Search results for: Welding electrode

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

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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: F. Roger, A. Traidia, B. Reynier

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Arc welding creates a weld pool to realize continuity between pieces of assembly. The thermal history of the weld is dependent on heat transfer and fluid flow in the weld pool. The metallurgical transformation during welding and cooling are modeled in the literature only at solid state neglecting the fluid flow. In the present paper we associate a heat transfer – fluid flow and metallurgical model for the 16MnD5 steel. The metallurgical transformation model is based on Leblond model for the diffusion kinetics and on the Koistinen-Marburger equation for Marteniste transformation. The predicted thermal history and metallurgical transformations are compared to a simulation without fluid phase. This comparison shows the great importance of the fluid flow modeling.

Keywords: Arc welding, Weld pool, Fluid flow, Metallurgical transformations.

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Authors: A. A. Ugla

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The present paper aims to investigate the effects of the welding process parameters and cooling state on the weld bead geometry, mechanical properties and microstructure characteristics for weldments of AISI 304L stainless steel. The welding process was carried out using TIG welding with pulsed/non-pulsed current techniques. The cooling state was introduced as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. This paper clarifies microstructure- mechanical property relationship of the welded specimens. In this work, the selected pulse frequency levels were 5-500 Hz in order to study the effect of low and high frequencies on the weldment characteristics using filler metal of ER 308LSi. The key findings of this work clarified that the pulse frequency has a significant effect on the breaking of the dendrite arms during the welding process and so strongly influences on the tensile strength and microhardness. The cooling state also significantly affects on the microstructure texture and thereby, the mechanical properties. The most important factor affects the bead geometry and aspect ratio is the travel speed and pulse frequency.

Keywords: Microstructure, mechanical properties, pulse frequency, high pulse frequency, austenitic stainless steel, TIG welding.

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Authors: Bintao Wu, Xiangfang Xu, Yugang Miao, Duanfeng Han

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Joining of 1mm thick aluminum 6061 to titanium TC4 was conducted using Bypass-current MIG welding-brazed, and stable welding process and good bead appearance were obtained. The Joint profile and microstructure of Ti/Al joints were observed by optical microscopy and SEM and then the structure of the interfacial reaction layers were analyzed in details. It was found that the intermetallic compound layer at the interfacial top is in the form of columnar crystal, which is in short and dense state. A mount of AlTi were observed at the interfacial layer near the Ti base metal while intermetallic compound like Al3Ti, TiSi3 were formed near the Al base metal, and the Al11Ti5 transition phase was found in the center of the interface layer due to the uneven distribution inside the weld pool during the welding process. Tensile test results show that the average tensile strength of joints is up to 182.6 MPa, which reaches about 97.6% of aluminum base metal. Fracture is prone to occur in the base metal with a certain amount of necking.

Keywords: Bypass-current MIG welding-brazed, Al alloy, Ti alloy, joint characteristics, mechanical properties.

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Authors: D.Katherasan, Madana Sashikant, S.Sandeep Bhat, P.Sathiya

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Bead-on-plate welds were carried out on AISI 316L (N) austenitic stainless steel (ASS) using flux cored arc welding (FCAW) process. The bead on plates weld was conducted as per L25 orthogonal array. In this paper, the weld bead geometry such as depth of penetration (DOP), bead width (BW) and weld reinforcement (R) of AISI 316L (N) ASS are investigated. Taguchi approach is used as statistical design of experiment (DOE) technique for optimizing the selected welding input parameters. Grey relational analysis and desirability approach are applied to optimize the input parameters considering multiple output variables simultaneously. Confirmation experiment has also been conducted to validate the optimized parameters.

Keywords: bead-on-plate welding, bead profiles, desirability approach, grey relational analysis

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Authors: Thammarak Srimarut, Witthaya Mekhum

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This study analyzed and developed a model for monk’s food bowl production on occupational health safety and environment at work for the encouragement of Rattanakosin local wisdom at Banbart Community. The process of blowpipe welding was necessary to produce the bowl which was very dangerous or 93.59% risk. After the employment of new sitting posture, the work risk was lower 48.41% or moderate risk. When considering in details, it was found that: 1) the traditional sitting posture could create work risk at 88.89% while the new sitting posture could create the work risk at 58.86%. 2) About the environmental pollution, with the traditional sitting posture, workers exposed to the polluted fume from welding at 61.11% while with the new sitting posture workers exposed to the polluted fume from welding at 40.47%. 3) On accidental risk, with the traditional sitting posture, workers exposed to the accident from welding at 94.44% while with the new sitting posture workers exposed to the accident from welding at 62.54%.

Keywords: Occupational health safety, environment at work, Monk’s food bowl.

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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: Shaharin A. Sulaiman, Mizuan Minhat

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This paper presents development of an ignition system using spark electrodes for application in a research explosion vessel. A single spark is aimed to be discharged with quantifiable ignition energy. The spark electrode system would enable study of flame propagation, ignitability of fuel-air mixtures and other fundamental characteristics of flames. The principle of the capacitive spark circuit of ASTM is studied to charge an appropriate capacitance connected across the spark gap through a large resistor by a high voltage from the source of power supply until the initiation of spark. Different spark energies could be obtained mainly by varying the value of the capacitance and the supply current. The spark sizes produced are found to be affected by the spark gap, electrode size, input voltage and capacitance value.

Keywords: Ignition, Spark Electrode, Flame

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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: Isaac Cassar, Trevor Davis, Yi-Kai Lo, Wentai Liu

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Retinal prostheses have been successful in eliciting visual responses in implanted subjects. As these prostheses progress, one of their major limitations is the need for increased resolution. As an alternative to increasing the number of electrodes, virtual electrodes may be used to increase the effective resolution of current electrode arrays. This paper presents a virtual electrode technique based upon time-offsets between stimuli. Two adjacent electrodes are stimulated with identical pulses with too short of pulse widths to activate a neuron, but one has a time offset of one pulse width. A virtual electrode of twice the pulse width was then shown to appear in the center, with a total width capable of activating a neuron. This can be used in retinal implants by stimulating electrodes with pulse widths short enough to not elicit responses in neurons, but with their combined pulse width adequate to activate a neuron in between them.

Keywords: Electrical stimulation, Neuroprosthesis, Retinal implant, Retinal Prosthesis, Virtual electrode.

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Authors: Raj Kumar Rajak, Bharat Mishra

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Bio-batteries represent an entirely new long-term, reasonable, reachable and ecofriendly approach to produce sustainable energy. In the present experimental work, we have studied the effect of generation of power by bio-battery using different electrode pairs. The tests show that it is possible to generate electricity using cow dung as an electrolyte. C-Mg electrode pair shows maximum voltage and SCC (Short Circuit Current) while C-Zn electrode pair shows less OCV (Open Circuit Voltage) and SCC. We have chosen C-Zn electrodes because Mg electrodes are not economical. By the studies of different electrodes and cow dung, it is found that C-Zn electrode battery is more suitable. This result shows that the bio-batteries have the potency to full fill the need of electricity demand for lower energy equipment.

Keywords: Bio-batteries, electricity, cow dung, electrodes, non-conventional.

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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: 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: Yusuke Ayato, Takashi Itahashi, Akiko Takatsu, Kenji Kato, Naoki Matsuda

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In situ observation of absorption spectral change of heptil viologen cation radical (HV+.) was performed by slab optical waveguide (SOWG) spectroscopy utilizing indium-tin-oxide (ITO) electrodes. Synchronizing with electrochemical techniques, we observed the adsorption process of HV+.on the ITO electrode. In this study, we carried out the ITO-SOWG observations using KBr aqueous solution containing different concentration of HV to investigate the concentration dependent spectral change. A few specific absorption bands, which indicated HV+.existed as both monomer and dimer on ITO electrode surface with a monolayer or a few layers deposition, were observed in UV-visible region. The change in the peak position of the absorption spectra from adsorption species of HV+. were correlated with the concentration of HV as well as the electrode potential.

Keywords: absorption phenomena, heptil viologen, indium-tin-oxide (ITO) electrode, in situ, slab optical waveguide(SOWG) spectroscopy,

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Authors: Chun-Yao Lee, Siang-Ren Wang

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The purpose of this paper is to discuss the influence of resistance characteristic on the high conductive concrete considering the various voltage and environment. The four-electrode method is applied to the tailor-made high conductive concrete with appropriate proportion. The curve of resistivity with the changes of voltage and environment is plotted and the changes of resistivity are explored. The result based on the methods reveals that resistivity is less affected by the temperature factor, and the four-electrode method would be an applicable measurement method on a site inspection.

Keywords: Conductive concrete, Resistivity.

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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: M. Ardelean, F. Manea, A. Pop, J. Schoonman

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The presence of pharmaceuticals in the environment and especially in water has gained increasing attention. They are included in emerging class of pollutants, and for most of them, legal limits have not been set-up due to their impact on human health and ecosystem was not determined and/or there is not the advanced analytical method for their quantification. In this context, the development of various advanced analytical methods for the quantification of pharmaceuticals in water is required. The electrochemical methods are known to exhibit the great potential for high-performance analytical methods but their performance is in direct relation to the electrode material and the operating techniques. In this study, two types of carbon-based electrodes materials, i.e., boron-doped diamond (BDD) and carbon nanofiber (CNF)-epoxy composite electrodes have been investigated through voltammetric techniques for the detection of naproxen in water. The comparative electrochemical behavior of naproxen (NPX) on both BDD and CNF electrodes was studied by cyclic voltammetry, and the well-defined peak corresponding to NPX oxidation was found for each electrode. NPX oxidation occurred on BDD electrode at the potential value of about +1.4 V/SCE (saturated calomel electrode) and at about +1.2 V/SCE for CNF electrode. The sensitivities for NPX detection were similar for both carbon-based electrode and thus, CNF electrode exhibited superiority in relation to the detection potential. Differential-pulsed voltammetry (DPV) and square-wave voltammetry (SWV) techniques were exploited to improve the electroanalytical performance for the NPX detection, and the best results related to the sensitivity of 9.959 µA·µM^-1 were achieved using DPV. In addition, the simultaneous detection of NPX and fluoxetine -a very common antidepressive drug, also present in water, was studied using CNF electrode and very good results were obtained. The detection potential values that allowed a good separation of the detection signals together with the good sensitivities were appropriate for the simultaneous detection of both tested pharmaceuticals. These results reclaim CNF electrode as a valuable tool for the individual/simultaneous detection of pharmaceuticals in water.

Keywords: Boron-doped diamond electrode, carbon nanofiber-epoxy composite electrode, emerging pollutants, pharmaceuticals.

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Authors: Trevor E. Davis, Isaac Cassar, Yi-Kai Lo, Wentai Liu

Abstract:

This study models the use of transcutaneous electrical nerve stimulation on skin with a disk electrode in order to simulate tissue damage. The current density distribution above a disk electrode is known to be a dynamic and non-uniform quantity that is intensified at the edges of the disk. The non-uniformity is subject to change through using various electrode geometries or stimulation methods. One of these methods known as edge-retarded stimulation has shown to reduce this edge enhancement. Though progress has been made in modeling the behavior of a disk electrode, little has been done to test the validity of these models in simulating the actual heat transfer from the electrode. This simulation uses finite element software to couple the injection of current from a disk electrode to heat transfer described by the Pennesbioheat transfer equation. An example application of this model is studying an experimental form of stimulation, known as edge-retarded stimulation. The edge-retarded stimulation method will reduce the current density at the edges of the electrode. It is hypothesized that reducing the current density edge enhancement effect will, in turn, reduce temperature change and tissue damage at the edges of these electrodes. This study tests this hypothesis as a demonstration of the capabilities of this model. The edge-retarded stimulation proved to be safer after this simulation. It is shown that temperature change and the fraction of tissue necrosis is much greater in the square wave stimulation. These results bring implications for changes of procedures in transcutaneous electrical nerve stimulation and transcutaneous spinal cord stimulation as well.

Keywords: Bioheat transfer, Electrode, Neuroprosthetics, TENS, Transcutaneous stimulation.

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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: 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: R. Alipour, F.Najarian

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Explosive welding is a process which uses explosive detonation to move the flyer plate material into the base material to produce a solid state joint. Experimental tests have been carried out by other researchers; have been considered to explosively welded aluminium 7039 and steel 4340 tubes in one step. The tests have been done using various stand-off distances and explosive ratios. Various interface geometries have been obtained from these experiments. In this paper, all the experiments carried out were simulated using the finite element method. The flyer plate and collision velocities obtained from the analysis were validated by the pin-measurement experiments. The numerical results showed that very high localized plastic deformation produced at the bond interface. The Ls_dyna_971 FEM has been used for all simulation process.

Keywords: Explosive Welding, Johnson-Cook Equation, Finite Element, JWL Equation.

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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: Mahendran Samykano, Ram Mohan, Shyam Aravamudhan

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The objective of this work is to study the effect of two key factors - external magnetic field and applied current density during template-based electrodeposition of nickel nanowires using an electrode distance of 20 mm. Morphology, length, crystallite size and crystallographic characterization of the grown nickel nanowires at an electrode distance of 20mm are presented. For this electrode distance of 20 mm, these two key electrodeposition factors when coupled was found to reduce crystallite size with a higher growth length and preferred orientation of Ni crystals. These observed changes can be inferred to be due to coupled interaction forces induced by the intensity of applied electric field (current density) and external magnetic field known as magnetohydrodynamic (MHD) effect during the electrodeposition process.

Keywords: Anodic alumina oxide, electrodeposition, nanowires, nickel.

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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

Abstract:

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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