Bypass-current plasma arc welding of aluminum alloy: thermal behavior, residual stress, and distortion

2022 ◽  
Author(s):  
Yugang Miao ◽  
Ziran Wang ◽  
Ji Liu ◽  
Yuyang Zhao ◽  
Yifan Wu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Thermal Behavior ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc

Review of Wire Arc Additive Manufacturing for 3D Metal Printing

2019 ◽  
Vol 13 (3) ◽  
pp. 346-353 ◽  
Author(s):  
Johnnieew Zhong Li ◽  
Mohd Rizal Alkahari ◽  
Nor Ana Binti Rosli ◽  
Rafidah Hasan ◽  
Mohd Nizam Sudin ◽  
...  
Keyword(s):  
Residual Stress ◽  
Arc Welding ◽  
Inert Gas ◽  
Plasma Arc Welding ◽  
Heat Sources ◽  
Plasma Arc ◽  
Tungsten Inert Gas Welding ◽  
Metal Printing ◽  
3D Metal Printing ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce costs and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components. In this paper, wire-based and wire arc technology processes for 3D metal printing, including their advantages and limitations are reviewed. The optimization parametric study and modification of WAAM to reduce both residual stress and distortion are tabulated, summarized, and discussed.

scholarly journals Effect of Plasma Arc Welding on Residual Stress and Distortion of Thin Titanium Sheet

2019 ◽  
Vol 22 (6) ◽  
Author(s):  
Muthusamy Arunkumar ◽  
Veeman Dhinakaran ◽  
Nallathambhi Sivashanmugam ◽  
Vijay Petley
Keyword(s):  
Residual Stress ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Titanium Sheet

Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates

2021 ◽  
Vol 33 (8) ◽  
pp. 087103
Author(s):  
Bin Xu ◽  
Shinichi Tashiro ◽  
Manabu Tanaka ◽  
Fan Jiang ◽  
Shujun Chen
Keyword(s):  
Aluminum Alloy ◽  
Fluid Flow ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Physical Mechanisms ◽  
Variable Polarity ◽  
Variable Polarity Plasma Arc

Plasma-arc welding of aluminum alloy cryogenic piping

1977 ◽  
Vol 13 (2) ◽  
pp. 143-145
Author(s):  
V. I. Astakhin ◽  
A. S. Bychkov ◽  
V. A. Konovalov ◽  
R. M. Meirov
Keyword(s):  
Aluminum Alloy ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc

scholarly journals Comparative evaluation of methods of arc and hybrid plasma-arc welding of aluminum alloy 1561 using consumable electrode

2017 ◽  
Vol 2017 (4) ◽  
pp. 30-34 ◽  
Author(s):  
V.N. Korzhik ◽  
◽  
N.A. Pashchin ◽  
O.L. Mikhoduj ◽  
A.A. Grinyuk ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Arc Welding ◽  
Comparative Evaluation ◽  
Consumable Electrode ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Hybrid Plasma ◽  
Evaluation Of Methods

Interface characteristics and formation mechanism of plasma arc welding-brazing aluminum alloy/ultrahigh-strength steel joint

2021 ◽  
Vol 118 (4) ◽  
pp. 405
Author(s):  
Di Wu ◽  
Wenhua Geng ◽  
Hongmei Li ◽  
Lei Wang ◽  
Ke Yu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Formation Mechanism ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Interface Zone ◽  
Ultrahigh Strength ◽  
Ultrahigh Strength Steel ◽  
Interface Characteristics

A butt welding-brazing joint of 5A06 aluminum alloy and DP1180 ultrahigh-strength steel was carried out by using plasma arc welding (PAW) with Al-Si welding wire. Interface characteristics, formation mechanism and mechanical properties of the joint were investigated. The results showed that the dissimilar joint contained bond zone, weld zone and Al/steel interface zone. During PAW, the inter-diffusion of Fe and Al and the interfacial reaction occurred, and the double-layer structure intemtallics (IMCs) composed of Fe4Al13 layer and Fe2Al5 layer were produced in the interface zone. The thickness and morphology of both IMC layers depended on different positions in the interface zone. The Fe2Al5 layer thickness decreased obviously and its morphology changed from continuous layer to discontinuous layer with the decrease of welding heat input. The average tensile strength of the joint was 88 MPa and the joint fractured at the Al/steel interface zone with the highest hardness (524 HV). The interface zone IMCs were the main factor of affecting the mechanical properties of aluminum alloy and ultrahigh-strength steel PAW joint.

scholarly journals Science intensive technologies of welding in aluminum alloy vehicle manufacturing

2016 ◽  
Vol 1 (5) ◽  
pp. 3-9 ◽  
Author(s):  
В. Овчинников ◽  
V. Ovchinnikov
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Welded Joints ◽  
Friction Welding ◽  
Arc Welding ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Railway Transport

The effectiveness of aluminum alloy use for manufacturing gears of tank trucks, cement trucks and fright car bodies of railway transport is shown. For these objects manufacturing it is efficiently to use aluminum alloys 1565 and B 1341 the welded joints of which are made with the use of science intensive techniques of plasma-arc welding and friction welding with an agitation.

scholarly journals Comparative evaluation of methods of arc and hybrid plasma-arc welding of aluminum alloy 1561 using consumable electrode

2017 ◽  
Vol 2017 (4) ◽  
pp. 32-37 ◽  
Author(s):  
V.N. Korzhik ◽  
◽  
N.A. Pashchin ◽  
O.L. Mikhoduj ◽  
A.A. Grinyuk ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Arc Welding ◽  
Comparative Evaluation ◽  
Consumable Electrode ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Hybrid Plasma ◽  
Evaluation Of Methods
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