Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding

Huang, Hui; Yin, Xianqing; Feng, Zhili; Ma, Ninshu

doi:10.3390/ma12010141

Cited by 13 publications

(11 citation statements)

References 33 publications

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“…They concluded that the history of the material after forming had a considerable effect on the amount of residual stresses in the subsequent steps of the manufacturing process chain. Huang et al [13] reported similar results in Q235 steel, concluding that the initial distortions from forming can largely influence the buckling distortion during welding. Papadakis et al [14] studied the influence of preliminary manufacturing processes, i.e.…”

Section: Introductionmentioning

confidence: 67%

“…The protruding areas exhibited larger deviations, e T5 similar to those after the forming process. The discrepancy between simulations and measurements in the final geometry of a welded component was analysed by Huang et al [13] in terms of the residual stresses present in the material from the rolling process. However, no residual stresses were assumed to be present in the material studied in this work prior forming.…”

Section: Resultsmentioning

confidence: 99%

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Prediction of shape distortions during forming and welding of a double-curved strip geometry in alloy 718

Caro

Odenberger

Schill³

et al. 2020

Int J Adv Manuf Technol

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The finite element method (FEM) has considerably contributed to the development of advanced manufacturing methods for metal structures. The prediction of the final shape of a component is of great interest to the manufacturing industry. The level of demand may increase due to multistage processes. Therefore, including all steps of the manufacturing chain in the simulations is a key to being successful. This has been done for a long time in the stamping industry, which involves sequences of forming, trimming, and springback. However, more complex manufacturing procedures that include assembling of formed parts with forgings and castings via welding have been modelled with simplifications, resulting in a reduced prediction accuracy. In the present study, a double-curved part manufactured from alloy 718 is formed at 20°C and laser-welded using the bead-on-plate procedure. The coupling of different manufacturing analyses, including cold forming, trimming, result mapping, welding, cooling, and springback, is achieved using LS-DYNA. Additionally, the effect of adding a damage and failure model in the forming simulation is studied. The results of the forming analysis are used as inputs for the material model *MAT_CWM in the welding simulation. The anisotropic thermomechanical properties of alloy 718 are determined at temperatures up to 1000°C. Encouraging agreement is found between the model predictions and the results of forming and welding tests. The findings underscore the importance of including the material history and accurate process conditions along the manufacturing chain to both the prediction accuracy of shape distortions, and to the potential of the industry.

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Section: Introductionmentioning

confidence: 67%

Section: Resultsmentioning

confidence: 99%

Prediction of shape distortions during forming and welding of a double-curved strip geometry in alloy 718

Caro

Odenberger

Schill³

et al. 2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…The welding heat input is an important factor in forming weld deformations. It was stated by Huang et al [19], that the relationship between heat input and maximum deflection is not linear. There is a critical heat input beyond which the out-of-plane distortion starts to grow very quickly.…”

Section: Introductionmentioning

confidence: 98%

Influence of Tack Welds Distribution and Welding Sequence on the Angular Distortion of Tig Welded Joint

Tomków

Sobota²,

Krajewski

2020

FU Mech Eng

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In this paper the influence of tack welds distribution and welding sequence on angular distortion of the Tungsten Inert Gas (TIG) welded joint was tested. Additionally, the effect of welding current on angular distortion was assessed. For research X2CrTiNb18 (AISI 441) stainless steel (2.5 mm thick) was chosen. During research specimens were prepared with different distributions of tack welds. Then they were welded by different welding sequences with the use of different welding current values. After welding the angular distortion of each specimen was measured by using the coordinate measuring machine. In the next step specimens were cut. Cross-sections were polished and the metallographic macroscopic testing was conducted to check the geometry of performed welds. Performed experiments allowed determining the optimal tack weld sequence and welding parameters for welding thin stainless steel sheets.

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“…However, it can give rise to distortion known as longitudinal or buckling distortion due to the occurrence of the expansion process during the welding process and shrinkage when the weld begins to cool [ 14 ]. Over the last few decades, studies have developed several methods of planning and controlling this distortion [ 15 , 16 ]. In general, control of welding distortion and residual stresses can be accomplished using mechanical effects, thermal effects, or a combination of the two techniques and can be performed either during welding or after [ 17 , 18 , 19 ].…”

Section: Introductionmentioning

confidence: 99%

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

et al. 2023

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The tandem metal inert gas (MIG) process uses two wires that are continuously fed through a special welding torch and disbursed to form a single molten pool. Within the contact tip of the modern approach, the wires are electrically insulated from one another. This study identified the effect of welding electrode spacing on the distortion of AA5052 aluminum plates and different mechanical properties including hardness and thermal cycle using grey relational analysis. Plate distortion was subsequently predicted using the grey prediction model GM (1, 6). This research used a pair of 400 mm × 75 mm × 5 mm of AA5052 plates and electrode distances of 18, 27, and 36 mm. The welding current, voltage, welding speed, and argon flow rate were 130 A, 23 V, 7 mm/s, and 17 L/min, respectively. The temperature was measured using a type-K thermocouple at 10, 20, 30, and 40 mm from the center of the weld bead. The smallest distortion at an electrode distance of 27 mm was 1.4 mm. At an electrode distance of 27 mm, the plate may reach a proper peak temperature where the amount of heat input and dissipation rate are similar to those for electrode distances of 18 mm and 36 mm. The highest relative VHN of 57 was found in the BM, while the lowest, 46, was found in the WM, showing good agreement with their respective grain sizes. Six parameters were designed using grey relational analysis (GRA) and subsequently employed in the grey prediction model GM (1, 6). Process evaluation results show that predictions for welding distortions are consistent with actual results, thus, the GM (1, 6) model can be used as a predictive model for welding distortions of 5052 aluminum plates.

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Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding

Cited by 13 publications

References 33 publications

Prediction of shape distortions during forming and welding of a double-curved strip geometry in alloy 718

Prediction of shape distortions during forming and welding of a double-curved strip geometry in alloy 718

Influence of Tack Welds Distribution and Welding Sequence on the Angular Distortion of Tig Welded Joint

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

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