Thick Plate Welding Research Articles

Intelligent Perception and Seam Tracking System for Thick Plate Weldments Based on Constant-Focus Optical Path

To achieve efficient and accurate thick plate welding, as well as to precisely extract and plan the paths of complex three-dimensional weld seams in large steel structures, this study introduces a novel vision-guided approach for robotic welding systems utilizing a constant-focus laser sensor. This methodology specifically targets and mitigates several critical shortcomings inherent in conventional vision-guided welding techniques, including limited detection ranges, diminished precision in both detection and tracking, and suboptimal real-time performance. For preprocessed weld images, an improved grayscale extreme centroid method was developed to extract the center of the light stripe. Furthermore, a sophisticated feature point extraction algorithm, which integrates a maximum distance search strategy with a least-squares fitting procedure, was developed to facilitate the precise and timely identification of weld seam characteristic points. To further optimize the outcomes, a cylindrical filtering mechanism was employed to eliminate substantial discrepancies, whereas local Non-Uniform Rational B-Spline (NURBS) curve interpolation was utilized for the generation of smooth and accurate trajectory plans. A spatial vector-based pose adjustment strategy was then implemented to provide robust guidance for the welding robot, ensuring the successful execution of the welding operations. The experimental results indicated that the proposed algorithm achieved a tracking error of 0.3197 mm for welding workpieces with a thickness of 60 mm, demonstrating the method’s substantial potential in the manufacturing sector, especially in the domain of automated welding.

Laser Hybrid Welding—An Advanced Joining Technique for Welding of Thick Plates of Maraging Steel

Laser Hybrid Welding—An Advanced Joining Technique for Welding of Thick Plates of Maraging Steel

Passive vision based three-dimensional seam tracking using a stereo vision system with a single HDR camera

Seam tracking is a crucial feature that an automatic welding system must have. The laser tracking algorithm offers high accuracy but faces challenges in identifying seams with extremely narrow gaps, as the deformation of the laser stripe becomes difficult to detect in such cases. In contrast, the passive vision-based algorithm can effectively capture narrow gap information from the welding scene, making it more suitable for recognizing narrow seams. However, most of proposed passive vision-based seam tracking is based on “teaching and playback” mode and can only realize planar tracking. In medium and thick steel plate welding, the workpieces are so large that the “teaching and playback” based control algorithm is unsuitable. Therefore, in this paper, a stereo vision system with a single camera and the corresponding calibration algorithm are developed to achieve three dimensional seam tracking. Compared to stereo system with dual camera, the proposed system is cheaper and easier to synchronize acquisition. Moreover, to get out of the “teaching and playback” control strategy, a vector control algorithm without cumulative error is proposed. Results of nine experiments show that the average error of the proposed seam tracking system is less than 1.0662mm and the maximum error is 1.8030mm.

A Primary Study on the Applicability of Gel-Type Filler Materials to Root Pass Welds of the Thick Plate

Welding generally uses filler material to create deposited weld metal. Filler materials play a significant role in welding by providing the material needed to fill and form the joint. Existing filler materials are limited in the workspace and welding position and need help responding flexibly to welds of complex shapes. This study conducted primary research to develop a gel-type filler material with adhesion and flexibility that can cope with limited workspace and location. We attempted to provide a new approach to welding by mixing metal powder and binder to create a gel-type filler material. Root pass welding of thick plates was performed using a laser heat source. The bead appearance and cross-section of the weld zone were observed according to the type and composition of the metal powder, the binder content, and the method of synthesizing the metal powder. The physical characteristics of the weld were analyzed through observation of the hardness and microstructure of the weld.

Intelligent Grinding System for Medium/Thick Plate Welding Seams in Construction Machinery Using 3D Laser Measurement and Deep Learning

With the rapid development of the construction machinery industry, thick plate welds are increasingly needing efficient, accurate, and intelligent processing. This study proposes an intelligent grinding system using 3D line laser measurement and deep learning algorithms to solve the problems of inefficiency and inaccuracy existing in traditional weld grinding methods. This study makes use of 3D line laser measurement technology and deep learning algorithms in tandem, which perform automated 3D measurement and analysis to extract key parameters of the weld seam, in conjunction with deep learning algorithms applied on image data of the weld seam for the automatic classification, positioning, and segmentation of the weld seam. The entire work is divided into the following: image acquisition, motion control, and image processing. Based on various weld seam detection algorithms, the selected model was MNet-based DeepLab-V3. An intelligent trimming system for welding seams based on deep learning was constructed. Experiments were conducted to verify the feasibility and accuracy of the 3D line laser measurement technology for weld seam inspections, and that the deep learning algorithm can effectively identify the type and location of the weld seam, thus predicting the trimming strategy. With an accuracy far superior to conventionally based methods in accurate detection and regrinding of weld surface defects, the system proves advantageous for improved weld regrinding productivity and quality. It was determined that the system presents significant advantages in reinforcing weld regrinding when it comes to efficiency and quality, thus initiating a paradigm of using intelligent treatments for medium/thick plate welds in the construction machinery industry.

Single-pass ultra-high-power laser welding of thick nickel-based GH3535 superalloy: Microstructure evolution and microhardness

In comparison to narrow-gap laser welding, the ultra-high-power laser welding (UHPLW) represents an efficient method for single-pass welding of 22 mm thick GH3535 superalloy. This paper explored the microstructure evolution and microhardness distribution along the direction of weld penetration. The results showed that the direction of grain growth changed from horizontal to an inclined downward direction towards the bottom of the joint along the penetration direction. Precipitates distributed in the interdendritic region were identified as M2C and M6C carbides. The rapid cooling rate in the lower zone (LZ) of the joint resulted in slight elemental microsegregation and a lower volume fraction of precipitates than in other zones. The smaller grain size and the higher volume fraction of the precipitates resulted in a higher microhardness in the middle zone (MZ) of the entire joint. The study results will facilitate the application of UHPLW for the efficient welding of GH3535 thick plates.

Research status of insufficient sidewalls penetration in narrow gap TIG welding of thick metal plates

Research status of insufficient sidewalls penetration in narrow gap TIG welding of thick metal plates

Penetration state recognition for tungsten inert gas welding via an alternating cusp-shaped magnetic field-assisted molten pool-oscillation

To ensure optimal penetration in direct current (DC) argon tungsten arc welding, a method was proposed to recognize the molten pool penetration during molten pool oscillation under alternating cusp-shaped magnetic field (ACSMF). An arc discharge model is established to analyze the oscillation mechanism of the molten pool under ACSMF. The periodic variation of arc shape induces the periodic oscillation to establish a mapping relationship with the fluctuation of arc voltage waveform. At the excitation current of 3 A and frequency of 10 Hz, the arc voltage waveform undergoes abrupt changes at 1.26 V and 1.37 V, corresponding to the critical and the full penetration states, respectively. The errors in identifying moving penetration are 0.8 % and 0.7 %, with a full penetration weld, demonstrating a penetration rate of 100 %, indicating effective penetration recognition. Arc sensing technology for tungsten inert gas (TIG) welding under ACSMF is poised for gradual application in single-side welding and double-side forming of medium and thick plates. It is anticipated to evolve towards real-time identification technology for molten pool penetration monitoring.

Characteristics Comparison and Case Study of Traditional Anti-Slip Saddles and Innovative Rolling Saddles in Highway Long-Span Bridges

The cable saddle structure is the main support component for long-span bridges to transmit cable force, which is of great significance for the structural force system. Nowadays, the main cable saddle structures used in long-span bridges are mainly traditional anti-slip saddles and innovative rolling saddles. To clarify the characteristics of the saddles in long-span bridges, the design principles, mechanical properties, and casting process of these two types of saddle structures were researched. A rolling saddle in a bridge project was taken as an example and its mechanical situation in the roller area was investigated. The results showed that the stress concentration phenomenon is prone to occurring in the rolling saddle because of the line contact in the contact area and the rolling saddle is mainly subjected to vertical force. Thus, attention should be paid to the von Mises stress in the contact area between the saddle base and the roller shaft, the lower surfaces of both ends of the roller shaft, and the top surface of the tower, to avoid material damage. Furthermore, the casting process of the anti-slip saddle structure is mature, but also faced with problems due to the welding of thick plates, and urgently needs to be improved and upgraded. The rolling saddle is used with the all-welded casting process, but its technology is relatively immature and the requirements for the roller shaft material performance are strict. The research results can provide a reference for the selection and design of the saddle structure in long-span bridges.

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.

Development of a robust welding process for electron beam welding of thick plates for construction of offshore wind turbines

AbstractDue to its high energy intensity and the associated high welding depth, electron beam welding is particularly suitable for welding steel plates with high wall thicknesses. These are used, for example, in offshore wind power systems. However, due to the cooling conditions, the required cold toughness for offshore applications is often not achieved. The aim is to develop S355 ML steels – within the EN10025 4 standard – for welding monopiles for wind turbines. For this purpose, three parameters with different energy input are developed on three steels. The tests are carried out on plates with a wall thickness of 80 mm, whereby a full penetration weld must be achieved. The resulting top and bottom bead of the welds meet the standard DIN EN ISO 13919‐1. The parameters have an energy per unit length of 9.5 kJ mm−1 to 15.5 kJ mm−1. The resulting weld seams have an average width of 5.5 mm to 7.5 mm, and burn‐off of the manganese alloy element is observed, particularly on the top side of the seam. In addition, T8/5 times close to the weld seam of 11 s to 27 s are estimated using a simulation.

Single-pass high-power laser-Arc hybrid welding of thick stainless steel clad plates: Microstructure and mechanical properties

In order to solve the existing problem of low efficiency of multi-layer and multi-pass welding methods for thick stainless steel clad plate (SSCP), this paper proposes high-power laser-arc hybrid welding (HP-LAHW) single-pass weld thick SSCP. The effects of wire feeding rate (WFR) on the weld's composition distribution, microstructure and mechanical properties were investigated. The weld morphology is nail-shaped, consisting of a wide arc zone (ArcZ) within the stainless steel layer and a long narrow laser zone (LaserZ), mainly in the carbon steel layer. With the increase of WFR, the dilution rate of the carbon steel layer to the ArcZ decreases first and then increases. The influence of WFR on the microstructure and mechanical properties of the weld is observed mainly in the ArcZ. When the WFR reaches 6 m/min, the composition of the microstructure within the ArcZ will change from martensite, ferrite, and a small amount of granular austenite to ferrite and a small amount of austenite, resulting in the microhardness of the ArcZ decreasing rapidly from 398 HV to 210 HV. The solidification type and microstructure transformation mechanisms within the weld were elucidated based on quantitative calculations of the chromium and nickel equivalent ratios. The microstructure of the LaserZ in all welds is predominantly martensitic due to the rapid cooling rate, which makes the tensile properties of the weld higher than the base metal (BM). The results of this study provide technical support for realizing high-efficiency and high-performance single-pass HP-LAHW of thick SSCP.

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.

Thermal modeling of friction stir welding of thick high-density polyethylene plates

The process temperatures in the friction stir welding of thick polymer plates play a significant role in the joint's quality since the process is characterized by mixed solid and viscous flow states. The heat generation mechanism in each state is fundamentally different, with heat being generated by friction in the solid-state and by viscous shear flow in the viscous state. In this study, the heat generation and dissipation in the friction stir welding of 14 mm thick high-density polyethylene plates were studied numerically through solving the direct heat conduction problem. Two models of heat generation were used in the numerical solution and the effect of the pin rotational speed on the process temperatures was investigated. It was shown that the utilization of a mixed heat generation model consisting of both the solid state and the viscous shear flow considerably improves the numerical model predictions. The temperature predictions were validated through welding experiments and showed a temperature difference of 3 %. Furthermore, it was found that the welding process stabilizes at rotational speeds higher than 800 rpm, where no considerable change occurs in the volume of the viscous flow region and the welding power requirement. The numerical results based on the combined solid-viscous heat model were in good agreement with the experimental thermal histories.

Welding of 20 mm thick EH40 steel by means of a single-pass hybrid laser-arc welding technique

In the naval applications, as well as for infrastructure and construction sectors, welding of thick steel plates (>15 mm) has become of crucial importance. Nowadays, the common techniques involve several passes of traditional Gas Metal Arc Welding (GMAW) to fill a gap with a precise geometry. These techniques are, inevitably, time consuming due to the necessity of multiple passes, material consuming because of the volume of the gap which needs to be filled, and complicated due to the precise preparation of the joints. To overcome these drawbacks, we propose here a Hybrid Laser-Arc Welding (HLAW) technique in a configuration which allowed us to achieve a sound weld of two plates, 20 mm thick, of naval steel EH40 in a single pass. The goal has been obtained with a 15 kW fiber laser and a welding speed of 1500 mm/min. The most important result of this research is that the welds have been performed in a simple butt configuration, with straight edges of the plates and without any chamfer or additional preparation. Moreover, the length of the weld seam, 1 meter, guarantees the stability and the solidity of the process, its scalability over longer plates, and thus, an easy implementation on an industrial machine for massive production.

Single pass laser vacuum welding of thick steel plates using electromagnetic support

The increasing demand for renewable energy produced by offshore wind turbines goes along with an increased demand in the production of offshore wind turbine foundations, so called “monopiles”, which are made by joining thick metal sheets. The industrial standard of multi-layer submerged arc welding (SAW) for joining of thick metal sheets is the current bottleneck in the production of monopiles. A possible increase in productivity by the implementation of high-power laser welding in a newly developed mobile vacuum chamber (MoVac) and an electromagnetic root support is the subject of this study. Single run butt welds are performed in flat position on S355 mild steel of thicknesses up to 80 mm using a disc laser system with 1030 nm wavelength and a maximum output of 60 kW. The laser optic is fixed on the MoVac-System which is held and manipulated by an articulated robot.

Study on the Comparison of Electron Beam Welding and Hybrid Laser-Arc Welding of Thick High-Manganese Steel Plate for Cryogenic Applications

Environmental protection policies have led to a focus on clean energy from Liquefied Natural Gas (LNG) and thus, its demand is increasing. Several studies for the development of cryogenic materials and fabrication technologies for storage and delivery of LNG are presented worldwide. Recently, International Maritime Organization (IMO) acknowledged that high-manganese steel was one such cryogenic material for application in LNG storage. Thus, high-manganese steel is expected to be increasingly used in the cryogenic storage industry because of its excellent material properties such as low-temperature toughness and tensile strength. A variety of researches on the welding technologies are available, including arc welding, laser welding and hybrid laser-arc welding. However, electron beam welding (EBW) has not been widely studied. In this work, EBW was investigated for the thick high-manganese steel plate and its mechanical properties were evaluated and compared with the characteristics of hybrid laser-arc welding. Our study indicates that EBW exhibits better mechanical properties than the hybrid laser-arc welding and it can be an effective potential candidate technology for welding of thick high-manganese steel plate with application in cryogenic storage tank.

Nonlinear mechanical behavior and stress amplification effect correction of thin plate welded structure considering initial deformation

With the continuous development of light weight of ships, thin plate welded structures are widely used in superstructure of large hull structures and high-speed boats. However, the thin-plate welded structure has a special nonlinear mechanical behavior because of its small stiffness, more complicated welding deformation. The nonlinear mechanical behavior of thin plate welded structure is mainly caused by large slenderness ratio and complex initial buckling deformation, which can be characterized and quantified by defining global deformation angle αG and local deformation angle αL. Because of the welding angle deformation and welding dislocation, there is obvious stress amplification effect at the welding corner, but the traditional stress amplification correction formula is only suitable for thick plate welding structure. Aiming at the nonlinear mechanical behavior and secondary bending moment effect of thin plate welded structure, an analytical model of thin plate welded structure with initial deformation is established by combining theoretical derivation and numerical method. The results show that the additional bending moment effect caused by local welding deformation angle cannot be ignored. Finally, combined with a series of fatigue tests, the additional bending moment caused by bending deformation and angular deformation of typical welded joints is analyzed, and the notch stress field and fatigue strength correction of thin plate welded structures with initial defects are realized.

Numerical modelling of high-power laser spot melting of thin stainless steel

Numerical modelling is an important scientific tool in laser materials processing to study different melting, evaporation, and solidification phenomena. It can assist in understanding why certain defects are formed, and thus may provide solution paths for how to decrease certain defects and to increase the quality of a product. Laser spot melting in heat conduction mode represents a simple case and is an excellent first step to build and test solvers prior to moving on to more complicated cases such as laser keyhole welding of thick plates. Modelling of laser spot melting requires only a limited computational domain and allows more complex physics to be added gradually. In this work, a thin 3.0 mm thick stainless steel plate was melted with high-power fiber laser and numerically simulated using a native and custom-build solver based on the VOF method within OpenFOAM. The process was captured with a high-speed imaging camera and simulation results are compared with the experimental results. It was found that temperature-dependent surface tension plays a vital role in controlling melt flow directions within melt pool.

Influencing mechanisms of weld root tip on microstructure and mechanical properties of electron beam welded joints of titanium alloy thick plates

The welding of titanium alloy thick plates often formed a narrow weld seam in the weld root, named as ‘weld root tip’, because of insufficient fusion, which could reduce the joint properties. In this study, 30 mm-thick Ti-5Al-5Mo-5V-1Cr-1Fe alloy was butt welded via electron beam welding to reveal the influencing mechanisms of the weld root tip on joint microstructure and mechanical properties. The subparallel or parallel weld seam with the weld angles of 0°–3° between the centre line and edge of the fusion zone removed the weld root tip, achieving almost the same mechanical properties with those of the welding zone.