Plate Welding Research Articles

Numerical simulation of welding residual stresses in 6082-T6 thin aluminum alloy

Thin plate aluminum alloys of the 6082 series are widely used in welded car bodies because of their excellent characteristics such as light weight and high strength. For welded joints, residual stresses significantly affect fatigue strength properties, especially in thin plate welding. In this study, the residual stresses arising from inert gas welding of thin sheet aluminum alloy metals were investigated using numerical simulation techniques. The thermo-elastic–plastic method was used to calculate simulated weld temperature and stress fields. Temperature and stress variations during the welding process were discussed to investigate the causes of residual stresses. The changes in stress during the experimental welding process were tracked, and the results were in agreement with the simulations. The impact of process parameters on welding stress was analyzed through simulation and experimentation. The results showed that residual stress decreases as speed increases and increases as power increases.

Prediction and optimization method for welding quality of components in ship construction

Welding process, as one of the crucial industrial technologies in ship construction, accounts for approximately 70% of the workload and costs account for approximately 40% of the total cost. The existing welding quality prediction methods have hypothetical premises and subjective factors, which cannot meet the dynamic control requirements of intelligent welding for processing quality. Aiming at the low efficiency of quality prediction problems poor timeliness and unpredictability of quality control in ship assembly-welding process, a data and model driven welding quality prediction method is proposed. Firstly, the influence factors of welding quality are analyzed and the correlation mechanism between process parameters and quality is determined. According to the analysis results, a stable and reliable data collection architecture is established. The elements of welding process monitoring are also determined based on the feature dimensionality reduction method. To improve the accuracy of welding quality prediction, the prediction model is constructed by fusing the adaptive simulated annealing, the particle swarm optimization, and the back propagation neural network algorithms. Finally, the effectiveness of the prediction method is verified through 74 sets of plate welding experiments, the prediction accuracy reaches over 90%.

Robot welding process planning and process parameter prediction of medium-thick plate based on three-line laser

In order to realize the intelligence and flexibility of V- groove robot welding of medium-thick plates, a multi-layer welding process control strategy for welding with a weaving robot is proposed based on three-wire structural light vision. For the optical localization of the welding start point, a “rough first, accurate later” guidance approach is proposed. A technique utilizing Gaussian-weighted plane fitting is employed to model the groove and extract information about the weld shape. The welding torch’s orientation planning is based on the angular bisector of the groove, and the GA-BP neural network is utilized to forecast welding parameters for various welding techniques. It is shown that the strategy in this paper can guide the robot to complete the welding job. The error between the guide start point and the actual welding start point does not exceed 2 mm, and the predicted welding parameter results align with the welding technology standards.

Multi-pass butt welding of thick TA5 titanium-alloy plates by MIG: Microstructure and properties

A 35 mm-thick TA5 titanium alloy plate was successfully joined by metal inert-gas (MIG) welding. The welded joints were analyzed in a more integrated and comprehensive manner. The joint microstructure was analyzed by OM, SEM, EBSD, and TEM. Mechanical properties were analyzed by tensile, impact, and microhardness tests. The corrosion resistance of the joints was determined by FeCl3 immersion corrosion. Experimental results showed that the mechanical properties and corrosion resistance of the fusion zone (FZ) were poorer than those of the base material (BM). The mechanical properties of the welded joints were related to the acicular grains in the FZ. The 260 A joints showed relatively good mechanical properties. With increased welding current, the proportion and size of the acicular grains increased, and the strength of the joint increased, but the plastic toughness decreased. When the welding current was too small, anisotropy occurred in the FZmiddle, which affected the mechanical properties of the joints. The corrosion resistance of the FZ was lower than that of the BM, and the corrosion resistance of the three groups of joints decreased in the order 300 A > 230 A > 260 A.The welding current affected the corrosion resistance of the FZ by influencing the grain size of the FZ, the frequency of the HAGBs, and the GND density.

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.

Study on CFRP-Strengthened Welded Steel Plates with Inclined Welds Considering Welding Residual Stress.

Welded steel plates are widely used in various structural applications, and the presence of inclined welds is often encountered in practical scenarios. Carbon fiber reinforced polymer (CFRP) has been proven to be effective for strengthening steel structures. However, the behavior of CFRP-strengthened welded steel plates with inclined welds, particularly considering the influence of welding residual stress, is limited. This paper aims to investigate the tensile behavior of CFRP-strengthened welded Q355 steel plates with inclined welds considering welding residual stress (WRS). First, WRS data were obtained by the X-ray diffraction (XRD) method at different locations. The maximum tensile and compressive residual stresses are 0.39 and 0.14 times the yield strength of the steel, respectively. Then, finite element models were established to investigate the effects of weld angles, weld width, and height on the WRS distribution of welded steel plates. Finally, the tensile performance of CFRP-strengthened welded plates with WRS was studied by numerical simulation. The results showed that the weld angles have little effect on the distribution pattern of residual stress but significantly affect the peak tensile WRS. When the weld angle changes from 0° to 60°, the peak tensile WRS decreases significantly from 0.32 to 0.06 times the yield strength of steel; furthermore, the influence of weld width and height on WRS is relatively limited. Under tension loading, the maximum stress occurs near the weld. The ends of the weld enter the yielding state later than the middle part of the weld due to the distribution of the WRS. As the weld angle increases and the length of the weld increases, the stress in the weld zone decreases, while the stress in the base material zone correspondingly increases. In addition, CFRP strengthening can reduce the magnitude of stress. This study provides preliminary references for understanding the tensile behavior of CFRP-strengthened welded steel plates with inclined welds.

Experimental and numerical investigation on optimization of welding parameters and prediction of temperature distribution during shielded metal arc welding of ultra high hard armor steel joints

In this investigation, Ultra-high Hard Armor (UHA) steel plate by Shielded Metal Arc Welding (SMAW) process using the Austenitic Stainless Steel (ASS) electrode. In the first part of this investigation, using the finite element method (FEM), thermal analysis parameters were optimized using bead on plate welds in software code, known as SYSWELD. In the second part, using optimized parameters, a coupled thermo-mechanical analysis on multipass welded fabrication was carried out. Weld thermal cycles were analyzed by simulation and compared with experimentally measured temperature profiles. A double ellipsoidal heat source model was used to simulate the SMAW process. The heating rate and cooling rate were calculated along with residual stresses. This range of heating and cooling rate resulted in untempered martensite in the heat-affected zone (HAZ), confirmed by microstructure analysis and hardness mapping. Good validation was found between the measured and simulated 2D model with a 4–10% variation. This study suggests that numerical simulation is the capable technique in understanding the thermal and mechanical properties that influence the welding of ultra-high hard armor steels joints.

Metallurgical Characterization of Micro Friction Stir Spot Welding (μFSSW) Parameters on Similar Materials AA1100

The Micro Friction Stir Spot Welding (μFSSW) process is a metal plate welding technique with a relatively thin plate thickness. The advantages of this welding are the higher quality of the weld and the relatively low deformation. This study aimed to determine the effect of depth of penetration, dwell time, and tool geometry on the trend of material flow on the macro-structure of the welds produced in μFSSW technique using AA1100 thin aluminum plates. In this study, the parameters that are changed are the depth of the chisel, dwell time, and tool geometry. In this study, the parameters of the penetration depth were divided into 500 microns, dwell time was split into three lengths of time (300 ms, 500 ms, and 700 ms), and tool geometry was divided into two types of tool geometries (tool-1 and tool-2). In addition, the macro test was carried out to determine the depth of the weld, contour profile, and stretch macrostructure. The results of the macro test will be used to analyze the material flow relationship in each weld zone on the welding results of all existing parameters. Based on the results of the study, the effect of depth of penetration, dwell time, and tool geometry on the weld depth and metallography (hook width, hook height, and effective top sheet thickness) of welds using AA1100 thin plates is influential along with various tool geometries and the deeper the weld penetration and the longer stirring time, although the results are not always directly proportional.

Effect of variable-thickness webs on shear buckling performance of welded steel plate girders: Numerical analysis and proposed design rules

The use of welded steel members with varying thickness webs is becoming more popular and is often used as plate girders to accommodate varying loading distributions. Such variable-thickness steel plates are more susceptible to experiencing out-of-plane shear buckling, particularly in the thinner sections. However, no research work has been described investigating the shear buckling strength of welded steel plate girders with variable-thickness webs. This study presents an extensive numerical analysis to examine the shear buckling strength of such steel members with variable-thickness webs. Finite element (FE) models incorporating the material non-linearity and initial geometric imperfections were developed. To validate the modelling approach employed in this investigation, a total of 41 experimental results reported by the authors and other researchers were used. A detailed parametric study was subsequently undertaken, exploring various variables including local geometrical imperfections, aspect ratio, thickness change ratio, residual stress, and yield strength. To assess the accuracy of the current design regulations, the test and parametric study results were compared against design strengths. Upon comparison, the current design regulations as specified in Chinese Code (GB 50017), American Specification (ANSI/AISC 360-10) and Eurocodes (EN 1993-1-5) are over-conservative when computing the strength of such members with variable-thickness webs. Finally, new design rules covering both cases of variable-thickness and constant-thickness webs are proposed. A reliability analysis was conducted, and the values of β were 2.87, 3.00, and 3.04, respectively, indicating that new design methods developed in this study could closely determine the shear buckling strength of such welded steel plate girders with variable-thickness webs.

Estimating welding deformation of ultra-thin mild steel bead-on-plate joints by means of inherent strain method

The inherent strain method as an efficient computational tool has been widely used to predict welding deformation for large and complex structures with thin and medium-thick plates. For ultra-thin plate welded structures, geometric non-linear phenomena often arise during welding because of the low stiffness. In this study, the welding deformation of 0.8 mm thick bead-on-plate mild steel joints was studied by both experimental method and thermal-elastic-plastic finite element method (T-E-P FEM), and the influences of weld lengths on Tendon force, transverse shrinkage and angular distortion were examined experimentally and numerically. Meanwhile, a non-linear elastic finite element method based on the inherent strain theory using ABAQUS software as a platform was developed to reproduce the welding deformation of the ultra-thin bead-on-plate joints with different weld lengths, and the adaptability of the inherent strain method to ultra-thin plate weldments was clarified.

A digital twin approach toward unlocking elasto-plastic fatigue crack growth rates under negative load ratios

This paper introduces a novel digital twin solution for unlocking the elasto-plastic fatigue crack growth within an S550 steel under negative load ratios. The digital twin transforms solely strain data from a strain-interfaced welded plate joint specimen to the load–displacement curve to compute cyclic J-integral values using the η approach, eliminating the need for load and displacement measurements. The accurate computation of the elasto-plastic ΔJ effectively extends the fatigue crack growth relationship derived from standard fracture specimens. The extended fatigue crack growth relationship accurately predicts the fatigue life of specimens under separate step-up and step-down variable amplitude loading regimes.

Fatigue behaviour of root crack in stiffener-to-deck plate weld at crossbeam of orthotropic bridge decks

Steel Orthotropic Bridge Decks (OBDs) are widely used in long-span and movable bridges. Fatigue resistance analysis plays an important role in the design or assessment of OBDs. One possible fatigue failure is the crack initiating from the weld root of stiffener-to-deck plate connections at crossbeams. A full-scale experimental investigation in this study using a 20 mm thick deck plate with a dimension of 9.4 m × 5.1 m, including three crossbeams, represents the modern designed OBDs. The experiments show an arrest of crack propagation with a final crack depth of approximately 75% of the deck plate thickness. On the contrary, through thickness cracks develop in deck plates of 10 or 12 mm. Hot spot stress based fatigue detail categories (DC) using various failure criteria derived from the tests. Analysis with the effective notch stress shows that the DC has low sensitivity to the amount of weld penetration. The results of analyses with the eXtended Finite Element Method (XFEM), employed to analyse the fatigue crack propagation path and crack arrest, are in line with the experimental study.

Improving the Formation and Quality of Weld Joints on Aluminium Alloys during TIG Welding Using Flux Backing Tape

This work aimed to compare the quality and properties of the welded joints of AMg6 aluminium alloy produced via conventional TIG welding with the properties of those produced with flux backing tape. This study focussed on the relative length of oxide inclusions (Δoi) and the amount of the excess root penetration (hroot) of the AMg6 alloy weld beads. The results show the influence of the thickness of the flux layer of the backing tape on the formation and quality on the AMg6 alloy welds, along with the effect of flux backing tape and edge preparation on the mechanical properties of the 6 and 8 mm thick welded plates. In accordance with the results obtained, the joints produced by means of TIG welding with flux back backing tape and without edge preparation have higher mechanical properties. Moreover, the TIG welding of AMg6 alloy using flux backing tape reduces the total welding time by 55%, reduces filler wire consumption by 35%, reduces shielding gas consumption by 43% and electricity consumption by 60% per 1 linear meter of the weld line.

Structural design and adaptive tracking control of automatic welding robot for liquefied natural gas containment system

Liquefied natural gas (LNG) is commonly transported by LNG carriers and stored in cargo containment systems. The primary barrier of the MARK III cargo containment system is welded to a closed space with corrugated stainless steel plates. To meet the requirements of excellent sealing and thermal insulation for cargo containment, the welding process of the corrugated plate need to be strictly controlled, which poses a challenge to the development of related welding equipment. In this paper, we present a new five-axis automatic welding robot system used for plasma arc welding on corrugated surfaces. The moment transfer scheme of the dual linkage mechanism makes the rotary movement of the robot more accurate and stable which gives the system with simpler control algorithm and better overall force characteristics. To ensure tracking accuracy, a novel sensing method based on a LASER sensor, two contact sensors, and an angle sensor is proposed to implement multiple functions such as tracking the welding arc length, identifying corrugation shapes, and detecting welding gun posture. Based on the devised tracking sensor system and welding robot, a servo-control system with a surface-tracking welding control algorithm is established. The experimental results show that the robot system's welding speed is about 7 times that of hand welding and the welding qualification rate was 99%, significantly improving welding efficiency and quality as a critical equipment technology in the process of corrugated plate welding.

Tool-pin profile effects on thermal and material flow in friction stir butt welding of AA2219-T87 plates: computational fluid dynamics model development and study

Tool-pin profile effects on thermal and material flow in friction stir butt welding of AA2219-T87 plates: computational fluid dynamics model development and study

Microstructure and residual stress distribution of electron beam-welded joints of a 50 mm-thick TA15 titanium alloy plate

Abstract Vacuum electron beam welding was applied to a 50 mm-thick TA15 titanium alloy plate. Microstructure observation and microhardness testing were performed. Meanwhile, the residual stress on the surface at different distances from the weld centre was measured via the hole drilling method. A finite element model for electron beam welding of the TA15 titanium alloy plate was constructed on commercial finite element software. Experimental results showed that the microstructure of the weld zone consisted of a basket martensitic phase. The highest microhardness in the weld zone was 409 HV, and the microhardness of the base metal was the lowest. The maximum gradient change area was located at the HAZ near the base metal. The peak value of longitudinal residual stress from the simulation was 880 MPa, which was in the weld metal. The sharp change area of longitudinal residual stress gradient was located in the base metal near HAZ.

Simulation of the laser welding of porous and monolithic metallic plates

Simulation of the laser welding of porous and monolithic metallic plates

Design of field shaper suitable for plate and experimental research on welding of dissimilar materials

Magnetic pulse welding realizes solid-state connection through a high-speed collision of materials, which can effectively overcome the welding difficulties of light metal materials. In the magnetic pulse welding system, in order to improve the welding efficiency, a field shaper is usually applied between the multi-turn coil and the workpiece to concentrate the magnetic field in the welding area, thereby improving the electromagnetic force. However, a large number of researchers are currently on the tube-welded field shaper, and very few researchers have studied the structure of the plate-welded field shaper. Therefore, this paper proposed a new field shaper for plate welding. The effect of the structure parameter of the field shaper on the magnetic field and electromagnetic force on the aluminum plate was analyzed in the COMSOL multiphysics software. The optimal structure parameters of the field shaper were selected. The plastic deformation and the generation of jets under different voltages and the welding of the same/dissimilar metal materials at different standoff distances were studied experimentally, which verifies the feasibility of the new field shaper.

Numerical Study of the Cold Metal Transfer (CMT) Welding of Thin Austenitic Steel Plates with an Equivalent Heat Source Approach

The CMT (cold metal transfer) arc welding process is a valuable joining method for assembling thin sheets, minimizing heat transfers, and reducing subsequent deformations. The study aims to simulate the CMT welding of thin stainless-steel sheets to predict temperature fields and deformations. Both instrumented tests and numerical simulations were conducted for butt-welding of sheets with a thickness of 1 to 1.2 mm. Weld seam samples were observed to identify equivalent heat sources for each configuration. The electric current and voltage were monitored. Temperature measurements were performed using K-type thermocouples, as well as displacement measurements via the DIC (digital image correlation) technique. Thermomechanical simulations, considering phase changes and the actual seam geometry induced by filler material, were conducted using an equivalent heat source approach. A unique heat exchange coefficient accounting for thermal losses was identified. By incorporating these losses into thermal calculations, a good agreement was found between measured and calculated temperatures. Mechanical calculations allowed for the recovery of the horse saddle form after actual welding, with a relative difference of less than 10% in angular distortion between calculated and measured values.

Stability analysis and porosity inhibition mechanism of oscillating laser-arc hybrid welding process for medium-thick plate TC4 titanium alloy

The influence of oscillating laser frequency and oscillation diameter on the stability and porosity of laser-arc hybrid welding of titanium alloys were investigated. The microstructure and basic mechanical properties of oscillating laser-arc hybrid welded joints were revealed. The results show that the oscillating laser significantly improved the macroscopic morphology of the joints, reducing the porosity from 5.48 % to 0.12 %. In the conventional laser-arc hybrid welding process, the number of keyhole surface closures was more and the time of droplet transition was longer, resulting in poor process stability. When the frequency was 150 Hz and the diameter was 1.5 mm at oscillating laser conditions, the number of keyhole closures within 200 ms was significantly reduced to 5 times compared to the conventional laser-arc hybrid welding (23 times). The droplet transition was stable, which resulted in a more stable hybrid welding process. In addition, after one oscillation cycle, the forward distance of the laser was relatively short, which can reopen the smaller pores generated in the previous cycle, leading to a significant reduction in porosity. When the frequency and diameter of oscillation decreased, the fluctuation for keyhole morphology was greater and the droplet transition was instability, resulting in an increase in porosity; When the oscillation increased, the fluctuation of the keyhole outer diameter was larger and the penetration depth decreased, which was not conducive to the welding of medium-thick plates. In the oscillating laser-arc hybrid welding process, columnar crystals in the middle of the molten pool grew towards the surface, reducing the segregation of impurities in the weld center. As a result, the elongation percentage of the joints was improved by 36.58 % compared to the conventional laser joints.