Mitigation of Distortion in an Edge-Welded Bar by Optimization Control of the Welding Current and Speed Profile During Welding

2012 ◽  
Author(s):  
Mahyar Asadi ◽  
John A. Goldak ◽  
Christopher Bayley
Keyword(s):  
Control Problem ◽  
Process Parameters ◽  
Unit Length ◽  
Welding Process ◽  
Welding Current ◽  
Welding Distortion ◽  
Optimization Control ◽  
Fast Cooling ◽  
Tension Loading ◽  
Parameter Profile

Welding distortion is usually controlled by clamping techniques that can be tack welds, pre-bending, and tension loading. Side heating or fast cooling can also mitigate the distortion in some applications. In addition to the clamping techniques, process parameters affect the distortion so that if one can control the welding process parameters, an optimized profile of such parameters could alleviate the distortion. It is shown in this paper that the distortion can be mitigated by using an optimized profile of welding current and travelling speed. These profiles keep the power per unit length of welding constant. It is shown that an increasing welding current at the beginning and the end of the welding path on an edge welded bar of Aluminum could result in a bar that is closer to flat compared to the constant welding current. Developing an optimized weld process parameter profile requires a trustable computational model to implement a control problem using a predictive model for distortion in front of the weld pool in order to adjust the welding current and speed. Unlike using a constant welding current for the full path of weld, the path length is divided into several sub-paths. For each of weld sub-path the control problem learns from the previous sub-path and tries to find the new value for the welding current and speed that minimize the distortion using predictive Computational Weld Mechanics (CWM). Final deflections of the bar are also compared between a constant welding current and optimized profile of welding current.

scholarly journals Welding Process Optimization of WELDOX960 High Strength Steel

2018 ◽  
Vol 207 ◽  
pp. 04005
Author(s):  
Min Hu
Keyword(s):  
Penetration Depth ◽  
Process Optimization ◽  
Process Parameters ◽  
Welding Speed ◽  
High Strength Steel ◽  
Welding Process ◽  
Welding Current ◽  
High Strength ◽  
Influence Of Process Parameters ◽  
Steel Analysis

This paper studies WELDOX960 high strength steel, analysis of the welding ability of WELDOX960 high strength steel. Analyze the weld ability of WELDOX960 high-strength steel materials, and study the influence of process parameters such as welding current, welding voltage, and welding speed on penetration depth and weld width in the automated welding process. Through this test, the welding process is optimized to ensure the weld quality. The results show that WELDOX960 high-strength steel adopts multi-layer and multi-pass welding to form better welds.

Effects of the Process Parameters on Beads by Plasma Arc Welding of the Membrane for LNG Ships

2007 ◽  
Vol 26-28 ◽  
pp. 507-510 ◽  
Author(s):  
B.J. Kim ◽  
Y.R. Son ◽  
J.O. Yun ◽  
Jeong Soo Lee
Keyword(s):  
Process Parameters ◽  
Gas Flow ◽  
Welding Process ◽  
Welding Current ◽  
Tensile Tests ◽  
Optimum Process ◽  
Plasma Welding ◽  
Lap Welding ◽  
Etched Surface ◽  
Membrane Sheet

The membrane, which forms the primary barrier of the cargo tank onboard LNG carrier, is made of corrugated sheets, angle pieces and sealing caps and so on. These components are manufactured from SUS 304L sheets of 1.2mm thickness and assembled by the plasma welding. There are several welding defects such as overlap, excessive convexity, excessive concavity of weld and incomplete inclusion in the plasma welding. These unacceptable portions of the weld should be removed and repaired in order to prevent propagation of the defects. So a study is undertaken to determine the optimum process parameters such as the welding current, traveling speed, gas flow rates and frequency in the plasma lap welding process for LNG ships in order to prevent these defects. The polished and etched surface of the welded membrane sheet is examined if the cross section shows a properly made weld. And the tensile tests are conducted to consider if the tensile strength is less than the minimum required for the parent metal of the membrane sheet.

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.

Analysis of Arc Welded Thin-Walled Cylinders to Investigate the Effects of Welding Process Parameters on Residual Stresses

2008 ◽  
Vol 575-578 ◽  
pp. 763-768
Author(s):  
Afzaal M. Malik ◽  
Ejaz M. Qureshi ◽  
Naeem Ullah Dar
Keyword(s):  
Residual Stresses ◽  
Process Parameters ◽  
Arc Welding ◽  
Research Work ◽  
Three Dimensional ◽  
Welding Process ◽  
Welding Current ◽  
Element Model ◽  
Welding Parameters ◽  
Thin Walled

The research work presents a computational methodology based on three-dimensional finite element model to simulate the gas tungsten arc welding (GTAW) of thin-walled cylinders. The aim was to study the effects of two basic welding parameters (welding speed and welding current) on weld induced residual stresses. The complex phenomenon of arc welding was numerically solved by sequentially coupled transient, non-linear thermo-mechanical analysis. The accuracy of the numerical model was validated through experiments for temperature distribution and residual stresses. The results reveals that the present simulation strategy can be used as a proper tool to get the optimized welding process parameters and minimize the in service failures of thinwalled structures due to residual stresses.

scholarly journals Comparison between PCA analysis and Grey based Taguchi analysis of TIG welding process parameters on Duplex stainless steel

2021 ◽  
pp. 67-74
Author(s):  
Sandip Mondal ◽  
Goutam Nandi ◽  
Pradip Kumar Pal
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Process Parameters ◽  
Gas Flow ◽  
Welding Process ◽  
Principal Component ◽  
Welding Current ◽  
Tig Welding ◽  
Welding Parameters ◽  
Welding Quality

Tungsten inert gas (TIG) welding on Duplex stainless steel (DSS) is more easy, comfortable and useful, if the process is precisely understood and controlled through development of the science & technology. TIG welding on DSS has been performed with the help of specific controlled welding process parameters. Welding quality has been strongly depended on these process parameters. In this study, some valuable welding parameters are chosen. These are welding current, shielding gas flow rate and speed of welding. These process parameters of TIG welding for ASTM/UNS 2205 DSS welds are optimized by using Principal Component Analysis (PCA) method and Grey based Taguchi’s L9 Orthogonal array (OA) experimental plan with the conception of signal to noise ratio (N/S). After that, compression results of above mentioned two analyses of TIG welding process parameters have been calculated. The quality of the TIG welding on DSS has been evaluated in term of ultimate tensile strength, yield strength and percentage of elongation. Compression results of both analyses indicate application feasibility for continuous improvement of welding quality on DSS in different components of chemical, oil and gas industries.

scholarly journals Investigating the Effect of Metal Inert Gas Welding Parameters on AA10119 Mild Steel Quality by Taguchi Method

2021 ◽  
pp. 57-63
Author(s):  
Jephthah A. Ikimi ◽  
Aigbovbiosa A. Momodu ◽  
Erhuvwu Totore
Keyword(s):  
Tensile Strength ◽  
Mild Steel ◽  
Process Parameters ◽  
Welding Speed ◽  
Welding Process ◽  
Welding Current ◽  
Inert Gas ◽  
Welding Parameters ◽  
Optimal Setting ◽  
The Right

In welding, the quality of welded joints is greatly influenced by the welding process parameters. Thus, in order to achieve a good weld quality, there is exigency to select the right welding process parameters. The focus of this study is to investigate the effect of Metal Inert Gas (MIG) welding process parameters; welding current, welding voltage and welding speed on the tensile strength of mild steel AA10119 welded plates. The experiment was designed using Taguchi’s L9 orthogonal array with three levels. Kaierda MIG MAG Inverter CO2 Welder Model E-180 welding machine was used to conduct the experiments with three repetitions. From the analysis carried out by applying Taguchi’s method, the result shows that the welding speed and welding current have the most significant influence on tensile strength of the weld and an optimum parameter setting of A3B2C2 was suggested; welding current 240 A, welding voltage 25 V and welding speed 0.010 m/s. The mean tensile strength at this optimal setting A3B2C2 was predicted to be 442 N/mm2.

scholarly journals EFFECT OF A-TIG WELDING PROCESS PARAMETERS ON PENETRATION IN MILD STEEL PLATES

2014 ◽  
pp. 76-79
Author(s):  
VIKESH VIKESH ◽  
PROF. JAGJIT RANDHAWA ◽  
DR, N. M. SURI
Keyword(s):  
Mild Steel ◽  
Process Parameters ◽  
Optimal Parameter ◽  
High Surface ◽  
Welding Process ◽  
Welding Current ◽  
Tig Welding ◽  
Major Drawback ◽  
A Tig Welding ◽  
Active Flux

TIG welding is mostly used to weldthin sections for high surface finish. A major drawback in the processis having very small penetration as compare to other arc welding process. The problem can be avoided by using active flux in conventional TIG welding. In the present study investigate theoptimization of A-TIG welding process on mild steel for an optimal parameter by using Taguchi technique. Theeffect of various process parameters (welding current (I), welding speed (V), active flux) .IN the present study efforts were made to increase the weld penetration by appling the active flux and to optimize the process parameters.

A Study on Development of the Optimal Neural Network in GMA Welding Process

2014 ◽  
Vol 936 ◽  
pp. 1759-1763
Author(s):  
Qian Qian Wu ◽  
Ji Hye Lee ◽  
Jong Pyo Lee ◽  
Min Ho Park ◽  
Young Su Kim ◽  
...  
Keyword(s):  
Neural Network ◽  
Process Parameters ◽  
Gma Welding ◽  
High Reliability ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Quality ◽  
Optimal Parameters ◽  
On Line

Gas Metal Arc (GMA) welding is considered as a multi-parameter process that it’s hard to find optimal parameters for good welding. To overcome the problem, an artificial neural network based on the backpropagation algorithm was built to realize the relationships between process parameters and welding quality as output parameter. In this study, Mahalanobis Distance (MD) was employed to evaluate the availability of a given welding parameters which was proved to performance well in multivariate statistics. Input parameters such as welding current and arc voltage were chosen due to their significant influence on the welding quality. To improve the precision of given parameters’ evaluation, neural networks with different configurations were verified. The analyses on the measured and predicted MD by the proposed neural network were conducted. The proposed neural network based on the error backpropogation algorithm was proved to have high reliability to evaluate process parameters, which further makes it available in on-line monitoring system.

Optimization of Welding Process Parameters for Rotating Arc Welding Sensor Based on Genetic Algorithm

2008 ◽  
Vol 575-578 ◽  
pp. 769-773
Author(s):  
Jian Ping Jia ◽  
Hua Zhang ◽  
Hui Huang
Keyword(s):  
Genetic Algorithm ◽  
Process Parameters ◽  
Arc Welding ◽  
High Speed ◽  
Tracking System ◽  
Welding Process ◽  
Welding Current ◽  
Seam Tracking ◽  
Rotating Arc ◽  
Input Variables

The high speed rotating arc welding sensor (RAWS) driven by motor with air axis is widely used in seam tracking system. Using the characters of the RAWS, the purpose of this study based on Genetic Algorithm (GA) is to optimize welding process parameters of the RAWS for obtaining satisfied seam geometry. The output variables are penetration, width and height of the seam geometry. These output variables are determined by input variables, which are the welding current, welding voltage, welding speed, rotating arc radius, rotating arc frequency and rotating arc direction. Experimentations are made according to the optimal welding process parameters, and the result shows that the GA is an effective method to optimize the welding process parameters of the RAWS. The described computational methodology enables obtaining a seam with desired geometry.

scholarly journals Ultrafast Parallel Micro-Gap Resistance Welding of an AuNi9 Microwire and Au Microlayer

Micromachines ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 51
Author(s):  
He Zhang ◽  
Shang Wang ◽  
Bingying Wu ◽  
Weiwei Zhang ◽  
Chunjin Hang ◽  
...  
Keyword(s):  
Melting Point ◽  
Process Parameters ◽  
Electrical Contact ◽  
Welding Process ◽  
Welding Current ◽  
Resistance Welding ◽  
Dynamic Resistance ◽  
Welding Time ◽  
Welding Temperature ◽  
Welding Pressure

Welding between an AuNi9 microwire and Au microlayer is of great importance for fabricating electrical contact structures for high precision inertial devices, satellite slip ring brushes, robots, etc. In this paper, the achievement of parallel micro-gap resistance welding (PMRW) with 200-μm AuNi9 microwires on a 3-μm Au layer was presented. The study on the orthogonal design of the experiment was carried out. The effect of the process parameters (welding current, welding time, and welding pressure) was discussed in reference to the morphologies and tensile force of the joint using range analysis. It is shown that too much or too little heat input will decrease the welding performance. A group of optimized process parameters (0.275 kA welding current, 3 ms welding time, and 28.7 N welding pressure) was obtained. During the welding process, the dynamic resistance of the whole welding system was measured, which can reflect the welding quality. Finite element simulation is utilized to calculate the welding temperature. The highest temperature was located in the center area of the AuNi9 microwire, reaching 1397.2 °C, which is higher than the melting point of AuNi9. By contrast, the highest temperature for the pad was 826.47 °C (lower than the melting point of Au). Hence, under optimized process parameters, a transient interfacial reaction between the liquid AuNi9 microwire and solid Au pad occurred, and the strength of the welded joint reached 5.54 N.

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