Welding Simulation of Non-Nominal Structures With Clamps

2015 ◽  
Vol 15 (2) ◽  
Author(s):  
Samuel Lorin ◽  
Christoffer Cromvik ◽  
Fredrik Edelvik ◽  
Rikard Söderberg
Keyword(s):  
Weld Joint ◽  
Welding Process ◽  
Industrial Applications ◽  
Rigid Bodies ◽  
Welding Distortion ◽  
Butt Weld ◽  
Welding Simulation ◽  
Will Force ◽  
Geometric Variation ◽  
Variation Simulation

In any industrial assembly process, there are a number of sources of variation. Variation in the manufacturing process leads to component variation, which, together with fixture variation and variation stemming from the joining process, propagates to the final product. In order to analyze and diminish the effect of variation, it is important to identify and be able to simulate the phenomena contributing to final variation. In this paper, the focus is variation in welding distortion arising from non-nominal components that are joined. In the welding process, it has been shown that variation in components and in fixtures influences the size and distribution of weld-induced distortion. Hence, in order to accurately simulate geometric variation of an assembly joined by weld joints, variation simulation and welding simulation need to be performed in combination. Previous research that focused on the combination of variation simulation and welding simulation has not considered components that are clamped. Instead the components were treated as rigid bodies at non-nominal positions prior to welding. In many industrial applications, clamps are used when assemblies are welded, and it is therefore important to quantify the influence that clamping has on welding of non-nominal components. In this paper, we simulate the combination of variation in components and fixtures with welding, considering that the components are clamped prior to welding. Although clamps will force the components closer to their nominal positions along the weld joint, they also introduce a stress field in the structure, which together with the welding process may cause additional distortion. Two case studies are performed and analyzed: a T-weld joint and a butt-weld joint. The results show that welding distortion depends on fixture error even in the presence of clamps.

On the effect of heat input in plasma microwelding of maraging steel

2017 ◽  
Vol 233 (3) ◽  
pp. 807-822
Author(s):  
Tinku Saikia ◽  
Mayuri Baruah ◽  
Swarup Bag
Keyword(s):  
Finite Element ◽  
Maraging Steel ◽  
Process Parameters ◽  
Weld Joint ◽  
Heat Input ◽  
Process Model ◽  
Welding Process ◽  
Fusion Welding ◽  
Welding Distortion ◽  
Influence Of Process Parameters

Maraging steel in known as ultra-high strength and toughness material widely used in aerospace industry and defense system. The joining of this material by fusion welding process experiences gigantic metallurgical transformation that have significant contribution toward the development of welding distortion, and transformation of austenite into martensite at very low temperature with significant increase in specific volume. In this study, a set of bead-on-plate welding is executed at microscale to establish feasible range of process parameters using plasma arc as a source of heat. Although, high-concentrated heat does not produce much distortion, the heat input to the weld joint experiences the difference in possible distortion. A finite element–based numerical process model is also developed to investigate the differential influence of process parameters on thermo-mechanical behavior of weld joint. An inverse approach is followed to estimate the unknown input parameters by integrating the finite element model with optimization algorithm. The integrated model predicts the shape and size of weld geometry and welding distortion that are well agreed with experimental values.

Variation Simulation of Welded Assemblies Using a Thermo-Elastic Finite Element Model

2014 ◽  
Vol 14 (3) ◽  
Author(s):  
Samuel Lorin ◽  
Christoffer Cromvik ◽  
Fredrik Edelvik ◽  
Lars Lindkvist ◽  
Rikard Söderberg
Keyword(s):  
Finite Element ◽  
Element Model ◽  
Welding Distortion ◽  
Elastic Model ◽  
Reasonable Accuracy ◽  
Statistical Accuracy ◽  
Manufactured Products ◽  
Geometric Variation ◽  
Variation Simulation

Every series of manufactured products has geometric variation. Variation can lead to products that are difficult to assemble or products not fulfilling functional or aesthetic requirements. In this paper, we will consider the effects of welding in variation simulation. Earlier work that has been combining variation simulation with welding simulation has either applied distortion based on nominal welding conditions onto the variation simulation result, hence loosing combination effects, or has used transient thermo-elasto-plastic simulation, which can be very time consuming since the number of runs required for statistical accuracy can be high. Here, we will present a new method to include the effects of welding in variation simulation. It is based on a technique that uses a thermo-elastic model, which previously has been shown to give distortion prediction within reasonable accuracy. This technique is suited for variation simulations due to the relative short computation times compared to conventional transient thermo-elasto-plastic simulations of welding phenomena. In a case study, it is shown that the presented method is able to give good predictions of both welding distortion and variation of welding distortions compared to transient thermo-elasto-plastic simulations.

Variation Simulation of Welded Assemblies Using a Thermo-Elastic Finite Element Model

2013 ◽  
Author(s):  
Samuel Lorin ◽  
Christoffer Cromvik ◽  
Fredrik Edelvik ◽  
Lars Lindkvist ◽  
Rikard Söderberg
Keyword(s):  
Finite Element ◽  
Element Model ◽  
Welding Distortion ◽  
Elastic Model ◽  
Reasonable Accuracy ◽  
Statistical Accuracy ◽  
Manufactured Products ◽  
Geometric Variation ◽  
Variation Simulation

Every series of manufactured products has geometric variation. Variation can lead to products that are difficult to assemble or products not fulfilling functional or aesthetical requirements. In this paper, we will consider the effects of welding in variation simulation. Earlier work that have been combining variation simulation with welding simulation have either applied distortion based on nominal welding conditions onto the variation simulation result, hence loosing combination effects, or have used transient thermo-elasto-plastic simulation, which can be very time consuming since the number of runs required for statistical accuracy can be high. Here, we will present a new method to include the effects of welding in variation simulation. It is based on a technique that uses a thermo-elastic model, which previously has been shown to give distortion prediction within reasonable accuracy. This technique is suited for variation simulations due to the relative short computation times compared to conventional transient thermo-elasto-plastic simulations of welding phenomena. In a case study, it is shown that the presented method is able to give good predictions of both welding distortion and variation of welding distortions compared to transient thermo-elasto-plastic simulations.

Welding simulation of circumferential weld joint using TIG welding process

2021 ◽  
Author(s):  
Hitesh Arora ◽  
K. Mahaboob Basha ◽  
D. Naga Abhishek ◽  
B. Devesh
Keyword(s):  
Weld Joint ◽  
Welding Process ◽  
Tig Welding ◽  
Welding Simulation

scholarly journals Welding of high-entropy alloys and compositionally complex alloys—an overview

2021 ◽  
Author(s):  
Michael Rhode ◽  
Tim Richter ◽  
Dirk Schroepfer ◽  
Anna Maria Manzoni ◽  
Mike Schneider ◽  
...  
Keyword(s):  
Weld Joint ◽  
Single Phase ◽  
Welding Process ◽  
Industrial Applications ◽  
High Entropy Alloys ◽  
Trade Off ◽  
High Entropy ◽  
Crystalline Defects ◽  
Joint Properties ◽  
Two Phases

AbstractHigh-entropy alloys (HEAs) and compositionally complex alloys (CCAs) represent new classes of materials containing five or more alloying elements (concentration of each element ranging from 5 to 35 at. %). In the present study, HEAs are defined as single-phase solid solutions; CCAs contain at least two phases. The alloy concept of HEAs/CCAs is fundamentally different from most conventional alloys and promises interesting properties for industrial applications (e.g., to overcome the strength-ductility trade-off). To date, little attention has been paid to the weldability of HEAs/CCAs encompassing effects on the welding metallurgy. It remains open whether welding of HEAs/CCAs may lead to the formation of brittle intermetallics and promote elemental segregation at crystalline defects. The effect on the weld joint properties (strength, corrosion resistance) must be investigated. The weld metal and heat-affected zone in conventional alloys are characterized by non-equilibrium microstructural evolutions that most probably occur in HEAs/CCAs. The corresponding weldability has not yet been studied in detail in the literature, and the existing information is not documented in a comprehensive way. Therefore, this study summarizes the most important results on the welding of HEAs/CCAs and their weld joint properties, classified by HEA/CCA type (focused on CoCrFeMnNi and AlxCoCrCuyFeNi system) and welding process.

Variation Simulation of Compliant Metal Plate Assemblies Considering Welding Distortion

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Wooyoung Choi ◽  
Hyun Chung
Keyword(s):  
Welding Process ◽  
Offshore Structures ◽  
Welding Distortion ◽  
Influence Coefficient ◽  
Mechanical Assembly ◽  
Offshore Structure ◽  
Shipbuilding Industry ◽  
Proposed Model ◽  
Variation Simulation ◽  
Joining Process

The shipbuilding industry employs numerous cutting and joining processes to build the ship and offshore structure. Welding, as the primary joining process, inherently causes distortion and accounts for most of the major geometrical variation in the intermediate products (IPs), thus adversarially affecting the downstream assembly processes. Because of the welding process, the variation analysis of compliant assemblies in shipbuilding is clearly different from that of the automobile and aerospace industries, where the distortion during the joining process is negligible. This paper proposes a variation simulation model including the effects of joining process distortion for ships and offshore structures. The proposed model extends the concepts of the sources of variation and the method of influence coefficient (MIC) for a compliant mechanical assembly to include the welding distortions. The proposed model utilizes welding distortion patterns and a transformation matrix to efficiently model the deformation due to the joining process. Also the welding distortions are represented as stochastic values due to its randomness. The model is verified by case study simulation and by a comparison with welding experimental results.

scholarly journals Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

2021 ◽  
Vol 11 (10) ◽  
pp. 4694
Author(s):  
Christian Wacker ◽  
Markus Köhler ◽  
Martin David ◽  
Franziska Aschersleben ◽  
Felix Gabriel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
High Energy ◽  
Welding Distortion ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Industrial Use ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

Brittle Fracture Analysis of a Dissimilar Metal Weld

2013 ◽  
Author(s):  
A. Blouin ◽  
S. Chapuliot ◽  
S. Marie ◽  
J. M. Bergheau ◽  
C. Niclaeys
Keyword(s):  
Brittle Fracture ◽  
Weld Joint ◽  
Threshold Stress ◽  
Base Alloy ◽  
Welding Process ◽  
Loading Conditions ◽  
Brittle To Ductile Transition ◽  
Dissimilar Metal ◽  
Dissimilar Metal Weld ◽  
Metal Weld

One important part of the integrity demonstration of large ferritic components is based on the demonstration that they could never undergo brittle fracture. Connections between a ferritic component and an austenitic piping (Dissimilar Metal Weld — DMW) have to respect these rules, in particular the Heat Affected Zone (HAZ) created by the welding process and which encounters a brittle-to-ductile transition. Within that frame, the case considered in this article is a Ni base alloy narrow gap weld joint between a ferritic pipe (A533 steel) and an austenitic pipe (316L stainless steel). The aim of the present study is to show that in the same loading conditions, the weld joint is less sensitive to the brittle fracture than the surrounding ferritic part of the component. That is to say that the demonstration should be focused on the ferritic base metal which is the weakest material. The bases of this study rely on a stress-based criterion developed by Chapuliot et al., using a threshold stress (σth) below which the cleavage cannot occur. This threshold stress can be used to define the brittle crack occurrence probability, which means it is possible to determine the highest loading conditions without any brittle fracture risk.

Thermomechanical Analysis of the Welding Process Using the Finite Element Method

1975 ◽  
Vol 97 (3) ◽  
pp. 206-213 ◽  
Author(s):  
E. Friedman
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Analytical Models ◽  
The Finite Element Method ◽  
Nonuniform Temperature ◽  
Butt Weld ◽  
Transverse Bending ◽  
Finite Element Formulations

Analytical models are developed for calculating temperatures, stresses and distortions resulting from the welding process. The models are implemented in finite element formulations and applied to a longitudinal butt weld. Nonuniform temperature transients are shown to result in the characteristic transverse bending distortions. Residual stresses are greatest in the weld metal and heat-affected zones, while the accumulated plastic strain is maximum at the interface of these two zones on the underside of the weldment.

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