Abstract: Adhesively bonded joints are preferred over the
conventional methods of joining such as riveting, welding, bolting
and soldering. Some of the main advantages of adhesive joints
compared to conventional joints are the ability to join dissimilar
materials and damage-sensitive materials, better stress distribution,
weight reduction, fabrication of complicated shapes, excellent
thermal and insulation properties, vibration response and enhanced
damping control, smoother aerodynamic surfaces and an
improvement in corrosion and fatigue resistance. This paper presents
the behavior of adhesively bonded joints subjected to combined
thermal loadings, using the numerical methods. The joint
configuration considers aluminum as central adherend with six
different outer adherends including aluminum, steel, titanium, boronepoxy,
unidirectional graphite-epoxy and cross-ply graphite-epoxy
and epoxy-based adhesives. Free expansion of the joint in x
direction was permitted and stresses in adhesive layer and interfaces
calculated for different adherends.
Abstract: Explosive welding is a process which uses explosive
detonation to move the flyer plate material into the base material to
produce a solid state joint. Experimental tests have been carried out
by other researchers; have been considered to explosively welded
aluminium 7039 and steel 4340 tubes in one step. The tests have been
done using various stand-off distances and explosive ratios. Various
interface geometries have been obtained from these experiments. In
this paper, all the experiments carried out were simulated using the
finite element method. The flyer plate and collision velocities
obtained from the analysis were validated by the pin-measurement
experiments. The numerical results showed that very high localized
plastic deformation produced at the bond interface. The
Ls_dyna_971 FEM has been used for all simulation process.
Abstract: In this paper, the strength of a stabilizer is determined when the static and fatigue multiaxial loading are applied. Stabilizer is a part of suspension system in the heavy truck for stabilizing the cabin against the vibration of the road which composes of a thin-walled tube joined to a forge component by fillet weld. The component is loaded by non proportional random sequence of torsion and bending. Residual stress of welding process is considered here for static loading. This static loading with road irregularities are applied in this study as fatigue case that can affected in the fillet welded area of this part. The stresses in the welded structure are calculated using FEA. In addition, the fatigue with multi axial loading in the fillet weld is also investigated and the critical zone of the stabilizer is specified and presented by graphs. Residual stresses that have been resulted by the thermal forces are considered in FEA. Force increasing is the element of finding the critical point of the component.
Abstract: Existing underground pipe jacking methods use a
reinforcing rod in a steel tube to obtain structural stiffness. However,
some problems such as inconvenience of works and expensive
materials resulted from limited working space and reinforcing works
are existed. To resolve these problems, a new pipe jacking method,
namely PST (Prestressed Segment Tunnel) method, was developed
which used joint to connect the steel segment and form erection
structure. For evaluating the flexural capacity of the PST method
structure, a experimental test was conducted. The parameters
considered in the test were span-to-depth ratio of segment, diameter of
steel tube at the corner, prestressing force, and welding of joint. The
flexural behaviours with the effect of load capacity in serviceability
state according to different parameters were examined.. The frame
with long segments could increase flexural stiffness and the specimen
with large diameter of concave corner showed excellent resistance
ability to the negative moment. In addition, welding of joints increased
the flexural capacity.
Abstract: In this study the mixed mode fracture mechanics
parameters were investigated for high tensile steel butt welded joint
based on modified Arcan test and finite element analysis was used to
evaluate the effect of crack length on fracture criterion. The nondimensional
stress intensity factors, strain energy release rates and Jintegral
energy on crack tip were obtained for various in-plane
loading combinations on Arcan specimen starting from pure mode-I
to pure mode-II loading conditions. The specimen and apparatus were
modeled by finite element method and analyzed under various
loading angles (between 0 to 90 degrees with 15 degree interval) to
simulate the pure mode-I, II and mixed mode fracture. Since the
analytical results are independent from elasticity modules for
isotropic materials, therefore the results in elastic fields can be used
for Arcan specimens. The main objective of this study was to
evaluate the geometric calibration factors for modified Arcan test
specimen in order to obtain fracture toughness under mixed mode
loading conditions.
Abstract: Solidification cracking and hydrogen cracking are some defects generated in the fusion welding of ultrahigh carbon steels. However, friction stir welding (FSW) of such steels, being a solid-state technique, has been demonstrated to alleviate such problems encountered in traditional welding. FSW include different process parameters that must be carefully defined prior processing. These parameters included but not restricted to: tool feed, tool RPM, tool geometry, tool tilt angle. These parameters form a key factor behind avoiding warm holes and voids behind the tool and in achieving a defect-free weld. More importantly, these parameters directly affect the microstructure of the weld and hence the final mechanical properties of weld. For that, 3D finite element (FE) thermo-mechanical model was developed using DEFORM 3D to simulate FSW of carbon steel. At points of interest in the joint, tracking is done for history of critical state variables such as temperature, stresses, and strain rates. Typical results found include the ability to simulate different weld zones. Simulations predictions were successfully compared to experimental FSW tests. It is believed that such a numerical model can be used to optimize FSW processing parameters to favor desirable defect free weld with better mechanical properties.
Abstract: This paper reports the tensile fracture location
characterizations of dissimilar friction stir welds between 5754
aluminium alloy and C11000 copper. The welds were produced using
three shoulder diameter tools; namely, 15, 18 and 25 mm by varying
the process parameters. The rotational speeds considered were 600,
950 and 1200 rpm while the feed rates employed were 50, 150 and
300 mm/min to represent the low, medium and high settings
respectively. The tensile fracture locations were evaluated using the
optical microscope to identify the fracture locations and were
characterized. It was observed that 70% of the tensile samples failed
in the Thermo Mechanically Affected Zone (TMAZ) of copper at the
weld joints. Further evaluation of the fracture surfaces of the pulled
tensile samples revealed that welds with low Ultimate Tensile
Strength either have defects or intermetallics present at their joint
interfaces.
Abstract: This paper investigates the development of weld zone
in Resistance Spot Welding (RSW) which focuses on weld nugget and Heat Affected Zone (HAZ). The effects of four factors namely
weld current, weld time, electrode force and hold time were studied using a general 24 factorial design augmented by five centre points. The results of the analysis showed that all selected factors except
hold time exhibit significant effect on weld nugget radius and HAZ size. Optimization of the welding parameters (weld current, weld
time and electrode force) to normalize weld nugget and to minimize
HAZ size was then conducted using Central Composite Design (CCD) in Response Surface Methodology (RSM) and the optimum
parameters were determined. A regression model for radius of weld nugget and HAZ size was developed and its adequacy was evaluated.
The experimental results obtained under optimum operating conditions were then compared with the predicted values and were
found to agree satisfactorily with each other
Abstract: The non-destructive testing of launch tube weld with
radiography was investigated and evaluated with AWS D1.1
standard. The paper started with preparation of launch tube and
radiographic inspection. X-Ray inspection then was done and gotten
the result. The judgment of inspection results were concluded by
certified person and finally, the evaluation with AWS D1.1 standard
was conducted as well.
The result shown that weld position P1 was not conformed to
AWS D1.1 which allowed size of incomplete penetration did not
exceed 4 mm. The other welds were corresponded to as mentioned
standard. Additionally, the corrective actions for incomplete
penetration either provided for future actions.
Abstract: Fatigue is the major threat in service of steel structure
subjected to fluctuating loads. With the additional effect of corrosion
and presence of weld joints the fatigue failure may become more
critical in structural steel. One of the apt examples of such structural
is the sailing ship. This is experiencing a constant stress due to
floating and a pulsating bending load due to the waves. This paper
describes an attempt to verify theory of fatigue in fracture mechanics
approach with experimentation to determine the constants of crack
growth curve. For this, specimen is prepared from the ship building
steel and it is subjected to a pulsating bending load with a known
defect. Fatigue crack and its nature is observed in this experiment.
Application of fracture mechanics approach in fatigue with a simple
practical experiment is conducted and constants of crack growth
equation are investigated.
Abstract: In the present paper, a set of parametric FE stress
analyses is carried out for two-planar welded tubular DKT-joints
under two different axial load cases. Analysis results are used to
present general remarks on the effect of geometrical parameters on
the stress concentration factors (SCFs) at the inner saddle, outer
saddle, toe, and heel positions on the main (outer) brace. Then a new
set of SCF parametric equations is developed through nonlinear
regression analysis for the fatigue design of two-planar DKT-joints.
An assessment study of these equations is conducted against the
experimental data; and the satisfaction of the criteria regarding the
acceptance of parametric equations is checked. Significant effort has
been devoted by researchers to the study of SCFs in various uniplanar
tubular connections. Nevertheless, for multi-planar joints
covering the majority of practical applications, very few
investigations have been reported due to the complexity and high
cost involved.
Abstract: For the characterization of the weld defect region in the radiographic image, looking for features which are invariant regarding the geometrical transformations (rotation, translation and scaling) proves to be necessary because the same defect can be seen from several angles according to the orientation and the distance from the welded framework to the radiation source. Thus, panoply of geometrical attributes satisfying the above conditions is proposed and which result from the calculation of the geometrical parameters (surface, perimeter, etc.) on the one hand and the calculation of the different order moments, on the other hand. Because the large range in values of the raw features and taking into account other considerations imposed by some classifiers, the scaling of these values to lie between 0 and 1 is indispensable. The principal component analysis technique is used in order to reduce the number of the attribute variables in the aim to give better performance to the further defect classification.
Abstract: Friction Stir Welding (FSW) is a solid state welding
process invented and patented by The Welding Institute (TWI) in the
United Kingdom in 1991 for butt and lap welding of metals and plastics. This paper highlights the benefits of friction stir welding
process as an energy efficient and a green technology process in the
field of welding. Compared to the other conventional welding processes, its benefits, typical applications and its use in joining
similar and dissimilar materials are also presented.
Abstract: Solutions for the temperature profile around a moving
heat source are obtained using both analytic and finite element
(FEM) methods. Analytic and FEM solutions are applied to study the
temperature profile in welding. A moving heat source is represented
using both point heat source and uniform distributed disc heat source
models. Analytic solutions are obtained by solving the partial
differential equation for energy conservation in a solid, and FEM
results are provided by simulating welding using the ANSYS
software. Comparison is made for quasi steady state conditions. The
results provided by the analytic solutions are in good agreement with
results obtained by FEM.
Abstract: An attempt has been made to determine the strength
and impact properties of Cr-Mo steel weld and base materials by
varying the current during manual metal arc welding. Toughness over
a temperature range from -32 to 100°C of base, heat affected zone
(HAZ) and weld zones at three current settings are made. It is
observed that the deterioration in notch toughness at any zone with
the temperature decreases. The values of notch toughness for all
zones at -32°C are almost same for any current settings. The values
of notch toughness at HAZ area are higher than that of weld area due
to the coarsening of ferrite grain of HAZ occurs with higher heat
input. From microhardness and microstructure result, it can be
concluded that large inclusion content in weld deposit is the cause of
lower notch toughness value.
Abstract: This paper presents kinematic and dynamic analysis of a novel 8-DOF hybrid robot manipulator. The hybrid robot manipulator under consideration consists of a parallel robot which
is followed by a serial mechanism. The parallel mechanism has three translational DOF, and the serial mechanism has five DOF so that the overall degree of freedom is eight. The introduced
manipulator has a wide workspace and a high capability to reduce
the actuating energy. The inverse and forward kinematic solutions are described in closed form. The theoretical results are verified by
a numerical example. Inverse dynamic analysis of the robot is presented by utilizing the Iterative Newton-Euler and Lagrange dynamic formulation methods. Finally, for performing a multi-step
arc welding process, results have indicated that the introduced manipulator is highly capable of reducing the actuating energy.
Abstract: This paper proposed a stiffness analysis method for a
3-PRS mechanism for welding thick aluminum plate using FSW
technology. In the molding process, elastic deformation of lead-screws
and links are taken into account. This method is based on the virtual
work principle. Through a survey of the commonly used stiffness
performance indices, the minimum and maximum eigenvalues of the
stiffness matrix are used to evaluate the stiffness of the 3-PRS
mechanism. Furthermore, A FEA model has been constructed to verify
the method. Finally, we redefined the workspace using the stiffness
analysis method.
Abstract: Arc welding creates a weld pool to realize continuity between pieces of assembly. The thermal history of the weld is dependent on heat transfer and fluid flow in the weld pool. The metallurgical transformation during welding and cooling are modeled in the literature only at solid state neglecting the fluid flow. In the present paper we associate a heat transfer – fluid flow and metallurgical model for the 16MnD5 steel. The metallurgical transformation model is based on Leblond model for the diffusion kinetics and on the Koistinen-Marburger equation for Marteniste transformation. The predicted thermal history and metallurgical transformations are compared to a simulation without fluid phase. This comparison shows the great importance of the fluid flow modeling.
Abstract: This paper presents the results of a study aimed at
establishing the temperature distribution during the welding of
magnesium alloy sheets by Pulsed Current Gas Tungsten Arc
Welding (PCGTAW) and Constant Current Gas Tungsten Arc
Welding (CCGTAW) processes. Pulsing of the GTAW welding
current influences the dimensions and solidification rate of the fused
zone, it also reduces the weld pool volume hence a narrower bead. In
this investigation, the base material considered was 2mm thin AZ 31
B magnesium alloy, which is finding use in aircraft, automobile and
high-speed train components. A finite element analysis was carried
out using ANSYS, and the results of the FEA were compared with
the experimental results. It is evident from this study that the finite
element analysis using ANSYS can be effectively used to model
PCGTAW process for finding temperature distribution.
Abstract: Undoubtedly, chassis is one of the most important
parts of a vehicle. Chassis that today are produced for vehicles are
made up of four parts. These parts are jointed together by screwing.
Transverse parts are called cross member.
This study reviews the stress generated by cyclic laboratory loads
in front cross member of Peugeot 405. In this paper the finite element
method is used to simulate the welding process and to determine the
physical response of the spot-welded joints. Analysis is done by the
Abaqus software.
The Stresses generated in cross member structure are generally
classified into two groups: The stresses remained in form of residual
stresses after welding process and the mechanical stress generated by
cyclic load. Accordingly the total stress must be obtained by
determining residual stress and mechanical stress separately and then
sum them according to the superposition principle.
In order to improve accuracy, material properties including
physical, thermal and mechanical properties were supposed to be
temperature-dependent. Simulation shows that maximum Von Misses
stresses are located at special points. The model results are then
compared to the experimental results which are reported by
producing factory and good agreement is observed.