Effect of the welding process on microstructure, microhardness and residual stresses of capacitor discharge stud welded joint

2021 ◽  
pp. 1-23
Author(s):  
Qian Zhang ◽  
Bao-Zhu Zhang ◽  
Yun Luo ◽  
Gang Yang ◽  
Hong-xiang Zheng
Keyword(s):  
Residual Stresses ◽  
Weld Joint ◽  
Weld Seam ◽  
Welded Joint ◽  
Weld Zone ◽  
Welding Process ◽  
Capacitor Discharge ◽  
Stud Welding ◽  
Carbon Plate ◽  
Extension Length

Abstract Capacitor discharge (CD) stud welding is a common and fast connection technology. This paper presents an experimental and simulation study of the stud weld joint of copper stud and carbon plate. An optimized stud welding process was proposed based on microstructure, microhardness and residual stresses of CD stud welded joint. The results show that a narrow weld seam with widmanstaten structure were formed because of quickly cooling. For the longer stud extension length, the width of weld zone becomes wider and the microstructure becomes more uniform. As the increase of welding voltage and stud extension length, the microhardness increases then decreases. However, the residual stresses are increased with welding voltage increases, while they are decreased with the increases of stud extension length. The optimized welding voltage and stud extension length should be designed to 90 V and 5 mm, respectively. This study will provide a great significance to the stud welding on site.

Analysis of Welded Joint Under Residual Stresses

2014 ◽  
Author(s):  
H. P. Jawale ◽  
Rahul Singh
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joint ◽  
Weld Zone ◽  
Welding Process ◽  
Fatigue Behaviour ◽  
Hole Drilling ◽  
Building Structures ◽  
Residual Stress Field ◽  
Stress Relieving

Welded joint is most commonly used for building structures and machine components. Welding process involves heating followed by uneven cooling causing residual stress field. In conjunction with stresses due to external loads, in-service behaviour is affected due to residual stress in welded components. It induces defects, also alters crack initiation life, fatigue behaviour, breaking strength, corrosion resistance and increases the susceptibility of structure to failure by fracture. The residual stress is function of cooling rate and the size of weld. The role of residual stress associated with welding is therefore very important while designing mechanical parts. Conventional methods like heat treatment and shot-peening techniques becomes difficult to be applied for reduction of residual stress in general purpose applications. The work presented in this paper describes the measurement of residual stress using stress relieving method, based on hole-drilling technique. Subsequently, residual stresses are relived and measured using strain rosette near the weld zone. These strains value is converted in to stress value. Residual stress is quantified with respect to yield strength, making it possible to be considered for safe designing of weld components.

Investigation on the effects of the joint type on the driven out bead in the welded pipes produced by high-frequency induction welding

2020 ◽  
pp. 146442072097343
Author(s):  
M Ghaffarpour ◽  
D Akbari ◽  
H Moslemi Naeini
Keyword(s):  
Mechanical Properties ◽  
Weld Joint ◽  
High Frequency ◽  
Weld Zone ◽  
Welding Process ◽  
Solid Material ◽  
Outer Diameter ◽  
Metallurgical Properties ◽  
Semi Solid ◽  
High Frequency Induction

In this paper, the effects of the joint type on the driven-out bead of the roll-formed pipes, welded by high-frequency induction welding process are studied. The main goal is to predict and reduce the volume of the bead driven out in the weld seam. Moreover, it aims to move the semi-solid bead during welding to the outer diameter of the pipe. This study has two prior aims: to produce a defect-free joint and to improve the mechanical and metallurgical properties. In order to optimize the weld joint, various joint types have been investigated by experimental tests and simulation. Lastly, destructive tests were used to determine if the desired mechanical properties of the weld joint were obtained. The metallurgical properties and the derivation of the semi-solid material in the weld zone have both been investigated in terms of microstructure. According to the results, the proper joint type improves the mechanical properties by 5% and reduces the volume of the weld bead about 45%.

Welding Technology Research for the Train Bogie

2013 ◽  
Vol 423-426 ◽  
pp. 784-787
Author(s):  
Gang Wang ◽  
Zhi Gang Chen
Keyword(s):  
High Resistance ◽  
Weld Joint ◽  
Welded Joint ◽  
Welding Process ◽  
Technology Research ◽  
Process Scheme ◽  
High Quality ◽  
Process Testing ◽  
Welding Technology ◽  
High Fatigue

Train bogie weld joint requirements with well toughness, high fatigue resistance and high resistance to overload. This article analied the weldability of SMA490BW steel, Combining with the characteristics of train bogie structure, a welding process scheme which had been used in practical productionwas worked out . Process testing and assessment results showed the process can obtain high quality welded joint.

scholarly journals Thermal and structural modelling of arc welding processes: A literature review

2019 ◽  
Vol 52 (7-8) ◽  
pp. 955-969 ◽  
Author(s):  
Hitesh Arora ◽  
Rupinder Singh ◽  
Gurinder Singh Brar
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Arc Welding ◽  
Weld Zone ◽  
Welding Process ◽  
Thermomechanical Analysis ◽  
Inert Gas ◽  
Welding Distortion ◽  
Structural Modelling ◽  
Welding Processes

This paper presents a state-of-the-art critical review of the thermal and structural modelling of the arc welding process. During the welding process, high temperature in the welding zone leads to generation of unwanted residual stresses and results in weld distortion. Measurement of the temperature distribution was a key issue and challenge in the past decade. Thermomechanical analysis is among the best-known techniques to simulate and investigate the temperature distribution, welding distortion and residual stresses in the weld zone. The main emphasis of this review is the thermal and structural modelling of welding processes and the measurement of welding residual stresses using different techniques. The study also provides information about the various types of heat sources and models used to predict the weld bead characteristics and thermomechanical analysis for different welding processes such as tungsten inert gas welding, metal inert gas welding and shielded metal arc welding.

Microstructure and Mechanical Properties of GMAW Welded Joints Er-Containing Aluminum Alloy

2020 ◽  
Vol 993 ◽  
pp. 92-99
Author(s):  
Hao Zhen Guo ◽  
Li Cui ◽  
Hui Huang ◽  
Xiao Guo ◽  
Ding Yong He
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Penetration Depth ◽  
Welded Joint ◽  
Weld Zone ◽  
Welding Process ◽  
Welding Current ◽  
Depth Range ◽  
Arc Voltage ◽  
Microstructure And Mechanical Properties

This present work explored the welding process of gas metal arc welding for 4mm 5E61 Er-containing aluminum alloy, and then analyzed the microstructure and mechanical properties of the welded joint. The results demonstrated that when the welding current was 160A-220A, the welded joint penetration depth range was 5.75mm to 6.72mm, the melting width ranging from 9.68mm to 11.61mm. When the arc voltage increased from 17.5V to 22.5V, the penetration depth of the welded joint reduced from 6.95mm to 5.57mm, and the melting width ranged from 6.64mm to 11.86mm. When the welding current was 170A, the arc voltage was 17.5V, and the welding speed was 10mm/s. In the third case, a fully penetrated welded joint can be obtained and the joint strength was the highest value. The yield strength reached 192 MPa, the tensile strength can be 301 MPa, and the fracture location occurred in the HAZ. The weld zone of the welded joint mainly consist of the equiaxed dendrites size of 50 μm. The micro-hardness of the weld zone was lower than that of the base metal, and there was no obvious softening phenomenon in the heat affected zone.

scholarly journals Evaluation of residual stresses in a tube-to-plate welded joint

2019 ◽  
Vol 300 ◽  
pp. 19005 ◽  
Author(s):  
Andrea Chiocca ◽  
Francesco Frendo ◽  
Leonardo Bertini
Keyword(s):  
Residual Stresses ◽  
Numerical Simulations ◽  
Thermal Cycle ◽  
Transient Analysis ◽  
Welded Joint ◽  
Base Material ◽  
Welding Process ◽  
Deep Understanding ◽  
Experimental Tests ◽  
Temperature Dependent

A deep understanding of the manufacturing process is needed in order to achieve safety and quality requirements for parts and components; to this regard, residual stresses play an important role in welded structures. Residual stresses are mainly caused by the extremely severe thermal cycle to which the welded metal and base material are subjected to during welding process and their knowledge leads to a better static and fatigue assessment of welded joints. This work deals with the study of residual stresses for a tube to plate T-joint, made of S355JR carbon steel. The work was carried out by both numerical simulations and experimental tests. The numerical simulations were performed by Ansys FE code through a structural-thermal full transient analysis to evaluate stress, strain and temperature in each node at each step of the simulation. The “birth and death” method was employed, together with temperature-dependent material properties.A2Danda3D simulation were performed, in order to evaluate possible differences due to the welding process. Numerical results were compared to some preliminary measurements obtained through an incremental cut made on the plate.

Finite Element Analysis of Residual Stresses in TT-Welded Joint of a Fixed Jacket Platform

2006 ◽  
Author(s):  
Kh. Rostami ◽  
A. R. M. Gharabaghi ◽  
M. R. Chenaghlou ◽  
A. Arablouei
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Thermal Stresses ◽  
Welded Joint ◽  
Welding Process ◽  
Element Analysis ◽  
Welded Steel ◽  
Buckling Strength ◽  
Structural Distortions ◽  
Weld Toe

Welded steel tubular joints are the kind of connections used extensively in the construction of fixed jacket platforms. The welding process creates considerable tensile residual stresses near the toe of TT-joint due to the rapid cooling and contraction of final welding layers. Welding produces thermal stresses that cause structural distortions, which influence the buckling strength of the structure. In this study thermal elasto-plastic analysis is carried out using ANSYS finite element techniques to evaluate the thermo-mechanical behavior and the residual stresses of the TT-joint. Moreover, the technique of element birth and death is employed to simulate the weld filler variation with time in TT-joint. The results show the considerable tensile residual stress near the weld toe that it may cause crack initiation in this region and threats the fatigue life of joint.

Influence of filler material on the microstructure, mechanical properties, and residual stresses in tungsten inert gas welded Ti-5Al-2.5Sn alloy joints

2021 ◽  
pp. 146442072110124
Author(s):  
Asim Iltaf ◽  
Fahd Nawaz Khan ◽  
Tauheed Shehbaz ◽  
Massab Junaid
Keyword(s):  
Mechanical Properties ◽  
Residual Stresses ◽  
Fusion Zone ◽  
Welded Joint ◽  
Weld Zone ◽  
Martensitic Transformations ◽  
Inert Gas ◽  
Physical Chemical ◽  
Pile Up ◽  
Compressive Residual Stresses

The microstructure and defects in the weld zone affect the weldment characteristics. One way to improve the microstructure and reduce the defects in the weld zone is by using a filler during welding which influences the physical, chemical, and mechanical properties of the manufactured component. In the present study, tungsten inert gas (TIG) was used to weld Ti-5Al-2.5Sn alloy using different titanium alloy fillers; Ti-6Al-4V, Ti-5Al-2.5Sn, and autogenous weldments were also produced. The welded joints were characterized in terms of their microstructure, mechanical properties, and residual stresses in its various regions. The weldment with Ti-6Al-4V as filler exhibited a higher proportion of α′ martensite in fusion zone, as compared to the welded joint with Ti-5Al-2.5Sn alloy as filler, owing to the higher proportions of β stabilizers present in Ti-6Al-4V alloy. The α’ martensite was present in basketweave and acicular morphology in all the weldments, with and without fillers. Ti-6Al-4V filler welded joint showed higher tensile strength (approximately 1144 MPa) and relatively higher hardness than Ti-5Al-2.5Sn filler welded joint (approximately 1027 MPa) and autogenous weldment (approximately 770 MPa), due to increased amount of martensite in its fusion zone. As compared to the weldment produced with Ti-5Al-2.5Sn filler, the welded joint produced without filler and with Ti-6Al-4V as a filler had more compressive residual stresses at surface (approximately 25% higher), leading to less amount of pile up after nanoindentation. This was attributed to the generation of compressive strains due to martensitic transformations in the fusion zone of both these weldments.

scholarly journals Friction welding of Aluminium Alloy 6063 with copper

2020 ◽  
Vol 170 ◽  
pp. 02004
Author(s):  
Yashwant Chapke ◽  
Dinesh Kamble ◽  
Saoud Md. Salim Shaikh
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Weld Joint ◽  
Friction Welding ◽  
Joint Strength ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Material ◽  
Work Piece ◽  
Electrical Conductors

Friction welding process is a forging welding process in which work piece are joined due to heat produced by friction between two joining surfaces and upset pressure is applied by non-rotating work piece. Joining of aluminum alloy with dissimilar material is important research area to focus on as maximum aircraft structures havexx Aluminum alloy frame and aerospace designers familiar with Aluminum alloy and its design considerations. After comparison of mechanical properties and application of light weight alloys aluminum alloys, tungsten, stainless steel and copper, copper selected as dissimilar material to join with Aluminum alloy AA6063. AA 6063 also known as architectural alloy selected based upon its properties. This dissimilar joint of AA6063 and Copper has application in electrical conductors as copper is good electrical conductivity and used in maximum electrical conductors. In this research work AA6063 joined with Copper successfully using Rotary Friction Welding process. Through process study effective process parameters like Friction Pressure, Upset Pressure, Spindle Speed, and Friction Time identified and their effect on weld joint strength were studied.Testing for measuring UTS of friction welded joint conducted. Using DOE tool optimized set process parameters for friction welding identified and their effect on weld joint strength studied experimentally. Maximum UTS of 222.787 MPa for Friction welded joint achieved, bend test also performed on friction welded samples.

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