Butt Joint Research Articles

Fatigue design of stress relief grooves to prevent weld root fatigue in butt-welded cast steel to ultra-high-strength steel joints

In the welded joints, fatigue failures typically originate from defects or notch-like geometries under cyclic loading. This study investigates the impact of stress relief grooves (SRG) on the fatigue performance of butt-welded cast steel to ultra-high-strength steel components using experimental fatigue tests and finite element method. The experiments examined the fatigue properties of hybrid joints between G26CrMo4 cast steel (t = 20 mm) and S960 steel plate (t = 6 mm) with and without SRG. Gas metal arc welding process was used to weld the butt joints that had a permanent root backing machined on the cast steel part, causing a crack-like defect to the weld root. Additionally, the top surfaces of the welded parts were aligned, resulting in a significant axial misalignment in the butt joint. The SRG, positioned close to the weld root, was found to have a beneficial influence on the joint’s fatigue performance by a factor of 1.2 when using the nominal stress criterion. However, the fatigue capacity was still roughly 35% lower compared to the symmetrical equivalent due to the secondary bending stress, caused by axial misalignment. The finite element analyses indicated that the SRG reduces the amount of secondary stresses at the weld root leading to lower total structural stress. The study recommends using the FAT80 (m = 3) design curve in the structural stress method, for similar butt-welds having a crack-like defect, parallel to the loading direction, at the weld root. However, for welded joints with crack-like defects, it is advisable to use linear elastic fracture mechanics rather than relying solely on stress-based local approaches.

The influence of combination of surface roughness and nanostructure of adhesive on the strength of adhesively bonded joints

Nowadays, adhesively bonded joints are frequently employed in engineering designs as they enable the manufacture of joints with great strength while remaining light. These joints used in aviation sectors, where lightness and reliability are important, are generally designed to join metal-metal, metal-composite and composite-composite adherends. The surface roughness of the adherends with its degree and the way the adhesive interacts with the surface are the most crucial parameters in these applications. In the current work, surface roughness and normal stress strength of nano-composite adhesive in butt joint subjected to tensile loading were investigated. DP460 liquid structural epoxy from 3 M was used as adhesive, AA2024-T3 aluminum alloy as adherend, Graphene-COOH and Carbon Nanotube-COOH as nanostructures while sandpaper and sandblasting methods were used for introducing roughness to the adherend surfaces. A two dimensional axisymmetric FE model was developed to get an insight about the joint failure. When the failure load obtained from experiments was examined, an increasing trend in maximum force values was noticed with an increase in surface roughness, but this increase in joint strength decreased when the surface roughness increased to very high values. In addition, minimum surface roughness reduces the adhesive's adhesion to the surface, thus reducing the normal stress strength of the joint. When 1 % Graphene-COOH nanostructure was added to the adhesive, the ultimate normal stress of the joints increased from 9 % to 21 %. However, when the same percentage of Carbon Nanotube-COOH was added, the increase was from 27 % to 62 %. Different normal stress values of the joints were obtained using by sanding and sandblasting methods even though the roughness resulting from the two treatments was similar.

Application of Convolutional Neural Networks for Classifying Penetration Conditions in GMAW Processes Using STFT of Welding Data

For manufacturing components with thick plates, such as in the heavy equipment and shipbuilding industries, the gas metal arc welding (GMAW) process is applied. Among the components that apply the thick plate GMAW process, there are groove butt joints, which are fabricated through multi-pass welding. Various welding qualities are managed in multi-pass welding, and the root-pass weld is controlled to ensure complete joint penetration (CJP). Currently, the state of complete joint penetration during root-pass welding is managed visually, making it difficult to confirm the penetration condition in real time. Therefore, there is a need to predict the penetration condition in real time. In this study, we propose a convolutional neural network (CNN)-based prediction model that can classify penetration conditions using welding current and voltage data from the root pass of V-groove butt joints. The root gap of the joints was varied between 1.0 and 2.0 mm, and the wire feed rate was adjusted. During welding, the current and voltage were measured. The welding current and voltage are transformed into a short-time Fourier transform (STFT) representation depicting the arc and wire extension lengths. The transformed dynamic resistance STFT information serves as the input variable for the CNN model. Preprocessing steps, including thresholding, are applied to optimize the input variables. The CNN architecture comprises three convolutional layers and two pooling layers. The model classifies penetration conditions as partial joint penetration (PJP), CJP, and burn-through, achieving a high accuracy of 97.8%. The proposed method facilitates the non-destructive evaluation of the root-pass welding quality without expensive monitoring equipment, such as vision cameras. It is expected to be immediately applied to the thick plate welding process using readily available welding data.

Influence of Convexity on the Strength of One-Sided Butt Joints with Incomplete Fusion

Influence of Convexity on the Strength of One-Sided Butt Joints with Incomplete Fusion

Thermal and Mechanical Investigation of Friction Stir Welding with Disparate Materials AA6061 and AA7075

Background:: The primary objective of this study is to assess the impact of welding conditions on the mechanical properties of friction stir-welded butt joints created from two distinct aluminium alloys, namely, AA6061 and AA7075. Friction stir welding (FSW), known for its innovation and low-energy solid-state bonding technique, was employed in this research. Methods:: FSW experiments were carried out on both AA6061 and AA7075 alloys using a computer numerical control (CNC) machine. The selection and design of the tool geometry were meticulous, with an emphasis on new pin profiles that are nearly flat at the weld contact point. Precisely, four distinct tool geometries were machined from HC-HCr (High carbon, high chromium steel): Circular, Square, Tapered third, and Triangular. Critical process variables that significantly influence weld quality include rotation speed (800 rpm-1400 rpm) and traverse speed (12 to 25 mm/min). These variables were carefully optimized to achieve flawless welds. During the friction stir welding process, the nugget zone undergoes significant deformation, leading to the formation of a new microstructure that substantially impacts the mechanical properties of the joint. Results:: This study comprehensively investigates the thermal and mechanical properties of friction stir welding using aluminium alloys AA6061 and AA7075, considering various tool shapes. Among the four tool shapes employed, two were found to yield higher hardness values (referred to as BH). Notably, the square-shaped tool produced the highest temperature, reaching up to 690ºC, as determined by thermocouple readings. Based on the findings, the optimal FSW parameters for enhancing hardness involve an axial feed and spindle speed of 800 rpm combined with a feed rate of 15 mm/min. These parameters were identified as crucial for achieving the desired mechanical properties in the friction stir-welded joints. Conclusion:: This study presents new developments in FSW technology, which may have patent implications.

Effect of post-weld heat treatment on the microstructure, phase composition and mechanical properties of dissimilar Al-Mg-Li/Al-Cu-Li laser welded joints

Butt joints of the V-1461 and 1424 heat treated aluminum–lithium alloys of the third generation were welded with a CO2 laser and studied in detail for the first time. In particular, spatial distributions of the formed phases and their evolution upon post-weld heat treatment (PWHT), determining the mechanical properties of the joints, were investigated. The PWHT included quenching and subsequent artificial aging. The key factors, affecting the metallurgical processes in a weld pool, were the following: 1) the alloying elements and the thermal properties of the alloys, 2) the dynamics of the local non-equilibrium melting, the convective transfer of the molten metal in the weld pool and its subsequent solidification, 3) the cooling rate, and 4) the PWHT procedure. By using synchrotron radiation and scanning electron microscopy, new θ(Al2Cu), T1(Al2CuLi) and S1(Al2MgLi) phases were found in the weld metal that were absent in both base metals. This phenomenon reduced the mechanical properties of the joints to the levels, corresponding to about 50 % of the 1424 alloy as the weakest one. Quenching contributed to the formation of the δ′(Al3Li) strengthening phase in the weld metal. As a result, the ultimate tensile strength increased up to 70 % and elongation up to 95 % of the corresponding levels of the 1424 alloy. Artificial aging made it possible to form the T1(Al2CuLi) strengthening phase, to increase the content of the δ′(Al3Li) one, as well as to improve the mechanical properties of the joint. In this case, the ultimate tensile strength was 411 MPa, the yield point was 327 MPa and elongation was 1.7 %. These values were close to those for the 1424 alloy (about 80 %, 89 % and 23 %, respectively).

The Effect of Friction Stir Weld (FSW) Process Parameters on Tensile Strength, Macro Structure, and Hardness in Results of AA7075 Butt Joints

Friction Stir Welding (FSW) is an innovative technique that enhances the conventional method of joining metals. Notably ecofriendly due to its energy efficiency, FSW involves minimal energy input, reduces pollution, and saves time and costs. It finds applications in diverse sectors such as automotive, aerospace, and industry. Each material requires specific process parameters, which leads to this study focusing on identifying suitable parameters for AA7075 aluminum with a 6mm thickness. Using a tool featuring a tapered cylindrical thread pin and a flat shoulder, the study aims to investigate the influence of FSW process parameters, rotation speed, and traverse speed on the mechanical strength of butt joint connections. The study's experimental design varies these parameters and evaluates the joints through tensile strength testing, hardness testing, and macrostructural analysis. Utilizing Response Surface Methodology (RSM), the data highlights the impact of rotation and traverse speed on tensile strength. Hardness test results present variations within heat zones, analyzing the effects of the mentioned variables. The findings demonstrate minimal flash and successful surface outcomes but also identify wormholes within the stir zone (SZ). Tensile strength testing reveals a definite correlation between RPM and traverse speed with joint strength. In contrast, hardness testing indicates that these parameters do not significantly affect joint hardness. Macrostructure examination suggests RPM and traverse speed have negligible effects on the heat-affected zone. In conclusion, FSW presents a sustainable and effective welding approach with implications for multiple industries, and this research provides insights into optimizing its parameters for specific aluminum materials.

Flexural performance of full-scale two-span Nail-Laminated Timber Concrete composite slabs

This study examines the flexural performance of six 9-m full-scale two-span Nail-Laminated Timber Concrete (NLTC) composite slabs. The slabs were made with lumber beams edge-joined with double nailing, end-joined with butt joints, and the reinforced concrete topping connected with a set of notches, inclined screws, or a combination of both. The multi-span configuration of slabs reduces their deflections simply and effectively. Five-point monotonic bending tests were considered for all slabs. Before full-scale slabs, compressive and tensile pull-out tests of Timber-Concrete Composite (TCC) shear connections were performed, including notches and inclined screws. Tensile pull-out tests of shear connections were also included to emulate the negative bending moments that occur in the middle of the slabs. Failure modes, load–mid-span deflection relation, bending stiffness, and timber-concrete slip were evaluated for all slabs. A detailed 3D micro-Finite Element (FE) model of the shear connections was built in ANSYS software, whereas a macro-FE model of NLTC slabs was made in SAP2000, demonstrating a good fit for the timber-concrete interaction and the load-carrying capacity of the composite slab at the serviceability range. Moreover, an analytical elastic TCC beam with the Girhammar method was assessed and demonstrated as more precise than the traditional γ-method. Finally, an accurate prediction of the numerical and analytical (Girhammar) models for the bending stiffness at service loads up to 30% of capacity is observed, with errors in a range of 2–23% and 9–74%, respectively.

Optimization of process parameters of cold metal transfer arc welding of AA 6061 aluminium Alloy-AZ31B magnesium alloy dissimilar joints using response surface methodology

The fabrication of dissimilar metal joints, particularly between AA 6061 aluminum alloy (Al) and AZ31B magnesium alloy (Mg), poses significant technical challenges due to their distinct metallurgical characteristics and the inherent difficulties associated with welding such materials. These challenges include the propensity for intermetallic compound formation, thermal cracking, and differences in thermal and mechanical properties between the two alloys. Cold Metal Transfer (CMT) welding, known for its low heat input and controlled metal transfer, offers a potential solution to these issues. However, optimizing the process parameters to ensure strong, defect-free joints requires a systematic approach. This study aims to optimize CMT welding parameters using parametric mathematical modeling (PMM) to produce high-strength Al and Mg dissimilar joints and to study the effects of CMT parameters on tensile strength (TS) and weld metal hardness (WMH), as well as the microstructural features of AA 6061 aluminum alloy/AZ31B magnesium alloy (Al/Mg) dissimilar joints. Al/Mg dissimilar butt joints were produced by the CMT process using ER4043 as filler wire. CMT, a low-heat input welding technique, was used to mitigate issues such as intermetallic compounds (IMCs), wider heat-affected zone (HAZ), and distortion. The CMT parameters, particularly wire feed speed (WFS), welding speed (WS), and arc length correction (ALC), were optimized using response surface methodology (RSM) to maximize the TS and WMH of the Al/Mg dissimilar joints. Polynomial regression was employed to create PMMs that integrated these CMT parameters to forecast the TS and WMH of the joints. An analysis of variance (ANOVA) was applied to assess the feasibility of the PMMs. The results indicated that the Al/Mg dissimilar joints, produced using a WFS of 4700 mm/min, a WS of 280 mm/min, and an ALC of 10%, exhibited higher TS and WMH values of 33 MPa and 95.8 HV, respectively. The PMMs provided precise forecasts for the TS and WMH of the Al/Mg joints with an error rate of less than 1% and a confidence level of 97%.

Features of Mechanical Properties and Residual Stress Distribution in Butt Joint of HSB690-SM355 Dissimilar Steel

Features of Mechanical Properties and Residual Stress Distribution in Butt Joint of HSB690-SM355 Dissimilar Steel

Comparative numerical analysis between butt and lap joints of Mg alloy friction stir welding with considering tilted tool effect

Magnesium (Mg) alloy, as an important lightweight structural metal, can be effectively joined by the friction stir welding (FSW) method. Understanding FSW temperature and material flow coupling process in butt and lap welding configurations has important theoretical significance. In this study, the tilted tool induced incomplete contact distance is calculated by process parameters and slip rate, and the deflection of the contact interface is related to the tool torque. The non-uniform boundary conditions are considered. The numerical model is proposed and experimentally validated by using the measured temperatures and thermo-mechanically affected zone (TMAZ) profiles. The comparative numerical analysis between butt and lap welding with three levels of process parameters is further conducted. The peak temperature and material flow velocity along the specified circumferences in FSBW are more than 10 K and 4 mm/s higher than these in FSLW, respectively. When the rotation rate increases from 600 rpm to 800 rpm, the peak temperature and material flow velocity along the specified circumferences increase about 20 K and 9 mm/s, respectively. When the welding speed decreases from 150 mm/min to 30 mm/min, the temperature and material flow velocity fluctuations along the specified circumference decreases about 25 K and 14 mm/s, respectively.

Enhancing tensile properties of MIG welded AA6061 joints: Effect of pulse mode and post-weld heat treatment

Metal-Inert Gas (MIG) welding is one of the most important welding technologies commonly used in the manufacturing industry due to its high degree of automation and welding adaptability. However, softening is prone to occur in fusion zone (FZ) and heat affected zone (HAZ) of AA6061 MIG welded joint, which limits its application. In this work, AA6061 was welded by MIG welding with different pulse modes, and the post-welding heat treatment was carried out. The results show that the dual pulse MIG (DP-MIG) and PWHT can significantly improve the mechanical properties of AA6061 butt joint, and its ultimate tensile strength (UTS) is 331.3 MPa, even more than 90% of the base material (BM). In this paper, the microstructure of welded joints under different pulse conditions before and after PWHT was compared, and the relationship between the welding process, microstructure, and mechanical properties was established Furthermore, the influence mechanisms of pulse mode and PWHT on the mechanical properties of welded joints were explained in detail.

Microstructure and Properties of Dissimilar Butt Joints of Aluminum to Copper by Cold Metal Transfer with Preheating

Microstructure and Properties of Dissimilar Butt Joints of Aluminum to Copper by Cold Metal Transfer with Preheating

Impact of the tool shoulder diameter to pin diameter ratio and welding speed on the performance of friction sir-welded AA7075-T651 Al alloy butt joints

This study investigates the friction stir welding (FSW) of aluminum alloy 7075-T651, mainly focusing on managing heat generation during the process. The critical parameters influencing heat amount and the material flow including FSW tool shoulder diameter (SD) and travel speed (TS) were investigated. Two far different SD of 10 mm and 20 mm with constant pin diameter (PD) of 5.70 mm that resulted in PD: SD ratios of 1:1.75 and 1: 3.50, respectively, were employed. Furthermore, three different travel speeds of 25, 50, and 75 mm min−1 at a constant rotation rate of 600 rpm were used in combination with the two PD: SD ratios. The macrographic and radiographic results indicated that the smallest PD: SD ratio has successfully achieved sound friction stir welded (FSWed) joints for the same travel speeds. Results also indicated that a significant amount of material deformed under a high PD: SD ratioat a high TS of 75 mm min−1, while flash increased with reducing PD: SD ratio.Mechanical properties were compared, revealing that hardness in the nugget zone (NZ) decreased with a lower TS of 25 mm min−1. A small PD: SD ratioallowed for more symmetrical heat distribution, supported by the hardness map. The ultimate tensile strength decreased with increasing TS, and the highest ultimate strength, reaching 319 MPa, was observed with a 1:1.75 ratio and TS of 25 mm min−1. X-ray diffraction analysis (XRD) found an increase in peaks with increasing shoulder diameter and the number of peaks increased with decreasing travel speeds.

Investigation of Microstructure and Mechanical Properties of High-Depth-to-Width-Ratio Horizontal NG-GMAW Joint for S500Q Steel.

A novel high depth-to-width ratio of 15:1 narrow-gap gas metal arc welding technique was developed for the welding of S500Q steel in a horizontal butt joint. The bead arrangement of the I groove was optimized to produce a high-quality connection with the upper sidewall of the joint. The microstructure and mechanical properties were observed and evaluated by optical microscopy, scanning electron microscopy, tensile testing, and micro-hardness and impact toughness testing at 1/5, 2/5, 3/5, and 4/5 thickness of the joint. The 3/5 T position exhibited the highest strength, which was attributed to the presence of finer carbide precipitates. The highest micro-hardness appeared at 4/5 T. The highest impact toughness appeared at 3/5 T. The formation of coarse granular bainite was the major reason for the decrease in impact toughness in other regions. A microscopic fracture at 1/5 T and 3/5 T was further analyzed. It was observed that the width of the fibrous zone at 3/5 T was significantly larger than that at 1/5 T. The radial zones at 1/5 T were observed to exhibit cleavage, with secondary cracks on the fracture surface.

Development of laser-arc hybrid welding process of butt joint for bogie pipe crossbeam components

High-speed railway vehicle bogies are the main load-bearing components, which are welded together from steel plates and tubes. Butt joint and T-joint are the main types and the joint thickness is between 8–20mm. The stability of laser-arc hybrid welding (LAHW) process correlated strongly with keyhole behaviour. In this paper, the common quality defects in full penetration root pass by LAHW were analysed. Controlling the root gap is adopted to stabilize the keyhole, to improve the stability of weld quality. A novel type of butt joint with micro structure based on Y-shaped grooves has been designed, to meet both the requirement of controlling root gap and industrial large-scale batch production. Two new structure parameters, 2 mm of the remaining blunt edge thickness and 0.3 mm of the half width of root opening, were proved by the flat plates welding test. Finally, the joint with micro structure and the root pass welding parameters were transferred to the welding process of tube crossbeam components. The LAHW process verification was completed, and the test results showed the process meets the requirements of ISO 15614.

Effect of Welding Gap of Thin Plate Butt Welds on Inherent Strain and Welding Deformation of a Large Complex Box Structure.

In this study, an effective numerical model was developed for the calculation of the deformation of laser-welded 3 mm 304L stainless steel plates with different gaps (0.2 mm, 0.5 mm, and 1.0 mm). The welding deformation would become larger when the welding gaps increased, and the largest deformation values along the Z direction, of 4 mm, were produced when the gap value was 1.0 mm. A larger plastic strain region was generated in the location near the weld seam, since higher plastic deformation had occurred. In addition, the tensile stress model was also applied at the plastic strain zone and demonstrated that a larger welding gap led to a wider residual stress area. Based on the above results, inherent deformations for butt and corner joints were calculated according to inherent strain theory, and the welding formation for the complex structure was calculated with different gaps. The numerical results demonstrated that a larger deformation was also produced with a larger welding gap and that it could reach the highest value of 10.1 mm. This proves that a smaller welding gap should be adopted during the laser welding of complex structures to avoid excessive welding deformation.

Tailor-joining of Ti6Al4V skin with V-shaped assembly error using enhanced PLBW scheme: Keyhole dynamics and metal bridging behavior

Building thin-walled titanium alloy skin using conventional laser beam welding (LBW) frequently suffers from undesirable seam quality due to the V-shaped notch; a typical assembly error occurs after skin rolling with a specific sheet thickness range. This work proposed an improved scheme with metal bridging capacity and liquid film stability to overcome this by executing a pulsed laser beam and spot irradiation in a flat-top mode. Welding was performed on 1.5 mm-thick Ti6Al4V sheets configured in the butt joint with a reserved notch geometry, which is 20 degrees between the groove surface. We also conducted numerical modeling and solutions concerning the heat-flow-phase dynamics using an enhanced ray tracing algorithm. Results show that the as-build weld beads, characterized by middle rippers, slight depression, and edge ridges, present superb continuity and uniformity when applying an average heat input of 40–90 J/mm and a pulse energy of 187.5–750 J. Effective metal bridging across the notch error is achieved at both pulse duration and interval phases due to not only the complete melting of welding side but also the enhanced melt film stability against the surface tension. The cooling of the weld pool starts with a sharp temperature drop at ∼3×105 K/s (on average) during the keyhole collapsing regime, then slows down due to the damped up-down oscillation of the free surface combined with the natural convection-conduction effect. The flow pattern of molten metal changes from squeezing-like to vortexes and finally to a backfilling mode, depending on the evolution of keyhole geometry. Although the keyhole dynamics differs, various process conditions regarding heat input and pulse energy yield effective metal bridging of a single weld spot and sufficient refusion between the adjacent weld spots, ensuring the well-overlapped weld bead formation.

Experimental study on mechanical behaviour of friction stir welded aluminium alloy butt joints

The purpose of this paper is to understand the softening extent and stress-strain behavior of the normal-strength 6061-T6, 6013-T6, and high-strength 7075-T6 aluminium alloy butt joints using the novel friction stir welding (FSW) technique. A total of 107 monotonic tensile coupons and 33 Vickers hardness coupons were prepared from 8- or 12-mm thick welded plates using various tool rotation speed, welding transverse speed and tool configurations. The surface morphology, stress-strain curves and hardness distribution laws after welding were evaluated. The W-shaped hardness profiles were clearly observed, with the fracture location positively correlated at the lowest point of Vickers hardness near the edge of the weld toe. The strength reduction and softening extent of extruded aluminium alloys in T6 temper induced by FSW were superior to those of aluminium alloys using fusing welding process outlined in the Chinese and European standards, indicating the effectiveness and applicability of the FSW technique in the formation of components and connections for aluminium alloy structures. Additionally, the current widely used constitutive models generally yielded under-estimations on the strength under large strains. The developed three-stage Ramberg-Osgood model, using seven key input parameters, significantly improved the accuracy and consistent predictions in the full-range stress-strain curve of FSW aluminium alloys. Furthermore, the suggested model could still achieve a great balance between accuracy and practicality when using just three common available parameters with the employment of predictive expressions on other four parameters.

Effect of beam current on microstructure, tensile properties and corrosion behaviour of electron beam welded zircaloy-4 joints

ABSTRACT Butt joints of zircaloy-4 were made using electron beam (EB) welding. The effect of beam current (15–20 mA) on weld zone size, microstructure, porosity, mechanical and corrosion properties has been investigated. Local temperature and cooling rate were estimated, and the average cooling rate increased from 2.4 to 6.3°C ms–1 with a decrease in beam current in the said range. Joints prepared at lower beam current possessed smoother weld surface, narrow weld bead, and fine lamellar type widmanstätten structure in the fusion zone (FZ). The length of the α-Zr lamella (from 105 to 37 µm) and interlamellar space (from 0.8 to 0.3 µm) decreased with a decrease in beam current. The XCT result revealed that porosity increased with an increase in beam current, and large-size micro pores of 180 µm were present in joints prepared at high beam current. The hardness of the welded samples increased by 13–20% than the base metal. The joint prepared with a low beam current possessed higher ductility (29%) and a minimum corrosion rate (0.0085 mmpy in 3.5 wt-% of NaCl solution) than the joint made with a higher beam current.