Numerical study of the residual stress and welding deformation of mid-thick plate of AA6061-T6 in the multi-pass MIG welding process

2021 ◽  
Author(s):  
Shusen Zhao ◽  
Yanmin Li ◽  
Rui Huang ◽  
Zhanshu He
Keyword(s):  
Residual Stress ◽  
Thick Plate ◽  
Numerical Study ◽  
Welding Process ◽  
Welding Deformation ◽  
Mig Welding

scholarly journals Numerical analysis of thermal deformation and residual stress in automotive muffler by MIG welding

2018 ◽  
Vol 5 (4) ◽  
pp. 382-390 ◽  
Author(s):  
S.H. Lee ◽  
E.S. Kim ◽  
J.Y. Park ◽  
J. Choi
Keyword(s):  
Residual Stress ◽  
Numerical Analysis ◽  
Cross Section ◽  
Molten Pool ◽  
Thermal Deformation ◽  
Welding Process ◽  
Experimental Results ◽  
Welding Deformation ◽  
Mig Welding ◽  
The Cross

Abstract In the automotive industry, metal inert gas (MIG) of welding technology is widely used for automotive muffler fabrication. However, the muffler is distorted by thermal deformation during the welding process. In this paper, the prediction of MIG welding-induced deformation and residual stress are simulated by SYSWELD software. The cross-section shapes of the molten pool predicted by the numerical analysis are compared to the experimental results. In the results of the stress, while compressive stresses are produced in regions away from the weld, high tensile stresses are produced in regions near the weld. Deformation values are calculated as 2.5 mm. The location of the actual welding deformation was similar to the experimental results. Based on the results, the methods to optimize the welding procedure will be provided by SYSWELD to improve muffler productivity. Highlights The prediction of MIG welding-induced deformation and residual stress are simulated by SYSWELD software. The cross-section shapes of the molten pool predicted by the numerical analysis are compared to the experimental results. The location of the actual welding deformation are similar to the experimental results. Based on the results, the methods will be provided by SYSWELD to improve muffler productivity.

Study on Welding Deformation and Residual Stress of H-Section Beam Based on Finite Element Method

2017 ◽  
Vol 753 ◽  
pp. 305-309 ◽  
Author(s):  
Xu Lu
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Finite Element ◽  
Source Parameters ◽  
Welding Process ◽  
Steel Structure ◽  
Bottom Plate ◽  
Welding Deformation ◽  
Element Simulation ◽  
Main Components

The welding H-section beam has good mechanical properties with its superior structure. So they become the main components of steel structure and have been widely used. In this paper, the welded H-section beam is used as the research object. The finite element simulation model is established. The heat source parameters are determined. The deformation of the steel due to the welding process is studied. The results show that the bottom plate and the bottom plate inward bending is about 2.32mm cause by welding process. The residual stress can reach 400MPa.

Comparison of Residual Stress Between MIG Welding and Friction Stir Welding

2012 ◽  
Vol 155-156 ◽  
pp. 1218-1222
Author(s):  
Lei Wang ◽  
Mitsuyosi Tsunori
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Stress Distribution ◽  
Yield Strength ◽  
Room Temperature ◽  
Welding Process ◽  
Residual Stress Distribution ◽  
Mig Welding ◽  
Friction Stir ◽  
Friction Stir Welding Process

Residual stress distribution plays a very important role in welded structures, the aim of present work is to find out the effect of different welding methods on the residual stress distribution by means of neutron diffraction measurements and FE models simulation. 4 mm thick DH-36 steel plates were butt welded by MIG welding process and 5 mm thick AA 2024 aluminium alloy plates were butt welded by friction stir welding process. Results show that residual stresses of MIG welding process are higher than those of friction stir welding process. The peak residual stress of MIG weld is close to the room temperature uniaxial yield strength of DH-36 while the peak residual stress of friction stir weld is just about 50% of the room temperature uniaxial yield strength of AA2024. The size effect of MIG welded and effect of welding speeds of friction stir welded on the residual stress distribution have also been studied in the paper.

The Effect of Strength Mis-Match and Residual Stress in ECA of Girth Welds With Internal Circumferential Cracks

2009 ◽  
Author(s):  
Ali Mirzaee Sisan ◽  
Afshin Motarjemi
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Driving Forces ◽  
Numerical Study ◽  
Welding Process ◽  
Detailed Comparison ◽  
Weld Strength ◽  
Residual Stress Field ◽  
Girth Welds ◽  
Welded Pipe

A numerical study was carried out to quantify the effect of a residual stress field on subsequent fracture behaviour of a girth welded pipe with an internal circumferential long crack when subjected to high applied strain loading. In order to introduce an initial residual stress field similar to a welding process in a pipe, a quenching process was numerically simulated and associated residual stress profiles were modified and mapped into the finite element (FE) models. A detailed comparison between the crack driving force for various cases with and without residual stress and weld strength mismatch was carried out for cases under a high plastic deformation regime. The BS7910 procedure was also used to predict crack driving forces using its current assumption of interaction of residual stress with primary loads. The results obtained from the FE analyses were compared with the BS7910 predictions.

scholarly journals Multi-Objective Optimization of MIG Welding and Preheat Parameters for 6061-T6 Al Alloy T-Joints Using Artificial Neural Networks Based on FEM

Coatings ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 998
Author(s):  
Qing Shao ◽  
Fuxing Tan ◽  
Kai Li ◽  
Tatsuo Yoshino ◽  
Guikai Guo
Keyword(s):  
Process Parameters ◽  
Welding Speed ◽  
Heat Input ◽  
Pareto Front ◽  
Welding Process ◽  
Residual Deformation ◽  
Welding Deformation ◽  
Mig Welding ◽  
Preheat Temperature ◽  
Multi Objective

To control the welding residual stress and deformation of metal inert gas (MIG) welding, the influence of welding process parameters and preheat parameters (welding speed, heat input, preheat temperature, and preheat area) is discussed, and a prediction model is established to select the optimal combination of process parameters. Thermomechanical numerical analysis was performed to obtain the residual welding deformation and stress according to a 100 × 150 × 50 × 4 mm aluminum alloy 6061-T6 T-joint. Owing to the complexity of the welding process, an optimal Latin hypercube sampling (OLHS) method was adopted for sampling with uniformity and stratification. Analysis of variance (ANOVA) was used to find the influence degree of welding speed (7.5–9 mm/s), heat input (1500–1700 W), preheat temperature (80–125 °C), and preheat area (12–36 mm). The range of research parameters are according to the material, welding method, thickness of the welding plate, and welding procedure specification. Artificial neural network (ANN) and multi-objective particle swarm optimization (MOPSO) was combined to find the effective parameters to minimize welding deformation and stress. The results showed that preheat temperature and welding speed had the greatest effect on the minimization of welding residual deformation and stress, followed by the preheat area, respectively. The Pareto front was obtained by using the MOPSO algorithm with ε-dominance. The welding residual deformation and stress are the minimum at the same time, when the welding parameters are selected as preheating temperature 85 °C and preheating area 12 mm, welding speed is 8.8 mm/s and heat input is 1535 W, respectively. The optimization results were validated by the finite element (FE) method. The error between the FE results and the Pareto optimal compromise solutions is less than 12.5%. The optimum solutions in the Pareto front can be chosen by designers according to actual demand.

Analysis on the Welding Thermal Field and Residual Stress of Thick Plate

2015 ◽  
Vol 1095 ◽  
pp. 693-697
Author(s):  
Jiu Hong Jiang ◽  
Qiang Wang ◽  
Wen Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Thick Plate ◽  
Thermal Field ◽  
Welding Process ◽  
Source Model ◽  
Simulation Software ◽  
Welding Residual Stress ◽  
Element Simulation ◽  
Thick Steel

A 60mm Q345 rigid thick plate with V groove welding connection was modeled in order to simulate the welding residual stress by finite element method. Both element birth and death technique and double ellipse heat source model were introduced to simulate the welding process. The welding thermal field and residual stress of thick steel plate were analyzed by finite element simulation software ANSYS.Then the thermal field and residual stress distribution were visually demonstrated. The result shows that the thermal field shaped like a spindle during welding period and the residual stress at the mid-section in lateral, longitudinal and thickness direction of the welding joint is lower than the stress at the surface of the welding connection.

scholarly journals Numerical study for reliability assessment of a corroding pipe to flange weld joint over its lifetime

2021 ◽  
Vol 41 (1) ◽  
Author(s):  
Mourad Nahal ◽  
Abdelaziz Lakehal ◽  
Rabia Khelif
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Weld Joint ◽  
Numerical Study ◽  
Reliability Assessment ◽  
Welding Process ◽  
Stress Effects ◽  
Corrosion Rates ◽  
Welded Connection ◽  
Stress Models

Numerical model of a corroded weld joint connecting pipe to flange using a finite element method was developed, and coupled with usual stress models. The structure material has been characterized experimentally. Monte Carlo simulations, FORM and SORM methods have been applied for estimating reliability and failure probability under corrosion and residual stress effects. A numerical case with various corrosion rates was conducted to determine the reliability of the welded connection pipe to flange. The obtained results show that the heat affected zone is very sensitive to corrosion effects due to the welding process.

Modeling and Simulation of Mecano-Welding Process for Cylinders

2012 ◽  
Author(s):  
Zhengkun Feng ◽  
Henri Champliaud
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Arc Welding ◽  
Thick Plate ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
The Third ◽  
Metal Arc Welding ◽  
Roll Bending ◽  
Arc Welding Process

Pyramidal three-roll bending is widely used in manufacture due to its simple configuration and advantage for thick plate roll bending. However, there remain two planar zones near the front and rear ends of the bent shape. A mecano-welding process which provides improved circularity of the bent shape is proposed in this paper. This process includes three sub-processes: the first sub-process is the roll bending from a plate with cylindrical rolls; the second sub-process is the gas metal arc-welding process used to join the gap of the bent tubular section; the third sub-process is the rerun roll bending of the welded shape. Results of the numerical simulation of the first two sub-processes under the well-known ANSYS and ANSYS/LS-DYNA environment are reported. The bent shape after the first roll bending, the distributions of the temperature and residual stress after the welding are illustrated and discussed.

A Numerical Study on Mock-Up Downsizing to Predict Residual Stresses at CRDM Welds

2010 ◽  
Author(s):  
Ik-Joong Kim ◽  
Jae-Uk Jeong ◽  
Jae-Boong Choi ◽  
Young-Jin Kim ◽  
Sung-Woo Kim ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Nuclear Power ◽  
Power Plants ◽  
Numerical Study ◽  
Welding Process ◽  
Piping System ◽  
Experimental Conditions ◽  
Control Rod ◽  
Set Up

Since several defects caused by PWSCC (Primary Water Stress Corrosion Cracking) have been observed at the piping system of nuclear power plants, during the last two decades, lots of analytical and experimental researches have been performed to find out the relationship between the residual stress and PWSCC initiations. The present research deals with prediction of the residual stress at welding parts of CRDM (Control Rod Drive Mechanism). Especially, numerical investigations are carried out to support relevant experimental set-up because it is not easy to prepare large-sized mock-ups comparable to real geometry. First, preliminary examination was performed to establish an optimized welding process simulation procedure to accurately predict weld residual stresses. Then, detailed parametric FE analyses were carried out to examine effects of varying geometries and experimental conditions. Key findings were obtained from the FE analyses, which were used for finalizing the configuration of mock-up, are fully discussed in this manuscript.

Hybrid Welding vs Conventional Welding: A Solution to Residual Stress and Distortion Mitigation?

2017 ◽  
Author(s):  
Sébastien Gallee ◽  
Rémi Lacroix ◽  
Vincent Robin ◽  
Florence Gommez ◽  
Erwan Jourden
Keyword(s):  
Residual Stress ◽  
Heat Source ◽  
Welding Process ◽  
Quality Standard ◽  
Experimental Measurements ◽  
Hybrid Welding ◽  
Mig Welding ◽  
Steel Sheets ◽  
Laser Heat Source ◽  
Process Productivity

The present paper deals with the hybrid laser/MIG welding process, which allows to assembly high thickness steel sheets. The laser heat source added to the MIG torch improves the process productivity while respecting quality standard. The multi-pass welding simulation of a plate is presented in this paper and numerical results are compared to experimental measurements (temperature and stresses).

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