scholarly journals Effect of Coating and Welding Wire Composition on AHSS GMA Welds

2021 ◽  
Vol 100 (12) ◽  
pp. 396-409
Author(s):  
ABDELBASET R. H. MIDAWI ◽  
◽  
ELLIOT BIRO ◽  
SRINATH KISTAMPALLY
Keyword(s):  
Base Material ◽  
Welding Process ◽  
High Strength ◽  
Butt Joint ◽  
Lap Joints ◽  
Weld Strength ◽  
Material Strength ◽  
Filler Materials ◽  
Lap Joint ◽  
Welding Wire

Advanced high-strength steels (AHSS) such as complexphase (CP) and high-formability (HF) steel offer weightsaving advantages for automotive applications such as chassis and frame applications. To prevent material oxidation, materials are often galvanized to protect the substrate from corrosion. However, the weldability of coated AHSS becomes challenging due to the trapping of zinc in the weld molten pool, which could lead to weld defects such as porosity and liquid metal embrittlement cracks. This work focused on the weldability of AHSS (CP800 and 980HF) using the gas metal arc welding process. The roles of both galvanized iron coating and filler material on weld strength were investigated. The welds were performed using two different filler materials: a low-strength filler (ER70S-6) and a high-strength filler (ER100S-6) material. In addition, two different joint configurations were studied: lap joints and butt joints. The results showed that the butt joint had a higher strength compared to the lap joints. Furthermore, the strength of the butt joint overmatched the base material strength in all of the tested materials (both in galvanized and uncoated). In general, lap joint strength undermatched the base material strength, which was attributed to the rotation during tensile testing that induced unaccounted bending stress on the lap joint, while using a higherstrength welding wire improved the tensile strength material in the lap joint configuration. The hardness profiles in the 980HF steel also showed a significant hardness mismatch due to the formation of a fully martensitic microstructure in the heat-affected zone, which led to suppressing the deformation across the lap joint.

scholarly journals A Study on Rotary Friction Welding of Titanium Alloy (Ti6Al4V)

2019 ◽  
Vol 2019 ◽  
pp. 1-9 ◽  
Author(s):  
Ho Thi My Nu ◽  
Truyen The Le ◽  
Luu Phuong Minh ◽  
Nguyen Huu Loc
Keyword(s):  
Mechanical Properties ◽  
Titanium Alloys ◽  
Friction Welding ◽  
Base Material ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Experimental Results ◽  
Thermomechanical Model ◽  
Rotary Friction Welding

The selection of high-strength titanium alloys has an important role in increasing the performance of aerospace structures. Fabricated structures have a specific role in reducing the cost of these structures. However, conventional fusion welding of high-strength titanium alloys is generally conducive to poor mechanical properties. Friction welding is a potential method for intensifying the mechanical properties of suitable geometry components. In this paper, the rotary friction welding (RFW) method is used to study the feasibility of producing similar metal joints of high-strength titanium alloys. To predict the upset and temperature and identify the safe and suitable range of parameters, a thermomechanical model was developed. The upset predicted by the finite element simulations was compared with the upset obtained by the experimental results. The numerical results are consistent with the experimental results. Particularly, high upset rates due to generated power density and forging pressure overload that occurred during the welding process were investigated. The performances of the welded joints are evaluated by conducting microstructure studies and Vickers hardness at the joints. The titanium rotary friction welds achieve a higher tensile strength than the base material.

Modeling the interrelationship between the parameters for improving weld strength in plastic hot plate welding: A DEMATEL approach

2019 ◽  
Vol 52 (2) ◽  
pp. 117-141
Author(s):  
K Mathiyazhagan ◽  
Krishna Kumar Singh ◽  
V Sivabharathi
Keyword(s):  
Product Design ◽  
Manufacturing Process ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength ◽  
Weld Strength ◽  
Melting Time ◽  
Hot Plate ◽  
Plate Temperature ◽  
Hot Plate Welding

Application of plastics is increasing day by day since plastics offer many distinct advantages as compared to metals. Plastics has mainly good thermal and electrical insulation properties, corrosion resistance, chemical inertness, and high strength to weight ratio. Additionally, these are cheaper in cost as compared to conventional materials. Plastics are additionally easy to process. Nowadays, product requirements are getting critical and thus product design is getting more complex in shape. To manufacture intricate complex shape creates complexity in manufacturing process which is sometimes very difficult or almost not feasible to produce with single manufacturing process. To manufacture such critical products, welding is a complimentary process. Type of weld joint and welding process can be selected based on the product design and load application on the product. Hot plate welding is very simple welding process as compared to other plastic welding process and most commonly used. Good quality weld is the prime objective of welding process. Weld strength is dependent on several parameters which may be process parameters as well as product parameters. The objective of this study is to identify the key parameters in hot plate welding process of the plastics using Decision Making Trial and Evaluation Laboratory which is one of the prioritization techniques. Results of the study focus on understanding the key parameters affecting the weld strength. Study shows that hot plate temperature, welding time, and melting time are the key parameters affecting the weld strength.

Distortion Prediction of Welded Thin Plate Lap Joints by Finite Element Analysis and Experiment

2019 ◽  
Vol 796 ◽  
pp. 175-182
Author(s):  
Mohamad Nizam Ayof ◽  
Ruzaini Mohd Nawi ◽  
Nur Izan Syahriah Hussein ◽  
Nor Zulaikha Zainol
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Gas Metal Arc Welding ◽  
Three Dimensional ◽  
Welding Process ◽  
Element Model ◽  
Lap Joints ◽  
Lap Joint ◽  
Element Analysis ◽  
Metal Arc Welding

Welding process is an efficient joining process of metals that is achieved by gas metal arc welding (GMAW) process. Localized heating during welding process can result in distortion of the welded plate. The estimation of magnitude and distribution of distortion are important to maintain the quality of products. Finite element method is implemented to investigate the distortions behavior of thin steel plate, cold rolled (SPCC) material in lap joint using GMAW process. A three-dimensional, two-step thermomechanical finite element model study was applied to analyze and evaluate distortion behavior in lap joint. The result of distortion from finite element analysis (FEA) was compared to experimental data to validate the accuracy of the method.

Towards Tool Path Numerical Simulation in Modified Friction Stir Spot Welding Processes

2009 ◽  
Vol 83-86 ◽  
pp. 1220-1227
Author(s):  
Gianluca Buffa ◽  
Livan Fratini
Keyword(s):  
Spot Welding ◽  
Tool Path ◽  
Base Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Lap Joints ◽  
Hollomon Parameter ◽  
Friction Stir ◽  
Strain And Strain Rate ◽  
Welding Processes

Spot welding can be considered a very common joining technique in automotive and transportation industries as it permits to obtain effective lap-joints with short process times and what is more it is easily developed through robots and automated systems. Recently the Friction Stir Spot Welding (FSSW) process has been proposed as a natural evolution of the already known Friction Stir Welding (FSW) process, allowing to obtain sound spot joints that do not suffer from the insurgence of typical welding defects due to the fusion of the base material. In the paper, a modified Friction Stir Spot Welding (FSSW) process, with a spiral circular movement given to the tool after the sinking stage, is proposed. A continuum based numerical model for Friction Stir Spot Welding process is developed, that is 2D Lagrangian implicit, coupled, rigid-viscoplastic. This model is used to investigate the distribution of the main field variables, namely temperature, strain and strain rate, as well as the Zener-Hollomon parameter which, in turn, strongly affects the Continuous Dynamic Recrystallization (CDRX) process that takes place in the weld nugget. Numerical and experimental results are presented showing the effects of the process parameters on the joint performances and the mechanical effectiveness of the modified process.

Experimental Study on the Effects of Rotational Speed and Attack Angle on High Density Polyethylene (HDPE) Friction Stir Welded Butt Joints

2011 ◽  
Vol 189-193 ◽  
pp. 3583-3587 ◽  
Author(s):  
Sina Saeedy ◽  
M.K. Besharati Givi
Keyword(s):  
Rotational Speed ◽  
High Density Polyethylene ◽  
Base Material ◽  
Welding Process ◽  
High Density ◽  
Attack Angle ◽  
Material Strength ◽  
Weld Quality ◽  
Welding Condition ◽  
Friction Stir

Friction stir welding (FSW) is a novel solid-state welding process and has been employed in several industries such as aerospace and automotive. Several parameters such as rotational speed, welding speed, axial force and attack angle play critical roles in FSW process in order to analyze the weld quality. The aim of this study is to investigate the effects of different rotational speeds and attack angles on the weld quality of high density polyethylene (HDPE). In the optimum welding condition, 75% of the base material strength is achieved. SEM micrographs show the changes of the weld microstructure which result in the reduction of the strength and the percent of elongation.

Feasibility study of welding dissimilar Advanced and Ultra High Strength Steels

2020 ◽  
Vol 59 (1) ◽  
pp. 54-66
Author(s):  
Francois Njock Bayock ◽  
Paul Kah ◽  
Antti Salminen ◽  
Mvola Belinga ◽  
Xiaochen Yang
Keyword(s):  
Heat Input ◽  
High Strength Steel ◽  
Gas Metal Arc Welding ◽  
Base Material ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Hardness Test ◽  
Welding Parameter ◽  
Welding Parameters

AbstractThis study concerns the weldability of dissimilar Ultra high-strength steel (UHSS) and advanced high-strength steel (AHSS), which is used in the modern machine industry. The materials offered superior strength as well as relatively low weight, which reduces microstructure contamination during a live cycle. The choice of the welding process base of the base material (BM) and welding parameters is essential to improve the weld joint quality. S700MC/S960QC was welded using a gas metal arc welding (GMAW) process and overmatched filler wire, which was performed using three heat input (7, 10, and 15 kJ/cm). The weld samples were characterized by a Vickers-hardness test, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). The test reveals a decrease of softening areas in the HAZ and the formation of the stable formation of Bainite-Ferrite for S700MC and Bainite-martensite for S960QC when the heat input of 10 kJ/cm is used. It is recommended to use the GMAW process and Laser welding (Laser beam-MIG), with an optimal welding parameter, which will be achieved a high quality of manufacturing products.

scholarly journals Validated Multi-Physical Finite Element Modelling of the Spot Welding Process of the Advanced High Strength Steel DP1200HD

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5411
Author(s):  
Konstantin Prabitz ◽  
Marlies Pichler ◽  
Thomas Antretter ◽  
Holger Schubert ◽  
Benjamin Hilpert ◽  
...  
Keyword(s):  
Finite Element ◽  
High Strength Steel ◽  
Spot Welding ◽  
Base Material ◽  
Welding Process ◽  
High Strength ◽  
Parameter Determination ◽  
Fe Model ◽  
Advanced High Strength Steel ◽  
Local Risk

Resistance spot welding (RSW) is a common joining technique in the production of car bodies in white for example, because of its high degree of automation, its short process time, and its reliability. While different steel grades and even dissimilar metals can be joined with this method, the current paper focuses on similar joints of galvanized advanced high strength steel (AHSS), namely dual phase steel with a yield strength of 1200 MPa and high ductility (DP1200HD). This material offers potential for light-weight design. The current work presents a multi-physical finite element (FE) model of the RSW process which gives insights into the local loading and material state, and which forms the basis for future investigations of the local risk of liquid metal assisted cracking and the effect of different process parameters on this risk. The model covers the evolution of the electrical, thermal, mechanical, and metallurgical fields during the complete spot welding process. Phase transformations like base material to austenite and further to steel melt during heating and all relevant transformations while cooling are considered. The model was fully parametrized based on lab scale material testing, accompanying model-based parameter determination, and literature data, and was validated against a large variety of optically inspected burst opened spot welds and micrographs of the welds.

scholarly journals Assessment and Comparison of the Mechanical Properties of Laser Welded Joints in Docol 1200M and Strenx S700MC Steel Alloy Grades Under Impact Loads

2020 ◽  
Vol 11 (1) ◽  
pp. 17-30
Author(s):  
Paweł PROCHENKA ◽  
Jacek JANISZEWSKI
Keyword(s):  
Tensile Test ◽  
Split Hopkinson Pressure Bar ◽  
Rolling Direction ◽  
Base Material ◽  
Welding Process ◽  
Tensile Tests ◽  
Material Strength ◽  
Hopkinson Pressure Bar ◽  
Test Conditions ◽  
Static Tensile

The article evaluates the strength and ductility of laser butt joints made of 2 mm Docol 1200 M martensitic steel sheets based on the hardness, quasi-static and dynamic tensile tests. Technological research of laser welding process was carried out on welding cell using IPG fiber – based welding source with 6 kW maximum power. The tests were carried out for parallel and perpendicular orientation of specimens by rolling direction. In addition, the obtained results were compared with the analogous results obtained during the Strenx S700 MC steel tests. Dynamic tests were performed using the tensile split Hopkinson pressure bar technique with strain rates of 103 s-1. The obtained results showed that the strength of Docol 1200 M under dynamic tensile test conditions are similar to the material strength under static tensile test conditions. However, due to the breaking of the specimens in the heat affected zone, the strength of the welded joint is much lower than in base material, which was not observed during the Strenx S700 MC steel tests.

Application of Neural Network for the Prediction of Tensile Properties of Friction Stir Welded Composites

2016 ◽  
Vol 880 ◽  
pp. 128-131 ◽  
Author(s):  
Arun Kumar Shettigar ◽  
Subramanya Prabhu ◽  
Rashmi Malghan ◽  
Shrikantha Rao ◽  
Mervin Herbert
Keyword(s):  
Neural Network ◽  
Back Propagation ◽  
Base Material ◽  
Welding Process ◽  
Weld Strength ◽  
Back Propagation Algorithm ◽  
Friction Stir ◽  
Error Back Propagation ◽  
The Neural Network ◽  
Tool Pin

In this paper, an attempt has been made to apply the neural network (NN) techniques to predict the mechanical properties of friction stir welded composite materials. Nowadays, friction stri welding of composites are predominatally used in aerospace, automobile and shipbuilding applications. The welding process parameters like rotational speed, welding speed, tool pin profile and type of material play a foremost role in determining the weld strength of the base material. An error back propagation algorithm based model is developed to map the input and output relation of friction stir welded composite material. The proposed model is able to predict the joint strength with minimum error.

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