Welding in the World最新文献

{"title":"Fatigue Strength Evaluation of Welded Joints Based on Notch Strains and the Influence of Weld Modelling","authors":"Josef Neuhäusler,&nbsp;Maximilian Kling,&nbsp;Klemens Rother","doi":"10.1007/s40194-025-02054-x","DOIUrl":"10.1007/s40194-025-02054-x","url":null,"abstract":"<div><p>This study focuses on the estimation of the fatigue life of welded joints, considering elastic–plastic notch strains. Various finite element modelling approaches such as idealized geometries or measured geometries of weld toes will be discussed. By means of Monte Carlo simulations, partial safety factors are derived, which provide the possibility to account for the geometrical variability of the weld toe geometry. For computational efficiency, neural networks are employed to estimate notch stresses rapidly, revealing the influence of geometry parameters, like the notch radius or the flank angle at the weld toe and the weld throat thickness, but also variations of the wall thickness and angular misalignment. In addition, fatigue life evaluation using damage parameters applicable to low cycle, high cycle, and very high cycle fatigue will be presented.New experimental constant amplitude fatigue data from 84 tests on T- and butt joints made of X6CrNiTi18-10 stainless steel, including different sheet thicknesses, weld dimensions, weld types and weld seam variations, are used for validation of the proposed approach. Additionally, 144 tests from literature on materials S960M and X6CrNiTi18-10 are employed to validate the approach. For practical applications on component type specimen, 36 rectangular hollow section joints are used for additional validation. In summary, the study demonstrates that idealized weld modelling, following IIW-recommendations, coupled with an expanded effective notch stress approach, can enhance agreement between model predictions and experimental results. The derived partial safety factors facilitate the safe design of welded joints based on notch strains.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 8","pages":"2371 - 2385"},"PeriodicalIF":2.5,"publicationDate":"2025-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02054-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145167481","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Behaviour of resistance spot welded thermomechanically rolled high strength steel under tensile shear and cross-tension loads","authors":"István Borhy,&nbsp;Marcell Gáspár","doi":"10.1007/s40194-025-02069-4","DOIUrl":"10.1007/s40194-025-02069-4","url":null,"abstract":"<div><p>Over the past decades, vehicle manufacturers have been striving to reduce vehicle weight to minimize energy consumption and emissions in line with key priorities of the environmental objectives of the European Union. These goals can be met by using high strength steels, but their application raises numerous challenges in welding. In general, the railway vehicle body consists of ribs-stiffened shell structure which bears the load together with chassis. By substituting mild steel with high strength steel in these structural elements, joined by resistance spot welding (RSW), significant weight reduction can be achieved. It is possible to use thermomechanically rolled high strength steels with relatively low carbon equivalent which can be ideal for the RSW of railway vehicles. In this paper, the results of tensile shear (TST) and cross-tension (CTS) tests of resistance spot-welded joints made of 3-mm thick S700M thermomechanically rolled high strength steel are presented. The main research scope was to develop a resistance welding technology including the determination of optimal welding parameters based on TST and CTS tests. The optimal technological parameters were nearly the same for the two loading circumstances; however, a bit shorter cycle was justified during the optimization for the cross-tension strength. The value of the tensile shear force exceeded the minimum value specified by the AWS recommendation D8.1M by more than 22% with an electrode indentation depth of 5.56% in average.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 7","pages":"2171 - 2180"},"PeriodicalIF":2.5,"publicationDate":"2025-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02069-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145165957","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Hybrid ultrasonic arc welding of nickel-based alloys: improved cavitation and grain refinement","authors":"Yunhao Xia,&nbsp;Bolun Dong,&nbsp;Yangyang Fan,&nbsp;Qihao Chen,&nbsp;Xiaoyu Cai,&nbsp;Sanbao Lin","doi":"10.1007/s40194-025-02070-x","DOIUrl":"10.1007/s40194-025-02070-x","url":null,"abstract":"<div><p>Hybrid ultrasonic welding experiments on Inconel 625 alloy were carried out to address the challenges of refining microstructure. The welding process phenomena and resulting microstructures were systematically analyzed. Four distinct welding methods—conventional tungsten inert gas (C-TIG), ultrasonic-frequency pulsed TIG (UFP-TIG), ultrasonic vibration-assisted TIG (UV-TIG), and hybrid ultrasonic TIG (HU-TIG)—were compared in terms of grain morphology, grain size distribution, and overall refinement. In the weld zone adjacent to the fusion line, hybrid ultrasonic treatment demonstrated a superior effect on grain morphology adjustment. The results show that HU-TIG effectively suppresses columnar growth and increases the proportion of equiaxed grains, yielding a finer microstructure than the other methods. The synergy of ultrasonic-frequency pulsing and mechanical ultrasonic vibration enhances cavitation activity in the molten pool, promoting dendrite fragmentation and homogenizing elemental distribution. Moreover, ultrasonic-frequency pulsed arcs alter the physical properties of the molten pool, enabling the melt to respond more effectively to ultrasonic cavitation.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 10","pages":"3115 - 3127"},"PeriodicalIF":2.5,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145062149","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Shunt current-assisted one-step resistance element welding of vibration-damping aluminum to ultra-high-strength hot-press-formed steel","authors":"EunBeen Gong,&nbsp;Sunusi Marwana Manladan,&nbsp;Nellikode Savyasachi,&nbsp;Siva Prasad Murugan,&nbsp;Ki-Man Bae,&nbsp;Jong-Jin Baek,&nbsp;Changwook Ji,&nbsp;Yeong-Do Park","doi":"10.1007/s40194-025-02065-8","DOIUrl":"10.1007/s40194-025-02065-8","url":null,"abstract":"<div><p>To satisfy recent demands for reducing NVH (noise, vibration, harshness), vehicle weight, and improving collision safety, the development of reliable processes for dissimilar joining of lightweight vibration-damping aluminum to ultra-high strength steels is required. The resistance element welding (REW) process to join the dissimilar material involves a two-step process of pre-drilling a hole in the aluminum to insert the element and then welding to join the element to steel. Consequently, this increases cycle time and makes it challenging to ensure joint quality due to potential robot teaching errors. To overcome these limitations, an innovative one-step REW process was proposed to shorten the two-step REW process into a single process. However, the thermoplastic resin layer at the interface of the vibration-damping aluminum limits current conduction, posing challenges for REW. The current study introduces stainless-steel clips to bypass the thermoplastic resin layer between the vibration-damping aluminum, which limits the current conduction during the one-step REW process. The adjacent REW joint ensures further bypass of the current and acts as an initial weld point (shunt weld) for continuous one-step REW. Optimization of the welding variables was carried out to achieve excellent joint performance in terms of joint formation. Subsequently, the quality evaluation of the joint was done based on the evaluation of microstructure and mechanical properties. This process significantly enhances productivity with one-step REW instead of the traditional two-step welding. It surpasses the difficulty of welding the vibration-damping aluminum to HPF (hot press forming) steel.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 7","pages":"2159 - 2170"},"PeriodicalIF":2.5,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145165332","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Deep learning for predicting welding distortions in T-joints","authors":"Mahdi Karimi,&nbsp;Narges Mokhtari,&nbsp;Jasmin Jelovica","doi":"10.1007/s40194-025-02056-9","DOIUrl":"10.1007/s40194-025-02056-9","url":null,"abstract":"<div><p>Stiffened panels are common structural units in marine vessels, civil and aerospace structures. Production via welding can lead to excessive distortion of their plates, which negatively affects structural integrity and dimensional accuracy. Conventional practical approaches for distortion control are costly, making simulation models attractive tools to mitigate distortions. Prediction of welding distortions using finite element (FE) simulations is computationally intensive, especially when used repeatedly in design and optimization. Effective surrogate models in the form of deep learning could alleviate this issue, but the selection and construction of deep neural networks for this purpose are presently unclear. This study focuses on predicting welding-induced distortions in a T-joint. Two neural networks—a multilayer perceptron (MLP) and a convolutional neural network (CNN)—are employed to predict distortions. Two case studies are conducted for each model, exploring variations in geometry and welding sequences. The database is generated from FE simulations of the gas metal arc welding (GMAW) process. The effects of welding order and direction on distortions are studied, concluding that an appropriate selection of welding sequence and direction can reduce distortion by up to 40%. This data is then used to train the neural networks. The MLP and CNN models are designed and trained to predict distortion fields by tuning their architecture and other hyperparameters. Results demonstrate that both models are effective; however, the CNN achieves higher accuracy for complex distortion patterns, highlighting its suitability for more intricate scenarios. </p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 8","pages":"2483 - 2507"},"PeriodicalIF":2.5,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145165280","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High-resolution thermal imaging for melt pool dynamics studies in TIG welding process","authors":"Vinicius Lemes Jorge,&nbsp;Issam Bendaoud,&nbsp;Fabien Soulié,&nbsp;Cyril Bordreuil","doi":"10.1007/s40194-025-02055-w","DOIUrl":"10.1007/s40194-025-02055-w","url":null,"abstract":"<div><p>Challenges in terms of reliability still surround thermal measurement methods in welding processes. However, the temperature distribution within the weld pool can provide important resources for understanding behaviors and explaining phenomena. This work aims to study the effect of gravity on the temperature distribution within the weld pool under different welding positions using an in-house developed equipment. First, a combination of optical settings and a calibration procedure were established. Experiments were carried out with the same welding parameters under flat, horizontal, vertical upward, and vertical downward positions. The thermal field from the backside of fully penetrated thin plates was accessed using the TIG process. The device allowed a well-delimited and detailed weld pool thermal field assessment. Dimensionless numbers were quantified, and Marangoni shear stress was plotted on the weld pool surface. Along the transversal weld pool direction, a symmetrical heat distribution was stated in the flat position, while an asymmetrical one was observed in the others. The Marangoni effect played a crucial role in all the experiments, emerging as the dominant driving force in 1G and 2G positions. It governed the fluid flow within the weld pool by influencing temperature gradients over time, which, in turn, altered the direction and magnitude of shear stress on the free surface. Notably, in the 2G position, the observed asymmetry in the weld pool features may be attributed to the combined effects of buoyancy and Marangoni forces acting together. Finally, through the developed equipment, it was possible to evaluate the impacts of gravity on the heat distribution within the weld pool and demonstrate its contribution to dynamics studies.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 9","pages":"2789 - 2804"},"PeriodicalIF":2.5,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145164826","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Combined heating rate and restraint condition effect on stress relief cracking during PWHT of thick-walled Cr–Mo-V steel SAW joints","authors":"Michael Rhode,&nbsp;Denis Czeskleba,&nbsp;Hannah Fleißner-Rieger,&nbsp;Jonathan Nietzke,&nbsp;Thomas Kannengiesser","doi":"10.1007/s40194-025-02062-x","DOIUrl":"10.1007/s40194-025-02062-x","url":null,"abstract":"<div><p>Creep-resistant steels such as 13CrMoV9-10 are utilized in the manufacture of thick-walled pressure vessels and are typically joined by submerged arc welding (SAW). However, these materials are susceptible to stress relief cracking (SRC) if the required post weld heat treatment (PWHT) is not applied correctly. Existing PWHT guidelines, encompassing heating rate and dwell (or holding) time at a given temperature, are derived from a synthesis of empirical knowledge and typically free-shrinkage weld experiments to assess the susceptibility to SRC. Therefore, this study discusses the combined effect of the PWHT heating rate under free-shrinkage compared to restrained shrinkage. Welding experiments were conducted (using plates with a thickness of 25 mm) for both shrinkage conditions for a variety of heating rates and maximum temperatures. In-situ acoustic emission analysis was used to locate propagating SRCs during PWHT. Hardness measurements, mechanical property characterization (Charpy impact strength), and microstructure correlation were used to evaluate the SRC susceptibility. The results suggested that the influence of heating rate could not be directly related to SRC formation and that the initial weld microstructure prior to PWHT was more relevant in terms of very high hardness in the coarse grain heat affected zone, especially that of the last beads in the top layer of the welding sequence. This was seen in the form of random, unexpected SRC occurrence in only one specimen at a heating rate commonly used in welding practice (approximately 100 K/h). In this context, the additional effect of an external shrinkage restraint on SRC must be considered in the form of increasing mechanical loads during welding, which are typically not within the scope of welding practice. To mitigate the probability of SRC during PWHT, it is imperative to reduce the welding heat input and to restrict the structural shrinkage restraint of the weld joint.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 10","pages":"3097 - 3113"},"PeriodicalIF":2.5,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02062-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145062258","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"","authors":"","doi":"","DOIUrl":"","url":null,"abstract":"","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 10","pages":"3223 - 3241"},"PeriodicalIF":2.5,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145062260","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Research on the welding strategy and welding technology for medium-thick plates based on three-line structured light vision","authors":"Junjie He,&nbsp;Liyang Cui,&nbsp;Tianqi Wang,&nbsp;Lei Wang","doi":"10.1007/s40194-025-02052-z","DOIUrl":"10.1007/s40194-025-02052-z","url":null,"abstract":"<div><p>Weld reconstruction technology based on visual sensors is a crucial component of intelligent robotic welding systems. In thick-wall workpieces with big groove multi-layer automatic welding, precise measurement of the workpiece and weld seams directly affects subsequent weld path planning and posture planning of the welding torch. To address this issue, this study employs a three-line structured light measurement system for weld profile detection. A sub-plane fitting algorithm is proposed for 3D reconstruction of weld grooves, accompanied by a rapid workpiece coordinate system establishment method using three-line structured light to ensure accurate boundary segmentation. However, direct welding based on reconstructed feature points cannot guarantee high-quality results. Therefore, we investigated the effects of key process parameters, such as welding position, direction of welding, and torch inclination angle on weld bead geometry. A second-order general rotational composite design was implemented to develop regression models correlating welding parameters with weld bead characteristics. Finally, integrated process planning combining reconstruction data with optimized welding parameters was implemented for torch trajectory and orientation planning. Experimental results demonstrate that this methodology effectively satisfies quality control requirements for automated welding of thick-walled structural components.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 10","pages":"3223 - 3241"},"PeriodicalIF":2.5,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145142309","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Real-time determination of weld penetration status during A-TIG welding of stainless steel employing deep learning approach","authors":"N. Chandrasekhar,&nbsp;Vasudevan Muthukumaran,&nbsp;C. R. Das","doi":"10.1007/s40194-025-02021-6","DOIUrl":"10.1007/s40194-025-02021-6","url":null,"abstract":"<div><p>Deep learning approach involving a convolutional neural network (CNN) has been developed to perform semantic segmentation in captured real-time images of the weld pool and determine the weld penetration status in real-time during activated TIG welding (A-TIG). A robotic welding machine with a CMOS camera attached to the welding torch was employed to capture real-time images of the weld pool. Welding experiments were conducted by varying the current from 90 to 300A in steps to achieve various levels of weld penetration depth in the range of 2–10 mm. The above weld penetration range has been categorised into four classes of weld penetration status. A CNN model with VGG 16 architecture has been applied as an encoder in the U-Net framework for weld pool image classification. The accuracy of classification was 99% and the model execution time was 90 ms in a computer for prediction in a single frame of the image. To reduce the model execution time further, a few lightweight architectures were chosen as encoders for the U-Net model and their performance was compared. Among them, the most accurate EfficientNet-B0 was chosen for real-time implementation. The developed model was executed in real-time to predict the weld penetration status in NVIDIA Jetson Nano embedded hardware. The classification accuracy determined for the four classes was found to be in the range of 94 to 98% for the validation experiments. The execution time was found to be reduced to 55 ms for prediction of the weld penetration status in a frame of weld pool image.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 9","pages":"2727 - 2744"},"PeriodicalIF":2.5,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02021-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145171456","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}