Abstract: The paper describes the results from a research project about repair of welds. The repair was carried out by grinding the flawed seams and re-welding them. The main task was to determine the FAT classes of original state and after repair of seams according to the assessment procedures, such as nominal, structural and effective notch stress approach. The first part shows the results of the tests, the second part encloses numerical analysis and evaluation of results to determine the fatigue strength classes according to three assessment procedures.
Abstract: Manufacturing technologies are becoming continuously
more diversified over the years. The increasing use of robots for
various applications such as assembling, painting, welding has also
affected the field of machining. Machining robots can deal with
larger workspaces than conventional machine-tools at a lower cost
and thus represent a very promising alternative for machining
applications. Furthermore, their inherent structure ensures them a
great flexibility of motion to reach any location on the workpiece with
the desired orientation. Nevertheless, machining robots suffer from
a lack of stiffness at their joints restricting their use to applications
involving low cutting forces especially finishing operations. Vibratory
instabilities may also happen while machining and deteriorate the
precision leading to scrap parts. Some researchers are therefore
concerned with the identification of optimal parameters in robotic
machining. This paper continues the development of a virtual robotic
machining simulator in order to find optimized cutting parameters in
terms of depth of cut or feed per tooth for example. The simulation
environment combines an in-house milling routine (DyStaMill)
achieving the computation of cutting forces and material removal
with an in-house multibody library (EasyDyn) which is used to
build a dynamic model of a 3-DOF planar robot with flexible links.
The position of the robot end-effector submitted to milling forces is
controlled through an inverse kinematics scheme while controlling
the position of its joints separately. Each joint is actuated through
a servomotor for which the transfer function has been computed
in order to tune the corresponding controller. The output results
feature the evolution of the cutting forces when the robot structure
is deformable or not and the tracking errors of the end-effector.
Illustrations of the resulting machined surfaces are also presented.
The consideration of the links flexibility has highlighted an increase
of the cutting forces magnitude. This proof of concept will aim
to enrich the database of results in robotic machining for potential
improvements in production.
Abstract: Commercially SA 516 Grade 70 is frequently used for the manufacturing of pressure vessels, boilers and storage tanks etc. in fabrication industry. Heat input is the major parameter during welding that may bring significant changes in the microstructure as well as the mechanical properties. Different welding technique has different heat input rate per unit surface area. Materials with large thickness are dealt with different combination of welding techniques to achieve required mechanical properties. In the present research two schemes: Scheme 1: SMAW (Shielded Metal Arc Welding) & GTAW (Gas Tungsten Arc Welding) and Scheme 2: SMAW & SAW (Submerged Arc Welding) of hybrid welding techniques have been studied. The purpose of these schemes was to study hybrid welding effect on the microstructure and mechanical properties of the weldment, heat affected zone and base metal area. It is significant to note that the thickness of base plate was 12 mm, also welding conditions and parameters were set according to ASME Section IX. It was observed that two different hybrid welding techniques performed on two different plates demonstrated that the mechanical properties of both schemes are more or less similar. It means that the heat input, welding techniques and varying welding operating conditions & temperatures did not make any detrimental effect on the mechanical properties. Hence, the hybrid welding techniques mentioned in the present study are favorable to implicate for the industry using the plate thickness around 12 mm thick.
Abstract: This paper reports the effects of laser energy on the characteristics of bubbles generated in the weld zone and the formation of new chemical bonds at the Polyethylene Terephthalate (PET)/Ti joint interface in laser joining of PET to Ti. The samples were produced by using different laser energies ranging from 1.5 J – 6 J in steps of 1.5 J, while all other joining parameters remained unchanged. The types of chemical bonding at the joint interface were analysed by the x-ray photoelectron spectroscopy (XPS) depth-profiling method. The results show that the characteristics of the bubbles and the thickness of the chemically bonded interface, which contains the laser generated bonds of Ti–C and Ti–O, increase markedly with increasing laser energy input. The tensile failure load of the joint depends on the combined effect of the amount and distribution of the bubbles formed and the chemical bonding intensity of the joint interface.
Abstract: A vibrating-fork sensor can measure the level height of solids and liquids and operates according to the principle that vibrations created by piezoelectric ceramics are transmitted to the vibrating fork, which produces resonance. When the vibrating fork touches an object, its resonance frequency changes and produces a signal that returns to a controller for immediate adjustment, so as to effectively monitor raw material loading. The design of the vibrating fork in a vibrating-fork material sensor is crucial. In this paper, ANSYS finite element analysis software is used to perform modal analysis on the vibrations of the vibrating fork. In addition, to design and produce a superior vibrating fork, the dimensions and welding shape of the vibrating fork are compared in a simulation performed using the Taguchi method.
Abstract: The present paper aims to investigate the effects of the welding process parameters and cooling state on the weld bead geometry, mechanical properties and microstructure characteristics for weldments of AISI 304L stainless steel. The welding process was carried out using TIG welding with pulsed/non-pulsed current techniques. The cooling state was introduced as an input parameter to investigate the main effects on the structure morphology and thereby the mechanical property. This paper clarifies microstructure- mechanical property relationship of the welded specimens. In this work, the selected pulse frequency levels were 5-500 Hz in order to study the effect of low and high frequencies on the weldment characteristics using filler metal of ER 308LSi. The key findings of this work clarified that the pulse frequency has a significant effect on the breaking of the dendrite arms during the welding process and so strongly influences on the tensile strength and microhardness. The cooling state also significantly affects on the microstructure texture and thereby, the mechanical properties. The most important factor affects the bead geometry and aspect ratio is the travel speed and pulse frequency.
Abstract: The design of fish processing equipment greatly impacts how easy the cleaning process for the equipment is. This is a critical issue in fish processing, as cleaning of fish processing equipment is a task that is both costly and time consuming, in addition to being very important with regards to product quality. Even more, poorly cleaned equipment could in the worst case lead to contaminated product from which consumers could get ill. This paper will elucidate how equipment design changes could improve the work for the cleaners and saving money for the fish processing facilities by looking at a case for product design improvements. The design of fish processing equipment largely determines how easy it is to clean. “Design for cleaning” is the new hype in the industry and equipment where the ease of cleaning is prioritized gets a competitive advantage over equipment in which design for cleaning has not been prioritized. Design for cleaning is an important research area for equipment manufacturers. SeaSide AS is doing continuously improvements in the design of their products in order to gain a competitive advantage. The focus in this paper will be conveyors for internal logistic and a product called the “electro stunner” will be studied with regards to “Design for cleaning”. Often together with SeaSide’s customers, ideas for new products or product improvements are sketched out, 3D-modelled, discussed, revised, built and delivered. Feedback from the customers is taken into consideration, and the product design is revised once again. This loop was repeated multiple times, and led to new product designs. The new designs sometimes also cause the manufacturing processes to change (as in going from bolted to welded connections). Customers report back that the concrete changes applied to products by SeaSide has resulted in overall more easily cleaned equipment. These changes include, but are not limited to; welded connections (opposed to bolted connections), gaps between contact faces, opening up structures to allow cleaning “inside” equipment, and generally avoiding areas in which humidity and water may gather and build up. This is important, as there will always be bacteria in the water which will grow if the area never dries up. The work of creating more cleanable design is still ongoing, and will “never” be finished as new designs and new equipment will have their own challenges.
Abstract: In this paper, a two-dimensional method is developed to simulate the fillet welds in a stiffened cylindrical shell, using finite element method. The stiffener material is aluminum 2519. The thermo-elasto-plastic analysis is used to analyze the thermo-mechanical behavior. Due to the high heat flux rate of the welding process, two uncouple thermal and mechanical analysis are carried out instead of performing a single couple thermo-mechanical simulation. In order to investigate the effects of the welding procedures, two different welding techniques are examined. The resulted residual stresses and distortions due to different welding procedures are obtained. Furthermore, this study employed the technique of element birth and death to simulate the weld filler variation with time in fillet welds. The obtained results are in good agreement with the published experimental and three-dimensional numerical simulation results. Therefore, the proposed 2D modeling technique can effectively give the corresponding results of 3D models. Furthermore, by inspection of the obtained residual hoop and transverse stresses and angular distortions, proper welding procedure is suggested.
Abstract: This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.
Abstract: Proper selection of welding parameters for getting
excellent weld is a challenge. HAZ simulation helps in identifying
suitable welding parameters like heating rate, cooling rate, peak
temperature, and energy input. In this study, the influence of weld
thermal cycle of heat affected zone (HAZ) is simulated for
Submerged Arc Welding (SAW) using Gleeble ® 3800 thermomechanical
simulator. A (Micro-alloyed) MA steel plate of thickness
18 mm having yield strength 450MPa is used for making test
specimens. Determination of the mechanical properties of weld
simulated specimens including Charpy V-notch toughness and
hardness is performed. Peak temperatures of 1300°C, 1150°C,
1000°C, 900°C, 800°C, heat energy input of 22KJ/cm and preheat
temperatures of 30°C have been used with Rykalin-3D simulation
model. It is found that the impact toughness (75J) is the best for the
simulated HAZ specimen at the peak temperature 900ºC. For parent
steel, impact toughness value is 26.8J at -50°C in transverse
direction.
Abstract: In this study, the butt welding of the commercial AZ31 magnesium alloy sheets have been carried out by using Tungsten Inert Gas (TIG) welding process with alternative and pulsed current. Welded samples were examined with regards to hardness and microstructure. Despite some recent developments in welding of magnesium alloys, they have some problems such as porosity, hot cracking, oxide formation and so on. Samples of the welded parts have undergone metallographic and mechanical examination. Porosities and homogeneous micron grain oxides were rarely observed. Orientations of the weld microstructure in terms of heat transfer also were rarely observed and equiaxed grain morphology was dominant grain structure as in the base metal. As results, fusion zone and few locations of the HAZ of the welded samples have shown twin’s grains. Hot cracking was not observed for any samples. Weld bead geometry of the welded samples were evaluated as normal according to welding parameters. In the results, conditions of alternative and pulsed current and the samples were compared to each other with regards to microstructure and hardness.
Abstract: Fe-2%Mn-0.5%Si-0.2C steel was welded and corroded
at 600, 700 and 800oC for 20 h in 1 atm of N2/H2S/H2O-mixed gas in
order to characterize the high-temperature corrosion behavior of the
welded joint. Corrosion proceeded fast and almost linearly. It
increased with an increase in the corrosion temperature. H2S formed
FeS owing to sulfur released from H2S. The scales were fragile and
nonadherent.
Abstract: In general, it is desirable to finish the weld quickly,
before a large volume of surrounding metal heats up and expands.
The welding process used, type, welding current and speed of travel,
thus, affect the degree of shrinkage and distortion of a weldment. The
use of mechanized welding equipment reduces welding time, metal
affected zone and consequently distortion. This article helps to define
what weld distortion is and then provide a practical understanding of
the causes of distortion, effects of shrinkage in butt joint welded
assemblies using TI6AL4VA and Aluminium AA2024 alloy sheet.
The beam offset position to the joint interface towards titanium and
aluminium side. The factors affecting distortion during welding is
also given. Test results reveal that welding speed is the significant
parameter to decide the extent of distortion. Also welding from Al
side reduces the distortion while Ti side increases the distortion.
Abstract: Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.
Abstract: A Friction stir welding tool is a critical component to
the success of the process. The tool typically consists of a rotating
round shoulder and a threaded cylindrical pin that heats the work
piece, mostly by friction, and moves the softened alloy around it to
form the joint. In this research work, an attempt has been made to
investigate the relationship between FSW variables mainly tool
profile, rotating speed, welding speed and the mechanical properties
(tensile strength, yield strength, percentage elongation, and micro
hardness) of friction stir welded aluminum alloy 5083 joints. From
the experimental details, it can be assessed that the joint produced by
using Triflute profile tool has contribute superior mechanical and
structural properties as compared to Tapered unthreaded & Threaded
tool for 1000rpm.
Abstract: Inspired by the Formula-1 competition, IMechE
(Institute of Mechanical Engineers) and Formula SAE (Society of
Mechanical Engineers) organize annual competitions for University
and College students worldwide to compete with a single-seat racecar
they have designed and built. Design of the chassis or the frame is a
key component of the competition because the weight and stiffness
properties are directly related with the performance of the car and the
safety of the driver. In addition, a reduced weight of the chassis has
direct influence on the design of other components in the car. Among
others, it improves the power to weight ratio and the aerodynamic
performance. As the power output of the engine or the battery
installed in the car is limited to 80 kW, increasing the power to
weight ratio demands reduction of the weight of the chassis, which
represents the major part of the weight of the car. In order to reduce
the weight of the car, ION Racing team from University of
Stavanger, Norway, opted for a monocoque design. To ensure
fulfilment of the competition requirements of the chassis, the
monocoque design should provide sufficient torsional stiffness and
absorb the impact energy in case of possible collision. The study reported in this article is based on the requirements for
Formula Student competition. As part of this study, diverse
mechanical tests were conducted to determine the mechanical
properties and performances of the monocoque design. Upon a
comprehensive theoretical study of the mechanical properties of
sandwich composite materials and the requirements of monocoque
design in the competition rules, diverse tests were conducted
including 3-point bending test, perimeter shear test and test for
absorbed energy. The test panels were homemade and prepared with
equivalent size of the side impact zone of the monocoque, i.e. 275
mm x 500 mm, so that the obtained results from the tests can be
representative. Different layups of the test panels with identical core
material and the same number of layers of carbon fibre were tested
and compared. Influence of the core material thickness was also
studied. Furthermore, analytical calculations and numerical analysis
were conducted to check compliance to the stated rules for Structural
Equivalency with steel grade SAE/AISI 1010. The test results were
also compared with calculated results with respect to bending and
torsional stiffness, energy absorption, buckling, etc. The obtained results demonstrate that the material composition
and strength of the composite material selected for the monocoque
design has equivalent structural properties as a welded frame and thus
comply with the competition requirements. The developed analytical
calculation algorithms and relations will be useful for future
monocoque designs with different lay-ups and compositions.
Abstract: The floor beams of steel buildings, cold-formed steel
floor joists in particular, often require large web openings, which may
affect their shear capacities. A cost effective way to mitigate the
detrimental effects of such openings is to weld/fasten reinforcements.
A difficulty associated with an experimental investigation to establish
suitable reinforcement schemes for openings in shear zone is that
moment always coexists with the shear, and thus, it is impossible to
create pure shear state in experiments, resulting in moment
influenced results. However, Finite Element Method (FEM) based
analysis can be conveniently used to investigate the pure shear
behaviour of webs including webs with reinforced openings. This
paper presents the details associated with the finite element analysis
of thick/thin-plates (representing the web of hot-rolled steel beam,
and the web of a cold-formed steel member) having a large
reinforced opening. The study considered simply-supported
rectangular plates subjected to in-plane shear loadings until failure
(including post-buckling behaviour). The plate was modelled using
geometrically non-linear quadrilateral shell elements, and non-linear
stress-strain relationship based on experiments. Total Langrangian
with large displacement/small strain formulation was used for such
analyses. The model also considered the initial geometric
imperfections. This study considered three reinforcement schemes,
namely, flat, lip, and angle reinforcements. This paper discusses the
modelling considerations and presents the results associated with the
various reinforcement schemes under consideration.
Abstract: This research paper portrays a comparative analysis of
thermomechanical behaviour of Shielded Metal Arc Welding
(SMAW) and Gas Tungsten Arc Welding (GTAW) of low carbon
steel of AISI 1020 grade butt joints. The thermal history has been
obtained by experimental work. We have focused on temperature
dependent cooling rate as depicted by Adam’s two-dimensional
model. The effect of moving point heat source of SMAW and GTAW
on mechanical properties has been judged by optical and scanning
electron micrographs of different regions in weld joints. The
microhardness study has been carried to visualize the joint strength
due to formation of different phases.
Abstract: The purposes of hydraulic gate are to maintain the
functions of storing and draining water. It bears long-term hydraulic
pressure and earthquake force and is very important for reservoir and
waterpower plant. The high tensile strength of steel plate is used as
constructional material of hydraulic gate. The cracks and rusts,
induced by the defects of material, bad construction and seismic
excitation and under water respectively, thus, the mechanics
phenomena of gate with crack are probing into the cause of stress
concentration, induced high crack increase rate, affect the safety and
usage of hydroelectric power plant. Stress distribution analysis is a
very important and essential surveying technique to analyze
bi-material and singular point problems. The finite difference
infinitely small element method has been demonstrated, suitable for
analyzing the buckling phenomena of welding seam and steel plate
with crack. Especially, this method can easily analyze the singularity
of kink crack. Nevertheless, the construction form and deformation
shape of some gates are three-dimensional system. Therefore, the
three-dimensional Digital Image Correlation (DIC) has been
developed and applied to analyze the strain variation of steel plate with
crack at weld joint. The proposed Digital image correlation (DIC)
technique is an only non-contact method for measuring the variation of
test object. According to rapid development of digital camera, the cost
of this digital image correlation technique has been reduced.
Otherwise, this DIC method provides with the advantages of widely
practical application of indoor test and field test without the restriction
on the size of test object. Thus, the research purpose of this research is
to develop and apply this technique to monitor mechanics crack
variations of weld steel hydraulic gate and its conformation under
action of loading. The imagines can be picked from real time
monitoring process to analyze the strain change of each loading stage.
The proposed 3-Dimensional digital image correlation method,
developed in the study, is applied to analyze the post-buckling
phenomenon and buckling tendency of welded steel plate with crack.
Then, the stress intensity of 3-dimensional analysis of different
materials and enhanced materials in steel plate has been analyzed in
this paper. The test results show that this proposed three-dimensional
DIC method can precisely detect the crack variation of welded steel
plate under different loading stages. Especially, this proposed DIC
method can detect and identify the crack position and the other flaws
of the welded steel plate that the traditional test methods hardly detect
these kind phenomena. Therefore, this proposed three-dimensional
DIC method can apply to observe the mechanics phenomena of
composite materials subjected to loading and operating.
Abstract: The wider growing Finite Element Method (FEM)
application is caused by its benefits of cost saving and environment
friendly. Also, by using FEM a deep understanding of certain
phenomenon can be achieved. This paper observed the role of
material properties and volumetric change when Solid State Phase
Transformation (SSPT) takes place in residual stress formation due to
a welding process of ferritic steels through coupled Thermo-
Metallurgy-Mechanical (TMM) analysis. The correctness of FEM residual stress prediction was validated by
experiment. From parametric study of the FEM model, it can be
concluded that the material properties change tend to over-predicts
residual stress in the weld center whilst volumetric change tend to
underestimates it. The best final result is the compromise of both by
incorporates them in the model which has a better result compared to
a model without SSPT.