scholarly journals Study on Effect of Laser Process Parameters on Laser Transmission Weld Parameters using ANSYS

2021 ◽  
Vol 23 (07) ◽  
pp. 1050-1057
Author(s):  
Girish Kumar R ◽  
◽  
Abhay Agarwal ◽  
Utkarsha Mohan ◽  
Shounak Dey ◽  
...  
Keyword(s):  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Element Model ◽  
Weld Interface ◽  
Negative Influence ◽  
Maximum Temperature ◽  
Laser Transmission Welding ◽  
Weld Width ◽  
Weld Parameters

In recent years, a mode of welding that has garnered a considerable amount of interest is the laser transmission welding of thermoplastics. Laser transmission welding is now being used as an alternative to adhesives to join two thermoplastics. In this study, a finite element model has been developed to simulate the laser transmission welding of polypropylene. The movement of the laser beam was done using a Moving Heat Source in Ansys®. Process parameters namely laser power, welding speed, and the number of passes have been studied in order to investigate their effects on the temperatures and the weld widths achieved during welding. It was found that an increase in the laser power had a positive effect on the maximum temperature at the weld interface as well as the weld width. Similarly, an increase in the welding speed had a negative influence on the maximum temperature at the weld interface as well as the weld width.

Experimental Investigation on Laser Transmission Welding of Polycarbonate and Acrylic

2021 ◽  
pp. 160-180
Author(s):  
Dhiraj Kumar ◽  
Sudipta Paitandi ◽  
Arunanshu Shekhar Kuar ◽  
Dipankar Bose
Keyword(s):  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Optimum Parameter ◽  
Optimization Technique ◽  
Welding Process ◽  
Parameter Setting ◽  
Laser Transmission Welding ◽  
Weld Width

This chapter presents the effect of various process parameters, namely laser power, pulse frequency, and welding speed, on the weld shear strength and weld width using a diode laser system. Here, laser transmission welding of transparent polycarbonate and black carbon filled acrylic each of 2.8 mm thickness have been performed to create lap joint by using low power laser. Response surface methodology is applied to develop the mathematical model between the laser welding process parameters and the responses of weld joint. The developed mathematical model is tested for its adequacy using analysis of variance and other adequacy measures. It has been observed that laser power and welding speed are the dominant factor followed by frequency. A confirmation test has also been conducted to validate the experimental results at optimum parameter setting. Results show that weld strength of 34.3173 N/mm and weld width of 2.61547 mm have been achieved at optimum parameter setting using desirability function-based optimization technique.

Modeling of Weld Lap-Shear Strength for Laser Transmission Welding of Thermoplastic Using Artificial Neural Network

2012 ◽  
Vol 445 ◽  
pp. 454-459 ◽  
Author(s):  
M.R. Nakhaei ◽  
N.B. Mostafa Arab ◽  
F. Kordestani
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Shear Strength ◽  
Laser Welding ◽  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Laser Transmission Welding ◽  
Lap Shear Strength ◽  
Lap Shear

Laser welding of plastic materials has a wide range of applications in the packaging, medical, electronics and automobile industries provided it can predict high quality welds compared with other joining methods. Laser welding process parameters can affect the quality of welds. In this paper, Artificial Neural Network (ANN) is used to model the effects of laser power, welding speed, clamp pressure and stand-off distance on weld lap-shear strength in laser transmission welding (LTW) of acrylic (polymathy methacrylate). A set of experimental data on diode laser weld lap-shear strengths was used to train and test the ANN from which the neurons relations were gradually extracted to develop a model. The developed ANN model can be used for the analysis and prediction of the complex relationships between the above mentioned process parameters and weld lap-shear strength. The results indicated that increase in laser power and clamp pressure increases the weld lap-shear strength whereas welding speed and stand off distance had a decreasing affect on shear strength at high value.

Effect of process parameters on temperature and force distribution during friction stir welding of armor-marine grade aluminum alloy

2020 ◽  
Vol 235 (1-2) ◽  
pp. 144-154 ◽  
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra
Keyword(s):  
Friction Stir Welding ◽  
Real Time ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Low Cost ◽  
Maximum Force ◽  
Maximum Temperature ◽  
Force Distribution ◽  
Friction Stir

This research investigates the effect of process parameters on real-time temperature and forces distribution during friction stir welding of AA7039. Experiments are conducted at different rotational speed, welding speed, and tilt angle conditions. For the experimentation, a low-cost real-time force-measuring fixture is indigenously developed in-house. However, eight K-type L-shaped thermocouples are used to examine the real-time temperature distribution. The forces in the z-direction are of a higher magnitude than the x-direction. The maximum force in the z-direction of 3.25 kN is witnessed for 2° tilt angle and a minimum of 2.1 kN for 26 mm/min of welding speed. The maximum force in the x-direction of 0.97 kN is obtained at 2° tilt angle and a minimum of 0.27 kN is obtained at 1.3° tilt angle. The maximum temperature of 390 °C is observed at 1812 r/min, whereas a minimum of 283 °C is observed at 43 mm/min of welding speed. The variations in temperature and force distribution during friction stir welding are also evaluated by utilizing two phenomenological models.

scholarly journals Numerical Simulation of Moving Heat Flux during Selective Laser Melting of AlSi25 Alloy Powder

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 877
Author(s):  
Cong Ma ◽  
Xianshun Wei ◽  
Biao Yan ◽  
Pengfei Yan
Keyword(s):  
Numerical Simulation ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Molten Pool ◽  
Laser Power ◽  
Scanning Speed ◽  
Powder Layer ◽  
Maximum Temperature ◽  
Three Dimensional Model ◽  
Laser Melting

A single-layer three-dimensional model was created to simulate multi-channel scanning of AlSi25 powder in selective laser melting (SLM) by the finite element method. Thermal behaviors of laser power and scanning speed in the procedure of SLM AlSi25 powder were studied. With the increase of laser power, the maximum temperature, size and cooling rate of the molten pool increase, while the scanning speed decreases. For an expected SLM process, a perfect molten pool can be generated using process parameters of laser power of 180 W and a scanning speed of 200 mm/s. The pool is greater than the width of the scanning interval, the depth of the molten pool is close to scan powder layer thickness, the temperature of the molten pool is higher than the melting point temperature of the powder and the parameters of the width and depth are the highest. To confirm the accuracy of the simulation results of forecasting excellent process parameters, the SLM experiment of forming AlSi25 powder was carried out. The surface morphology of the printed sample is intact without holes and defects, and a satisfactory metallurgical bond between adjacent scanning channels and adjacent scanning layers was achieved. Therefore, the development of numerical simulation in this paper provides an effective method to obtain the best process parameters, which can be used as a choice to further improve SLM process parameters. In the future, metallographic technology can also be implemented to obtain the width-to-depth ratio of the SLM sample molten pool, enhancing the connection between experiment and theory.

Linear Friction Welding of IN-718 Process Optimization and Microstructure Evolution

2006 ◽  
Vol 15-17 ◽  
pp. 357-362 ◽  
Author(s):  
Caroline Mary ◽  
Mohammad Jahazi
Keyword(s):  
Process Parameters ◽  
Microstructure Evolution ◽  
Friction Welding ◽  
Welding Process ◽  
Weld Interface ◽  
Maximum Temperature ◽  
Linear Friction Welding ◽  
Influence Of Process Parameters ◽  
Linear Friction ◽  
The Matrix

Linear Friction Welding (LFW) of IN-718 Superalloy was investigated under several processing conditions. The influence of process parameters such as frequency (60Hz to 100Hz), amplitude (2mm to 3mm) and frictional pressure (50MPa to 110MPa) on the microstructure and mechanical properties of welded specimens was determined. Optical and scanning electron microscopy, and micro-hardness testing were used to characterize the welded areas as well as the Thermo-Mechanically Affected Zones (TMAZ). In-situ thermocouple measurements were performed to follow temperature evolution in the specimens during the different phases of the LFW process. The analysis of the results indicated that for some specific conditions (f=80Hz, a=2mm and P=70MPa) a maximum temperature of 1200°C was attained during the last stage of the welding process, the burn-off phase. This temperature, very close to the alloy melting range, would be sufficient to cause partial liquation in this zone. Microscopic examinations revealed the presence of oxide particles aligned around the weld interface. Their concentration and distribution, varying with process parameters, affect the weld integrity. The TMAZ characterised by a global loss of strength (from 334HV to 250HV) is associated with temperatures exceeding 800°C and causing γ’ and γ’’ reversion. A narrow band of the TMAZ, exposed to high strains and temperatures, showed evidences of dynamic recovery and recrystallization (up to 67% of reduction in the matrix grain size). Visual and microscopic examination of the flash layer, revealed two distinct zones. Microstructure evolution and microhardness variations were associated to process parameters and the optimum conditions for obtaining defect free weldments were determined.

scholarly journals Mechanical and Metallurgical Properties of CO2 Laser Beam INCONEL 625 Welded Joints

2021 ◽  
Vol 11 (15) ◽  
pp. 7002
Author(s):  
Harinadh Vemanaboina ◽  
Edison Gundabattini ◽  
Suresh Akella ◽  
A. C. Uma Maheshwar Rao ◽  
Ramesh Kumar Buddu ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Laser Beam ◽  
Co2 Laser ◽  
Process Parameters ◽  
Welding Speed ◽  
Welded Joints ◽  
Laser Power ◽  
Inconel 625 ◽  
Bead Geometry ◽  
Full Penetration

In the frame of the circular economy, welding of Ni-based superalloys has gained increasing importance when applied, for instance, to repairing highly expensive components widely used in strategical sectors, such as the defense and aerospace industries. However, correct process parameters avoiding metallurgical defects and premature failures need to be known. To reach this goal, Inconel 625 butt-welded joints were produced by CO2 laser beam welding and different combinations of process parameters. The experimental investigation was carried out with three parameters in two levels with an L4 orthogonal array. Laser power, welding speed, and shielding gas flow rate were varied, and the results were reported in terms of mechanical properties, such as microhardness, tensile strength, distortion, residual stress, and weld bead geometry, and metallurgy. At a lower welding speed of 1 m/min, the full penetration was observed for 3.0 kW and 3.3 kW laser powers. However, sound welds (porosity-free) were produced with a laser power of 3.3 kW. Overall, the obtained full-penetration specimens showed a tensile strength comparable with that of the parent material with residual stresses and distortions increasing with the increase in heat input.

Experimental and Finite Element Modeling of Friction Stir Seal Welding of Tube-Tubesheet Joint

2012 ◽  
Vol 445 ◽  
pp. 771-776 ◽  
Author(s):  
Fadi Al-Badour ◽  
N. Merah ◽  
A.N. Shuaib ◽  
A. Bazoune
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Axial Load ◽  
Solidus Temperature ◽  
Metal Flow ◽  
Material Model ◽  
Element Model ◽  
Fusion Welding ◽  
Maximum Temperature ◽  
Friction Stir

Tube-tubesheet joints are critical in some applications, where contact between shell and tube side fluids is not tolerable. To ensure joint tightness, standards (ASME and TEMA) recommend performing a combination of rolling-or expansion of tube-tubesheet and seal welding. Available techniques for seal welding are based on fusion welding that sometimes results in a number of defects such as cracking and porosity formation, and such defects may take a newly fabricated heat exchanger out of service. In this work, friction stir welding (FSW) was used for tube-tubesheet seal joint and simulated using a 3D thermo-mechanical finite element model (FEM). The model was analyzed using a commercial finite element (FE) package. The model included the thermal effect of the tool workpiece interaction along with axial load, ignoring the metal flow around the tool. The material model took into account temperature dependency of thermal and mechanical properties. The model objectives were to evaluate the temperature distribution and residual stress in the workpiece resulting from the thermal cycle and axial load during welding for various process parameters, and to study how residual stresses in adjacent roller expanded tubes are affected during welding. The FE results show that the maximum temperature at the welding zone does not exceed the solidus temperature (except at high tool rotational speeds); the process can thus be classified as cold working. Moreover, adjacent tubes temperature does not exceed the annealing temperature. An experimental setup was designed and manufactured to show the feasibility of the process in this constrained size joints and to validate the numerical results. A test cell and a special FSW tool were designed and manufactured for this purpose. Many tests were performed with welding quality depending on process parameters.

scholarly journals Investigation of the Effect of Process Parameters on the Break of Laser-welded Drill Bits

2020 ◽  
Vol 3 (2) ◽  
pp. 76-80
Author(s):  
Attila Zsolt Kenéz ◽  
Gyula Bagyinszki
Keyword(s):  
Process Parameters ◽  
Welding Speed ◽  
Laser Power ◽  
Test Results ◽  
Shielding Gas ◽  
Technological Parameters ◽  
Drill Bits ◽  
Welding Position

AbstractThe geometry and microstructure of the seam can be influenced by changing technological parameters such as laser power, welding speed, focus distance and shielding gas. In this research we examine the effect of laser power and focus distance on the quality of the breaking torque value while the welding speed and the shielding gas is unchanged. From the test results, we found that changing the defocus has no effect; a change in laser power affects ~15 %, while a change in welding position significantly affects the breaking torque.

Laser Transmission Welding of Nylon Tubes and Plates

2010 ◽  
Vol 132 (5) ◽  
Author(s):  
A Kritskiy ◽  
G. Zak ◽  
P. J. Bates
Keyword(s):  
Shear Strength ◽  
Laser Beam ◽  
Process Parameters ◽  
Laser Power ◽  
Angular Speed ◽  
Joint Shear Strength ◽  
Laser Transmission Welding ◽  
Joint Shear ◽  
Number Of Passes ◽  
Conical Mirror

In this study, nylon tubes were welded to nylon plaques using laser transmission welding. A conical mirror inserted inside the tube was used to guide the laser beam along the weld path around the inner circumference of the tube. The effect of beam location with respect to the tip of conical mirror on beam distortion was modeled and assessed experimentally. The effects of the laser power, the angular speed, and the number of passes on the joint shear strength were examined. Process parameters that gave good joint strengths were identified.

scholarly journals An FEA based study of thermal behaviour of ultrasonically welded phosphor bronze sheets

2021 ◽  
Vol 15 (2) ◽  
pp. 8057-8071
Author(s):  
Bharat Sanga ◽  
Reeta Wattal ◽  
D. S. Nagesh
Keyword(s):  
Element Model ◽  
Weld Interface ◽  
Heat Fluxes ◽  
Weld Strength ◽  
Maximum Temperature ◽  
Interface Temperature ◽  
Bonding Ratio ◽  
Simulated Temperature ◽  
Lower Temperature ◽  
Strong Linear Relationship

The ultrasonic joining of phosphor bronze sheets is analyzed using a 3-D finite element model for the study and prediction of the thermal profiles at the weld interface. The heat fluxes are calculated and assigned as boundary conditions during the thermal simulation. The forecast of temperature is done under various welding conditions. The maximum temperature obtained by transient simulation at the weld interface is 366.74℃. The continuous reduction in the temperature is observed towards the extremes of the weld metal. The sonotrode and the anvil achieve a lower temperature in comparison to the weld interface. The effect of clamping force and bonding ratio on the interface temperature is observed as positive. The model is validated with an error of 1.576% between the observed and predicted temperature results and a correlation co-efficient 0.96 is established between the simulated temperature results and the weld strength. Sufficiently strong joints were obtained at the optimum welding conditions with 74% joint efficiency. It is evident that the interface temperature has a strong linear relationship with joint strength and is a major deciding factor for achieving strong joints.

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