scholarly journals The influence of residual stresses on laser beam welding processes of aluminium sheets

Procedia CIRP ◽  
2020 ◽  
Vol 94 ◽  
pp. 713-717
Author(s):  
Christian Hagenlocher ◽  
Jonas Wagner ◽  
Johannes Michel ◽  
Rudolf Weber ◽  
Maximilian Bachmann ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Laser Beam ◽  
Laser Beam Welding ◽  
Aluminium Sheets ◽  
Welding Processes

scholarly journals Thermal Analysis Simulation for Laser Butt Welding of Inconel625 Using FEA

2018 ◽  
Vol 7 (4.10) ◽  
pp. 85 ◽  
Author(s):  
Harinadh Vemanaboina ◽  
G. Edison ◽  
Suresh Akella ◽  
Ramesh Kumar Buddu
Keyword(s):  
Heat Source ◽  
Residual Stresses ◽  
Laser Beam ◽  
Laser Welding ◽  
Process Parameters ◽  
Heat Input ◽  
Laser Beam Welding ◽  
Source Model ◽  
Heat Source Model ◽  
Welding Processes

Laser welding process is employed in the manufacturing of critical components where the final assembly units necessitate strict tolerances like low distortions and residual stresses. Laser beam welding offers several advantages like low heat input, very narrow heat affected zone, low residual stresses, low distortions and good mechanical joint properties in the weld joints when compared to the conventional techniques like Tungsten Inert Gas Arc welding processes. However, the implementation of laser beam welding holds certain challenges like process parameters optimization, experimental set-up and handling and expensive costs. In order to minimize the complex experimental process, simulation techniques using Finite Element Methods (FEM) are employed in order to estimate the heat input and weld process optimization prior to the experiments. This greatly helps in the optimization and estimation of the incurred stresses and distortions with the adapted weld process with known input weld process parameters. The present work reports the Gaussian heat source model for the laser welding of Inconel 625 Alloy plates. The developed moving heat source model is presented and demonstrated with the thermal profiles in terms of the thermal histogram, temperature profiles in the joint cross sections through welded region, interface across the joints.  

scholarly journals Development of laser welding of high strength aluminium alloy 2024-T4 with controlled thermal cycle

2020 ◽  
Vol 326 ◽  
pp. 08005
Author(s):  
Mete Demirorer ◽  
Wojciech Suder ◽  
Supriyo Ganguly ◽  
Simon Hogg ◽  
Hassam Naeem
Keyword(s):  
Laser Beam ◽  
Laser Welding ◽  
Heat Input ◽  
Thermal Cycle ◽  
Laser Beam Welding ◽  
Base Material ◽  
High Strength ◽  
Cooling Rates ◽  
Aa 2024 ◽  
Welding Processes

An innovative process design, to avoid thermal degradation during autogenous fusion welding of high strength AA 2024-T4 alloy, based on laser beam welding, is being developed. A series of instrumented laser welds in 2 mm thick AA 2024-T4 alloys were made with different processing conditions resulting in different thermal profiles and cooling rates. The welds were examined under SEM, TEM and LOM, and subjected to micro-hardness examination. This allowed us to understand the influence of cooling rate, peak temperature, and thermal cycle on the growth of precipitates, and related degradation in the weld and heat affected area, evident as softening. Although laser beam welding allows significant reduction of heat input, and higher cooling rates, as compared to other high heat input welding processes, this was found insufficient to completely supress coarsening of precipitate in HAZ. To understand the required range of thermal cycles, additional dilatometry tests were carried out using the same base material to understand the time-temperature relationship of precipitate formation. The results were used to design a novel laser welding process with enhanced cooling, such as with copper backing bar and cryogenic cooling.

Finite Element Simulation of Laser Beam Welding Induced Residual Stresses and Distortions in a T-Joint Configuration for Aeronautic Structures

2009 ◽  
Author(s):  
Muhammad Zain-ul-abdein ◽  
Daniel Ne´lias ◽  
Jean-Franc¸ois Jullien ◽  
Dominique Deloison
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Laser Beam ◽  
Boundary Conditions ◽  
Laser Beam Welding ◽  
Temperature Fields ◽  
Heat Transfer Analysis ◽  
Small Scale ◽  
Joint Configuration ◽  
Simulation Results

Laser beam welding has found its application in the aircraft industry for the fabrication of fuselage panels in a T-joint configuration. However, the inconveniences like distortions and residual stresses are inevitable consequences of welding. The effort is made in this work to experimentally measure and numerically simulate the distortions induced by laser beam welding of a T-joint with industrially used thermal and mechanical boundary conditions on the thin sheets of aluminium 6056-T4. Several small scale experiments were carried out with various instrumentations to establish a database necessary to verify the simulation results. Finite element (FE) simulation is performed with Abaqus and the conical heat source is programmed in FORTRAN. Heat transfer analysis is performed to achieve the required weld pool geometry and temperature fields. Mechanical analysis is then performed with industrial loading and boundary conditions so as to predict the distortion and the residual stress pattern. A good agreement is found amongst the experimental and simulation results.

Prediction of laser beam welding-induced distortions and residual stresses by numerical simulation for aeronautic application

2009 ◽  
Vol 209 (6) ◽  
pp. 2907-2917 ◽  
Author(s):  
Muhammad Zain-ul-Abdein ◽  
Daniel Nelias ◽  
Jean-François Jullien ◽  
Dominique Deloison
Keyword(s):  
Numerical Simulation ◽  
Residual Stresses ◽  
Laser Beam ◽  
Laser Beam Welding

scholarly journals Numerical analysis of the effect of residual stresses in formed aluminum sheet metal parts on the hot crack formation during laser beam welding

Procedia CIRP ◽  
2020 ◽  
Vol 94 ◽  
pp. 708-712
Author(s):  
Jonas Wagner ◽  
Christian Hagenlocher ◽  
Rudolf Weber ◽  
Maximilian Bachmann ◽  
Celalettin Karadogan ◽  
...  
Keyword(s):  
Numerical Analysis ◽  
Residual Stresses ◽  
Laser Beam ◽  
Sheet Metal ◽  
Crack Formation ◽  
Laser Beam Welding ◽  
Aluminum Sheet ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Hot Crack

Evaluation of High Penetration Hybrid Laser-GMAW Welding Process Productivity Applied in the Joining of Thick Plates and Pipelines

2022 ◽  
Author(s):  
Rafael Gomes Nunes Silva ◽  
Max Baranenko Rodrigues ◽  
Milton Pereira ◽  
Koen Faes
Keyword(s):  
Laser Beam ◽  
Arc Welding ◽  
Manufacturing Industry ◽  
Operating Time ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Major Influence ◽  
Thick Plates ◽  
High Penetration ◽  
Welding Processes

Abstract Welding processes are present in all sectors of the industry, highlighting the manufacturing industry of thick plates and pipelines. In these applications, welding processes have a major influence on costs, schedules, risk analysis and project feasibility. Conventional arc welding processes, such as the gas metal arc welding (GMAW) process, have limitations when applied to high thickness joints due to their maximum achievable penetration depth. On the other hand, the laser beam welding (LBW) welding process, despite reaching high penetration depths, has several limitations mainly regarding the geometric tolerance of the joint. In this regard, the hybrid laser-arc welding (HLAW) process emerges as a promising bonding process, combining the advantages of the GMAW and LBW processes into a single melting pool. Despite the many operational and metallurgical advantages, the HLAW process presents a high complexity due to the high number of parameters involved and the interaction between the laser beam and the electric arc. The present work discusses the challenges involved in the parametrization of the HLAW process applied to the joining of thick plates and pipes, and empirically evaluated a comparison between the HLAW and GMAW processes, showing a reduction of operating time of approximately 40 times, and a reduction of consumption of shielding gas and filler material of approximately 20 times, evidencing the technical and financial contribution of the hybrid process.

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