Multi-properties optimization of welding parameters of wire arc additive manufacture in dissimilar joint of iron-based alloy and nickel-based superalloy using grey-based Taguchi method

2021 ◽  
pp. 095440622110089
Author(s):  
Yufeng Xia ◽  
Mengxia Peng ◽  
Haihao Teng ◽  
Yanhong Chen ◽  
Xue Zhang
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Welding Speed ◽  
Welding Parameters ◽  
Additive Manufacture ◽  
Feed Speed ◽  
Nickel Based Superalloy ◽  
Wire Feed Speed ◽  
Iron Based ◽  
Wire Feed

In order to adapt to the high temperature and heavy load process environment of large forgings, a novel die with “fist-like” structure was designed. The iron-based welding material (RMD248) as the “bone” layer and the nickel-based superalloy welding material (ERNiCr-3) as the “skin” layer were welded on the matrix by wire arc additive manufacture (WAAM). In this work, the grey based Taguchi methodology was used to optimize welding parameters (welding voltage, welding speed and wire feed speed) considering excellent multi-properties (hardness and ultimate tensile strength of high-temperature tensile test) of the dissimilar joint of RMD248 and ERNiCr-3. Further, analysis of variance was done to ascertain the influence of welding parameters on response parameters. Experimental results showed that welding speed was the most effective input parameter followed by wire feed speed and welding voltage. Finally, optimal result was verified through confirmation experiments. Meanwhile, the effect of welding speed on the microstructure and mechanical properties of joint was studied. The microstructures were characterized by optical microscopy (OM), energy dispersive spectrometer (EDS). The results indicated that the microstructure of RMD248 was consisted of more retained austenite at lower welding speed. For ERNiCr-3, the finer columnar crystal structure at higher welding speed was observed. At lower welding speed, the microhardness of RMD248 was just slightly lower, but that of ERNiCr-3 was significantly higher, and the ultimate tensile strength was higher. Therefore, the specimen at lower welding speed had better comprehensive mechanical properties.

scholarly journals Development of mathematical model and optimization of GMA welding parameters of IS 2062 grade A steel weldments

2021 ◽  
Vol 15 (56) ◽  
pp. 84-93
Author(s):  
Saadat Ali Rizvi ◽  
Wajahat Ali
Keyword(s):  
Mathematical Model ◽  
Gas Flow ◽  
Gma Welding ◽  
Welding Parameters ◽  
Feed Speed ◽  
Weld Quality ◽  
Gas Flow Rate ◽  
Arc Voltage ◽  
Wire Feed Speed ◽  
Wire Feed

In this experimental works, the effect of GMA welding process parameters, such as arc voltage, wire feed speed, and gas flow rate on the mechanical quality of IS 2062 structural steel of grade A has been studied. Process parameters play an important role in determining the weld quality. In this research work response surface methodology (RSM) technique via design expert (DOE) 12 version software was applied to determining the weld quality and also to develop a mathematical model that can predict the main effect of the above said parameters on weld quality i.e. toughness and hardness. A set of experiments has been conducted to collect the data using a central composite design and ANOVA was used to predict the impact of welding parameters on toughness and hardness and Comparison also made between the actual result and predicted value and from the result that is clear that toughness and hardness of weldment is significantly affected by arc voltage, wire feed speed, and follow by gas flow rate.

Robotic Friction Stir Welding of AA5754 Aluminum Alloy Sheets at Different Initial Temper States

2014 ◽  
Vol 622-623 ◽  
pp. 540-547 ◽  
Author(s):  
Massimo Callegari ◽  
Archimede Forcellese ◽  
Matteo Palpacelli ◽  
Michela Simoncini
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Speed ◽  
Process Condition ◽  
Hybrid Structure ◽  
Welding Parameters ◽  
Friction Stir ◽  
Robotic Friction Stir Welding

Robotic friction stir welding experiments were performed on AA5754 aluminium alloy sheets, 2.5 mm in thickness, in two different temper states (H111 and O-annealed). A six axes robot with a hybrid structure, characterised by an arm with parallel kinematics and a roll-pitch-roll wrist with serial kinematics, was used. The effect of the process parameters on the macro-and micro-mechanical properties and microstructure of joints was widely analysed. It was shown that, under the same process condition, the mechanical properties of the joints are strongly influenced by the initial temper state of the alloy. In particular, as AA5754-H111 is welded, the ultimate tensile strength is not significantly affected by the process parameters whilst the ultimate elongation significantly depends on the welding speed. In AA5754-O, both ultimate values of tensile strength and elongation are affected by the welding speed whilst a negligible effect of the rotational speed can be observed. Irrespective of the welding parameters, the H111 temper state leads to mechanical properties higher than those given by the O-annealed state. An investigation has been also carried out in order to evaluate the micro-hardness profiles and microstructure of the FSWed joints in order to understand the mechanisms operating during robotic friction stir welding.

scholarly journals Effect of molybdenum addition on microstructure and mechanical properties of plain carbon steel weld

10.30544/245 ◽  
2016 ◽  
Vol 22 (4) ◽  
pp. 269-284
Author(s):  
Jyoti Menghani ◽  
Kunal Dwivedi
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Process Parameters ◽  
Welding Speed ◽  
Welding Process ◽  
Grain Structure ◽  
Welding Parameters ◽  
Bead Width ◽  
Arc Voltage ◽  
Molybdenum Carbides

The present investigation has two main objectives; first is optimization of welding process parameters of submerged arc welding (SAW) using Taguchi philosophy and second is to improve the mechanical properties such as strength and microhardness of weld joint by alloying with varying amounts of molybdenum. For optimization of welding process, parameters Taguchi philosophy have been applied on a mild steel plate (AISI C- 1020) of 10 mm thickness with 60o groove angle with arc voltage and welding speed as variables and bead width as output variables. A mathematical relationship between bead width, arc voltage and welding speed has also been found using multiple regression analysis for the present base metal plate geometry. After optimizing welding parameters, molybdenum has been added individually to the welding area in varying percentages. The properties of alloyed and unalloyed weld metal bead are compared. The mechanical characterization of weld has been done in terms of microhardness, tensile strength, whereas microstructural characterization has been performed using optical microscopy, XRD and EDS. The presence of molybdenum resulted in bainite structure in weld bead having a refined grain structure, enhancement in tensile strength and microhardness. The XRD results showed the formation of molybdenum carbides justifying the increase in microhardness value.

scholarly journals Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding

2015 ◽  
Vol 2015 ◽  
pp. 1-5 ◽  
Author(s):  
Anusit Ampaiboon ◽  
On-Uma Lasunon ◽  
Bopit Bubphachot
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Regression Model ◽  
Flow Rate ◽  
Welding Speed ◽  
Feed Rate ◽  
Gas Flow ◽  
Welding Parameters ◽  
Gas Flow Rate ◽  
Wire Feed

We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10–20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

scholarly journals Study of Laser Welding of HCT600X Dual Phase Steels

2014 ◽  
Vol 22 (1) ◽  
pp. 93-98
Author(s):  
Pavol Švec ◽  
Viliam Hrnčiar ◽  
Alexander Schrek
Keyword(s):  
Tensile Strength ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Welding Speed ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Dual Phase ◽  
Welded Steel ◽  
Steel Sheets

AbstractThe effects of beam power and welding speed on microstructure, microhardnes and tensile strength of HCT600X laser welded steel sheets were evaluated. The welding parameters influenced both the width and the microstructure of the fusion zone and heat affected zone. The welding process has no effect on tensile strength of joints which achieved the strength of base metal and all joints fractured in the base metal.

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