Inductor for Uniform Bulk Heat Treatment of Welded Butt Joints of Railway Rails

2021 ◽  
Vol 313 ◽  
pp. 72-81
Author(s):  
O. Prokof’iev ◽  
R. Gubatyuk ◽  
S. Rymar ◽  
V. Sydorets ◽  
Valery Kostin
Keyword(s):  
Heat Treatment ◽  
Reactive Power ◽  
Butt Joint ◽  
Heating Zone ◽  
Butt Joints ◽  
Butt Welding ◽  
Bulk Heating ◽  
Urgent Task ◽  
Variable Distance ◽  
Temperature Levels

To improve the structure of metal in welded butt joints of railway rails produced by flash-butt welding and increase the reliability of butt joints, it is advisable to carry out their induction heat treatment using high-frequency currents. Solving the problem of a uniform bulk heating of weld metal of railway rails in a narrow area during its heat treatment remains an urgent task. The work describes the principle of designing an inductor without magnetic cores for carrying out a uniform bulk heat treatment of welded butt joints of railway rails for realization of favorable phase transformations of metal and normalization of its structure. The principle is based on the physical laws of propagation of electromagnetic fields and electric currents in the inductor and a rail. Based on the carried out investigations, an inductor was designed that has a variable shape along the perimeter of a rail and a variable distance from it, as well as a partial splitting of the inductor busbar for current parallelization, which provides a uniform bulk heating of a rail butt joint. Splitting of the inductor busbar allowed adjusting the propagation of currents in the inductor and a rail in such a way as to avoid overheating of a rail in its particular areas without a significant increase in the distance between the inductor and a rail, and respectively without a significant increase in the reactive power of the “inductor-product” system. The carried out experiments on heating the welded butt joint of a rail by the designed inductor showed the indices of uniformity and rate of its bulk heating, which are acceptable for heat treatment of rails both on the surface as well as in the depth of a rail in a narrow heating zone with providing the required temperature levels.

Combined Butt Joint Welding and Post Weld Heat Treatment Simulation Using SYSWELD and ABAQUS

2011 ◽  
Vol 225 (1) ◽  
pp. 1-10 ◽  
Author(s):  
A A Deshpande ◽  
D W J Tanner ◽  
W Sun ◽  
T H Hyde ◽  
G McCartney
Keyword(s):  
Heat Treatment ◽  
Butt Joint ◽  
Post Weld Heat Treatment ◽  
Weld Heat

Microstructure and mechanical properties of ADC12/6063-T6 aluminum alloy butt joint achieved by metal inert gas groove welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2120-2124
Author(s):  
Ye Wang ◽  
Mi Zhao ◽  
Hongyu Xu ◽  
Maoliang Hu ◽  
Zesheng Ji
Keyword(s):  
Mechanical Properties ◽  
Arc Welding ◽  
Welding Process ◽  
Weld Interface ◽  
Butt Joint ◽  
Inert Gas ◽  
Butt Joints ◽  
Arc Welding Process ◽  
The Impact ◽  
Silicon Particles

Metal inert gas arc welding process was implemented to join 6063T6 wrought alloy and ADC12 die-casting alloy using ER4047 filler metal. The microstructure of the weld seam and weld interface was investigated. The bonding strength of the butt joints was tested by Charpy U-notch impact test and tensile test. The results showed that a sound welding butt joint with finely silicon particles and excellent mechanical properties was formed, and the size of the silicon particles was nearly 2 μm. Compared with 6063T6 wrought alloy, the impact absorbing energies and the tensile strengths of the butt joint were higher and reached 1.173 kJ/cm2 and 205 MPa, respectively, and the fractures of all tensile specimens occur at the 6063T6 aluminum.

Mechanical Behavior of Friction Stir Welded AA-6061 Thick Plates in Different Heat Treatment Conditions

2021 ◽  
Vol 875 ◽  
pp. 203-210
Author(s):  
Talha Ahmed ◽  
Wali Muhammad ◽  
Zaheer Mushtaq ◽  
Mustasim Billah Bhatty ◽  
Hamid Zaigham
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Aging Treatment ◽  
Travel Speed ◽  
Butt Joint ◽  
Tensile Fracture ◽  
Friction Stir ◽  
Treatment Conditions ◽  
Heat Treated ◽  
Joint Form

In this study, mechanical properties of friction stir welded Aluminum Alloy (AA) 6061 in three different heat treatment conditions i.e. Annealed (O), Artificially aged (T6) and Post Weld Heat Treated (PWHT) were compared. Plates were welded in a butt joint form. Parameters were optimized and joints were fabricated using tool rotational speed and travel speed of 500 rpm and 350 mm/min respectively. Two sets of plates were welded in O condition and out of which one was, later, subjected to post weld artificial aging treatment. Third set was welded in T6 condition. The welds were characterized by macro and microstructure analysis, microhardness measurement and mechanical testing. SEM fractography of the tensile fracture surfaces was also performed. Comparatively better mechanical properties were achieved in the plate with PWHT condition.

scholarly journals Effect of Backing Plate Materials in Micro-Friction Stir Butt Welding of Dissimilar AA6061-T6 and AA5052-H32 Aluminum Alloys

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 933
Author(s):  
SeongHwan Park ◽  
YoungHwan Joo ◽  
Myungchang Kang
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Heat Loss ◽  
Butt Joint ◽  
Thin Plates ◽  
Butt Welding ◽  
Friction Stir ◽  
Backing Plate ◽  
Base Materials ◽  
Tilting Angle

Thin sheets of lightweight aluminum alloys, which are increasingly used in automotive, aerospace, and electronics industries to reduce the weight of parts, are difficult to weld. When applying micro-friction stir welding (μ-FSW) to thin plates, the heat input to the base materials is considerably important to counter the heat loss to the jig and/or backing plate. In this study, three different backing-plate materials—cordierite ceramic, titanium alloy, and copper alloy—were used to evaluate the effect of heat loss on weldability in the μ-FSW process. One millimeter thick AA6061-T6 and AA5052-H32 dissimilar aluminum alloy plates were micro-friction stir welded by a butt joint. The tensile test, hardness, and microstructure of the welded joints using a tool rotational speed of 9000 rpm, a welding speed of 300 mm/min, and a tool tilting angle of 0° were evaluated. The heat loss was highly dependent on the thermal conductivity of the backing plate material, resulting in variations in the tensile strength and hardness distribution of the joints prepared using different backing plates. Consequently, the cordierite backing plate exhibited the highest tensile strength of 222.63 MPa and an elongation of 10.37%, corresponding to 86.7% and 58.4%, respectively, of those of the AA5052-H32 base metal.

scholarly journals Flash Welding of Microcomposite Wires for Pulsed Power Applications

Metals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 1053
Author(s):  
Nikolaj Višniakov ◽  
Jelena Škamat ◽  
Olegas Černašėjus ◽  
Artūras Kilikevičius
Keyword(s):  
Welded Joint ◽  
Butt Joint ◽  
Pulsed Power ◽  
Magnetic Systems ◽  
Butt Welding ◽  
Welding Technology ◽  
Welding Defects ◽  
Welding Joints ◽  
Strength And Plasticity ◽  
Flash Welding

This paper presents the experimental results of Cu-Nb wire joining upon applying flash welding technology. The present research is aimed at investigating the structure, electrical and mechanical properties of butt welding joints of Cu-Nb conductors, usable for coils of pulsed magnetic systems. The butt joint structure was found to be free of welding defects. The structure of the butt welded joint provides an insignificant increase in electrical resistance and sufficient ultimate strength and plasticity of the joint. The tensile strength of the welded sample reaches 630 MPa.

Simple Contact Stiffness Model Validation for Tie Bolt Rotor Design With Butt Joints and Pilot Fits

2019 ◽  
Vol 142 (1) ◽  
Author(s):  
Aaron M. Rimpel ◽  
Matthew Leopard
Keyword(s):  
Natural Frequencies ◽  
Contact Stiffness ◽  
Butt Joint ◽  
Design Stage ◽  
Design Calculation ◽  
Butt Joints ◽  
Modeling Approach ◽  
Stiffness Model ◽  
Joint Location ◽  
Simple Contact

Abstract Tie bolt rotors for centrifugal compressors comprise multiple shaft components that are held together by a single tie bolt. The axial connections of these rotors—including butt joints, Hirth couplings, and Curvic couplings—exhibit a contact stiffness effect, which tends to lower the shaft bending frequencies compared to geometrically identical monolithic shafts. If not accounted for in the design stage, shaft bending critical speed margins can be compromised after a rotor is built. A previous paper had investigated the effect of tie bolt force on the bending stiffness of stacked rotor assemblies with butt joint interfaces, both with and without pilot fits. This previous work derived an empirical contact stiffness model and developed a practical finite element modeling approach for simulating the axial contact surfaces, which was validated by predicting natural frequencies for several test rotor configurations. The present work built on these previous results by implementing the same contact stiffness modeling approach on a real tie bolt rotor system designed for a high pressure centrifugal compressor application. Each joint location included two axial contact faces, with contact pressures up to five times higher than previously modeled, and a locating pilot fit. The free-free natural frequencies for different amounts of tie bolt preload force were measured, and the frequencies exhibited the expected stiffening behavior with increasing preload. However, a discontinuity in the data trend indicated a step-change increase in the contact stiffness. It was shown that this was likely due to one or more of the contact faces becoming fully engaged only after sufficient tie bolt force was applied. Finally, a design calculation was presented that can be used to estimate whether contact stiffness effects may be ignored, which could simplify rotor analyses if adequate contact pressure is used.

Simple Contact Stiffness Model Validation for Tie Bolt Rotor Design With Butt Joints and Pilot Fits

2019 ◽  
Author(s):  
Aaron M. Rimpel ◽  
Matthew Leopard
Keyword(s):  
Natural Frequencies ◽  
Contact Stiffness ◽  
Butt Joint ◽  
Design Stage ◽  
Design Calculation ◽  
Butt Joints ◽  
Modeling Approach ◽  
Stiffness Model ◽  
Joint Location ◽  
Simple Contact

Abstract Tie bolt rotors for centrifugal compressors comprise multiple shaft components that are held together by a single tie bolt. The axial connections of these rotors — including butt joints, Hirth couplings, and Curvic couplings — exhibit a contact stiffness effect, which tends to lower the shaft bending frequencies compared to geometrically identical monolithic shafts. If not accounted for in the design stage, shaft bending critical speed margins can be compromised after a rotor is built. A previous paper had investigated the effect of tie bolt force on the bending stiffness of stacked rotor assemblies with butt joint interfaces, both with and without pilot fits. This previous work derived an empirical contact stiffness model and developed a practical finite element modeling approach for simulating the axial contact surfaces, which was validated by predicting natural frequencies for several test rotor configurations. The present work built on these previous results by implementing the same contact stiffness modeling approach on a real tie bolt rotor system designed for a high pressure centrifugal compressor application. Each joint location included two axial contact faces, with contact pressures up to five times higher than previously modeled, and a locating pilot fit. The free-free natural frequencies for different amounts of tie bolt preload force were measured, and the frequencies exhibited the expected stiffening behavior with increasing preload. However, a discontinuity in the data trend indicated a step-change increase in the contact stiffness. It was shown that this was likely due to one or more of the contact faces becoming fully engaged only after sufficient tie bolt force was applied. Finally, a design calculation was presented that can be used to estimate whether contact stiffness effects may be ignored, which could simplify rotor analyses if adequate contact pressure is used.

Effects of Pipe Dimensions and Outer Surface-Buttering Weld Conditions on Residual Stress Distributions

2008 ◽  
Author(s):  
Nobuyoshi Yanagida
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Outer Surface ◽  
Hoop Stress ◽  
Axial Stress ◽  
Butt Joint ◽  
Stress Distributions ◽  
The Finite Element Method ◽  
Butt Joints ◽  
Inner Surface

Effects of pipe dimensions and outer surface-buttering weld conditions on residual stress distributions were evaluated using the finite element method. Residual stresses were analyzed for 508–mm-diameter (500A) pipe 38.1 mm thick, 508–mm-diameter (500A) pipe 15.1 mm thick, and 267–mm-diameter (250A) pipe 15.1 mm thick. After the residual stresses at pipe butt joints were analyzed, residual stresses at these joints subjected to the outer surface-buttering welds were analyzed. Residual stresses were determined for various weld widths, thicknesses, and heat inputs. These analyses indicate that tensile axial stress occurred at inner surface of the pipe butt joint and that it decreased with increasing the outer surface buttering-weld width or heat input. They also indicate that compressive hoop stress occurred at inner surface of the joint and that outer surface-buttering weld increased it. The outer surface-buttering weld conditions that generate compressive residual stress at the inner surface of the pipe butt joints were determined.

Mixed Finite Element Analysis of Elastomeric Butt-Joints

2005 ◽  
Vol 129 (1) ◽  
pp. 11-18 ◽  
Author(s):  
P. A. Kakavas ◽  
G. I. Giannopoulos ◽  
N. K. Anifantis
Keyword(s):  
Finite Element ◽  
Strain Energy ◽  
Poisson Ratio ◽  
Mixed Finite Element ◽  
Three Dimensional ◽  
Butt Joint ◽  
Element Formulation ◽  
Butt Joints ◽  
Element Analysis ◽  
Strain Energy Density Function

This paper presents a mixed finite element formulation approximating large deformations observed in the analysis of elastomeric butt-joints. The rubber has been considered as nearly incompressible continuum obeying the Mooney/Rivlin (M/R) strain energy density function. The parameters of the model were determined by fitting the available from the literature uniaxial tension experimental data with the constitutive equation derived from the M/R model. The optimum value of the Poisson ratio is adjusted by comparing the experimentally observed diametral contraction of the model with that numerically obtained using the finite element method. The solution of the problem has been obtained utilizing the mixed finite element procedure on the basis of displacement/pressure mixed interpolation and enhanced strain energy mixed formulation. For comparison purposes, an axisymmetric with two-parameter M/R model and a three-dimensional (3D) with nine-parameters M/R model of the butt-joint are formulated and numerical results are illustrated concerning axisymmetric or general loading. For small strains the stress and/or strain distribution in the 2D axisymmetric butt-joint problem was compared with derived analytical solutions. Stress distributions along critical paths are evaluated and discussed.

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