Metallurgical Characterization of Penetration Shape Change in Workpiece Vibration-Assisted Tandem-Pulsed Gas Metal Arc Welding

Zargari, Habib Hamed; Ito, Kazuhiro; Miwa, Tsuyoshi; Parchuri, Pradeep Kumar; Yamamoto, Hajime; Sharma, Abhay

doi:10.3390/ma13143096

Cited by 12 publications

(6 citation statements)

References 28 publications

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“…It can be seen from the figure that ultrasonic vibration improved the mobility of the metal at the bottom of the weld, especially the strengthening of the flow behavior of the material along the thickness direction, so that the material flow intersection behavior of the metal at the top and bottom of the weld was more adequate. The thickness variation of the weak connection region at the bottom affects the local mechanical properties [23], so the homogeneity of the weld properties under the action of ultrasonic vibration was better.…”

Section: Fracture Behaviormentioning

confidence: 99%

Effect of Ultrasonic Vibration in Friction Stir Welding of 2219 Aluminum Alloy: An Effective Model for Predicting Weld Strength

Xue

Zhou

2022

Metals

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Friction stir welding (FSW) is today used as a premier solution for joining non-ferrous metals, although there are many limitations in its application. One of the objectives of this study was to propose an innovative welding technique, namely ultrasonic-assisted friction stir welding (UAFSW) with longitudinal ultrasonic vibration applied to the stirring head. In this paper, UAFSW mechanical properties and microstructure analysis were performed to demonstrate that the fluidity of the weld area was improved and the strengthened phase organization was partially preserved, due to the application of ultrasonic vibration. The addition of 1.8 kW of ultrasonic vibration at 1200 rpm and 150 mm/min welding parameters resulted in a 10.5% increase in the tensile strength of the weld. The ultimate tensile strength of 2219 aluminum alloy UAFSW was analyzed and predicted using mathematical modeling and machine learning techniques. A full factorial design method with multiple regression, random forest, and support vector machine was used to validate the experimental results. In predicting the tensile behavior of UAFSW joints, by comparing the evaluation metrics, such as R2, MSE, RMSE, and MAE, it was found that the RF model was 22% and 21% more accurate in the R2 metric compared to other models, and RF was considered as the best performing machine learning method.

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Section: Fracture Behaviormentioning

confidence: 99%

Effect of Ultrasonic Vibration in Friction Stir Welding of 2219 Aluminum Alloy: An Effective Model for Predicting Weld Strength

Xue

Zhou

2022

Metals

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“…Mechanical oscillations in the welding process are typically generated by vibrating the part at a resonant frequency using a vibrator from the VSR process at frequencies below 150 Hz [ 12 , 13 , 14 , 15 , 16 , 17 ]. Higher-resonance frequency vibrations are achieved with electromagnetic or electrodynamic vibrators [ 18 , 19 , 20 , 21 ]. Our research utilized a vibrating table capable of creating quasi-resonance conditions across a wide frequency range up to 9500 Hz, allowing for controlled acceleration directionality.…”

Section: Introductionmentioning

confidence: 99%

Vibration-Assisted Welding of 42CrMo4 Steel: Optimizing Parameters for Improved Properties and Weldability

Luca,

Roata,

Croitoru

et al. 2024

Materials

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This study advances the vibration-assisted welding (VAW) technique for joining medium-carbon, low-alloy steels, which are typically challenging to weld. Traditional welding methods suggest low linear energy and mandatory pre- and post-heating due to these steels’ poor weldability. However, VAW employs a vibrating table to maintain part vibration throughout the automatic MIG/MAG welding process. This study tested the VAW technique on 42CrMo4 steel samples, achieving satisfactory weld quality without the need for pre- and post-heating treatments. This research revealed that while vibration frequencies between 550 Hz and 9.5 kHz minimally affect the appearance of the weld joint, the oscillation acceleration has a significant impact. The acceleration along the weld axis (ax), combined with the welding speed and vibration frequency, affects the weld surface’s appearance, particularly its scaly texture and size. Lateral acceleration (ay) alters the seam width, whereas vertical acceleration (az) affects penetration depth at the root. Notably, if the effective acceleration (aef) surpasses 40 m/s2, there is a risk of molten metal expulsion from the weld pool or piercing at the joint’s base. The quality of the joints was assessed through macroscopic and microscopic structural analyses, micro-hardness tests in the weld zone, and bending trials. The mechanical properties of the VAW samples were found to be acceptable, with hardness slightly exceeding that of the samples subjected to pre- and post-heating. Moreover, the VAW process significantly reduced energy consumption and operational time. The employed vibration system, with a power rating of 100 W, operates for just a few minutes, resulting in substantially lower energy usage compared to the traditional pre- and post-heating method, which typically requires a 5 kW electric furnace.

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“…As a new welding technology to achieve high e ciency, tandem metal inert gas (MIG) welding has the advantages of good mechanical properties of joints and high welding e ciency [4]. Moreover, tandem MIG welding can effectively reduce the probability of occurrence of welding pore defects, re ne the grain of the weld zone, and obtain high-quality sh scale weld [5].…”

Section: Introductionmentioning

confidence: 99%

Effect of ultrasonic impact time on microstructure and properties of 7A52 aluminum alloy tandem MIG welded joint

Chen

Yang

2021

Int J Adv Manuf Technol

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7A52 (Al-Zn-Mg-Cu) alloy is a high-strength aluminum alloy, its welded joints are often accompanied by defects such as poor wear resistance and low fatigue strength. Herein, we try to optimize the welded joint of 7A52 aluminum alloy by using ultrasonic impact treatment (UIT). Generally, the mechanical properties such as microhardness and fatigue strength of the welded joint after UIT will be improved. 7A52 aluminum alloy tandem metal inert gas (MIG) welded joints with UIT time per unit area of 2.5 min, 5 min, 10 min, 15 min, 30 min, and 75 min were studied. Through the surface topography, microstructure observation, and mechanical properties test, the time parameters of excessive treatment, lack of treatment, and proper treatment were selected, and the effects of UIT, excessive treatment, lack of treatment, and proper treatment on fatigue strength were analyzed. Test results show that, the mechanical properties of welded joints after UIT are improved. The proper treatment time is 15min and its fatigue strength is 37.86MPa, respectively under the stress ratio of 0.1. Compared to the original welding condition with a fatigue strength of 28.61MPa, the fatigue strength of the welded joints of 7A52 aluminum alloy increased by 32.33%. The largest percentage of grain size reduction occurs when the UIT is 15 min. Moreover, excessive treatment and lack of treatment will not further re ne the grains and optimize the mechanical properties.

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Metallurgical Characterization of Penetration Shape Change in Workpiece Vibration-Assisted Tandem-Pulsed Gas Metal Arc Welding

Cited by 12 publications

References 28 publications

Effect of Ultrasonic Vibration in Friction Stir Welding of 2219 Aluminum Alloy: An Effective Model for Predicting Weld Strength

Effect of Ultrasonic Vibration in Friction Stir Welding of 2219 Aluminum Alloy: An Effective Model for Predicting Weld Strength

Vibration-Assisted Welding of 42CrMo4 Steel: Optimizing Parameters for Improved Properties and Weldability

Effect of ultrasonic impact time on microstructure and properties of 7A52 aluminum alloy tandem MIG welded joint

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