Study Computational Simulation and Experimental of Butt-Joint by Visual-Weld Software and MIG Welding Process

2019 ◽  
Vol 889 ◽  
pp. 161-167
Author(s):  
Quoc Manh Nguyen
Keyword(s):  
Welding Speed ◽  
Bending Strength ◽  
Early Stage ◽  
Intermetallic Layer ◽  
Computational Simulation ◽  
Welding Process ◽  
Butt Joint ◽  
Low Carbon ◽  
Mig Welding ◽  
Welding Stress

The aim of this paper is to present the simulation and experiment of the welding butt-joint aluminum alloys to low carbon steel using Visual-weld software and the metal inert gas (MIG) welding process. The workpiece is set up in a virtual environment with an area of 150 x 70 x 5 mm, a welding speed at 3.5 mm/s, and a heating source of 2.5 kW. The finite element method (FEM) is used as a powerful tool in simulating, calculating and predicting the welding stress and distortion at the early stage of the design process and development of welding products. The metallurgical process, deformation, hardness, etc. are investigated using the FEM in Sysweld software. The microstructure of the intermetallic layer is observed using scanning electron microscopy. The hardness of the intermetallic layer is examined using Vickers hardness testing. Tensile strength and bending strength are examined by tensile and compress multimeter equipment. To improve the quality of the aluminum/steel welds, the IMCs layer should be as small as possible. The experimental results are better if the welding current of range of 95 – 100 A and the welding speed is from 3.5 to 4 mm/s.

scholarly journals Study the Effect of Welding Heat Input on the Microstructure, Hardness, and Impact Toughness of AISI 1015 Steel

2018 ◽  
Vol 14 (1) ◽  
pp. 118-127 ◽  
Author(s):  
Emad Kh. Hamd ◽  
Abbas Sh. Alwan ◽  
Ihsan Khalaf Irthiea
Keyword(s):  
Corrosion Rate ◽  
Weld Joint ◽  
Heat Input ◽  
Plate Thickness ◽  
Welding Process ◽  
Welding Current ◽  
Low Carbon ◽  
Mig Welding ◽  
The Impact ◽  
Weld Heat

In the present study, MIG welding is carried out on low carbon steel type (AISI 1015) by using electrode ER308L of 1.5mm diameter with direct current straight polarity (DCSP). The joint geometry is of a single V-butt joint with one pass welding stroke for different plate thicknesses of 6, 8, and 10 mm. In welding experiments, AISI 1015 plates with dimensions of 200×100mm and edge angle of 60o from both sides are utilized. In this work, three main parameters related to MIG welding process are investigated, which are welding current, welding speed, heat input and plate thickness, and to achieve that three groups of plates are employed each one consists of three plates. The results indicate that increasing the weld heat input (through changing the current and voltage) leads to an increase in widmanstatten ferrite (WF), acicular ferrite (AF) and polygonal ferrite (PF) in FZ region, and a reduction in grain size. It is observed that the micro-hardness of welded AISI 1015 plate increases as the weld heat input decreases. As well as increasing the weld heat input results in an increase in the width of WM and HAZ and a reduction in the impact energy of the weld joint of AISI 1015 at WM region. Also, it is noted the corrosion rate of weld joint increases with increase of Icorr due to increasing in welding current (heat input), corrosion rate increased up to (0.126µm/yr.) with increasing of heat input up to (1.27 KJ/mm).  

scholarly journals Multi-Objective Optimization of MIG Welding and Preheat Parameters for 6061-T6 Al Alloy T-Joints Using Artificial Neural Networks Based on FEM

Coatings ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 998
Author(s):  
Qing Shao ◽  
Fuxing Tan ◽  
Kai Li ◽  
Tatsuo Yoshino ◽  
Guikai Guo
Keyword(s):  
Process Parameters ◽  
Welding Speed ◽  
Heat Input ◽  
Pareto Front ◽  
Welding Process ◽  
Residual Deformation ◽  
Welding Deformation ◽  
Mig Welding ◽  
Preheat Temperature ◽  
Multi Objective

To control the welding residual stress and deformation of metal inert gas (MIG) welding, the influence of welding process parameters and preheat parameters (welding speed, heat input, preheat temperature, and preheat area) is discussed, and a prediction model is established to select the optimal combination of process parameters. Thermomechanical numerical analysis was performed to obtain the residual welding deformation and stress according to a 100 × 150 × 50 × 4 mm aluminum alloy 6061-T6 T-joint. Owing to the complexity of the welding process, an optimal Latin hypercube sampling (OLHS) method was adopted for sampling with uniformity and stratification. Analysis of variance (ANOVA) was used to find the influence degree of welding speed (7.5–9 mm/s), heat input (1500–1700 W), preheat temperature (80–125 °C), and preheat area (12–36 mm). The range of research parameters are according to the material, welding method, thickness of the welding plate, and welding procedure specification. Artificial neural network (ANN) and multi-objective particle swarm optimization (MOPSO) was combined to find the effective parameters to minimize welding deformation and stress. The results showed that preheat temperature and welding speed had the greatest effect on the minimization of welding residual deformation and stress, followed by the preheat area, respectively. The Pareto front was obtained by using the MOPSO algorithm with ε-dominance. The welding residual deformation and stress are the minimum at the same time, when the welding parameters are selected as preheating temperature 85 °C and preheating area 12 mm, welding speed is 8.8 mm/s and heat input is 1535 W, respectively. The optimization results were validated by the finite element (FE) method. The error between the FE results and the Pareto optimal compromise solutions is less than 12.5%. The optimum solutions in the Pareto front can be chosen by designers according to actual demand.

ANALISA KEKUATAN MEKANIS SAMBUNGAN LAS KAMPUH V TUNGGAL DAN V GANDA PADA BAJA KARBON RENDAH DENGAN PROSES PENGELASAN SMAW

2021 ◽  
Vol 12 (2) ◽  
pp. 103
Author(s):  
Sudarsono Sudarsono ◽  
Hidayat Hidayat ◽  
Aminur Aminur ◽  
Sarwo Pranoto ◽  
Prinob Aksar
Keyword(s):  
Tensile Strength ◽  
Bending Strength ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Bending Test ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Low Carbon ◽  
Shielded Metal Arc Welding ◽  
Metal Arc Welding

Welding is one of the methods widely used in the joining of metals for structural elements. One of the factors that influence the strength of welded metals is types of welding joints. Suitability of the type of welding joint with geometries of base metals is required to obtain welded metal products with optimum properties. In this study an attempt is made to investigate mechanical properties of welded metals with two different types of joints (single-V and double-V) using the shielded metal arc welding (SMAW) process. Low carbon steel with bevel angle of 60° was used in this study. Welding process was performed using current of 70 A with a constant welding speed. The flexural properties and uniaxial tensile properties are studied by three-point bending test and uniaxial tensile test respectively. Test results show that the tensile strength and the bending strength of single-V specimens is 521.64 N/mm2 and 525.11 N/mm2 respectively. In addition, the tensile strength and the bending strength of double-V specimens is 517.33 N/mm2 and  504.24 N/mm2 respectively

Analysis of Physical and Mechanical Properties of Backhoe’s Bucket Repairment with Cladding Methode

2020 ◽  
Vol 841 ◽  
pp. 254-258
Author(s):  
Yustiasih Purwaningrum ◽  
Muhammad Hafiz ◽  
Risky Suparyanto
Keyword(s):  
Mechanical Properties ◽  
Bending Strength ◽  
Welding Process ◽  
Physical And Mechanical Properties ◽  
Hardness Test ◽  
Raw Material ◽  
Bending Test ◽  
Basic Material ◽  
Test Results ◽  
Low Carbon

Buckets are the most important component in backhoe construction, the bucket functions as a digger and carrier component in an excavator. Due to the heavy working media of the excavator so that this component is the most easily damaged part, damage that often occurs is wear caused by friction arising so that the thickness of the bucket is reduced which can eventually cause cracks in the bucket and in continuous use can cause the bucket to crack and broken. Cladding method is done to shorten the time or simplify the repair process is to directly patch the damaged part with a welding layer and then do the grading using a grinding. This study aims to determine the physical and mechanical properties of the material from the cladding process when compared with the raw material, the variations used are raw material, cladding with filler welding, and cladding with plates. The welding process is carried out with GMAW (Gas Metal Arc Welding) and low carbon steel. Welding results will be tested tensile strength, bending strength , impact test, hardness test, chemical composition, and corrosion rate. From the hardness test results showed that the weld metal from plate variation has the highest hardness value of 443 VHN. From the results of tensile testing the basic material has the highest value with 359.08 MPa. From the bending test results the highest value obtained from filler verification with 494.01 Mpa and the highest impact price obtained from the plate variation cladding method with a value of 1.49 J / mm2

scholarly journals Magnetic Field Effects on 4G Positions in Shielded Metal Arc Welding Process

2020 ◽  
Vol 9 (3) ◽  
pp. 694-703 ◽  
Keyword(s):  
Magnetic Field ◽  
Arc Welding ◽  
Molten Pool ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Butt Joint ◽  
Low Carbon ◽  
Magnetic Field Effects ◽  
Shielded Metal Arc Welding ◽  
Metal Arc Welding

With the advancement of welding techniques, Arc-welding is one of the most commonly and widely used welding technique for variety of purposes. The underside of welding to be performed makes the molten pool going downward because of gravity vector pulling affects the molten pool. The main purpose of this study is to study how the molten of electrode produced reduce on going downward and produce a good root fusion in overhead position of welding in single V-butt joint with the help of magnetic field on the workpiece. The study of magnet characteristic which includes thebehaviour of molten pool toward magnetic field, the macrostructure and microstructure and its strength should be carried out. Each magnet strength has their own characteristics that affects toward weldment on base metal.As a result, it can be concluded that having a magnetic field applies on base metal A36 low carbon steel may reduce the molten pool from going downward. The selection of a correct magnet strength and welding process may produce good and quality weldment especially in terms of its weld properties and geometry.

The Numerical Simulation on Welding Stress Field of High Strength Steel for Axle Case Steel 390Q

2011 ◽  
Vol 239-242 ◽  
pp. 2370-2375
Author(s):  
Yan Yu ◽  
Feng Xue Wang ◽  
Jun Chen ◽  
Zhen Liu
Keyword(s):  
Stress Field ◽  
Welding Speed ◽  
Weld Zone ◽  
Three Dimensional ◽  
High Strength ◽  
Simulation Method ◽  
Butt Joint ◽  
Welding Parameters ◽  
Welding Stress ◽  
Stress Simulation

This paper takes the butt joint of axle case steel as research object, simulates the real-time three dimensional dynamics CO2 shielded welding of welding stress field by FEM software ANSYS and obtains the axle case steel 390Q’s transient stress field of weld zone at different welding speed. On that basis, the feasible dynamic simulation method of three-dimensional stress welding field which provides theoretical basis and guidelines for optimizing welding technology and norm welding parameters was proposed. The result of welding stress simulation shows that the welding stress is the lowest when the optimum welding speed is 5mm/s.

scholarly journals Effect of Welding Current on Weldments Properties in MIG and TIG Welding

2018 ◽  
Vol 7 (4.37) ◽  
pp. 192
Author(s):  
Aysha Sh. Hasan ◽  
Obed M. Ali ◽  
Adnan M. Alsaffawi
Keyword(s):  
Welding Process ◽  
Welding Current ◽  
Electrical Current ◽  
Butt Joint ◽  
Medium Carbon Steel ◽  
Tig Welding ◽  
Mig Welding ◽  
Lap Joint ◽  
Noticeable Effect ◽  
Medium Carbon

Welding is an important process commonly used to join the different materials together. There are many methods for welding process;therefore, the specifications of weldments will depend on the type of welding process. In this study, investigation of the effect of electrical current on the weldment mechanical propertieswas conducted. Medium carbon steel & stainless steel were welded using two types of joints (single Lap joint and single v-groove Butt joint). The results showedthat the temperature increased with increasing the electrical current. A significant effect of electrical current on the ultimate tensile strength of the weldments is obtaineddepending on the joint type rather than welding type.Furthermore, there was a noticeable effect for the joining method on the heat generated.The heat generated increases with increasing the electrical current for all weldments (lap & butt) joint in both TIG & MIG welding process. However,the amount of heat generated was for TIG welding process specimens higher than from MIG welding process specimens for Butt and Lap type joints. 

Macro-Micro Analysis on 2-Layer Semiautomatic MIG Welding of AA5052 Material Using ER5356 Electrode

2020 ◽  
Vol 867 ◽  
pp. 204-212
Author(s):  
Mudjijana ◽  
Rela Adi Himarosa ◽  
Sudarisman
Keyword(s):  
Tensile Strength ◽  
Welding Speed ◽  
Welding Process ◽  
Charpy Impact ◽  
Angular Distortion ◽  
Mig Welding ◽  
Lightweight Structures ◽  
Metal Aluminum ◽  
Micro Analysis ◽  
Dial Indicator

Lightweight structures have widely been used due to their weight saving. Aluminum alloys are among the alternative for their material, and they are mostly manufactured by employing welding process using the same filler material as the base metal. Aluminum welding process can be conducted employing 2-layer semiautomatic MIG when the thickness of the plate is no more than 5 mm. Porosity in aluminum alloy welding is considerably difficult to avoid due to hydrogen and oxygen environment. Macro-micro analyses on 2-layer semiautomatic MIG welding of AA5052 material using ER5356 electrode have been carried out. A pair of AA5052 plates of 400 mm x 75 mm x 5 mm were clamped at three points of one side and welded using 2-layer semiautomatic MIG welding using ER5356 filler such that angular distortion can happen. Welding speed of 6, 7, and 8 mm/s using electrical voltage of 23 Volt, current of 130 Ampere, filler diameter of 0.8 mm, and shielded using argon gas. After completion of the welding, angular distortion was measured using dial indicator possessing accuracy of 0.01 mm. Welding result was micro-Vickers (VHN0.1) hardness, tension and Charpy impact, as well as micro structure using OM and SEM-EDS. The highest tensile strength was found at welding speed of 7 mm/s, angular distortion of 6.780, average VHN0.1 of the BM, HAZ, and WM of 47.82, 49.14, and 51.75, respectively. Tensile strength of 156.5 MPa and joint efficiency of 70%, BM failure strain of 17%, Charpy impact of 0.26 J/mm2. SEM-EDX at spot shows that the amount of Mg is not significant for being Al2Mg3 precipitate such that Vickers hardness distribution do not show any difference among BM, HAZ, and WM.

scholarly journals Temperature Field in MIG Welding of Thin Plate of Stainless Steel

2021 ◽  
Vol 31 (5) ◽  
pp. 81-88
Keyword(s):  
Stainless Steel ◽  
Temperature Field ◽  
Welding Process ◽  
Simulation Method ◽  
Butt Joint ◽  
Heat Transfer Process ◽  
Welding Parameters ◽  
Mig Welding ◽  
Calculation Results ◽  
Welding Processes

This paper studies the butt welded joint of SUS316L stainless steel. The butt joint is not beveled, has a gap and is welded in one pass by MIG welding process. First, the welding parameters of this weld are determined through calculation and test welding for the butt joint of two plates of 3 mm in thickness. Then these welding parameters are used as input data to calculate and determine the temperature field by two methods: the calculation method based on the theory of heat transfer process and the numerical simulation method of welding processes that relies on SYSWELD software on the basis of the finite element method. The calculation results of the two methods were compared with each other and tested by experiment to show the reliability of calculation and simulation results.

Investigation on Weld Induced Distortion of Butt Joint Using a Local/Global Simulation Approach

2012 ◽  
Vol 576 ◽  
pp. 189-192
Author(s):  
Mohd Shahar Sulaiman ◽  
Yupiter H.P. Manurung ◽  
Mohd Redza Ridhwan ◽  
N.L. Robert ◽  
M.A.R. Ridzwan ◽  
...  
Keyword(s):  
Low Carbon Steel ◽  
Welding Process ◽  
Computation Time ◽  
Butt Joint ◽  
Fast Computation ◽  
Low Carbon ◽  
Simulation Approach ◽  
Global Approach ◽  
Linear Elastic ◽  
Fabrication Cost

In this paper, a local/global approach has been used to predict weld induced distortion in butt joint. This approach combines non-linear thermo-elastic plastic and linear elastic analyses to compute final distortion triggered by the welding process. Distortion can lead to dimensional inaccuracy and thus causing the rise in fabrication cost. In this study, Finite Element Method (FEM) software Sysweld and Pam-Assembly were used for computing the welding deformation. The material used for the simulation was low carbon steel with thickness of 4 mm. Based on the result obtained, it was observed that this approach provides fast computation time and efficient solution.

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