Optimization design of resistance spot welding parameters of magnesium alloy

By means of the quadratic regression combination design process, the regression equations of nugget diameter and tensile shear load of spot welded joint were established. Effects of welding parameters on the nugget diameter and the tensile shear load were investigated. The results show that effect of welding current on nugget diameter is the most evident. And higher welding current will result in bigger nugget diameter. Besides, interaction effect of electrode force and welding current on tensile shear load is the most evident compared with others. The optimum welding parameters corresponding to the maximum of tensile shear load have been obtained by programming using Matlab software, which is 4, 7 kN electrode force, 28 kA welding current and 4 cycle welding time. Under the condition of the optimum welding parameters, the joint having no visible defects can be obtained, nugget diameter and tensile shear load being 6. 8 mm and 3 256 N, respectively.

Study on DC welding parameters of Al-alloy shaping based on arc-welding robot

The Al-alloy arc-welding shaping system based on arc-welding robot is established, and the Al-alloy shaping manufacture is realized with the DC （direct current） gas metal arc welding （GMAW）. The research indicates that the metal transfer type of DC GMA W, heat input and the initial temperature of the workpiece greatly affect the Al-alloy shaping based on arc welding robot. On the penetration, the weld width and the reinforcement, the influence of welding parameters is analyzed by generalized regression neural network （GRNN） fitting.

Relation between welding parameter and acoustic emission information during laser deep penetration welding

In laser non penetration deep penetration welding process, welding material will vaporize, metal vapor and ambient gas will produce a higher degree ionization, which forms plasma of high concentration. In the case of forming a small hole, plasma will eject from the hole, and form acoustic emission (AE) signals. Because AE information has many advantages such as non contact measuring, fast response, and high ratio of signal to noise, it can be used as a monitor variable for in process control. By studying AE information, information of welding pool and small hole can be obtained. According to characteristic of AE information, this paper reveals the correlation between welding parameters and AE signals, and provides a good base for further quality control.

Multi-objective optimization of gas metal arc welding parameters and sequences for low-carbon steel (Q345D) T-joints

Q345D high-quality low-carbon steel has been extensively employed in structures with stringent weld- ing quality requirements. A multi-objective optimization of welding stress and deformation was presented to design reasonable values of gas metal arc welding parameters and sequences of Q345D T-joints. The optimized factors included continuous variables （welding current （I）, welding voltage （U） ahd welding speed （V）） and discrete variables （welding sequence （S） and welding direc- tion （D））. The concepts of the pointer and stack in Visual Basic （VB） and the interpolation method were introduced to optimize the variables. The optimization objectives included the different combina- tions of the angular distortion and transverse welding stress along the transverse and longitudinal dis- tributions. Based on the design of experiments （DOE） and the polynomial regression （PR） model, the finite element （FE） results of the T-joint were used to establish the mathematical models. The Pareto front and the compromise solutions were obtained by using a multi-objective particle swarm optimization （MOPSO） algorithm. The optimal results were validated by the corresponding results of the FE method, and the error between the FE results and the two-objective results as well as that be-tween the FE results and the three-objective optimization results were less than 17.2% and 21.5%, respectively. The influence and setting regularity of different factors were discussed according to the compromise solutions.

Influence of welding parameters on microstructure and mechanical properties of electron beam welded Ti60 to GH3128 joint with a Cu interlayer

Effects of welding parameters on the microstructure and mechanical properties of Ti/Cu/Ni joint welded by electron beam were investigated.High welding heat input increased the melting quantity of Ti60 titanium alloy and promoted the formation of Ti-Cu intermetallic compounds(IMC)such as Ti_(2)Cu and Ti_(3)Cu_(4),increasing the brittleness of the joints.Low welding heat input was not conducive to the complete melting of the copper interlayer,and the unmelted copper reduced the performance of the joints.Under the optimal welding parameters,Ti-Ni IMCs in the weld would be replaced by(Cu,Ni)solid solutions((Cu,Ni)_(ss)).However,Ti-Cu IMC layers cannot be eliminated entirely by changing the welding parameters.The maximum tensile strength of the joints was 201 MPa.The fracture of the joints occurred at the Ti-Cu IMC layer,which was a typical brittle fracture.

Effects of welding parameters and post-heat treatment on mechanical properties of friction stir welded AA2195-T8 Al-Li alloy

In this study, the effects of main welding parameters （rotation speed （ω） and welding speed （υ）） on the microstructure, micro-hardness distribution and tensile properties of friction stir welded （FSW） 2195-T8 Al-Li alloy were investigated. The effects of T6 post-treatments at different solution and aging conditions on the mechanical properties and microstructure characteristics of the FSW joints were also investigated. The results show that with increasing to and v, both strength and elongation of the joints increase first, and then decrease with further increase of ω and υ. All the joints under varied welding parameters show significant strength loss, and the strength reaches only 65% of the base metal, The effect of T6 post-heat treatment on the mechanical properties of the joints depends on the solution and aging conditions. Two heat treatment processes （480 ℃×0.5 h quenching＋ 180 ℃× 12 h, 520 ℃× 0.5 h quenching＋ 180 ℃×12h aging） are found to increase the joint strength. Furthermore, low temperature quenching （480℃） is more beneficial to the joint strength. The joint strength can reach 85% of the base metal. Whereas both low temperature aging （140 ℃× 56h） and stepped aging （ 100 ℃× 12 h ＋ 180 ℃× 3 h） processes decrease the joint strength. After heat treatment all the joints show decreased ductility due to the obvious grain coarsening in the nugget zone （NZ） and thermo-mechanically affected zone （TMAZ）.

Correlation between laser-wire distance and Nd：YAG laser ＋ P-GMA hybrid welding heat input parameters

In laser ＋ P-GMA hybrid welding, laser-wire distance is an important parameter to describe the distance from laser spot to the center of the pulsed gas metal arc. The experiments results show that the optimal laser-wire distance with the deepest weld penetration increases with welding current and laser power being increased and decreases with welding speed being increased. Welding current, laser power and welding speed determine the hybrid welding heat input in laser ＋ arc hybrid welding process, so there is a correlation between the optimal laser-wire distanee and the hybrid heat input welding parameters for the deepest weld penetration： the optimal laser-wire distance increases with the heat input being increased. The positive correlation between the optimal laser-wire distance and the hybrid welding heat input is induced by the characteristics of the limited influence of P-GMA welding process on laser transmission and the dependence of weld penetration of hybrid welding on laser power.

Gas Pool Coupled Activating TIG Welding Method with Coupling Arc Electrode

Gas pool coupled activating TIG(GPCA?TIG) welding put forward in?house can dramatically enhance weld penetration of TIG welding through introducing active element oxygen to reverse the Marangoni convection flow in the molten pool. In order to further improve the welding productivity, the normal solid tungsten electrode is replaced by a kind of coupling arc electrode. The changes of arc pressure distribution along anode surface and the weld appearance were evaluated. On this basis, the dependences of weld shape characterized with weld depth, width and undercut on the main welding parameters were discussed. The results indicate, the substitution of coupling arc electrode can lead to an obvious decrease of arc pressure. Compared to hollow tungsten electrode and twin tungsten electrodes, the coupling arc electrode is much easier to manufacture and has more compacter structure. Combined with the symmetric distribution of arc pressure in di erent directions, this electrode has extensive adaptability. In the GPCA?TIG welding with coupling arc electrode, both the substitution of coupling arc electrode and the introduction of outer active gas oxygen can reduce the possibilities of producing humping bead and undercut. Their joint action makes this welding method have the capability of realizing high travel speed and deep penetration welding.

Analysis on the joint tensile strength and fractography of TiNi shape memory alloy precise pulse resistance butt welding

This paper studies mechanical property and fractography of the welded joints obtained in different welding parameters such as welding heat and welding press with/without gas shield in TiNi shape memory alloy precise pulse resistance butt welding using tensile strength test, XRD, SEM and TEM measures. The optimum welding parameters obtaining high tensile strength welded joint are got. On the condition of welding press magneting current 2 A and welding heat 75%, the joint strength is the highest. This is important for to study other properties of TiNi shape memory alloy further. The experimental results state that argon gas shield have different effects on different welding parameters, less on welding press, but great on welding heat. But excessive welding press and welding heat have great effects on joint tensile strength. Too high welding heat can produce the new intermetallic compound, this intermetallic compound lead to dislocation density to increase and form the potential crack initiation, which can easily make the joint fracture under stress effect and decrease the shape memory ratio of joint for high density dislocation groups existing in the twinned martensite.

Resistance welding of carbon fibre reinforced polyetheretherketone composites using metal mesh and PEI film

Weldability of polyetheretherketone(PEEK) with polyetherimide(PEI) is tested. And carbon fiber reinforced PEEK laminates are resistance welded using stainless steel mesh heating element. The effects of the welding time and welding pressure on the lap shear strength of joints are investigated. Results show that PEEK can heal with PEI well in welding condition and the lap shear strength of PEEK/CF(carbon fibre) joint increases linearly with welding time, but reaches a maximum value when welding pressure ranging from 0.3 MPa to 0.5 MPa with constant welding time. The fracture characteristics of surface are analyzed by SEM techniques, and four types of fracture modes of lap shear joints are suggested.

Research on key control technologies of all-position automatic welding machine

The pipeline all-position automatic welding machine system is a special welding system for automatically welding circumferential joint of pipeline on site, which has been widely used to the long-distance pipeline construction projects due to the advantages of automatic control for welding parameters at all-position, moving speed of bugs and operating. In this paper, the key control technologies of PAWM all-position automatic welding machine （ developed by Pipeline Research Institute of CNPC） such us the automatic control system, control software, personal digital assistant （PDA） software and complex programmable logic device （ CPLD ） program as well us the control method of welding parameter have been described detailedly. With the higher welding quality, higher welding effwiency and lower labor intensity, PA WM all-position automatic welding machine has been successfully applied in many famous pipeline construction projects.

Artificial Neural Network Application to the Friction Stir Welding of Al 6061 Alloy to Stainless Steel 304

The joining of a 6-mm thickness Al 6061 to Stainless steel 304 has been performed by solid state welding. A selection method of optimum friction welding condition using neural networks is proposed. The data used for analyses are the friction stir welding condition, the input parameters of the model consist of welding speed and tool rotation speed. The outputs of the ANN (Artificial Neural Network)model includes resulting parameters, namely, maximum reached temperature,and heating rate for both aluminum alloy 6061 and stainless steel 304 during friction stir welding process.The results of analysis suggest that the proposed method is an effective one to select an optimum welding condition.Good performance of the ANN model was achieved. The combined influence of welding speed and tool rotation speed on the maximum reached temperature and heating rate for both aluminum alloy 6061and stainless steel 304 friction stir welding was simulated. A comparison was made between the output of the ANN program and finite element model. The calculated results were in good agreement with that of finite element model.

A new simulation model and its application in CO_2 short-circuiting transfer welding

A new simulation model of CO 2 short circuiting transfer welding may be employed to develop a new pattern of welding machine and to predict welding process parameters to obtain the optimum welding technology properties. In this paper, a new simulating model is developed according to the AWP (adapting welding physics process) waveform control method. Good agreement is shown between the predicted and experimentally determined results. The model will make an important promotion in the development of CO 2 arc welding technique.

Laser vision based adaptive fill control system for TIG welding

The variation of joint groove size during tungsten inert gas （TIG） welding will result in the non-uniform fill of deposited metal. To solve this problem, an adaptive fill control system was developed based on laser vision sensing. The system hardware consists of a modular development kit （MDK） as the real-time image capturing system, a computer as the controller, a D/A conversion card as the interface of controlled variable output, and a DC TIG welding system as the controlled device. The system software is developed and the developed feature extraction algorithm and control strategy are of good accuracy and robustness. Experimental results show that the system can implement adaptive fill of melting metal with high stability, reliability and accuracy. The groove is filled well and the quality of the weld formation satisfies the relevant industry criteria.

Path planning for MIG surfacing of robot-based remanufacturing system

Robot-based remanufacturing system can scan the worn parts and develop the corresponding models, compare them with the standard model, calculate the weld deposit, implement welding path planning, and repair the worn parts with MIG surfacing automatically. This paper investigates the welding path planning after calibrating, scanning and model rebuilding. The following aspects are contained： introducing the planning principle, selecting the suitable welding process based on welding parameters （current and speed）, calculating welding overlap quantity by the superposition method. Also, it has been verified that good weld profile can be obtained with the optimized parameters.

Friction Stir Weldabilities of AA1050-H24 and AA6061-T6 Aluminum Alloys

The friction stir weldabilities of the strain-hardened AA1050-H24 and precipitate-hardened AA6061-T6 aluminum alloys were examined to reveal the effects of material properties on the friction stir welding behavior. The experimental results are obtlained. (1) For AA1050-H24, the weld can possess smoother surface ripples; there is no elliptical weld nugget in the weld; there is no discernible interface between the stir zone and the thermomechanically affected zone; and the internal defect of the weld looks like a long crack and is located in the lower part of the weld. (2) For AA6061-T6, the weld usually possesses slightly rougher surface ripples; an elliptical weld nugget clearly exists in the weld; there are discernible interfaces among the weld nugget, thermomechanically affected zone and heat affected zone; and the internal defect of the weld is similar to that of the AA1050-H24 weld. (3) The effective range of welding parameters for AA1050-H24 is narrow, while the one for AA6061-T6 is very wide. (4) The maximum tensile strength efficiency of the AA1050-H24 joints is similar to that of the AA6061-T6 joints, i.e. 79% and 77%, respectively.

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

Widespread use of aluminum alloys for the fabrication of car body parts is conditional to the use of appropriate welding methods,especially if dissimilar welding must be performed with automotive steel grades.Friction stir welding(FSW)is considered to be a reasonable solution to obtain sound aluminum-steel joints.In this context,this work studies the effects of tool position and force control in dissimilar friction stir welding of AA6061 aluminum alloy on DC05 low carbon steel in lap joint configuration,also assessing proper welding parameter settings.Naked eye and scanning electron microscopy(SEM)have been used to detect macroscopic and microscopic defects in joints,as well as to determine the type of intermixture between aluminum and steel.The joint strength of sound joints has been assessed by shear tension test.Results point out that tool force control allows for obtaining joints with better quality and strength in a wider range of process parameters.A process window has been determined for tool force conditions to have joints with adequate strength for automotive purposes.