Welding International最新文献

{"title":"Estimation of heat source model parameters for partial penetration of TIG welding using numerical optimization method","authors":"Sumanlal M. S., Sivasubramaniyan N. S., Joy Varghese V. M., Shafeek M, Ananthan D. Thampi","doi":"10.1080/09507116.2023.2242777","DOIUrl":"https://doi.org/10.1080/09507116.2023.2242777","url":null,"abstract":"Abstract Heat source parameters have a greater influence on the accuracy of numerical modelling for predicting residual stress and temperature field. Experimental measurements of stress and temperature during arc welding are cumbersome due to dynamic transfer of heat happening in a very short span of time. So, for modelling such a high temperature process, determining the heat source model parameters are critical. In this article, a novel method for figuring out the double ellipsoid heat distribution model’s heat source parameters is demonstrated. Here, finite element analysis (FEA) is done to predict the weld bead dimensions, thermal and structural cycles of tungsten inert gas (TIG) welding of AISI S304 stainless steel plates. 25 different sets of heat source parameters are generated for 100 and 120 A input power separately. Using this generated values, weld bead dimensions are determined from the simulation. The optimization is done with the Taguchi technique taking root mean square error (RMSE) value of heat source parameters and measured weld bead dimensions as response parameters. The model is validated using experimental data and the effects of each parameter on weld pool formation during TIG welding are also studied. Optimum values of heat source parameters for stainless steel AISI 304 at 100 A welding current are 2.3283, 2.3687 and 2.667, respectively, and that for 120 A weld current are 2.5909, 2.613 and 3.4949, respectively. The prediction of temperature and welding residual stress (WRS) distribution using optimizing heat source model parameters shows closer approximation with experimental results. The demonstrated model is very much reliable and simple to predict the heat source parameters for TIG welding with partial penetration with a very lesser number of operations and minimum error.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"400 - 416"},"PeriodicalIF":0.0,"publicationDate":"2023-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43922069","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Design performance optimization of laser beam welded joints made for vehicle chassis application using deep neural network-based Krill Herd method","authors":"Sanjay S. Surwase, S. Bhosle","doi":"10.1080/09507116.2023.2233889","DOIUrl":"https://doi.org/10.1080/09507116.2023.2233889","url":null,"abstract":"Abstract The welding to be performed must be defect free, offer lower residual stress and strain, be compact in size and withstand different load conditions. However, the existing investigations in this scenario are still not modernized. Therefore, in this study, a specific welding method called laser beam welding (LBW) is performed and different weld parameters have been inspected and analysed. Advanced instruments based on the non-destructive (ND) are implemented to find the variable LBW responses such as weld bead defects, residuals and strain. The experimentation has been designed using Design Expert software, response surface methodology (RSM) and Box Behnken design (BBD) and verified by analysis of variance (ANOVA) analysis and FIT statistics. Moreover, a hybrid deep neural network-based Krill Herd optimization (DNN-KHO) is implemented to predict the output parameters like, undercut (µm), overlap (µm), total strain (mm/mm) and residual stress (MPa) during welding. The proposed DNN-KHO was also used to optimize LBW input parameters such as, peak power (W), weld speed (mm/s), gas flow rate (l/min) and beam diameter (µm) simultaneously. Predictions show that the proposed DNN-KHO algorithm outperformed by 21.53%, 45.428% and 41.31% higher in accuracy compared to respective hybrid random forest based grey wolf method (RF-GWO), RF and DNN predictions.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"365 - 386"},"PeriodicalIF":0.0,"publicationDate":"2023-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47838120","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Prediction of ultimate tensile strength of friction stir welding joint using deep learning-based-multilayer perceptron and long short term memory networks","authors":"Ujjaval Modi, Shuja Ahmed, Akhand Rai","doi":"10.1080/09507116.2023.2236936","DOIUrl":"https://doi.org/10.1080/09507116.2023.2236936","url":null,"abstract":"Abstract Friction stir welding (FSW) is a solid-state joining technique where the joint strength is mainly influenced by three process parameters, namely, spindle speed (N), welding speed (V), and plunge force (Fz). The modelling of complex relationships between the process parameters and joint strength requires many experiments, which is a challenging, time-consuming, and non-economical affair. To tackle this problem, computational mathematical models such as deep learning (DL) can be employed to predict the joint strength reliably. In this paper, DL techniques, namely, deep multilayer perceptron (DMLP) and long short-term memory (LSTM) networks have been proposed for such a purpose. The DL networks were first trained with the FSW experimental data and then, the pre-trained models were used for predicting the weld strength. It was found that the DMLP and LSTM models provided lower prediction errors, which are RMSE of 3.30 and 7.63, respectively, and can be effectively utilized for determining weld quality. The proposed DL-based techniques were further compared with the traditional models – the shallow artificial neural network (SANN) model having an RMSE of 27.11 and the ANFIS model having an RMSE of 5.31. DMLP was found to be superior in determining the weld strength most accurately.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"387 - 399"},"PeriodicalIF":0.0,"publicationDate":"2023-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44863590","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of annealing on the interfacial microstructure and mechanical properties of explosively welded AZ80 magnesium alloy and A6005C aluminium alloy","authors":"Mami Mihara-Narita, Konosuke Asai, H. Mori, N. Saito, Y. Chino, H. Sato, Yoshimi Watanabe","doi":"10.1080/09507116.2023.2228039","DOIUrl":"https://doi.org/10.1080/09507116.2023.2228039","url":null,"abstract":"Abstract Effects of annealing on the interfacial microstructure, mechanical properties, and residual stress of the explosively welded AZ80 magnesium alloy and A6005C aluminium alloy cladding plate were investigated. By explosive welding, a thin interlayer composed by an intermetallic compound, i.e. γ-Mg17Al12 phase, was formed at the interface of the cladding plate. After annealing at both 373 K and 473 K, the thickness of the interlayer increased. After annealing at 473 K, the interlayer changed from a single layer of γ-Mg17Al12 phase to a double layer of γ-Mg17Al12 phase and β-Al3Mg2 phase, resulting in a decrease in shear strength. As a result of nanoindentation measurement at the interface, the hardness was remarkably high in the β-Al3Mg2 phase. It was suggested that this phase became the crack initiation site for brittle fracture and the shear strength is decreased. Measurements of the residual stress using synchrotron radiation X-rays at the interface of cladding plate revealed the tendency of the generation of tensile residual stress on AZ80 magnesium alloy side and compressive residual stress on A6005C aluminium alloy side. After annealing at 473 K, residual stress in AZ80 magnesium alloy side and A6005C aluminium alloy side changed to compressive and tensile stresses, respectively, and these stress values became smaller in both cases. On the other hand, after annealing at 373 K, compressive residual stress was observed in both AZ80 magnesium alloy side and A6005C aluminium alloy side.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"16 1","pages":"597 - 606"},"PeriodicalIF":0.0,"publicationDate":"2023-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139364327","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of resistance spot welding technology applying multi-stage adaptive control for narrow pitch spot welding of high strength steel sheets","authors":"Chikaumi Sawanishi, Hiroshi Matsuda, Yasuaki Okita, Rinsei Ikeda","doi":"10.1080/09507116.2023.2228036","DOIUrl":"https://doi.org/10.1080/09507116.2023.2228036","url":null,"abstract":"In order to expand the application of high strength steel sheets to automotive bodies, stabilizing nugget diameter of resistance spot welds is required in the presence of several industrial disturbances. This study aims to ensure the nugget diameter of high strength steel sheets regardless weld spacing by utilizing adaptive control technology based on real-time feedback of heat quantity. Short weld spacing leads to expulsion from the sheet surface applying conventional adaptive control welding for mild steel sheets, whereas decrease in nugget diameter due to reduction of effective welding current for high strength steel sheets. On the other hand, two-stage adaptive control method enables to ensure nugget diameter regardless of steel strength even with 10 mm weld spacing, in which heat quantity was controlled independently in each stage of welding. The mechanism of these phenomena was revealed by verifying the influence of physical properties of steel and welding current pattern on the shunting phenomena using numerical simulation.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135260368","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Friction stir lap welding between A6061/SPC270 thin sheets using welding tool with scroll shoulder","authors":"Yuheng Liu, T. Yasui, Toshiaki Fukuhara, Shuhei Yamaguchi, Katashi Hirosawa, T. Mori","doi":"10.1080/09507116.2023.2222485","DOIUrl":"https://doi.org/10.1080/09507116.2023.2222485","url":null,"abstract":"Abstract Dissimilar materials welding between A6061 and SPC270 thin sheets was performed through friction stir lap welding and the effects of welding tool shape and clearance were investigated. The welding process was carried out on the 3-axis vertical machining center without tilt angle, using welding tools with flat or scroll shoulder surfaces. The highest tensile shear strength of 208.2 MPa using the flat shoulder was achieved under tool rotation speed of 2000 rpm and welding speed of 500 mm/min. Groove-like defects were found at the advancing side of this welding joint, which was thought to be caused by the deficiency of plastic material flow. Scroll shoulder improved the plastic material flow of aluminum alloys and weld surface without defects. However, cavities were formed in joints welding with a clearance of 0.1 mm near the interface between A6061 and SPC270. Reduction of clearance suppressed the formation of cavities and tensile shear strength of 217.9 MPa was achieved with the clearance of 0 mm. The welding interface was observed by SEM and TEM for microstructure investigation. Welding interface temperature during FSLW was measured and the factors for welding strength variation were also discussed in this paper.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"468 - 480"},"PeriodicalIF":0.0,"publicationDate":"2023-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45938875","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of plate deformation around the nugget during tensile test on tensile shear strength of resistance spot welded lap joints","authors":"Takanori Kitamura, Tetsuya Akiyama, Mitsuhiro Imamura, Tomoya Kawabata, Atsuro Uemura, Chinatsu Mihara, Koki Iwatani","doi":"10.1080/09507116.2023.2222958","DOIUrl":"https://doi.org/10.1080/09507116.2023.2222958","url":null,"abstract":"AbstractAbstractResistance spot welding is used in automobile body assembly. Tensile shear test is one of the strength evaluation methods for welded joints. Generally, in tensile shear tests of lap joints, rotational deformation occurs in the joint due to offset of the load axis. In this paper, the effect of rotational deformation of resistance spot welded lap joints on tensile shear strength was investigated. A high-strength steel plate HT590 was used. First, tensile shear tests were conducted using only resistance spot welding (Normal) and a specimen in which the welded joint part was sandwiched between two steel blocks to suppress rotational deformation. For the specimens sandwiched between steel blocks, a specimen was prepared with a constrained point parallel (P) to the tensile direction and a specimen with a constrained point vertical (V) to the tensile direction. And the length of the steel blocks was varied in five ways for the tensile shear test. The results showed that the tensile shear strength increased as the length of the steel block increased. However, the suppression of rotational deformation didn’t have a significant effect on tensile shear strength. In tensile shear tests of lap joints, opening of the lap plates occurs in addition to rotational deformation. Therefore, tensile shear tests were conducted using a specimen with two steel blocks sandwiched at the edge of the lap to suppress the opening of the plates. The experiment was reproduced and investigated by FEM analysis. The results showed that the tensile shear strength increased in the deformation-suppressed specimens compared to Normal specimens. In other words, it is clear that the suppression of plate opening has an effect on the increase in tensile shear strength. The above results indicate that suppression of plate opening is effective in increasing tensile shear strength.Keywords: Resistance spot weldinghigh tensile strength steeltensile shear strengthrotational deformationopening of the platesFEM analysistensile shear test","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134891861","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Importance of shielding and mechanical characterization of GTAW on Ti-6AL-4V alloy sheet","authors":"K. Anbalagan, S. Ramasubramanian, Charles David, S. Manivannan, A. Kannan, D. Mohan","doi":"10.1080/09507116.2023.2224929","DOIUrl":"https://doi.org/10.1080/09507116.2023.2224929","url":null,"abstract":"Abstract Welding and joining Titanium and its alloys are always challenging because getting a contamination-free joint is difficult with arc welding. For this concern, an attempt was made with and without shielding arrangements using the Gas Tungsten Arc Welding (GTAW) process on the Ti-6Al-4V alloy sheet. To study the presence of oxygen and other elements with respect to surface colourization at the weld zone, an Energy-dispersive X-ray spectroscopy (EDX) analysis is carried out. Based on the EDX analysis, post-flow and pre-flow shielding gases are also included in the operation window. Bead on Plate (BoP) trials are performed using the shielding arrangement setup and selected parameters on the thin sheets (2 mm) of Ti-6Al-4V. After examining the BoP trails, defect-free joins in a 2 mm sheet are fabricated using the optimal welding parameters. The microstructure of the joint is captured and compared with the simulation work. Compared to the base metal, coarse and enormous grains are identified at the weld zone. Due to the proper shielding, no cracks appeared in the joint subjected to the three-point bend test. The considerable heat input during the GTAW process resulted in the nucleation of (ά) in FZ, as spotted in the TEM images. The microhardness value at FZ for base metal is 373 HV and 332 HV, respectively. It is confirmed that the suggested shielding setup could prevent contamination in welds resulting in better mechanical properties.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"324 - 333"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45931432","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on arc characteristics under high-frequency sine wave pulse current and effect of weld appearance and microstructure of AISI444 ferritic stainless steel","authors":"Z. Dong, Yiwen Li, J. Miu, Z. Liu, Chen-Hsuan Chang, Yunlong Chang","doi":"10.1080/09507116.2023.2222550","DOIUrl":"https://doi.org/10.1080/09507116.2023.2222550","url":null,"abstract":"Abstract Based on the principle of LC resonance, high-frequency sine wave pulse DC TIG welding (HFSWP DC TIG) was developed, and welding experiments were conducted on AISI444 ferritic stainless steel (FSS). The arc characteristics of HFSWP DC TIG and its effect on weld appearance and microstructure were studied theoretically and experimentally. The experimental results show that under the same conditions, compared with constant-current DC conventional arc welding (CAW), the arc pressure and arc thermal efficiency of HFSWP DC TIG are improved, and the weld penetration of the weld is increased by nearly two times. The weld microstructure is single-phase ferrite, and carbonitride, Laves phase, and phase are formed in the joint. In addition, according to the theoretical calculation of the pulse current waveform, the reason why the arc pressure of the high-frequency sine wave pulse current is increased compared with the constant-current DC and high-frequency square wave (triangular wave) pulse current is explained. The mechanism of arc shape and weld appearance change is described from the microscopic point of view, and the reason for the appearance of equiaxed grain in the weld is analyzed. HFSWP DC TIG provides a new idea for the improvement of high-frequency pulse technology.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"309 - 323"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43798694","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Laser-MIG hybrid welding of aluminium alloy extrusions for high-speed trains: effects of gap width on microstructure and properties","authors":"Xiaohui Han, Zhibin Yang, Yin Ma, Zhendong Mao, G. Ma","doi":"10.1080/09507116.2023.2233887","DOIUrl":"https://doi.org/10.1080/09507116.2023.2233887","url":null,"abstract":"Abstract 6A01-T5 aluminum alloy extrusions with a thickness of 4.5 mm were welded by laser-MIG hybrid welding, and the effects of gap width on the microstructure and properties were studied in details. The results indicated that the priorities of the welding parameters on the tensile strength of joints were laser power, defocusing amount and arc current when the welding speed was constant. The gap tolerance of the optimal welding parameters could reach up to 1.1 mm. The morphology and size of the microstructures were similar when the gap width was no larger than 1.1 mm. The grain boundaries became obvious and even cracks appeared near the fusion line when the gap width increased to 1.5 mm. The microhardness distributions almost the same with the different gap widths: highest in the base materials zone, secondly in the heat-affected zone, then in the weld zone, and lowest near the fusion line. The microhardness values reduced in each zone except base materials when the gap width increased to 1.5 mm. The tensile strength reduced as the gap width increased, the specimens all fractured near the fusion line due to where had the lowest microhardness and the fracture showed ductile failure mode.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":"37 1","pages":"334 - 343"},"PeriodicalIF":0.0,"publicationDate":"2023-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48470528","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}