The Cold Metal Transfer process is investigated to join zinc coated steel with aluminium alloy by braze-welding. A 4043 filler metal is deposited on the surface of the coated steel, and the effect of the current waveform on the metal transfer and the heat transferred to the base metal is investigated. The reduction in the 'boost phase' duration of the current waveform decreases the volume of liquid drops at the wire tip and allows to increase the short-circuit frequency, inducing a similar or higher deposit rate. Regular deposits are obtained when the linear energy remains below ,500 J mm
21. The heat transferred to the base metal, and thus the thickness of the intermetallic layer formed at the Al/steel interface, is lower for an equivalent deposit rate when the short-circuit frequency is high.
In this work, two indirect approaches are compared to estimate the efficiency of the cold metal transfer welding process with two different current waveforms. The first approach is based on an analytical heat transfer model coupled with thermocouple measurements. The second method includes numerical heat transfer simulation of aluminium filler on the galvanised steel sheet. Then a diffusional-growth model allows evaluating the thickness of the Fe-Al intermetallic layer that was compared it to that of the experimental one. Results show that both methods give very similar process efficiencies. The process efficiency reaches a high value (0.92) with current waveforms using high-intensity pulses of short duration, whereas it decreases to 0.78 with current waveforms using low-intensity pulses of long duration.
The welded structures have a broad applicability (car industry, aeronautical, marine, pipelines, etc.). The welding being an assembled process, presents both advantages and disadvantages. A simple existing defect after welding can generate a catastrophic fracture. This work studies the fatigue crack growth of double butt weld with toe crack. Two types of pipeline material are studied with knowing API 5L grades X60 and X70 where tension form of loading is applied. In order to predict the fatigue behavior of the welded structure, a constant amplitude loading is applied where the influence of the stress ratio over the fatigue life is presented
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