A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To o...A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To obtain sound numerical results, the therrno-mechanical behaviour was simulated using a direct-coupled formulation. Nine different simulation sequences were carried out by single-pass TIG welding of an octagonal pipe-plate joint, and the distributions of longitudinal and transverse residual stresses both on the outer and inner surfaces of the pipe were analyzed. The results suggest that the final residual stresses in the weld and its vicinity are not affected by the initial residual stresses of the structure. Selecting a suitable welding sequence can reduce the final residual stress in an octagonal pipe-plate joint.展开更多
The hollow spherical joints welded with circular pipes applied to the National Swimming Center of China are subjected to large bending moments, but the influence of bending moments is not considered in the design equa...The hollow spherical joints welded with circular pipes applied to the National Swimming Center of China are subjected to large bending moments, but the influence of bending moments is not considered in the design equations in Technical Specification for Latticed Shells. Based on the von Mises yield criterion, multilinear isotropic hardening rule and associated flow rule, the elasto-plastic finite element model is put forward to analyze the behavior of the joints, and a calculation method for the joints under bending moments or eccentric loads is proposed. It is shown by the analytical results of joint that the stiffening rib can improve the ultimate bearing capacity by 10% for joints under axial tensile load, by 40% for joints under axial compressive load, and by 50% for joints under bending moment. The unified calculation equations for joints with or without stiffening rib are put forward, which can be applied to calculating the ultimate bearing capacity of the hollow spherical joints with circular pipes under eccentric loads.展开更多
Titanium tube and stainless steel tube plate were welded by an innovative friction welding of tube to tube plate using an external tool (FWTPET). Copper was used as an interlayer for joining the dissimilar materials a...Titanium tube and stainless steel tube plate were welded by an innovative friction welding of tube to tube plate using an external tool (FWTPET). Copper was used as an interlayer for joining the dissimilar materials and also to minimize the effect of intermetallics formed at the joint interface. The process parameters that govern FWTPET process are plunge rate, rotational speed, plunge depth, axial load and flash trap profile. Among them, the flash trap profile of the tube has a significant influence on the joint integrity. Various flash trap profiles like vertical slots, holes, zig-zag holes, and petals were made on the titanium tube welded to the stainless steel tube plate. Macroscopic and microscopic studies reveal defect-free joints. The presence of copper interlayer and intermetallics was evident from X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) studies. The microhardness survey was presented across and along the interface. A novel test procedure called “plunge shear test” was developed to evaluate the joint properties of the welded joints. The highest shear fracture load of 31.58 kN was observed on the sample having petals as flash trap profile. The sheared surfaces were further characterized using SEM for fractography.展开更多
Within offshore installations, making tubing connections conduct electricity is a developing interest. Being able to use tubing structures to carry the drive power needed downhole avoids installation of cables and lin...Within offshore installations, making tubing connections conduct electricity is a developing interest. Being able to use tubing structures to carry the drive power needed downhole avoids installation of cables and lines. The challenge is making the connection good enough with minimum possible power loss. At the same time, the connection has to secure the transfer of the rated power without any danger of overheating. An overheating can eventually result in a welded connection. Previous studies on contact design have mainly focused on low level contact force, while this study aims to find out the influence of surface roughness and connection strength, at macro level, on contact resistance of tubing connections so as to know the power transfer capability of the connection. First, the connection is simplified by ＂rolling out＂ the tubes to flat sheet metals and the voltage drop at rated current was measured at various loads. Then experiment was conducted on contact pairs with two different surface finish qualities and three different contact fits. The results show that smoother surfaces ease the flow of current while high interference fit increases the contact stability. The influence of surface topography becomes insignificantly low at high connection interference.展开更多
Hydrogen diffusion coefficients of different regions in the welded joint of X80 pipeline steel were measured using the electro-chemical permeation technique. Using ABAQUS software, hydrogen diffusion in X80 pipeline s...Hydrogen diffusion coefficients of different regions in the welded joint of X80 pipeline steel were measured using the electro-chemical permeation technique. Using ABAQUS software, hydrogen diffusion in X80 pipeline steel welded joint was studied in consideration of the inhomogeneity of the welding zone, and temperature-dependent thermo-physical and mechanical properties of the metals. A three dimensional finite element model was developed and a coupled thermo-mechanical-diffusion analysis was performed. Hydrogen concentration distribution across the welded joint was obtained. It is found that the postweld residual hydrogen exhibits a non-uniform distribution across the welded joint. A maximum equivalent stress occurs in the immediate vicinity of the weld metal. The heat affected zone has the highest hydrogen concentration level, followed by the weld zone and the base metal.Simulation results are well consistent with theoretical analysis.展开更多
基金Project(61075005)supported by the Fund of State Key Laboratory of Advanced Design and Manufacture for Vehicle Body in Hunan University,ChinaProject(09JJ1007)supported by Preeminent Youth Fund of Hunan Province,ChinaProject(51075132)supported by the National Natural Science Foundation of China
文摘A three-dimensional finite element approach based on ABAQUS code was developed to investigate the effect of welding sequence on welding residual stress distribution in a thin-walled 6061 aluminum alloy structure. To obtain sound numerical results, the therrno-mechanical behaviour was simulated using a direct-coupled formulation. Nine different simulation sequences were carried out by single-pass TIG welding of an octagonal pipe-plate joint, and the distributions of longitudinal and transverse residual stresses both on the outer and inner surfaces of the pipe were analyzed. The results suggest that the final residual stresses in the weld and its vicinity are not affected by the initial residual stresses of the structure. Selecting a suitable welding sequence can reduce the final residual stress in an octagonal pipe-plate joint.
基金National Natural Science Foundation of China (No 50608054)
文摘The hollow spherical joints welded with circular pipes applied to the National Swimming Center of China are subjected to large bending moments, but the influence of bending moments is not considered in the design equations in Technical Specification for Latticed Shells. Based on the von Mises yield criterion, multilinear isotropic hardening rule and associated flow rule, the elasto-plastic finite element model is put forward to analyze the behavior of the joints, and a calculation method for the joints under bending moments or eccentric loads is proposed. It is shown by the analytical results of joint that the stiffening rib can improve the ultimate bearing capacity by 10% for joints under axial tensile load, by 40% for joints under axial compressive load, and by 50% for joints under bending moment. The unified calculation equations for joints with or without stiffening rib are put forward, which can be applied to calculating the ultimate bearing capacity of the hollow spherical joints with circular pipes under eccentric loads.
基金financial support provided by UGC-DAE-CSR (CSR-KN/CRS-04/201213/738) through fellowship
文摘Titanium tube and stainless steel tube plate were welded by an innovative friction welding of tube to tube plate using an external tool (FWTPET). Copper was used as an interlayer for joining the dissimilar materials and also to minimize the effect of intermetallics formed at the joint interface. The process parameters that govern FWTPET process are plunge rate, rotational speed, plunge depth, axial load and flash trap profile. Among them, the flash trap profile of the tube has a significant influence on the joint integrity. Various flash trap profiles like vertical slots, holes, zig-zag holes, and petals were made on the titanium tube welded to the stainless steel tube plate. Macroscopic and microscopic studies reveal defect-free joints. The presence of copper interlayer and intermetallics was evident from X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) studies. The microhardness survey was presented across and along the interface. A novel test procedure called “plunge shear test” was developed to evaluate the joint properties of the welded joints. The highest shear fracture load of 31.58 kN was observed on the sample having petals as flash trap profile. The sheared surfaces were further characterized using SEM for fractography.
文摘Within offshore installations, making tubing connections conduct electricity is a developing interest. Being able to use tubing structures to carry the drive power needed downhole avoids installation of cables and lines. The challenge is making the connection good enough with minimum possible power loss. At the same time, the connection has to secure the transfer of the rated power without any danger of overheating. An overheating can eventually result in a welded connection. Previous studies on contact design have mainly focused on low level contact force, while this study aims to find out the influence of surface roughness and connection strength, at macro level, on contact resistance of tubing connections so as to know the power transfer capability of the connection. First, the connection is simplified by ＂rolling out＂ the tubes to flat sheet metals and the voltage drop at rated current was measured at various loads. Then experiment was conducted on contact pairs with two different surface finish qualities and three different contact fits. The results show that smoother surfaces ease the flow of current while high interference fit increases the contact stability. The influence of surface topography becomes insignificantly low at high connection interference.
基金Project(BK2011258)supported by the Natural Science Foundation of Jiangsu Province,China
文摘Hydrogen diffusion coefficients of different regions in the welded joint of X80 pipeline steel were measured using the electro-chemical permeation technique. Using ABAQUS software, hydrogen diffusion in X80 pipeline steel welded joint was studied in consideration of the inhomogeneity of the welding zone, and temperature-dependent thermo-physical and mechanical properties of the metals. A three dimensional finite element model was developed and a coupled thermo-mechanical-diffusion analysis was performed. Hydrogen concentration distribution across the welded joint was obtained. It is found that the postweld residual hydrogen exhibits a non-uniform distribution across the welded joint. A maximum equivalent stress occurs in the immediate vicinity of the weld metal. The heat affected zone has the highest hydrogen concentration level, followed by the weld zone and the base metal.Simulation results are well consistent with theoretical analysis.
