Karayaka sheep based on urinary excretion of purine derivatives (xanthine, hypoxanthine, uric acid, and allantoin) by the use of spot urine sampling under field conditions. In the trial, 10 Karayaka sheep from 2 to 3 years of age were used. The animals were grazed in a pasture for ten months and fed with concentrate and vetch plus oat hay for the other two months (January and February) indoors. Highly significant linear and cubic relationships (P<0.001) were found among months for purine derivatives index, purine derivatives excretion, purine derivatives absorption, microbial-N and DOMI. Through urine sampling and the determination of levels of excreted urinary PD and Purine Derivatives / Creatinine ratio (PDC index), microbial-N values were estimated and they indicated that the protein nutrition of the sheep was insufficient.

In conclusion, the prediction of protein nutrition of sheep under the field conditions may be possible with the use of spot urine sampling, urinary excreted PD and PDC index. The mean purine derivative levels in spot urine samples from sheep were highest in June, July and October. Protein nutrition of pastured sheep may be affected by weather changes, including rainfall. Spot urine sampling may useful in modeling the feed consumption of pasturing sheep. However, further studies are required under different field conditions with different breeds of sheep to develop spot urine sampling as a model.

Keywords: Karayaka sheep, spot sampling, urinary purine derivatives, PDC index, microbial-N, feed intake.

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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: N. H. Othman, N. Udin, M. Ishak, L. H. Shah

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This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.

Keywords: Friction stir welding, magnesium AZ31, cylindrical taper tool, taper pin ratio.

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Authors: Rajendra Prasad Mahapatra, K. Vimal Kumar

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There are many automotive accidents due to blind spots and driver inattentiveness. Blind spot is the area that is invisible to the driver's viewpoint without head rotation. Several methods are available for assisting the drivers. Simplest methods are — rear mirrors and wide-angle lenses. But, these methods have a disadvantage of the requirement for human assistance. So, the accuracy of these devices depends on driver. Another approach called an automated approach that makes use of sensors such as sonar or radar. These sensors are used to gather range information. The range information will be processed and used for detecting the collision. The disadvantage of this system is — low angular resolution and limited sensing volumes. This paper is a panoramic sensor based automotive vehicle monitoring..

Keywords: Panoramic sensors, Blind spot, Convex lens, Computer Vision, Sonar.

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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: Limin Zhao, Xingfa Gu, C. Tao Yu

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one of the significant factors for improving the accuracy of Land Surface Temperature (LST) retrieval is the correct understanding of the directional anisotropy for thermal radiance. In this paper, the multiple scattering effect between heterogeneous non-isothermal surfaces is described rigorously according to the concept of configuration factor, based on which a directional thermal radiance model is built, and the directional radiant character for urban canopy is analyzed. The model is applied to a simple urban canopy with row structure to simulate the change of Directional Brightness Temperature (DBT). The results show that the DBT is aggrandized because of the multiple scattering effects, whereas the change range of DBT is smoothed. The temperature difference, spatial distribution, emissivity of the components can all lead to the change of DBT. The “hot spot" phenomenon occurs when the proportion of high temperature component in the vision field came to a head. On the other hand, the “cool spot" phenomena occur when low temperature proportion came to the head. The “spot" effect disappears only when the proportion of every component keeps invariability. The model built in this paper can be used for the study of directional effect on emissivity, the LST retrieval over urban areas and the adjacency effect of thermal remote sensing pixels.

Keywords: Directional thermal radiance, multiple scattering, configuration factor, urban canopy, hot spot effect

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Authors: T. C. B. N. Assunção, J. L. Silvino, P. Resende

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The winding hot-spot temperature is one of the most critical parameters that affect the useful life of the power transformers. The winding hot-spot temperature can be calculated as function of the top-oil temperature that can estimated by using the ambient temperature and transformer loading measured data. This paper proposes the estimation of the top-oil temperature by using a method based on Least Squares Support Vector Machines approach. The estimated top-oil temperature is compared with measured data of a power transformer in operation. The results are also compared with methods based on the IEEE Standard C57.91-1995/2000 and Artificial Neural Networks. It is shown that the Least Squares Support Vector Machines approach presents better performance than the methods based in the IEEE Standard C57.91-1995/2000 and artificial neural networks.

Keywords: Artificial Neural Networks, Hot-spot Temperature, Least Squares Support Vector, Top-oil Temperature.

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Authors: Zhou Xiong, Kang Shao Bo, Yang Bo

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To date, high-performance structural steel has been widely used for columns in construction practices due to its significant advantages over conventional steel. However, the same design approach with conventional steel columns is still adopted in the design of high-performance steel columns. As a result, its superior properties cannot be fully considered in design. This paper conducts a test and finite element analysis on the overall stability behaviour of welded Q460GJ steel box columns. In the test, four steel columns with different slenderness and width-to-thickness ratio were compressed under an axial compression testing machine. And finite element models were established in which material nonlinearity and residual stress distributions of test columns were included. Then, comparisons were made between test results and finite element result, it showed that finite element analysis results are agree well with the test result. It means that the test and finite element model are reliable. Then, we compared the test result with the design value calculated by current code, the result showed that Q460GJ steel box columns have the higher overall buckling capacity than the design value. It is necessary to update the design curves for Q460GJ steel columns so that the overall stability capacity of Q460GJ box columns can be designed appropriately.

Keywords: Axial compression, Finite element analysis, Overall stability, Q460GJ steel, Welded box columns.

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

Abstract:

Minor problems arising from optimizations by welding of fixed prostheses frameworks can be identified by macroscopic and microscopic visual inspection. The purpose of this study was to highlight the visible discontinuities present in the laser welds of dental Ni-Cr alloys. Ni-Cr base metal alloys designated for fixed prostheses manufacture were selected for the experiments. Using cast plates, preliminary tests were conducted by laser welding. Macroscopic visual inspection was done carefully to assess the defects of the welding rib. Electron microscopy images allowed visualization of small discontinuities, which escapes visual inspection. Making comparison to Ni-Cr alloys taken in the experiment and laser welded, after visual analysis, the best welds appear for Heraenium NA alloy.

Keywords: macroscopic visual inspection, electron microscopyimages, Ni-Cr dental alloys, laser welding.

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Authors: Junwon Seo, Bipin Adhikari, Euiseok Jeong

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This paper is intended to evaluate the structural performance of welded electronic road signs under various damage scenarios (DSs) using a finite element (FE) model calibrated with full-scale ultimate load testing results. The tested electronic road sign specimen was built with a back skin made of 5052 aluminum and two channels and a frame made of 6061 aluminum, where the back skin was connected to the frame by welding. The size of the tested specimen was 1.52 m long, 1.43 m wide, and 0.28 m deep. An actuator applied vertical loads at the center of the back skin of the specimen, resulting in a displacement of 158.7 mm and an ultimate load of 153.46 kN. Using these testing data, generation and calibration of a FE model of the tested specimen were executed in ABAQUS, indicating that the difference in the ultimate load between the calibrated model simulation and full-scale testing was only 3.32%. Then, six different DSs were simulated where the areas of the welded connection in the calibrated model were diminished for the DSs. It was found that the corners at the back skin-frame joint were prone to connection failure for all the DSs, and failure of the back skin-frame connection occurred remarkably from the distant edges.

Keywords: Computational analysis, damage scenarios, electronic road signs, finite element, welded connections.

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Authors: Chava Sunil Kumar, P.S. Subrahmanyan, J. Amarnath

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In this paper variation of spot price and total profits of the generating companies- through wholesale electricity trading are discussed with and without Central Generating Stations (CGS) share and seasonal variations are also considered. It demonstrates how proper analysis of generators- efficiencies and capabilities, types of generators owned, fuel costs, transmission losses and settling price variation using the solutions of Optimal Power Flow (OPF), can allow companies to maximize overall revenue. It illustrates how solutions of OPF can be used to maximize companies- revenue under different scenarios. And is also extended to computation of Available Transfer Capability (ATC) is very important to the transmission system security and market forecasting. From these results it is observed that how crucial it is for companies to plan their daily operations and is certainly useful in an online environment of deregulated power system. In this paper above tasks are demonstrated on 124 bus real-life Indian utility power system of Andhra Pradesh State Grid and results have been presented and analyzed.

Keywords: OPF, ATC, Electricity Market, Bid, Spot Price

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Authors: Yousef S. Al-Othman

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The growth and expansion of the industrial facilities comes proportional to the market increasing demand of products and services. Furthermore, raw material producers such as oil companies usually undergo massive revamping projects to maintain a synchronized supply. These revamping projects are usually delivered through challenging construction projects held and associated with daily site risks related to the construction process. Henceforth, a case study related to these risks and corresponding on-spot corrective measurements has been made on a certain number of construction project contractors at Kuwait Oil Company (KOC) to derive the benefits and overall effectiveness of the on-spot corrective measurements during the construction phase of a project, and how would the same help in avoiding major incidents, ensuring a smooth, cost effective and on time delivery of the project. Findings of this case study shall have an added value to the overall risk management process by minimizing the daily site risks that may affect the project lead time, resulting in an undisturbed on-site construction process.

Keywords: Oil and gas, risk management, construction projects, project lead time.

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Authors: Fajaruddin Mustakim, Motohiro Fujita

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This paper present the study carried out of accident analysis, black spot study and to develop accident predictive models based on the data collected at rural roadway, Federal Route 50 (F050) Malaysia. The road accident trends and black spot ranking were established on the F050. The development of the accident prediction model will concentrate in Parit Raja area from KM 19 to KM 23. Multiple non-linear regression method was used to relate the discrete accident data with the road and traffic flow explanatory variable. The dependent variable was modeled as the number of crashes namely accident point weighting, however accident point weighting have rarely been account in the road accident prediction Models. The result show that, the existing number of major access points, without traffic light, rise in speed, increasing number of Annual Average Daily Traffic (AADT), growing number of motorcycle and motorcar and reducing the time gap are the potential contributors of increment accident rates on multiple rural roadway.

Keywords: Accident Trends, Black Spot Study, Accident Prediction Model

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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: E. M. Anawa, A. G. Olabi

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

Keywords: Micro-hardness, Microstructure, laser welding, dissimilar jointed materials.

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Authors: Khalil A. Yaghi, Samer Barakat

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Complex systems are composed of several plain interacting independent entities. Interaction between these entities creates a unified behavior at the global level that cannot be predicted by examining the behavior of any single individual component of the system. In this paper we consider a welded frame of an automobile trailer as a real example of Complex Technical Systems, The purpose of this paper is to introduce a Statistical method for predicting the life cycle of complex technical systems. To organize gathering of primary data for modeling the life cycle of complex technical systems an “Automobile Trailer Frame" were used as a prototype in this research. The prototype represents a welded structure of several pieces. Both information flows underwent a computerized analysis and classification for the acquisition of final results to reach final recommendations for improving the trailers structure and their operational conditions.

Keywords: Complex Technical System (CTS), AutomobileTrailer Frame, Automobile Service.

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Authors: Kh.Farhangdoust, H.Kamankesh

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Undoubtedly, chassis is one of the most important parts of a vehicle. Chassis that today are produced for vehicles are made up of four parts. These parts are jointed together by screwing. Transverse parts are called cross member. This study reviews the stress generated by cyclic laboratory loads in front cross member of Peugeot 405. In this paper the finite element method is used to simulate the welding process and to determine the physical response of the spot-welded joints. Analysis is done by the Abaqus software. The Stresses generated in cross member structure are generally classified into two groups: The stresses remained in form of residual stresses after welding process and the mechanical stress generated by cyclic load. Accordingly the total stress must be obtained by determining residual stress and mechanical stress separately and then sum them according to the superposition principle. In order to improve accuracy, material properties including physical, thermal and mechanical properties were supposed to be temperature-dependent. Simulation shows that maximum Von Misses stresses are located at special points. The model results are then compared to the experimental results which are reported by producing factory and good agreement is observed.

Keywords: Chassis, cross member, residual stress, resistancespot weld.

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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: 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: Omid A. Zargar

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In this project three type of tools, straight cylindrical, taper cylindrical and triangular tool all made of High speed steel (Wc-Co) used for the friction stir welding (FSW) aluminum alloy H20–H20 and the mechanical properties of the welded joint tested by tensile test and vicker hardness test. Besides, mentioned mechanical properties compared with each other to make conclusion. The result helped design of welding parameter optimization for different types of friction stir process like rotational speed, depth of welding, travel speed, type of material, type of joint, work piece dimension, joint dimension, tool material and tool geometry. Previous investigations in different types of materials work pieces; joint type, machining parameter and preheating temperature take placed. In this investigation 3 mentioned tool types that are popular in FSW tested and the results completed other aspects of the process. Hope this paper can open a new horizon in experimental investigation of mechanical properties for friction stir welded joint with other different type of tools like oval shape probe, paddle shape probe, three flat sided probe, and three sided re-entrant probe and other materials and alloys like titanium or steel in near future.

Keywords: Friction stir welding (FSW), tool, CNC milling machine, aluminum alloy H20, Vickers hardness test, tensile test, straight cylindrical tool, taper cylindrical tool, triangular tool.

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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: 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: 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

Abstract:

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: 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: Esmaeil Poursaeidi, Mostafa Kamalzadeh Yazdi

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Different problems may causes distortion of the rotor, and hence vibration, which is the most severe damage of the turbine rotors. In many years different techniques have been developed for the straightening of bent rotors. The method for straightening can be selected according to initial information from preliminary inspections and tests such as nondestructive tests, chemical analysis, run out tests and also a knowledge of the shaft material. This article covers the various causes of excessive bends and then some applicable common straightening methods are reviewed. Finally, hot spotting is opted for a particular bent rotor. A 325 MW steam turbine rotor is modeled and finite element analyses are arranged to investigate this straightening process. Results of experimental data show that performing the exact hot spot straightening process reduced the bending of the rotor significantly.

Keywords: Distortion, FEM, Hot Spot Area, Rotor Straightening

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Authors: Amin Esmaeilzadeh, Mohammad Sadeghi, Farhad Kolahan

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Arc welding is an important joining process widely used in many industrial applications including production of automobile, ships structures and metal tanks. In welding process, the moving electrode causes highly non-uniform temperature distribution that leads to residual stresses and different deviations, especially buckling distortions in thin plates. In order to control the deviations and increase the quality of welded plates, a fixture can be used as a practical and low cost method with high efficiency. In this study, a coupled thermo-mechanical finite element model is coded in the software ANSYS to simulate the behavior of thin plates located by a 3-2-1 positioning system during the welding process. Computational results are compared with recent similar works to validate the finite element models. The agreement between the result of proposed model and other reported data proves that finite element modeling can accurately predict the behavior of welded thin plates.

Keywords: Welding, thin plate, buckling distortion, fixture locators, finite element modelling.

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Authors: B. L. Gadiga

Abstract:

This study assesses the major ecological zones in Nigeria with the view to understanding the spatial pattern of vegetation zones and the implications on conservation within the period of sixteen (16) years. Satellite images used for this study were acquired from the SPOT-VEGETATION between 1998 and 2013. The annual NDVI images selected for this study were derived from SPOT-4 sensor and were acquired within the same season (November) in order to reduce differences in spectral reflectance due to seasonal variations. The images were sliced into five classes based on literatures and knowledge of the area (i.e. <0.16 Non-Vegetated areas; 0.16-0.22 Sahel Savannah; 0.22-0.40 Sudan Savannah, 0.40-0.47 Guinea Savannah and >0.47 Forest Zone). Classification of the 1998 and 2013 images into forested and non forested areas showed that forested area decrease from 511,691 km² in 1998 to 478,360 km² in 2013. Differencing change detection method was performed on 1998 and 2013 NDVI images to identify areas of ecological concern. The result shows that areas undergoing vegetation degradation covers an area of 73,062 km² while areas witnessing some form restoration cover an area of 86,315 km². The result also shows that there is a weak correlation between rainfall and the vegetation zones. The non-vegetated areas have a correlation coefficient (r) of 0.0088, Sahel Savannah belt 0.1988, Sudan Savannah belt -0.3343, Guinea Savannah belt 0.0328 and Forest belt 0.2635. The low correlation can be associated with the encroachment of the Sudan Savannah belt into the forest belt of South-eastern part of the country as revealed by the image analysis. The degradation of the forest vegetation is therefore responsible for the serious erosion problems witnessed in the South-east. The study recommends constant monitoring of vegetation and strict enforcement of environmental laws in the country.

Keywords: Vegetation, NDVI, SPOT-vegetation, ecology, degradation.

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

Abstract:

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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