Analysis of the Weld Quality of Plasma Arc Welds: A Case Study of Conductor Welds in an Electrical Stator

2009 ◽  
Author(s):  
Hugo I. Medelli´n-Castillo ◽  
Dirk F. de Lange ◽  
Fernando Rami´rez ◽  
Eliel Ferna´ndez
Keyword(s):  
Process Parameters ◽  
Metal Flow ◽  
Flow Characteristics ◽  
Welding Process ◽  
Mechanical Tests ◽  
Weld Quality ◽  
Plasma Arc ◽  
Simulation Tools ◽  
Trial And Error Method

Plasma arc welding (PAW) is a technique used in the electrical component industry for joining electrical conductors in devices such as motors and alternators. With the limited number of theoretical methods and simulation tools to predict the metal flow characteristics and its interaction with the process parameters during the welding process, weld design must still rely on the designers experience and the trial and error method. As a consequence, the process parameters and the weld quality may not be as originally expected at the design process. Based on the fact that a good quality of the final product has to be guaranteed, the analysis of the PAW process and the resulting weld quality is presented in this paper. The aim of the work was to obtain a clear perspective on the influence of various process parameters on the weld quality. In order to measure the influence on quality, first “quality” was defined. Secondly, there were various options to measure the quality, some of them being destructive, others being non-destructive. The development of the measurement methods was then proposed based on electrical tests, mechanical tests and visual inspection of the welds. Finally, using these methods and the experimental data obtained from the actual welding process, a new approach to evaluate the weld quality was proposed and is presented in this paper. The results reveal that the electrical impedance, the mechanical strength and the geometry (visual measure) of the weld are related and can be used to estimate the weld quality.

scholarly journals An Innovative Welding Solution For Polymer Films in Packaging: Effect of Process Parameters

2021 ◽  
Author(s):  
Queen Tannous ◽  
Yves Bereaux ◽  
Pierre Mousseau ◽  
Anaïs Barasinski ◽  
Rémi Deterre ◽  
...  
Keyword(s):  
Process Parameters ◽  
Polymer Films ◽  
Welding Process ◽  
Rotational Frequency ◽  
Welding Interface ◽  
Optimization And Control ◽  
And Control ◽  
Future Work ◽  
Influential Parameters

In this paper, we present an innovative welding process for packaging applications developed by SEALESTER Company. For polymer films, studies have revealed that the welding interface must reach a specific temperature, known as “sealing initiation temperature”, to obtain a sealed joint. In this paper, we will be studying the effect of the process parameters on the evolution of temperature at the welding interface. For this purpose, thermocouples have been placed between the films at different points of the trajectory to measure the temperature evolution. Process parameters and temperature measurements were recorded in each experiment. Results show that the most influential parameters are the temperature and the linear velocity of the tool. Rotational frequency affects the heat distribution on the sealing surface. A minimum pressure must be applied. In conclusion, this new process can produce sealed polymer packages. Future work will consist of studying the quality of obtained seal in addition to optimization and control of the process.

scholarly journals Mould Filling Ability Characterisation of Cast Aluminium Alloys Using Design of Experiments

2012 ◽  
Vol 2012 ◽  
pp. 1-10 ◽  
Author(s):  
Samavedam Santhi ◽  
S. B. Sakri ◽  
Dharwada Hanumantha Rao ◽  
Srinivasan Sundarrajan
Keyword(s):  
Process Parameters ◽  
Aluminium Alloys ◽  
Metal Flow ◽  
Filling Ability ◽  
Mould Filling ◽  
Liquid Metal Flow ◽  
Factor Combination ◽  
Flow Heat ◽  
Heat Transfer And Solidification

Mould filling ability characteristic has been influencing the liquid metal flow, heat transfer, and solidification there by affecting the quality of aerospace castings. Mould filling is a critical parameter in the production of sound and quality castings, especially in the case of complex-shaped castings where section thickness is varying considerably. The mould filling ability of aluminium alloys LM6 and LM25 has been studied in the present investigation. Experimentation has been carried out using orthogonal array experimental layout. The process parameters studied in the present investigation are alloy composition, sand fineness, mould coating, and pouring temperature. The mould filling ability of selected aluminium alloy has been studied using pin test piece with cylindrical cores. The results from experimentation are analyzed to find the influence of the process parameters on mould filling ability. Based on the above, LM6 alloy has been found to have better mould filling ability characteristics and the analysis of variance has also revealed the same optimum factor combination.

scholarly journals Characteristics of Welding and Arc Pressure in the Plasma–TIG Hybrid Welding Process

2018 ◽  
Author(s):  
Bo Wang ◽  
Xunming Zhu ◽  
Hongchang Zhang ◽  
Hongtao Zhang ◽  
Jicai Feng
Keyword(s):  
Arc Welding ◽  
Gas Flow ◽  
Welding Process ◽  
Hybrid Welding ◽  
Plasma Arc ◽  
Arc Pressure ◽  
Arc Current ◽  
Arc Welding Process ◽  
Welding Processes

In this article, a novel hybrid welding process called plasma-TIG coupled arc welding was proposed to improve the efficiency and quality of welding by utilizing the full advantage of plasma and TIG welding processes. The two arcs of plasma and TIG were pulled into each other into one coupled arc under the effect of Lorentz force and plasma flow force during welding experiments. The arc behavior of coupled arc was studied by means of it’s arc profile, arc pressure and arc force conditions. The coupled arc pressure distribution measurements were performed. The effects of welding conditions on coupled arc pressure were evaluated and the maximum coupled arc pressure was improved compared with single-plasma arc and single-TIG arc. It was found that the maximum arc pressure was mainly determined by plasma arc current and plasma gas flow. According to the results, the proposed coupled arc welding process have both advantages of plasma arc and TIG method, and it has a broad application prospect.

scholarly journals Parametric Optimization Of Gas Metal Arc Welding Process By Using Grey Based Taguchi Method On Aisi 409 Ferritic Stainless Steel

2016 ◽  
Vol 13 (1) ◽  
pp. 6-11
Author(s):  
Nabendu Ghosh ◽  
Pradip Kumar ◽  
Goutam Nandi
Keyword(s):  
Tensile Strength ◽  
Stainless Steel ◽  
Ultimate Tensile Strength ◽  
Yield Strength ◽  
Ferritic Stainless Steel ◽  
Process Parameters ◽  
Parametric Optimization ◽  
Gas Metal Arc Welding ◽  
Welding Process

Abstract Welding input process parameters play a very significant role in determining the quality of the welded joint. Only by properly controlling every element of the process can product quality be controlled. For better quality of MIG welding of Ferritic stainless steel AISI 409, precise control of process parameters, parametric optimization of the process parameters, prediction and control of the desired responses (quality indices) etc., continued and elaborate experiments, analysis and modeling are needed. A data of knowledge - base may thus be generated which may be utilized by the practicing engineers and technicians to produce good quality weld more precisely, reliably and predictively. In the present work, X-ray radiographic test has been conducted in order to detect surface and sub-surface defects of weld specimens made of Ferritic stainless steel. The quality of the weld has been evaluated in terms of yield strength, ultimate tensile strength and percentage of elongation of the welded specimens. The observed data have been interpreted, discussed and analyzed by considering ultimate tensile strength ,yield strength and percentage elongation combined with use of Grey-Taguchi methodology.

Selective Laser Melting of the Inconel 718 Nickel Superalloy

2014 ◽  
Vol 698 ◽  
pp. 333-338 ◽  
Author(s):  
Vadim Sh. Sufiiarov ◽  
Evgenii V. Borisov ◽  
Igor A. Polozov
Keyword(s):  
Selective Laser Melting ◽  
Process Parameters ◽  
Inconel 718 ◽  
Melting Process ◽  
Nickel Superalloy ◽  
Mechanical Tests ◽  
Laser Melting ◽  
Influence Of Process Parameters ◽  
Inconel 718 Superalloy

The results of the research on selective laser melting process of the Inconel 718 superalloy powder under conditions of additive manufacturing of parts for special purposes are presented. The influence of process parameters on the quality of manufactured parts is shown. Process parameters which allow manufacturing parts with the density close to 100%, are determined. Also, the results of mechanical tests and investigation of microstructure are presented.

Sensitivity analysis for process parameters influencing weld quality in robotic GMA welding process

2003 ◽  
Vol 140 (1-3) ◽  
pp. 676-681 ◽  
Author(s):  
I.S. Kim ◽  
Y.J. Jeong ◽  
I.J. Son ◽  
I.J. Kim ◽  
J.Y. Kim ◽  
...  
Keyword(s):  
Sensitivity Analysis ◽  
Process Parameters ◽  
Gma Welding ◽  
Welding Process ◽  
Weld Quality

A Simulation of Spot Welding Process

2014 ◽  
Vol 657 ◽  
pp. 226-230 ◽  
Author(s):  
Viorel Cohal
Keyword(s):  
Process Parameters ◽  
Growth Curve ◽  
Spot Welding ◽  
Welding Process ◽  
Process Parameter ◽  
Welding Parameters ◽  
Welding Machine

The paper presents the optimization of spot welding parameters using offline simulation. The procedure of making simulation with SORPAS® is similar to the procedure of doing practical welding process, which can be divided into the following three steps:Data preparation - the materials and geometries of the workpieces and electrodes are defined, the type of welding machine is selected and the process parameters are specified.Running simulation of welding - the parts are welded in the selected welding machine with the specified process parameter settings. The simulations can be carried out in four ways: single simulations, batch simulations, automated optimizations and weld planning.Evaluation of results - the results of welding and quality of weld are evaluated thus the design and parameter settings are verified. With the optimization procedures the weld growth curve can be obtained.

Sign in / Sign up

Export Citation Format

Share Document