scholarly journals Steel Sheets Laser Lap Joint Welding—Process Analysis

Materials ◽  
2020 ◽  
Vol 13 (10) ◽  
pp. 2258 ◽  
Author(s):  
Hubert Danielewski ◽  
Andrzej Skrzypczyk
Keyword(s):  
Numerical Simulation ◽  
Laser Beam ◽  
Steel Sheet ◽  
Process Analysis ◽  
Welding Process ◽  
Parameters Estimation ◽  
Welding Parameters ◽  
Lap Joint ◽  
Beam Radiation ◽  
Keyhole Effect

This article presents the results of steel-sheet lap-joint-welding using laser beam radiation. The use of a laser beam and keyhole effect for deep material penetration in lap joint welding was presented. Thermodynamic mechanism of laser welding is related to material properties and process parameters. Estimation of welding parameters and joint properties’ analysis was performed through numerical simulation. The article presents a possibility of modeling laser lap-joint welding by using Simufact Welding software based on Marc solver and thermo-mechanical solution. Numerical calculation was performed for surface and conical volumetric heat sources simulating laser absorption and keyhole effect during steel sheet welding. Thermo-mechanical results of fusion zone (FZ), heat-affected zone (HAZ) and phase transformations calculated in numerical simulation were analyzed. The welding parameters for partial sealed joint penetration dedicated for gas piping installations were estimated from the numerical analysis. Low-carbon constructional steel was used for numerical and experimental analyses. A trial joint based on the estimated parameters was prepared by using a CO2 laser. Numerical and experimental results in the form of hardness distributions and weld geometry were compared. Metallographic analysis of the obtained weld was presented, including crystallographic structures and inclusions in the cross section of the joint.

Using of Welding Virtual Numerical Simulation as the Technical Support for Industry

2016 ◽  
Vol 1138 ◽  
pp. 49-55
Author(s):  
Marek Slováček ◽  
Josef Tejc ◽  
Mojmír Vaněk
Keyword(s):  
Numerical Simulation ◽  
Numerical Simulations ◽  
Welded Joints ◽  
Welding Process ◽  
Austenitic Steels ◽  
Welding Parameters ◽  
Efficient Production ◽  
Weld Joints ◽  
Mechanical Properties Prediction

Welding as a modern, highly efficient production technology found its position in almost all industries. At the same time the demands on the quality of the welded joints have been constantly growing in all production areas. Great demand on the quality of the welded joints consequently causes more experimental or prototype – so called – validation joints that take place before the welding of final construction. These experiments, prototypes aim at – for instance – defining the appropriate welding technology, material, pre-heating, welding parameters, clamping condition and optimizing the welding process. Naturally, these experiments and prototypes make production more expensive. Numerical simulations of welding – in the area of production preparation as well as of production proper – have been frequently used recently. Numerical simulations supported by experimental measurements can simulate the actual welding process very close to reality. The new material models for hardness and mechanical properties prediction based on numerical simulation solution will be introduced.The paper covers some typical welding cases from energy industrial sector. The homogenous and heterogeneous weld joints from modern energy Cr-Mo-Ni-V steels (including modern austenitic steels) were done as prototype welding. The numerical simulation of these weld joints including post weld heat treatment process were done and welding technologies were optimised based on the numerical simulation results. The calculated hardness was compared with real measurements. During project the complete material properties which are needed for numerical simulation were measured. Simplify numerical lifetime prediction of weld joints including results from numerical welding analyse (as residual stresses and plastic deformation) were done.

Laser Transmission Welding of a Lap-Joint: Thermal Imaging Observations and three–dimensional Finite Element Modeling

2007 ◽  
Vol 129 (9) ◽  
pp. 1177-1186 ◽  
Author(s):  
L. S. Mayboudi ◽  
A. M. Birk ◽  
G. Zak ◽  
P. J. Bates
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Laser Beam ◽  
Thermal Imaging ◽  
Thermal Model ◽  
Three Dimensional ◽  
Welding Process ◽  
Lap Joint ◽  
Laser Transmission Welding ◽  
Joint Geometry

Laser transmission welding (LTW) is a relatively new technology for joining plastic parts. This paper presents a three-dimensional (3D) transient thermal model of LTW solved with the finite element method. A lap-joint geometry was modeled for unreinforced polyamide (PA) 6 specimens. This thermal model addressed the heating and cooling stages in a laser welding process with a stationary laser beam. This paper compares the temperature distribution of a lap-joint geometry exposed to a stationary diode laser beam, obtained from 3D thermal modeling with thermal imaging observations. It is shown that the thermal model is capable of accurately predicting the temperature distribution when laser beam scattering during transmission through the polymer is included in the model. The weld dimensions obtained from the model have been compared with the experimental data and are in good agreement.

scholarly journals Connection Status Research of the Resistance Spot Welding Joint Based on a Rectangular Terminal Electrode

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 659
Author(s):  
Xiaoqi Zhang ◽  
Lingbo Wei ◽  
Guocheng Xu ◽  
Chunsheng Wang
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Process Analysis ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Current Time ◽  
Axis Direction ◽  
Resistance Spot ◽  
Welding Pressure

Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed how the rectangular terminal electrode shape and its dimensions influence the RSW joint dimensions. The process analysis results showed that the RSW nuggets welded with rectangular terminal electrode are normally elliptical in shape, and the dimensions of the long axis direction and the short axis direction have a certain proportion. As the welding current increases, the nuggets dimensions in long direction increase first and then decrease, and the internal grain structure also varies. As the welding time increases, the nugget size in long direction increase first and then steady and rarely splash occurs. As the welding pressure increase, the nugget dimensions in long direction increase first and then decrease, and the splash easily occurs under large welding pressure. However, when the welding pressure is too small, the unique adjacent double fusion nugget formed. By adopting proper welding parameters, the nugget size and quality can be controlled. This provides an important basis for the application of rectangular terminal electrode in RSW welding process.

scholarly journals Microstructural Characterization and Mechanical Properties of Laser Beam-Welded Dissimilar Joints between A6000 Aluminum Alloy and Galvanized Steel

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 543
Author(s):  
Nkopane Angelina Ramaphoko ◽  
Samuel Skhosane ◽  
Nthabiseng Maledi
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Laser Beam ◽  
Laser Welding ◽  
Heat Input ◽  
Welding Process ◽  
Galvanized Steel ◽  
Vehicle Body ◽  
Welding Parameters ◽  
Dissimilar Joints

This paper presents the laser beam welding process of a lap joint between galvanized steel (Z225) and an aluminum alloy (A6000) from an IPG fiber laser. Welding of steel to aluminum has become popular in the automotive industry as a means of reducing the total vehicle body mass. This approach reduces fuel consumption and, ultimately, carbon emissions. Laser welding parameters used to control heat input for the study were laser power ranging between 800 and 1200 W, as well as laser welding speeds between 2 and 4 m/min. Distinct features of the dissimilar joints were microscopically examined. The SEM-EDS technique was employed to study the intermetallic phases along the Fe-Al interface. The outcome revealed the presence of “needle-like phases” and “island-shaped phases” at high heat inputs. Traces of both Fe2Al5 and FeAl3 phases were detected. For low heat input, there was evidence of insufficient fusion. Weld width was influenced by welding parameters and increased with an increase in heat input. Mechanical properties of the joints indicated that the microhardness values of the weld joints were higher than those of both base metals. The maximum tensile shear strength obtained was 1.79 kN for a sample produced at 1200 W and 3 m/min.

Study on the Numerical Simulation of the Resistance Spot Welding Process of Magnesium Alloy

2011 ◽  
Vol 189-193 ◽  
pp. 3431-3436
Author(s):  
Jun Wang ◽  
Yun Yan Hu ◽  
Hui Xia Wang ◽  
Yu Feng Zhang
Keyword(s):  
Numerical Simulation ◽  
Magnesium Alloy ◽  
Spot Welding ◽  
Pressure Gauge ◽  
Welding Process ◽  
Welding Current ◽  
Welding Parameters ◽  
Linear Expansion Coefficient ◽  
Welding Quality ◽  
Plate Electrode

Spot welding of magnesium alloy was a complex processes of thermal, electrical, mechanical and metallurgical mutual coupling, meanwhile its’ low melting point, high thermal conductivity, and high linear expansion coefficient increased the welding quality control difficultly. Basing on SYSWELD, a numerical simulation of effects of welding current, welding time, thickness of plate, electrode pressure gauge and size on the nugget shape and welding quality of ZA31B was demonstrated. The relationship between the size of the nugget dimensions and the welding parameters was established by a large number of simulation and experimental study. The experimental results showed that the analogue result was consistent with the test results, and it could be used to guide the actual production.

Thermal Imaging Studies and 3-D Thermal Finite Element Modeling of Laser Transmission Welding of a Lap-Joint

2006 ◽  
Author(s):  
L. S. Mayboudi ◽  
A. M. Birk ◽  
G. Zak ◽  
P. J. Bates
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Laser Beam ◽  
Thermal Imaging ◽  
Thermal Model ◽  
Three Dimensional ◽  
Welding Process ◽  
Lap Joint ◽  
Laser Transmission Welding ◽  
Joint Geometry

Laser transmission welding (LTW) is a relatively new technology for joining plastic parts. This paper presents a three-dimensional (3-D) transient thermal model of LTW solved with the finite element method (FEM). A lap-joint geometry was modelled for unreinforced nylon 6 specimens. This thermal model addressed the heating and cooling stages in a laser welding process with a stationary laser beam. This paper compares the temperature distribution of a lap-joint geometry exposed to a stationary diode laser beam, obtained from 3-D thermal modelling with thermal imaging observations. It is shown that the thermal model is capable of accurately predicting the temperature distribution when laser beam scattering during transmission through the polymer is included in the model. The weld dimensions obtained from the model have been compared with the experimental data and are in good agreement.

scholarly journals Prediction of HAZ Microstructure and Hardness for Q960E Joints Welded by Triple-Wire GMAW Based on Thermal and Numerical Simulation

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 4898
Author(s):  
Ke Yang ◽  
Fei Wang ◽  
Dingshan Duan ◽  
Bo Xia ◽  
Chuanguang Luo ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Cooling Rate ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Prediction Method ◽  
High Strength ◽  
Thermal Simulation ◽  
Coarse Grained ◽  
Welding Parameters

Since heat affected zone (HAZ) is the weak area of welded joints, this article proposes a method to predict the HAZ microstructure and hardness for the triple-wire gas metal arc welding (GMAW) process of Q960E high strength steel. This method combines welding thermal simulation and numerical simulation. The microstructures and hardness of Q960E steel under different cooling rates were obtained by thermal simulation and presented in a simulated HAZ continuous cooling transformation (SH-CCT) diagram. The cooling rate in HAZ were obtained by numerical simulation with ANSYS software for the triple-wire welding of Q960E thick plates. By comparing the cooling rate with the SH-CCT diagram, the microstructure and hardness of the HAZ coarse-grained region were accurately predicted for multiple heat input conditions. Further, an ideal heat input was chosen by checking the prediction results. This prediction method not only helps us to optimize the welding parameters, but also leads to an overall understanding of the process-microstructure-performance for a complex welding process.

scholarly journals Numerical Simulation of Laser Welding Dissimilar Low Carbon and Austenitic Steel Joint

2020 ◽  
Vol 10 (1) ◽  
pp. 491-498
Author(s):  
Hubert Danielewski ◽  
Andrzej Skrzypczyk ◽  
Szymon Tofil ◽  
Grzegorz Witkowski ◽  
Sławomir Rutkowski
Keyword(s):  
Numerical Simulation ◽  
Heat Source ◽  
Laser Welding ◽  
Fusion Zone ◽  
Welding Process ◽  
Butt Joint ◽  
Austenitic Steels ◽  
Welding Parameters ◽  
Low Carbon ◽  
Joint Properties

AbstractNumerical simulation of laser welding dissimilar joint was presented. Results of butt joint for low carbon and austenitic steels are studied. Numerical calculations based on thermo-mechanical method and phase transformation were used for estimating weld dimensions and joint properties. Unconventional welding method where focused photons beam are used as a heat source were presented. Problems with welding of dissimilar joints, where different composition and thermo physical material properties affect on this phenomena complexity are solved using numerical methods and laser welding technology. Simulation of low carbon and stainless steel joints using SimufactWelding software are presented. Model of heat source within geometry and parameters was programmed. Laser beam welding simulation was performed for estimating parameters for complete joints penetration. Programming welding boundary condition and heat source geometry welding parameters with output power and welding speed rate was estimated. Materials used in simulation process and experimental welding was low carbon construction S235JR and stainless 316L steels in sheets form. Joint properties such as fusion zone and heat affected zones dimensions and stress-strain distribution were calculated. Estimation of complete joint characteristics was obtained using thermo-mechanical simulation method and Marc solver engine.. Experimental trial butt joint welding were performed based on estimated parameters. Welding process was performed using 6kW CO2 laser system. Based on numerical simulation, microstructure analysis, hardness distribution and chemical distribution of fusion zone, properties of obtained joint was studied. Model for simulation of dissimilar laser welding joint was obtained, and properties of obtained joint based on simulation and experiment was studied.

Effects of bottom plate in friction stir welding of AA6061-T6

2020 ◽  
Vol 118 (1) ◽  
pp. 108
Author(s):  
M.A. Vinayagamoorthi ◽  
M. Prince ◽  
S. Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Axial Load ◽  
Weld Zone ◽  
Welding Process ◽  
Bottom Plate ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Friction Stir ◽  
Weld Joints ◽  
Fine Grain

The effects of 40 mm width bottom plates on the microstructural modifications and the mechanical properties of a 6 mm thick FSW AA6061-T6 joint have been investigated. The bottom plates are placed partially at the weld zone to absorb and dissipate heat during the welding process. An axial load of 5 to 7 kN, a rotational speed of 500 rpm, and a welding speed of 50 mm/min are employed as welding parameters. The size of the nugget zone (NZ) and heat-affected zone (HAZ) in the weld joints obtained from AISI 1040 steel bottom plate is more significant than that of weld joints obtained using copper bottom plate due to lower thermal conductivity of steel. Also, the weld joints obtained using copper bottom plate have fine grain microstructure due to the dynamic recrystallization. The friction stir welded joints obtained with copper bottom plate have exhibited higher ductility of 8.9% and higher tensile strength of 172 MPa as compared to the joints obtained using a steel bottom plate.

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