Study on Double-pulse Welding Process of Aluminum Alloy Based on Fuzzy Self-tuning of PID Parameters

2020 ◽  
Author(s):  
Weidong Mao ◽  
Shengliang Li ◽  
Peirong Liu ◽  
Jiaxiang Xue
Keyword(s):  
Aluminum Alloy ◽  
Welding Process ◽  
Double Pulse ◽  
Self Tuning ◽  
Pulse Welding

scholarly journals Double-Pulse Triple-Wire MIG Welding of 6082-T6 Aluminum Alloy: Process Characteristics and Joint Performances

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1388
Author(s):  
Ke Yang ◽  
Fei Wang ◽  
Hongbing Liu ◽  
Peng Wang ◽  
Chuanguang Luo ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
High Efficiency ◽  
Welding Process ◽  
Pulse Frequency ◽  
Double Pulse ◽  
Fish Scale ◽  
Mig Welding ◽  
Process Characteristics ◽  
Pulse Welding

High-efficiency and high-quality welding has always been the focus of welding research. This article proposes a novel double-pulse, triple-wire MIG welding process for the welding of 6082-T6 aluminum alloy. The process characteristics of welding arc and droplet transfer were studied, and the performances of weld formation, morphology, hardness, and tensile strength were tested for the 1 Hz, 3 Hz, and 5 Hz double-pulse welding and normal-pulse welding. It was found that in the welding process, the pulsed arc steadily alternated among three welding wires without arc interruption, and the arc length changed periodically with the double-pulse frequency. The droplets transferred with a stable one-pulse-one-drop mode. Besides, a proper double-pulse frequency, e.g., 3 Hz in this case, was conducive to forming good welds with regular fish-scale patterns and no pores. The tensile strength of the joint could reach 64% of the base material’s tensile strength, and its fracture belonged to plastic fracture, which occurred in the HAZ. This new welding method will have great potential in aluminum alloy welding.

Weld Width Control System for Pulsed MIG Welding of Aluminum Alloy

2011 ◽  
Vol 299-300 ◽  
pp. 908-911
Author(s):  
Li Hui Lu ◽  
Ding Fan ◽  
Jian Kang Huang ◽  
Ming Zhu ◽  
Yu Shi
Keyword(s):  
Aluminum Alloy ◽  
Control System ◽  
Welding Process ◽  
Pulse Method ◽  
High Energy ◽  
Double Pulse ◽  
Mig Welding ◽  
Heat Accumulation ◽  
Weld Width ◽  
Vision Sensing

Due to strong heat accumulation and low surface tension of aluminum alloy, weld width will become wider, even subsidence in pulsed MIG welding process of aluminum alloy at constant parameters. A variable double-pulse method for weld width control is proposed. Weld width control is realized by changing double-pulse duty cycle that is the ratio of high-energy pulse time in a double-pulse cycle to adjust heat input based on the vision sensing for weld width. A rapid prototyping control system is built on the basis of vision sensing and xPC Target real-time environment. Then variable double-pulse MIG welding process test is done and proves the feasibility of the control scheme. On this basis, weld width control test in pulsed MIG welding of aluminum alloy is carried out and obtains a good weld with beautiful formation and uniform weld width. The results show that weld width control can be realized well with the variable double-pulse method in pulsed MIG welding of aluminum alloy.

Double-pulse femtosecond laser peening of aluminum alloy AA5038: Effect of inter-pulse delay on transient optical plume emission and final surface micro-hardness

2016 ◽  
Vol 109 (21) ◽  
pp. 211902 ◽  
Author(s):  
E. I. Ageev ◽  
V. Yu. Bychenkov ◽  
A. A. Ionin ◽  
S. I. Kudryashov ◽  
A. A. Petrov ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Femtosecond Laser ◽  
Double Pulse ◽  
Laser Peening ◽  
Micro Hardness ◽  
Pulse Delay ◽  
Final Surface ◽  
Plume Emission

Dimensional Analysis of Thermal Fields Surrounding Friction Stir Welding Process

2014 ◽  
Author(s):  
Lewis N. Payton ◽  
Vishnu Vardhan Chandrasekaran ◽  
Wesley S. Hunko
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Temperature Fields ◽  
Analytical Comparison ◽  
Friction Stir ◽  
Thermal Fields ◽  
Designed Experiment ◽  
Pi Theorem ◽  
Alloy 6061

A dimensionless correlation is developed based on Buckingham’s Pi-Theorem to estimate the temperature fields generated by the movement of a tool during the Friction Stir Welding of an aluminum alloy (6061-T6). Symmetrical thermocouple measurements are taken during a statistically designed experiment using different factor levels (RPM, Traverse, etc). Analytical comparison (using multivariate ANOVA) validates the predicted dimensionless correlation including the often-reported difference between the advancing versus retreating side of the Friction Stir Tool.

An alternative approach to thermal analysis using inverse problems in aluminum alloy welding

2017 ◽  
Vol 27 (3) ◽  
pp. 561-574 ◽  
Author(s):  
Elisan dos Santos Magalhaes ◽  
Cristiano Pedro da Silva ◽  
Ana Lúcia Fernandes Lima e Silva ◽  
Sandro Metrevelle Marcondes Lima e Silva
Keyword(s):  
Thermal Analysis ◽  
Heat Flux ◽  
Aluminum Alloy ◽  
Inverse Problems ◽  
Welding Process ◽  
Experimental Methodology ◽  
Function Technique ◽  
Content Type ◽  
Radiation Coefficient ◽  
Welding Processes

Purpose The purpose of this article is the determination of the temperature fields in a weld region has always been an obstacle to the improvement of welding processes. As an alternative, the use of inverse problems to determine the heat flux during the welding process allows an analysis of these processes. Design/methodology/approach This paper studies an alternative for the thermal analysis of the tungsten inert gas welding process on a 6,060 T5 aluminum alloy. For this purpose, a C++ code was developed, based on a transient three-dimensional heat transfer model. To estimate the amount of heat delivered to the plate, the specification function technique was used. Lab experiments were carried out to validate the methodology. A different experimental methodology is proposed to estimate the emissivity (radiation coefficient). Findings The maximum difference between experimental and numerical temperatures is lower than 5 per cent. The determined emissivity value for the aluminum 6,060 T5 presented a good agreement with literature values. The thermal fields were analyzed as function of the positive polarity. The specification function method proved to be an adequate tool for heat input estimation in welding analysis. Originality/value The proposed methodology proves to be a cheaper way to estimate the heat flux on the sample. The estimated power curves for the welding process are presented. The methodology to calculate the emissivity (radiation coefficient) was validated.

scholarly journals Increasing of the Mechanical Properties of Friction Stir Welded Joints of 6061 Aluminum Alloy by Introducing Alumina Particles

2017 ◽  
Vol 17 (2) ◽  
pp. 29-40 ◽  
Author(s):  
M. A. Tashkandi ◽  
J. A. Al-Jarrah ◽  
M. Ibrahim
Keyword(s):  
Aluminum Alloy ◽  
Base Metal ◽  
Welded Joints ◽  
Volume Fraction ◽  
Welding Process ◽  
Welding Zone ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
Alumina Particles ◽  
Welding Line

AbstractThe main aim of this investigation is to produce a welding joint of higher strength than that of base metals. Composite welded joints were produced by friction stir welding process. 6061 aluminum alloy was used as a base metal and alumina particles added to welding zone to form metal matrix composites. The volume fraction of alumina particles incorporated in this study were 2, 4, 6, 8 and 10 vol% were added on both sides of welding line. Also, the alumina particles were pre-mixed with magnesium particles prior being added to the welding zone. Magnesium particles were used to enhance the bonding between the alumina particles and the matrix of 6061 aluminum alloy. Friction stir welded joints containing alumina particles were successfully obtained and it was observed that the strength of these joints was better than that of base metal. Experimental results showed that incorporating volume fraction of alumina particles up to 6 vol% into the welding zone led to higher strength of the composite welded joints as compared to plain welded joints.

scholarly journals The effects of welding current and purging gas on mechanical properties and microstructure of tungsten inert gas welded aluminum alloy 5083 H116

2018 ◽  
Vol 197 ◽  
pp. 12007 ◽  
Author(s):  
Ekak Novianto ◽  
Priyo Tri Iswanto ◽  
Mudjijana Mudjijana
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Salt Water ◽  
Surface Hardness ◽  
Welding Process ◽  
Welding Current ◽  
Inert Gas ◽  
Aluminum Alloy 5083 ◽  
Welding Sequence ◽  
Weld Current

Aluminum alloy 5083 H116 has an exceptional performance in extreme environments, moderately high strength, outstanding corrosion resistance in salt water and high impact strength at cryogenic temperature. In the present study, Aluminum alloy AA 5083 H116 plates were joined by tungsten inert gas (TIG) process by single and double sided welding. Welding current used was 53 A and 80 A with the addition of purging gas during welding process. The effects on micro structure and mechanical properties like surface hardness and tensile strength of the welded region were studied. The results have shown that optimum current out of the two weld current used is 53 A. Better microstructures, tensile and hardness were found in the welded joint for the weld current 53 A where the tensile obtained in the softened zone was approximately 87% than that of the base metal (BM). With increasing of TIG current, the width of PMZ increased. In addition, the doubled sided welding sequence also produced broader PMZ area.

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