Part Repairing Using a Hybrid Manufacturing System

2007 ◽  
Author(s):  
Lan Ren ◽  
Kunnayut Eiamsa-ard ◽  
Jianzhong Ruan ◽  
Frank Liou
Keyword(s):  
Manufacturing System ◽  
Energy Savings ◽  
Welding Process ◽  
Hybrid Manufacturing ◽  
Present Part ◽  
Cutting Processes ◽  
Main Component ◽  
Time And Energy ◽  
The Military ◽  
Welding Processes

At present, part remanufacturing technology is gaining more interest from the military and industries due to the benefits of cost reduction as well as time and energy savings. This paper presents the research on one main component of part remanufacturing technology, which is part repairing. Traditionally, part repairing is done in the repair department using welding processes. However, the limitations of the traditional welding process are becoming more and more noticeable when accuracy and reliability are required. Part repairing strategies have been developed utilizing a hybrid manufacturing system in which the laser-aided deposition and CNC cutting processes are integrated. Part repairing software is developed in order to facilitate the users. The system and the software elevate the repairing process to the next level, in which accuracy, reliability, and efficiency can be achieved. The concept of the repairing process is presented in this paper, and verification and experimental results are also discussed.

scholarly journals Comprehensive Analysis of the Microstructure and Mechanical Properties of Friction-Stir-Welded Low-Carbon High-Strength Steels with Tensile Strengths Ranging from 590 MPa to 1.5 GPa

2021 ◽  
Vol 11 (12) ◽  
pp. 5728
Author(s):  
HyeonJeong You ◽  
Minjung Kang ◽  
Sung Yi ◽  
Soongkeun Hyun ◽  
Cheolhee Kim
Keyword(s):  
Mechanical Properties ◽  
Tensile Test ◽  
Joint Strength ◽  
Solid Phase ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Low Carbon ◽  
Friction Stir ◽  
Welding Processes

High-strength steels are being increasingly employed in the automotive industry, requiring efficient welding processes. This study analyzed the materials and mechanical properties of high-strength automotive steels with strengths ranging from 590 MPa to 1500 MPa, subjected to friction stir welding (FSW), which is a solid-phase welding process. The high-strength steels were hardened by a high fraction of martensite, and the welds were composed of a recrystallized zone (RZ), a partially recrystallized zone (PRZ), a tempered zone (TZ), and an unaffected base metal (BM). The RZ exhibited a higher hardness than the BM and was fully martensitic when the BM strength was 980 MPa or higher. When the BM strength was 780 MPa or higher, the PRZ and TZ softened owing to tempered martensitic formation and were the fracture locations in the tensile test, whereas BM fracture occurred in the tensile test of the 590 MPa steel weld. The joint strength, determined by the hardness and width of the softened zone, increased and then saturated with an increase in the BM strength. From the results, we can conclude that the thermal history and size of the PRZ and TZ should be controlled to enhance the joint strength of automotive steels.

Microstructure and mechanical property improvement of dissimilar metal joints for TC4 Ti alloy to Nitinol NiTi alloy by laser welding

2021 ◽  
Vol 0 (0) ◽  
Author(s):  
Yan Zhang ◽  
DeShui Yu ◽  
JianPing Zhou ◽  
DaQian Sun ◽  
HongMei Li
Keyword(s):  
Tensile Strength ◽  
Laser Welding ◽  
Mechanical Performance ◽  
Niti Alloy ◽  
Welding Process ◽  
Ti Alloy ◽  
The One ◽  
Fusion Weld ◽  
Welding Processes ◽  
Cu Interlayer

Abstract To avoid the formation of Ti-Ni intermetallics in a joint, three laser welding processes for Ti alloy–NiTi alloy joints were introduced. Sample A was formed while a laser acted at the Ti alloy–NiTi alloy interface, and the joint fractured along the weld centre line immediately after welding without filler metal. Sample B was formed while the laser acted on a Cu interlayer. The average tensile strength of sample B was 216 MPa. Sample C was formed while the laser acted 1.2 mm on the Ti alloy side. The one-pass welding process involved the creation of a joint with one fusion weld and one diffusion weld separated by the remaining unmelted Ti alloy. The mechanical performance of sample C was determined by the diffusion weld formed at the Ti alloy–NiTi alloy interface with a tensile strength of 256 MPa.

scholarly journals The use of nocturnal flights for barrier crossing in a diurnally migrating songbird

2021 ◽  
Vol 9 (1) ◽  
Author(s):  
Christie D. Lavallée ◽  
Saeedeh Bani Assadi ◽  
Alicia M. Korpach ◽  
James D. Ray ◽  
Jason D. Fischer ◽  
...  
Keyword(s):  
Energy Savings ◽  
Open Water ◽  
Gps Tracking ◽  
Future Research ◽  
Barrier Crossing ◽  
Migration Patterns ◽  
Migration Strategies ◽  
Diurnal Migrant ◽  
Time And Energy ◽  
High Degree

Abstract Background The migration patterns of land birds can generally be divided into those species that migrate principally during the day and those that migrate during the night. Some species may show individual plasticity in the use of day or night flight, particularly when crossing large, open-water or desert barriers. However, individual plasticity in circadian patterns of migratory flights in diurnally migrating songbirds has never been investigated. Methods We used high precision GPS tracking of a diurnal, migratory swallow, the purple martin (Progne subis), to determine whether individuals were flexible in their spring migration strategies to include some night flight, particularly at barrier crossing. Results Most (91%) of individuals made large (sometimes > 1000 km), open-water crossings of the Caribbean Sea and the Gulf of Mexico that included the use of night flight. 32% of all water crossings were initiated at night, demonstrating that night flight is not only used to complete large crossings but may confer other advantages for diurnal birds. Birds were not more likely to initiate crossings with supportive winds, however crossings were more likely when they reduced travel distances. Our results are consistent with diurnal birds using night flight to help achieve time- and energy-savings through ‘short cuts’ at barrier crossings, at times and locations when foraging opportunities are not available. Conclusions Overall, our results demonstrate the use of nocturnal flight and a high degree of individual plasticity in migration strategies on a circadian scale in a species generally considered to be a diurnal migrant. Nocturnal flights at barrier crossing may provide time and energy savings where foraging opportunities are low in an otherwise diurnal strategy. Future research should target how diel foraging and refueling strategies support nocturnal flights and barrier crossing in this and other diurnal species.

Advanced submerged arc welding processes for Arctic structures and ice-going vessels

2016 ◽  
Vol 232 (1) ◽  
pp. 114-127
Author(s):  
Pavel Layus ◽  
Paul Kah ◽  
Viktor Gezha
Keyword(s):  
Case Studies ◽  
Arc Welding ◽  
Oil And Gas ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
The Arctic ◽  
Correct Selection ◽  
Advantages And Disadvantages ◽  
Welding Processes ◽  
Submerged Arc

The Arctic region is expected to play an extremely prominent role in the future of the oil and gas industry as growing demand for natural resources leads to greater exploitation of a region that holds about 25% of the world’s oil and gas reserves. It has become clear that ensuring the necessary reliability of Arctic industrial structures is highly dependent on the welding processes used and the materials employed. The main challenge for welding in Arctic conditions is prevention of the formation of brittle fractures in the weld and base material. One mitigating solution to obtain sufficiently low-transition temperatures of the weld is use of a suitable welding process with properly selected parameters. This work provides a comprehensive review with experimental study of modified submerged arc welding processes used for Arctic applications, such as narrow gap welding, multi-wire welding, and welding with metal powder additions. Case studies covered in this article describe welding of Arctic steels such as X70 12.7-mm plate by multi-wire welding technique. Advanced submerged arc welding processes are compared in terms of deposition rate and welding process operational parameters, and the advantages and disadvantages of each process with respect to low-temperature environment applications are listed. This article contributes to the field by presenting a comprehensive state-of-the-art review and case studies of the most common submerged arc welding high deposition modifications. Each modification is reviewed in detail, facilitating understanding and assisting in correct selection of appropriate welding processes and process parameters.

Numerical Analysis of Residual Stresses and Distortions in Aluminium Alloy Welded Joints

2015 ◽  
Vol 809-810 ◽  
pp. 443-448 ◽  
Author(s):  
Tomasz Kik ◽  
Marek Slovacek ◽  
Jaromir Moravec ◽  
Mojmir Vanek
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminium Alloy ◽  
Thermal Cycle ◽  
Technology Development ◽  
Welding Process ◽  
Simulation Software ◽  
Structure Knowledge ◽  
Welding Processes ◽  
Element Method

Simulation software based on a finite element method have significantly changed the possibilities of determining welding strains and stresses at early stages of product design and welding technology development. But the numerical simulation of welding processes is one of the more complicated issues in analyses carried out using the Finite Element Method. A welding process thermal cycle directly affects the thermal and mechanical behaviour of a structure during the process. High temperature and subsequent cooling of welded elements generate undesirable strains and stresses in the structure. Knowledge about the material behaviour subjected to the welding thermal cycle is most important to understand process phenomena and proper steering of the process. The study presented involved the SYSWELD software-based analysis of MIG welded butt joints made of 1.0 mm thickness, 5xxx series aluminium alloy sheets. The analysis of strains and the distribution of stresses were carried out for several different cases of fixing and releasing of welded elements.

Microstructural Effects between AHSS Dissimilar Joints Using MIG and TIG Welding Process

2015 ◽  
Vol 1766 ◽  
pp. 29-35 ◽  
Author(s):  
G.Y. Pérez Medina ◽  
M. Padovani ◽  
M. Merlin ◽  
A.F. Miranda Pérez ◽  
F.A. Reyes Valdés
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
High Hardness ◽  
Inert Gas ◽  
Mechanical Degradation ◽  
Low Alloy Steels ◽  
Dissimilar Joints ◽  
Lap Shear ◽  
Welding Processes

ABSTRACTGas tungsten arc welding-tungsten inert gas (GTAW-TIG) is focused in literature as an alternative choice for joining high strength low alloy steels; this study is performed to compare the differences between gas metal arc welding-metal inert gas (GMAW-MIG) and GTAW welding processes. The aim of this study is to characterize microstructure of dissimilar transformation induced plasticity steels (TRIP) and martensitic welded joints by GMAW and GTAW welding processes. It was found that GMAW process lead to relatively high hardness in the HAZ of TRIP steel, indicating that the resultant microstructure was martensite. In the fusion zone (FZ), a mixture of phases consisting of bainite, ferrite and small areas of martensite were present. Similar phase’s mixtures were found in FZ of GTAW process. The presence of these mixtures of phases did not result in mechanical degradation when the GTAW samples were tested in lap shear tensile testing as the fracture occurred in the heat affected zone. In order to achieve light weight these result are benefits which is applied an autogenous process, where it was shown that without additional weight the out coming welding resulted in a high quality bead with homogeneous mechanical properties and a ductile morphology on the fracture surface. Scanning electron microscopy (SEM) was employed to obtain information about the specimens that provided evidence of ductile morphology.

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.

Infrared Sensing for On-Line Weld Geometry Monitoring and Control

1995 ◽  
Vol 117 (3) ◽  
pp. 323-330 ◽  
Author(s):  
P. Banerjee ◽  
S. Govardhan ◽  
H. C. Wikle ◽  
J. Y. Liu ◽  
B. A. Chin
Keyword(s):  
Plate Thickness ◽  
Welding Process ◽  
Temperature Gradients ◽  
Monitoring And Control ◽  
Depth Of Penetration ◽  
Bead Width ◽  
Weld Geometry ◽  
On Line ◽  
And Control ◽  
Welding Processes

This paper describes a method for on-line weld geometry monitoring and control using a single front-side infrared sensor. Variations in plate thickness, shielding gas composition and minor element content are known to cause weld geometry changes. These changes in the weld geometry can be distinctly detected from an analysis of temperature gradients computed from infrared data. Deviations in temperature gradients were used to control the bead width and depth of penetration during the welding process. The analytical techniques described in this paper have been used to control gas tungsten arc and gas metal arc welding processes.

scholarly journals Numerical Simulation Mode of Spot Contact Welding Processes

2021 ◽  
pp. 85-91
Author(s):  
А.С. Угловский ◽  
И.М. Соцкая ◽  
Е.В. Шешунова
Keyword(s):  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameters ◽  
Low Carbon ◽  
Detailed Data ◽  
Welding Quality ◽  
Welding Processes ◽  
Contact Welding

Цель рассмотрения численного метода заключалась в получении подробных данных, позволяющих оценить проведение сварочного процесса: изменение объёма сварного шва, радиуса сварного шва, радиуса зоны термического влияния. При проведении моделирования авторами выведены зависимости параметров точечной сварки низкоуглеродистой стали толщиной до 3,2 мм. Данные зависимости будут определять качество сварных швов. Соответствующее сочетание параметров точечной сварки обеспечит прочное соединение и хорошее качество сварки. The purpose of the numerical method consideration was to obtain detailed data allowing evaluating the performance of the welding process: changing the volume of the weld, the radius of the weld, the radius of the weld-affected zone. During the simulation the authors have derived dependencies of the parameters of spot welding of low-carbon steel up to 3.2 mm thick. These dependencies will determine the quality of the welds. The correct combination of spot welding parameters will ensure a firm joint and good welding quality.

scholarly journals Residual Stresses Distribution Posterior to Welding and Cutting Processes

2021 ◽  
Author(s):  
Asma Manai
Keyword(s):  
Fatigue Life ◽  
Residual Stresses ◽  
Weld Seam ◽  
Considerable Change ◽  
Cutting Process ◽  
Local Material ◽  
Weld Residual Stress ◽  
Exact Size ◽  
Cutting Processes ◽  
Welding Processes

Welding is a joining process that leads to considerable change in the local material and the formation of welding residual stresses (RS). Welding residual stresses can be compressive (beneficial for the fatigue life) or tensile (harmful for the fatigue life). In this chapter, a probabilistic analysis of residual stresses distribution posterior to welding processes is carried out. Several researchers stated that the type of the introduced stresses either compressive or tensile depends on several factors. Some of these factors are listed in this chapter. Welding of mega-structures is carried out in the workshops, then a cutting process takes place to construct the exact size of the structural components. This cutting process has a significant effect on the weld residual stresses re-distribution. A study of the re-distribution of the weld residual stress after cutting was performed. It was found that independent of the weld seam length, the residual stresses re-distributed up to 60 % of the weld seam length.

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