Abstract
One of the most important negative consequence in the fusion welding processes is the generation of tensile residual stresses in welded joints. The main goals of this work are to determine the optimal combination of welding parameters to minimize the residual stress level and the influence of each welding parameter in that feature to weld 6082-T6 aluminum alloy plates using the GMAW welding process. To achieve these goals was implemented the Taguchi orthogonal array (L27) to define the design of numerical and experimental tests. All combinations were simulated in the Simufactwelding 6.0 software, from which it was possible to obtain the values of maximum residual stresses. The data treatment was carried out, reaching the combination of levels for each parameter. With ANOVA analysis was found that the parameter with the greatest influence in the residual stress generation was the welding speed, while the parameter with the least influence was the torch angle. Also, to minimize the residual stresses it was observed that the optimal combination of welding parameters is welding current intensity of 202 A, welding speed of 10 mm/s, and 30° of inclination of the angular torch. The two simulations that resulted in the highest and lowest residual stresses were validated experimentally by the hole drilling method to measure the residual stresses.
Highlights
Aluminum alloys gathers wide range of acceptance and potential application in automobile, aerospace, ship building industries, off shore structures and construction of bridges due to the low weight, superior strength to weight ratio and other anti-corrosive properties of this material [1]
The main goals of this work are to determine the optimal combination of welding parameters to minimize the residual stress level and the influence of each welding parameter in that feature to weld 6082-T6 aluminum alloy plates using the gas-metal arc welding (GMAW) welding process
With ANOVA analysis was found that the parameter with the greatest influence in the residual stress generation was the welding speed, while the parameter with the least influence was the torch angle
Summary
Aluminum alloys gathers wide range of acceptance and potential application in automobile, aerospace, ship building industries, off shore structures and construction of bridges due to the low weight, superior strength to weight ratio and other anti-corrosive properties of this material [1]. One of the most common welding techniques for aluminum alloys is gas-metal arc welding (GMAW), which offers advantages such as deep penetration, smooth weld bead, high welding speed, large metal deposition rate, lower spatter, lower distortion and shrinkage, and lesser probability of porosity and fusion defects and the possibility to be robotized [9,10,11,12] This process, due to the high temperatures involved, causes thermomechanical distortion and generation of residual stresses [13], which can lead to a premature collapse of the welded structure. Goldak et al [24] presented a numerical solution in the form of a semi-ellipsoidal and double-ellipsoidal heat source (applied methodology), more recently, Nasiri and Enzinger [25] proposed an analytical solution for heating flux in welding called adaptive function These authors measured temperature values close to the melting line and determined the relative error less than 5% concerning the experimental method. The 27 combinations were simulated using the Software Simufacwelding® 6.0, from which it was possible to recall the values of the maximum principal stresses (MaxPS)
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