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 Investigations on force generation and joint properties of dissimilar thickness friction stir corner welded AA 5086 alloy

2020 ◽  
Vol 40 (1) ◽  
pp. 67-74
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Process ◽  
Spindle Motor ◽  
Parent Material ◽  
Force Generation ◽  
Friction Stir ◽  
Current Consumption ◽  
Spindle Motor Current

The force generation, joint mechanical and metallurgical properties of friction stir corner welded non-heat treatable AA 5086 aluminum alloy are investigated in this paper. The friction stir welding process is carried out with the plate thicknesses of 6 mm and 4 mm. The welding speed, tool rotational speed and tool plunge depth were considered as the process parameters to conduct the welding experiments. The machine spindle motor current consumption and tool down force generation during friction stir welding were analyzed. The microstructures of various joint regions were observed. The tensile samples revealed the tensile strength of 197 MPa with tool rotational and welding speeds of 1,000 rev/min and 150 mm/min respectively, which is 78 % of parent material tensile strength. A maximum micro hardness of 98 HV was observed at thermomechanically joint affected zone, which was welded with tool rotation of 1,000 rev/min and welding speed of 190 mm/min.

scholarly journals Study of Laser Welding of HCT600X Dual Phase Steels

2014 ◽  
Vol 22 (1) ◽  
pp. 93-98
Author(s):  
Pavol Švec ◽  
Viliam Hrnčiar ◽  
Alexander Schrek
Keyword(s):  
Tensile Strength ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Welding Speed ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Dual Phase ◽  
Welded Steel ◽  
Steel Sheets

AbstractThe effects of beam power and welding speed on microstructure, microhardnes and tensile strength of HCT600X laser welded steel sheets were evaluated. The welding parameters influenced both the width and the microstructure of the fusion zone and heat affected zone. The welding process has no effect on tensile strength of joints which achieved the strength of base metal and all joints fractured in the base metal.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

scholarly journals ANALISA KEKUATAN WELDING REPAIR BAJA AISI 420 DENGAN METODA GMAW

2019 ◽  
Vol 18 (3) ◽  
pp. 297-306
Author(s):  
Cecep Slamet Abadi ◽  
Rosidi Rosidi ◽  
Idrus Assagaf
Keyword(s):  
Tensile Strength ◽  
Tensile Test ◽  
Test Object ◽  
Impact Test ◽  
Welding Process ◽  
Charpy Impact ◽  
Hardness Test ◽  
Test Material ◽  
Aisi 420 ◽  
The Impact

Welding technology is used because besides being easy to use, it can also reduce costs so it is cheaper. Especially for welding repair. From the welding repair the extent to which the strength of GMAW welds can repair components from the molded plastic mold room made of AISI 420 stainless steel. Repair of the print room components using deposit welding is tested using tensile strength and hardness as realization of resistance when holding the rate of liquid plastic entering the print room by 25 to 40 MPa, depending on the plastic viscosity, the precision of the mold and the filling level of the print room. Deposition welding method as a welding repair can affect a procedure to be able to produce a component that is safe and capable of being used in accordance with the provisions. The welding process used is reverse polarity GMAW DC with 125 A current and ER 70 S welding wire diameter 1.2 mm. Test material AISI 420. Tests carried out were tensile test, impact test and hardness test in weld metal, HAZ and base metal. From the Charpy impact test and tensile test obtained the value of welding strength which is close to the strength of the complete object, which is equal to 65%. The energy absorbed by the impact test object with GMAW welding is 5.4 Joule while for the whole test object is 8.1 Joule. The welding tensile strength is 520 MPa compared to the tensile tensile strength of 820 MPa.

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.

Sustainable Analysis of Process Parameters during MIG Welding of 1018 Mild Steel

2022 ◽  
Vol 13 (1) ◽  
pp. 0-0
Keyword(s):  
Tensile Strength ◽  
Energy Consumption ◽  
Mild Steel ◽  
Process Parameters ◽  
Negative Impact ◽  
Sustainable Manufacturing ◽  
Welding Process ◽  
Travel Speed ◽  
Contour Plot ◽  
Mig Welding

The present work analyses MIG in terms of strength and consumption of energy during joining of similar AISI 1018 Mild Steel plates. Sustainable manufacturing is the creation of various manufactured products that generally use different processes that will minimize negative impact on environment, conserve natural resources and energy, are also safe for the employees, consumers and communities as well as economically sound. Sustainable manufacturing highlights on the necessity of an energy effective process that optimize consumption of energy. AISI 1018 mild steel is extensively used in automotive industries for pins, worms, dowels gears, non-critical tool components etc. Main important output responses are Tensile Strength and energy consumption during MIG Welding Process by taking Current, Travel Speed and Voltage as effective input variables. The main objective is to optimize energy consumption as well as tensile strength also determination of main influential process parameters on energy Consumption and tensile strength by using Taguchi Method. Contour plot has been also shown.

INFLUENCING AND ANALYSIS OF TIG WELDING PROCESS ON MECHANICAL PROPERTIES OF EXTRUDED ALUMINUM PARTS

2017 ◽  
Vol 41 (4) ◽  
pp. 499-515
Author(s):  
Pushp Kumar Baghel ◽  
Doddalahally Shivalingaiah Nagesh
Keyword(s):  
Tensile Strength ◽  
Welding Speed ◽  
Influencing Factor ◽  
Welding Process ◽  
Pulse Frequency ◽  
Tig Welding ◽  
Peak Current ◽  
Base Current ◽  
Dissimilar Aluminum Alloys ◽  
Pulse On Time

Pulse TIG welding is widely used in critical engineering applications comprising of dissimilar aluminum alloys. This study investigates simultaneous effect of important welding process parameters (i.e peak current, base current, pulse frequency, pulse on time, welding speed) on weld quality (Ultimate tensile strength, yield strength, percentage elongation, micro-hardness, impact toughness) are evaluated. Desirable welding characteristics are obtained at optimum peak current of 196.81 Amp, base current of 133.0 Amp, pulse frequency of 6.04 Hz, pulse on time 49.9%, welding speed of 171.16mm/min. The welding speed is found to be significant influencing factor affecting the tensile strength and hardness of weld joint.

Development of Predictive Model for Quality Output of Welding Process of Steel NST 37-2 Using Response Surface Methodology

2018 ◽  
Vol 29 ◽  
pp. 12-18
Author(s):  
Lateef O. Mudashiru ◽  
Emmanuel O. Sangotayo ◽  
Samuel O. Alamu
Keyword(s):  
Tensile Strength ◽  
Welding Speed ◽  
Welding Process ◽  
Welding Current ◽  
Steel Sample ◽  
Quality Data ◽  
Optimum Process ◽  
Current Electrode ◽  
Welded Steel ◽  
Output Quality

The present study investigated the effect of operating parameters in modeling the output quality of welding process of steel sample. A three factor, three levels Box-Behnken Design (BBD) of RSM was applied to determine the effects of three independent variables (welding speed (A), welding current (B) and electrode potential (C)) on the tensile strength and to also develop a model for predicting the output quality. Data analysis shows that A, C, AB, BC, A2, B2and C2are the terms which significantly affected the ultimate tensile strength of the sample at 95% confidence level. The experimental values were very close to the predicted values and were not statistically different at p<0.05. The maximum tensile strength of 228 MPa was obtained at 250 A current, electrode diameter of 3.25 mm and 50 cm/min welding speed, respectively. The regression model obtained has provided a basis for selecting optimum process parameters for the improving output quality (tensile strength) of the welded steel sample.

Comparison between Plasma-MIG and MIG Procedures on 5A06 Aluminum Alloy

2008 ◽  
Vol 575-578 ◽  
pp. 1382-1388 ◽  
Author(s):  
Hong Ming Gao ◽  
Yan Bai ◽  
Lin Wu
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Mechanical Performance ◽  
Weld Zone ◽  
Welding Process ◽  
Deposition Efficiency ◽  
Eutectic Structure ◽  
Melting Rate ◽  
Mig Welding ◽  
5A06 Aluminum Alloy

10mm-5A06 aluminum alloy was butt-welded in a single pass by the plasma-gas metal arc (plasma-MIG) welding procedure, the joints were subjected to X-ray inspection, the microstructure and mechanical performance of weld were also studied. The results indicate that plasma-MIG welding is superior to regular conventional MIG welding on the aspects of reducing weld porosity, increasing joint quality and improving deposition efficiency. Good weld joint with less porosity and excellent mechanical properties is obtained, which can reach as 92.62% tensile strength and 85.12% elongation percentage as base metal. Dimples in which the precipitated phase is the solid solution based on Al3Mg2 are observed in fracture scanning electron micrograph and the fracture mode is ductile rupture. α-Al and Al3Mg2 ,α-Al and eutectic structure are observed respectively in fusion area and in weld zone. The wire feed rate and melting rate can come to 14.5m/min and 80g/min respectively for the 1.6mm welding wire by the plasma-MIG welding process on the premise that the tensile strength of the joints meet the requirements.

scholarly journals Investigating the Effect of Metal Inert Gas Welding Parameters on AA10119 Mild Steel Quality by Taguchi Method

2021 ◽  
pp. 57-63
Author(s):  
Jephthah A. Ikimi ◽  
Aigbovbiosa A. Momodu ◽  
Erhuvwu Totore
Keyword(s):  
Tensile Strength ◽  
Mild Steel ◽  
Process Parameters ◽  
Welding Speed ◽  
Welding Process ◽  
Welding Current ◽  
Inert Gas ◽  
Welding Parameters ◽  
Optimal Setting ◽  
The Right

In welding, the quality of welded joints is greatly influenced by the welding process parameters. Thus, in order to achieve a good weld quality, there is exigency to select the right welding process parameters. The focus of this study is to investigate the effect of Metal Inert Gas (MIG) welding process parameters; welding current, welding voltage and welding speed on the tensile strength of mild steel AA10119 welded plates. The experiment was designed using Taguchi’s L9 orthogonal array with three levels. Kaierda MIG MAG Inverter CO2 Welder Model E-180 welding machine was used to conduct the experiments with three repetitions. From the analysis carried out by applying Taguchi’s method, the result shows that the welding speed and welding current have the most significant influence on tensile strength of the weld and an optimum parameter setting of A3B2C2 was suggested; welding current 240 A, welding voltage 25 V and welding speed 0.010 m/s. The mean tensile strength at this optimal setting A3B2C2 was predicted to be 442 N/mm2.

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