FEA of SAW penetration of Ramor 500 steel

2020 ◽  
Vol 62 (12) ◽  
pp. 1192-1198
Author(s):  
Ali Kaya Gur ◽  
Semih Taskaya ◽  
Subramaniam Shankar ◽  
Thangamuthu Mohanraj
Keyword(s):  
Three Dimensional ◽  
Welding Process ◽  
Source Model ◽  
Strength Properties ◽  
Steel Plates ◽  
Constant Current ◽  
Welding Seam ◽  
Depth Increase ◽  
Thermal Cooling ◽  
Submerged Arc

Abstract Ramor 500 steel plates are used as a ballistic material due to their greater hardness and strength properties. This steel can be produced with a 2-30 mm thickness sheet which may attain 505-590 HV hardness. In the present work, Ramor 500 steel pairs are joined using a submerged arc welding (SAW) process and taking various parameters into consideration. An austenitic additional wire is used for the welding process which contains Cr, Ni, and Mn. The source model prototype was developed using ANSYS software and considering a time-dependent three dimensional thermal model with source cooling. The highest tensile stress voltage value was determined in the sample applying a constant current of 250 A, 25 V and 30 cm × min-1welding speed. It was observed that the welding seam width increases as welding tension grows and that welding height and depth increase and decrease more or less in tandem. A ANSYS thermal cooling analysis revealed that welding tension grows with heat transfer which increases 15 mm from the main center of the welding area.

Effect of Welding Sequence on the Residual Stress Distribution in a Stiffened Plate

2016 ◽  
Author(s):  
Bai-Qiao Chen ◽  
C. Guedes Soares
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Lower Layer ◽  
Plate Thickness ◽  
Three Dimensional ◽  
Welding Process ◽  
Residual Stress Distribution ◽  
Steel Plates ◽  
Tension Zone ◽  
Welding Sequence

This work investigates the temperature distribution, deformation and residual stress in steel plates as a result of different sequences of welding. The single-pass gas tungsten arc welding process is simulated by a three dimensional nonlinear thermo-elasto-plastic approach. It is observed that the distribution of residual stress varies through the direction of plate thickness. It is concluded that the welding sequence affects not only the welding deformation but also the residual stress mainly in the lower layer of the plates. An in-depth discussion on the pattern of residual stress distribution is presented, especially on the width of the tension zone. Smaller residual tension zone and slightly lower compressive stress are found in thicker plate.

scholarly journals Multiwire submerged arc welding of steel structures

2012 ◽  
Vol 3 (3) ◽  
pp. 228-233
Author(s):  
R. Dhollander ◽  
S. Vancauwenberghe ◽  
W. De Waele ◽  
N. Van Caenegem ◽  
E. Van Pottelberg
Keyword(s):  
Arc Welding ◽  
Plate Thickness ◽  
Welding Process ◽  
Steel Structures ◽  
Submerged Arc Welding ◽  
Steel Plates ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
The Matrix ◽  
Submerged Arc

The assembly of large structures made out of thick steel plates requires a welding process bywhich multiple wires can be used simultaneously. To reproduce these industrial processes in a researchenvironment, OCAS has invested in a multiwire submerged arc welding (SAW) setup. In this multiwiresetup, up to five wires in tandem configuration can be used.The objective of this master thesis is to establish a deeper knowledge of process parameters used to weldsteel plates in a thickness range of 12,7 up to 25 mm, by means of the submerged arc welding process.Based on literature, a test matrix is composed in which the number of wires, the plate thickness and otherweld parameters are the variables. In addition, a specific plate preparation for each plate thickness isderived from the literature. The preformed weld trails will be evaluated on weld bead geometry andmetallographic properties. There is further experimental examination required, which will result in therevising of the matrix.

Investigating the effect of electrode preheating in novel water-cooled advanced submerged arc welding process

2018 ◽  
Vol 233 (10) ◽  
pp. 2015-2029 ◽  
Author(s):  
Ankush Choudhary ◽  
Munish Kumar Gupta ◽  
Manoj Kumar
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
Steel Plates ◽  
Statistical Regression ◽  
Weld Metals ◽  
Arc Welding Process ◽  
Metal Hardness ◽  
Submerged Arc ◽  
Plate Distance

In this paper, a novel developed water-cooled advanced submerged arc welding (WASAW) process has been designed and established. The developed WASAW process can be utilized for higher preheating currents at 100% duty cycle. Subsequently, a multi-pass welding investigation has been carried out on AISI 1023 steel plates as per the L8 Taguchi orthogonal array by varying WASAW input factors namely voltage (V), wire feed rate (WFR), welding speed (WS), nozzle to plate distance (NPD), and preheat current (I), respectively. The relationships between selected WASAW process parameters and responses namely tensile strength (TS), yield strength (YS), percentage elongation (E), and weld metal hardness (H) has been established with statistical regression analysis and ANOVA method. Then, the effect of each input factor and their interactions on selected responses was analyzed using single effect and 3D surface plots. Lately, the fractography analysis of tensile fractured surfaces has been carried out to study the failure in all weld metals. Finally, Jaya and genetic algorithms have been applied to optimize the WASAW performance. Overall, the outcomes reveal that developed WASAW process yields a substantial enhancement in the mechanical behavior of all weld metals.

Studies on Temperature Variation and Angular Distortion in Submerged Arc Welded Butt Joint

2013 ◽  
Vol 699 ◽  
pp. 656-661 ◽  
Author(s):  
Arora Hitesh ◽  
Prince Pal Singh ◽  
Ajay Hooda
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Welding Current ◽  
Source Model ◽  
Butt Joint ◽  
Fusion Welding ◽  
Angular Distortion ◽  
Transient Temperature ◽  
Large Structures ◽  
Submerged Arc

Large structures are usually made by joining different elements. Fusion welding is one of the most fundamental technique, which is used to make large metallic joints. During fusion welding a large amount of heat is generated which melts the joint surroundings and a joint is created after solidification. Joint configuration is mostly affected by the material parameters and process type. In this paper, a thermo-mechanical simulation of fusion welding of submerged arc welding is performed using ANSYS. A moving heat source model based on Double-Ellipsoidal heat flux distribution is modelled. The transient temperature distributions and temperature variations of the welded plates are calculated during welding process. Effect of welding speed, welding current on temperature profile and angular distortion of plates is further investigated.

Prediction of Toughness through Evaluation of Alloying Elements Distribution Pattern at Heat-Affected Zone in Submerged-Arc Welding Process of API X70 Steel

2013 ◽  
Vol 467 ◽  
pp. 35-40
Author(s):  
Majid Sharifi ◽  
Najmoddin Arab ◽  
Gholamreza Khalaj
Keyword(s):  
Arc Welding ◽  
Boron Content ◽  
Welding Process ◽  
Alloying Elements ◽  
Welding Seam ◽  
Three Samples ◽  
Copper Manganese ◽  
Arc Welding Process ◽  
Submerged Arc ◽  
Haz Toughness

Six 56" × 19.8 mm, API X70 PSL2 pipes were produced from three different plate suppliers and then three samples in pipe transverse direction and perpendicular to welding seam were taken out from welding area of each supplier. Sampling carried out from weld metal, HAZ and base metal of each sample, then all 27 prepared samples were analyzed. Afterwards the amounts of 14 alloying elements were considered. The results showed that content of Carbon, Sulfur, Boron, Phosphorous, Copper, Manganese, Aluminum, Titanium and Molybdenum have been increased in the HAZ and Silicon, Nickel, Chrome, Vanadium and Niobium decreased. So it is predicted that an increase in Carbon, Aluminum, Phosphorous, Sulfur and Boron content, also a decrease in Silicon, Chrome and Nickel will cause a drop in the HAZ toughness and an increase in Titanium, Manganese, Copper and Molybdenum content, also decrease in Vanadium and Niobium will cause a rise in HAZ toughness.

Analysis of the Influence of the Heat Input and Bead Volume on HAZ Hardness for Submerged Arc Welding Process of Mild Steel Plates

2011 ◽  
Vol 284-286 ◽  
pp. 2469-2472
Author(s):  
Aniruddha Ghosh ◽  
Somnath Chattopadhyaya ◽  
S. Mukherjee
Keyword(s):  
Mild Steel ◽  
Heat Input ◽  
Arc Welding ◽  
Welding Process ◽  
Travel Speed ◽  
Submerged Arc Welding ◽  
Steel Plates ◽  
Critical Set ◽  
Arc Welding Process ◽  
Submerged Arc

In Submerged Arc Welding process involves critical set of variables which are needed to control. An attempt has been made in this paper to find out- the influence of the heat input and bead volume on HAZ Hardness for Submerged Arc Welding Process of Mild steel plates. Mild steel plates are welded by changing input variables (current, voltage, travel speed, i.e. heat input) and Rockwell hardness no. has been observed on welded portion and at the zone adjacent to the welded portion. A detailed analysis of the microstructure changes is carried out to understand the HAZ softening phenomenon.

Numerical analysis on temperature field in single-wire flux-aided backing-submerged arc welding

2017 ◽  
Vol 31 (16-19) ◽  
pp. 1744044
Author(s):  
Juan Pu ◽  
Ming Fang Wu ◽  
Haichao Pan
Keyword(s):  
Temperature Field ◽  
Arc Welding ◽  
Thermal Field ◽  
Three Dimensional ◽  
Welding Process ◽  
High Heat ◽  
Submerged Arc Welding ◽  
Single Wire ◽  
Transient Model ◽  
Submerged Arc

Single-wire flux-aided backing-submerged arc welding (FAB-SAW) technology has been widely used to weld thick steel plate due to its easy assembly and high heat input. The microstructure and property of welded joint are closely related to the thermal field of FAB-SAW process. In this research, the feature of thermal field for single-wire FAB-SAW was investigated. Based on the heat transfer mechanism, a three-dimensional transient model for thermal field was developed based on the influence of steel thickness, groove angle and ceramic backing. The temperature profile in single-wire FAB-SAW of D36 steel under different welding conditions was simulated by ANSYS. The characteristic of thermal field was analyzed and the influences of groove angle on temperature field for different plate thicknesses were discussed. The calculated geometries and dimensions of weld cross-section under different conditions show a good agreement with the experimental results. This newly built model can describe the thermal field accurately, which would be helpful to understanding the thermophysical mechanism of FAB-SAW and optimizing the welding process.

Design of CaO–SiO2–CaF2 and CaO–SiO2–Al2O3 Based Submerged Arc Fluxes for Series of Bead on Plate Pipeline Steel Welds—Effect on Carbon and Manganese Content, Grain Size and Microhardness

2019 ◽  
Vol 141 (3) ◽  
Author(s):  
Lochan Sharma ◽  
Rahul Chhibber
Keyword(s):  
Grain Size ◽  
Arc Welding ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
Pressure Vessels ◽  
Constant Current ◽  
Welding Parameters ◽  
Chemical Compositions ◽  
Optimization Approach ◽  
Submerged Arc

Submerged arc welding is mainly used to weld high thickness steel plates in various applications such as offshore oil drilling platforms, bridges, building construction, and pressure vessels. Suitable flux composition and welding parameters play an important role in determining the good bead quality, which further affects the mechanical properties of welded joint. Agglomerated fluxes were formulated based on CaO–SiO2–CaF2 and CaO–SiO2–Al2O3 flux system using constrained mixture design and extreme vertices design approach. The chemical compositions of the bead on plate have been studied using formulated fluxes. Twenty one beads on plate experiments were conducted at constant current, voltage, and welding speed using submerged arc welding process. In the present study, chemical composition, grain size, and microhardness properties of series of bead on plate weld deposits (for API 5 L X70 grade pipe line) were optimized by using multiobjective optimization approach.

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