Parametric optimization of friction stir welding parameters of marine grade aluminium alloy using response surface methodology

Friction stir welding between AA5052-H32aluminium plates is performed by central composite design technique of response surface methodology.It is found that the welding parameters such as tool pin profile,tool rotational speed,welding speed,and tool tilt angle play a major role in deciding the joint characteristics.The joints fabricated using tapered square pin profile tool with a tool rotational speed of600r/min,welding speed of65mm/min,and tool tilt angle of1.5°result in an unexpected weld efficiency of93.51%.Mathematical models are developed to map the correlation between the parameters and responses(ultimate tensile strength and elongation)and these models are optimized to maximize the ultimate tensile strength of the friction stir welded joint.Response plots generated from the mathematical models are used to interpret the interaction effects of the welding parameters on the response variables.Adequacy of the developed models is validated using analysis of variance(ANOVA)technique.Results from the confirmatory experiments plotted in scatter diagram show a good agreement with predicted models.Different grain structures in various zones of the weld are examined by observing the micro and macro structures of the weld.

Effects of welding parameters and welding sequence on residual stress and distortion in Al6061-T6 aluminum alloy for T-shaped welded joint

The distribution of temperature and then the distribution of residual stress and distortion in the stiffened aluminum alloy Al6061-T6 plates under the metal inert gas(MIG)welding process were investigated by three dimensional thermo-mechanical coupled finite element model using Ansys software.The properties of materials were considered temperature-dependent and the filler metal was added to the workpiece by the element birth and death technique.In three modes of current,two different speeds and two various sequences,the distribution of residual stress and distortion were calculated and analyzed.The results showed that increase in welding speed decreased the vertical deflection in the plate,transverse shrinkage and angular distortion of plate and the lateral deflection of stiffener,but increased the maximum longitudinal tensile stress in the plate and stiffener.Furthermore,increase in current increased the residual stress and deformation in the plate and stiffener,and the change in the welding sequence changed the distribution of the distortion in the plate and the stiffener without significant change in the distribution of the longitudinal residual stress.

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.

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.

Influence of welding parameters on nitrogen content in welding metal of 32Mn-7Cr-1Mo-0.3N austenitic steel

The transfer behavior of nitrogen into the welding metal during gas tungsten arc welding process of 32Mn-7Cr-1Mo-0.3N steel was investigated. The effects of gas tungsten arc welding process variables, such as the volume fraction of nitrogen in shielding gas, arc holding time and arc current on the nitrogen content in the welding metal were also evaluated. The results show that the volume fraction of nitrogen in gas mixture plays a major role in controlling the nitrogen content in the welding metal. It seems that there exhibits a maximum nitrogen content (depending) on the arc current and arc holding time. The optimum volume fraction of nitrogen in shielding gas is 4% or so. The role of gas tungsten arc welding processing parameters in controlling the transfer of nitrogen is further (confirmed) by the experimental results of gas tungsten arc welding process with feeding metal.

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.

Effect of welding parameters on the heat-affected zone of AISI409 ferritic stainless steel

One of the main problems during the welding of ferritic stainless steels is severe grain growth within the heat-affected zone （HAZ） In the present study, the microstmctural characteristics of tungsten inert gas （TIG） welded AISI409 ferritic stainless steel were investigated by electron backscattered diffraction （EBSD）, and the effects of welding parameters on the grain size, local misorientation, and low-angle grain boundaries were studied. A 3-D finite element model （FEM） was developed to predict the effects of welding parameters on the holding time of the HAZ above the critical temperature of grain growth. It is found that the base metal is not fully recrystallized. During the welding, complete recrystallization is followed by severe grain growth. A decrease in the number of low-angle grain boundaries is observed within the HAZ. FEM results show that the final state of residual sWains is caused by competition between welding plastic strains and their release by recrystallization. Still, the decisive factor for grain growth is heat input.

Identification welding parameters using complex criteria of quality

In the present paper,the graphical method determination of optimal welding parameters of GMAW is described.Some quality complex criteria that are the ratio of weld sizes have been proposed. These criteria allow optimizing the shape of the weld metal zone,reducing the likelihood of hot cracks formation,and reducing the stress concentration of the weld at the toe. In the proposed methodology,the earlier described equations connecting the welding parameters and the weld dimensions of mild and low-alloy steels are explored. Determination of the optimal welding parameters is carried out graphically taking into account the variance of the welding parameters. An example of using the proposed method destined to determine the optimum welding parameters is provided. It is shown that its accuracy is sufficiently good for a practical application.

Research on sinusoid modulated pulse MIG welding methodology

This article proposed a new methodology and the principle of sinusoid modulated pulse MIG welding, and systematically established the universal mathematical model of computation of the parameters of the sinusoid modulation pulse, achieving that the welding energy input can be effectively controlled and precisely regulated, the transition of pulse change is smooth and the welding process is stable and reliable. With the characteristics of sinusoidal waveform, such as infinite derivative continuity, eternal periodicity and limited control parameters, this article established the theoretical foundation for choiceness, unification and optimization of the parameters during the new sinusoid modulated pulse MIG welding. Bead-on-plate overlay welding is carried out on the pure aluminum sheet test sample for the test. The result indicated that during the welding process, the real-time current waveform is stable and clear; both the corresponding voltage and the instant welding energy waveform are very stable; the repeatability of the U-I graph plotted is high; its family of lines is clear, neat, and its distribution is concentrated showing that the welding process is stable and the neat and high quality ripple weld seam may be produced.

Optimizing pulsed current gas tungsten arc welding parameters of AA6061 aluminium alloy using Hooke and Jeeves algorithm

Though the preferred welding process to weld aluminium alloy is frequently constant current gas tungsten arc welding (CCGTAW),it resulted in grain coarsening at the fusion zone and heat affected zone(HAZ).Hence,pulsed current gas tungsten arc welding(PCGTAW) was performed,to yield finer fusion zone grains,which leads to higher strength of AA6061 (Al-Mg-Si) aluminium alloy joints.In order to determine the most influential control factors which will yield minimum fusion zone grain size and maximum tensile strength of the joints,the traditional Hooke and Jeeves pattern search method was used.The experiments were carried out based on central composite design with 31 runs and an algorithm was developed to optimize the fusion zone grain size and the tensile strength of pulsed current gas tungsten arc welded AA6061 aluminium alloy joints.The results indicate that the peak current (Ip) and base current (IB) are the most significant parameters,to decide the fusion zone grain size and the tensile strength of the AA6061 aluminum alloy joints.

WELDABILITY OF Cu-W ALLOY AND COPPER USING FRICTON WELDING METHOD

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Application of response surface methodology to optimize process parameters in friction welding of Ti-6Al-4V and SS304L rods

A method to decide near optimal settings of the process parameters in friction welding was proposed.The success of the friction welding process is based on various input parameters like friction pressure,friction time,upset pressure and upset time and output parameters like tensile strength,hardness and material loss.Ti-6Al-4V and SS304L(SS) materials were joined by friction welding process using interlayer techniques.The Box-Behnken design and response surface methodology(RSM) were applied to deciding the number of experiments to be performed and identify the optimum process parameters for obtaining better joint strength.The results were highly encouraging.Join strength of 523 MPa was obtained at a friction pressure of 12 N/mm^2,upset pressure of40 N/mm^2,friction time of 1.2 s and upset time of 7 s.

Effect of process parameters on the morphology of aluminum/copper alloy lap joints by red and blue hybrid laser welding

In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduced for welding.T2 copper and 6063 aluminum thin plates were lap welded by coaxial dual-beam laser welding.The morphology of weld cross section was compared to explore the influence of process parameters on the formation of lap joints.The microstructure characteristics of the weld zone were observed and compared by optical microscope.The results show that the addition of laser beam swing can eliminate the internal pores of the weld.With the increase of the swing width,the weld depth decreases,and the weld width increases first and then decreases.The influence of welding speed on the weld cross section morphology is similar to that of swing width.With the increase of welding speed,the weld width increases first and then decreases,while the weld depth decreases all the time.This is because that the red laser is used as the main heat source to melt the base metals,with the increase of red laser power,the weld depth increases.As an auxiliary laser source,blue laser reduces the total energy consumption,consequently,the effective heat input increases and the spatter is restrained effectively.As a result,the increase of red laser power has an enhancement effect on the weld width and weld depth.When the swing width is 1.2 mm,the red laser power is 550 W,the blue laser power is 500 W,and the welding speed is 35 mm/s,the weld forming is the best.The lap joint of T2 copper and 6063 aluminum alloy thin plate can be connected stably with the hybrid of blue laser.The effect rules of laser beam swing on the weld formation were obtained,which improved the quality of the joints.

Internal residual stress measurement on linear friction welding of titanium alloy plates with contour method

The internal residual stress within a TC 17 titanium alloy joint welded by linear friction welding （LFW） was measured by the contour method, which is a relatively new and destructive technique to obtain a full map of internal residual stress. The specimen was first cut into two parts; the out-of-plane displacement contour formed by the release of the residual stress was then measured; finally, taking the measured contour of the cut plane as the boundary conditions, a linear elastic finite element analysis was carried out to calculate the corresponding distribution of residual stress normal to the cut plane. The internal stress distribution of the TC 17 titanium alloy LFWjoint was also analyzed. The results show that the tensile residual stress in the TC17 LFW weld is mainly present within a region about 12 mm from the weld centerline; the peak tensile residual stress occurs at the weld centerline and reaches 360 MPa （about one third of the yield strength of TC17 alloy）; within the weld zone of the TC17 LFW weld, the through-thickness stress is not uniform, and the internal stress is larger than that near the top or bottom surface.

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.

Determination of energy coupling to material in laser welding by a novel “sandwich” method

A mathematical energy coupling model was developed to analyze the light transmission in the keyhole and energy distribution on the keyhole wall.The main characteristics of the model include：1） a prototype of the keyhole and the inverse Bremsstrahlung absorption coefficient in the keyhole plasma are obtained from the experiments;2） instead of using a parallel incident beam,a focused laser beam with real Gaussian intensity distribution is implemented;3） both Fresnel absorption and inverse Bremsstrahlung absorption during multiple reflections are considered.The calculation results show that the distribution of absorbed laser intensity by the keyhole wall is not uniform.The maximum laser energy is absorbed by the bottom of the keyhole,although no rays irradiate directly onto the bottom.According to analysis of beam focusing characteristics,the location of the focal plane plays a more important role in the laser energy absorption by the front wall than by the rear wall.

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.