scholarly journals Thermal and structural modelling of arc welding processes: A literature review

2019 ◽  
Vol 52 (7-8) ◽  
pp. 955-969 ◽  
Author(s):  
Hitesh Arora ◽  
Rupinder Singh ◽  
Gurinder Singh Brar
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Arc Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Inert Gas ◽  
Welding Distortion ◽  
Structural Modelling ◽  
Welding Processes

This paper presents a state-of-the-art critical review of the thermal and structural modelling of the arc welding process. During the welding process, high temperature in the welding zone leads to generation of unwanted residual stresses and results in weld distortion. Measurement of the temperature distribution was a key issue and challenge in the past decade. Thermomechanical analysis is among the best-known techniques to simulate and investigate the temperature distribution, welding distortion and residual stresses in the weld zone. The main emphasis of this review is the thermal and structural modelling of welding processes and the measurement of welding residual stresses using different techniques. The study also provides information about the various types of heat sources and models used to predict the weld bead characteristics and thermomechanical analysis for different welding processes such as tungsten inert gas welding, metal inert gas welding and shielded metal arc welding.

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.

Evolution of Temperature Distribution and Microstructure in Multipass Welded AISI 321 Stainless Steel Plates With Different Thicknesses

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Soheil Nakhodchi ◽  
Ali Shokuhfar ◽  
Saleh Akbari Iraj ◽  
Brian G. Thomas
Keyword(s):  
Stainless Steel ◽  
Temperature Distribution ◽  
Residual Stresses ◽  
Arc Welding ◽  
Welding Process ◽  
Steel Plates ◽  
Temperature History ◽  
Transient Temperature ◽  
Multipass Welding ◽  
Aisi 321

Prediction of temperature distribution, microstructure, and residual stresses generated during the welding process is crucial for the design and assessment of welded structures. In the multipass welding process of parts with different thicknesses, temperature distribution, microstructure, and residual stresses vary during each weld pass and from one part to another. This complicates the welding process and its analysis. In this paper, the evolution of temperature distribution and the microstructure generated during the multipass welding of AISI 321 stainless steel plates were studied numerically and experimentally. Experimental work involved designing and manufacturing benchmark specimens, performing the welding, measuring the transient temperature history, and finally observing and evaluating the microstructure. Benchmark specimens were made of corrosion-resistant AISI 321 stainless steel plates with different thicknesses of 6 mm and 10 mm. The welding process consisted of three welding passes of two shielded metal arc welding (SMAW) process and one gas tungsten arc welding (GTAW) process. Finite element (FE) models were developed using the DFLUX subroutine to model the moving heat source and two different approaches for thermal boundary conditions were evaluated using FILM subroutines. The DFLUX and FILM subroutines are presented for educational purposes, as well as a procedure for their verification.

Sequential Transient Numerical Simulation of Inertia Friction Welding Process

2008 ◽  
Author(s):  
Medhat Awad El-Hadek ◽  
Mohammad S. Davoud
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Friction Welding ◽  
Welding Process ◽  
Transient Temperature ◽  
Inertia Friction Welding ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Full Field ◽  
Welding Processes

Inertia friction welding processes often generate substantial residual stresses due to the heterogeneous temperature distribution during the welding process. The residual stresses which are the results of incompatible elastic and plastic deformations in weldment will alter the performance of welded structures. In this study, three-dimensional (3D) finite element analysis has been performed to analyze the coupled thermo-mechanical problem of inertia friction welding of a hollow cylinder. The analyses include the effect of conduction and convection heat transfer in conjunction with the angular velocity and the thrust pressure. The results include joint deformation and a full-field view of the residual stress field and the transient temperature distribution field in the weldment. The shape of deformation matches the experimental results reported in the literature. The residual stresses in the heat-affected zone have a high magnitude but comparatively are smaller than the yield strength of the material.

scholarly journals Hardfacing of AISI 1020 Steel by Arc Welding in Comparison with TIG Welding Processes

2012 ◽  
Vol 5 (1) ◽  
pp. 119-126 ◽  
Author(s):  
G. R. C. Pradeep ◽  
A. Ramesh ◽  
B. Durga Prasad
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Tig Welding ◽  
Inert Gas ◽  
Sliding Velocity ◽  
Tungsten Inert Gas Welding ◽  
Wear Properties ◽  
Machine Parts ◽  
Arc Welding Process ◽  
Welding Processes

Hardfacing techniques are used for enhancing the life of various machine parts by rebuilding the worn out or eroded or corroded areas in them. In this paper, an attempt has been made to determine the better welding process to hardface AISI 1020 steel based on study of wear and other factors. Two types of welding processes - Arc welding and tungsten inert gas welding (TIG) have been compared. The study revealed that the specimens prepared using TIG welding process yielded better wear properties compared to the specimen prepared using Arc welding process till 1.256 m/s sliding velocity. Also it was observed that the Arc welding process yielded better wear properties for sliding velocities above 1.571 m/s. An attempt was made to study the reasons for getting the said results.© 2013 JSR Publications. ISSN: 2070-0237 (Print); 2070-0245 (Online). All rights reserved.doi: http://dx.doi.org/10.3329/jsr.v5i1.11899        J. Sci. Res. 5 (1), 119-126 (2013) 

Thermomechanical Analysis of Tungsten Inert Gas Welding Process for Predicting Temperature Distribution and Angular Distortion

2019 ◽  
Vol 35 (3) ◽  
pp. 241-249
Author(s):  
Harendra Kumar Narang ◽  
Chandan Pandey ◽  
Jayant Gopal Thakare ◽  
Nitin Saini ◽  
Manas Mohan Mahapatra ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Inert Gas ◽  
Angular Distortion ◽  
Tungsten Inert Gas Welding

Analysis of weld characteristics of micro-plasma arc welding and tungsten inert gas welding of thin stainless steel (304L) sheet

2016 ◽  
Vol 230 (6) ◽  
pp. 1005-1017 ◽  
Author(s):  
Sadaf Batool ◽  
Mushtaq Khan ◽  
Syed Husain Imran Jaffery ◽  
Ashfaq Khan ◽  
Aamir Mubashar ◽  
...  
Keyword(s):  
Arc Welding ◽  
Research Work ◽  
Welding Process ◽  
Inert Gas ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Tungsten Inert Gas Welding ◽  
Welding Processes ◽  
Micro Plasma Arc Welding ◽  
And Tungsten

This research work focuses on comparison of the weld geometry, distortion, microstructure and mechanical properties of thin SS 304 L sheets (0.8 mm thickness) welded using micro-plasma arc welding and tungsten inert gas welding process. Initial experiments were performed to identify suitable processing parameters for micro-plasma arc welding and tungsten inert gas welding processes. Microstructures of welds were analysed using scanning electron microscopy, X-ray diffraction and energy dispersive spectroscopy. The results indicate that the joint produced by micro-plasma arc welding exhibited higher tensile strength, higher ductility, smaller dendrite size and a narrow heat affected zone. Samples welded by micro-plasma arc welding process had lower distortion as compared to that welded by tungsten inert gas process. Micro-plasma arc welding was shown to be the suitable process for welding of thin 304 L sheets owing to its higher welding speed and better weld properties as compared to the tungsten inert gas welding process.

scholarly journals Numerical and Experimental Validation of Gas Metal Arc Welding on AISI 441 Ferritic Stainless Steel Through Mechanical and Microstructural Analysis

2022 ◽  
Author(s):  
SERAFINO CARUSO ◽  
DOMENICO UMBRELLO
Keyword(s):  
Grain Size ◽  
Residual Stresses ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Production Costs ◽  
Metal Arc Welding ◽  
Residual Stresses And Strains ◽  
Welding Processes

Abstract Residual stresses and strains, distortion, heat affected zone (HAZ), grain size changes and hardness variation during gas metal arc welding (GMAW), are fundamental aspects to study and control during welding processes. For this reason, numerical simulations of the welding processes represent the more frequently used tool to better analyse the several aspects characterizing this joining process with the aim to reduce lead time and production costs. In the present study an uncoupled 3D thermo-mechanical analysis was carried out by two commercial finite element method (FEM) software to model an experimental single bead GMAW of AISI 441 at different process set-up. The experimental HAZ and measured temperatures were used to calibrate the heat source of both the used numerical codes, then a validation procedure was done to test the robustness of the two developed analytical procedures. One software was used to predict the residual stresses and strains and the distortions of the welded components, while in the second software a user routine was implemented, including a physical based model and the Hall-Petch (H-P) equation, to predict grain size change and hardness evolution respectively. The results demonstrate that the predicted mechanical and microstructural aspects agree with those experimentally found showing the reliability of the two codes in predicting the thermal phenomena characterizing the HAZ during the analysed welding process.

A Comparison Study between Friction Stir Welding and Metal Inert Gas Welding in Joining Similar Al-Al Strips

2014 ◽  
Vol 925 ◽  
pp. 180-184 ◽  
Author(s):  
Hasan I. Dawood ◽  
Kahtan S. Mohammed ◽  
Mumtaz Y. Rajab ◽  
Nurafifah R. Ismail
Keyword(s):  
Friction Stir Welding ◽  
Arc Welding ◽  
Pure Aluminum ◽  
Welding Process ◽  
Cost Effective ◽  
Power Input ◽  
Butt Joint ◽  
Inert Gas ◽  
Friction Stir ◽  
Welding Processes

In this study, two sets of pure aluminum strips 3 mm in thickness were friction stir welding (FSW) together in a regular Butt joint pattern. Two rotational speeds of 1750 RPM and 2720 RPM were utilized to perform the welding process. The transverse speed and the axial load were kept constant at 45 mm/min and 6.5 kN respectively. As a welding tool, cylindrical shoulder and pin geometry was selected. For comparison purposes other similar strip pair sets were butt welded using the conventional metal inert gas arc welding technique (MIGAW). The welding quality, power input, microstructure, macrostructure and the mechanical properties of the weld joints yielded from these two welding techniques were examined. The types of the fumes and the amount of the released gases during these two welding processes were measured and compared. The results proved that the solid state friction stir welding is clean, cost effective and environment friendly process as opposed to the conventional metal inert gas arc welding.

Thermo-Mechanical Analysis of Residual Stresses in Arc Welded Thin-Walled Cylinders

2008 ◽  
Author(s):  
Ejaz M. Qureshi ◽  
Afzaal M. Malik ◽  
Naeem Ullah Dar
Keyword(s):  
Residual Stresses ◽  
Arc Welding ◽  
Structural Integrity ◽  
Weld Zone ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Mechanical Analysis ◽  
Outer Diameter ◽  
Low Carbon ◽  
Thin Walled

The problem of reduced strength of the structures in and around the weld zone due to the residual stresses in arc welding process is a major concern of the welding industry for decades. The prediction of the transient and residual stress fields during and after the completion of the welding process is of critical importance to ensure the structural integrity of welded structures. Circumferentially welded thin-walled cylinders are widely utilized in many engineering applications including the oil transportation system, boiler and pressure vessel industries. This paper presents a detailed three-dimensional finite element (FE) study to investigate the welding induced residual stresses in circumferentially welded thin-walled cylinders. The complex phenomenon of arc welding is numerically solved by sequentially coupled transient, non-linear thermo-mechanical analysis approach to simulate Gas Tungsten Arc (GTA) Welding process. Single pass butt-welded geometry with single “V” groove for two 300 mm outer diameter cylinders with 3 mm wall thickness and 150 mm length are used in numerical simulations. Temperature dependent thermo-mechanical behavior for low carbon steel is modeled and filler metal deposition by using the element birth and kill features is incorporated. Widely accepted double ellipsoidal GOLDAK heat source model for arc welding is introduced and implemented. Simulation of the entire welding process is accomplished by using author written subroutines in ANSYS®, general purpose FE software. The accuracy of the developed FE simulation strategy is validated with experimentation for temperature distribution and residual stresses.

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