Reverse engineering is conducted based on the analysis of an already existing product. The results of such an analysis can be used to improve the functioning of the product or develop new organizational, economic, information technology, and other solutions that increase the efficiency of the entire business system, in particular 3D printed products. Therefore, the main aim of this research is to focus on evaluation of the load-bearing capacity of already existing 3D printed metals in order to see their suitability for the intended application and to obtain their relevant mechanical properties. To this end, 3D printed metallic bars with almost square cross-sections were acquired from an external company in China without any known processing parameters, apart from the assumption that specimens No. 1–3 are printed horizontally, and specimens No. 4–7 are printed vertically. Various experiments were conducted to study microstructural characteristics and mechanical properties of 3D printed metals. It was observed that specimens No. 1–6, were almost similar in hardness, while specimen No. 7 was reduced by about 4.5% due to the uneven surface. The average value of hardness for the specimens was found to be approximately 450 HV, whereas the load-extension graphs assessed prior point towards the conclusion that the specimens’ fractured in a brittle status, is due to the lack of plastic deformation. For different specimens of the 3D printed materials, the main defects were identified, namely, lack of fusion and porosity are directly responsible for the cracks and layer delamination, prevalent in SLM printed metals. An extensive presence of cracks and layer delamination prove that the printing of these metallic bars was completed in a quick and inaccurate manner, which led to higher percentages of lack of fusion due to either low laser power, high scan speed, or the wrong scan strategy.
Abstract-This research focuses on simulation of the dissimilar materials' welding, stainless steel and mild steel, using finite element and experiment to enhance the method and better understand the transient temperature profiles and the stress distribution in a cladded pipe. The microstructural come as fenestrated and the computer results show that the temperature distribution in the modelled pipe is a function of the thermal conductivity of each weld metal as well as the distance away from the heat source.Index Terms-Transient temperature response, dissimilar material joint, girth weld, microstructure I. INTRODUCTIONT is known that the welding of cylindrical objects is complex and poses a source of concern in manufacturing processes. There are several benefits of welding as a joining technology which includes cost effectiveness, flexibility in design, enhanced structural integrity, and composite weight reduction. However, thermal stresses are usually initiated on the weld and the base metal [1][2][3][4][5]. Poorly welded joints result in leakages, pipe failures and bursts, which lead to possible environmental hazards, loss of lives and properties. Welding of dissimilar materials is carried out in-house using Gas Metal Arc Weld (GMAW), and a finite element analysis (FEA) on pipe models having different clad thicknesses of 2mm and 12mm, respectively, and the temperature versus distance profile obtained. The 12mm cladded pipe results are discussed in this paper.The process of carrying out welding using an arc weld entails melting down the base metal and, in this research, it also involves melting down the clad metal. In the course of carrying out the welding, filler metals are also melted such that the solution formed by heating up all these materials and holding them at that range of temperature long enough permits the diffusion of constituents into the molten solution; this is followed by cooling down rapidly in order to maintain these constituents within the solution. The result of this procedure generates a metallurgical structure positioning insitu the material which supplies superior tensile strength. The bulk of the material immediately after the fusion zone (FZ), which has its characteristics altered by the weld, is termed Heat Affected Zone (HAZ). The volume of material within the HAZ undergoes considerable change which could be Manuscript
Welding of two dissimilar materials was carried out in-house with the aid of a Tungsten Arc weld having dynamic measurement of temperature profiles in the vicinity areas of the welding track using high temperature thermocouples. Comparison was shown previously of the simulated and measured transient temperatures versus finite element simulation. Stress analyses of the pipe were carried out using FEA simulations with two different clad thicknesses. Results of thermal analysis showed a close match and laboratory tests revealed the occurrences at the welded joints, FZ and HAZ; the result of stress analysis also showed a good agreement when validated with ND experimental results.
This study investigates and evaluates the welding residual stresses and deformations in the dissimilar material MSSS metals in order to verify the clamping effect on the residual stresses and deformations and entails comparison with the finite element simulation, the critically reflected longitudinal ultrasonic stress measurement and the hole-drilling residual stresses in a Butt-welded plate courtesy of Javadi et al [1]. The angular shrinkage measurement and vertical displacement were used to achieve this objective. The outcome of the study proved that the measurement of residual stress using protractor is an effective way of differentiating the influence of clamps on the longitudinal stresses.
This paper continues the research previously done by authors on computer simulation of the dissimilar welded joints with varying clad thicknesses using numerical methods. For different cladding thicknesses comprising of stainless steel and mild steel, stress curves have been generated. The welding of the two dissimilar materials has been carried out in-house with the aid of a tungsten arc weld with dynamic measurement of the temperature profile in vicinity of the welding track using high temperature thermocouples. Comparison of the experimentally measured stresses from literature versus the simulation results shows close agreement.
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