Effect of strain hardening and strain softening on welding distortion and residual stress of A7N01-T4 aluminum alloy by simulation analysis

The effect of strain hardening and strain softening behavior of flow stress changing with temperature on welding residual stress, plastic strain and welding distortion of ATN0 1-T4 aluminum alloy was studied by finite simulation method. The simulation results show that the weld seam undergoes strain hardening in the temperature range of 180-250 ℃, however, it exhibits strain softening at temperature above 250 ℃ during welding heating and cooling process. As a result, the strain hardening and strain softening effects counteract each other, introducing slightly influence on the welding residual stress, residual plastic strain and distortion. The welding longitudinal residual stress was determined by ultrasonic stress measurement method for the flat plates of A7N01-T4 aluminum alloy. The simulation results are well accordant with test ones.

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.

Numerical Simulation on Interfacial Creep Failure of Dissimilar Metal Welded Joint between HR3C and T91 Heat-Resistant Steel

The maximum principal stress, von Mises equivalent stress, equivalent creep strain, stress triaxiality in dissimilar metal welded joints between austenitic（HR3C） and martensitic heat-resistant steel（T91） are simulated by FEM at 873 K and under inner pressure of 42.26 MPa. The results show that the maximum principal stress and von Mises equivalent stress are quite high in the vicinity of weld/T91 interface, creep cavities are easy to form and expand in the weld/T91 interface. There are two peaks of equivalent creep strains in welded joint, and the maximum equivalent creep strain is in the place 27-32 mm away from the weld/T91 interface, and there exists creep constrain region in the vicinity of weld/T91 interface. The high stress triaxiality peak is located exactly at the weld/T91 interface. Accordingly, the weld/T91 interface is the weakest site of welded joint. Therefore, using stress triaxiality to describe creep cavity nucleation and expansion and crack development is reasonable for the dissimilar metal welded joint between austenitic and martensitic steel.

Microstructure and Strain Hardening of a Friction Stir Welded High-Strength Al–Zn–Mg Alloy

Microstructural evolution and strain hardening behavior of a friction stir welded（FSWed） high-strength7075Al-T651 alloy were evaluated.The nugget zone was observed to consist of fine and equiaxed recrystallized grains with a low dislocation density and free of original precipitates,but containing uniformly distributed dispersoids.The strength,joint efficiency,and ductility of the FSWed joints increased with increasing welding speed.A joint efficiency of ＊91% was achieved at a welding speed of 400 mm/min and rotational rate of 800 r/min,while the ductility remained basically the same as that of the base metal.There was no obvious strain rate sensitivity observed in both base metal and welded joints.While both the base metal and FSWed joints exhibited stage III and IV hardening characteristics,the hardening capacity,strain hardening exponent,and strain hardening rate all increased after friction stir welding.

Microstructure Characterization of the Fusion Zone of an Alloy 600-82 Weld Joint

Characterization of the microstructure of the fusion zone of an Alloy 600-82 weld joint was conducted, with focus on the weld residual strain distribution and the comparison of the microstructure of heat affected zone （HAZ） with that of cold worked alloy. Peak of the residual strain was observed to approach to the fusion boundary in HAZ while the strain increased from the top of the weld to the root. Strain distribution in the HAZ was found to be concentrated adjacent to grain boundaries （GBs）, with a peak of approximately three times of that in grain. Further, triple junctions of the GB appear to cause a higher strain concentration than single GBs. The microstructure of HAZ consists of partially tangled dislocations, which is different from slip bands of high density dislocations in cold worked alloy. This may cause a relatively higher intergranular cracking resistance of HAZ due to the difficulty in transferring tangled dislocations to GB in HAZ under deformation.