Welding Wire Research Articles

Analysis and Optimization of Laser Beam Welding Parameters for Aluminium Composite (Al-Zn-Cu Alloy) by Grey Relational Optimization

Aluminium and its composites are widely used in production to enhance the strength of lightweight objects. In this study, an AA7075/SiC composite was fabricated using a stir casting route. Multi-objective optimization and finite element analysis were performed with various process parameters on a manufactured aluminium composite (AA7075 + SiC) undergoing a laser beam welding process. Four welding parameters, i.e., pulse frequency, power, welding speed (transverse), and wire size were taken for laser welding as per the L-9 orthogonal array for experimental study. Tensile strength, deflection, temperature distribution, Rockwell hardness (fusion zone), and Rockwell hardness (heat affected zone) were taken as output parameters after welding. The standard deviation objective weighting–grey relational optimization method optimized the process parameter. ANSYS APDL 23 software was utilized to simulate the entire laser welding method with a cylindrical heat source to predict the temperature distribution in the butt-welded plates. This software uses finite element analysis and gives a deviation of only 5.85% for temperature distribution with experimental results. This study helps to understand the effect of various parameters on the welding strength of the aluminium composite.

Interpretation of mechanical properties gradient in laser-welded joints: Experiments and grain morphology-dependent crystal plasticity modeling

The grain size and morphology of laser welds show a gradient distribution, leading to variations in mechanical properties. This study proposes a microscopic crystal plasticity constitutive (CPC) model to examine the effect of ER4047 welding wire on the mechanical properties of laser-welded aluminum alloy joints. A finite element model updating strategy was used to fully invert the morphological mechanical parameters, marking a significant advancement. This study combines mesoscale electron backscatter diffraction (EBSD) observations with macroscopic uniaxial tensile tests to obtain crystal plasticity finite element analysis and strain field data from digital image correlation. The mechanical property gradient of the welded joints was systematically analyzed from a crystal perspective. The CPC parameters were inverted for different grain sizes and morphologies. The study found that using ER4047 welding wire significantly enhanced the mechanical properties of the welded joints, especially in the welding zone. As grain size increased, the yield strength of the material decreased, while the hardening modulus increased. Additionally, the cast characteristics of columnar crystal morphology reduced both yield strength and hardening modulus.

Obtaining wear-resistant coatings by surfacing with powder core welding wire

Obtaining wear-resistant coatings by surfacing with powder core welding wire

New welding wire for welding high-strength quenched and tempered steels

New welding wire for welding high-strength quenched and tempered steels

Grain refinement of Inconel 625 during wire-based directed energy deposition additive manufacturing by in-situ added TiB2 particles: Process development, microstructure evolution and mechanical characterization

In this study, a novel method for enhancing the quality of components fabricated by wire and arc additive manufacturing (WAAM) was developed. This approach employs an innovative mechanism featuring an actuator that dispenses a solution containing refinement particles (TiB2 inoculants), in conjunction with a soldering flux that vaporizes prior to reaching the electric arc. This leaves the particles to adhere to the welding wire or be carried by the shielding gas. By implementing this device, TiB2 particles were successfully incorporated into the molten pool during the WAAM process of Inconel 625 at levels of 0.31 and 0.56 wt%. Microstructural analysis reveals a significant reduction in the size of interdendritic segregation regions when TiB2 particles are introduced. Electron backscatter diffraction analysis further reveals the transformation of columnar grains into equiaxed grains. The average grain area decreased from 1823 μm2 in the as-built sample to 583 μm2 in the sample with a TiB2 content of 0.56 wt%. In addition, an improvement in the Inconel 625 fabricated by WAAM mechanical strength was observed due to the use of TiB2 inoculants, which was primarily attributed to the effect of the grain size refinement.

Impact of Ultrasonic Welding Parameters on Weldability and Sustainability of Solid Copper Wires with and without Varnish.

This article contains an advanced analysis of the properties of solid wire electrical contacts produced by ultrasonic welding, both with and without varnish. The main disadvantage of ultrasonic welding of thin wires is the inability to achieve acceptable peel force and tensile strength, which is mainly due to the deformation and thinning of the wires. This study deals with ultrasonic welding using a ring of thin solid copper wires that minimises the deformation and thinning of the wires. The influence of welding parameters such as energy, pressure and amplitude were systematically analysed. Based on these parameters, the optimum welding programme and control method was determined to weld unvarnished and varnished wires. The investigations included electrical resistance tests, optical microscopy, micro-hardness measurements, peel tests and tensile tests, and the measurement of energy consumption. The results showed no significant differences in microstructure and hardness between varnished and unvarnished joints. Ultrasonic joints of varnished wires achieved lower electrical conductivity (by 38%), lower tensile strength (by 3%) and higher peel strength (by 7%), while the welding process was more sustainable in terms of energy (by 6.6%) and time consumption (without preprocessing).

Microstructure Evolution and Forming Characteristics of Post-Weld Composite Treatment of 6061 Aluminum Alloy Tailor Welded Blanks

The mechanical properties and cross-sectional geometric dimensions of the fusion zone (FZ), heat affected zone (HAZ), and base metal (BM) of 6xxx series aluminum alloys are inconsistent after filler wire welding, which reduces the formability of aluminum alloy tailor welded blanks (TWBs). This paper proposes a post-weld cold rolling-solution heat treatment (PWCR-SHT) composite process, and the effects of weld excess metal, plastic deformation, and SHT on the formability of aluminum alloy TWBs are studied. The results show that the PWCR-SHT composite process eliminates the weld excess metal and internal pores, reduces the stress concentration at the weld toe, eliminates the local strain hardening behavior, and causes recrystallization in the FZ region. The cupping value of aluminum alloy TWBs using SHT is 105% of BM, in comparison, the cupping value of aluminum alloy TWBs using the PWCR-SHT composite process is 119% of BM, which is the result of the combined effect of geometric dimensions consistency and mechanical properties consistency.

Membandingkan Kekuatan Pengelasan Single Dan Double Kawat Inti Elektroda (Filler Rod) Menggunakan Las Smaw

Advances in welding technology are very helpful in making, repairing or repairing chassis jobs that have a high level of difficulty and requirements. Especially in the chassis, many welding elements are involved because welded joints have an important role to support the body, engine, and vehicle load. In practical work at CV. Pringgandani Welding Analysis Comparing the Strength of Welding Results of Single Electrode Core Wire and Double Electrode Core Wire (Filler Rod) Using SMAW welding which is carried out for chassis welding which is claimed by mechanics in welding with a depth and width of more than 5 mm, it is better to use double electrode core wire which can speed up and strengthen the weld. Then a test is carried out to prove the results of the Single Wire Electrode Core and Double Electrode Core Wire (Filler Rod) welds which are stronger and faster in the process. By testing the weld results on an iron plate with dimensions of 250 mm x 50 mm x 10 mm, the welding process uses the SMAW (Shielded Metal Arc Welding) welding method. Using an E6013 type electrode with a diameter of 2 mm with a current of 90 A, polarity DCEP (Direct Current Electrode Positive) The welding position used is the 1G position or horizontal position with the welding process using a single v-groove bevel butt joint and an angle of 60o with a weld width of 10 mm and a weld depth of 8 mm. The plate samples used were two samples. In sample 1 using a single wire core electrode, and sample 2 using a double wire core electrode. All samples were made of tensile test specimens with the ASME-IX standard, a tensile test was carried out to determine and prove the respective strengths of the welding results of Single Wire Core Electrode and Double Wire Core Electrode (Filler Rod).

SAL5087 bright welding wire two acid polishing process and its effect on surface roughness

Abstract In order to obtain bright aluminum alloy wires and eliminate the environmental and human hazards of traditional chemical polishing, the H3PO4-H2SO4 system chemical polishing process was developed for SAL5087, and the surface roughness was measured by laser confocal microscopy and the surface morphology was observed by sweeping electron microscopy as the evaluation index of the polishing quality. The process optimization was carried out by orthogonal experiments and the role of each component was analyzed. The experiments showed that phosphoric acid dominates the polishing process, which can effectively enhance the polishing effect under the synergistic effect with various additives. The surface roughness of the polished wire was reduced to 0.257 μm in the optimum process, and the surface was free of defects such as burrs and scratches.

Influence of arc energy on the microstructure and corrosion behavior of ER2209 duplex stainless steel deposited on Q345B low-alloy steel by GMAW

In order to eliminate the complex effects of thermal cycling and the thermal effects of the next pass on multi-layer multi-pass welding of low-alloy steel and duplex stainless steel, ER2209 welding wire was single-layer single-pass deposited on the surface of Q345B hot-rolled plate by gas metal arc welding (GMAW). The microstructure and corrosion resistance of welded joints were studied by different arc energies. The results showed that the arc energy had a significant impact on the “tongue-shaped” morphology and the width of heat affect zone in the welded joint, which in turn affected the corrosion performance of the welded joints. Due to the least distribution of “tongue-shaped” morphology and minimum width of heat affected zone in the welded joint with arc energy of 0.645kJ/mm, it owned the best corrosion resistance. The weld metals of the welded joints were composed of ferrite and austenite phases. The ferrite phases were distributed along grain boundaries and intergranular. As the heat input increases, the distribution of ferrite phase along grain boundaries gradually decreased. The corrosion products and corrosion morphology of the welded joint were also investigated and the corrosion mechanism was discussed in detail. The research results of this article provide a theoretical basis for improving the corrosion performance of multi-layer multi-pass welded joints of low-alloy and duplex stainless dissimilar steels.

The Influence of Alloy Composition on Microstructure and Performance of Mixed-Smelting Alloy and Weld Metal.

In the present work, the Q345B low-alloy steel with different contents and ER309L stainless steel were melted together to obtain new alloys. The aim was to design the composition of weld metal (Q345B low-alloy steel as the base material and ER309L welding wire as the filler material) and improve the corrosion resistance of the weld metal. During the welding process, the composition of the weld metal was controlled to match the new alloys by changing the welding heat input. A relationship curve between fusion ration and welding heat input was obtained. The research focused on analyzing the effect of mixed-smelting ratio between Q345B and ER309L and welding heat input on the microscopic structure and corrosion performance of the prepared samples. The results show that the melted alloys containing 20% to 30% Q345B consist of a ferrite (δ) phase and austenite (A) phase, the samples containing 45% to 50% Q345B consist of a martensite (M) phase and austenite (A) phase, and the sample containing 40% Q345B consists of a martensite (M) phase, ferrite (δ) phase, and austenite (A) phase. As the mixed-smelting ratio of Q345B/ER309L increased, the corrosion resistance of samples decreased gradually. For the weld metal, the fusion ration between Q345B base material and ER309L welding wire increases with the welding heat input. When the heat input changed from 0.645 kJ/mm to 2.860 kJ/mm, the composition of the weld metal was consistent with the melted alloys containing 20-45% Q345B. The microstructure and corrosion resistance of the weld metal could be designed by the melting means, which has important guiding significance for engineering applications.

Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys

It is difficult for traditional aluminum alloy manufacturing technology to meet the requirements of large-scale and high-precision complex shape structural parts. Wire Arc additive manufacturing technology (WAAM) is an innovative production method that presents the unique advantages of high material utilization, a large degree of design freedom, fast prototyping speed, and low cast. As a result, WAAM is suitable for near-net forming of large-scale complex industrial production and has a wide range of applications in aerospace, automobile manufacturing, and marine engineering fields. In order to serve as a reference for the further development of WAAM technology, this paper provides an overview of the current developments in WAAM both from the digital control system and processing parameters in summary of the recent research progress. This work firstly summarized the principle of simulation layering and path planning and discussed the influence of relative technological parameters, such as current, wire feeding speed, welding speed, shielding gas, and so on. It can be seen that both the welding current and wire feeding speed are directly proportional to the heat input while the travel speed is inversely proportional to the heat input. This process regulation is an important means to improve the quality of deposited parts. This paper then summarized various methods including heat input, alloy composition, and heat treatment. The results showed that in the process of WAAM, it is necessary to control the appropriate heat input to achieve minimum heat accumulation and improve the performance of the deposited parts. To obtain higher mechanical properties (tensile strength has been increased by 28%–45%), aluminum matrix composites by WAAM have proved to be an effective method. The corresponding proper heat treatment can also increase the tensile strength of WAAM Al alloy by 104.3%. In addition, mechanical properties are always assessed to evaluate the quality of deposited parts. The mechanical properties including the tensile strength, yield strength, and hardness of the deposited parts under different processing conditions have been summarized to provide a reference for the quality evaluation of the deposition. Examples of industrial products fabricated by WAAM are also introduced. Finally, the application status of WAAM aluminum alloy is summarized and the corresponding future research direction is prospected.

Dilution induced variation of microstructure and mechanical properties on Co-Cr-Fe-Ni high entropy alloy coatings prepared by laser cladding

The remarkable properties of some series of high entropy alloys (HEAs) have garnered extensive interest in the development of HEA coatings. In this study, we prepared non-equiatomic Co-Cr-Fe-Ni HEA coatings using laser cladding method with Co-Cr-Fe-Ni cable-type welding wire (CTWW) as the filling material and investigated the effect of dilution rate on the microstructure evolution of coatings. By changing the wire feeding speed, a large dilution rate range was obtained which is from over 80 % to below 20 % and a variation of the coating's microstructure and mechanical properties was discovered within this large dilution rate range. All of the coatings are dense and uniform, with good metallurgical bonding. A pivotal discovery was made when the dilution rate decreased from approximately 35 %–40 % to below this threshold. The coating transitions from face centered cubic (FCC) and body centered cubic (BCC) dual-phase to FCC single-phase, accompanied by a precipitous drop in hardness from approximately 425 HV to below 175 HV. The interlaced distribution and dislocation pile-up of the layered BCC eutectic structure within the FCC phase are the main reasons for this dramatic change. Therefore, controlling the dilution rate is an effective way to regulate the performance of Co-Cr-Fe-Ni HEA coatings.

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

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

The influence of various welding wires on microstructure, and mechanical characteristics of AA7075 Al-alloy welded by TIG process

Owing to their exceptional mechanical properties, the various welding wires used to combine aluminum can meet the needs of many engineering applications that call for components with both good mechanical and lightweight capabilities. This study aims to produce high-quality welds made of AA7075 aluminum alloy using the GTAW technique and various welding wires, such as ER5356, ER4043, and ER4047. The microstructure, macrohardness, and other mechanical characteristics, such as tensile strength and impact toughness, were analyzed experimentally. To check the fracture surface of the AA7075 welded joints, the specimens were examined using optical and scanning electron microscopy (SEM). A close examination of the samples that were welded with ER5356 welding wire revealed a fine grain in the weld zone (WZ). In addition, the WZ of the ER4043 and ER4047 welded samples had a coarse grain structure. Because the hardness values of the welded samples were lower in the WZ than in the base metal (BM) and heat-affected zone (HAZ), the joints filled with ER5356 welding wire provided the highest hardness values compared to other filler metals. Additionally, the ER4047 filler metal yielded the lowest hardness in the weld zone. The welding wire of ER5356 produced the greatest results for ultimate tensile stress, yield stress, welding efficiency, and strain-hardening capacity (Hc), whereas the filler metal of ER4043 produced the highest percentage of elongation. In addition, the ER4047 fracture surface morphology revealed coarser and deeper dimples than the ER5356 fine dimples in the welded joints. Finally, the highest impact toughness was obtained at joints filled with the ER4047 filler metal, whereas the lowest impact toughness was obtained at the BM.

Microstructure and wear properties of carbide reinforced high-entropy alloy coatings on EA4T steel via vibration assisted TIG-cladding using WC core spiral AlCuNiCrTi-CWW

Aiming at the difficulty preparing high-entropy alloy (HEA) coating by adding carbide powder using TIG-cladding, the WC core spiral CWW prefabricated vibration assisted TIG-cladding method is proposed in this work. The HEA coating (S1-coating) was prepared on the EA4T steel using AlCuNiCrTi cable-type welding wire (CWW) via TIG-cladding, then the WC reinforced HEA coating (S2-coating) was produced using spiral AlCuNiCrTi-CWW with WC powder core by TIG-cladding. Finally, another WC reinforced HEA coating (S3-coating) via vibration assistance TIG-cladding using the same material as S2-coating. The S1-coating is composed of BCC and FCC solid solutions. Except for the same phases as S1-coating, TiC appeared in the S2-coating and the S3-coating. Due to the grain refinement effect caused by vibration, the S3-coating has the maximum microhardness (725HV), lowest friction coefficient (0.42) and the smallest volume wear rate (0.1397 × 10−4 mm3/N·m). The addition of vibration assistance effectively improves the microhardness and wear resistance of the coating without changing CWW composition.

Study on Microstructure and Properties of LZ50 Axle Steel Repaired by Laser Additive Remanufacturing

ER308L stainless steel welding wire was used for laser repair of LZ50 train axle steel sample. A large number of defects, such as microcracks, pore shrinkage and porosity, can be found in the re-manufacturing sample. A wave-like structure was formed at the boundary of the fusion zone between the augmented repair material and the base material, and the structure in this zone was consist of about 83% martensite and about 17% austenite, In the ER308L stainless steel welding wire repair zone, columnar equiaxed crystals with different lengths and morphology were formed, all of which pointed to the center of the molten pool. After repair, the tensile strength of the specimens decreased from 601.34MPa to 427.81MPa, and the elongation decreased from 16% to 5%, The fracture mode was a combination of ductile fracture and brittle fracture.

Study on microstructure and mechanical properties of 5052 aluminum alloy MIG welded joint for high-speed train

In this paper, the MIG welding process is utilized to weld a 3 mm thick 5052 aluminum alloy plate by using ER5356 welding wire as filler. The effects of different welding speeds on the microstructure and mechanical properties of the weld are systematically studied utilizing a metallographic microscope, x-ray diffractometer, scanning electron microscope, room temperature tensile, and microhardness. It was found that there were pore defects in the samples at lower or higher welding speeds, and there was no penetration at the maximum welding speed. When the welding speed is 650 mm min−1, the weld is well-formed, the surface is flat without pores, the fish scale is evenly distributed, and the weld shows good penetration. The intermetallic compounds of all the welds are mainly composed of α(Al), Mg2Si, Al3Fe, and Al3Mg2. The mechanical properties of the samples show that the hardness of the weld reaches the maximum value of 56.7HV at this welding speed, and the tensile strength and elongation are 210 MPa and 14.3%, respectively. The fracture is located at the junction of the base metal and the heat-affected zone, and the fracture type showed typical ductile fracture.

A new Ti–Al–Cr–Mo–Zr titanium alloy welding wire: Stability, microstructure and mechanical properties

In order to improve the plasticity of titanium alloy welded joints, relevant scholars currently focus primarily on studying the mechanism of action of alloying elements Mo and V, such as reducing the phase transition temperature of the welded seam and ensuring a certain amount of β phase residue in the welded seam. In addition to improving the stability and strengthening ability of titanium alloy welded joint, it can also maintain a certain degree of plasticity of the welded joint. However, the poor impact toughness is still the key problem that restricts its long-term stable service in the harsh environment. Our work designed and developed a new Ti–Al–Cr–Mo–Zr solid welding wire, with the synergistic effect of Al, Cr, Mo and Zr, the welded seam microstructure and grain can be refined while ensuring the enough stiffness of the welding wire and its flatness during wire feeding into the designated working area. It ensures good wetting and spreading flow performance of the liquid molten pool metal in the welding process, so better welded seam formation can be obtained. The relative contents of α′ martensite and β phase in the welded seam are 76.79% and 23.21%, respectively. The residual β phase is interspersed between the α′ martensite of the slats. The β phase provides a path for the plastic deformation of the welded joint, making it easier for dislocation slip to pass the β/α′ interface. At the same time, more dislocation slip channels and a small number of fine twins can be found in the interior of α′ martensite, which can ensure the strength while taking into account the toughness. After testing, it is found that the average tensile strength of welded joints is 901 MPa, which is close to 95% of the base metal (BM), the average post-fracture elongation of welded joints is 21%, and the impact toughness value at room temperature is distributed between 25 J and 33 J, which meets the requirements of the synergistic effect of welded joint strength and plastic toughness. It is suitable for long-term stable service of Ti64 titanium alloy welding structure under harsh working conditions.

Microstructure and mechanical properties of low cost co-free high strength steel fabricated by plasma arc-based directed energy deposition

Arc-based directed energy deposition (DED) is characterized by high efficiency and excellent manufacturing flexibility, making it a promising choice for fabricating large structural components. High power density plasma arc-based directed energy deposition (PA-DED) was employed to fabricate high strength steel (HSS) component with a new Co-free welding wire. The microstructure and mechanical properties of the component were investigated in detail. The results showed that the matrix microstructure consisted mainly of martensite and ferrite. Austenite was observed in the bottom and middle samples, and the bottom sample exhibited the highest austenite content. All the samples in different regions exhibited a pronounced {100} 〈001〉 cube texture. The vertical samples had worse tensile properties than horizontal samples, which would be contributed to the interlayer bands and preferred orientation. The horizontal-middle samples demonstrated the highest tensile strength (UTS: 1207.8 ± 14 MPa, EL: 15.91 ± 1.03%). All deposited samples showed strong plastic deformation characteristics, illustrating that the new Co-free HSS components manufactured by PA-DED might replace conventional high-alloy HSS components for industrial applications.