Welding Practice Research Articles

Implementation of Product-Based Learning on Welding and Plate Practices II Course Oriented to Infrastructure Needs of the Department of Mechanical Engineering Education UNM

Product-Based Learning (PBL) enables students not only to learn theory, but also to be directly involved in the production process of real goods or projects, so that the practicum skills needed in the industry can be formed more optimally. This research method used is mixmethode. The results showed that the implementation of PBL in the Welding and Plate Practice II course has great potential to develop student skills that are relevant to industry needs and support the department's infrastructure. The results of PBL implementation also reached a score of 4,304 with a percentage of 48.3% in the “Excellent” category, proving the effectiveness of this method in successfully supporting students' technical skills. Nevertheless, some obstacles such as limited laboratory facilities and lack of cross-disciplinary collaboration and industry involvement are still a challenge

Learning Outcomes of Psychomotor Domains in Welding Technology: VR Welding Kit Assessment: A Systematic Literature Review

Aim. This systematic literature review aims to analyse existing studies that have investigated the impact of VR welding kits on the development of psychomotor skills, knowledge acquisition, and overall learning experience. By synthesising findings from a variety of sources, this review seeks to provide insight into the strengths, limitations, and potential areas for further research in this domain. Method. This systematic literature review involved an extensive search of electronic databases such as PubMed, Google Scholar, and IEEE Xplore to identify relevant studies that focused on the impact of VR welding kits on psychomotor skills development and knowledge acquisition. Result. Findings from a systematic literature review reveal a range of results related to the impact of VR welding kits on psychomotor skills development and knowledge acquisition. Most of the research highlights the positive effects of utilising VR technology in welding education. VR welding kits were invented to improve learners’ psychomotor skills by providing a realistic and interactive simulation environment. Conclusion. Ongoing research in this domain will be critical to refining and integrating VR welding technology into welding education and practice, ultimately positioning the industry for a future that improves productivity, safety, and competitiveness. Cognitive Value. Allowing students to practice and refine welding techniques in a safe and controlled setting, ultimately leading to increased proficiency and confidence in practical applications. The insights gained from this review have significant implications for educators, training programs, and the welding industry.

Investigations into mechanical properties of 50 and 70 mm thick high strength S690 butt-welded sections

A comprehensive investigation into the mechanical properties of 50 and 70 mm thick high strength S690 steel plates and their butt-welded sections under tension was presented in this paper, and a total of 40 tensile tests were conducted. Firstly, a total of 18 proportional coupons with circular cross-sections were extracted at three different layers within the plate thicknesses. Tensile tests on all of these coupons were carried out to obtain their mechanical properties, and their variations across the plate thicknesses were also examined. Secondly, submerged arc welding was adopted to prepare butt-welded sections between these thick steel plates with various heat input energy. Micrographic examinations on typical heat-affected zones of the welded sections were also performed. Standard tensile tests on a total of 22 proportional coupons with rectangular cross-sections were carried out to obtain their mechanical properties, and the full range deformation characteristics of these coupons were assessed and compared, in particular, their tensile strengths and elongations at fracture. This paper presents important experimental evidence on the mechanical properties of these high strength steel plates of practical thicknesses in construction, and also of their butt-welded sections. It is demonstrated that there is little or even no reduction in their mechanical properties of these butt-welded sections, provided that the welding processes are properly controlled according to established welding practice. Hence, full strength butt-welded sections between these thick high strength S690 steel are readily achieved in practice, similar to those of the commonly adopted S355 steel. These important findings are contrary to general understanding as many researchers and engineers consider that the mechanical properties of these high strength S690 steel are reduced significantly after welding, irrespective of their plate thicknesses.

Friction stir welding and processing of pipes: a status report on joining, materials, and industry applications

Purpose The purpose of this paper is to compile a comprehensive status report on pipes/piping networks across different industrial sectors, along with specifications of materials and sizes, and showcase welding avenues. It further extends to highlight the promising friction stir welding as a single solid-state pipe welding procedure. This paper will enable all piping, welding and friction stir welding stakeholders to identify scope for their engagement in a single window. Design/methodology/approach The paper is a review paper, and it is mainly structured around sections on materials, sizes and standards for pipes in different sectors and the current welding practice for joining pipe and pipe connections; on the process and principle of friction stir welding (FSW) for pipes; identification of main welding process parameters for the FSW of pipes; effects of process parameters; and a well-carved-out concluding summary. Findings A well-carved-out concluding summary of extracts from thoroughly studied research is presented in a structured way in which the avenues for the engagement of FSW are identified. Research limitations/implications The implications of the research are far-reaching. The FSW is currently expanding very fast in the welding of flat surfaces and has evolved into a vast number of variants because of its advantages and versatility. The application of FSW is coming up late but catching up fast, and as a late starter, the outcomes of such a review paper may support stake holders to expand the application of this process from pipe welding to pipe manufacturing, cladding and other high-end applications. Because the process is inherently inclined towards automation, its throughput rate is high and it does not need any consumables, the ultimate benefit can be passed on to the industry in terms of financial gains. Originality/value To the best of the authors’ knowledge, this is the only review exclusively for the friction stir welding of pipes with a well-organized piping specification detailed about industrial sectors. The current pipe welding practice in each sector has been presented, and the avenues for engaging FSW have been highlighted. The FSW pipe process parameters are characteristically distinguished from the conventional FSW, and the effects of the process parameters have been presented. The summary is concise yet comprehensive and organized in a structured manner.

Review on numerical simulation of ultrasonic impact treatment (UIT): Present situation and prospect

Ultrasonic Impact Treatment (UIT) is a surface treatment method that uses ultrasound to create high-frequency, high-intensity impact loads on the surface of metallic materials to improve material properties and durability. The current state of research on the numerical simulation of UIT is reviewed in this paper. Firstly, the working principle of UIT strengthening is introduced, which includes the application of high-intensity UIT to the surface of metallic materials. The UIT strengthening technology has achieved significant success in the industrial field, resulting in plastic deformation, surface compression and residual stress, thereby significantly improving material properties. Secondly, the influence of UIT on the microstructure is reviewed. It is found that the grain refinement and dislocation are successfully predicted by finite element simulation and other methods. The influence of UIT on residual stress is reviewed. It is found that UIT can effectively transform harmful tensile stress into compressive stress, and it has been found that it can be used to guide the industrial practice of welding, laser cladding and additive manufacturing. In general, UIT technology shows important potential in metal material processing, which is of great significance for improving material properties and promoting industrial practice.

Corrosion failure of stainless-steel in caustic soda lines

Abstract The paper deals with the case studies of stainless steel piping corrosion in caustic soda transfer lines at a hydrocarbon processing plant, in the Asian region. The lines were in service of transferring the caustic soda solution from the storage tank farm to different process units, for subsequent use in reaction vessels. To maintain a minimum temperature of the fluid to avoid its precipitation, the lines were accompanied by a steam heat-tracer, throughout the line route. The material of construction (MOC) of the line was stainless steel type 316. After a period of about 3.5 years, 2” caustic line suffered fluid leakage, which was noticed through significant salt accumulation over insulation at one location. A valve was also noticed to leak through a weld at a 1.5” distribution line. The affected components were removed from service and subjected to detailed inspection and laboratory investigation, using advanced tools of metallurgical analysis and characterization. It was found that leakage in 2” line had occurred due to poor workmanship used during the repair of a manufacturing defect at the affected location and leakage of the valve had taken place due to the use of improper welding practice (in the case of subjected weld). In addition, the significant role of metallurgical defects in the parent metal was also disclosed to result in the observed failures. In addition, the contribution of process excursions can’t be completely ruled out. Finally, remedial measures are given to avoid the recurrence of such failure.

Virtual reality in welding training and education: A literature review

The welding workforce is facing a deficit of skilled welders, highlighting the need to develop more efficient and effective welding training methods. Virtual reality (VR) technologies have been adopted to create VR welding simulations for educational and training purposes. The purpose of this literature review was to collect and analyze peer-reviewed research, published between 2012-2022, regarding VR technology applications in welding training. The concept of Engagement in Blended Learning Environments served as our research framework. In the context of welding, VR welding training is a relatively new approach that functions as a blended learning environment. During data collection, we identified 31 articles; however, following analysis and coding, 13 were excluded, for a final N=18. Through a process of triangulation, we identified themes across existing research to highlight trends, recommendations for real-world welding practice, and recommendations for future research. Four main research themes emerged from the literature: 1. Comparison of Approaches, 2. VR as a Teaching Tool, 3. System Development, and 4. System Testing. Six future research recommendations were identified and grouped, including the recommendation to compare virtual weld performances to live weld performances. Four practitioner-based recommendation themes were identified, including the recommendation for instructors to develop their own knowledge and skills related to VR welding technology. From this review, we identified gaps in the existing literature and made recommendations for future research on VR welding training.

Ergonomic Posture Assessment Approaches for New Welder: A Study in Technical Institution

Welding practical work is a compulsory learning process for all mechanical engineering students in Malaysian polytechnics, students will spend 2 to 4 hours a week doing practical work. Because of that, this situation can cause problems for students when performing tasks, including body posture and manual handling during practical work which can result in musculoskeletal disorders (MSD), in addition non-standard instructions for performing tasks also happen. This study aims to identify the risk of postural problems during welding practical work and suggest an appropriate ergonomic posture assessment to reduce the risk of MSD. In order to assess the position of body posture during welding practical work at technical education institutions, the Rapid Upper Limb Assessment (RULA) and Rapid Entire Body Assessment (REBA) tools were used to observe body posture during practical work and specifically to see the bending level of body parts during work welding practice. Analysis and evaluation were carried out using REBA and RULA and found that the final score for RULA was at a value of 7 and the score for REBA was 9 in the same welding practical. Based on these two scores it was found that welders are at high risk to getting cumulative trauma disorder (CTD) which can also result in MSD. In conclusion, both REBA and RULA body posture assessment tools can be used to assess body posture when carrying out practical work, however, REBA is more suitable because there is an assessment of the leg part which usually involves the leg part while welding, either standing, sitting or squatting (CTD).

Effect of post-welding heat treatment on mechanical and microstructural properties of friction stir welded dissimilar magnesium alloys

Magnesium (Mg) alloys have undergone a huge exploration to expand their applications because of their exceptional unique characteristics and their status as one of the lightest metals. Friction stir welding (FSW) is a well-known welding practice for Mg alloys. Heat treatment can enhance the weld joint's physical properties and performance. In the current work, FSW joint of AZ31 and AZ61 Mg alloys were heat treated at 260 °C for 15 min. It has been examined how post-weld heat treatment (PWHT) affects the microstructure and mechanical characteristics of AZ31-AZ61 Mg alloy FSW joints. PWHT has been found to have a remarkable impact on the weld joint. The weld's stirring zone yielded noticeably coarser grains. After heat treatment, the joint's elongation improved by around 39%. After PWHT, the stir zone showed the highest microhardness 69 Hv (reduced by about 11.87%). The impact toughness of the FSW joint was reduced after PWHT by about 6%.

Hybrid optimization strategy for evaluating sustainable performance of the electron beam welding process

With the escalation of climate change, the practice of sustainable welding has become imperative in today's manufacturing industries. Sustainable welding practice via advanced modeling and optimization techniques is a recent idea that has highly been emphasized in various studies for the sustainable production of components. This work, therefore, assess the sustainable performance of the electron beam welding (EBW) process using a novel hybrid optimization search strategy (FL-AHP-TLBO) that optimizes two sustainable characteristics i.e. net energy (Enet) as ‘environmental consideration’ and depth of penetration (P), weldment area (WA), ultimate tensile strength (UTS) being three quality factors as ‘economic consideration’. The optimization approach combines soft computing fuzzy logic (FL) modelling with the teaching-learning-based optimization (TLBO) algorithm to simultaneously optimize these factors while an analytical hierarchy process (AHP) is used to determine the optimal weightage for each factor. The approach yields a minimum fitness value of − 0.39945 at optimum parameter setting V= 60 kV, I= 38 mA, S= 1200 mm/min, and O= 600 Hz. On validation, the methodology improves the sustainable measures by 1.115% for P, 2.5150% for WA, 7.0423% for Enet, and 2.5836% for UTS. The proposed methodology also was found simple and adequate with a faster convergence rate, higher consistency, and results in an overall improvement of 7.377% over the traditional optimization approaches.

Learn Welding Techniques to Improve Work Skills in Vocational School Students

Welding training is a learning activity about the science and practice of welding, so that the trainees know the correct welding methods and can practice them. It is hoped that this training activity can become one of the competency provisions for the training participants, in this case the youth of the Pondok Benda sub-district, South Tangerang. In order for this activity to run smoothly, a scientific method was established, namely a theoretical explanation of welding and practice. The participants in this activity were teenagers who were members of the Pondok Benda sub-district, South Tangerang youth organization, which totaled 45 people. The activity was carried out at the community hall RW 014 Pondok Benda, South Tangerang, on Saturday, July 30 2022. This activity went smoothly and the participants were very enthusiastic. It was evident that many questions were asked, the participants' responses were very enthusiastic, and the participants were very enthusiastic about participating in the welding practice. This activity was welcomed positively, because according to one of the training participants, this activity can form welding skills that are useful for the world of work.

An Approach to Best Welding Practice. Part – XXI. Section – III- BV-B(i)

An Approach to Best Welding Practice. Part – XXI. Section – III- BV-B(i)

An Approach to Best Welding Practice. Part – XXI. Section – III- BV-B(i)

An Approach to Best Welding Practice. Part – XXI. Section – III- BV-B(i)

Perancangan Meja Las yang Ergonomis berdasarkan Analysis REBA di Universitas Sebelas Maret

Welding practice is one type of practice with a fairly long duration. Therefore, an ergonomic welding table design is needed so that the practice can practice safely and comfortably. The purpose of this study was to evaluate existing designs with the REBA analysis approach and then redesign the more ergonomic welding table. Data collection technique using purposive sampling technique. The proposed welding table design is based on anthropometric data of 30 UNS Mechanical Engineering Education students class of 2018, 2019, and 2020. The design design of this welding table uses SolidWork 2019 software. The calculation of ergonomic risk evaluation with REBA resulted in a score of 6 meaning that immediate improvement is needed and requires further investigation. The results of this study obtained a new welding table design design that has dimensions: 42 cm in length, 40 cm in width, and 2,010 cm in height. This welding table also provides space to put the welding machine under the welding table. Thus, the improvement of the design of the welding table will increase the efficiency of the implementation of the practice. In addition, the practice will be safer and more comfortable because the welding table has adjusted to the posture of the average student.

Cold welding of ultrathin metallic glass nanowires with side-to-side contact using molecular dynamics simulations

Cold welding can effectively join a wide variety of components, forming high quality assemblies. In this work, the cold welding behaviors of Cu-Zr metallic glass nanowires (MGNWs) in the form of side-to-side contact are investigated by molecular dynamics simulation. The mechanical performance of the welded MGNW is inspected by uniaxial tensile tests. Cold welding processes of MGNWs with various sizes and under different welding conditions are explored. Our results show that the strength of the welded MGNW at 50 K is less than 60% of that of the crude nanowire. At the same welding velocity, the change of welding time within a certain range does not influence the welding quality obviously. The increase in overlap width makes the welded MGNW stronger. The enhancement of welding temperature facilitates the atom diffusion activity, and thus strengthens the contact regions, improving the welding quality. We also compare the side-to-side contact and head-to-head contact cold welding. It is found that the former endows the welded MGNW with lower strength but better plasticity. This work provides a preliminary theoretical guideline on the cold welding of MGNWs for further experiments and to facilitate the engineering practice of cold welding.

An Approach to Best Welding Practice. Part – XXI. Section – III- B - IVb

An Approach to Best Welding Practice. Part – XXI. Section – III- B - IVb

An Approach to Best Welding Practice. Part – XXI. Section – III- B - IVa

An Approach to Best Welding Practice. Part – XXI. Section – III- B - IVa

Welding training for the community in Loa Janan Ilir District, Samarinda City

The majority of the people in Harapan Baru Village, Loa Janan Ilir Sub-district work as manual laborers, for example as bricklayers, market workers, and construction workers. In addition, employment opportunities are also limited in number. Therefore, this community service is intended to provide SMAW welding training in collaboration with the Loa Janan Ilir District Community Empowerment Institute. The method used is the lecture, question and answer, and welding practice. The materials given are SMAW welding machine operating procedures, SMAW welding components and various welding joints. The result is to provide insight into the material and practice of SMAW welding as a provision for entrepreneurship and work seeking.

Pulse spray gas metal arc welding of advanced high strength S650MC automotive steel

With an increasing demand for safer and greener vehicles, mild steel and high strength steel are being replaced by much stronger advanced high strength steels of thinner gauges. However, the welding process of advanced high strength steels is not developed at the same pace. The performance of these welded automotive structural components depends largely on the external and internal quality of weldment. Gas metal arc welding (GMAW) is one of the most common methods used in the automotive industry to join car body parts of dissimilar high strength steels. It is also recognized for its versatility and speed. In this work, after a review of GMAW process and issues in welding of advanced high strength steels, a welding experiment is carried out with varying heat input by using spray and pulse-spray transfer GMAW method with filler wires of three different strength levels. The experiment results, including macro-microstructure, mechanical properties, and microhardness of weld samples, are investigated in detail. Very good weldability of S650MC is demonstrated through the weld joint efficiency > 90%; no crack in bending of weld joints, or fracture of tensile test sample within weld joint or heat affected zone (HAZ), or softening of the HAZ. Pulse spray is superior because of thinner HAZ width and finer microstructure on account of lower heat input. The impact of filler wire strength on weldability is insignificant. However, high strength filler wire (ER100SG) may be chosen as per standard welding practice of matching strength.

The State of the Art of Underwater Wet Welding Practice: Part 2

Developments in underwater wet welding (UWW) over the past four decades are reviewed, with an emphasis on the re-search that has been conducted in the last ten years. Shielded metal arc welding with rutile-based coated electrodes was established as the most applied process in the practice of wet welding of structural steels in shallow water. The advancements achieved in previous decades had already led to control of the chemical composition and microstructure of weld metals. Research and development in consumables formulation have led to control of the amount of hydrogen content and the level of weld porosity in the weld metal. The main focus of research and development in the last decade was on weldability of naval and offshore structural steels and acceptance of welding procedures for Class A weld classification according to American Welding Society D3.6, Underwater Welding Code. Applications of strictly controlled welding techniques, including new postweld heat treatment procedures, allowed for the welding of steels with carbon equivalent values greater than 0.40. Classification societies are meticulously scrutinizing wet welding procedures and wet weld properties in structural steels at depths smaller than 30 m prior to qualifying them as Class A capable. Alternate wet welding processes that have been tested in previous decades — such as friction stir welding, dry local habitat, and gas metal arc welding — have not achieved great success as originally claimed. Almost all of the new UWW process developments in the last decade have focused on the flux cored arc welding (FCAW) process. Part 1 of this paper covered developments in microstructural optimization and weld metal porosity control for UWW. Part 2 discusses the hydrogen pickup mechanism, weld cooling rate control, design, and qualification of consumables. It ends with a description of the advancements in FCAW applications for UWW.