Pub Date : 2023-08-03DOI: 10.1080/09507116.2023.2251377
R. Ranjan, S. Jha
Abstract Vibration-assisted welding (VAW) has emerged to be a feasible alternative to thermal and post-weld vibration treatments for arc welds in order to minimize stress concentrations and distortions thereby improving mechanical characteristics. Limited research is available considering low frequency vibration. The main objective is to develop an experimental setup to analyze the properties of welded connections made with shielded metal arc welding (SMAW) using low-frequency mechanical vibrations. Mild steel (MS) plates with dimensions of 100 mm by 50 mm and thickness of 5 mm are considered in this study. Heat inputs of 80 Amps, 100 Amps and 120 Amps were taken into consideration as input current. Vibration was varied between 0 and 100 Hz at every 20 Hz interval to study the Hardness, Tensile Strength and Impact Strength of welded joints. Microstructure of welded MS plates has been analyzed using SEM analysis. Experimental results revealed improved mechanical properties due to the application of low-frequency vibrations that may tend to increase the welding speed thus reducing time and enabling stronger, durable and reliable welded joints. A fine grain structure is seen for Low-frequency vibration-assisted welded butt joints implying improved mechanical properties due to excitation of weld pool.
{"title":"Effect of low frequency vibration-assisted shielded metal arc welding on the properties of mild steel","authors":"R. Ranjan, S. Jha","doi":"10.1080/09507116.2023.2251377","DOIUrl":"https://doi.org/10.1080/09507116.2023.2251377","url":null,"abstract":"Abstract Vibration-assisted welding (VAW) has emerged to be a feasible alternative to thermal and post-weld vibration treatments for arc welds in order to minimize stress concentrations and distortions thereby improving mechanical characteristics. Limited research is available considering low frequency vibration. The main objective is to develop an experimental setup to analyze the properties of welded connections made with shielded metal arc welding (SMAW) using low-frequency mechanical vibrations. Mild steel (MS) plates with dimensions of 100 mm by 50 mm and thickness of 5 mm are considered in this study. Heat inputs of 80 Amps, 100 Amps and 120 Amps were taken into consideration as input current. Vibration was varied between 0 and 100 Hz at every 20 Hz interval to study the Hardness, Tensile Strength and Impact Strength of welded joints. Microstructure of welded MS plates has been analyzed using SEM analysis. Experimental results revealed improved mechanical properties due to the application of low-frequency vibrations that may tend to increase the welding speed thus reducing time and enabling stronger, durable and reliable welded joints. A fine grain structure is seen for Low-frequency vibration-assisted welded butt joints implying improved mechanical properties due to excitation of weld pool.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-08-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41624960","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}
Pub Date : 2023-08-03DOI: 10.1080/09507116.2023.2251378
Rajnish Singh, Yogesh Kumar
Abstract The friction stir welding process is a solid-state technique for joining similar and dissimilar alloys. The advanced fixture was designed and fabricated for welding of the aluminum plate by a hybrid fabricated fixture on a vertical milling center. The storage tank was designed and attached at the bottom of the base plate of the fixture. The three different cooling media used in the cooling tank as air, water, and coolant. The welded samples were examined for mechanical and metallurgical performance. The optimization of process parameters was done for the tensile Test as output. The coolant as a fluid in the tank results in maximum tensile strength at 500 rpm. The microstructural characterization of the heat-affected zone was also done. The weld thinning and quenching are the main problems of direct cooled FSW. This problem is not found in the indirect cooled FSW welding method. The storage tank provided uniform heating and cooling during welding that reduced the thermal quench and microstructural problems. The SEM and EDX mapping images showed the effect of different cooling media on the FSW samples. The microhardness was analyzed to identify different microstructural zone and the hardness of welded part.
{"title":"Microstructural analysis of cooling tank-assisted hybrid friction stir welded aluminium alloys: a novel approach","authors":"Rajnish Singh, Yogesh Kumar","doi":"10.1080/09507116.2023.2251378","DOIUrl":"https://doi.org/10.1080/09507116.2023.2251378","url":null,"abstract":"Abstract The friction stir welding process is a solid-state technique for joining similar and dissimilar alloys. The advanced fixture was designed and fabricated for welding of the aluminum plate by a hybrid fabricated fixture on a vertical milling center. The storage tank was designed and attached at the bottom of the base plate of the fixture. The three different cooling media used in the cooling tank as air, water, and coolant. The welded samples were examined for mechanical and metallurgical performance. The optimization of process parameters was done for the tensile Test as output. The coolant as a fluid in the tank results in maximum tensile strength at 500 rpm. The microstructural characterization of the heat-affected zone was also done. The weld thinning and quenching are the main problems of direct cooled FSW. This problem is not found in the indirect cooled FSW welding method. The storage tank provided uniform heating and cooling during welding that reduced the thermal quench and microstructural problems. The SEM and EDX mapping images showed the effect of different cooling media on the FSW samples. The microhardness was analyzed to identify different microstructural zone and the hardness of welded part.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-08-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45674543","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}
Pub Date : 2023-08-03DOI: 10.1080/09507116.2023.2252733
Mukesh Chandra, Abhinav Kumar, Sumit K. Sharma, K. H. Kazmi, Sonu Rajak
Abstract Wire-arc additive manufacturing (WAAM) is becoming the most important metal additive manufacturing process in many industries. In this paper, one of the common problems of irregularity in the metal deposition in WAAM has been addressed and solved using machine learning (ML). A deep learning-based convolutional neural network (CNN) was used to classify the two classes of deposited beads, i.e. ‘regular bead’ and ‘irregular bead’. A digital camera was installed with a WAAM setup to obtain the images of beads after deposition. A single layer of deposition was conducted on a substrate using aluminium 5356 alloy filler wire using robotic-controlled gas-metal arc welding (GMAW) setup. The performance of the ML model was validated using classification accuracy and processing time. The developed CNN model was checked with three types of proposed datasets. The dataset containing the training and testing ratio of 60:40 achieved an accuracy of 86.53% and 88.08% with 30 and 60 epochs respectively for testing. The proposed ML model was successful in anomaly detection in the deposited bead of WAAM and hence it helps in improving the quality of deposited layers and mechanical properties of fabricated parts.
{"title":"Deep learning for anomaly detection in wire-arc additive manufacturing","authors":"Mukesh Chandra, Abhinav Kumar, Sumit K. Sharma, K. H. Kazmi, Sonu Rajak","doi":"10.1080/09507116.2023.2252733","DOIUrl":"https://doi.org/10.1080/09507116.2023.2252733","url":null,"abstract":"Abstract Wire-arc additive manufacturing (WAAM) is becoming the most important metal additive manufacturing process in many industries. In this paper, one of the common problems of irregularity in the metal deposition in WAAM has been addressed and solved using machine learning (ML). A deep learning-based convolutional neural network (CNN) was used to classify the two classes of deposited beads, i.e. ‘regular bead’ and ‘irregular bead’. A digital camera was installed with a WAAM setup to obtain the images of beads after deposition. A single layer of deposition was conducted on a substrate using aluminium 5356 alloy filler wire using robotic-controlled gas-metal arc welding (GMAW) setup. The performance of the ML model was validated using classification accuracy and processing time. The developed CNN model was checked with three types of proposed datasets. The dataset containing the training and testing ratio of 60:40 achieved an accuracy of 86.53% and 88.08% with 30 and 60 epochs respectively for testing. The proposed ML model was successful in anomaly detection in the deposited bead of WAAM and hence it helps in improving the quality of deposited layers and mechanical properties of fabricated parts.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-08-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49058761","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}
Pub Date : 2023-07-27DOI: 10.1080/09507116.2023.2222488
Yasuo Kadoya, Yuki Oshino, H. Nishimura, Fumiaki Toyama, S. Yamane
Abstract When metals are joined by welding, the strength and other qualities of the products vary greatly depending on the welding conditions. In this paper, authors focus on ring mash welding used for powertrain components that transmit engine drive. This welding is required to be strong enough to withstand large loads. However, it is difficult to find appropriate welding conditions because there are many welding parameters, such as the welding current, applied force and shapes to be welded. Moreover, since the welding point is inside the base metal, it is difficult to understand the phenomena and the deformation process during welding. Therefore, it takes much time to determine welding conditions through repeated experiments and to develop and improve the welding process. Since the numerical analysis of welding phenomena is supported by theoretical analysis and plays an important role in quality assurance of welded products, the authors tried to make the numerical model using the fundamental experimental results. In this study, the visualization of the phenomena and the relationship between the welding current and the applied force made clear using the numerical simulation. The effect of welding conditions on the welding results when they are varied.
{"title":"Development of numerical model in ring mash welding","authors":"Yasuo Kadoya, Yuki Oshino, H. Nishimura, Fumiaki Toyama, S. Yamane","doi":"10.1080/09507116.2023.2222488","DOIUrl":"https://doi.org/10.1080/09507116.2023.2222488","url":null,"abstract":"Abstract When metals are joined by welding, the strength and other qualities of the products vary greatly depending on the welding conditions. In this paper, authors focus on ring mash welding used for powertrain components that transmit engine drive. This welding is required to be strong enough to withstand large loads. However, it is difficult to find appropriate welding conditions because there are many welding parameters, such as the welding current, applied force and shapes to be welded. Moreover, since the welding point is inside the base metal, it is difficult to understand the phenomena and the deformation process during welding. Therefore, it takes much time to determine welding conditions through repeated experiments and to develop and improve the welding process. Since the numerical analysis of welding phenomena is supported by theoretical analysis and plays an important role in quality assurance of welded products, the authors tried to make the numerical model using the fundamental experimental results. In this study, the visualization of the phenomena and the relationship between the welding current and the applied force made clear using the numerical simulation. The effect of welding conditions on the welding results when they are varied.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-07-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46115718","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}
Al/Cu dissimilar welding is a key technology for weight reduction in fabricating high-functional products, however, conventional tungsten inert gas (TIG) welding is difficult to be applied due to a large fusion area. The constricted nozzle equipped inside the conventional TIG torch has been developed and can improve the position accuracy of tungsten electrode and arc plasma characteristics, moreover increase the heat input density. In this study, 0.5 mm-thick Al and Cu dissimilar sheets were butt welded using pulsed TIG welding with the constricted nozzle under two welding speed-current combinations of 50 mm/s-85 A and 100 mm/s-105 A. The 50 mm/s-85 A joint exhibited that Al and Cu mixed each other in the entire weld metal, containing two intermetallic compounds (IMC) of Al2Cu and Al4Cu9 mainly in the Al side. In contrast, both elements hardly mixed each other in the 100 mm/s-105 A weld metal and the interface exhibited hook-like shape at a nearly constant pitch, depending on the welding speed and pulse frequency. Consequently, the formation of IMC layers was limited. Based on the three-dimensional images reconstructed using a serial sectioning technique, the hook-shaped Al/Cu interface was also formed inside the weld metal. The mixed-zone volume per unit weld length of the 100 mm/s-105 A joint was estimated to be about 0.12 mm3/mm, and is much smaller than that of the 50 mm/s-85 A joint (0.97 mm3/mm). The average tensile strength of the 100 mm/s-105 A joint were higher than those of the 50 mm/s-85 A joint, suggesting that the hook-shaped Al/Cu interface together with the reduced mixed zone seems to increase the joint strength.
{"title":"Strengthening of Al/Cu dissimilar joint due to complicated interface produced by pulsed TIG welding with a constricted nozzle","authors":"Hajime Yamamoto, Yusuke Yanagi, Kazuhiro Ito, Hisaya Komen, Manabu Tanaka, Akihisa Murata","doi":"10.1080/09507116.2023.2234693","DOIUrl":"https://doi.org/10.1080/09507116.2023.2234693","url":null,"abstract":"Al/Cu dissimilar welding is a key technology for weight reduction in fabricating high-functional products, however, conventional tungsten inert gas (TIG) welding is difficult to be applied due to a large fusion area. The constricted nozzle equipped inside the conventional TIG torch has been developed and can improve the position accuracy of tungsten electrode and arc plasma characteristics, moreover increase the heat input density. In this study, 0.5 mm-thick Al and Cu dissimilar sheets were butt welded using pulsed TIG welding with the constricted nozzle under two welding speed-current combinations of 50 mm/s-85 A and 100 mm/s-105 A. The 50 mm/s-85 A joint exhibited that Al and Cu mixed each other in the entire weld metal, containing two intermetallic compounds (IMC) of Al2Cu and Al4Cu9 mainly in the Al side. In contrast, both elements hardly mixed each other in the 100 mm/s-105 A weld metal and the interface exhibited hook-like shape at a nearly constant pitch, depending on the welding speed and pulse frequency. Consequently, the formation of IMC layers was limited. Based on the three-dimensional images reconstructed using a serial sectioning technique, the hook-shaped Al/Cu interface was also formed inside the weld metal. The mixed-zone volume per unit weld length of the 100 mm/s-105 A joint was estimated to be about 0.12 mm3/mm, and is much smaller than that of the 50 mm/s-85 A joint (0.97 mm3/mm). The average tensile strength of the 100 mm/s-105 A joint were higher than those of the 50 mm/s-85 A joint, suggesting that the hook-shaped Al/Cu interface together with the reduced mixed zone seems to increase the joint strength.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-07-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135707574","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}
Pub Date : 2023-07-25DOI: 10.1080/09507116.2023.2230657
Yasunori Tanaka, K. Koshiba, T. Iizuka, Mayumi Ito, K. Higashimine, K. Tatsumi
Abstract This research group evaluated the bondability of sinter bonding using Ni nanoparticles, which have a high melting point and excellent corrosion resistance, as a new metal nanoparticle bonding material, and found that bonding is possible at bonding temperatures below 400 °C when the particle size is less than 100 nm. Furthermore it was found that Ni nanoparticles can be directly bonded to Al, which is considered difficult to bond directly with solder materials containing tin (Sn) or lead (Pb), and that high bonding strength can be obtained. In addition, the bonding strength of Ni nanoparticles to Al was higher when bonded in air than in a reduction atmosphere of N2+H2 (3%), indicating that there were differences in bonding properties depending on the bonding atmosphere. In this study, we compared the bonding properties to Al in different bonding atmospheres. In the N2+H2 (3%) reducing atmosphere, the bonding strength was not increased even when the bonding temperature was increased. On the other hand, the bonding strength was significantly increased with increasing bonding temperature over 330 °C in air. The failure mode was also rupture in the bonding layer, and good bonding was achieved at the Ni/Al bonding interface. Observation of the bonding interface between Ni nanoparticles and Al using Transmission electron microscope (TEM) showed the presence of an interlayer of oxide film at both bonding interfaces in air and in the N2+H2 (3%) reduction atmosphere. And the oxide layer at the interface bonded in air was thicker, indicating that the structure at the interface between the Ni layer, the oxide layer and the Al layer has changed. It was suggested that the difference in oxide film formation behavior, structure, and thickness affects the bondability due to the difference in the bonding atmosphere.
摘要 该研究小组使用熔点高、耐腐蚀性能优异的纳米镍粒子作为新型金属纳米粒子接合材料，对烧结接合的接合性进行了评估，发现当粒径小于 100 nm 时，可在接合温度低于 400 °C 时进行接合。此外，研究还发现镍纳米粒子可直接与铝键合，而铝被认为很难直接与含锡（Sn）或铅（Pb）的焊接材料键合，并且可以获得很高的键合强度。此外，镍纳米粒子与铝在空气中键合时的键合强度比在 N2+H2 (3%) 还原气氛中键合时的键合强度高，这表明键合气氛不同，键合性能也不同。在本研究中，我们比较了在不同的键合气氛中与铝的键合特性。在 N2+H2 (3%) 还原气氛中，即使提高键合温度，键合强度也不会增加。另一方面，在 330 °C 以上的空气中，随着粘合温度的升高，粘合强度显著增加。失效模式也是键合层破裂，镍/铝键合界面实现了良好的键合。使用透射电子显微镜（TEM）观察镍纳米颗粒和铝之间的键合界面发现，在空气和 N2+H2 (3%) 还原气氛中，两个键合界面都存在一层氧化膜夹层。在空气中结合界面的氧化层更厚，表明镍层、氧化层和铝层之间的界面结构发生了变化。研究表明，由于键合气氛的不同，氧化膜形成行为、结构和厚度的差异会影响键合性能。
{"title":"Direct bonding of Ni nanoparticles to a semiconductor Al electrode in air and its form","authors":"Yasunori Tanaka, K. Koshiba, T. Iizuka, Mayumi Ito, K. Higashimine, K. Tatsumi","doi":"10.1080/09507116.2023.2230657","DOIUrl":"https://doi.org/10.1080/09507116.2023.2230657","url":null,"abstract":"Abstract This research group evaluated the bondability of sinter bonding using Ni nanoparticles, which have a high melting point and excellent corrosion resistance, as a new metal nanoparticle bonding material, and found that bonding is possible at bonding temperatures below 400 °C when the particle size is less than 100 nm. Furthermore it was found that Ni nanoparticles can be directly bonded to Al, which is considered difficult to bond directly with solder materials containing tin (Sn) or lead (Pb), and that high bonding strength can be obtained. In addition, the bonding strength of Ni nanoparticles to Al was higher when bonded in air than in a reduction atmosphere of N2+H2 (3%), indicating that there were differences in bonding properties depending on the bonding atmosphere. In this study, we compared the bonding properties to Al in different bonding atmospheres. In the N2+H2 (3%) reducing atmosphere, the bonding strength was not increased even when the bonding temperature was increased. On the other hand, the bonding strength was significantly increased with increasing bonding temperature over 330 °C in air. The failure mode was also rupture in the bonding layer, and good bonding was achieved at the Ni/Al bonding interface. Observation of the bonding interface between Ni nanoparticles and Al using Transmission electron microscope (TEM) showed the presence of an interlayer of oxide film at both bonding interfaces in air and in the N2+H2 (3%) reduction atmosphere. And the oxide layer at the interface bonded in air was thicker, indicating that the structure at the interface between the Ni layer, the oxide layer and the Al layer has changed. It was suggested that the difference in oxide film formation behavior, structure, and thickness affects the bondability due to the difference in the bonding atmosphere.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139355085","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}
Pub Date : 2023-07-21DOI: 10.1080/09507116.2023.2230650
Iori Kojima, C. Iwamoto, Yuka Shimizu, T. Matsuda, A. Hirose
Abstract When joining between GA980 and A6061 plates by the FSSW, brittle intermetallic compounds and Zn-contained region are formed at the joint interface. These local reaction products determine the strength of the joint. Therefore, the bonding interface microstructure analysis is crucial to control the process and improve strength. This study performed microstructural analysis near the joint interface on GA980/A6061 joints bonded by the FSSW. The detailed variation of the IMC thickness along with the bonded interface and the microstructure of the Zn-contained region in A6061 plate was clarified. In the A6061 plate, a simple shear texture was observed with the Al <110> direction in the tool rotational direction and the Al {111} plane perpendicular to the direction of the elongated grains. In elongated Al grains surrounded by high-angle grain boundaries, the grains were divided by the low-angle grain boundaries.
{"title":"Microstructure of the interface between aluminum alloy and galvannealed steel plates jointed by FSSW multi-step loading process","authors":"Iori Kojima, C. Iwamoto, Yuka Shimizu, T. Matsuda, A. Hirose","doi":"10.1080/09507116.2023.2230650","DOIUrl":"https://doi.org/10.1080/09507116.2023.2230650","url":null,"abstract":"Abstract When joining between GA980 and A6061 plates by the FSSW, brittle intermetallic compounds and Zn-contained region are formed at the joint interface. These local reaction products determine the strength of the joint. Therefore, the bonding interface microstructure analysis is crucial to control the process and improve strength. This study performed microstructural analysis near the joint interface on GA980/A6061 joints bonded by the FSSW. The detailed variation of the IMC thickness along with the bonded interface and the microstructure of the Zn-contained region in A6061 plate was clarified. In the A6061 plate, a simple shear texture was observed with the Al <110> direction in the tool rotational direction and the Al {111} plane perpendicular to the direction of the elongated grains. In elongated Al grains surrounded by high-angle grain boundaries, the grains were divided by the low-angle grain boundaries.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139356857","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}
Pub Date : 2023-07-06DOI: 10.1080/09507116.2023.2230658
N. Sahara, Shotaro Yamashita, K. Ono, K. Saida
Abstract This study conducted a basic investigation to improve the solidification cracking susceptibility of carbon steel. BTR is one of the susceptibilities to solidification cracking, and it is said that solidification cracking susceptibility is reduced when BTR is smaller. BTR of three commercial filler metals was evaluated by using Trans-Varestraint test. EPMA and EDS analysis of the weld metal microstructure revealed two compounds. The white structure was composed of silicon, manganese, and sulphur, and the black structure was Ti-based compound. Theoretical analysis of BTR was conducted by applying a two-phase peritectic solidification model in FA mode and considering MnS crystallization during solidification segregation. The analysis results indicated that BTR of carbon steel is attributed to the difference in solidification completion temperatures, and carbon is the most deleterious element. Also, MX compound (Ti, C, N) crystallized in addition to MnS at the end of solidification. Theoretical analysis was conducted for Ti virtual addition materials because MX compound (Ti, C, N) crystallization by Ti addition may lead to BTR reduction by trapping C in the liquid phase. The results showed that Ti addition reduced BTR. The amount of C in the residual liquid phase was reduced by an increase in MX compound (Ti, C, N) crystallization due to Ti addition. Based on theoretical considerations, it can be concluded that Ti addition to carbon steel is effective in reducing BTR.
摘要 本研究对改善碳钢凝固裂纹敏感性进行了基础调查。BTR是凝固开裂的敏感性之一，BTR越小，凝固开裂的敏感性越低。我们使用 Trans-Varestraint 试验评估了三种商用填充金属的 BTR。对焊缝金属微观结构的 EPMA 和 EDS 分析显示出两种化合物。白色结构由硅、锰和硫组成，黑色结构为钛基化合物。通过应用 FA 模式下的两相包晶凝固模型，并考虑凝固偏析过程中的 MnS 结晶，对 BTR 进行了理论分析。分析结果表明，碳钢的 BTR 归因于凝固完成温度的差异，而碳是最有害的元素。此外，在凝固末期，除 MnS 外，还有 MX 化合物（Ti、C、N）结晶。对 Ti 虚拟添加材料进行了理论分析，因为通过添加 Ti 而结晶的 MX 化合物（Ti、C、N）可能会在液相中捕获 C，从而导致 BTR 降低。结果表明，Ti 的添加降低了 BTR。由于添加了钛，MX 化合物（Ti、C、N）结晶增加，残留液相中的 C 量减少。基于理论考虑，可以得出结论：在碳钢中添加 Ti 能有效降低 BTR。
{"title":"Evaluation of solidification cracking susceptibility factors in carbon steel and availability of Ti addition based on theoretical analysis","authors":"N. Sahara, Shotaro Yamashita, K. Ono, K. Saida","doi":"10.1080/09507116.2023.2230658","DOIUrl":"https://doi.org/10.1080/09507116.2023.2230658","url":null,"abstract":"Abstract This study conducted a basic investigation to improve the solidification cracking susceptibility of carbon steel. BTR is one of the susceptibilities to solidification cracking, and it is said that solidification cracking susceptibility is reduced when BTR is smaller. BTR of three commercial filler metals was evaluated by using Trans-Varestraint test. EPMA and EDS analysis of the weld metal microstructure revealed two compounds. The white structure was composed of silicon, manganese, and sulphur, and the black structure was Ti-based compound. Theoretical analysis of BTR was conducted by applying a two-phase peritectic solidification model in FA mode and considering MnS crystallization during solidification segregation. The analysis results indicated that BTR of carbon steel is attributed to the difference in solidification completion temperatures, and carbon is the most deleterious element. Also, MX compound (Ti, C, N) crystallized in addition to MnS at the end of solidification. Theoretical analysis was conducted for Ti virtual addition materials because MX compound (Ti, C, N) crystallization by Ti addition may lead to BTR reduction by trapping C in the liquid phase. The results showed that Ti addition reduced BTR. The amount of C in the residual liquid phase was reduced by an increase in MX compound (Ti, C, N) crystallization due to Ti addition. Based on theoretical considerations, it can be concluded that Ti addition to carbon steel is effective in reducing BTR.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-07-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139362332","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}
Pub Date : 2023-07-05DOI: 10.1080/09507116.2023.2230647
Tamaki Ito, J. Choi, Motomichi Yamamoto, K. Taniguchi, Y. Okita, H. Matsuda
Abstract The demand for steel/aluminum alloy dissimilar joints has increased for light-weighting the automobile body. However, it is well known that joining both metals by conventional welding methods, the brittle intermetallic compound (IMC) is generated at the interface, and it significantly deteriorates the joint strength. In this paper, the hot-wire laser brazing process using the twin-spot irradiation was proposed and its conditions were optimized to achieve the high brazing speed and the high joint strength on a lap-fillet joint of the steel/aluminum alloy dissimilar combination. The twin spots of a circle (ϕ5) and rectangular (5 × 11) laser beams aligned at spot ends achieved the high brazing speed up to 6 m/min, stable brazing phenomena and sound bead appearance. The joints fabricated using the optimized conditions realized the very thin IMC thickness under 2 μm and high joint strength over the yield strength of the base steel sheet.
{"title":"High-speed hot-wire laser brazing technology for steel/aluminum alloy dissimilar joint using twin beam irradiation","authors":"Tamaki Ito, J. Choi, Motomichi Yamamoto, K. Taniguchi, Y. Okita, H. Matsuda","doi":"10.1080/09507116.2023.2230647","DOIUrl":"https://doi.org/10.1080/09507116.2023.2230647","url":null,"abstract":"Abstract The demand for steel/aluminum alloy dissimilar joints has increased for light-weighting the automobile body. However, it is well known that joining both metals by conventional welding methods, the brittle intermetallic compound (IMC) is generated at the interface, and it significantly deteriorates the joint strength. In this paper, the hot-wire laser brazing process using the twin-spot irradiation was proposed and its conditions were optimized to achieve the high brazing speed and the high joint strength on a lap-fillet joint of the steel/aluminum alloy dissimilar combination. The twin spots of a circle (ϕ5) and rectangular (5 × 11) laser beams aligned at spot ends achieved the high brazing speed up to 6 m/min, stable brazing phenomena and sound bead appearance. The joints fabricated using the optimized conditions realized the very thin IMC thickness under 2 μm and high joint strength over the yield strength of the base steel sheet.","PeriodicalId":23605,"journal":{"name":"Welding International","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139362654","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}
Pub Date : 2023-07-03DOI: 10.1080/09507116.2023.2242777
Sumanlal M. S., Sivasubramaniyan N. S., Joy Varghese V. M., Shafeek M, Ananthan D. Thampi
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.
{"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":null,"pages":null},"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}
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