Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding
Abstract
:1. Introduction
2. Materials and Methods
2.1. Experimental Study for the Database
2.1.1. Materials
2.1.2. Bead-on-Plate Welding Experiment
2.2. Databases for Algorithm
2.2.1. Database #1: Bead Area with Current-Velocity Parameter
2.2.2. Database #2: Angular Distortion with Heat Input-Thickness Parameter
2.3. Algorithm for the Prediction of Angular Distortion
- Input information on weld joint geometry and the welding conditions in the current layer.Weld joint geometry consists of bevel angles, the thickness, the root gap, the root face, and the thickness below the weld root. The welding condition is the average of all passes in the current layer.
- Calculate the cross-sectional area of the bead using Database #1 and the input data of Step 1.Database #1 is composed of the relationship between the current-velocity parameter and the bead area.
- Calculate the beat height from the bead area and the weld joint geometry.As shown in Figure 8, every layer has a trapezoidal shape in the case of the V-groove joint. Geometrically, the height of the trapezoid can be calculated with the bead area (), bevel angles (, ), and the bottom length of the bead (). The subscript i denotes the layer number, and j is for the bead number in the corresponding layer. The layer height () was updated as j was incremented one by one in the current layer i. The calculation was repeated until was greater than the reference height in Equation (4). At the time of termination, was determined as the bead height of the ith layer as written in Equation (9), and the value j was stored as the total number of beads in this layer.The current thickness plus the bead height will be used as the thickness for the calculation of the next layer, which is written as Equation (10).
- Calculate the top length of the layer:The top length () can be obtained by Equation (11) with the bottom length () and the height of the current layer (). The top length is used as the bottom length for the calculation of the next layer.
- Calculate the angular distortion at the current pass:In the current layer i, the angles from Bead Number 1 – j are extracted through Database #2 using the heat input and thickness (). The data were the thickness calculated in the previous layer. Database #2 was made up of the relationship between the heat input, the thickness, and the angular distortion. When the heat input-thickness parameter was less than 0 or greater than 25 kJ/mm, the output of the angular distortion was zero.
- The layer number i increased by one, and Steps 1–5 above were repeated.The value j was initialized to one before each layer calculation. The calculation terminated when was greater than the thickness of the base material.
- Calculate the accumulated angular distortion by summing the angles produced for each pass.
3. Results and Discussions
3.1. Algorithm Validation through Experiment
3.2. Effect of the Number of Welding Passes on Angular Distortion
3.3. Effect of Parent Material Thickness on Angular Distortion
3.4. Effect of Previous Weld Beads on Angular Distortion
3.5. Effect of Bead Size on Angular Distortion
3.6. Effect of Weld Joint Geometry on Angular Distortion
4. Conclusions
- Information on the welding conditions and the weld joint geometry was the input.
- The bead area was calculated through Database #1, which consisted of the current-velocity parameter and bead size.
- The bead height was obtained from the geometric relationship between the bead area and the joint geometry, where the bead height plus previous thickness were used as the thickness in the next layer calculation.
- The angular distortion was estimated through Database #2, which is composed of the heat input-thickness parameters and the angular distortion.
- Accumulated angular distortions were obtained by iterative calculation of the above procedures.
- The bead cross-sectional area was proportional to the square of the electric current divided by the welding speed, and the angular distortion was a function of the heat input divided by the square of the thickness.
- The effect of the previous layer on reduction in angular distortion should be applied to the prediction method.
- In the same weld joint, the angular distortion with the number of passes created a single curve regardless of the welding conditions, so the final angle was determined by the final pass number. The predictive curve, on the other hand, varied with the shape of the weld joint.
- There existed a region where the angular distortion was the maximum at a specific thickness and heat input. In the case of V-butt welding, the change in angular distortion was greatest in between the third and fifth welding pass.
- Reducing the number of passes with a large bead size decreased the welding angular distortion in the same joint.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
Abbreviations
HAZ | Heat-affected zone |
FCAW | Flux cored arc welding |
GMAW | Gas metal arc welding |
SAW | Submerged arc welding |
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Type | Chemical Compositions (Mass %) | Mechanical Properties as Welded | |||||
---|---|---|---|---|---|---|---|
C | Mn | Ni | Cr | Yield strength | Tensile strength | Elongation | |
LR-AH32 (base) | 0.16 | 1.12 | 0.04 | 0.03 | 348 MPa | 495 MPa | 30% |
E81T1-K2C (wire) | 0.03 | 1.28 | 1.49 | 0.03 | 549 MPa | 617 MPa | 31% |
Thickness (mm) | Voltage (V) | Current (A) | Speed (cm/min) | Number of Layers |
---|---|---|---|---|
11.5 | 29 | 285 | 15, 20, 22, 25 | 1, (6–13 passes per layer) |
12 | 29 | 285 | 25, 30, 40, 60 | 4, (4–27 passes per layer) |
15 | 29 | 285 | 25, 30, 40, 60 | 2, (6–13 passes per layer) |
19.5 | 29 | 285 | 25, 30, 40, 60 | 2, (6–13 passes per layer) |
28 | 29 | 285 | 25, 30 | 2, (6–13 passes per layer) |
45 | 29 | 285 | 25, 30, 40, 60 | 2, (6–13 passes per layer) |
Thickness (mm) | Voltage (V) | Current (A) | Speed (cm/min) | Effective Heat Input (kJ/mm) |
---|---|---|---|---|
19.5, 28 | 29 | 285 | 60, 40, 20, 25 | 0.7, 1.0, 1.3, 1.6 |
Effective Heat Input (kJ/mm) | 0.7 | 1.0 | 1.3 | 1.6 |
---|---|---|---|---|
Experiment (degree), [Number of passes] | 7.3, [22] | 7.5, [16] | 6.9, [12] | 6.9, [11] |
Calculation (degree), [Number of passes] | 7.9, [24] | 7.2, [16] | 6.6, [12] | 6.7, [12] |
Error (%) | −7.7 | 3.9 | 3.2 | 3.3 |
Error (%) = (Experiment − Calculation)/Experiment × 100 |
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Seong, W.-J. Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding. Materials 2019, 12, 1435. https://doi.org/10.3390/ma12091435
Seong W-J. Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding. Materials. 2019; 12(9):1435. https://doi.org/10.3390/ma12091435
Chicago/Turabian StyleSeong, Woo-Jae. 2019. "Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding" Materials 12, no. 9: 1435. https://doi.org/10.3390/ma12091435
APA StyleSeong, W. -J. (2019). Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding. Materials, 12(9), 1435. https://doi.org/10.3390/ma12091435