Welding Device Research Articles

Research on Mechanized Plasma Gouging of Weldable Construction Steels

Grooving or gouging is a process of thermal processing of metals or welded semi-finished products. The gouging process is generally used to process the root of butt welds to remove possible welding defects. The possibility to obtain and characterize the surfaces after manual and mechanized plasma cutting in the field of bridges and viaducts from highways to construction sites in order to increase the quality of butt-welded joints is analyzed in this article. In order to mechanize the process, a linear universal displacement device for welding, cutting, or slitting that ensures the uniform movement of the torch was designed and executed herein. As a result, with the help of this device and the tests performed on a construction steel S355J2 after mechanized plasma cutting, the cut samples obtained facilitated the analysis of the macrostructure and microstructure of the thermally influenced zone and of the intermediate zone between the thermally influenced zone and the base material as well as their hardness. By mechanizing the cutting process, the productivity and quality of the surfaces obtained by this process has increased. The plasma gouging process is an ecological process and by mechanizing it, the manufacturing cost can be reduced.

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.

Effects of soldering temperature and preheating temperature on the properties of Sn–Zn solder alloys using wave soldering

Purpose This study aims to address the problem of low-temperature wave soldering in industry production with Sn-9Zn-2.5 Bi-1.5In alloys and develop qualified process parameters. Sn–Zn eutectic alloys are lead-free solders applied in consumer electronics due to their low melting point, high strength, and low cost. In the electronic assembly industry, Sn–Zn eutectic alloys have great potential for use. Design/methodology/approach This paper explored developing and implementing process parameters for low-temperature wave soldering of Sn–Zn alloys (SN-9ZN-2.5BI-1.5 In). A two-factor, three-level design of the experiments experiment was designed to simulate various conditions parameters encountered in Sn–Zn soldering, developed the nitrogen protection device of waving soldering and proposed the optimal process parameters to realize mass production of low-temperature wave soldering on Sn–Zn alloys. Findings The Sn-9Zn-2.5 Bi-1.5In alloy can overcome the Zn oxidation problem, achieve low-temperature wave soldering and meet IPC standards, but requires the development of nitrogen protection devices and the optimization of a series of process parameters. The design experiment reveals that preheating temperature, soldering temperature and flux affect failure phenomena. Finally, combined with the process test results, an effective method to support mass production. Research limitations/implications In term of overcome Zn’s oxidation characteristics, anti-oxidation wave welding device needs to be studied. Various process parameters need to be developed to achieve a welding process with lower temperature than that of lead solder(Sn–Pb) and lead-free SAC(Sn-0.3Ag-0.7Cu). The process window of Sn–Zn series alloy (Sn-9Zn-2.5 Bi-1.5In alloy) is narrow. A more stringent quality control chart is required to make mass production. Practical implications In this research, the soldering temperature of Sn-9Zn-2.5 Bi-1.5In is 5 °C and 25 °C lower than Sn–Pb and Sn-0.3Ag-0.7Cu(SAC0307). To the best of the authors’ knowledge, this work was the first time to apply Sn–Zn solder alloy under actual production conditions on wave soldering, which was of great significance for the study of wave soldering of the same kind of solder alloy. Social implications Low-temperature wave soldering can supported green manufacturing widely, offering a new path to achieve carbon emissions for many factories and also combat to international climate change. Originality/value There are many research papers on Sn–Zn alloys, but methods of achieving low-temperature wave soldering to meet IPC standards are infrequent. Especially the process control method that can be mass-produced is more challenging. In addition, the metal storage is very high and the cost is relatively low, which is of great help to provide enterprise competitiveness and can also support the development of green manufacturing, which has a good role in promoting the broader development of the Sn–Zn series.

Portable tack welding device

The main purpose of this study was to develop a portable electronic tack welding device and determine its tacking time duration, power consumption and tacking operation. This was based from the principles of resistance spot welding with the purpose of joining sheet metals by fusing through resistance heating on tacking operation. This study employed developmental method of research wherein an innovation was made in a spot welding. The data were gathered using actual experimentation and evaluation sheet. The device was evaluated by Forty (40) evaluators including twenty (20) professors in the academe and twenty (20) experts in the field of electrical, automotive and metal craft industry. This study was limited to the development of the portable electronic tack welding device intended for fusing steel sheets ranging from gauge # 21 to gauge # 25. The parameters measured were the tacking duration, the power consumption and the fused result of the tacking operation on varied steel sheet thickness and will undergo in three (3) trials of testing. The level of acceptability was evaluated in terms of its design, composition and operating performance. The study showed that the tacking duration of the device showed that as the gauge thickness increased the slower is the tacking time however there was an increased in the power consumption. Likewise, the device was able to fuse together the given thickness of steel sheets after the tacking operation. The device was also evaluated its overall acceptability in terms of design, composition and operating performance as “very acceptable”.

Friction Stir Welding in Liquid Working Environment (SFSW) of EN AW 1200 Aluminum Alloy

Friction stir welding is an important topic within ISIM Timisoara, with several research projects being implemented in this field. Friction stir welding in liquid working environment aims to avoid overheating of the welding tool and device during the joining process and achieve better results compared to FSW welding in ambient environment. The paper presents results obtained by ISIM Timisoara in the framework of a national research project (in progress), regarding the friction stir welding in liquid environment (SFSW) of the EN AW 1200 aluminum alloy. The experimental research aimed at an analysis of the SFSW welded joints for the EN AW 1200 aluminum alloy, made with four different welding tool geometries, under the same working conditions regarding the FSW welding machine and the technological process parameters.

Research of the stress-strain state of the loaded assembly for friction welded device

This article presents the results of the study of methods for friction welding of dissimilar materials and the calculations to determine the structural strength of the most loaded part of a special friction welding device were made. The analysis showed that the friction welding method has wide technological capabilities and it is used in various industries. The designs of existing devices and machines for friction welding were also investigated. It was revealed that the method of friction welding in the conditions of machine-building plants of the Republic of Kazakhstan (RK) has not found application due to the little knowledge and high cost of technological equipment. The authors have developed a special device for friction welding of dissimilar materials. To optimize the parameters of the parts, in particular the bracket part, the stress-strain state calculations were performed using the ANSYS software package and the strength calculation by determining the acting external critical loads. The results of the calculation showed the applicability of the developed design of the bracket part.

Fuse welding and tin integration automatic machining device

In order to solve the problems of low efficiency and difficulty in adding tin to the end cap in the production process of the fuse, the unstable amount of tin resulted in over-welding and fake-welding. This paper designed and manufactured a set of automatic equipment for welding and adding tin to the fuse. The feeding device can accurately feed the end cap; a set of disc cutter structures with a feeding machine is used to cut the tin wire, and the cut tin wire accurately falls into the end cap of the fuse. The heating device is designed to melt the tin wire into liquid in the end cap. The cooling device makes the liquid tin condense into a solid in the end cap to realize the function of automatically adding tin to the end cap of the fuse. Through the actual production verification, it is proved that the equipment structure is reasonable and can meet the actual production requirements.

Development of Constructions for Friction Welding Devices Based on a Lathe with a Pneumatic Power Drive

The purpose of the study is to improve the design and expand the technological capabilities of special friction welding equipment based on a lathe. In order to eliminate the shortcomings identified during the laboratory test, the modernization of the structures of this device was carried out. Based on the conducted analytical studies, a power unit was selected and designed, which allows to provide the required forging pressure and thereby ensures the quality of the weld. Modeling was performed in the Siemens NX 12 application package and drawings were developed, the principle of operation was modeled and the assembly scheme was developed.

Digital tools as part of a robotic system for adaptive manipulation and welding of objects

<span>The aim of this article is to describe the design and verification of digital tools usable for sharing information within a team of workers and machines that manage and execute production carried out by a robotic system. The basic method is to define the structure of the digital tool and data flows necessary to enable an exchange of data needed to perform robotic manipulation and robotic welding of variable products minimizing at the same time strenuous human activity. The proposed structure of data interconnects a set of intelligent sensors with control of 18 degrees of freedom of 3 robotic manipulators, a welding device, and a production information system. Part of the work was also to verify the functionality of the proposed structure of the digital tools. In the first phase, simulations using a digital twin prototype of the workplace for robotic manipulation and robotic welding were performed to verify the functionality the digital tools. Subsequently, a digital tool was tested in the environment of a real prototype workplace for robotic manipulation and robotic welding. Simulation results and data obtained from the prototype tests proved the functionality of the digital tool inclusive of the production information system.</span>

Fusion Bonding Possibility for Incompatible Polymers by the Novel Ultrasonic Welding Technology: Effect of Interfacial Compatibilization.

Fusion bonding for polymers has been successfully welded for the same and dissimilar materials. However, it is difficult to bond incompatible polymers due to poor interfacial adhesion. Usually, interfacial compatibilization can resolve this problem. According to the mechanism, an interlayer solder sheet (ISS) consisting of maleic anhydride-functionalized polypropylene (PP-g-MAH) and polyamide6 (PA6) was introduced into the ultrasonic welding (USW) device. In this way, it successfully realized the weldability between PP and PA6. The welding strength of PP–PA6 reached 22.3 MPa, about 84% welding strength for the PP body and 63% tensile strength for PP. Fourier transform infrared (FTIR) spectroscopy, X-ray diffraction (XRD), and scanning electron microscopy (SEM) showed the formation of PP-g-PA6 copolymer in blends. This copolymer played the role of an emulsifier, which enhanced the interfacial adhesion between PP and PA6 in two phases, leading to micron-scale homogeneity. In the USW process, the copolymer could act as a bridge between PP and PA6 molecular chains to realize the fusion bonding of incompatible polymers. Finally, we proposed the fusion bonding model for PP–PA6 interfaces.

Planning and experimental studies of selection the optimal welding mode by the friction of fitting rods

The methods of friction welding of various materials have been studied, as well as the design and capabilities of the device for friction welding have been determined. The design of the device for friction welding on the basis of a lathe has been developed taking into account the established requirements and recommendations of machine building enterprises. To study the influence of technological factors on the quality of welded joint formation, a full factorial experiment (FFE) of type 22 was set up according to the plan. The adequacy of the planned experiment was confirmed by calculations (Fcalcul. = 1.1 < Ftabl. = 4.46.) on the basis of which a full-scale experiment was carried out. According to the results of the experimental plan, it was found that the heating time of the work pieces being welded has the most significant effect on the total length of the seam upsetting. The optimal mode with the correct formation of the burr has been chosen. The convergence of the full-scale test results with the planning of the Type 22 full factor experiment has been identified, resulting in the determination of the optimal mode.

Summary of Research Progress on Friction Stir Welding of Dissimilar Metals

Background: Friction stir welding technology is widely applied in the welding of dissimilar metal materials because of its high welding efficiency, low welding process cost, high welding joint strength and reliability, and green environmental protection. The research on the processing methods and working principle of friction stir welding of dissimilar metals is beneficial to improve the mechanical properties of the joint and reduce weld defects. Therefore, the development of reliable friction stir welding technologies for dissimilar metals joining has been paid increasing attention in recent years. Objective: The study aims to satisfy the processing of various dissimilar metals and improve the joint performance and weld defects. Friction stir welding has developed into bobbin tool friction stir welding and stationary shoulder friction stir welding. Methods: This paper retraces various current representative patents relative to friction stir welding, bobbin tool friction stir welding, and stationary shoulder friction stir welding. Results: Through the investigation of a large number of patents on friction stir welding, the main current existing problems, such as poor mechanical properties of the joints and defects in the welds, are summarized and analyzed. In addition, the development trend of friction stir welding in dissimilar metal welding is also discussed. Conclusion: The research on friction stir welding methods and devices is beneficial to improve the mechanical properties of welded joints and reduce weld defects. More correlative patents will be invented in the future.

Assumptions for Modeling of the Hot Plate Welding Process Considering the Automatic Welding Machine Design

Drive and conveyor belts are widely used in processing and mining industries. One of their types, which are often used in light-duty applications, are the belts with round cross-section and several millimeters in diameter. They are often made of thermoplastic elastomers, in particular ofweldable polyurethane. Their production process requires to carry out the operation of joining the belt ends to obtain a closed loop. This operation is often carried out by means of butt welding utilizing the hot plate method. This process is often performed by hand using simple tools. Authors took an effort to design the automatic welding machine, which can make durable joints of this type automatically. The design works comprise control system configuration which calls for identifying the technological parameters of the process, being the reason for undertaking the research works on the hot plate welding process. The main aim of this activity was to formulate of the mathematical model of the hot plate welding of round drive belts which is necessary to identify the process parameters and the correlations between them. In the paper, the assumptions for the hot plate welding process modeling were presented. During their formulating, technical conditions were taken into consideration resulting from some of the characteristics observed in an automatic welding device prototype which had been implemented for industry production.

Particle aerosolization with energy devices: A comparative study.

ObjectiveTo compare the degree of particle aerosolization with the use of several energy devices used in tonsillectomy and other common upper airway procedures.MethodsThree different energy devices were measured. These included (a) monopolar electrocautery, (b) bipolar electrocautery, and (c) thermal welding device (TWD). Each device was applied to fresh cadaveric cow tongue and porcine nose. Aerosolized particles produced by these devices were measured using a calibrated electronic particle counter. Measurements were recorded over the course of 3 minutes. Particle sizes were measured at 0.3, 0.5, 1.0, 5, and 10 μm.ResultsIn comparing types of tissues and particle sizes, TWD had the lowest aerosolizing burden among the three devices. By analyzing the highest particle value of TWD against both monopolar and bipolar, monopolar electrocautery proved to have the highest aerosolization exposure with statistical significance at 0.5 and 10 μm. No statistical significance was found when comparing TWD against monopolar electrocautery.DiscussionOur study demonstrates there is a difference in aerosolization burden dependent on the type of device utilized. TWD proved to have the lowest burden whereas monopolar electrocautery had the highest.ConclusionTWD produces less aerosolization than conventional monopolar electrocautery when cauterizing or ablating tissue in an experimental setting. The degree of aerosolization was comparable to bipolar electrocautery.Level of Evidence2.

Case Study on Numerical Calculation of a Disc Bush in the Disc Harrow in the Welding Version

The optimization of production processes in companies comes down to two main measures influencing the economic factor. The first one is the reduction of interval micro-periods between operations, and the second is to use post-production waste as much as possible. These treatments apply to virtually all industries regardless of the final product effect. This article describes the application of a special welding device for welding the workpiece with a bush type, designed for fixing the plate in the plate gun. As a result of its application, a significant reduction of time needed to produce one bush has been achieved, and thus the amount of time in a unit of time has been increased. As part of the implementation work, the bush design changes were also made, which made it possible to reduce post-production waste not suitable for current production, but allowing its use for other purposes. The results of the work were implemented in the company producing agricultural machinery in Lublin.

Effect of pulse frequency on weld appearance of Al alloy in pulse power ultrasonic assisted GMAW

This paper investigated the effect of pulsed power ultrasonic on the appearance, microstructure and mechanical properties of aluminum alloy using self-developed pulsed power ultrasonic wave assisted gas metal arc welding (PU-GMAW) device. The feature of the method was to combine arc and pulsed power ultrasonic field coaxially. The results indicated that, compared with conventional GMAW, the weld penetration of PU-GMAW was much increased and the melting area increased by around 49%. Further, weld melting area enlarged as pulse frequency increased. The average hardness of the weld metal of PU-GMAW was about 15 HV higher than that of GMAW. At the end, the mechanism of melting area enlargement and weld penetration enhancement was discussed, which was attributed to the increase of the welding heat input.

Study of microstructure geometry and properties of laser beam welded joints made of S960QL structural steel and S304 corrosion-resistant steel

Contemporary grades of structural steels are produced using a very advanced thermo-mechanical treatment processes, so their properties strongly depend on the obtained structure. Corrosion-resistant austenitic steels have a high hot cracking tendency. Therefore, it is advantageous to use welding technologies, such as laser welding, that limit the size of the joint and its heat-affected zones and thus the deformations caused by the welding process. Laser welding is also characterized by small amount of heat transferred into the material during the process which limits the hot cracking tendency. During the tests, 8 samples made of S960QL steel and S304 steel, were prepared using a Trumpf TruDisk 3302 laser welding device. The produced samples were subjected to macro- and microscopy metallographic tests. Static tensile test and bend test were also performed as well as a hardness Vickers test under a load of 100N. Good quality joints were obtained, characterized by a small number of welding imperfections, small size of the weld and heat affected zone, as well as satisfactory mechanical properties.

Influence of marine corrosion on the roughness of the dry hyperbaric underwater MAG welding joints

The maintenance and repairing actions for underwater metallic structures from maritime and offshore field are usually achieved using the gas metal arc welding processes. The welding processes applied should take into consideration different underwater conditions, and experiments should be conducted for different pressures. In the first part of the study, the authors focused on the investigation of the EH 36 shipbuilding steel behaviour subjected to dry hyperbaric metal active gas (MAG) using semi-automatic welding devices. Hereinafter, the authors analyse, by using the electrochemical method, the behaviour of the welded joints to marine corrosion. In the last part of the investigation, the corrosion influence on the roughness of the specimen’s surfaces, depending on the potentiodynamic polarization curves, is approached. The experiments revealed that increasing of pressure conditions leads to an increased corrosion resistance and moreover, to a decrease of the specimen surfaces roughness.

Optimization of Manufacturing Process and Experimental Verification of Vulnerable Part in Reactor

The technical requirements of the control rod driving mechanism of the third generation PWR nuclear power plant are higher. The latch parts are designed with double tooth structure and welded on the wear-resistant surface by cobalt-based alloy surfacing. According to the structural characteristics and manufacturing process difficulties, a special welding device is developed. According to the test and finite element simulation, the related process parameters are optimized. The trial production of the parts was completed, and the parts were tested by metallography, liquid permeation test, hardness test and thermal life test. The results show that the latch parts have high hardness and wear resistance, and meet the requirements of the driving mechanism operation life of the third generation PWR nuclear power plant.

Research on action sequence optimization method of Micro-Crystal resonator spot welding device

To realize spot welding process of the id and base for micro-crystal resonator quickly and accurately, the action sequence is need to be designed for its spot welding device reasonably. The device’s performance indexes are proposed and its preliminary action sequence is designed based the functional structure and process flow. Stateflow tool is used to the device’s simulation model is established and the state transition diagram is obtained by Stateflow with the finite state machine theory. According to the simulation result, the action sequence for the spot welding device is optimized, and its final action sequence is determined. It shows that he optimized design can meet the function requirements for micro-crystal resonator spot welding device through the simulation analysis and prototype test.