A Study on Welding Deformation in Fiber Laser Welding of 9% Nickel Steel through Finite Element Analysis Part I: Implementation of Welding Heat Source Model

Due to various environmental regulations, the demand for natural gas, i.e., a clean energy, is expected to increase continuously. In terms of efficient storage and transportation of natural gas, liquefied natural gas has an advantageous volume of 1/600 compared to natural gas, but the materials that can be used at a cryogenic temperature of −163 °C are limited. A 9% nickel steel is a material recommended by IMO through IGC. It has excellent mechanical properties compared to other cryogenic materials, but its use has been limited due to its disadvantages in arc welding. Therefore, the main topic of this study is the automatic welding of 9% nickel steel using fiber laser and its purpose is to predict the welding deformation during fiber laser welding. First, an investigation was conducted to find the fiber laser welding heat source. A model that can cover all the models in prior studies such as curve, exponential, conical, conical-conical combination, and conical-cylinder combination models was proposed and the heat source model was constructed in a multi-layer format. Heat transfer analysis was performed using the ratio of a heat source radius and heat energy of each layer as a variable and the pass or failure of a heat source was determined by comparing the analysis results to the experimental results. By changing the variables in conjunction with the optimization algorithm, the main parameters of a passed heat source model were verified in a short period of time. In addition, the tendency of parameters according to the welding speed was checked.

Fast Prediction for Resistance Spot Welding Deformation Using Inherent Strain Method and Nugget Model

In a car body, there exist thousands of resistance spot welds, which may induce large deformation during the manufacturing process. Therefore, it is expected that automotive industries will develop a method and a computing system for the fast and simple prediction of its deformation. Although the inherent strain method has been used for the fast prediction of arc welding deformation, it has not been applied to resistance spot welding so far. Additionally, the electrical-thermal-mechanical coupling analysis for the deformation induced by resistance spot welding is complicated and much more time-consuming. Therefore, in this study, a nugget model of the resistance spot weld has been developed, and the inherent strain method is extended for use in the fast prediction of resistance spot welding deformation. In addition, the deformation of a vehicle part with 23 resistance spot welds was efficiently predicted within around 90 min using the inherent strain method, displaying good accuracy compared with the measurement.

A Study on Minimizing Welding Deformation of Joints for the Sealing of Emission After-Treatment Structure

As the environmental pollution issue has recently become significant, environmental regulations in Europe and the United States are being strengthened. Thus, there is a demand for the quality improvement of emission after-treatment systems to satisfy the strengthened environmental regulations. Reducing the amount of welding heat distortion by optimization of the welding order of each part could be a solution for quality improvement since the emission after-treatment system consists of many parts and each assembly is produced by welding individual ones. In this research, a method to derive a welding sequence that effectively minimizes welding deformation was proposed. A two-stage simulation was performed to obtain the optimal welding sequence. In the first stage, the welding sequence was derived by analyzing the number of welding groups in each assembly of a structure. The derived welding sequence was verified by performing a thermal elasto-plastic analysis and comparing it with the experimental results.

Influence of welding deformation on anti-collapse performance of single-layer reticulated shell structures with prestressed cables

In this paper, the ABAQUS finite element software is used to model and analyze the single-layer reticulated shell structure. And the method of removing the constraints of key components is used to analyze the anti-continuous collapse performance of this reticulated shell structure under the action of geometric defects and welding deformation. Welding deformation is mainly caused by welding and prestressed cable tensioning of single-layer reticulated shell. The results show that the removal of the key columns under the reticulated shell will lead to the continuous collapse of the upper part, which leads to the continuous collapse of the whole structure, and the welding deformation can make the continuous collapse of the whole reticulated shell more obvious. Thus determining the influence of geometric defects and temperature shrinkage deformation on the anti-continuous collapse performance.

Influence of welding sequence on the mechanical properties of a latticed shell formed by orthogonal and oblique members

With the development of economy and the improvement of people’s aesthetic level, large-span latticed shells are increasingly used. Such structures are commonly large in volume and huge in welding. In order to select an optimum welding sequence and avoid correcting complex welding deformation, a latticed shell formed by orthogonal and oblique members was taken as the research object in this paper. The finite element models of single and whole latticed shells were established respectively, and according to the equal deformation principle, the influence of different welding sequence on the deformation and internal force of the structure in each construction stage was quantitatively analyzed. The results show that in the welding and assembling stage of small assembling units in the single latticed shell, welding sequence has the greatest impact on the longitudinal deformation, and the change rate of the longitudinal deformation is up to 83.63%; whereas in the tension, sliding and closure stages of each piece of the latticed shell, the transverse deformation is most affected by welding sequence, and the change rate is 33.05%; in different construction stages, the axial stress of the latticed shell is less vulnerable to welding sequence. Furthermore, it is feasible to control the welding shrinkage deformation by selecting a reasonable welding sequence, and the symmetrical welding sequence from both ends to the middle should be adopted during construction.

Multi-Objective Optimization of MIG Welding and Preheat Parameters for 6061-T6 Al Alloy T-Joints Using Artificial Neural Networks Based on FEM

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.