Induction Assisted Hybrid-Welding Processes to Join Heavy-Walled Steel Components

2014 ◽  
Vol 698 ◽  
pp. 231-236
Author(s):  
Jörg Neumeyer ◽  
Bernard Nacke
Keyword(s):  
Thermal Conductivity ◽  
Numerical Simulation ◽  
Temperature Drop ◽  
Welding Process ◽  
Electric Arc ◽  
Heating Process ◽  
Hybrid Welding ◽  
Metal Sheets ◽  
Short Time ◽  
Welding Processes

In order to weld heavy-walled metal sheets (16mm and more) a hybrid process, that includes an electric arc and the laser beam, is frequently applied at present. Due to the high thermal conductivity of metals and the enormous temperature gradient between the laser-welded area and the not welded region around the bond, there is a great heat flow and the welded material is cooled down in very short time. This high decrease of temperature leads to decayed metallurgical qualities. In order to slow down the temperature drop, an inductive process is applied to the hybrid welding device. Because of the high thickness of the metal sheets both an inductive preheating and an inductive post-heating process are added. To configure an optimal design for the inductors the numerical simulation is used and especially the heat generation of the welding process has to be included in a physical realistic way.

Concept of the Model Robotized Cell for Plasma-GMAW Hybrid Welding

2014 ◽  
Vol 613 ◽  
pp. 43-52 ◽  
Author(s):  
Zbigniew Pilat ◽  
Jacek Szulc
Keyword(s):  
New Technologies ◽  
New Technology ◽  
Welding Process ◽  
Hybrid Welding ◽  
Weld Penetration ◽  
Production Lines ◽  
Concept Model ◽  
Metal Sheets ◽  
The One ◽  
Welding Processes

Activities in the field of increasing the productivity of the production lines for welding thick metal sheets are focused in two directions. On the one hand, new technologies are being developed for welding, deeper weld penetration and faster welding process. On the other hand are focused on automation of these operations, which have the effect of reducing cost and increasing efficiency. Improved are also the working conditions of people employed in the welding processes. In both these directions the hybrid welding Plasma-GMAW could fulfill all requirements as a new technology. The article gives the concept model of the complete robotized welding cell, in which this method will be implemented and tested.

scholarly journals Numerical simulation on plasma property in TIG-MIG hybrid welding process

2013 ◽  
Vol 31 (4) ◽  
pp. 22s-25s ◽  
Author(s):  
Hisashi MISHIMA ◽  
Shinichi TASHIRO ◽  
Shuhei KANEMARU ◽  
Manabu TANAKA
Keyword(s):  
Numerical Simulation ◽  
Welding Process ◽  
Hybrid Welding ◽  
Plasma Property

Examination of the Welding Processes when Welding of Steel in Protective Gas Atmosphere of Gases with the Application of Modeling and Numerical Simulation

2017 ◽  
Vol 737 ◽  
pp. 133-139
Author(s):  
Helena Kravarikova
Keyword(s):  
Numerical Simulation ◽  
Computational Models ◽  
Three Dimensional ◽  
Welding Process ◽  
Real System ◽  
Temperature Fields ◽  
Software Systems ◽  
Butt Weld ◽  
Protective Gas ◽  
Welding Processes

Modelling and numerical simulation of technological welding processes is the creative experimental method. Simulation replaces a real system computer model. To create the model can be applied to many experiments under predetermined conditions and analysis of the results. The results can be optimized and implemented to a real system. In a relatively short time, it is possible to solve complex processes occurring in the melting phase of the welding process, using the most advanced computer technology. Appropriately selected algorithm of model experiments can help study the course of temperature fields and formation of stresses and strains in solving the problems in the field of welding. The result of thermal and structural tasks of numerical simulation using FEM are the temperature fields, stress fields and strain generated in the process of welding and welded parts during cooling. Procedure of solving the tasks can be applied to any weld shape and any material of welded parts. The results published in the paper were obtained by solving the thermal and stress- strain tasks in the ANSYS program. Modelling and numerical simulation open possibilities for the three dimensional analysis of the phenomena studied. Based on the development of numerical methods and their application, it is possible to create computational models. Their implementation in software systems opens new possibilities for the area of numerical simulation of technological welding processes. The paper described simulation fillet and butt weld made of stainless steel 17242.

scholarly journals Characteristics of Welding and Arc Pressure in the Plasma–TIG Hybrid Welding Process

2018 ◽  
Author(s):  
Bo Wang ◽  
Xunming Zhu ◽  
Hongchang Zhang ◽  
Hongtao Zhang ◽  
Jicai Feng
Keyword(s):  
Arc Welding ◽  
Gas Flow ◽  
Welding Process ◽  
Hybrid Welding ◽  
Plasma Arc ◽  
Arc Pressure ◽  
Arc Current ◽  
Arc Welding Process ◽  
Welding Processes

In this article, a novel hybrid welding process called plasma-TIG coupled arc welding was proposed to improve the efficiency and quality of welding by utilizing the full advantage of plasma and TIG welding processes. The two arcs of plasma and TIG were pulled into each other into one coupled arc under the effect of Lorentz force and plasma flow force during welding experiments. The arc behavior of coupled arc was studied by means of it’s arc profile, arc pressure and arc force conditions. The coupled arc pressure distribution measurements were performed. The effects of welding conditions on coupled arc pressure were evaluated and the maximum coupled arc pressure was improved compared with single-plasma arc and single-TIG arc. It was found that the maximum arc pressure was mainly determined by plasma arc current and plasma gas flow. According to the results, the proposed coupled arc welding process have both advantages of plasma arc and TIG method, and it has a broad application prospect.

scholarly journals Determining the dynamics of carbon monoxide formation during gas welding processes

2021 ◽  
Vol 5 (10 (113)) ◽  
pp. 33-39
Author(s):  
Viacheslav Berezutskyi ◽  
Inna Khondak ◽  
Nataliia Berezutska
Keyword(s):  
Carbon Monoxide ◽  
Arc Welding ◽  
Welding Process ◽  
Electric Arc ◽  
Working Medium ◽  
Carbon Monoxide Formation ◽  
Electric Arc Welding ◽  
Welding Processes ◽  
Additional Device ◽  
Respiratory Area

This paper reports a study of the air medium where welding processes take place, with special attention paid to the evolution of carbon monoxide (CO) in the working medium in the process of gas welding. Plots were constructed and polynomial dependences were obtained to show a change in the concentration of carbon monoxide in the air of the working area during gas welding. It was confirmed experimentally that the concentration of carbon monoxide exceeds the permissible sanitary and hygienic indicators MPC (20 mg/m3) during gas welding. As a result of the experiment, the effectiveness of the use of an additional device was proven, namely an umbrella gas concentrator, in order to capture welding gases that are formed during gas welding. It was established that the MPC is exceeded under certain working conditions and welding wire. The carbon monoxide formation during gas welding was analyzed; these processes were compared with electric arc welding. The mathematical dependences derived make it possible to assess the risks of the welders’ work and conclude that the electric arc welding is characterized by a much higher rate of CO evolution from the beginning of the welding process (8.5 mg/s), that speed then decreases over 20 s by 2 times (to 4.5 mg/s). In 90 s, the speed becomes constant, to 2 mg/s. In comparison, gas welding has almost the same rate of CO formation, namely 0.3–0.9 mg/s. By changing the types of welding wires used in gas welding and taking into consideration the type of material that needs to be welded (including the period of its use), it is possible to influence the volume of CO emissions entering the working area and an employee’s respiratory area

scholarly journals The Phenomena and Criteria Determining the Cracking Susceptibility of Repair Padding Welds of the Inconel 713C Nickel Alloy

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 634
Author(s):  
Katarzyna Łyczkowska ◽  
Janusz Adamiec
Keyword(s):  
Critical Strain ◽  
Surface Defects ◽  
Temperature Drop ◽  
Welding Process ◽  
Melting Zone ◽  
Hot Cracking ◽  
Aircraft Engines ◽  
Maximum Deformation ◽  
Inconel 713C ◽  
Welding Processes

The creep-resistant casting nickel alloys (e.g., Inconel 713C) belong to the group of difficult-to-weld materials that are using for precise element production; e.g., aircraft engines. In precision castings composed of these alloys, some surface defects can be observed, especially in the form of surface discontinuities. These defects disqualify the castings for use. In this paper, the results of technological tests of remelting and surfacing by the Tungsten Inert Gas method (TIG) in an argon shield and TecLine 8910 gas mixture are presented for stationary parts of aircraft engines cast from Inconel 713C alloy. Based on the results of metallographic studies, it was found that the main problem during remelting and pad welding of Inconel 713C castings was the appearance of hot microcracks. This type of defect was initiated in the partial melting zone, and propagated to the heat affected zone (HAZ) subsequently. The transvarestraint test was performed to determine the hot-cracking criteria. The results of these tests indicated that under the conditions of variable deformation during the remelting and pad welding process, the high-temperature brittleness range (HTBR) was equal 246 °C, and it was between 1053 °C and 1299 °C. In this range, the Inconel 713C was prone to hot cracking. The maximum deformation for which the material was resistant to hot cracking was equal to 0.3%. The critical strain speed (CSS) of 1.71 1/s, and the critical strain rate for temperature drop (CST), which in this case was 0.0055 1/°C, should be used as a criteria for assessing the tendency for hot cracking of the Inconel 713C alloy in the HTBR. The developed technological guidelines and hot-cracking criteria can be used to repair Inconel 713C precision castings or modify their surfaces using welding processes.

scholarly journals Adaptive Control of Resistance Spot Welding Based on a Dynamic Resistance Model

2019 ◽  
Vol 24 (4) ◽  
pp. 86 ◽  
Author(s):  
Kas ◽  
Das
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Controller Design ◽  
Welding Process ◽  
Dynamic Resistance ◽  
Resistance Spot ◽  
Control Scheme ◽  
Metal Sheets ◽  
One Step ◽  
Welding Processes

Resistance spot welding is a process commonly used for joining a stack of two or three metal sheets at desired spots. Such welds are accomplished by holding the metallic workpieces together by applying pressure through the tips of a pair of electrodes and then passing a strong electric current for a short duration. This kind of welding process often suffers from two common drawbacks, namely, inconsistent weld quality and inadequate nugget size. In order to address these problems, a new theoretical approach of controlling resistance spot welding processes is proposed in this paper. The proposed controller is based on a simplified dynamical model of the resistance spot welding process and employs the principle of adaptive one-step-ahead control. It is essentially an adaptive tracking controller that estimates the unknown process parameters and adjusts the welding voltage continuously to make sure that the nugget resistance tracks a desired reference resistance profile. The modeling and controller design methodologies are discussed in detail. Also, the results of a simulation study to evaluate the performance of the proposed controller are presented. The proposed control scheme is expected to reduce energy consumption and produce consistent welds.

Numerical Simulation and Experiment Analysis of MIG Welding for Aluminum Alloy Extrusion

2012 ◽  
Vol 430-432 ◽  
pp. 1311-1314
Author(s):  
Zheng Zhi Luo ◽  
Yi Su Pan
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Three Dimensional ◽  
Welding Process ◽  
Element Model ◽  
Mig Welding ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Welding Processes ◽  
Aluminum Alloy Extrusion

Welding characteristics of MIG welding for aluminum alloy extrusions are studied. In this article, the aluminum alloy is EN AW-6005A. The welding heat source and the welding processing of aluminum alloy extrusions are discussed. A three dimensional finite element model has been developed to dynamically simulate the welding process. The investigations focus on the comparison the welding heat resource of simulation and section of the experiments parts. And the residual stress of numerical simulation and tests are compared. It’s help to optimize the MIG welding processes and improve the welding quality for aluminum alloy extrusion.

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