Overview on the digitized production of welded steel structures

This paper presents a concept and practical topics involved in digitized production. The term “production” denotes the design, fabrication, and service life of a product, which in this case elaborates on welded steel structures. This includes the required information for guiding all the process stages of the chosen material back to its re-melting, following the material flow in a fully digitized form. This concept enables an increase in production quality at a higher level while minimizing the risk of human errors. Automation of the short-run production of steel structures for demanding applications is also a key goal, together with securing a cost-efficient process. Typically, such structures are fabricated from high- or ultra-high-strength steels. Though challenging, reaching these aims seems to be realistic by applying advanced fatigue design methods, using high-quality robotic welding and receiving information about the real loading of the structure.

First-Principles Calculations of Thermal and Electrical Transport Properties of bcc and fcc Dilute Fe–X (X = Al, Co, Cr, Mn, Mo, Nb, Ni, Ti, V, and W) Binary Alloys

The adiabatic shear sensitivity of ultra-high-strength steels is closely related to their thermal conductivity. Therefore, it is essential to investigate the effects of alloying elements on the thermal conductivity of ultra-high-strength steel. In this study, the variation in the scattering behavior of electrons with respect to temperature and the mechanism of three-phonon scattering were considered for obtaining the contributions of electrons and phonons, respectively, to the thermal conductivity of alloys while solving the Boltzmann transport equation. By predicting the effect of ten alloying elements on the electronic thermal conductivity (κe), it was found that, at 1200 K, the doping of iron with Ni and Cr endowed iron with κe values of 24.9 and 25.7 W/m K, respectively. In addition, the prediction for the lattice thermal conductivity (κL), which was performed without considering point defect scattering, indicated that elements such as Al, Co, Mn, Mo, V, and Cr demonstrate a positive effect on the lattice thermal conductivity, with values of 3.6, 3.7, 3.0, 3.1, 3.9, and 3.8 W/m K, respectively. The contribution of κL is only 5–15% of the total thermal conductivity (κtotal). The alloying elements exhibited a similar effect on κtotal and κe. Δκi; the change in thermal conductivity with respect to κ0 owing to the alloying element i was evaluated according to the total thermal conductivity. These values were used to understand the effect of the concentration of alloying elements on the thermal conductivity of iron. The Δκi values of Ni, Co, and W were 6.44, 6.80, and 6.06, respectively, indicating a reduction in the thermal conductivity of iron. This paper provides theoretical guidance for the design of ultra-high-strength steels with a high thermal conductivity.

New drawbead tester and numerical analysis of drawbead closure force

Currently, a great deal of controversy exists regarding the real forces generated in drawbeads during sheet metal forming processes. The present work focuses on the analysis of the uplift force. First, a detailed literature review is carried out to analyse previous experimental procedures used to measure uplift forces. It is found that previous setups do not perfectly replicate the real geometry of industrial drawbeads. In order to obtain reliable forces, an experimental drawbead tester capable of adequately replicating industrial drawbeads is developed. Later, a variety of steels ranging from mild steels to 3rd-generation ultra-high-strength steels are tested and reliable uplift and also restraining force values are obtained. The main purpose of the work is to share with the research community reliable experimental data that allows precise evaluation of the accuracy of current drawbead models and that supports the generation of new numerical and equivalent drawbead models. In parallel to the experimental procedure, a step forward in the understanding of the drawbead closing phenomena is also achieved through a 2D numerical model. The main purpose of the model is to identify the variables that greatly affect uplift force. Going beyond previous studies, in which some variables were analysed, the present work covers, in a holistic manner, the impact that material properties, the geometry of drawbeads and contact behaviour between sheet and drawbead have on the uplift force. It is determined that surprisingly minor geometrical deviations in the drawbead nominal geometry have a large impact on the uplift force.

Effect of the Root Gap on the Structure and Properties of High Strength Steel S700MC Welds

Nowadays, the use of high strength (HS) and ultra-high strength steels (UHS) increases, notably in welded constructions. These steels are mainly exploited in heavy loaded welded constructions such as bridges, cranes and excavators, in pressure vessels, vehicles, ships, drilling rigs etc. working at room or lower temperatures. As the welded constructions have specific requirements, the development of high strength and ultra-high strength steels imposes the need for research on the factors influencing their weldability. Among the possible negative implications are: cold cracks formation, softening of the heat affected zone, brittleness in the coarse grained zone. When complying with the generally accepted rules for welding, HS and UHS are readily welded by all conventional welding methods. Recommendations for welding of steels after normalization, thermo-mechanical treatment and quenching and tempering are given in the standard EN 1011 -1, 2. The use of thermo-mechanically treated (hot-rolled) steels with low carbon equivalent, such as S700MC, allows reduction in time required for welding as the preheating temperature is lowered or even preheating is not necessary. A more pronounced negative effect on the weld quality has the presence of different defects. S700MC can be welded by all conventional methods, and a reduction in the softened zone can be achieved by using appropriate welding parameters. Joint preparation for welding of HS and UHS steels is described in the standards EN ISO 9692-1:2013 and EN ISO 9692-2:2001. Nevertheless, the root gap is often the closing part in constructions and does not comply with the standard recommendations. That is why the effect of the root gap on welds has to be researched. The present work introduces results of a research studying the effect of the root gap on the structure and some mechanical and technological properties of S700MS welds, welded by submerged arc welding.

Joining of ultra-high-strength steels using resistance element welding on conventional resistance spot welding guns

Single-step joining of dissimilar material combinations between ultra-high-strength steels and high-strength aluminium alloys with sufficient mechanical joint properties by using conventional resistance spot welding equipment has not been reported yet. In this research paper, a novel single-step joining technology, so-called self-penetrating resistance element welding, is introduced. First, the motivation for this novel joining technology, the state of the art in joining, and the process characteristics are presented. In the results section, the welding rivet geometry is first determined using forming simulations and validated by head tensile tests. Followed by the description of the welding process and its characteristics, the mechanical joint properties are reported. The results show that a numerically optimised welding rivet geometry can guarantee sufficient joint strength. By this welding rivet geometry, a thermally assisted penetration of aluminium and therefore welding to steel is possible with and without adhesive. Furthermore, it is shown that the welding process can be designed by means of simulations. Finally, the shear tensile tests prove that an overall sufficient joint strength is ensured.

Microstructural Evolution and Tensile Strength of Laser-Welded Butt Joints of Ultra-High Strength Steels: Low and High Alloy Steels

The present study is focused on joining two ultra-high strength steels plates of 3 mm thickness using laser-welding. Abrasion resistant steel with martensitic structure, tensile strength (Rm) ≥ 2 GPa, and cold-deformed austenitic stainless steel, Rm 1.3 GPa, were used for the dissimilar butt joints. Two different laser energy inputs, 160 and 320 J/mm, were presented during welding. The weld morphology and microstructural evolution of the fusion zone were recorded using optical microscopy and electron back scattering diffraction (EBSD), respectively. The mechanical properties of the dissimilar joints were evaluated by hardness measurements and tensile tests. It was found that fusion zone has undergone a change in morphology and microstructure during welding depending upon the energy input. Analysis of the microstructural evolution in the fusion zone by EBSD examination showed that the presence of a mixture of small austenite grains in a matrix of martensite. The changes in hardness profiles and tensile strength under the experimental parameters were further reported.

Strain distribution during air bending of ultra-high strength steels

Air bending is a widely used method for forming ultra-high strength steels (UHSS). However, the limited formability of UHSS poses some challenges for the bending process in the form of strain localisation, surface defects, punch detachment (multi-breakage) and pseudo-polygonal “nut-like” shape of the bend. In this study, the bendability of three UHSS grades (700, 900 and 1100 MPa) is investigated with 3-point bending tests, utilising Digital Image Correlation (DIC) for measuring the strain distributions on the outer curvature. The differences in the extent of multi-breakage and the bend shapes are also studied, and these observations are correlated with the findings from the bending force and strain measurements. The differences between the investigated UHSS grades are significant. The 900 MPa grade produces more localised strain distributions and pronounced multi-breakage compared to the other grades, along with a more polygonal “nut-like” geometry. The reasons and effects of the multi-breakage phenomenon, as well as the causes for the observed differences in the behaviour of the materials are discussed in this paper. The presented results and the measurement data provide more information about the behaviour of the investigated materials in bending, and can be used for improving bending simulation, numerical models, and workshop instructions.