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.

scholarly journals Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 141 ◽  
Author(s):  
Hui Huang ◽  
Xianqing Yin ◽  
Zhili Feng ◽  
Ninshu Ma
Keyword(s):  
Finite Element ◽  
Thin Plate ◽  
Heat Input ◽  
Plane Deformation ◽  
Welding Process ◽  
Numerical Results ◽  
Tig Welding ◽  
Image Correlation ◽  
Welding Distortion ◽  
Out Of Plane

Transient distortion of thin plate in the welding process usually has a complicated mode and large magnitude. Quantitative measurement and prediction of full-field distortion are challenging and rarely reported up to now. In this study, the out-of-plane distortion of a thin plate during the Tungsten Inert Gas (TIG) welding process was measured using the digital image correlation (DIC) method. A simulation model based on thermal elastic–plastic finite element method (FEM) and DIC measured geometric imperfection were developed for accurate prediction of the transient welding distortion. The numerical results and experimental data agreed very well in both out-of-plane deformation modes and magnitudes of the plate at different stages of welding. The maximum out-of-plane distortion was larger than 4 mm during welding which can cause instability of arc length and heat input. The distance change between welding torch and plate surface was investigated under different initial deflections of the plate before welding. The plate with flat geometry shows the minimum transient and final gap change. In addition, the relationship between heat input and welding distortion was clarified through a series of numerical analyses. Optimization of welding heat input can be performed based on numerical results to avoid excessive welding distortion.

Effect of Process Parameters on Welding Variables during Linear Friction Welding of Ti-6Al-4V Alloy

2011 ◽  
Vol 314-316 ◽  
pp. 979-983
Author(s):  
Tie Jun Ma ◽  
Xi Chen ◽  
Wen Ya Li
Keyword(s):  
Titanium Alloy ◽  
Process Parameters ◽  
Friction Welding ◽  
Welding Process ◽  
Orthogonal Experimental Design ◽  
Linear Friction Welding ◽  
Influence Of Process Parameters ◽  
Linear Friction ◽  
Suitable Process ◽  
Axial Shortening

The orthogonal experimental design was conducted for linear friction welding of Ti-6Al-4V titanium alloy (TC4). The friction power and joint temperature were collected during the welding process. The influence of process parameters on the axial shortening was analyzed. The suitable process parameters were determined by investigating the joint appearance, the requirement of axial shortening and welding variables during welding. The results provide important reference for establishing process parameters of linear friction welding in practice.

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.

scholarly journals Study the Effect of Welding Heat Input on the Microstructure, Hardness, and Impact Toughness of AISI 1015 Steel

2018 ◽  
Vol 14 (1) ◽  
pp. 118-127 ◽  
Author(s):  
Emad Kh. Hamd ◽  
Abbas Sh. Alwan ◽  
Ihsan Khalaf Irthiea
Keyword(s):  
Corrosion Rate ◽  
Weld Joint ◽  
Heat Input ◽  
Plate Thickness ◽  
Welding Process ◽  
Welding Current ◽  
Low Carbon ◽  
Mig Welding ◽  
The Impact ◽  
Weld Heat

In the present study, MIG welding is carried out on low carbon steel type (AISI 1015) by using electrode ER308L of 1.5mm diameter with direct current straight polarity (DCSP). The joint geometry is of a single V-butt joint with one pass welding stroke for different plate thicknesses of 6, 8, and 10 mm. In welding experiments, AISI 1015 plates with dimensions of 200×100mm and edge angle of 60o from both sides are utilized. In this work, three main parameters related to MIG welding process are investigated, which are welding current, welding speed, heat input and plate thickness, and to achieve that three groups of plates are employed each one consists of three plates. The results indicate that increasing the weld heat input (through changing the current and voltage) leads to an increase in widmanstatten ferrite (WF), acicular ferrite (AF) and polygonal ferrite (PF) in FZ region, and a reduction in grain size. It is observed that the micro-hardness of welded AISI 1015 plate increases as the weld heat input decreases. As well as increasing the weld heat input results in an increase in the width of WM and HAZ and a reduction in the impact energy of the weld joint of AISI 1015 at WM region. Also, it is noted the corrosion rate of weld joint increases with increase of Icorr due to increasing in welding current (heat input), corrosion rate increased up to (0.126µm/yr.) with increasing of heat input up to (1.27 KJ/mm).  

Numerical and Experimental Analysis of Self Piercing Riveting Process with Carbon Fiber-Reinforced Plastic and Aluminium Sheets

2013 ◽  
Vol 554-557 ◽  
pp. 1045-1054 ◽  
Author(s):  
Welf Guntram Drossel ◽  
Reinhard Mauermann ◽  
Raik Grützner ◽  
Danilo Mattheß
Keyword(s):  
Finite Element ◽  
Carbon Fiber ◽  
Finite Element Model ◽  
Simulation Model ◽  
Process Parameters ◽  
Process Model ◽  
Element Model ◽  
Model Parameters ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced

In this study a numerical simulation model was designed for representing the joining process of carbon fiber-reinforced plastics (CFRP) and aluminum alloy with semi-tubular self-piercing rivet. The first step towards this goal is to analyze the piercing process of CFRP numerical and experimental. Thereby the essential process parameters, tool geometries and material characteristics are determined and in finite element model represented. Subsequently the finite element model will be verified and calibrated by experimental studies. The next step is the integration of the calibrated model parameters from the piercing process in the extensive simulation model of self-piercing rivet process. The comparison between the measured and computed values, e.g. process parameters and the geometrical connection characteristics, shows the reached quality of the process model. The presented method provides an experimental reliable characterization of the damage of the composite material and an evaluation of the connection performances, regarding the anisotropic property of CFRP.

Process Parameter Effects over Bead Properties during Material Deposition of PTAW Process

2020 ◽  
Vol 978 ◽  
pp. 55-63
Author(s):  
Soumen Mandal ◽  
Subrata Kumar ◽  
Manish Oraon
Keyword(s):  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Fusion Welding ◽  
Bead Geometry ◽  
Plasma Transferred Arc ◽  
Surface Method ◽  
Material Deposition ◽  
Bead Height ◽  
Plasma Transferred Arc Welding

The quality and geometry of deposited bead depend on their input process parameters and their interaction effects in fusion welding process. Minimum dilution and maximum bead size are the most desirable property in material processing applications. The effects of process parameters on dilution and bead geometry have been analysed during material deposition by Plasma Transferred Arc Welding (PTAW) process using the response surface method. The experimental data are used for modelling using three level factorial techniques. The mathematical models have been developed for bead height, width and dilution. The accuracy of the models has been checked using the analysis of variance. The effects of process parameters on bead geometry and dilution have been investigated.

Linear Friction Welding of IN-718 Process Optimization and Microstructure Evolution

2006 ◽  
Vol 15-17 ◽  
pp. 357-362 ◽  
Author(s):  
Caroline Mary ◽  
Mohammad Jahazi
Keyword(s):  
Process Parameters ◽  
Microstructure Evolution ◽  
Friction Welding ◽  
Welding Process ◽  
Weld Interface ◽  
Maximum Temperature ◽  
Linear Friction Welding ◽  
Influence Of Process Parameters ◽  
Linear Friction ◽  
The Matrix

Linear Friction Welding (LFW) of IN-718 Superalloy was investigated under several processing conditions. The influence of process parameters such as frequency (60Hz to 100Hz), amplitude (2mm to 3mm) and frictional pressure (50MPa to 110MPa) on the microstructure and mechanical properties of welded specimens was determined. Optical and scanning electron microscopy, and micro-hardness testing were used to characterize the welded areas as well as the Thermo-Mechanically Affected Zones (TMAZ). In-situ thermocouple measurements were performed to follow temperature evolution in the specimens during the different phases of the LFW process. The analysis of the results indicated that for some specific conditions (f=80Hz, a=2mm and P=70MPa) a maximum temperature of 1200°C was attained during the last stage of the welding process, the burn-off phase. This temperature, very close to the alloy melting range, would be sufficient to cause partial liquation in this zone. Microscopic examinations revealed the presence of oxide particles aligned around the weld interface. Their concentration and distribution, varying with process parameters, affect the weld integrity. The TMAZ characterised by a global loss of strength (from 334HV to 250HV) is associated with temperatures exceeding 800°C and causing γ’ and γ’’ reversion. A narrow band of the TMAZ, exposed to high strains and temperatures, showed evidences of dynamic recovery and recrystallization (up to 67% of reduction in the matrix grain size). Visual and microscopic examination of the flash layer, revealed two distinct zones. Microstructure evolution and microhardness variations were associated to process parameters and the optimum conditions for obtaining defect free weldments were determined.

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