Synthesis and generalisation of welding fundamentals to design new welding technologies: Status, challenges and a promising approach

Abstract

The present paper addresses the renewed need to focus on the physics of welding to realise the full potential of the latest welding technologies which include fibre and disc lasers, friction stir welding and inverter power supplies. The approach to understanding, synthesis and generalisation in other engineering branches is reviewed, highlighting the central role of handbook type solution in the conceptual design stage. It is shown that the multiphysics and multicoupled aspects of welding exceed the capabilities of other engineering approaches and the methodology of scaling is proposed as a promising alternative. The application of scaling to friction stir welding is shown through an example in which the maximum temperature in the metal is generalised into a power law, experimental and numerical data are synthesised into a general correction factor, and secondary effects are captured as dimensionless groups.

Decisive impact of Filler-free joining processes on the Microstructural evolution, tensile and impact properties of 9Cr-1Mo-V-Nb to 316 L(N) dissimilar joints

“…57 Based upon the tool speed condition, the shear layer thicknesses of dissimilar materials were selected in the range between 0.2–0.4, and the uniform shear layer thickness (δ eff ) is fixed as 0.1. 58,59 By using equations (4) and (5), the mixing ratio in the stir zone is estimated to be 0.4836:0.5164 of α and ϒ.…”

Calibrated expressions for welding and their application to isotherm width in a thick plate

“…These advancements mean that welders can now make use of plasma arcs, lasers, electron beams, explosives, and mechanical devices to join metals at the atomic level [2]. Despite the enormous progress in the last 30 years, there is a distinct lack of insightful, quantitative, physically relevant guidelines for welding problems [2]. For the most part, an empirical trial and error approach has been used in industry to solve complex welding problems.…”

1000 gems: Celebration of STWJ

“…Just imagine the contributions made by the elegant heat flow solutions that Rosenthal developed so many years ago and which still form the basis of many simplified models. It is in this light that the suggestion by Mendez 19 and others, 20,21 that handbook type analytical methods which capture the essence of the problem, should be developed for processes such as friction stir welding. We would like to encourage more work in this area, because by definition, large, computer intensive methods are not suited to back of the envelope estimates.…”