Analysis of Arc Welded Thin-Walled Cylinders to Investigate the Effects of Welding Process Parameters on Residual Stresses

2008 ◽  
Vol 575-578 ◽  
pp. 763-768
Author(s):  
Afzaal M. Malik ◽  
Ejaz M. Qureshi ◽  
Naeem Ullah Dar
Keyword(s):  
Residual Stresses ◽  
Process Parameters ◽  
Arc Welding ◽  
Research Work ◽  
Three Dimensional ◽  
Welding Process ◽  
Welding Current ◽  
Element Model ◽  
Welding Parameters ◽  
Thin Walled

The research work presents a computational methodology based on three-dimensional finite element model to simulate the gas tungsten arc welding (GTAW) of thin-walled cylinders. The aim was to study the effects of two basic welding parameters (welding speed and welding current) on weld induced residual stresses. The complex phenomenon of arc welding was numerically solved by sequentially coupled transient, non-linear thermo-mechanical analysis. The accuracy of the numerical model was validated through experiments for temperature distribution and residual stresses. The results reveals that the present simulation strategy can be used as a proper tool to get the optimized welding process parameters and minimize the in service failures of thinwalled structures due to residual stresses.

scholarly journals EFFECTS OF WELDING CURRENT AND SPEED ON RESIDUAL STRESS AND DISTORTION OF JOINING ST52 ROLLED PLATE IN DIFFERENT WELDING SEQUENCES

2020 ◽  
Vol 3 (2) ◽  
pp. 40-45
Author(s):  
Ali Aminifar ◽  
Alireza M. Haghighi
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Welding Current ◽  
Element Model ◽  
Rolled Plate ◽  
Main Step ◽  
Welding Parameters ◽  
Effective Parameters ◽  
Welding Sequences

Welding is a process of permanent joining parts by different welding methods. Residual stress and distortion are the most common phenomena of this process. Reduction of the residual stresses, distortion and improving the quality of welding are the important subjects of this field. Determining and analyzing the residual stresses and distortion is the main step for these purposes. Welding sequences, speed and current are the most effective parameters of this process. In this study, effects of welding parameters such as welding speed and current, in order to reduce residual stress and distortion of welding ST52 rolled plate in different welding sequences have been studied with three-dimensional thermo-mechanical finite element model by means of ANSYS APDL. By comparing different considered situations, the most efficient welding methods with the least residual stress and distortion by considering different welding sequences have been suggested. It obtains that welding the ST52 rolled plate from edge to edge with higher current and lower speed is the best option in fatigue and load-bearing situations, and welding from the center to both sides simultaneously with lower current and higher speed is the best option for assembly problems.

Welding Residual Stress of Flange-Plate Steel Reinforced Connections

2012 ◽  
Vol 446-449 ◽  
pp. 3495-3498
Author(s):  
Wei Wang ◽  
Chang Hao Zhang ◽  
Guan Feng Wang ◽  
Juan Zhang
Keyword(s):  
Residual Stresses ◽  
Three Dimensional ◽  
Welding Process ◽  
Welding Residual Stress ◽  
Welding Parameters ◽  
Heat Affect Zone ◽  
Moment Frame ◽  
Steel Moment Frame ◽  
Element Analysis ◽  
The Finite Element Analysis

The welding joint method is usually applied in the reinforcing process of the steel moment frame connections. The welding parameters are chosen and discussed and the finite element analysis is employed to analyze the completely penetration joint weld between the flange plates and the column flange. The three-dimensional thermo-structure simulation is conducted. Furthermore, the influence of the residual stresses on the the loading capacity of the reinforced connection is discussed. The temperature field during the welding process and the residual stresses distribution are given. The existence of the welding residual will highly increase the likelihood of brittle fracture of the steel in the heat affect zone.

scholarly journals Comparison between PCA analysis and Grey based Taguchi analysis of TIG welding process parameters on Duplex stainless steel

2021 ◽  
pp. 67-74
Author(s):  
Sandip Mondal ◽  
Goutam Nandi ◽  
Pradip Kumar Pal
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Process Parameters ◽  
Gas Flow ◽  
Welding Process ◽  
Principal Component ◽  
Welding Current ◽  
Tig Welding ◽  
Welding Parameters ◽  
Welding Quality

Tungsten inert gas (TIG) welding on Duplex stainless steel (DSS) is more easy, comfortable and useful, if the process is precisely understood and controlled through development of the science & technology. TIG welding on DSS has been performed with the help of specific controlled welding process parameters. Welding quality has been strongly depended on these process parameters. In this study, some valuable welding parameters are chosen. These are welding current, shielding gas flow rate and speed of welding. These process parameters of TIG welding for ASTM/UNS 2205 DSS welds are optimized by using Principal Component Analysis (PCA) method and Grey based Taguchi’s L9 Orthogonal array (OA) experimental plan with the conception of signal to noise ratio (N/S). After that, compression results of above mentioned two analyses of TIG welding process parameters have been calculated. The quality of the TIG welding on DSS has been evaluated in term of ultimate tensile strength, yield strength and percentage of elongation. Compression results of both analyses indicate application feasibility for continuous improvement of welding quality on DSS in different components of chemical, oil and gas industries.

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.

A Study on Welding Quality of Robotic Arc Welding Process Using Mahalanobis Distance Method

2013 ◽  
Vol 773-774 ◽  
pp. 759-765 ◽  
Author(s):  
Reenal Ritesh Chand ◽  
Ill Soo Kim ◽  
Ji Hye Lee ◽  
Jong Pyo Lee ◽  
Ji Yeon Shim ◽  
...  
Keyword(s):  
Process Parameters ◽  
Mahalanobis Distance ◽  
Arc Welding ◽  
Gma Welding ◽  
Welding Process ◽  
Experimental Results ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Welding Quality ◽  
Arc Welding Process

In robotic GMA (Gas Metal Arc) welding process, heat and mass inputs are coupled and transferred by the weld arc and molten base material to the weld pool. The amount and distribution of the input energy are basically controlled by the obvious and careful choices of welding process parameters in order to accomplish the optimal bead geometry and the desired mechanical properties of the quality weldment. To make effective use of automated and robotic GMA welding, it is imperative to predict online faults for bead geometry and welding quality with respect to welding parameters, applicable to all welding positions and covering a wide range of material thickness. To successfully accomplish this objective, two sets of experiment were performed with different welding parameters; the welded samples from SM 490A steel flats adopting the bead-on-plate technique were employed in the experiment. The experimental results of current and voltage waveforms were used to predict the magnitude of bead geometry and welding quality, and to establish the relationships between weld process parameters and online welding faults. MD (Mahalanobis Distance) technique is employed for investigating and modeling of GMA welding process and significance test techniques were applied for the interpretation of the experimental data. Statistical models developed from experimental results which can be used to control the welding process parameters in order to achieve the desired bead geometry based on weld quality criteria.

Simulation of Arc Welding Process

2013 ◽  
Vol 837 ◽  
pp. 55-60
Author(s):  
Viorel Cohal
Keyword(s):  
Residual Stresses ◽  
Arc Welding ◽  
Welding Process ◽  
Design Parameters ◽  
Welding Parameters ◽  
Physical Factors ◽  
Heat Sources ◽  
Original Design ◽  
Reliability Modeling ◽  
Arc Welding Process

This paper presents a program for modeling and optimization of the arc welding process. Interface of the program is divided: time-synchronized monitoring multiple welding robots, a quick calculation options are various parameters, quickly replace the original design parameters (sequence of welding, etc.), the high degree of reliability modeling of welding defects, overheated regions, distortion and residual stresses in structures, intuitive visualization and control mechanism of the modeling process. Process variables are easy to evaluate quickly by changing the welding parameters, leading to systematic optimization of fusion zones, heat-affected zones, residual stress, and distortions. The software provides tools for reporting display of distortion, temperature distribution, residual stresses, and curve progression of physical factors on fixed measuring points. As a production process tool, simulation offers an interface to RoboCad, as well as an export interface to robots. Welding paths can be simulated in real speed, direction, and inclination, and the program is capable of tracking different heat sources (Goldak model, volume sources, surface heat sources with Gauss distribution, and combinations of this). This paper presents RobotStudio simulation of welding of parts. Optimum welding parameters are set using Simufact.welding modeling.

A Study on Development of the Optimal Neural Network in GMA Welding Process

2014 ◽  
Vol 936 ◽  
pp. 1759-1763
Author(s):  
Qian Qian Wu ◽  
Ji Hye Lee ◽  
Jong Pyo Lee ◽  
Min Ho Park ◽  
Young Su Kim ◽  
...  
Keyword(s):  
Neural Network ◽  
Process Parameters ◽  
Gma Welding ◽  
High Reliability ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Welding Quality ◽  
Optimal Parameters ◽  
On Line

Gas Metal Arc (GMA) welding is considered as a multi-parameter process that it’s hard to find optimal parameters for good welding. To overcome the problem, an artificial neural network based on the backpropagation algorithm was built to realize the relationships between process parameters and welding quality as output parameter. In this study, Mahalanobis Distance (MD) was employed to evaluate the availability of a given welding parameters which was proved to performance well in multivariate statistics. Input parameters such as welding current and arc voltage were chosen due to their significant influence on the welding quality. To improve the precision of given parameters’ evaluation, neural networks with different configurations were verified. The analyses on the measured and predicted MD by the proposed neural network were conducted. The proposed neural network based on the error backpropogation algorithm was proved to have high reliability to evaluate process parameters, which further makes it available in on-line monitoring system.

A Study on Experimental Design Methods for the Automatic GMA Welding Process

2019 ◽  
Vol 294 ◽  
pp. 119-123
Author(s):  
Zong Liang Liang ◽  
Tae Jong Yun ◽  
Won Bin Oh ◽  
Bo Ram Lee ◽  
Ill Soo Kim
Keyword(s):  
Experimental Design ◽  
Taguchi Method ◽  
Arc Welding ◽  
Gma Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Bead Width ◽  
Arc Welding Process

Generally, the welding parameters directly affect the weld forming and the joint performance. Because many parameters are involved in the automatic arc welding process, it is not realistic to use traditional experimental methods, such as full factorial design. Therefore, it is important to find out the good experimental design method to determine the welding parameters for optimal joint quality with a minimal number of experiments. Therefore, this study is aimed at investigating the effect of DOE (Design of Experiment) methods on bead width of mild steel parts welded by the automatic GMA (Gas Metal Arc) welding process. In this work, Taguchi method was used for studying the effect of the welding parameters on optimization of bead width, while Box-Behnken method was utilized to develop a mathematical model relating the bead width to welding parameters such as welding voltage, arc current, welding speed and CTWD (Contact Tip to Work Distance). The S/N (Signal-to-Noise) ratio and the ANOVA (Analysis of Variance) were employed to find the optimal bead width. Confirmation tests were carried out to validate the effectiveness of the Taguchi method. The experimental results show that welding current mainly affected the bead width. The predicted bead width of 3.12mm was in good agreement with the confirmation tests. With the regression coefficient analysis in the Box-Behnken design, a relationship between bead width and four significant welding parameters was obtained. A second-order model has also been established between the welding parameters and the bead width as welding quality. The developed model is adequate to navigate the design space.

Optimization of A-GTAW welding parameters for naval steel (DMR 249 A) by design of experiments approach

2015 ◽  
Vol 231 (3) ◽  
pp. 320-331 ◽  
Author(s):  
Rishi Pamnani ◽  
M Vasudevan ◽  
P Vasantharaja ◽  
T Jayakumar
Keyword(s):  
Design Of Experiments ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Gas Tungsten Arc Welding ◽  
Welding Parameters ◽  
Single Pass ◽  
Gas Tungsten Arc ◽  
Gtaw Process ◽  
Gas Tungsten

DMR249A steel is indigenously developed high strength low alloy (HSLA) steel. The steel is being used for construction of Indian Aircraft Carrier and other new ships under construction at various ship yards in India. In order to enhance the depth of penetration (DOP) achievable in a single pass for gas tungsten arc welding (GTAW) process, activated fluxes were developed for the steel. The process is called activated flux gas tungsten arc welding (A-GTAW). Design of experiments (DOE) approach was employed using response surface methodology (RSM) and Taguchi technique to optimize the welding parameters for achieving maximum DOP in a single pass. Design matrix was generated using DOE techniques and bead on plate experiments were carried out to generate data for influence of welding process variables on DOP. The input variables considered were current, torch speed, and arc gap. The DOP was considered as response variable. The equations correlating DOP with the process parameters were developed for both the optimization techniques. The identified optimum process parameters were validated by carrying out bead on plate experiments. The RMS error of the predicted and measured DOP values for the validation experiments of the RSM (D-optimal) and Taguchi optimization technique was found to be 0.575 and 0.860, respectively. Thus, RSM (D-optimal) was observed to predict optimized welding process parameters for achieving maximum DOP with better accuracy during A-GTAW process.

Assessment of the Influence of Welding Parameters on Distortion

2014 ◽  
Vol 597 ◽  
pp. 208-212
Author(s):  
Fábio Renck Locatelli ◽  
Walter Jesus Paucar Casas ◽  
Ricardo Frederico Leuck Filho
Keyword(s):  
Welding Speed ◽  
Three Dimensional ◽  
Welding Process ◽  
Physical And Mechanical Properties ◽  
Element Model ◽  
Welding Parameters ◽  
Welding Sequence ◽  
Dimensional Finite Element ◽  
Definition Of ◽  
Three Dimensional Finite Element

The welding involves the transfer of high localized heat flow, which results in residual stresses in the welded body. The impossibility of relieving these stresses generates welding distortions that become a problem in dimensional setting of welded structures. This study aims to evaluate the influence of some parameters in the welding process in a T-type joint. Due to the complexity of the welded joint and the deposition rate, a three-dimensional finite element model was developed for the solution of the temperature field and distortions. The transient thermal analysis used the Goldak equation for definition of the heat flux transferred to the part. The nonlinear characteristics of the phenomenon as well as the dependence of physical and mechanical properties with the temperature were considered in this work. The parameters studied were the welding speed, welding sequence and cooling time between weld beads. The results suggest that the higher welding speed, the welding sequence forward and back and with cooling interval between beads present themselves as the best parameters for welding with lower distortions.

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