Weld Formation Research Articles

Study of Process, Microstructure, and Properties of Double-Wire Narrow-Gap Gas Metal Arc Welding Low-Alloy Steel

Narrow-gap arc welding is an efficient method that significantly enhances industrial production efficiency and reduces costs. This study investigates the application of low-alloy steel wire EG70-G in narrow-gap gas metal arc welding (GMAW) on thick plates. Experimental observations were made to examine the arc behavior, droplet transition behavior, and weld formation characteristics of double-wire welding under various process parameters. Additionally, the temperature field of the welding process was simulated using finite element software (ABAQUS 2020). Finally, the microstructure and microhardness of the fusion zone in a double-wire, single-pass filled joint under the different welding speeds were compared and analyzed. The results demonstrate that the use of double-wire GMAW in narrow-gap welding yielded positive outcomes. Optimal settings for wire feeding speed, welding speed, and double-wire lateral spacing significantly enhanced welding quality, effectively preventing side wall non-fusion and poor weld profiles in the welded joints. The microstructure of the fusion zone produced at a higher welding speed (11 mm/s) was finer, resulting in increased microhardness compared to welds obtained at a lower speed (8 mm/s). This is attributed to the shorter duration of the liquid molten pool and the faster cooling rate associated with higher welding speed. This research provides a reference for the practical application of double-wire narrow-gap gas metal arc welding technology.

Influencing of Molten Pool Dynamic Behavior on the Weld Formation during the Laser‐Arc Hybrid Welding of 12 mm Thick Steel

A numerical simulation model is put forward to study the molten pool dynamic behavior and clarify its influencing mechanism on the undercut defects in laser‐arc hybrid welding (LAHW). The undercut defect is a common and challenging problem to address. However, a controversy exists on whether the dynamic process of molten pool can affect undercut defects, and the potential mechanism has been still unclear. The results suggest that profile variation of molten pool surface is driven by surface tension gradient, and the existence of eddy can alter the morphology and surface tension distribution of molten pool, which is the main factor to homogenize the flow field. Compared with the short‐circuit transfer mode, the molten metal flows toward the welds edge at a constant velocity (2.5–3.75 m min−1) in the spray transfer mode, which improves the stability of molten pool flow. It can be observed that the irregular fluctuation of molten metal during the solidification process can directly cause the undercut defects.

Effect of shielding gas on keyhole stability and pores in laser-CMT hybrid welding of ultra-high strength steel

Laser-CMT hybrid welding (LCHW) is a highly efficient and high-quality welding technique, showing promise for welding ultra-high strength steel (UHSS) in the aerospace industry. However, the presence of pores significantly limits its application in this field. It has been observed that using an argon-rich gas can effectively stabilize the keyhole and prevent the formation of pores. Therefore, this study aims to investigate the effect of different shielding gases on keyhole stability and porosity. The weld profile, pores, electrical signal, droplet transfer, and molten pool internal flow were carefully characterized and compared with various shielding gases. The results show that increasing the CO2 content gradually reduces weld porosity. The optimal weld formation and porosity were achieved at a CO2 content of 25 %. With the CO2 content increases, the droplets shift from off-axis upwards to downwards. This shift increases the distance between the droplet and the keyhole, reducing the time for droplet growth and promoting droplet transfer. Furthermore, the surface tension pressure gradually decreases from 3.86 Kpa to 1.1 Kpa, and at Ar + 25 % CO2, itpromote the opening of keyhole and further suppress the formation of the protrusion on the keyhole rear wall. In addition, when the CO2 content reaches 25 %, the top metal of the molten pool changes from counterclockwise flow to clockwise flow, reducing the likelihood of keyhole collapse. These effects stabilize the keyhole and suppress the formation of pores.

A computational fluid dynamics-based girth welding model for large-diameter pipeline to reveal vertical weld formation mechanism

Welding quality significantly impacts the safety of large-diameter, long-distance pipelines. The molten pool flow, influenced by gravity, results in variations in the girth weld seam at different circumferential orientations. A three-dimensional transient computational fluid dynamics model was developed to study the multi-layer, multi-pass welding process of X80M pipeline, incorporating arc heat, droplet heat, gravity, and fluid flow in the molten pool. The model also simulates dual-torch automatic welding to examine heat transfer and flow characteristics. Notably, it reveals the morphological evolution of the girth weld seam from the 2 to 3 o'clock positions during continuous welding, an area lacking prior research. The results, validated by experiments, show good agreement between the simulation and thermal cycle curves. The weld pool solidifies from the sides toward the center, creating a concave shape due to downward metal flow, with dual-torch welding intensifying this effect. The second torch increases the concavity of filler layers, with depths rising by 21.81% and 32.20%. These findings offer new insights into pipeline girth welding.

Documenting weld pool behavior differences in variable-gap laser self-melting and wire-filling welding of titanium alloys

In large-scale welding processes involving complex geometries, variations in gap dimensions and the transition of filler wire form distinctive molten pool flow behaviors, significantly affecting weld formation and quality. This paper investigates the differences in the laser self-melting and wire-filling welding pool behavior of titanium alloy with variable gaps through both simulation and experimentation. An innovative three-dimensional transient heat-flow coupling model is developed to simulate laser welding with variable gap structures, incorporating the dynamics of the welding wire-filling process. The different laser welding modes and the filling process under the variable gap structure were numerically simulated. The results indicate that the maximum flow rate of the laser self-melting pool remains stable in proximity to the keyhole, reaching a maximum of approximately 2.491 m/s, with molten metal entering through the area surrounding the keyhole. As the gap size gradually increases to 0.2 mm during the laser self-fusion welding stage, keyhole instability becomes more pronounced. In transitioning from laser self-fusion to wire-filling welding, the welding wire behavior can be divided into three stages. The molten metal at the end of the welding wire is transferred to the liquid melt pool through a liquid metal bridge. The flow rate of this bridge initially rises before gradually decreasing, reaching a maximum flow rate of 1.606 m/s. Notably, the welding wire lags approximately 0.6 mm behind the laser's focal point, with the narrowest width of the liquid bridge measuring about 0.89 mm. Based on the simulation results and considering the melting transition time of the welding wire, the initiation time for the welding wire has been further adjusted to the first 10 ms when the gap threshold reaches 0.2 mm. Experimental verification confirms the successful laser welding of a 2 mm variable gap structure thin plate. This study elucidates the melt pool flow, keyhole fluctuations, and metal transition behaviors during the laser welding process, contributing to a deeper understanding of the complex heat and mass transfer dynamics inherent in variable gap structure laser self-melting and wire-filling welding. Ultimately, these insights aim to enhance the application of laser welding in adaptive welding for large structural components.

Orbital-Based Automatic Multi-Layer Multi-Pass Welding Equipment for Small Assembly Plates

To address the technical challenges, production quality issues, and inefficiencies caused by the heavy reliance on traditional manual processing of small assembly plates in the shipbuilding industry, this paper presents the design and analysis of a track-based automatic welding device. This equipment provides a solution for achieving batch and continuous welding in the field of automatic welding technology. The design section includes the mechanical design of the equipment’s core mechanisms, the design of the operating systems, the development of visual scanning strategies under working conditions, and the formulation of multi-layer and multi-pass welding processes. The analysis section comprises the static analysis of the equipment’s mechanical structure, kinematic analysis of the robotic arm, and inspection analysis of the device. Compared with manual welding, multi-layer and multi-pass welding experiments conducted using the equipment demonstrated stabilized welding quality for small assembly plates. Under the conditions of single plates with different groove positions and gaps, when the gap was 4 mm, processing efficiency increased by 7.35%, and processing time was reduced by 10.2%; when the gap was 5 mm, processing efficiency increased by 10.7%, and processing time decreased by 7.39%. The welding formation rate for the overall processing of single plate panels and web grooves increased by 11.48%, total material consumption decreased by 13.4%, and unit material consumption decreased by 13.5%. For mass production of small assembly plates of the same specifications, processing time was reduced by 16.7%, and there was a 41.4% reduction in costs. The equipment effectively addresses the low level of automation and heavy dependence on traditional manual processing in the shipbuilding industry, contributing to cost reduction and efficiency improvement.

Enhanced material flow and joint formation of FSWed AA2024 by using protruding cylinder tool

The optimization mechanism of the protruding cylinder on the modified tool for the performance of friction stir welding (FSW) joints in 2024 aluminum alloy was investigated. The results indicate that the presence of a protruding cylinder on the modified tool significantly improves the surface quality of the weld, increases the width and area of the weld nugget zone(WNZ), and refines the grain size. Additionally, the size of the precipitated phases is reduced, and their distribution becomes more uniform, which in turn enhances the tensile strength and hardness of the joint. Furthermore, the presence of a protruding cylinder facilitated material flow, stabilized the welding process, and contributed to the formation of uniform welds.

Steel Catenary Riser Fatigue Assessment: Fracture Mechanics Approach Versus S-N Curve Method.

In this paper, the fatigue resistance of a full-scale Steel Catenary Riser (SCR) girth weld is investigated using the Strength-Number of cycles (S-N) curve method based on weld formation quality and fracture mechanics approaches. The test results, presented in the form of S-N curves, are superior to the design curve E in BS 7608. Compared with the S-N curve determined by a resonant bending rig, the analytical fracture mechanics, i.e., engineering critical assessment (ECA) based on BS 7910, can provide a rational estimation of full-scale girth welds. For the numerical methods, the short crack growth phase is crucial to improving the accuracy and reliability of the assessment. For the girth weld with a concave root, the geometries of the weld cap are the predominant factors for fatigue life. Although the crack initiation site is always located at the outer surface regardless of the flushed or welded caps, the weld grinding treatment is still effective in promoting fatigue life.

Dissimilar unbeveled aluminum to steel butt joint achieved by laser-arc hybrid welding-brazing

In this study, unbeveled butt joints of 2 mm thick steel and aluminum plates were welded using a laser-arc hybrid process. The influence of welding speed and wire feed speed on joint weld formation, microstructures, and mechanical properties were investigated. The results indicate that using a laser-arc hybrid heat source enables good weld formation of steel/aluminum dissimilar metals without groove preparation, even under high welding speed conditions. The steel side interface formed Fe₂(Al,Si)₅ near the steel and Fe(Al,Si)₃ near the aluminum. As the welding heat input decreased, the thickness of the intermetallic compounds gradually reduced. With an increase in welding speed or wire feed speed, the tensile strength of the joint first increased and then decreased, reaching a maximum of 104.47 MPa. Cracks propagated rapidly along the intermetallic compound region, resulting in brittle fracture characteristics. The three-point bending test showed a maximum longitudinal bending angle of 53.82° and a maximum transverse bending angle of 36.54°.

Investigation on metal vapor characteristics and keyhole/melt pool dynamics in high-power laser welding with side gas flow

High-power laser welding processes involve intense interactions between the laser beam and the base material, resulting in severe welding defects such as humping, spattering, and undercutting. Utilizing side gas flow may provide an effective approach for minimizing these defects. However, the effects of side gas flow on the dynamic behavior and weld formation necessitate further investigation. In this study, an innovative analysis of metal vapor characteristics and keyhole/melt pool dynamics in high-power laser welding with side gas flow is presented, combining experimental and simulation results. A three-dimensional transient fluid flow model was developed, uniquely integrating an adaptive heat source, evaporation-condensation processes, and metal vapor energy attenuation to provide a novel perspective on the effects of side gas flow in high-power laser welding. The results display that side gas flow could suppress plasma, increase thermal input to the melt pool, and intensify the flow of liquid metal toward the pool bottom during high power laser welding, thereby enhancing weld seam penetration. The numerical results indicate that variations in flow rate significantly impact metal vapor morphology, with higher flow rates reducing both the average area and height of the metal vapor and effectively suppressing the size of metal vapor/plasma. When the side gas flow rate is 20 l/min, with the gas flow impact point located at the keyhole opening and the nozzle height set to 3 mm, the side gas flow significantly enhances the depth-to-width ratio of the weld seam in 316L stainless steel laser welding. This work can provide guidance for suppression of weld defects in high-power laser welding of medium-thick steel components, which has important theoretical significance and application value.

Lap joining of Ti6Al4V titanium alloy by vortex flow-based friction stir welding

The current study uses a novel vortex flow-based friction stir lap welding (VFSLW) process to weld 1.4 mm thick Ti6Al4V sheets, trying to replace the diffusion bonding in the superplastic forming/diffusion bonding process. The mechanical properties and joining mechanism of the VFSLW joint were investigated. Good weld formation was obtained at 300–350 rpm and 80 mm/min. No hook defect was formed in the lap interface. The lap joint fractured across the stir zone (SZ) in the top plate under the optimal parameters. The cracks initiated from the oxidation defect, where the oxides on the workpiece surface were involved in the SZ by the vortex during the welding. It suggests that a good argon shield is very important for the VFSLW of titanium alloy. The highest tensile strength reaches ∼890 MPa, up to 95 % of the base material. The formation of an α + β lamellar structure in the SZ is due to the peak welding temperature exceeding the β-transus temperature. In the bonded zone (BZ), a very thin layer with ultrafine α grains was formed by dynamic recrystallization in the α phase field, although its two sides are α + β lamellar structures. This is because of the oxidation on the workpiece surface during the welding process and the O element is a strong α stabilizer.

Study on Arc Behavior and Weld Formation of Magnetically Controlled Narrow Gap TIG Welding

Study on Arc Behavior and Weld Formation of Magnetically Controlled Narrow Gap TIG Welding

Effect of Beam Oscillation on Weld Formation, Porosity, Grain Structure, and Mechanical Properties in Electron Beam Welding 5B70 Aluminum Alloy

Effect of Beam Oscillation on Weld Formation, Porosity, Grain Structure, and Mechanical Properties in Electron Beam Welding 5B70 Aluminum Alloy

Improvement of technology and equipment for welding vertical joints with forced weld formation

Improvement of technology and equipment for welding vertical joints with forced weld formation

Coupling effect of dynamic power and oscillation path on butt weld formation and melt flow behavior during aluminum alloys

The influence of the coupling effect between dynamic power and oscillation path on the formation of weld seams and the fluid behavior of the molten pool during laser welding of 5A06 aluminum alloy was investigated through numerical simulation and experimentation. Three power modes were compared in the experiments: equal power (EP), delayed dynamic power (D-DP), and non-delayed dynamic power (ND-DP). The experimental results show that both D-DP and ND-DP modes are favorable to improve the mechanical properties. Among them, the joints formed under the D-DP mode exhibit the best mechanical properties, with an average tensile strength reaching ≈ 99.1% of the base material, which is an increase of ≈ 35.3% and ≈ 5.6% compared to the EP and ND-DP modes, respectively. Numerical simulation results indicate that the D-DP mode effectively mitigates the average flow velocity of the molten pool, reduces the collision effects between liquid flows, suppresses the impact of fluid on the keyhole walls, and improves the stability of the keyhole and the welding process, thereby enhancing the mechanical properties of the joints.

Dynamic behavior regulation of droplet transfer based on arc-bubble control by ultrasound-induced during underwater wet welding

In comparison to welding in air, the periodic formation of unstable arc bubbles is a significant factor contributing to the unstable mass transfer process during underwater wet welding (UWW). Up to now, there is no ideal method to control droplet transfer and improve arc stability. In this study, the ultrasound-induced method (UIM) was used to regulate the droplet transition behavior and improve the process stability. The behavior features and key mechanisms of arc-bubble and droplet transfer induced by ultrasound were revealed with the employment of highspeed camera and X-ray observation, respectively. The incident angle of ultrasound was taken as a variable to reveal its effects and mechanism of action on the behaviors of arc bubble and droplet transfer, weld formation quality, microstructure, and property of weld joint. The results show that ultrasound-induced a new rising mode of arc bubble, which can significantly reduce the repulsive resistance that come from the bubble rising on the droplet transfer process. Compared with underwater wet welding without ultrasound, the average diameter of molten droplets reduces from 3.2 mm to 1.7 mm, and the droplet transfer frequency increases from 7.8 Hz to 13 Hz as the incident angle of ultrasound increases to 60°. In addition, the weld seam without obvious defects could be produced by UWW with UIM, of which the Variation coefficient of weld reinforcement is reduced from 21.3 to 11.6 and 17.4 at an ultrasonic incident angle of 30° and 45°. With increasing of ultrasound incident angle, it showed that the microhardness of the weld joint has a slight increase. In the heat-affected zone, the microhardness for the joint increased from 290 HV to 320 HV while the incident angle increased to 60°. This research shows that an appropriate incident angle of ultrasound can obtain good-quality joints which has a stable metal transfer process in underwater wet welding.

A novel method for fully penetrated U-rib-to-deck joints: Single-sided oscillating laser arc hybrid welding

U-rib-to-deck (RTD) joints represent one of the most critical and vulnerable welding details of orthotropic steel decks. Aiming for full penetration and high-level service performance, a novel method with single-sided oscillating laser-arc hybrid welding (OLAHW) technique was proposed for the RTD joint. The weld formation, microstructure and mechanical properties were extensively investigated. The results indicated that the porosity and lack of fusion (LoF) defects effectively suppressed with the beam oscillation during LAHW process. The OLAHW technique has good spatial accessibility with larger laser beam incidence angle of 20° Beam oscillation led to an increase in acicular ferrite in the fusion zone (FZ) while simultaneously a reduction of martensite in the heat effected zone (HAZ). This was related to the cooling time, and the thermal simulation results revealed that the OLAHW sample demonstrated comparable cooling times in both the Laser-FZ and arc-FZ. Consequently, beam oscillation can generated more homogeneous microstructures and microhardness. Although the microhardness of the OLAHW sample in the FZ was increased compared to the conventional arc welding (CAW) and LAHW sample, the highest microhardness value remained within acceptable limits (380 HV). Moreover, the ultimate tensile strength of the OLAHW weld sample increased by 7 % compared to the CAW weld sample. The application of the OLAHW technique demonstrates its feasibility for engineering applications in orthotropic steel decks manufacturing.

Study on molten pool flow and hot cracking of narrow gap laser welding of 316LN stainless steel for fusion reactor

In this paper, narrow-gap laser welding (NGLW) of 316LN stainless steel was studied. The results indicated that continuous laser welding with filler wire (CLWFW) and pulsed laser welding with filler wire (PLWFW) can obtain good weld formation under the transition of the wire bridge, and when the pulsed laser was a trapezoidal wave, the hot cracks of the filling layer can be greatly inhibited. The intermittent output of the pulsed laser reduced the temperature gradient of the molten pool and enhanced the morphology of the caudal region of the molten pool. Meanwhile, timely liquid backfilling effectively relieved the stress concentration of the weld, thus inhibiting the generation of hot cracks. Besides, the intermittent pulse energy input had a stirring effect on the molten pool, which disturbed the growth direction of the dendrite grain and refined the grain; consequently, the impurity elements were fully diffused, and the distribution of elements in the weld center area was more uniform.

Microstructure and mechanical properties in electron beam scanning welded joints of super thick titanium alloy plates

It is generally difficult to obtain good weld formation and excellent properties in super thick titanium alloy joints via conventional electron beam welding (EBW) methods due to the fact that the melt pool flow becomes more unstable as the plate thickness increases. In this study, electron beam scanning welding (EBSW) was utilized to weld 100 mm Ti–6Al–3Nb–3Zr–1Mo titanium alloy plates to improve the weld formation and impact toughness through the scanning effect. The results revealed that there were spatter and cutting defects on the surface and inner pore defect in the normal EBW joint, which could be effectively eliminated via EBSW. The decrease of the amplitude of the fluid flow rate and the change of the velocity direction were mainly responsible for this. A large amount of lamellar α phase with similar orientation was formed in the fusion zone (FZ) due to the fast cooling rate. The joint coefficient for both EBSW and EBW reached 100%, with the joint tensile strength of ∼840 MPa. The impact energy of the FZ in the EBSW joint was 70.5 J, reaching 210.4% of that of the BM (33.5 J). The impact toughness increase ratio in this study was far larger than those for Ti alloy welds ever reported, which was mainly attributed to that the high angle α colony boundaries with high preferred orientation in the FZ deflected the crack propagation direction. This study provides a reference for the strength-toughness design of EBWed joints of super thick Ti6331 titanium alloy.

Laser transmission welding of Polyphenylsulfone resin using Sn film absorbent: Weld formation control and mechanical properties enhancement

Polyphenylsulfone resin (PPSU), holding significance across various domains, was successfully welded by the laser transmission welding (LTW). In order to optimize the morphology and mechanical properties of the weld seam, the Sn film was chosen as an intermediate layer and the mechanism governing the formation control and mechanical performance was unveiled. Without the addition of Sn film, weld formation was subpar, marked by defects such as bubbles occurring in the weld seam, particularly under moderate power conditions. After introducing Sn film as a metal absorbent, the molten pool pores were stabilized and the temperature distribution was optimized during LTW process, which promoted the welding process stability and facilitated the mixing and agitation of the molten pool. The Energy-dispersive X-ray Spectroscopy (EDS) and X-ray Photoelectron Spectroscopy (XPS) were conducted on cross-sections of the weld seam. Analysis revealed the formation of newly forged metallic bonds (SnC) between the metal and the PPSU, which were instrumental in bolstering the shear strength of the weld seam. After using the Sn as intermediate layer, the shear strength of welding joints increased from 23.21 MPa to 29.14 MPa. At optimal intermediate-layer thickness, the shear fracture exhibited predominantly a plastic tearing micro-pit morphology instead of brittle fracture rock pattern.