scholarly journals Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding

Materials ◽  
2019 ◽  
Vol 12 (1) ◽  
pp. 141 ◽  
Author(s):  
Hui Huang ◽  
Xianqing Yin ◽  
Zhili Feng ◽  
Ninshu Ma
Keyword(s):  
Finite Element ◽  
Thin Plate ◽  
Heat Input ◽  
Plane Deformation ◽  
Welding Process ◽  
Numerical Results ◽  
Tig Welding ◽  
Image Correlation ◽  
Welding Distortion ◽  
Out Of Plane

Transient distortion of thin plate in the welding process usually has a complicated mode and large magnitude. Quantitative measurement and prediction of full-field distortion are challenging and rarely reported up to now. In this study, the out-of-plane distortion of a thin plate during the Tungsten Inert Gas (TIG) welding process was measured using the digital image correlation (DIC) method. A simulation model based on thermal elastic–plastic finite element method (FEM) and DIC measured geometric imperfection were developed for accurate prediction of the transient welding distortion. The numerical results and experimental data agreed very well in both out-of-plane deformation modes and magnitudes of the plate at different stages of welding. The maximum out-of-plane distortion was larger than 4 mm during welding which can cause instability of arc length and heat input. The distance change between welding torch and plate surface was investigated under different initial deflections of the plate before welding. The plate with flat geometry shows the minimum transient and final gap change. In addition, the relationship between heat input and welding distortion was clarified through a series of numerical analyses. Optimization of welding heat input can be performed based on numerical results to avoid excessive welding distortion.

Benchmark Investigation of Welding-Induced Buckling and Its Critical Condition During Thin Plate Butt Welding

2019 ◽  
Vol 141 (7) ◽  
Author(s):  
Jiangchao Wang ◽  
Bin Yi
Keyword(s):  
Finite Element ◽  
Thin Plate ◽  
Measurement Data ◽  
Characteristic Parameter ◽  
Welding Distortion ◽  
Butt Welding ◽  
Buckling Behavior ◽  
Out Of Plane ◽  
Inherent Deformation ◽  
Good Agreement

Welding-induced buckling is a special type of welding distortion occurring during thin plate butt welding and was investigated using both experimental and computational approaches for this benchmark investigation. In addition, the characteristic parameter and its magnitude for the occurrence of welding-induced buckling were also presented. Fundamental theories of the inherent deformation, finite strains, and eigenvalues of the structure stiffness matrix were considered to investigate welding-induced buckling. A series of experiments on thin plate butt welding with different heat inputs were conducted, and buckling behavior was observed from the deformed shape and the distribution of out-of-plane welding distortion. Transient nonlinear thermal elastic–plastic finite element (TEP FE) and elastic finite element (FE) analyses were conducted to predict welding-induced buckling, and the results were in good agreement with the measurement data. Criteria for the occurrence of welding-induced buckling were proposed and discussed. Inherent deformation was considered as a characteristic parameter of buckling behavior during welding, and its critical magnitude was calculated using a loading incremental method and eigenvalue analysis with good agreement.

On the effect of heat input in plasma microwelding of maraging steel

2017 ◽  
Vol 233 (3) ◽  
pp. 807-822
Author(s):  
Tinku Saikia ◽  
Mayuri Baruah ◽  
Swarup Bag
Keyword(s):  
Finite Element ◽  
Maraging Steel ◽  
Process Parameters ◽  
Weld Joint ◽  
Heat Input ◽  
Process Model ◽  
Welding Process ◽  
Fusion Welding ◽  
Welding Distortion ◽  
Influence Of Process Parameters

Maraging steel in known as ultra-high strength and toughness material widely used in aerospace industry and defense system. The joining of this material by fusion welding process experiences gigantic metallurgical transformation that have significant contribution toward the development of welding distortion, and transformation of austenite into martensite at very low temperature with significant increase in specific volume. In this study, a set of bead-on-plate welding is executed at microscale to establish feasible range of process parameters using plasma arc as a source of heat. Although, high-concentrated heat does not produce much distortion, the heat input to the weld joint experiences the difference in possible distortion. A finite element–based numerical process model is also developed to investigate the differential influence of process parameters on thermo-mechanical behavior of weld joint. An inverse approach is followed to estimate the unknown input parameters by integrating the finite element model with optimization algorithm. The integrated model predicts the shape and size of weld geometry and welding distortion that are well agreed with experimental values.

scholarly journals Characterization and ballistic performance of thin pre-damaged resin-starved aramid-fiber composite panels

2021 ◽  
pp. 004051752110134
Author(s):  
Cerise A Edwards ◽  
Stephen L Ogin ◽  
David A Jesson ◽  
Matthew Oldfield ◽  
Rebecca L Livesey ◽  
...  
Keyword(s):  
Fiber Composite ◽  
Plane Deformation ◽  
Ballistic Impact ◽  
Image Correlation ◽  
Composite Panel ◽  
Composite Panels ◽  
Micro Computed Tomography ◽  
Ballistic Performance ◽  
Low Level ◽  
Out Of Plane

Military personnel use protective armor systems that are frequently exposed to low-level damage, such as non-ballistic impact, wear-and-tear from everyday use, and damage during storage of equipment. The extent to which such low-level pre-damage could affect the performance of an armor system is unknown. In this work, low-level pre-damage has been introduced into a Kevlar/phenolic resin-starved composite panel using tensile loading. The tensile stress–strain behavior of this eight-layer material has been investigated and has been found to have two distinct regions; these have been understood in terms of the microstructure and damage within the composite panels investigated using micro-computed tomography and digital image correlation. Ballistic testing carried out on pristine (control) and pre-damaged panels did not indicate any difference in the V50 ballistic performance. However, an indication of a difference in response to ballistic impact was observed; the area of maximal local out-of-plane deformation for the pre-damaged panels was found to be twice that of the control panels, and the global out-of-plane deformation across the panel was also larger.

scholarly journals In-Process Measurement of Three-Dimensional Deformations Based on Speckle Photography

2021 ◽  
Vol 11 (11) ◽  
pp. 4981
Author(s):  
Andreas Tausendfreund ◽  
Dirk Stöbener ◽  
Andreas Fischer
Keyword(s):  
Evaluation Method ◽  
Process Analysis ◽  
Plane Deformation ◽  
Three Dimensional ◽  
Machining Process ◽  
Image Correlation ◽  
Speckle Photography ◽  
Process Measurement ◽  
Out Of Plane ◽  
Plane Deformations

In the concept of the process signature, the relationship between a material load and the modification remaining in the workpiece is used to better understand and optimize manufacturing processes. The basic prerequisite for this is to be able to measure the loads occurring during the machining process in the form of mechanical deformations. Speckle photography is suitable for this in-process measurement task and is already used in a variety of ways for in-plane deformation measurements. The shortcoming of this fast and robust measurement technique based on image correlation techniques is that out-of-plane deformations in the direction of the measurement system cannot be detected and increases the measurement error of in-plane deformations. In this paper, we investigate a method that infers local out-of-plane motions of the workpiece surface from the decorrelation of speckle patterns and is thus able to reconstruct three-dimensional deformation fields. The implementation of the evaluation method enables a fast reconstruction of 3D deformation fields, so that the in-process capability remains given. First measurements in a deep rolling process show that dynamic deformations underneath the die can be captured and demonstrate the suitability of the speckle method for manufacturing process analysis.

Effects of Out-of-Plane Displacements on Load Capacity of Gusset Plates in Buckling Restrained Braced Frames

2018 ◽  
Vol 763 ◽  
pp. 892-899 ◽  
Author(s):  
Saul Y. Vazquez-Colunga ◽  
Chin Long Lee ◽  
Gregory A. MacRae
Keyword(s):  
Finite Element ◽  
Finite Element Methods ◽  
Load Capacity ◽  
Numerical Results ◽  
Numerical Analyses ◽  
Braced Frames ◽  
Gusset Plates ◽  
Out Of Plane ◽  
Buckling Restrained Braced Frames ◽  
Monotonic Load

This study sets out to investigate the effect of out-of-plane (OOP) displacements on the monotonic load capacity of gusset plates (GPs) via numerical analyses using finite element methods. Two models were used: a) models with in-plane (INP) actions only; and b) models with both INP and OOP actions. The numerical results show that the load capacity of GPs is reduced with the presence of OOP displacements. For an OOP drift of 2.5%, the reduced capacity ranges from 95% to 80% with an average of 88% of the load capacity when only INP actions were applied.

scholarly journals Comprehensive Analysis of TIG Welded Inconel–718 Alloy for Different Heat Input Conditions

2018 ◽  
Vol 7 (3.6) ◽  
pp. 206
Author(s):  
P Jerold Jose ◽  
M Dev Anand
Keyword(s):  
Tensile Properties ◽  
Heat Input ◽  
Inconel 718 ◽  
Welding Process ◽  
Welding Current ◽  
Tig Welding ◽  
Welding Parameters ◽  
Inconel 718 Alloy ◽  
Weld Joints ◽  
Welding Heat Input

In this research, the effects of heat input on tensile properties and microstructure were investigated for super alloy Inconel-718 sheets weld by Tungsten Inert Gas (TIG) welding process. The tensile properties and microstructure of weld joints were evaluated. The experiment was conducted with six different combinations of welding parameters like welding current, voltage and welding speed, which were give in six different welding heat input combinations of welding parameters. The experimental results shows that the welding joints weld with low welding heat input was yield higher tensile properties. From the experimentation it was understand that the tensile properties increases when the welding heat input decrease. Drastic grain coarsening was evidenced when the heat input was increases. For the weld joints experimented in this research it was also observed that amount of laves phase was increased with increase in the welding heat input which is the major fact for noticeable variation in the ultimate tensile strength of the weld joints welded by TIG welding process with different welding heat input. 

Finite Element Analysis Model of Corrosion Fatigue for TIG Welding Workpiece

2016 ◽  
Vol 707 ◽  
pp. 154-158
Author(s):  
Somsak Limwongsakorn ◽  
Wasawat Nakkiew ◽  
Adirek Baisukhan
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Corrosion Fatigue ◽  
Welding Process ◽  
Simulation Software ◽  
Tig Welding ◽  
Element Analysis ◽  
Fea Model

The proposed finite element analysis (FEA) model was constructed using FEA simulation software, ANSYS program, for determining effects of corrosion fatigue (CF) from TIG welding process on AISI 304 stainless steel workpiece. The FEA model of TIG welding process was developed from Goldak's double ellipsoid moving heat source. In this paper, the residual stress results obtained from the FEA model were consistent with results from the X-ray diffraction (XRD) method. The residual stress was further used as an input in the next step of corrosion fatigue analysis. The predictive CF life result obtained from the FEA CF model were consistent with the value obtained from stress-life curve (S-N curve) from the reference literaturature. Therefore, the proposed FEA of CF model was then used for predicting the corrosion fatigue life on TIG welding workpiece, the results from the model showed the corrosion fatigue life of 1,794 cycles with testing condition of the frequency ( f ) = 0.1 Hz and the equivalent load of 67.5 kN (equal to 150 MPa) with R = 0.25.

Ultimate Behavior of Single Shear Bolted Connections with Thin-Walled Aluminum Alloys(6061-T6)

2012 ◽  
Vol 446-449 ◽  
pp. 3441-3445 ◽  
Author(s):  
Tae Soo Kim ◽  
Yong Hyun Jo ◽  
Seung Hun Kim ◽  
Yong Taeg Lee
Keyword(s):  
Finite Element ◽  
Ultimate Strength ◽  
Plane Deformation ◽  
Free Edge ◽  
Fe Analysis ◽  
Test Results ◽  
Bolted Connections ◽  
Element Analysis ◽  
Out Of Plane ◽  
Single Shear

The purpose of this study is to investigate the ultimate behaviors of aluminum alloy bolted connections assembled with four bolts. Specimens for single shear bolted connections were tested and finite element analysis based on this test results was conducted. The validity of finite element(FE) analysis for predicting the structural behaviors such as ultimate strength, fracture mode and curling(out-of-plane deformation) occurrence was verified through the comparisons between test results and FE analysis results. It is known that the curling resulted in sudden strength drop. Moreover, FE models with free edge and restrained out-of-plane deformation for curled specimens are analyzed additionally, therefore, the influence of curling on the ultimate strength; strength reduction ratio is estimated.

scholarly journals A Study on Vertical Upward Welding of Dissimilar Material and Thickness of Thin Plates Using Novel TIG Welding Process

2019 ◽  
Author(s):  
Ngo Huu Manh ◽  
Nguyen Van Anh ◽  
Murata Akihisa ◽  
Hideno Terasaki
Keyword(s):  
Base Metal ◽  
Heat Input ◽  
Weld Zone ◽  
Welding Process ◽  
Welding Current ◽  
Tig Welding ◽  
Dissimilar Material ◽  
Thin Plates ◽  
Welding Defects ◽  
Welding Position

A study about influence of heat input on welding defects in vertical upward welding position for dissimilar material and thickness using a new variation of TIG welding torch is done with support of advanced inspection methods SEM and EBSD. With vertical upward welding position, control heat input plays an important role to keep the weld stabilization without defects. On the other hand, TIG welding process using a conventional TIG torch (conventional TIG welding process) has low efficiency and it is difficult to control heat input with high accuracy. So, it is considered that using conventional TIG torch is still a challenge for welding thin plates. In this case, a new variation of TIG torch has been developed. This torch used a constricted nozzle to improve plasma arc characteristics. As a result, it can control efficiently the heat input to prevent the excessive or insufficiency for joining thin sheets. For evaluation of welding quality, advanced examination methods SEM and EBSD were applied to directly observe the welding defects. From the results, the formation mechanism of blowhole inside weld zone in case of welding dissimilar material and thickness was discussed. It is pointed out that when sufficient welding current, the change from weld zone to base metal is uniform, no welding defects such as blowhole was seen. However, in case of low welding current, the thinner base metal is insufficient fusion and the change between weld zone and base metal is not uniform. The blowhole was observed at SS400 material side.

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