Gas Metal Arc Welded (GMAW) Joint Strength Comparison of Aluminum Sheet (5754) and Exturded (6063) Alloys

2007 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Armando Joaquin ◽  
Matthew Zaluzec ◽  
Chris Karas
Keyword(s):  
Flow Rate ◽  
Gas Flow ◽  
Gma Welding ◽  
Surface Condition ◽  
Power Input ◽  
Pulse Frequency ◽  
Weld Penetration ◽  
Phase 2 ◽  
Lap Joint ◽  
Gas Flow Rate

The development of lightweight vehicles, in particular aluminum intensive vehicles, require significant manufacturing process development for joining and assembling aluminum structures. Currently, 5xxx and 6xxx aluminum alloys are being used in various structural applications in a number of lightweight vehicles worldwide. Various joining methods, such as GMAW (it is also referred as Metal Inert Gas Welding), Laser and adhesive bonding have been investigated as technology enablers for high volume joining of 5xxx, and 6xxx series alloys. In this study, GMA welding was used to join 5754 non-heat-treatable alloy sheet and 6063-T6 heat treatable extrusion products. The objective of this study was to develop optimum weld process parameters for non-heat-treatable 5754 aluminum and heat treatble 6063-T6 alloys. For both the alloys, the lap joint configuration was used. The GMA welding equipment used in this study was an OTC/Daihen CPD-350 welding systems and DR-4000 pulse power supply. In the first phase of the experiments for 5754 aluminum alloy, the factors selected for the experiment were power input (torch speed, voltage, current, wire feed), pulse frequency, gas flow rate and surface condition. A full factorial design of experiment (DOE) was conducted (DOE #1) to understand the main and interaction effects on lap joint failure and weld penetration. Based on the results from phase 1 results, surface condition was eliminated in the phase 2 experiments. In phase 2 experiments for heat treatable alloys 6063 T6, the factors selected were power input (torch speed, voltage, current, wire feed), pulse frequency, gas flow rate, torch angle, and arc intensity. A partial factorial DOE was conducted (DOE # 2) primarily to understand the main effects and some two level interaction effects. For both phase 1 (non-heat treatable alloy 5754) and phase 2 (heat treatable alloy 6063-T6) experiments, the factors influence on the mechanical properties of the lap joint, metallurgy (weld penetration) and micro hardness were evaluated. Post weld analysis indicates for non heat treatable alloy 5754, power input and gas flow rate are the two signficant factors (statistically) based on lap shear load to failure and weld penentration data. For heat treatable alloy 6063, power input was the significant factor on joint load to failure, however, for weld penetration, power input, pulse frequency and gas flow rate were the significant factors. Based on the joint strength and weld penetration, optimum weld process factors were determined for both non-heat treatable alloy 5754 and heat treatble alloy 6063 T6.

Metal Inert Gas (MIG) Welding Process Optimization for Joining Aluminum 5754 Sheet Material Using OTC/Daihen Equipment

Manufacturing ◽  
2003 ◽  
Author(s):  
R. Koganti ◽  
C. Karas ◽  
A. Joaquin ◽  
D. Henderson ◽  
M. Zaluzec ◽  
...  
Keyword(s):  
Aluminum Alloys ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Power Input ◽  
Interaction Effects ◽  
Inert Gas ◽  
Weld Penetration ◽  
Mig Welding ◽  
Gas Flow Rate

The development of lightweight vehicles, in particular aluminum intensive vehicles, require significant manufacturing process development for joining and assembling aluminum structures. Currently, 5xxx and 6xxx aluminum alloys are being used in various structural applications in a number of lightweight vehicles worldwide. Various joining methods, such as MIG, Laser and adhesive bonding have been investigated as technology enables for high volume joining of 5xxx, and 6xxx series alloys. In this study, metal inert gas (MIG) welding is used to join 5754 non-heat-treatable alloy sheet products. The objective of this study is to develop optimum weld process parameters for non-heat-treatable 5754 aluminum alloys. The MIG welding equipment used in this study is an OTC/Daihen CPD-350 welding systems and DR-4000 pulse power supply. The factors selected to understand the influence of weld process parameters on the mechanical properties and metallurgy (weld penetration) include power input (torch speed, voltage, current, wire feed), pulse frequency, and gas flow rate. Test coupons used in this study were based on a single lap configuration. A full factorial design of experiment (DOE) was conducted to understand the main and interaction effects on joint failure and weld penetration. The joint strengths and weld penetrations are measured for various operating ranges of weld factors. Post weld analysis indicates, power input and gas flow rate are the two signficant factors (statistically) based on lap shear load to failure and weld penentration data. There were no 2-way or 3-way interaction effects observed in ths weld study. Based on the joint strength and weld penetration, optimum weld process factors were determined.

Degradation of Organophosphorus Pesticide in a Packed-Bed Plasma Reactor: Effects of Operating Parameters and Kinetics Study

2013 ◽  
Vol 781-784 ◽  
pp. 1637-1645 ◽  
Author(s):  
Ting Jun Ma ◽  
Yi Qing Xu
Keyword(s):  
Removal Efficiency ◽  
Flow Rate ◽  
Gas Flow ◽  
Plasma Reactor ◽  
Organophosphorus Pesticide ◽  
Packed Bed ◽  
Pulse Frequency ◽  
Gas Flow Rate ◽  
Peak Voltage ◽  
Initial Concentration

The degradation effectiveness and reaction kinetics of representative organophosphorus (OP) pesticide in a packed-bed plasma reactor have been studied. Important parameters, including peak voltage, pulse frequency, gas-flow rate, initial concentration, diameter of catalyst particles, and thickness of catalyst bed which influences the removal efficiency, were investigated. Experimental results indicated that rogor removal efficiency as high as 80% can be achieved at 35 kV with the gas flow rate of 800 mL/min and initial concentration of 11.2 mg/m3.The removal efficiency increased with the increase of pulsed high voltage, and pulse frequency, the decrease of the diameter of catalyst particles and the thickness of catalyst bed. Finally, a model was established to predict the degradation of the rogor, which generally can simulate the experimental measurements to some degree.

Optimization of Welding Parameters and Microstructure and Fracture Mode Characterization of GMA Welding by Using Taguchi Method on SS304H Austenitic Steel

2020 ◽  
Vol 22 (4) ◽  
pp. 1121-1132
Author(s):  
Saadat Ali Rizvi ◽  
Wajahat Ali
Keyword(s):  
Tensile Strength ◽  
Flow Rate ◽  
Fracture Mode ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Feed Speed ◽  
Gas Flow Rate ◽  
Tensile Test Specimen

AbstractThis study is centre on optimizing different welding parameters which affect the weldability of SS304H, Taguchi technique was employed to optimize the welding parameters and fracture mode characterization was studied. A number of experiments have been conducted. L9 orthogonal array (3×3) applied for it. Analysis of variance (ANOVA) and signal to noise ratio (SNR), a statistical technique was applied to determine the effect of different welding parameters such as welding current, wire feed speed and gas flow rate on weldability of SS304H. Tensile strength, toughness, micro hardness and mode of fracture was examined to determine weldability of SS304H and it was observed from result that welding voltage have major impact whereas gas flow rate has minour impact on ultimate tensile strength of the welded joints and optimum process parameters were found to be 23 V, 350 IPM travel speed of wire and 15 l/min gas flow rate for tensile strength and mode of fracture was ductile fracture for tensile test specimen.

scholarly journals Process Parameters Optimization for GMA Welding of AISI 1008 Steel Joints for Optimal Tensile Strength

2021 ◽  
Vol 31 (6) ◽  
pp. 349-354
Author(s):  
Cynthia S. Abima ◽  
Stephen A. Akinlabi ◽  
Nkosinathi Madushele ◽  
Esther T. Akinlabi
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Flow Rate ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Current ◽  
Parameters Optimization ◽  
Gas Flow Rate ◽  
Arc Voltage ◽  
Input Parameters

Parameters optimization has become a gateway to achieving quality welds with improved properties desirable for construction and industrial applications. The complex interaction of welding input parameters requires process optimization to achieve optimal responses (s). This study reports the optimization of input parameters for Gas Metal Arc Welding (GMAW) for optimal ultimate tensile strength in AISI 1008 steel joints. Three levels of arc voltage, welding current, and gas flow rate were selected as input parameters, while the targeted output response is the ultimate tensile strength. Taguchi’s method with an L-9 orthogonal matrix was adopted for the process optimization. The MINITAB 17 software was used to analyze the response through analysis of variance and signal-to-noise ratio. The result revealed that the parameter settings for optimal tensile strength for the GMA welding of 6 mm thick AISI 1008 steel joint are arc voltage set at 30 V, current at 180 A, and gas flow rate set at 17 L/mm. The analysis of variance showed that the arc voltage had the most significant influence on the ultimate tensile strength with a 39.76% contribution, followed by the gas flow rate with 31.15%, while the welding current had 6.28% contributions. The surface plots show that a lower-level voltage, higher-level welding current, and higher-level gas flow rate favoured maximum ultimate tensile strength.

SCIENTIFIC AND ENGINEERING PRINCIPLES OF EFFICIENT FUEL USE AND ENVIRONMENTALLY FRIENDLY GAS COMBUSTION IN STOVE PLATES. PART 1. MODERN STATE-OF-THE-ART AND DIRECTIONS FOR IMPROVEMENT THE GAS BURNING IN DOMESTIC GAS COOKERS

2017 ◽  
pp. 3-18 ◽  
Author(s):  
B.S. Soroka ◽  
V.V. Horupa
Keyword(s):  
Natural Gas ◽  
Flow Rate ◽  
Gas Flow ◽  
Renewable Energy Sources ◽  
Combustion Process ◽  
Orifice Diameter ◽  
Firing Process ◽  
Gas Flow Rate ◽  
Gas Combustion ◽  
Gas Stoves

Natural gas NG consumption in industry and energy of Ukraine, in recent years falls down as a result of the crisis in the country’s economy, to a certain extent due to the introduction of renewable energy sources along with alternative technologies, while in the utility sector the consumption of fuel gas flow rate enhancing because of an increase the number of consumers. The natural gas is mostly using by domestic purpose for heating of premises and for cooking. These items of the gas utilization in Ukraine are already exceeding the NG consumption in industry. Cooking is proceeding directly in the living quarters, those usually do not meet the requirements of the Ukrainian norms DBN for the ventilation procedures. NG use in household gas stoves is of great importance from the standpoint of controlling the emissions of harmful components of combustion products along with maintenance the satisfactory energy efficiency characteristics of NG using. The main environment pollutants when burning the natural gas in gas stoves are including the nitrogen oxides NOx (to a greater extent — highly toxic NO2 component), carbon oxide CO, formaldehyde CH2O as well as hydrocarbons (unburned UHC and polyaromatic PAH). An overview of environmental documents to control CO and NOx emissions in comparison with the proper norms by USA, EU, Russian Federation, Australia and China, has been completed. The modern designs of the burners for gas stoves are considered along with defining the main characteristics: heat power, the natural gas flow rate, diameter of gas orifice, diameter and spacing the firing openings and other parameters. The modern physical and chemical principles of gas combustion by means of atmospheric ejection burners of gas cookers have been analyzed from the standpoints of combustion process stabilization and of ensuring the stability of flares. Among the factors of the firing process destabilization within the framework of analysis above mentioned, the following forms of unstable combustion/flame unstabilities have been considered: flashback, blow out or flame lifting, and the appearance of flame yellow tips. Bibl. 37, Fig. 11, Tab. 7.

On the Influence of Fluctuating Flow Rate Upon the Performance and Behaviour of Isothermal Reacting Systems

1998 ◽  
Vol 63 (6) ◽  
pp. 881-898
Author(s):  
Otakar Trnka ◽  
Miloslav Hartman
Keyword(s):  
Flow Rate ◽  
Gas Flow ◽  
Fluidized Bed Reactor ◽  
Computational Techniques ◽  
Continuous Stirred Tank Reactor ◽  
Gas Flow Rate ◽  
Solid Reaction ◽  
Continuous Stirred Tank ◽  
And Performance ◽  
Reacting Systems

Three simple computational techniques are proposed and employed to demonstrate the effect of fluctuating flow rate of feed on the behaviour and performance of an isothermal, continuous stirred tank reactor (CSTR). A fluidized bed reactor (FBR), in which a non-catalytic gas-solid reaction occurs, is also considered. The influence of amplitude and frequency of gas flow rate fluctuations on reactant concentrations at the exit of the CSTR is shown in four different situations.

scholarly journals Investigation on influences of loose gas on gas-solid flows in a circulating fluidized bed (CFB) reactor using full-loop numerical simulation

2020 ◽  
Vol 0 (0) ◽  
Author(s):  
Pengju Huo ◽  
Xiaohong Li ◽  
Yang Liu ◽  
Haiying Qi
Keyword(s):  
Numerical Simulation ◽  
Flow Rate ◽  
Gas Flow ◽  
Circulating Fluidized Bed ◽  
Separation Efficiency ◽  
Circulation Rate ◽  
Solid Mass ◽  
Gas Flow Rate ◽  
Gas Leakage ◽  
Mass Circulation

AbstractThe influences of loose gas on gas-solid flows in a large-scale circulating fluidized bed (CFB) gasification reactor were investigated using full-loop numerical simulation. The two-fluid model was coupled with the QC-energy minimization in multi-scale theory (EMMS) gas-solid drag model to simulate the fluidization in the CFB reactor. Effects of the loose gas flow rate, Q, on the solid mass circulation rate and the cyclone separation efficiency were analyzed. The study found different effects depending on Q: First, the particles in the loop seal and the standpipe tended to become more densely packed with decreasing loose gas flow rate, leading to the reduction in the overall circulation rate. The minimum Q that can affect the solid mass circulation rate is about 2.5% of the fluidized gas flow rate. Second, the sealing gas capability of the particles is enhanced as the loose gas flow rate decreases, which reduces the gas leakage into the cyclones and improves their separation efficiency. The best loose gas flow rates are equal to 2.5% of the fluidized gas flow rate at the various supply positions. In addition, the cyclone separation efficiency is correlated with the gas leakage to predict the separation efficiency during industrial operation.

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