scholarly journals Pengaruh Double Chamfer terhadap Distribusi Suhu dan Daerah Zpl pada Sambungan Las Gesek AL6061 dengan Simulasi Komputer

2021 ◽  
Vol 12 (2) ◽  
pp. 433-445
Author(s):  
Mesti Nadya ◽  
◽  
Yudy Surya Irawan ◽  
Moch. Agus Choiron
Keyword(s):  
Temperature Distribution ◽  
Taguchi Method ◽  
Weld Metal ◽  
Computer Simulations ◽  
Heat Affected Zone ◽  
Friction Welding ◽  
Welding Process ◽  
Maximum Temperature ◽  
Initial Area ◽  
Aluminum Material

Welding is one of the metal joining processes in manufacturing. CDFW (continuous drive friction welding) is a welding process to join two workpieces by applying pressure at one end of the object and rotating another one where the friction action applies at interface. The purpose of this study is to study temperature distribution on the surface of the welding area and the heat-affected zone represented by a fully plasticized zone (Zpl) and to get an insight of a friction welding process. The variables of CDFW used were double chamfer angle, upset pressure, and burn off length. The initial area of friction was equal that is at a diameter of 14 mm. The method of modeling the CDFW friction welding is via computer simulations using ANSYS 18.1 software. This research uses aluminum material type Al6061. The Taguchi method was applied in designing the simulations. In this modeling, the model with the double chamfer of 15 °, the upset pressure of 120 MPa, and the burn-off length of 9 mm has a small ZPl area of 10.256 mm2. Whilst the specimen model, with a double chamfer angle of 45 °, the upset pressure of 240 MPa, and the burn-off length of 7 mm has a large Zpl area of 56.55mm2. The area of a narrow fully plasticized area caused by small chamfer angle and an upset pressure of 240 MPa. The area of fully plasticized zone shows how much material can be integrated during the friction welding process and how much strength of the weld metal. The model with the chamfer angle of 15 º, the upset pressure of 240 MPa, and the burn-off length of 9 mm has the widest temperature distribution and the highest maximum temperature. Meanwhile, the model with the chamfer angle of 30º, the upset pressure of 120 MPa, and the burn-off length of 9 mm has the narrowest temperature distribution and the lowest maximum temperature. The smaller chamfer angle increased upset pressure and burn-off length result in the wider temperature distribution, higher maximum temperature, and smaller Zpl.

scholarly journals Influence of Welding Parameters On Grain Size, Haz and Degree of Dilution in 6063-t5 Alloy. Optimisation Through the Taguchi Method of the Gmaw Welding Process.

2022 ◽  
Author(s):  
Jose Luis Meseguer Valdenebro ◽  
Eusebio José Martínez Conesa ◽  
Antonio Portoles
Keyword(s):  
Grain Size ◽  
Taguchi Method ◽  
Heat Affected Zone ◽  
Welding Process ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Taguchi’S Method ◽  
Gmaw Welding ◽  
Made In

Abstract The aim of this work is to carry out the design of experiments that determine the influence of the welding parameters using Taguchi’s method on the grain size, HAZ, and the degree of dilution in 6063-T5 alloy. The welding process used is GMAW and the welding parameters are power, welding speed and bevel spacing. The study of the influence of the welding parameters on the measurements made in the welding (which are the size of heat affected zone, the degree of dilution, and the grain size) allows one to determine the quality of the joint . In addition, the welding parameter most influential in minimising the three measurements will be determined.

An Effective Approach Based on Response Surface Methodology for Predicting Friction Welding Parameters

2016 ◽  
Vol 35 (3) ◽  
pp. 235-241
Author(s):  
Sare Celik ◽  
Aslan Deniz Karaoglan ◽  
Ismail Ersozlu
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Friction Welding ◽  
Welding Process ◽  
Raw Material ◽  
Maximum Temperature ◽  
Welding Parameters ◽  
Rotating Speed ◽  
Minimum Number ◽  
Normal Carbon

AbstractThe joining of dissimilar metals is one of the most essential necessities of industries. Manufacturing by the joint of alloy steel and normal carbon steel is used in production, because it decreases raw material cost. The friction welding process parameters such as friction pressure, friction time, upset pressure, upset time and rotating speed play the major roles in determining the strength and microstructure of the joints. In this study, response surface methodology (RSM), which is a well-known design of experiments approach, is used for modeling the mathematical relation between the responses (tensile strength and maximum temperature), and the friction welding parameters with minimum number of experiments. The results show that RSM is an effective method for this type of problems for developing models and prediction.

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.

Application of FIB/SEM/EBSD for Evaluation of Residual Strains and Their Relationship to Weld Metal Hydrogen Assisted Cold Cracking

2012 ◽  
Author(s):  
W. L. Costin ◽  
I. H. Brown ◽  
L. Green ◽  
R. Ghomashchi
Keyword(s):  
Residual Stresses ◽  
Weld Metal ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Ion Beam ◽  
Base Material ◽  
Welding Process ◽  
Cold Cracking ◽  
Predictive Methods ◽  
Residual Strains

Hydrogen assisted cold cracking (HACC) is a welding defect which may occur in the heat affected zone (HAZ) of the base metal or in the weld metal (WM). Initially the appearance of HACC was associated more closely with the HAZ of the base metal. However, recent developments in advanced steel processing have considerably improved the base material quality, thereby causing a shift of HACC to the WM itself. This represents a very serious problem for industry, because most of the predictive methods are intended for prevention of HACC in the HAZ of the base metal, not in the weld metal [1]. HACC in welded components is affected by three main interrelated factors, i.e. a microstructure, hydrogen concentration and stress level [2–4]. In general, residual stresses resulting from the welding process are unavoidable and their presence significantly influences the susceptibility of weld microstructures to cracking, particularly if hydrogen is introduced during welding [5]. Therefore various weldability tests have been developed over the years which are specifically designed to promote HACC by generating critical stress levels in the weld metal region due to special restraint conditions [4, 6–8]. These tests were used to develop predictive methods based on empirical criteria in order to estimate the cracking susceptibility of both the heat-affected zone and weld metal [4]. However, although the relationship between residual stress, hydrogen and HACC has received considerable attention, the interaction of residual stresses and microstructure in particular at microscopic scales is still not well understood [5, 9–21]. Therefore the current paper focuses on the development and assessment of techniques using Focused Ion Beam (FIB), Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction for the determination of local residual strains at (sub) micron scales in E8010 weld metal, used for the root pass of X70 pipeline girth welds, and their relationship to the WM microstructure. The measurement of these strains could be used to evaluate the pre-existing stress magnitudes at certain microstructural features [22].

scholarly journals NUMERICAL SIMULATION ON JOINING OF CERAMICS WITH METAL BY FRICTION WELDING TECHNIQUE

2013 ◽  
Vol 22 ◽  
pp. 190-195 ◽  
Author(s):  
N. RAJESH JESUDOSS HYNES ◽  
P. NAGARAJ ◽  
S. JOSHUA BASIL
Keyword(s):  
Numerical Simulation ◽  
Thermal Analysis ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Temperature Distribution ◽  
Friction Welding ◽  
Transient Liquid Phase ◽  
Sheet Thickness ◽  
Welding Process ◽  
Element Analysis

The joining of ceramic and metals can be done by different techniques such as ultrasonic joining, brazing, transient liquid phase diffusion bonding, and friction welding. Friction Welding is a solid state joining process that generates heat through mechanical friction between a moving workpiece and a stationary component. In this article, numerical simulation on thermal analysis of friction welded ceramic/metal joint has been carried out by using Finite Element Analysis (FEA) software. The finite element analysis helps in better understanding of the friction welding process of joining ceramics with metals and it is important to calculate temperature and stress fields during the welding process. Based on the obtained temperature distribution the graphs were plotted between the lengths of the joint corresponding to the temperatures. To increase the wettability, aluminium sheet was used as an interlayer. Hence, numerical simulation of friction welding process is done by varying the interlayer sheet thickness. Transient thermal analysis had been carried out for each cases and temperature distribution was studied. From the simulation studies, it is found that the increase in interlayer thickness reduces the heat affected zone and eventually improves the joint efficiency of alumina/aluminum alloy joints.

scholarly journals PENGARUH MEDIA PENDINGINAN TERHADAP KEKERASAN DAN STRUKTUR MIKRO HASIL PENGELASAN OXY ACETYLENE PADA MATERIAL BAJA ST-37

2017 ◽  
Vol 5 (2) ◽  
Author(s):  
Made Angga Priadi ◽  
I Nyoman Pasek Nugraha ◽  
Gede Widayana
Keyword(s):  
Weld Metal ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Quantitative Research ◽  
Welding Process ◽  
Air Cooling ◽  
Water Cooling ◽  
Independent Variable ◽  
The Mean ◽  
Cooling Media

Media pendingin merupakan suatu substansi yang berfungsi dalam menentukan kecepatan pendinginan yang dilakukan terhadap material yang telah diuji dalam perlakuan panas. Penelitian ini bertujuan untuk mengetahui tingkat kekerasan dan pengamatan struktur mikro material baja ST-37 yang dipengaruhi media pendinginan air, udara dan oli serta penelitian ini dapat memberikan bahan referensi bagi lingkup pendidikan teknik mesin dan sebagai acuan di dunia industri dalam menggunakan media pendingin pada proses pengelasan. Adapun jenis metode yang digunakan dalam penelitian ini adalah metode penelitian eksperimen. Terdapat dua jenis variable yang digunakan dalam penelitian ini yaitu variabel bebas yang berupa media pendingin air, media pendingin udara dan media pendingin oli dan variabel terikatnya berupa sifat kekerasan. Dari hasil penelitian yang telah dilakukan dimana kekerasan daerah logam induk dengan media pendingin air memperoleh nilai rata-rata sebesar 63,10 Kg/mm2, pendingin udara memperoleh nilai rata-rata sebesar 65,61 Kg/mm2, dan media pendingin oli memperoleh nilai rata-rata sebesar 62,68 Kg/mm2. Kekerasan pada daerah HAZ dengan media pendingin air memperoleh nila rata-rata sebesar 68,49 Kg/mm2, media pendingin udara memperoleh nilai rata-rata sebesar 71,05 Kg/mm2 dan media pendingin oli memperoleh nilai rata-rata sebesar 70,34 Kg/mm2. Kekerasan pada daerah logam las dengan media pendingin air memperoleh nilai rata-rata sebesar 60,99 Kg/mm2, media pendingin udara memperoleh nilai rata-rata sebesar 61,79 Kg/mm2 dan media pendingin oli memperoleh nilai rata-rata sebesar 60,79 Kg/mm2. Berdasarkan dari hasil yang telah didapatkan baik pada logam induk, daerah HAZ dan logam Las dimana tingkat kekerasan yang lebih baik diperoleh dari proses pendinginan udara dibandingkan dengan media pendingin air dan media pendingin oli dari proses pengelasan oxy acytelene.Kata Kunci : Baja ST-37, Kekerasan Material, media pendinginan. The cooling media is a substance which has a function to determine the speed refrigeneration which carried out of the material that has been tasted by heat treatment. The objective of the research is to know the level of hardness and the observation of steel ST-37 material which is affected by cooling media such as water, air, and oil. Also this research may give a reference for Engineering Department of Education and industry in using cooling media for welding process. There is a method that use in this research, that is called quantitative research. There are two variables that use in this research. Independent variable and dependent variable. An independent variable are water, air, and oil cooling media. On the other hand, a dependent variable is nature of hardness. In this research the researcher got a results where the mean of hardness of the base metal area with the water cooling media is 63.10 Kg/mm2, in air conditioning is 61Kg/mm2, and the oil cooling is 62.68 Kg/mm2. The mean of a hardness in Heat Affected Zone (HAZ) by water cooling media 68,49 Kg/mm2, air cooling media is 71,05 Kg/mm2 and an air cooling is 70,34 Kg/mm2. The mean of Hardness in the weld metal area with water cooling media is 60,99 Kg/mm2, air-cooling media is 61,79 Kg/mm2 and oil-cooling media is 60,79Kg/mm2. Based on the result which has been gotten from base metal, Heat Affected Zone (HAZ), and weld metal where the best hardness level is obtained from air-cooling process rather than water cooling media and oil cooling media from oxy acytelene welding process.keyword : Cooling media, steel ST-37, hardness properties.

Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails

2019 ◽  
Vol 234 (1) ◽  
pp. 65-79 ◽  
Author(s):  
Mohsen Ghazanfari ◽  
Parisa Hosseini Tehrani
Keyword(s):  
Heat Affected Zone ◽  
Experimental Studies ◽  
Welding Process ◽  
Material Model ◽  
Maximum Temperature ◽  
Hardness Profile ◽  
Railway Network ◽  
Butt Welding ◽  
Influence Of Temperature On

Continuously welded rails are widely used in the Iran railway network, which are generally built using the flash-butt welding process. To accurately model the flash-butt welding process, thermal analysis, and prediction of the welding residual stresses, the influence of upsetting force on the total electrical resistance and a material model with consideration of the influence of temperature on the material properties are included in the numerical modeling. In this paper, numerical and experimental studies, including the finite element method, thermography, metallography, and hardness testing are performed to determine the characteristics of the welded UIC60 rail. By studying the fractured flash-butt welded UIC60 rails, it is shown that the location of the crack initiation and the rail failure in the web and heat affected zone of the welded rails was similar as compared to the maximum tensile residual stress calculated by numerical simulation. According to the numerical and experimental results, it is shown that four key parameters – such as the maximum temperature during the welding process, the total welding time, the upsetting time, and the upsetting force – control the size, microstructure, and the hardness profile of the heat affected zone which directly affects the characteristics and quality of welding.

Sign in / Sign up

Export Citation Format

Share Document