Studies on Temperature Variation and Angular Distortion in Submerged Arc Welded Butt Joint

2013 ◽  
Vol 699 ◽  
pp. 656-661 ◽  
Author(s):  
Arora Hitesh ◽  
Prince Pal Singh ◽  
Ajay Hooda
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Welding Current ◽  
Source Model ◽  
Butt Joint ◽  
Fusion Welding ◽  
Angular Distortion ◽  
Transient Temperature ◽  
Large Structures ◽  
Submerged Arc

Large structures are usually made by joining different elements. Fusion welding is one of the most fundamental technique, which is used to make large metallic joints. During fusion welding a large amount of heat is generated which melts the joint surroundings and a joint is created after solidification. Joint configuration is mostly affected by the material parameters and process type. In this paper, a thermo-mechanical simulation of fusion welding of submerged arc welding is performed using ANSYS. A moving heat source model based on Double-Ellipsoidal heat flux distribution is modelled. The transient temperature distributions and temperature variations of the welded plates are calculated during welding process. Effect of welding speed, welding current on temperature profile and angular distortion of plates is further investigated.

A Simplified Numerical Approach for Finding the Temperature Distribution in Submerged arc Welding Process

2012 ◽  
Vol 622-623 ◽  
pp. 315-318
Author(s):  
Aparesh Datta ◽  
Subodh Debbarma ◽  
Subhash Chandra Saha
Keyword(s):  
Temperature Distribution ◽  
Heat Source ◽  
Arc Welding ◽  
Welding Process ◽  
Numerical Approach ◽  
High Heat ◽  
Submerged Arc Welding ◽  
Fusion Welding ◽  
Arc Welding Process ◽  
Submerged Arc

The quality of joining has assumed a greater role in fabrication of metal in recent years, because of the development of new alloys with tremendously increased strength and toughness. Submerged arc welding is a high heat input fusion welding process in which weld is produced by moving localized heat source along the joint. The weld quality in turn affected by thermal cycle that the weldment experiences during the welding. In the present study a simple comprehensive mathematical model has been developed using a moving heat source and analyzing the temperature on one section and then the temperature distribution of other section are correlated with time delay with reference analyzed section.

Sensing and Control of Double-Sided Arc Welding Process

2002 ◽  
Vol 124 (3) ◽  
pp. 695-701 ◽  
Author(s):  
Y. M. Zhang ◽  
S. B. Zhang ◽  
M. Jiang
Keyword(s):  
Arc Welding ◽  
Current Practice ◽  
Welding Process ◽  
Butt Joint ◽  
Large Structures ◽  
Arc Welding Process ◽  
And Control ◽  
Number Of Passes ◽  
Welding Productivity ◽  
Thick Material

The welding industry is driven to improve productivity without sacrificing quality. For thick material welding, the current practice is to use backing or multiple passes. The laser welding process, capable of achieving deep narrow penetration, can significantly improve welding productivity for such applications by reducing the number of passes. However, its competitiveness in comparison with traditional arc welding is weakened by its high cost, strict fit-up requirement, and difficulty in welding large structures. In this work, a different method, referred to as double-sided arc welding (DSAW) is developed to improve the arc concentration for arc welding. A sensing and control system is developed to achieve deep narrow penetration under variations in welding conditions. Experiments verified that the pulsed keyhole DSAW system developed is capable of achieving deep narrow penetration on a 1/2 inch thick square butt joint in a single pass.

Temperature Profile and its Effect on Hardness Numbers of a Mild Steel Butt Weld

2019 ◽  
Author(s):  
Qin Ma
Keyword(s):  
Heat Source ◽  
Mild Steel ◽  
Temperature Profile ◽  
Arc Welding ◽  
Rapid Heating ◽  
Welding Process ◽  
Fusion Welding ◽  
Transient Temperature ◽  
Shielded Metal Arc Welding ◽  
Butt Weld

Abstract Fusion welding of steel joints is common through history of industrial applications. Among those, Shielded Metal Arc Welding (SMAW) and Gas Tungsten Arc Welding (GTAW) are most common. Fusion welding process comprises of rapid heating and cooling cycles. Each cycle produces a non-uniform and transient temperature distribution and causes rapid thermal expansion followed by thermal contraction. Thus plastic deformation and thermal residual stresses can be induced in a welded joint when it cools down gradually to room temperature. In this study, temperature profiles of a hand-weld mild steel butt weld are analyzed by means of the finite element method (FEM) through ANSYS Mechanical APDL The moving heat source is simulated using the Gaussian distribution heat source model. A parametric study was then performed to evaluate the importance of certain key process parameters that affect the quality of a weldment. The effects of temperature profile on hardness numbers inside and away from the heat affected zone (HAZ) are discussed. It was found that the residual stress results obtained from the simulation agree with the distribution of hardness numbers tested on the weldment sample.

Development of Grounding Device to Reduce Current Variation in Submerged Arc Welding Process for Pressure Vessel Fabrication

2014 ◽  
Vol 1043 ◽  
pp. 268-272
Author(s):  
Supphachan Rajsiri ◽  
Kanokporn Penpondee ◽  
Sittiphun Tuntawiroon
Keyword(s):  
Pressure Vessel ◽  
Arc Welding ◽  
Welding Process ◽  
Welding Current ◽  
Electrical Current ◽  
Submerged Arc Welding ◽  
Long Distance ◽  
Spherical Cap ◽  
Radiographic Testing ◽  
Submerged Arc

This study developed a device to solve welding problems that occur in the manufacturing of a pressure vessel for cryogenic applications under the ASME Section VIII Division 1. The cylindrical body of the vessel was assembled with short pre-fabricated cylinders and caps using submerged arc welding. The rotatable grounding electrode was mounted to the top half of the spherical cap. However, the relatively long distance between the welding and the electrode grounding locations, especially in longer vessels, restricts the flow and the distribution of the electrical current. Radiographic testing identified lack of fusion as the major reason for the restricted flow of the electrical current. This also caused additional work on welding repair. To address this issue that compromised both top-outer and bottom-inner vertical positions for circumference welding, a new grounding device was developed to reduce the flow distance. The electrical conductivity was also improved through a series of welding tests. The investigation showed that a greater average welding current increased arc stability. Radiographic testing confirmed that the vessels were welded completely suggesting the grounding device utility for increasing welding joint soundness of the circumference weldment.

Effect of Weld Groove Area on Distortion of Butt Welded Joints in Submerged Arc Welding

2018 ◽  
Vol 8 (2) ◽  
pp. 33-44
Author(s):  
Mahendramani G ◽  
Lakshmana Swamy N
Keyword(s):  
Welded Joints ◽  
Arc Welding ◽  
Welding Process ◽  
Submerged Arc Welding ◽  
Point Of View ◽  
Angular Distortion ◽  
Heating And Cooling ◽  
Increase With Increase ◽  
Arc Welding Process ◽  
Submerged Arc

This article describes how welding is the most prominent process for joining components into complex assemblies or structures. The various distortions induced by the welding process due to the inherent local non-uniform heating and cooling cycles associated with the joining processes. The manufacturing and shipbuilding industries encounter problems of distortion. Restriction of any distortions by restraint may lead to higher residual stresses. The predictions of the degree of shrinkage and angular distortion in ship panels due to welding are of great importance from the point of view of dimensional control. In view of this, an experimental study has been performed to analyze the effect of groove area on angular distortion, transverse and longitudinal shrinkages of butt welded joints in submerged arc welding process for constant heat input. It is observed that the angular distortion decreases with increase in the groove area but the transverse and longitudinal shrinkages increase with increase in the groove area.

Dilution Control by Advanced Submerged Arc Welding

2012 ◽  
Vol 488-489 ◽  
pp. 1737-1741 ◽  
Author(s):  
Dinesh Kumar Shukla ◽  
Sunil Pandey
Keyword(s):  
Arc Welding ◽  
Raw Materials ◽  
Steel Substrate ◽  
Welding Process ◽  
Welding Current ◽  
Submerged Arc Welding ◽  
Electrode Wire ◽  
The Difference ◽  
Process Controls ◽  
Submerged Arc

Dilution is a vital element in surfacing and depends on the difference in chemical composition between the weld and the parent metal, the welding process and the technique used. Metal surfacing is becoming the natural choice for reducing the consumption of expensive raw materials, processing cost and proper resource utilization. Mechanical as well as the metallurgical properties are greatly influenced by the degree of dilution. The advanced submerged arc welding (ASAW) process controls the response parameters independently and breaks the fixed relationship between the wire feed rate (W) and the welding current (I). A study was conducted to investigate the effect of process variables on the dilution during the process. The preheating of the electrode wire used in Submerged Arc Welding process (SAW) for surfacing application was done with the modification in the existing setup. Stainless steel 308L electrode wire was used on mild steel substrate to study the effect of preheating on the dilution. The results show that ASAW process controls and significantly reduces the percent dilution as compared with the conventional SAW process. ASAW process reduces the heat input, use of consumables and increased productivity, is the added advantages over the conventional process.

scholarly journals A study of parametric effects on thermal profile of submerged arc welding process

2015 ◽  
Vol 12 (1) ◽  
pp. 43-56 ◽  
Author(s):  
Abhijit Sarkar ◽  
R.N. Rai ◽  
S.C. Saha
Keyword(s):  
Arc Welding ◽  
Plate Thickness ◽  
Welding Process ◽  
Source Model ◽  
Submerged Arc Welding ◽  
Welding Parameters ◽  
Parametric Effects ◽  
Weld Parameters ◽  
Arc Welding Process ◽  
Submerged Arc

In this study, a Numerical model is carried out to study the effect of welding parameters on the temperature variations in Submerged Arc Welding process (SAW) with moving heat source model (Gaussian distribution) by using finite difference method (FDM). The proposed method is validated from the experimental results and found is in good agreement with results obtained by experimental. The mathematical model of transient thermal is also recognized to simulate Peak temperature. Finally Parametric effects on temperature profiles based on numerical results, are carried out for different weld parameters including welding speed, heat input, and plate thickness. It has been shown that all those parameters are playing an essential role in affecting the temperature distribution.

ESTABLISHING RELATIONSHIP BETWEEN WELDING CURRENT AND WELD METAL DEPOSITION RATE FOR SOLID WIRE IN SUBMERGED ARC WELDING PROCESS

2020 ◽  
Vol 15 (2) ◽  
Author(s):  
Bashkar R ◽  
Balasubramanian V ◽  
Mani C
Keyword(s):  
Weld Metal ◽  
Deposition Rate ◽  
Arc Welding ◽  
Welding Process ◽  
Welding Current ◽  
Submerged Arc Welding ◽  
Metal Deposition ◽  
Wire Diameter ◽  
Filler Wire ◽  
Submerged Arc

Submerged Arc Welding (SAW) process is used to weld large, heavy metal deposition jobs with critical requirements, and this metal joining process alone is used to weld approximately 10% of the deposited weld metal worldwide. Any augmentation in productivity of SAW process, will immensely benefit the welding industry, as this process is widely used on variety of common metals and alloys. This paper focusses on establishing relationship between welding current and productivity (in terms of weld metal deposition rate as an index), for a given filler wire diameter. Productivity rates of most common solid filler wire sizes were studied, at different preset current values, covering full current range through bead-on-plate experiments. At each preset current value, the bead was first optimized for acceptable visual quality, by varying arc travel speed and voltage, then wire feed rate (of acceptable beads) was noted. The current density, heat input and corresponding weld metal deposition rate were calculated for establishing relationships. The established relationships can be effectively used, to estimate productivity from the preset current values, for a given solid wire diameter.

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