Numerical Approach to Welding Process and its Integration in Assessment of Fatigue life of Component

2021 ◽  
Author(s):  
Anup Khandagale ◽  
Amol Apte ◽  
Kedar Tare
Keyword(s):  
Fatigue Life ◽  
Welding Process ◽  
Numerical Approach

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.

Characterization of Local Deformation in Welded Joints Using a Combined Experimental and Numerical Approach

2014 ◽  
Vol 627 ◽  
pp. 241-244 ◽  
Author(s):  
Pawel Kucharczyk ◽  
Sebastian Münstermann
Keyword(s):  
Chemical Composition ◽  
Weld Metal ◽  
Welded Joints ◽  
Base Material ◽  
Welding Process ◽  
Numerical Approach ◽  
Geometrical Model ◽  
Local Deformation ◽  
Heat Treated ◽  
Welded Structure

The microstructure of welded joints differs significantly from that of the base material, what changes their mechanical properties and influences fatigue life. The aim of this work was the investigation of the local deformation field within a butt joint made of 10 mm thick structural steel S355. However, a direct sampling even of the weld metal was impossible due to small dimensions of butt joints. Therefore, the following procedure was utilized in order to manufacture big samples of the microstructure identical to that of the local weldment areas.A geometrical model of the welded structure describing the relevant areas e.g. weld metal, heat-affected zone was established. It was based on the results of the metallographic investigations, hardness mapping and electron-probe-micro-analysis of the local chemical composition. The welding process was numerically simulated using SYSWELD program to estimate the time-temperature-transition (TTT) curves for each identified area. The parameters of the heat input source were calibrated. Afterwards, the material of the defined chemical composition was heat-treated according to the TTT curves. For the validation purpose the heat-treated work pieces were evaluated in terms of microstructure and hardness distribution. Finally, the up-scaled samples of the respective bulk microstructure were manufactured and investigated in monotonic tests.

Finite Element Analysis Model of Corrosion Fatigue for TIG Welding Workpiece

2016 ◽  
Vol 707 ◽  
pp. 154-158
Author(s):  
Somsak Limwongsakorn ◽  
Wasawat Nakkiew ◽  
Adirek Baisukhan
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Corrosion Fatigue ◽  
Welding Process ◽  
Simulation Software ◽  
Tig Welding ◽  
Element Analysis ◽  
Fea Model

The proposed finite element analysis (FEA) model was constructed using FEA simulation software, ANSYS program, for determining effects of corrosion fatigue (CF) from TIG welding process on AISI 304 stainless steel workpiece. The FEA model of TIG welding process was developed from Goldak's double ellipsoid moving heat source. In this paper, the residual stress results obtained from the FEA model were consistent with results from the X-ray diffraction (XRD) method. The residual stress was further used as an input in the next step of corrosion fatigue analysis. The predictive CF life result obtained from the FEA CF model were consistent with the value obtained from stress-life curve (S-N curve) from the reference literaturature. Therefore, the proposed FEA of CF model was then used for predicting the corrosion fatigue life on TIG welding workpiece, the results from the model showed the corrosion fatigue life of 1,794 cycles with testing condition of the frequency ( f ) = 0.1 Hz and the equivalent load of 67.5 kN (equal to 150 MPa) with R = 0.25.

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.

Fatigue Research on Welding Joint of the Main Girder in Bridge Crane

2013 ◽  
Vol 711 ◽  
pp. 323-326
Author(s):  
Nan Liu ◽  
Dong Xiang ◽  
Peng Mou ◽  
Ying Ren ◽  
Ning Xie
Keyword(s):  
Fatigue Life ◽  
Welding Process ◽  
Scientific Basis ◽  
Main Beam ◽  
Bridge Crane ◽  
Mechanical Products ◽  
Weld Fatigue ◽  
Model Set ◽  
Set Up ◽  
Main Girder

Fatigue problems about large sized structure components ,such as bridge crane girder , has always been the bottleneck of mechanical products lightweight, reliability, security. In order to study fatigue problem about crane girder in the actual conditions, the dangerous spot of the girder is identified by using the finite element method to analyze structural stress. By simplified model , set up to reflect the main beam welding details of the characteristics of the small size of the process welding fatigue specimen model, and carried out a series of fatigue life test. Specimen fatigue test results quantitative descript the actual fatigue life of the bridge crane girder welded structures. By data fitting, the S-N curve equation of the bridge crane girder include the specific materials, the stress ratio, the welding process and special structure is obtained. It provides a scientific basis and practical methods to solve weld fatigue life design and the remaining life prediction about the crane girder.

A Method to Study Fatigue Life of Ultrasonically Welded Lithium-Ion Battery Tab Joints Using Electrical Resistance

2014 ◽  
Author(s):  
Nanzhu Zhao ◽  
Wei Li ◽  
Wayne W. Cai ◽  
Jeffrey A. Abell
Keyword(s):  
Fatigue Life ◽  
Lithium Ion Battery ◽  
Fatigue Test ◽  
Electrical Resistance ◽  
Hybrid Electric Vehicle ◽  
Damage Mechanics ◽  
Welding Process ◽  
Lithium Ion ◽  
Damage Variable ◽  
Life Model

The fatigue life of ultrasonically welded lithium-ion battery tab joints is studied for electric and hybrid-electric vehicle applications. Similar to metallic materials, the electrical resistance of these ultrasonic welds strongly depends on their quality and the crack growth under fatigue loading. A fatigue life model is developed using the continuum damage mechanics formulation, where the damage variable is defined using the electrical resistance of ultrasonic welds. Fatigue tests under various loading conditions are conducted with aluminum-copper battery tab joints made under various ultrasonic welding conditions. It is shown that the electrical resistance of ultrasonic welds increases characteristically during the fatigue life test. There is a threshold for the damage variable, after which the ultrasound welds fail rapidly. Due to welding process variation, welds made under the same process settings may have different fatigue performance. This quality difference may be classified using two parameters estimated from the fatigue life model. By monitoring the electrical resistance, it is possible to predict the remaining life of ultrasonically welded battery tab joints using only a portion of the fatigue test data. The prediction is more reliable by incorporating data beyond the half-life of the joints during the fatigue test.

scholarly journals A numerical approach to evaluate the fatigue life of monolimb

2006 ◽  
Vol 28 (3) ◽  
pp. 290-296 ◽  
Author(s):  
Nian-Zhong Chen ◽  
Winson C.C. Lee ◽  
Ming Zhang
Keyword(s):  
Fatigue Life ◽  
Numerical Approach

Aeromechanical Modeling of Rotating Fan Blades to Investigate High-Cycle and Low-Cycle Fatigue Interaction

2015 ◽  
Vol 137 (5) ◽  
Author(s):  
Priyanka Dhopade ◽  
Andrew J. Neely
Keyword(s):  
Fatigue Life ◽  
Fracture Mechanics ◽  
Low Cycle Fatigue ◽  
Numerical Approach ◽  
Combined Loading ◽  
Design Stage ◽  
Cycle Fatigue ◽  
Mechanics Analysis ◽  
The Individual ◽  
Loading Spectrum

Gas turbine engine components are subject to both low-cycle fatigue (LCF) and high-cycle fatigue (HCF) loads. To improve engine reliability, durability and maintenance, it is necessary to understand the interaction of LCF and HCF in these components, which can adversely affect the overall life of the engine while they are occurring simultaneously during a flight cycle. A fully coupled aeromechanical fluid–structure interaction (FSI) analysis in conjunction with a fracture mechanics analysis was numerically performed to predict the effect of representative fluctuating loads on the fatigue life of blisk fan blades. This was achieved by comparing an isolated rotor (IR) to a rotor in the presence of upstream inlet guide vanes (IGVs). A fracture mechanics analysis was used to combine the HCF loading spectrum with an LCF loading spectrum from a simplified engine flight cycle in order to determine the extent of the fatigue life reduction due to the interaction of the HCF and LCF loads occurring simultaneously. The results demonstrate the reduced fatigue life of the blades predicted by a combined loading of HCF and LCF cycles from a crack growth analysis, as compared to the effect of the individual cycles. In addition, the HCF aerodynamic forcing from the IGVs excited a higher natural frequency of vibration of the rotor blade, which was shown to have a detrimental effect on the fatigue life. The findings suggest that FSI, blade–row interaction and HCF/LCF interaction are important considerations when predicting blade life at the design stage of the engine. The lack of available experimental data to validate this problem emphasizes the utility of a numerical approach to first examine the physics of the problem and second to help establish the need for these complex experiments.

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