An innovative joint interface design for reducing intermetallic compounds and improving joint strength of thick plate friction stir welded Al/Mg joints

Friction stir welding of dissimilar Al/Mg thick plates still faces severe challenges, such as poor formability, formation of thick intermetallic compounds, and low joint strength. In this work, two joint configurations, namely inclined butt(conventional butt) and serrated interlocking(innovative butt), are proposed for improving weld formation and joint quality. The results show that a continuous and straight intermetallic compound layer appears at the Mg side interface in conventional butt joint, and the maximum average thickness reaches about 60.1 μm.Additionally, the Mg side interface also partially melts, forming a eutectic structure composed of Mg solid solution and Al_(12)Mg_(17) phase.For the innovative butt joint, the Mg side interface presents the curved interlocking feature, and intermetallic compounds can be reduced to less than 10 μm. The joint strength of innovative butt joint is more than three times that of conventional butt joint. This is due to the interlocking effect and thin intermetallic compounds in the innovative joint.

Numerical simulation of 80 ℃ temperature field distribution of thick plate multi-pass welding with SYSWELD

The PPG PITT-CHAR XP flame retardant system has been used by COOEC to preventing the thermal softening of steel in the high temperature,whose degradation temperature is 80 ℃.To prevent damage to PPG PITT-CHAR XP fire retardant paint from excessive heat during welding,it is necessary to get accurately reserved area near the welding joints prior to welding. For the foregoing reasons,the 80 ℃ temperature field distribution of thick plate multi-pass welding was analyzed with SYSWELD.The influence of welding groove form and time interval on welding temperature field was also analyzed. Results showed that the range of 80 ℃ welding temperature field increased with the increasing of weld layers at first and then it inclined to stable value. Interpass time setting was crucial to control the range of 80 ℃ welding temperature field. It was also found that double V groove had better thermal diffusivity than double-bevel groove.And double-bevel groove was better than single V groove.

Distribution of Welding Residual Stress of Mixed Steel U-Rib-Stiffened Plates

To analyze the effects of width and thickness of each composition element of mixed steel U-rib-stiffened plates on the welding residual stress distribution, the distribution of the U-rib and the plate residual stress was calculated using a simplified calculation method. The method involved welding the mixed steel U-rib-stiffened plates for a structure with different sizes and different strength ratios of U-rib to plate. Based on a welding residual stress numerical simulation method validated by the blind hole method test, the distribution law of the mixed steel U-rib stiffened plate was studied. The results showed that the change of plate width has little impact on the welding residual stress and that the ratio of the thicknesses of the plate to U-rib stiffeners, the thickness of the plate, and the thickness of the U-rib has a great influence on the distribution of the welding residual stress. The thickness of plate and steel strength also greatly influenced the distribution width of the residual tensile stress. While analyzing the compression capacity of U-rib-stiffened plates, the simplified distribution of welding residual stress was used.

Finite element analysis of controlling the TC4 thin plate weldment wave-like deformation by welding with impacting rotation

The new technology of welding with impacting rotation is put forward to decrease the wave-like deformation of the TC4 thin plate weldment. The thermal stress and strain are vital to understand the mechanism of controlling the wave-like deformation. In order to know the development of internal thermal stress and strain, finite element method is utilized for- the stress and strain are difficult to be investigated by experimental methods during the welding process. Temperature field, thermal stress evolution and distortion of thin plate are compared with the test results such as weld thermal cycle, residual stress sectioning measurement, and the deflection of the thin plate respectively. By the finite element analysis and test results verification, the meehaaism of the technology to control the wave-like deformation is brought forward, non-uniform thermal elastic strain between compressive plastic region and elastic extensive region is diminished by a certain amount of extensive plastic deformation by welding with impacting rotation process.

Transverse stress-strain evolution during welding of thin aluminum alloy plate

The FE simulation results of transverse stresses and strains during welding of thin aluminum alloy plate are presented. The results indicate that restraint condition is the main factor that determines whether or not hot cracking will occur. With rigid restraint hot cracking (crater cracking) will occur at the arc-stopping end, and such cracking usually will not occur without external restraint. But under restraint-free condition it is easy for terminal cracks to occur.

Design and test of a protective structure for the double vertical explosive welding of large titanium/steel plate

A comprehensive protective structure with rigidity and flexibility was put forward and designed in view of the quality and safety problems for the double vertical explosive welding of large titanium/steel cladding plate.The movement speed and displacement of the protective structure was calculated by establishing its physics model.The dynamics and stabilization properties were analyzed,and the protective structure parameters were optimized and devised.The comprehensive protective structure,which is composed of rigidity unit and flexibility wall,can bear the impact of detonation wave and the high-speed movement of the cladding plate.There are no damage and deformation in the protective structure and the cladding plate.The protective structure can be used many times.The bonding rate of the Ti/steel plate obtained was nearly 100%,and there is no deformation,surface cracks,and big wave and micro-defects.Therefore,the protective problems of the double vertical explosive welding can be solved effectively by the protective structure.

Microstructure and toughness of thick-gauge pipeline steel joint via double-sided friction stir welding combined with preheating

Fusion welding easily causes microstructural coarsening in the heat-affected zone(HAZ) of a thick-gauge pipeline steel joint. This is most significant in the inter-critically coarse-grained HAZ(ICCGHAZ), which considerably deteriorates the toughness of the joint. In the present work, 11-mm thick pipeline steel was joined by preheating and double-sided friction stir welding(FSW). A comparative study on the microstructure and toughness in the ICCGHAZs for FSW and gas metal arc welding(GMAW) was performed. The toughness in the ICCGHAZ for FSW was improved significantly than that in the ICCGHAZ for GMAW. Generally, the nugget zone(NZ) has a coarse microstructure in the FSW steel joint formed at the highest peak temperature. However, in the current study, the microstructure in the one-pass NZ was remarkably refined owing to the static recrystallization of ferrite. An excellent toughness was achieved in the NZ of the pipeline steel joint that employed FSW.

High-Velocity Projectile Impact Behaviour of Friction Stir Welded AA7075 Thick Plates

In this study, high velocity impact behaviour of friction stir welded AA7075-T651 25 mm thick plates were investigated using a 7.62 mm × 51 mm lead core and 7.62 mm × 39 mm steel core projectiles. Prior to ballistic trails, mechanical and metallurgical properties of friction stir welded AA 7075-T651 25 mm thick plates were studied. Microstructural and hardness studies revealed that friction stir welds constituted three distinct regions namely Weld Nugget(WN), Thermo-Mechanically Affected Zone(TMAZ) and Heat Affected Zone(HAZ). Base Material(BM) and all three weld regions were ballistically tested as per military standard NIJ.0108.01 using lead and steel core bullets at maximum permissible velocities of 830 ± 20 and 700 ± 30 m/s, respectively. It has been found that base material(AA7075-T651)and all three weld regions of 25 mm thick plates were able to resist perforation by both types of projectiles used. However depth of penetration has been found to increase from BM to WN, HAZ and TMAZ for both types of projectiles. In all cases steel core projectiles caused higher depth of penetration compared to those caused by lead core projectiles. TMAZs of the friction stir welds were found to be the weakest zone. The fracture that occurred in the base material was spall fragmentation indicating brittle failure, whereas all zones of friction stir welded AA7075-T651 targets with a front petalling, indicating ductile failure. The post-ballistic tested samples showed no significant change in the microstructure of the BM and WN. On the other hand, TMAZ and HAZ showed severe grain deformation in the direction of projectile penetration, and the formation of adiabatic shear bands(ASB). This work showed that 25 mm thick friction stir welded AA7075-T651 joints responded well to ballistic impact loads, making them a good choice for light combat vehicles.

Formation mechanism of transverse crack in repair welding for thick plate of Q345 high strength steel

Transverse cracks occur usually in repair welding for thick plate of high strength steel. It needs multiple times of repair welding. The quality of production and deliver deadline will be influenced. Therefore, it is very significant to investigate the cause and control of transverse crack in repair welding. In this paper, both ends restraint crack experiment is developed to produce delay transverse crack for high strength steel. Metallographic results show that four types of cracks are found in repair welding metal zone and heat affected zone. Large chevron transverse cracks are found in repair welding zone. Lots of micro transverse cracks are found in inter-layer repair welding metal zone, root HAZ and two ends of repair welding individually. The distribution character and formation mechanism of the transverse crack are further analyzed through hardness testing and residual stress measurement.

Compressive Behavior of Steel Members Reinforced by Patch Plate with Welding and Bonding

Repair and reinformcement of aged civil steel structures is one of the important issues for maintaining and using them for a long term. For repair and reinforcement of deteriorated civil steel structures due to fatigue and corrosion, patch plate reinforcement is widely applied. Bolting is generally used because of easy quality control and many construction achievements. However, bolting has downsides including holes made and weight increase. Welding is considered to overcome these demerits but in reality the application of welding is unsatisfactory due to the possibility of fatigue crack occurring from the welded part. In this study, a patch plate strengthening system of welded joint assisted with bonding has been proposed. The compressive behaviors of weld-bond jointed specimen were investigated by a series of experiments and FE analysis. It was confirmed that use of welding and bonding was effective to enhance compressive strength of specimen, due to better load-carrying capacity of patch plate compared with sole use of welding.

Nonlinear Study on the Mechanical Performance of Built-Up Cold-Formed Steel Concrete-Filled Columns under Compression

Given their numerous functional and architectural benefits,such as improved bearing capacity and increased resistance to elastic instability modes,cold-formed steel(CFS)built-up sections have become increasingly developed and used in recent years,particularly in the construction industry.This paper presents an analytical and numerical study of assembled CFS two single channel-shaped columns with different slenderness and configurations(backto-back,face-to-face,and box).These columns were joined by double-row rivets for the back-to-back and box configurations,whereas they were welded together for the face-to-face design.The built-up columns were filled with ordinary concrete of good strength.Finite element models were applied,using ABAQUS software,to assess mechanical performance and study the influence of assembly techniques on the behavior of cold-formed columns under axial compression.Analytical approaches based on Eurocode 3 and Eurocode 4 recommendations for un-filled and concrete-filled columns respectively were followed for the numerical analysis,and concrete confinement effects were also considered per American Concrete Institute(ACI)standards for face-to-face and box configurations.The obtained results indicated a good correlation between the numerical results and the proposed analytical methodology which did not exceed 8%.The failure modes showed that the columns failed due to instabilities such as local and global buckling.

Impact Strength Analysis of Plate Panels with Welding-Induced Residual Stress and Deformation

The paper describes the simulation of impact loads applied on plate panels with welding-induced residual stresses and deformation (WSD). Numerical simulations using FEM are carried out to study the influence of welding-induced residual stresses and deformation on the impact strength of plate panels. Welding is simulated using a three dimensional thermal mechanical coupled finite element method. The welding stress and deformation are taken as the initial imperfections in the impact strength analysis and their influence on the behavior of plate panels subjected to impact loadings. The impact loadings from the three directions, the lateral direction and two in-plane directions of the plate panels are studied. Results show a certain reduction in the impact strength due to the existence of welding stress and deformation in the plate panels. It is found that the reduction of impact force is strongly influenced by the welding deformation and the impact directions in the plate panels. This reduction is more significant when the impact force is in the lateral direction.

Ar-N_2 Shielding GTA Welding of Copper Thick Plates

The Ar-N2 gas tungsten arc(GTA) welding of 10 mm copper thick plates without preheating was investigated.The microstructure of weld metal and joints was observed and mechanical performance of weld metal was tested by using Cu-Ti welding metal with different Ti content.The Ar-N2 GTA weld of copper thick plates can eliminate the nitrogen porosities in the weld metal by adding element Ti in filler metal,which is caused by N2 gas in shield gas.The elimination degree of nitrogen porosities,the distribution of CuTiN intermetallic compound(IMC) and the mechanical performance of joints are associated with the change of the Ti content in the welding materials.And when Ti content is about 5%,nitrogen porosities is eliminated completely and the CuTiN IMC distribute dispersedly,the tensile strength and impact ductility of the joint achieve the best result,which almost reaches the lever of the base metal.

Semi-analytic Solution of Steady Temperature Fields During Thin Plate Welding

Usually, it is very difficult to find out an analytical solution to thermal conduction problems during high temperature welding. Therefore, as an important numerical approach, the method of lines （MOLs） is introduced to solve the temperature field characterized by high gradients. The basic idea of the method is to semi-discretize the governing equation of the problem into a system of ordinary differential equations （ODEs） defined on discrete lines by means of the finite difference method, by which the thermal boundary condition with high gradients are directly embodied in formulation. Thus the temperature field can be obtained by solving the ODEs. As a numerical example, the variation of an axisymmetrical temperature field along the plate thickness can be obtained.

Study on laser welding of the tin-plate can body

Laser beam welding is a new technique for the food can making.This research studied the welding technology and parameters for the tin-plate can and their influences on welding speed and quality,investigated the microstructure and properties of the weld,analysed distribution of tin in the weld metal and carried out the flanging test of the can body.The results show that laser weld- ing of the can body is characterized by high welding speed,fine appearance, good quality and stable and reliable process.This technology can fulfill the re- quirements of can making.

Effect of details of vertical stiffener on fatigue behavior of welding plate beams

The design of the vertical stiffener details is important in the anti-fa- tigue design of the welded steel plate beams.There still exist different opinions on the selection of the design parameters and the effect of the shear stress.In the present study,the effects of the welding process(semi-automatic welding, manual welding)and the connecting location of vertical stiffener(welded to the web or to the flange)on the fatigue behaviour in the regions subjected to the pure bending and subjected to the bending and shearing are investigated by test- ing the simulation beams of large scale.The analysis of the fatigue test results shows that the normal bending stress is the governing factor to the fatigue strength.

Overview of stainless-steel clad-plate welding

Types of bimetal clad plate, manufacturing methods, and their fields of application were summarized. In particular,key aspects of the welding of clad-rolled stainless steel were described, including the weldability of the base and clad metals, design criteria for the transition layer, the selection of the type of welding process and consumables used, types of blanking and welding bevels, preparation and assembly prior to welding, welding procedure requirements, post-weld cleaning and heat treatment, and welding quality inspection. This paper will serve as a reference for the welding technology used in future consumer applications in related fields.

Gas metal arc welding of duplex stainless clad steel plates

The 2205 duplex stainless ＋ DH36 clad steel plate was welded by gas metal arc welding（GMAW）, and the welding performance of the clad steel plate was investigated. The results show that the adaptability of the welding procedure for the base metal of carbon steel, the transition layer, and the cladding material is excellent. The test results indicate that the phase proportion and component dilution of the GMAW-welded joints of clad steel plate can be effectively controlled to yield joints with good mechanical properties and corrosion resistance.

Effect of heat treatment on the microstructure and mechanical properties of structural steel–mild steel composite plates fabricated by explosion welding

Two dissimilar steel plates,structural steel and mild steel,were joined by explosion welding to form a composite.The composite was then heat-treated by quenching at 840℃ for 30 min followed by tempering at 200℃ for 3 h.The microstructure was investigated under an optical microscope and a scanning electron microscope.The mechanical properties were measured using Vickers microhardness and Charpy impact tests.The results show a deformed interface with typical wave features at the welding zone,but no defects were observed.Moreover,the ferrite in the parent plate in the weld zone was elongated due to the strong plastic deformation from the explosion.After heat treatment,the hardness of the flyer plate(structural steel)was over HV0.2800,while that of the parent plate(mild steel)was HV0.2200.The increase in hardness was due to the presence of martensite.Moreover,the average impact energy was increased from 18.5 to 44.0 J following heat treatment;this is because of the formation of recrystallized grains at the weld interface,which is due to the dynamic recovery and local recrystallization,and the strong elemental diffusion that occurred between the two plates.