Welding Shape Control of Cross Member Backbone Assembly by Automatic Gas Metal Arc Yaskawa-MA1440 Type

2021 ◽  
Vol 877 ◽  
pp. 90-95
Author(s):  
Lydia Anggraini ◽  
Kalimi
Keyword(s):  
Shape Control ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Travel Speed ◽  
Machine Construction ◽  
Weld Strength ◽  
Automatic Welding ◽  
Leg Length ◽  
Steel Coil ◽  
Cross Member

In order to prevent distortion caused by heat which affects the material deformation, the properties controlled are required. The properties changes and the placement of the mounting position will effect the weld strength that causes cracks and broken joints, therefore it affects the safety of machine construction. Thus, the objective of this paper is to control the shape of cross member backbone assembly by gas metal arc welding (GMAW). The welding is produced by an automatic robot Yaskawa-MA1440 type. In order to obtain the good quality of the result, the welding shape is controlled by a parameters combination of voltage, current, and speed. Yaskawa-MA1440 type is used as the automatic welding machine. The main material used is cold rolled steel coil sheet MJSC270D-OD with a thickness of 1.2 mm. In addition, to control the welding shape, the specified shape design standard is followed include travel speed, gas flow, welding direction, torch tip distance to the workpiece, torch angle and welding angle. The results of visual and dimensional were also examined in this research. Furthermore, the macrostructure i.e. leg length, fusion penetration, throat thickness have been analyzed and confirmed based on the standards used in the auto body vehicle part company. The appropriate parameters for the finest welding shape are defined at the horizontal position using an electric current of 120 A and the welding voltage of 18 V (± 1 V). Thus, the measurement control of macrostructure is defined as reference parameters for mass production of cross member backbone assembly.

scholarly journals ENENTUAN PARAMETER PENGELASAN RANGKA UTAMA SEPEDA MOTOR MATIC BAGIAN DEPAN MENGGUNAKAN LAS MIG OTOMATIS (PANASONIC TM-1400G3)

POROS ◽  
2018 ◽  
Vol 15 (1) ◽  
pp. 44
Author(s):  
Yusril Irwan ◽  
Gatot Pamungkas
Keyword(s):  
Structure Analysis ◽  
Gas Flow ◽  
Low Carbon Steel ◽  
Welding Parameters ◽  
Vertical Position ◽  
Automatic Welding ◽  
Low Carbon ◽  
Leg Length ◽  
Welding Machine ◽  
Main Frame

Abstract: Main frame welding at the front automatic motorcycle of PT. XXX is the stage of (trial production). The welding machine is Panasonic TM-1400G3 MIG automatic welding machine with 75% Argon and 25% Ar-CO2. Main frame material low carbon steel STAM 390G. To obtain the welding results in accordance with the standards specified by the client, weld testing parameters are varied for each test, which are ampere and voltage. The constant welding parameters in this research are travel speed, gas flow, welding direction, tip distance to workpiece, torch angle and welding angle. All test results are inspected visually and dimensionally, if passed, it will be followed by inspection of macro structure analysis. The results measured on the macro structure analysis ar : penetration (a1), penetration (a2), bead welding, throuth, leg length and crown with standard measurement values determined by the client PT.XXX. The welding results (OK) in the macro structure analysis measurement are defined as reference parameters for mass production. The best parameters for main frame welding are vertical position down (3G) with 170 Ampere current and 20 Volt voltages, and for horizontal position (2G) with 180 ampere current parameters and 17 Volt voltages. 

Mechanical Properties and Microstructure of LR Grade a Thick Plate Welded by Double Side Gas Metal Arc Welding

2016 ◽  
Vol 851 ◽  
pp. 168-172
Author(s):  
Yustiasih Purwaningrum ◽  
Triyono ◽  
Tegar Rileh Argihono ◽  
Ryan Sutrisno
Keyword(s):  
Mechanical Properties ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Charpy Impact ◽  
Hardness Test ◽  
Charpy Impact Test ◽  
Optical Microscope ◽  
Steel Plates ◽  
Weld Metals ◽  
Metal Arc Welding

Mechanical and microstructure of double side weld with various angle groove was studied in this research. LR Gr A steel plates (12 mm thickness) were welded using GMAW with corresponding 180 A, 23 V, and 20 l/min respectively with current, voltage, and gas flow. Shielding gas and filler metals used are argon and ER 70S-6. The angle groove that used were 20⁰, 40⁰ and 60⁰. The measured of mechanical properties with regard to hardness, toughness and strength using, Vickers hardness test, Charpy impact test and tensile test respectively The microstructure examined with optical microscope. The results show that the highest hardness values found in welds with groove angle 40ͦ. The transition temperatures of weld metals are at temperatures between -20°C to 0°C. Weld metals with all variations of the groove angle has a value of less than 0.1 mmpy. Microstructure of base metals and HAZ were ferrite and pearlite. While the microstructure of weld metals are accicular ferrite, grain boundary ferrite and Widmanstatten ferrite.

Optimization of Automatic TIG Welding Parameters of AISI 304L ASS Welds Using Response Surface Methodology

2021 ◽  
Vol 406 ◽  
pp. 319-333
Author(s):  
Tahar Saadi ◽  
Mohamed Farid Benlamnouar ◽  
Nabil Bensaid ◽  
Amar Boutaghane ◽  
Mohamed Amine Soualili ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Gas Flow ◽  
Desirability Function ◽  
Welding Parameters ◽  
Automatic Welding ◽  
Aisi 304L ◽  
Rsm Optimization ◽  
Single Response

The present study, aims to investigate, under welding parameters of current, voltage and gas flow, the effects of welding parameters on tensile strength of AISI 304L ASS welds using response surface methodology (RSM). The RSM and variance analysis (ANOVA) were used to check the validity of quadratic regression model and to determine the significant parameter affecting tensile strength of welds. Hence, ANOVA clearly revealed that the contribution of each factor is 71.40% of voltage, 19.2% of current and 8.30% of gas flow. It was found that combined contributions of welding parameters contributes significantly to the metallurgical changes by varying fractions, morphology and grain size of metallic compounds. Furthermore, the optimum automatic welding conditions lead to produce the best possible weld quality in the range of our experiment using desirability function approach for single response of RSM optimization factors, in which it concluded that tensile strength components are influenced principally by voltage. Finally, the ranges for best welding conditions are proposed for serial industrial production.

scholarly journals An Image-Processing Method for Extracting Kinematic Characteristics of Droplets during Pulsed GMAW

2019 ◽  
Vol 9 (24) ◽  
pp. 5481 ◽  
Author(s):  
Peizhuo Zhai ◽  
Songbai Xue ◽  
Tao Chen ◽  
Jianhao Wang ◽  
Yu Tao
Keyword(s):  
Image Processing ◽  
Monitoring System ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Processing Algorithm ◽  
Automatic Welding ◽  
Threshold Method ◽  
Image Processing Algorithm ◽  
Kinematic Characteristics ◽  
Metal Arc Welding

Pulsed gas metal arc welding (GMAW) is widely applied in industrial manufacturing. The use of pulsed GMAW was found superior to the traditional direct-current (DC) welding method with respect to spatter, welding performance, and adaptability of all-position welding. These features are closely related to the special pulsed projected metal transfer process. In this paper, a monitoring system based on a high-speed camera and laser backlight is proposed. High-quality images with clear droplets and a translucent arc can be obtained at the same time. Furthermore, a novel image-processing algorithm is proposed in this paper, which was successfully applied to remove the interference of the arc. As a result, the edge and region of droplets were precisely extracted, which is not possible using only the threshold method. Based on the algorithm, centroid coordinates of undetached and detached droplets can be calculated, and more parameters of the kinematic characteristics of droplets can be derived, such as velocity, acceleration, external force, and momentum. The proposed monitoring system and image-processing algorithm give a simple and feasible way to investigate kinematic characteristics, which can provide a new method for possible applications in studying mathematic descriptions of droplet flight trajectory and developing a precise automatic welding system.

scholarly journals Single-Pass Cladding Process Using Hot-wire Gas Metal Arc Welding Technique

2019 ◽  
Vol 269 ◽  
pp. 01006
Author(s):  
Pattanawit Suntiniwat ◽  
Eakkachai Warinsiriruk ◽  
Sutep Joy-A-Ka
Keyword(s):  
Stainless Steel ◽  
Gas Metal Arc Welding ◽  
Ccd Camera ◽  
Travel Speed ◽  
Hot Wire ◽  
Single Pass ◽  
High Production Rate ◽  
Feeding Speed ◽  
Wire Feeding ◽  
Wire Filler

The aim of this study is to improve cladding process productivity by high production rate with low dilution process by specifying technique as hot-wire GMAW process. The base metal of carbon steel A516 Gr70 was cladded by austenitic stainless steel 309LSi for creating a buttering layer and stainless steel 308LSi for hot-wire filler for topping a cladding layer in a one-pass run. The studied parameters this experiment consist of the feeding ratio of hot wire feeding speed per GMAW wire feeding speed and travel speed. Welding phenomenon during welding was observed by CCD camera with specifying the optical device to see the appropriate condition. The result showed the hot-wire GMAW cladding process could reduce cycle time 3.5 times compare with conventional FCAW cladding process. Moreover, dilution of this process could decrease lower than 15% with acceptable FN 3 on the top of weld surface. Therefore, single pass cladding process achieved by using this method with low dilution by still keep microstructure capability.

Effect of shielding gas flow rate on arc behaviors in GMAW with single cable-typed wire

2019 ◽  
Vol 34 (01n03) ◽  
pp. 2040059
Author(s):  
Qingxian Hu ◽  
Lei Zhang ◽  
Juan Pu ◽  
Caichen Zhu
Keyword(s):  
Flow Rate ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Three Dimensional ◽  
Maximum Velocity ◽  
Maximum Flow ◽  
Maximum Pressure ◽  
Arc Plasma ◽  
Shielding Gas ◽  
Gas Flow Rate

A three-dimensional numerical model of arc in gas metal arc welding (GMAW) with single cable-typed wire was established based on the theory of arc physics. The influences of different shielding gas flow rates on the features of temperature field, velocity field and pressure field were investigated. The results showed that the maximum velocity of arc plasma along radial direction and the arc pressure on the surface of workpieces were increased obviously with the increase of the shielding gas flow rate, while the arc temperature was changed little. This phenomenon was mainly attributed to the increasing collisions between arc plasmas and the self-rotation action of cable-typed wires. The arc temperature at the tip of the cable-typed wire reached the maximum. The maximum flow velocity of arc plasma was located at the tip of wire (2–8 mm). The arc pressures in the central axis reached the maximum pressure. The simulation results were in agreement with the experimental results.

Enhancing fatigue resistance of activated tungsten inert gas welded UNS S32750 super duplex stainless steel by optimizing its technological properties

2020 ◽  
pp. 1-11
Author(s):  
A. Arunmani ◽  
T. Senthilkumar
Keyword(s):  
Stainless Steel ◽  
Fatigue Life ◽  
Duplex Stainless Steel ◽  
Fatigue Resistance ◽  
Process Parameters ◽  
Gas Flow ◽  
Welding Process ◽  
Travel Speed ◽  
Inert Gas ◽  
Super Duplex Stainless Steel

In engineering industries and heavy manufacturing plants, fatigue life of joints plays a pivotal role in determining the overall life span of the welded joint. In this paper, an advanced fusion joining technique, namely activated tungsten inert gas welding, was used for joining UNS S32750 super duplex stainless steel, with ZnO as activation flux. For the enhancement of fatigue resistance of joints, important welding process parameters were fluctuated according to a developed central composite design model. Empirical relationships were developed between the process parameters and the fatigue strength of the joints, which was correlated with the number of cycles to failure (NCF). Using analysis of variance, the significance of the developed fatigue model was ascertained. Using response surface methodology, optimization of process parameters for enhancement of fatigue resistance was done. It was observed that at the optimized activated tungsten inert gas weld process parameters of travel speed of welding torch at 69.85 mm/min, weld current at 125.20 A, and shielding gas flow rate at 14.77 L/min, a high fatigue life of 7.66396 × 108 NCF was obtained and the model was validated to very high predictability. Microstructural variations in the fatigue-tested specimens were evaluated for identifying the grain modifications.

Comparison of Hardness and Microstructures Produced Using GMAW and Hot-Wire TIG Mechanized Welding of High Strength Steels

2014 ◽  
Author(s):  
A. R. H. Midawi ◽  
E. B. F. Santos ◽  
A. P. Gerlich ◽  
R. Pistor ◽  
M. Haghshenas
Keyword(s):  
Weld Metal ◽  
Deposition Rate ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
High Strength Steels ◽  
Travel Speed ◽  
Pressure Vessels ◽  
High Deposition Rate ◽  
Hot Wire ◽  
Wire Feed

For high productivity weld fabrication, gas metal arc welding (GMAW) is typically used since it offers a combination of high deposition rate and travel speed. Recent advances in power supply technologies have increased the deposition rates in hot-wire tungsten inert gas (HW-TIG) welding, such that it is possible to achieve parameters which may be comparable to those used in GMAW for pressure vessels and some pipeline applications. However, these two processes have drastically different deposition efficiencies and heat input characteristics. The purpose of the present study is to examine GMAW and HW-TIG bead-on-plate deposits in terms of mechanical properties, deposition rate, and heat affected zone (HAZ) thermal cycles when identical travel speed and wire feed speeds are applied with a ER90S-G filler metal. The results demonstrate that HW-TIG can be applied with comparable travel and wire feed speeds to GMAW, while providing a more uniform weld bead appearance. Based on weld metal microhardness values, it is suggested the effective heat input is lower in HW-TIG compared to GMAW, since the average hardness of the weld metal is slightly higher.

Preparation of Titanium Metal Matrix Composites Using Additive Manufacturing

2017 ◽  
Vol 742 ◽  
pp. 129-136 ◽  
Author(s):  
Lilla Vály ◽  
David Grech ◽  
Erich Neubauer ◽  
Michael Kitzmantel ◽  
Ľuboš Bača ◽  
...  
Keyword(s):  
Metal Matrix Composites ◽  
Cross Sections ◽  
Metal Matrix ◽  
Gas Flow ◽  
Travel Speed ◽  
Processing Parameters ◽  
Layer By Layer ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Plasma Parameters

In this work, the “4M-System” (Machine for Multi-Material-Manufacturing) has been developed by RHP Technology for the manufacturing of Titanium Metal Matrix Composites. This equipment allows the Additive Layer Manufacturing (ALM) of large structures and uses a Plasma Transferred Arc (PTA) as a heat source for depositing feedstocks (powder/wire) layer by layer onto a substrate. Test coupons, made of Titanium powders and having different concentrations of B4C particles, were deposited to form Metal Matrix Composites. Various processing parameters such as deposition rate, travel speed of the torch as well as plasma parameters (power/current/gas flow) were assessed for getting pore- and crack-free samples. After deposition, the specimens were cut and the cross-sections were analysed by optical- and scanning electron microscopy. Furthermore, the hardness, Young’s Modulus, and tensile strength were measured. Ti-Metal Matrix Composite materials resulted in higher strength and Young´s Modulus in comparison to the pure Ti-metal matrix. Using the 4M-System, B4C particle reinforced Ti-MMC’s were successfully manufactured. Thus the 4M-System proved the capability of joining multi-material concepts, which also promises to create graded concentrations of reinforcement in the material.

Process parameters investigation of a laser-generated single clad for minimum size using design of experiments

2013 ◽  
Vol 19 (6) ◽  
pp. 452-462 ◽  
Author(s):  
Mehmet Ermurat ◽  
Mehmet Ali Arslan ◽  
Fehmi Erzincanli ◽  
Ibrahim Uzman
Keyword(s):  
Design Of Experiments ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Optimum Parameter ◽  
Travel Speed ◽  
Standoff Distance ◽  
Gas Flow Rate ◽  
Focal Distance ◽  
Content Type

Purpose – This paper aims to investigate the effect of four important process parameters (i.e. laser focal distance, travel speed, feeding gas flow rate and standoff distance) on the size of single clad geometry created by coaxial nozzle-based powder deposition by high power laser. Design/methodology/approach – Design of experiments (DOE) and statistical analysis methods were both used to find optimum parameter combinations to get minimum sized clad, i.e. clad width and clad height. Factorial experiment arrays were used to design parameter combinations for creating experimental runs. Taguchi optimization methodology was used to find out optimum parameter levels to get minimum sized clad geometry. Response surface method was used to investigate the nonlinearity among parameters and variance analysis was used to assess the effectiveness level of each problem parameters. Findings – The overall results show that wisely selected four problem parameters have the most prominent effects on the final clad geometry. Generally, minimum clad size was achieved at higher levels of gas flow rate, travel speed and standoff distance and at minimum spot size level of the laser focal distance. Originality/value – This study presents considerable contributions in assessing the importance level of problems parameters on the optimum single clad geometry created laser-assisted direct metal part fabrication method. This procedure is somewhat complicated in understanding the effects of the selected problem parameters on the outcome. Therefore, DOE methodologies are utilized so that this operation can be better modeled/understood and automated for real life applications. The study also gives future direction for research based on the presented results.

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