Search Results (280)

TC4 titanium alloy and 5083 aluminum alloy with different groove shapes were joined by laser-MIG hybrid welding–brazing using ER4043 filler wire. The effects of groove shape on the weld formation, intermetallic compounds and tensile property of the Ti/Al butt joints were investigated. The welds without obvious defects could be obtained with grooves of I-shape and V-shape on Ti side, while welds quality with grooves of V-shape on Al side and V-shape on both sides were slightly worse. The interfacial intermetallic compounds (IMCs) on the brazing interface were homogeneous in the joints with groove of V-shape on Ti side, and V-shape on both sides, which had similar thickness and were both composed of TiAl₃. Unlike the IMCs mainly composed of TiAl₃ at the I-shape groove interface, TiAl₃, TiAl, and Ti₃Al constituted the IMCs at the V-shape on Al side interface. The average tensile strength of Ti/Al joints with groove of I-shape was the highest at 238 MPa, and was lowest at 140 MPa with groove of V-shape on Al side. The tensile samples mainly fractured at IMCs interface and the fractured surfaces all exhibited mixed brittle–ductile fracture mode. Based on the above research results, I-shape groove was recommended for laser-arc hybrid welding–brazing of 4 mm thick Ti/Al dissimilar butt joints. Full article

Inconel 600 alloy has gained consideration as a favourable material for heat and power applications, particularly in turbine blades, due to its superior mechanical behaviour encompassing strength, toughness, oxidation resistance, and ductility. Tungsten Inert Gas (TIG) welding is one of the preferred techniques for joining these alloys. Therefore, the investigation of the mechanical behaviour after the welding process is crucial for selecting the appropriate technique for joining Inconel 600 sheets. This research focuses on investigating the microstructure and mechanical behaviour of TIG-welded Inconel 600 through a series of tests, such as tensile, fatigue, creep, and hardness evaluations. In addition, microstructural analysis is combined with these mechanical evaluations to simulate the operating conditions experienced by turbine blades. Key parameters such as yield strength, tensile strength, and elongation have been evaluated through these analyses. The Ramberg–Osgood relationship has been investigated using the engineering and true stress–strain curves obtained from the welded specimens. The results of the fatigue test illustrate the relationship between strain amplitude and the number of cycles to failure for single and double-edge notched specimens. The test was performed at two different loads including 400 MPa and 250 MPa at a constant temperature of 650 °C, and the corresponding strain-time curves were recorded. The results showed rapid creep failure at 650 °C, suggesting that TIG welding may need to be optimized for high temperature applications. Full article

The performance of high-density polyethylene (PE) pipes joints directly affects the total pipeline’s operation, and so studying the residual stress of butt fusion joints is crucial for enhancing the safety of gas pipelines. Based on a layer-by-layer ring cutting test method, we measured the distribution of residual stresses in the fusion zone and heat-affected zone of butt fusion joints for PE gas pipes. Firstly, the ring samples were cut, their diameter changes were measured, and the results were compared with those predicted by the theoretical calculations. This showed that the circumferential residual stresses of the butt fusion joint for the PE gas pipes are exponentially distributed in the base material (BM) zone, the weld zone (WZ) and the heat-affected zone (HAZ). Furthermore, the residual stresses in the HAZ are lower than those in the BM zone, and the smallest residual stresses were seen in the WZ. Finally, using X-ray diffraction (XRD) technology, the crystallinities in the BM zone, the WZ, and the HAZ of the butt joints were measured. The crystallinity gradually decreased from the WZ to the HAZ and the BM zone, and the crystallinity in each zone was also related to the magnitude of the residual stresses. Full article

One of the prospective methods of robotic welding with a consumable electrode in shield gas metal arc welding is the GMAW Rapid HF process (GRHF, HF-high frequency), in which welded joints with deep penetration welds are obtained thanks to the specially programmed welding characteristics of the arc. A pulsed frequency equalized to 5000 Hz was used to achieve consumable electrode arc stabilization and improve penetration. This work consists of two main sections, including the research and analysis of wire electrode melting and weld pool formation in the innovative GRHF process and its influences on joint strength and the economic advantages of welding. As a result of our research and strength tests, as well as an image analysis of phenomena occurring in the welding arc and weld pool, assumptions were developed about the use of the GRHF process, which is characterized by deep penetration welds without welding imperfections that reduce the quality of the welded joints and their strength. Welding conditions and parameters leading to welded joints characterized by high relative strength related to the weight of the used filler material were proposed. As a result of our research, it was found that the use of welding processes with deep penetration leads to material savings related to the reduced consumption of filler materials while maintaining the required high strength of welded joints. Savings of filler materials reaching 80% were achieved compared with hitherto used methods. At the same time, the maximum load-carrying capacity of welding joints was maintained. Full article

Laser welding–brazing experiments with 6061 aluminum alloy and Q235 steel were conducted using AlSi12 and ZnAl22 as filler metals. The macroscopic morphologies and microstructures of welding–brazing joints were analyzed by optical microscopy (OM) and scanning electron microscopy (SEM). The effects of Si and Zn elements in filler wires on the macroscopic morphologies, interfacial microstructures, tensile properties, and corrosion resistances of joints were studied. The results show that the wettability of ZnAl22-filler wire was better than that of AlSi12-filler wire. The fusion zone of the joint welded with AlSi12-filler wire consisted of α–Al solid solution and Al–Si eutectic mixture, while the interfacial reaction zone was composed of η-Fe₂(Al, Si)₅ and τ₅-Fe_1.8Al_7.2Si. The fusion zone of the joint formed using AlZn22-filler wire consisted of α–Al solid solution, η-Zn solid solution, and ZnAl eutectic structure. The joint welded with AlSi12-filler wire showed better tensile strength and corrosion resistance compared to that welded with ZnAl22-filler wire. Full article

In order to further study the effect of welding residual stress on the fatigue strength of a TC4 titanium alloy sheet during laser welding, a laser welding butt joint model for TC4 titanium alloy sheets was established using ABAQUS (2022) software. The temperature and residual stress fields generated during the welding process were comprehensively simulated, and the melt pool shape and residual stress magnitudes were experimentally verified. The experimental parameters included a laser power range of 900–1200 W, welding speeds of 12.5 and 25 mm/s, and a double-sided welding approach with a cooling interval of 20 s between passes. The findings indicate that welding residual stress is primarily concentrated around the weld and the heat-affected zone, predominantly as tensile stress, with the maximum value observed at the weld’s initiation point, reaching 920 MPa—close to the material’s tensile strength limit. Under ideal conditions (without considering welding residual stress), the fatigue life at the weld area is estimated to reach 188,799 cycles, while the fatigue life of the base material without welding is calculated to be 167,109 cycles. However, when accounting for welding residual stress, the fatigue strength of the sheet decreases significantly, with the minimum fatigue life occurring at the weld toe, measured at 10,471 cycles. This study demonstrates that welding residual stress has a substantial impact on the fatigue life of TC4 titanium alloy sheets, particularly in the heat-affected zone, where the fatigue life is reduced by nearly 94% compared to the ideal condition. These results provide critical insights for improving the fatigue performance of laser-welded TC4 titanium alloy components in engineering applications. Full article

To enhance the standardization and construction efficiency of prefabricated steel structures and to promote the application of cold-formed steel tubes with the advantages of high standardization, superior mechanical properties, and fast processing speeds, two types of composite beam to concrete-filled cold-formed high-strength square steel tubular column joints with different connection forms were designed in this study: the external diaphragm joint (ED joint) and the through diaphragm joint (TD joint). These joints were subjected to cyclic loading tests to evaluate the influence of the connection designs on key seismic performance parameters, such as failure modes, load-bearing capacities, the degradation of strength and stiffness, ductility, and energy dissipation capabilities. The results show that both the ED and TD joints experienced butt weld fractures at the bolted-welded connections on the beam, effectively transferring the plastic hinges from the joint zone to the beam and demonstrating good seismic performance. The ED joint specimen JD1 and the TD joint specimen JD2 exhibited similar load-bearing capacity, stiffness, strength degradation, and energy dissipation capacity. However, the TD joint showed lower ductility compared to the ED joint due to premature weld fractures. A nonlinear finite element model (FEM) was developed using MSC.MARC 2012, and the numerical simulation showed that the FEM could effectively simulate the hysteresis performance of the composite beam to concrete-filled, cold-formed, high-strength, square, steel tubular column joints with external and through diaphragms. Full article

This investigation aimed at evaluating the weldability of a 2.1 GPa-grade hot stamping steel (HSS) containing 0.40 wt.% carbon using laser butt welding. It is shown that the subject HSS can be properly joined by laser welding without welding defects, such as voids and micro-cracks. The mechanical properties of joints before and after hot stamping were examined using cross-weld uniaxial tension and Vickers hardness, while microstructure was systematically characterized using optical microscopy and electron backscatter diffraction. The experimental results demonstrate that fresh martensite was formed in the weld nugget after welding, leading to a hardness much higher than that of the base metal. Nevertheless, such cross-weld microstructural heterogeneity was erased after hot stamping and low-temperature baking heat treatments, resulting in a uniform microstructure of lath martensite across the weld. As a result, the joint after hot stamping and baking exhibited an ultimate tensile strength of 2140 MPa and a total elongation of 12.03%, with the fracture occurring in the base metal. Such excellent mechanical properties of the joint demonstrate the great weldability of the present 2.1 GPa-grade HSS during laser welding. Full article

Infrared (IR) magneto-optical (MO) bi-imaging is an innovative method for detecting weld defects, and it is important to process both IR thermography and MO imaging characteristics of weld defects. IR thermography and MO imaging can not only run simultaneously but can also run separately in special welding processes. This paper studies the sensing processing of eddy current IR thermography and MO imaging for detecting weld defects of laser spot welding and butt joint laser welding, respectively. To address the issues of high-level noise and low contrast in eddy current IR detection thermal images interfering with defect detection and recognition, a method based on least squares and Gaussian-adaptive bilateral filtering is proposed for denoising eddy current IR detection thermal images of laser spot welding cracks and improving the quality of eddy current IR detection thermal images. Meanwhile, the image gradient is processed by Gaussian-adaptive bilateral filtering, and then the filter is embedded in the least squares model to smooth and denoise the image while preserving defect information. Additionally, MO imaging for butt joint laser welding defects is researched. For the acquired MO images of welding cracks, pits, incomplete fusions, burn-outs, and weld bumps, the MO image processing method that includes median filtering, histogram equalization, and Wiener filtering was used, which could eliminate the noise in an image, enhance its contrast, and highlight the weld defect features. The experimental results show that the proposed image processing method can eliminate most of the noise while retaining the weld defect features, and the contrast between the welding defect area and the normal area is greatly improved. The denoising effect using the Natural Image Quality Evaluator (NIQE) and the Blind Image Quality Index (BIQI) has been evaluated, further demonstrating the effectiveness of the proposed method. The differences among weld defects could be obtained by analyzing the gray values of the weld defect MO images, which reflect the weld defect information. The MO imaging method can be used to investigate the magnetic distribution characteristics of welding defects, and its effectiveness has been verified by detecting various butt joint laser welding weldments. Full article

This study investigates the impact of different filler wires (ER5356, ER4043, and ER4047) on the microstructural and mechanical properties of EN AW-6082 Al alloy joints produced by tungsten inert gas (TIG) welding. Butt-welded samples with a single V-groove joint configuration were prepared using optimized welding parameters. The welded samples were subjected to visual inspection, microstructural analysis, hardness testing, tensile testing, and impact toughness evaluation. The results showed that all the welds were free of visible defects. Microstructural examination revealed that the ER5356 filler produced the finest grain structure of 18.03 ± 3 μm, while ER4047 resulted in the coarsest grains of 36.07 ± 5 μm. Correspondingly, the joints made with ER5356 exhibited the highest tensile stress of 278 ± 6 MPa, yield stress of 219 ± 5.4 MPa, hardness values of 72.7 ± 5 HV, and welding efficiency of 86.07%, whereas those made with ER4047 produced the lowest values. The hardness in the weld region was lower than that in the parent metal and heat-affected zone for all samples. However, ER4047 welds demonstrated superior impact toughness and strain-hardening capacity. The findings underscore the importance of filler metal selection in tailoring mechanical properties for high-performance applications. Full article

A 3D thermal elastic-plastic welding analysis ACT (Application Customization Toolkit) was developed in ANSYS, making welding analysis more accessible. The welding analysis was performed using a decoupled method, separated into thermal and structural analyses. To validate the results, comparisons were made with previous studies for two types of welding: T-joint fillet welding and butt welding. Subsequently, the residual stress and deformation obtained from the welding analysis were applied as initial imperfections in a compression analysis to evaluate the ultimate compressive strength with conventional compression analysis. This comparison allowed for a more realistic assessment of the effects of deformation and residual stress distribution on the structural behaviours. Full article

The grain growth in the fusion zone (FZ) and heat-affected zone (HAZ) of metal inert gas (MIG) welding processes negatively affect the mechanical properties of aluminum alloy MIG welds used in automotive components. Although the addition of Sc- and Zr-based filler wires can refine weld microstructures and enhance the mechanical properties, conditions resembling actual automotive component joints have not been sufficiently investigated. In this study, 5083-O aluminum alloy base material was welded into butt and lap joints using conventional 5000-series aluminum alloy filler wires (Al-5.0Mg) and wires containing Sc and Zr (Al-4.8Mg-0.7Sc-0.3Zr) under various heat input conditions. The mechanical properties of the welds were evaluated via tensile tests, and the microstructures in the FZ and HAZ were analyzed. In butt joints, Al-4.8Mg-0.7Sc-0.3Zr exhibited a finer and more uniform grain structure with increased tensile strength compared with those welded using Al-5.0Mg. The microstructure became coarser with the increased heat input, and the tensile strength tended to decrease. In lap joints, the tensile-shear strength of Al-4.8Mg-0.7Sc-0.3Zr was higher than that of Al-5.0Mg; it further increased with the increase in the amount of deposited metal. The coarsening of the microstructure with the increased heat input was disadvantageous for the tensile-shear strength, and the increased weld size offset the adverse effects of the coarse microstructure. These results indicate that the heat input and the amount of deposited metal must be optimized to ensure stiffness in various joints of automotive components. Full article

With the development of robotic welding automation, there is a strong interest in welding seam identification and localization methods with high accuracy, real-time performance, and robustness. This paper proposed a 3D workpiece weld identification and localization method based on DBSCAN (density-based spatial clustering of applications with noise) to realize stable feature extraction for multiple joint types. Firstly, this method employs combinatorial filtering to effectively eliminate non-target point clouds, including outliers and installation platform point clouds, which can minimize the computational load. Secondly, DBSCAN is used to classify workpiece point clouds into different clusters, which can be used for point cloud segmentation of flat workpieces and curved workpieces. Thirdly, the edge detection and feature extraction methods are used to obtain joint gap and weld feature points while combining the information of point clouds for different types of welds. Finally, based on the identification and localization of the welds, welding path planning and attitude planning are implemented. Experimentation results indicated that the proposed method exhibits robustness across various types of welded joints, including butt joints with straight seams, butt joints with curved seams, butt joints with curved workpieces, and lap joints. Meanwhile, the average error of joint gap detection was 0.11 mm and the processing time of a 90 mm straight-seam butt joint is 701.12 ms. Full article

Weathering steel possesses good atmospheric corrosion resistance and is increasingly applied in highway and railway bridges. The fatigue performance of the weld joint is an important issue in bridge engineering. This study experimentally investigates the microstructural properties and fracture crack growth behaviors of a Q370qENH bridge weathering steel weld joint. The FCG parameters of the base steel, butt weld, and HAZs, considering the effect of different plate thicknesses and stress ratios, are analyzed. Microstructural features, microhardness, and fatigue fracture surfaces are carefully inspected. The FCG rates of different weld regions in the stable crack growth stage are obtained using integral formulas based on the Paris and Walker law. The test results indicate that the heating and cooling process during the welding of Q370qENH steel creates improved microstructures with refined grain sizes and fewer impurities, thus leading to improved FCG performances in the HAZ and weld regions. The crack growth rate of Q370qENH weld regions increases with the stress ratio, and the influencing extent increasingly ranks as the base steel, HAZ, and the weld. The thick plate has a slightly slower fatigue crack growth rate for the Q370qENH weld joints. The Q370qENH base steel presents the highest fatigue crack growth rate, followed by the heat-treated and HAZ cases, while the weld area exhibits the lowest FCG rate. The Paris law coefficients of different regions of Q370qENH welds are presented. The collected data serve as a valuable reference for future analyses of fatigue crack propagation problems of Q370qENH steel bridge joints. Full article

The P91 martensitic steel and 304L austenitic stainless steels are two mainly used structural steels in power plants. The major problem in conventional multipass tungsten inert gas (TIG) welding of P91/304L steel is high heat input and joint distortion, increased cost and time associated with V groove preparation, filler rod requirement, preheating and welding in multiple passes, and labor efforts. Hence, in this study, a novel approach of robotically operated activated flux TIG (A-TIG) welding process and thin AlCoCrFeNi_2.1 eutectic high entropy alloy (EHEA) sheet as the interlayer was used to weld 6.14 mm thick P91 and 304L steel plates with 02 passes in butt joint configuration. The joints were qualified using visual examination, macro-etching, X-ray radiography testing and angular distortion measurement. The angular distortion of the joints was measured using a coordinate measuring machine (CMM) integrated with Samiso 7.5 software. The quality of the A-TIG welded joints was compared to the joints made employing multipass-TIG welding process and Inconel 82 filler rod in 07 passes. The A-TIG welded joints showed significant reduction in angular distortion and higher productivity. It showed a 55% reduction in angular distortion and 80% reduction in welding cost and time compared to the multipass-TIG welded joints. Full article