scholarly journals A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

Aerospace ◽  
2019 ◽  
Vol 6 (6) ◽  
pp. 74 ◽  
Author(s):  
Julia Madrid ◽  
Samuel Lorin ◽  
Rikard Söderberg ◽  
Peter Hammersberg ◽  
Kristina Wärmefjord ◽  
...  
Keyword(s):  
Design Of Experiments ◽  
Welding Process ◽  
Source Model ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Virtual Design ◽  
Welding Simulation ◽  
Aerospace Applications ◽  
Simulation Techniques ◽  
Short Time

During multidisciplinary design of welded aircraft components, designs are principally optimized upon component performance, employing well-established modelling and simulation techniques. On the contrary, because of the complexity of modelling welding process phenomena, much of the welding experimentation relies on physical testing, which means welding producibility aspects are considered after the design has already been established. In addition, welding optimization research mainly focuses on welding process parameters, overlooking the potential impact of product design. As a consequence, redesign loops and welding rework increases product cost. To solve these problems, in this article, a novel method that combines the benefits of design of experiments (DOE) techniques with welding simulation is presented. The aim of the virtual design of experiments method is to model and optimize the effect of design and welding parameters interactions early in the design process. The method is explained through a case study, in which weld bead penetration and distortion are quality responses to optimize. First, a small number of physical welds are conducted to develop and tune the welding simulation. From this activity, a new combined heat source model is presented. Thereafter, the DOE technique optimal design is employed to design an experimental matrix that enables the conjointly incorporation of design and welding parameters. Welding simulations are then run and a response function is obtained. With virtual experiments, a large number of design and welding parameter combinations can be tested in a short time. In conclusion, the creation of a meta-model allows for performing welding producibility optimization and robustness analyses during early design phases of aircraft components.

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.

Effects of Welding Parameters in Micro Friction Stir Lap Welding of Aluminum A1100

2013 ◽  
Vol 789 ◽  
pp. 356-359 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
A.A.D. Nugroho ◽  
D. Rahayu ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
...  
Keyword(s):  
Tilt Angle ◽  
Welding Process ◽  
Tool Material ◽  
Tensile Load ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Welding ◽  
Welding Processes

Technology of Friction Stir Welding (FSW) as a technique for joining metal is relatively new. In some cases on Aluminum joining, FSW gives better results compared with the Arc Welding processes, including the quality of welds and less distortion. FSW can even use milling machine or drilling machine, by replacing the tools and the appropriate accessories. The purpose of this study is to analyze the effect of process parameters onmicro Friction Stir Lap Weldingto the tensile load of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. Tool shoulder diameter was 3 mm, while the diameter pin was 2 mm and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of spindle speed (2300, 2600, and 2900 rpm), variable oftooltilt angle(0, 1, 2 degree) and a variable ofFeed rate(50, 60, 70 mm/min). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the tensile load. Analysis and optimization parameters between the micro FSLW parameters with the tensile load of welds, is used aResponse Surface Methods(RSM). From the result of experiment and analysis, it is shown that the important welding parameter in Micro Friction Stir Lap welding process is tilt angle.

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 Optimization of TIG Process Parameter in Improving Mechanical Properties of S304 Stainless Steel Using a Grey Based Taguchi Method

2021 ◽  
pp. 77-85
Author(s):  
Naveen Pandey ◽  
Dinesh Dubey
Keyword(s):  
Stainless Steel ◽  
Cold Work ◽  
Welding Process ◽  
Process Parameter ◽  
Inert Gas ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Optimum Level ◽  
Taguchi’S Design Of Experiments ◽  
Selection Of

Tungsten inert gas welding is popular known welding technique for ferrous & nonferrous. Stainless steel grade 3HQ (S30430) is a specialized wire grade with very wide usage for manufacturer of stainless steel fastener. It has now totally replaced Grade 384 and 305 for heading application. The stable austenitic structure makes 302HQ nonmagnetic, even after substantial cold work, and also results in excellent toughness, even down to cryogenic temperatures. This paper attempts in optimizing the Tungsten Inert Gas (TIG) welding process parameter. The effect of various parameters and their influence is important to determine the strength of welded joint. To obtain a good quality weld, it is therefore, essential to control the input welding parameters. Therefore appropriate selection of input welding parameter is necessary in order to obtain a good quality weld and subsequently increase the productivity of manufacturing industry. This paper present multi objective optimization using grey relation analysis (GRA) for S30430 with TIG process to determine the suitable selection of parameters Experiment were conducted according to Taguchi's design of experiments (DOE) with orthogonal array L9 is used, mathematical model was developed using parameters such as speed (mm/min), current (Amp), voltage (V), depth of penetration (mm). After conducting experiment and collecting data, signal to noise ratio were determined by using Minitab18 and it is used to obtain optimum level for every input parameter.

Establishing optimal friction stir welding parameters for AA2219-T87 Al-alloy using comprehensive RSM and GA approach

2021 ◽  
Author(s):  
Boddu Rajnaveen ◽  
Govada Rambabu ◽  
Kollabothina Prakash ◽  
Kotipalli Srinivasa Rao
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Welding Process ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Al Alloy ◽  
Regression Equations ◽  
Corrosion Properties ◽  
Friction Stir ◽  
Aa2219 Alloy

Abstract AA2219-T87 aluminium alloy has been used in aerospace applications because of its high strength, low density and resistance to corrosion. The copper in the alloy improves the hardness and lowers melting point, which makes two sections easily joined with a process called friction stir welding of aluminium alloy. In the present work, heat-treated AA2219 alloy was butt welded by solid-state friction stir welding process. This work aims to develop a suitable combination of welding parameters for producing defect-free weld joints of AA2219 alloy to improve tensile and corrosion properties. The most influencing control parameter for optimising the friction stir welding responses was determined using sophisticated design of experiments (DOE) techniques. Ultimate tensile strength and corrosion resistance are observed as responses in this study. To achieve the desired weld responses, a three-factor, three-level Box-behneken design was used. Analysis of Variance (ANOVA) was carried out to examine the interaction effect and significant welding parameter to set the optimal level of welding conditions. Multi-response regression equations have been developed using response surface methodology (RSM) to estimate the output characteristics of weld. The Genetic algorithm (GA) was used to optimise the predicted mathematical model under given optimization constraints. The results shown that the optimum responses are obtained at input factors rotational speed 300 rpm, welding speed 80 mm/min, and axial force of 10kN.

Multi Response Optimization of Spot Welding Process Parameters by Taguchi Method

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
S.P. Sundar Singh Sivam ◽  
A. Thirugnanam ◽  
K. Saravanan ◽  
D. Kumaran ◽  
M. Suresh
Keyword(s):  
Electrical Resistance ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Class Ii ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Resistance Spot ◽  
Steel Sheets

Electrode deterioration by deformation and chemical reaction during resistance spot welding of steel sheets confirming to AISI1020 is an issue for class II electrode. In view of this, the present study carried out the impacts of squeeze, weld, current and pressure on the nugget diameter, height, force and waviness of welding joint in electrical resistance spot welding of 0.8mm and 1.5 mm thickness of steel sheets with class II electrode to achieve the benefits of cost saving and quality products. A timer and current controlled electrical resistance spot welding machine having 120 kVA capacities were used. During welding process, current periods of 5, 10, 15, 20 and 25 were selected and it was adjusted by increasing from 8 to 10 kA. The optimum welding parameter for multi objectives was obtained using multi signal to noise ratio and the significant level of the welding parameters was further analysed by analysis of variance for all responses. Based on the confirmation test results, it is found out that the developed model can be effectively used to predict the size of weld zone which can improve the welding quality and performance in GRA. The details of welded joint generated by class II electrode were measured and results were analysed in detail.

Optimization of TIG Welding Process Parameters for X70-304L Dissimilar Joint Using Taguchi Method

2019 ◽  
Vol 297 ◽  
pp. 51-61 ◽  
Author(s):  
Mohamed Farid Benlamnouar ◽  
Mohamed Hadji ◽  
Riad Badji ◽  
Nabil Bensaid ◽  
Taher Saadi ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Gas Flow ◽  
Welding Process ◽  
Tig Welding ◽  
Experimental Designs ◽  
Dissimilar Joint ◽  
Dissimilar Welding ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Dissimilar Weld

The optimization of mechanical properties of the welded joints requires a statistical approach such as Taguchi experimental designs associated with experimental techniques and laboratory characterizations. The aim of this work is to propose a method of optimization of the mechanical performances of a TIG dissimilar welding of two grades of steels: a high strength low alloy steel X70 and an austenitic stainless steel 304L. The experimental designs were chosen according to the Taguchi method L9. The metallurgical characterization includes optical microscopy, SEM microscopy, EDX analyses and mechanical tests to establish a relationship between welding parameters, microstructures and mechanical behavior in different zones of a dissimilar weld joint. The results showed that the hardness is more strongly related to microstructural evolution than tensile strength of dissimilar joint. It was found that gas flow is the main significant TIG welding parameter affecting dissimilar weld characteristics.

Micro Thin Film Sensor Embedded in Metal Structures for In-Situ Process Monitoring During Ultrasonic Welding

2005 ◽  
Author(s):  
Xudong Cheng ◽  
Xiaochun Li
Keyword(s):  
Thin Film ◽  
Heat Generation ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Weld Strength ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Thin Film Sensors ◽  
Welding Interface

The objective of this research is to develop an effective method, i.e., ultrasonic metal welding (USMW), to embed micro thin film sensors for metal tooling, and use micro thin film thermocouple study the heat generation during USMW. A complete understanding of the fundamental mechanisms of USMW does not yet exist, and the function of heat generation on weld formation is especially in argument due to the lack of the method to measure the temperature at the welding interface. Continuing on the previous preliminary study [1] which proved that thin film sensors can survive ultrasonic welding process, significant advances were made to improve sensor reliability as well as sensor fabrication effectiveness. These include the development of a new approach for batch production of the sensor units, improvement of the adhesion between metal encapsulating layers for the sensor, as well as the adhesion between the sensing layer and the dielectric layer. Welding experiments are conducted using a series of welding parameter settings with the in-situ data acquisition of temperature 50 μm away from the welding interface. Attempts are then made to correlate the heat generation to welding parameters. With the mechanical testing of the weld strength, the possibility of using heat generation as a weld strength indicator is explored.

Numerical Modeling of High Power MAG Welding on the Plate

2008 ◽  
Vol 575-578 ◽  
pp. 757-762
Author(s):  
Jian Huang ◽  
Friedrich Wilhelm Bach ◽  
D. Windelberg
Keyword(s):  
Heat Source ◽  
High Power ◽  
Welding Process ◽  
Source Model ◽  
Mag Welding ◽  
Welding Parameters ◽  
Fe Model ◽  
Heat Source Model ◽  
Finite Element Software ◽  
Pool Surface

In the case of welding of T-joints in a special structure, the joining is realized through a total penetration of deck plates. For the deck plate’s thickness over 6 mm, high power MAG welding process should be applied. To help experimental optimizing of this welding technology, a 3D quasi-stationary numerical model was established to predict the penetration and weld form of the high power MAG welding on a thick plate. In the analysis a new volumetric heat source model was put forward which considers the heat directly from the arc und that from transferred droplets separately. Because the weld pool surface under the arc was strongly pressed, the droplet heat source in the model was located under the workpiece surface. The size of the droplet heat source model was determined on the base of physical principles and available experimental data. Using a commercial finite element software the weld form inclusive penetration under different welding parameters was then simulated. Through comparison with the experimental results the presented FE-model was verified.

scholarly journals Effect of Welding Parameter on the Corrosion Rate of Underwater Wet Welded SS400 Low Carbon Steel

2020 ◽  
Vol 10 (17) ◽  
pp. 5843
Author(s):  
E. Surojo ◽  
N. I. Wicaksana ◽  
Y. C. N. Saputro ◽  
E. P. Budiana ◽  
N. Muhayat ◽  
...  
Keyword(s):  
Carbon Steel ◽  
Corrosion Rate ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Electrode Polarization ◽  
Low Carbon ◽  
Underwater Welding ◽  
Underwater Wet Welding

This study aims to determine the effect of welding parameters on the corrosion rate of underwater wet welded SS400 low carbon steel. The underwater wet welding process was conducted using shielded metal arc welding (SMAW). Three welding electrodes, i.e., E7016, RB26 and RD26, were used in underwater wet welding performed with water depth variations 2.5 m, 5 m and 10 m. Welding current in the experiment was set to be 100 A and 110 A. After the welding stage, corrosion test was carried out on each joint in a 3.5%-NaCl solution using three-electrode polarization resistance methods. Corrosion testing results indicated that the lowest corrosion rate was found in underwater welding with current parameters of 100 A, 2.5-m depth and RB26 electrodes. The highest corrosion rate is obtained with the setting of underwater welding of 110-A current, 10-m depth and E7016 electrodes.

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