Influence of filler wire and wire feed speed on metallurgical and mechanical properties of MIG welding–brazing of automotive galvanized steel/5754 aluminum alloy in a lap joint configuration

2015 ◽  
Vol 82 (9-12) ◽  
pp. 1495-1506 ◽  
Author(s):  
Ali Mehrani Milani ◽  
Moslem Paidar ◽  
Alireza Khodabandeh ◽  
Saeed Nategh
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Galvanized Steel ◽  
Feed Speed ◽  
Filler Wire ◽  
Mig Welding ◽  
Lap Joint ◽  
Joint Configuration ◽  
Wire Feed Speed ◽  
Wire Feed

Multi-properties optimization of welding parameters of wire arc additive manufacture in dissimilar joint of iron-based alloy and nickel-based superalloy using grey-based Taguchi method

2021 ◽  
pp. 095440622110089
Author(s):  
Yufeng Xia ◽  
Mengxia Peng ◽  
Haihao Teng ◽  
Yanhong Chen ◽  
Xue Zhang
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Welding Speed ◽  
Welding Parameters ◽  
Additive Manufacture ◽  
Feed Speed ◽  
Nickel Based Superalloy ◽  
Wire Feed Speed ◽  
Iron Based ◽  
Wire Feed

In order to adapt to the high temperature and heavy load process environment of large forgings, a novel die with “fist-like” structure was designed. The iron-based welding material (RMD248) as the “bone” layer and the nickel-based superalloy welding material (ERNiCr-3) as the “skin” layer were welded on the matrix by wire arc additive manufacture (WAAM). In this work, the grey based Taguchi methodology was used to optimize welding parameters (welding voltage, welding speed and wire feed speed) considering excellent multi-properties (hardness and ultimate tensile strength of high-temperature tensile test) of the dissimilar joint of RMD248 and ERNiCr-3. Further, analysis of variance was done to ascertain the influence of welding parameters on response parameters. Experimental results showed that welding speed was the most effective input parameter followed by wire feed speed and welding voltage. Finally, optimal result was verified through confirmation experiments. Meanwhile, the effect of welding speed on the microstructure and mechanical properties of joint was studied. The microstructures were characterized by optical microscopy (OM), energy dispersive spectrometer (EDS). The results indicated that the microstructure of RMD248 was consisted of more retained austenite at lower welding speed. For ERNiCr-3, the finer columnar crystal structure at higher welding speed was observed. At lower welding speed, the microhardness of RMD248 was just slightly lower, but that of ERNiCr-3 was significantly higher, and the ultimate tensile strength was higher. Therefore, the specimen at lower welding speed had better comprehensive mechanical properties.

Effect of Brazing Flux Pb on Microstructure and Mechanical Property of CMT Weld-Brazed Lap Joint of 5052 Aluminum Alloy to Galvanized Q235 Steel

2014 ◽  
Vol 789 ◽  
pp. 290-296 ◽  
Author(s):  
Hua Qing Lai ◽  
Sheng Lu
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Fusion Zone ◽  
Base Metal ◽  
Testing Machine ◽  
Galvanized Steel ◽  
Lap Joint ◽  
Cold Metal Transfer ◽  
Tensile Testing Machine ◽  
Q235 Steel

5052 aluminum alloy and galvanized Q235 steel sheets with thickness of 1mm were lap welded/brazed by cold metal transfer technology (CMT) with ER4043 as the filler wire and Pb foil as the brazing flux. Scanning electron microscope (SEM), microscope with super-depth, X-ray diffraction (XRD), electronic universal tensile testing machine and hardness tester were employed to study the microstructure and mechanical properties of the joint. The results indicate that Pb foil effectively improved the mechanical properties of the joint with tensile strength up to 160Mpa which is higher than that of the joint without the brazing flux of Pb foil. Intermetallic compound (IMC) layer in the brazing joint unequally distributed in the interface of aluminum alloy and galvanized steel. The thickness of IMC layer was about 1~3.5um. The main phases of the IMC layer were FeAl and AlFe6Si. Fine equiaxial crystals existed in the weld metal while columnar crystals existed in the fusion zone of aluminum alloy. The hardness of fusion zone was higher than base metal while the hardness of heat affected zone was lower than base metal. In most case, the lap joint was broken in the junction of base metal and fusion zone.

Application of MIG Welding Process of Mild Steel Wire in Additive Manufacturing

2021 ◽  
Vol 877 ◽  
pp. 73-79
Author(s):  
Pattarawadee Poolperm ◽  
Wasawat Nakkiew ◽  
Nirut Naksuk
Keyword(s):  
Additive Manufacturing ◽  
Steel Wire ◽  
Welding Process ◽  
Feed Speed ◽  
Mig Welding ◽  
Microhardness Testing ◽  
Wire Feed Speed ◽  
Forming Characteristics ◽  
Arc Current ◽  
Wire Feed

The purpose of this study is to investigate the forming characteristics of single-pass Metal Inert Gas (MIG) welding wire for multi-layer additive manufacturing parts. Influences of arc current, arc voltage, arc distances, welding speed, wire feed speed, temperatures and heat input on layer formation were analyzed. The deposition of material by MIG process is controlled by a robot (ABB) controller for constructing walls of rectangular box shape. The samples were measured with a microhardness testing and tensile testing onto the welded bead created by the additive manufacturing technique. It was found that the mechanical properties of microhardness values are between 151.70 to 155.80 HV and the tensile strength values are between 472.71 to 491.12 MPa according to transverse and longitudinal sections of the specimens.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

Research of Automatic Welding Machine Controlling System Based Single-Chip

2012 ◽  
Vol 214 ◽  
pp. 700-704
Author(s):  
Jin Hu Song
Keyword(s):  
Production Efficiency ◽  
Feed Speed ◽  
Automatic Welding ◽  
Single Chip ◽  
Interface Circuit ◽  
Welding Machine ◽  
Welding Technology ◽  
Controlling System ◽  
Wire Feed Speed ◽  
Wire Feed

In this paper, a scheme for the structure and controlling design of an all-position automatic welding machine is studied, and also the automatic welding systemis explored in depth. In this system, the C8051F020 single chip is used as the controller and the DC servo-motor as the executive component. Through the interface circuit and software program of the single chip, the system can control and harmonize the wire-feed speed as well as the tread and swing of the welding tractor, and can meet the needs of the all-position welding technology, hence realizing the automation of welding, and increasing the welding production efficiency.

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