Sustainability of Fusion and Solid-State Welding Process in the Era of Industry 4.0

2021 ◽  
pp. 1-17
Author(s):  
Vijay S. Gadakh ◽  
Vishvesh J. Badheka
Keyword(s):  
Solid State ◽  
Industry 4.0 ◽  
Welding Process

Welding Procedure Establishment for Tubular Joints Welded by Single Station, Solid State Welding Machine

2010 ◽  
Author(s):  
Ganesan S. Marimuthu ◽  
Per Thomas Moe ◽  
Bjarne Salberg ◽  
Junyan Liu ◽  
Henry Valberg ◽  
...  
Keyword(s):  
Solid State ◽  
Oil And Gas ◽  
Welding Process ◽  
High Strength ◽  
Pipe Material ◽  
Tubular Joints ◽  
Welding Machine ◽  
Single Station ◽  
Welding Procedure ◽  
Treatment Procedures

Forge welding is an efficient welding method for tubular joints applicable in oil and gas industries due to its simplicity in carrying out the welding, absence of molten metal and filler metals, small heat-affected zone and high process flexibility. Prior to forging, the ends (bevels) of the joining tubes can be heated by torch or electromagnetic (EM) techniques, such as induction or high frequency resistance heating. The hot bevels are subsequently pressed together to establish the weld. The entire welding process can be completed within seconds and consistently produces superior quality joints of very high strength and adequate ductility. Industrial forge welding of tubes in the field is relatively expensive compared to laboratory testing. Moreover, at the initial stages of a new project sufficient quantities of pipe material may not be available for weldability testing. For these and several other reasons we have developed a highly efficient single station, solid state welding machine that carefully replicates the thermomechanical conditions of full-scale Shielded Active Gas Forge Welding Machines (SAG-FWM) for pipeline and casing applications. This representative laboratory machine can be used to weld tubular goods, perform material characterization and/or simulate welding and heat treatment procedures. The bevel shapes at mating ends of the tubes are optimized by ABAQUS® simulations to fine tune temperature distribution. The main aim of this paper is to establish a welding procedure for welding the tubular joints by the representative laboratory machine. The quality of the welded tubular joint was analyzed by macro/micro analyses, as well as hardness and bend tests. The challenges in optimizing the bevel shape and process parameters to weld high quality tubular joints are thoroughly discussed. Finally a welding procedure specification was established to weld the tubular joints in the representative laboratory machine.

Effect of Tool Shape on Temperature Field in Friction Stir Spot Welding

2013 ◽  
Vol 58 (2) ◽  
pp. 595-599 ◽  
Author(s):  
P. Lacki ◽  
Z. Kucharczyk ◽  
R.E. Śliwa ◽  
T. Gałaczyński
Keyword(s):  
Temperature Field ◽  
Solid State ◽  
Spot Welding ◽  
Plastic Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Frictional Heat ◽  
Maximum Temperature ◽  
Tool Geometry ◽  
Friction Stir

Friction stir welding (FSW) is one of the youngest methods of metal welding. Metals and its alloys are joined in a solid state at temperature lower than melting points of the joined materials. The method is constantly developed and friction stir spot welding (FSSW) is one of its varieties. In the friction stir spot welding process a specially designed tool is brought into rotation and plunged, straight down, in the joined materials. Heat is generated as a result of friction between the tool and materials, and plastic deformation of the joined materials. Softening (plastic zone) of the joined materials occurs. Simultaneously the materials are stirred. After removal of the tool, cooling down the stirred materials create a solid state joint. Numerical simulation of the process was carried out with the ADINA System based on the finite element method (FEM). The problem was considered as an axisymmetric one. A thermal and plastic material model was assumed for Al 6061-T6. Frictional heat was generated on the contact surfaces between the tool and the joined elements. The model of Coulomb friction, in which the friction coefficient depends on the temperature, was used. An influence of the tool geometry on heat generation in the welded materials was analysed. The calculations were carried out for different radiuses of the tool stem and for different angles of the abutment. Temperature distributions in the welded materials as a function of the process duration assuming a constant value of rotational tool speed and the speed of tool plunge were determined. Additionally, the effect of the stem radius and its height on the maximum temperature was analysed. The influence of tool geometry parameters on the temperature field and the temperature gradient in the welded materials was shown. It is important regarding the final result of FSSW.

Phenomenological Modeling of Fusion Welding Processes

MRS Bulletin ◽  
1994 ◽  
Vol 19 (1) ◽  
pp. 29-35 ◽  
Author(s):  
S.A. David ◽  
T. DebRoy ◽  
J.M. Vitek
Keyword(s):  
Solid State ◽  
Heat Source ◽  
Base Metal ◽  
Weld Pool ◽  
Welding Process ◽  
Poor Performance ◽  
Consumer Products ◽  
Phase Changes ◽  
Fusion Welding ◽  
Welding Processes

Welding is utilized in 50% of the industrial, commercial, and consumer products that make up the U.S. gross national product. In the construction of buildings, bridges, ships, and submarines, and in the aerospace, automotive, and electronic industries, welding is an essential activity. In the last few decades, welding has evolved from an empirical art to a more scientifically based activity requiring synthesis of knowledge from various disciplines. Defects in welds, or poor performance of welds, can lead to catastrophic failures with costly consequences, including loss of property and life.Figure 1 is a schematic diagram of the welding process showing the interaction between the heat source and the base metal. During the interaction of the heat source with the material, several critical events occur: melting, vaporization, solidification, and solid-state transformations. The weldment is divided into three distinct regions: the fusion zone (FZ), which undergoes melting and solidification; the heat-affected zone (HAZ) adjacent to the FZ, that may experience solid-state phase changes but no melting; and the unaffected base metal (BM).Creating the extensive experimental data base required to adequately characterize the highly complex fusion welding process is expensive and time consuming, if not impractical. One recourse is to simulate welding processes either mathematically or physically in order to develop a phenomenological understanding of the process. In mathematical modeling, a set of algebraic or differential equations are solved to obtain detailed insight of the process. In physical modeling, understanding of a component of the welding process is achieved through experiments designed to avoid complexities that are unrelated to the component investigated.In recent years, process modeling has grown to be a powerful tool for understanding the welding process. Using computational modeling, significant progress has been made in evaluating how the physical processes in the weld pool influence the development of the weld pool and the macrostructures and microstructures of the weld.

Solid State Welding Process for Aerospace Components

2015 ◽  
Vol 1119 ◽  
pp. 597-600
Author(s):  
Hyun Ho Jung ◽  
Ye Rim Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Kyung Ju Min ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Structural Integrity ◽  
Welding Process ◽  
Diffusion Welding ◽  
Intimate Contact ◽  
Friction Stir ◽  
Base Materials ◽  
Welding Processes ◽  
And Diffusion

Since solid state welded joint is formed from an intimate contact between two metals at temperatures below the melting point of the base materials, the structural integrity of welding depends on time, temperature, and pressure. This paper provides some of examples of friction stir welding and diffusion welding process for aerospace components. Friction stir welding process of AA2195 was developed in order to study possible application for a large fuel tank. Massive diffusion welding of multiple titanium sheets was performed and successful results were obtained. Diffusion welding of dissimilar metals of copper and stainless steel was necessary to manufacture a scaled combustion chamber. Diffusion welding of copper and steel was performed and it is shown that the optimum condition of diffusion welding is 7MPa at 890°C, for one hour. It is shown that solid state welding processes can be successfully applied to fabricate lightweight aerospace parts.

Numerical Modeling of Thermal Field Distribution during Friction Stir Welding (FSW) of Dissimilar Materials

2016 ◽  
Vol 254 ◽  
pp. 261-266
Author(s):  
Bogdan Radu ◽  
Cosmin Codrean ◽  
Radu Cojocaru ◽  
Cristian Ciucă
Keyword(s):  
Numerical Modeling ◽  
Friction Stir Welding ◽  
Solid State ◽  
Thermal Field ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Element Analysis ◽  
Friction Stir ◽  
The Cost

Friction Stir Welding (FSW) is an innovative solid state welding process, relatively new in industry, which allow welding of two or more materials which have very different properties, particularly thermal properties as fusion temperature, thermal expansion coefficient, specific heat and thermal conduction and have a predisposition to form intermetallic brittle phases, neither one of the components to be weld reach to the melting point. Being a solid state welding process temperature field is very important for the quality of the welded joint, and a lot of researches focused on this topic. This paper presents some results in modeling and estimation of thermal field developed during FSW of dissimilar joints, using Finite Element Analysis. Numerical modeling of thermal field allows engineers to predict, in advance, the evolution of temperature and to estimate the behavior of the welded materials during the welding process. This will reduce significantly the time and number of experiments that have to be carried out, in the process of establishing a good FSW technology, as well as reducing significantly the cost of the tests.

Solid-state joining of aluminum to titanium: A review

2021 ◽  
pp. 146442072110108
Author(s):  
Vijay S Gadakh ◽  
Vishvesh J Badheka ◽  
Amrut S Mulay
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
Titanium Alloys ◽  
Intermetallic Compounds ◽  
Welding Process ◽  
High Strength ◽  
Weld Interface ◽  
Fusion Welding ◽  
Cp Ti ◽  
Welding Processes

The dissimilar material joining of aluminum and titanium alloys is recognized as a challenge due to the significant differences in the physical, chemical, and metallurgical properties of these alloys, where the increasing demands for high strength and lightweight alloys in aerospace, defense, and automotive industries. Joining these two alloys using the conventional fusion techniques produces commercially unacceptable sound joints due to irregular, complex weld pool shapes, cracking and low strength, high residual stresses, cracks, and microporosity, and the brittle intermetallic compounds formation leads to poor formability or inferior mechanical properties. The formation of intermetallic compounds is inevitable but it is less severe in solid-state than in the fusion welding process. Hence, this article reviews on aluminum–titanium joining using different solid-state and hybrid joining processes with emphasis on the effect of process parameters of the different processes on the weld microstructure, mechanical properties along with the type of intermetallic compounds and defects formed at the weld interface. Among the various solid-state welding processes for aluminum–titanium joining, the following grades of aluminum and titanium alloys were employed such as cp Ti, Ti6Al4V, cp Al, AA1xxx, AA 2xxx, AA5xxx, AA6xxx, AA7xxx, out of which Ti6Al4V and AA6xxx alloys are the most common combination.

An Experimental Study of Process Parameters on Friction Stir Welded Aluminum Alloy 2219 Joint Properties

2017 ◽  
Vol 863 ◽  
pp. 3-7
Author(s):  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon ◽  
Ho Sung Lee
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Process Parameters ◽  
Process Condition ◽  
Welding Process ◽  
Frictional Heat ◽  
Friction Stir ◽  
Joint Properties ◽  
Aluminum Alloy 2219

Aluminum alloy 2219 is widely used in aerospace applications since it has a unique combination of good weldability and high specific strength. Furthermore, it can provide a high strength after heat treatment with superior properties in cryogenic environment so they have been widely used for cryogenic fuel tank of space launch vehicles. It is known that solid state welding like friction stir welding can improve the joint properties of this alloy. Friction stir welding is a solid state welding technology which two materials are welded together by the frictional heat due to the rotation of the tool. In this study, friction stir welding was performed on aluminum alloy 2219 sheets. The range of welding parameter is four rotation speeds from 350 to 800 rpm and six travel speeds from 120 to 420 mm/min. The results include the microstructural change after friction stir welding. The microstructure was characterized and material in the stirred zone experience sufficient deformation and heat input which cause the complete dynamic recrystallization. The present work represents the strength at each process condition and the optimum friction stir welding process parameters. The optimum weld efficiency obtained in this study was 76.5 %.

Fatigue Crack Growth on FSW AA2024-T3 Aluminum Joints

2012 ◽  
Vol 498 ◽  
pp. 126-138 ◽  
Author(s):  
Pedro Miguel Guimarães Pires Moreira ◽  
Paulo Manuel Salgado Tavares de Castro
Keyword(s):  
Growth Rate ◽  
Fatigue Crack ◽  
Solid State ◽  
Crack Growth Rate ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Base Material ◽  
Welding Process ◽  
Butt Joints ◽  
Friction Stir

Friction stir welding (FSW) is a solid-state joining process which emerged as an alternative technology to join high strength alloys that were difficult to weld with conventional techniques, [1]. Developments of this technique are being driven by aeronautic, aerospace and railway industries. An advantage of this joining technique is its low heat input when compared with arc welding processes. This feature allows the achievement of high mechanical properties, low distortion and low residual stresses, [2]. Also, since it is a solid-state welding process, hydrogen cracking or heat affected zone (HAZ) softening phenomena are limited. This paper presents a study of fatigue crack growth behaviour of friction stir welded butt joints of AA2024-T3, aluminium commonly used in riveted aeronautic fuselage structures. Crack growth studies are often carried out using uniform thickness joints, ASTM E647 [3]. Nevertheless, for some applications there is a need to join components with different thicknesses, which, under certain limits, can be welded using FSW. Crack growth tests on these joints are not standard. The present study concerns butt joints made using two plates with different thicknesses, 3.8mm and 4.0mm. The joints’ mechanical behaviour was studied performing static (tensile) and fatigue tests. The fatigue crack growth rate of cracks growing in different zones of the welded joint (nugget, heat affected zone - HAZ) and in base material was analysed. The microhardness profile was assessed in order to analyse the influence of the welding process in each weld zone. Further to higher static properties, welded joints present lower crack growth rate when compared with its base material.

Influence of Process Parameter on Microstructural Characteristics and Tensile Properties of Friction Welded ASS304L Alloy

2015 ◽  
Vol 766-767 ◽  
pp. 745-750 ◽  
Author(s):  
K. Umanath ◽  
K. Palanikumar
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
Stainless Steels ◽  
Friction Welding ◽  
Welding Process ◽  
Austenitic Stainless Steels ◽  
Microstructural Characteristics ◽  
Solid State Joining ◽  
Joining Process ◽  
Rotary Type

The rotary type continuous friction welding process is a solid state joining process by mechanically. It produces a joint in the forging pressure contact with rotating and motionless workpiece. The solid state joining process it produces welds with reduced distortion and improved mechanical properties. The austenitic stainless steels are widely used in shipbuilding field, nuclear field and automobile field because of their special mechanical and metallurgical properties. In this work, friction welding of austenitic stainless steel rods of 10mm diameter was investigated with an aim to understand the influence of friction welding process parameters. The details of microstructure analysis using optical microscopy are discussed.

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