Abstract
Objectives: ANSYS software has been used to predict temperature, stress, and heat flux distributions for dissimilar welding of MONEL 400 and AISI 304. Methods/Statistical Analysis: A total of twenty seven experiments have been performed for welding of MONEL 400 alloy and AISI 304 by using TIG welding process to find out the best possible welding parameters. The experiments conducted have been divided into three groups. In the first stage, second stage and third stage of experiments was conducted to study the welding process with AISI 304 filler rod, AISI 316 filler rod and MONEL 400 filler rod respectively. Findings: The developed stress is smaller at 350 amp current, AISI 304 filler rod, and 3.6 mm/s welding speed, which is noted as 0.31 × 10-15 MPa. The optimum TIG welding parameter for stress was obtained as 150 amp current, AISI 304 filler rod, and 3.6 mm/s welding speed. The mean value of generated temperature is higher at 350 amp current, AISI 316 filler rod, and 5.5 mm/s welding speed, which is observed as 75671°C. The optimum TIG welding parameters are 350 amp input current, AISI 316 filler electrode, and 3.6 mm/s welding speed for developed temperature. The optimum TIG welding parameter for heat flux was obtained as 350 amp current, MONEL 400 filler rod, and 5.5 mm/s welding speed. Application/Improvements: Dissimilar metal joints between MONEL 400 and AISI 304 are widely used in various applications fields like heat exchanger, chemical processing equipment etc. Keywords: AISI 304, ANSYS Software, Dissimilar Metal Weld, MONEL 400 Alloy, TIG welding, Welding Simulation
Highlights
Monel-400 is the important nickel based alloy that contains about 60–70% nickel, 20–29% copper
The signal to noise ratio of developed stress is lower at MONEL 400 filler rod
The followings are concluded from analysis: 1. The mean value of developed stress is smaller at 350 amp current, AISI 304 filler rod, and 3.6 mm/s welding speed which is noted as 0.31 × 10-15MPa. 2
Summary
Monel-400 is the important nickel based alloy that contains about 60–70% nickel, 20–29% copper. Monel-400 is characterized by its good corrosion resistance, good weld ability and high strength. It has many applications in chemical processing equipment, feed water heaters etc. The analysis effect of residual stress on welded cantilever beam was simulated which has been welded by TIG welding process[1]. The effect of thermalstrain cycle on residual strains on corrosion-resistant austenitic steels of cylindrical shells was studied using TIG butt welds[3]. The surface alloying of AISI 304 stainless steel with titanium was carried out using the heat generated from the Gas Tungsten Arc (GTA)[4]. The micro hardness was increased from 267.5 HV for the substrate to 2098 HV for the surface alloyed layer.
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