Abstract: Laser beam welding of dissimilar sheet metal
combinations such as Ti/Al, SS/Al and Cu/Al are increasingly
demanded due to high energy densities with less fusion and heat
affected zones. A good weld joint strength involves combinations of
dissimilar metals and the formation of solid solution in the weld pool.
Many metal pairs suffer from significant intermetallic phase
formation during welding which greatly reduces their strength. The
three different sheet metal mentioned above is critically reviewed and
phase diagram for the combinations are given. The aim of this study
is to develop an efficient metal combinations and the influence on
their interfacial characteristics. For that the following parameters
such as weld geometry, residual distortion, micro hardness,
microstructure and mechanical properties are analyzed
systematically.
Abstract: In this research article a comprehensive investigation
has been carried out to determine the effect of thermal cycle on
temperature dependent process parameters developed during gas
tungsten arc (GTA) welding of high carbon (AISI 1090) steel butt
joints. An experiment based thermal analysis has been performed to
obtain the thermal history. We have focused on different
thermophysical properties such as thermal conductivity, heat transfer
coefficient and cooling rate. Angular torch model has been utilized to
find out the surface heat flux and its variation along the fusion zone as
well as along the longitudinal direction from fusion boundary. After
welding and formation of weld pool, heat transfer coefficient varies
rapidly in the vicinity of molten weld bead and heat affected zone. To
evaluate the heat transfer coefficient near the fusion line and near the
rear end of the plate (low temperature region), established correlation
has been implemented and has been compared with empirical
correlation which is noted as coupled convective and radiation heat
transfer coefficient. Change in thermal conductivity has been
visualized by analytical model of moving point heat source. Rate of
cooling has been estimated by using 2-dimensional mathematical
expression of cooling rate and it has shown good agreement with
experimental temperature cycle. Thermophysical properties have been
varied randomly within 0 -10s time span.
Abstract: Joining of 1mm thick aluminum 6061 to titanium TC4
was conducted using Bypass-current MIG welding-brazed, and stable
welding process and good bead appearance were obtained. The Joint
profile and microstructure of Ti/Al joints were observed by optical
microscopy and SEM and then the structure of the interfacial reaction
layers were analyzed in details. It was found that the intermetallic
compound layer at the interfacial top is in the form of columnar
crystal, which is in short and dense state. A mount of AlTi were
observed at the interfacial layer near the Ti base metal while
intermetallic compound like Al3Ti, TiSi3 were formed near the Al base
metal, and the Al11Ti5 transition phase was found in the center of the
interface layer due to the uneven distribution inside the weld pool
during the welding process. Tensile test results show that the average
tensile strength of joints is up to 182.6 MPa, which reaches about
97.6% of aluminum base metal. Fracture is prone to occur in the base
metal with a certain amount of necking.
Abstract: This paper presents the results of a study aimed at establishing the temperature distribution during the welding of aluminum alloy plates by Pulsed Current Gas Tungsten Arc Welding (PCGTAW) and Constant Current Gas Tungsten Arc Welding (CCGTAW) processes. Pulsing of the GTA 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 aluminum alloy AA 6351 T6, 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 the study that the finite element analysis using ANSYS can be effectively used to model PCGTAW process for finding temperature distribution.
Abstract: A transient finite element model has been developed
to study the heat transfer and fluid flow during spot Gas Tungsten
Arc Welding (GTAW) on stainless steel. Temperature field, fluid
velocity and electromagnetic fields are computed inside the cathode,
arc-plasma and anode using a unified MHD formulation. The
developed model is then used to study the influence of different
helium-argon gas mixtures on both the energy transferred to the
workpiece and the time evolution of the weld pool dimensions. It is
found that the addition of helium to argon increases the heat flux
density on the weld axis by a factor that can reach 6.5. This induces
an increase in the weld pool depth by a factor of 3. It is also found
that the addition of only 10% of argon to helium decreases
considerably the weld pool depth, which is due to the electrical
conductivity of the mixture that increases significantly when argon is
added to helium.
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.