Showing 121 results for Welding
A. Hajitabar, H. Naffakh-Moosavy,
Volume 4, Issue 2 (1-2019)
Abstract
The effect of electron beam welding current changes on the microstructure and mechanical properties of the Nb-based alloy has been investigated. The electron beam welding was applied with 4 different currents of 20, 24, 30 and 35 mA on 3mm thick plates. The aspects including different welding regions, geometry and depth of welding penetration, as well as the effect of heat input on the weldability are investigated. The mechanical properties including tensile and microhardness values of the weld was also measured. The results show that in a sample with a 30 mA welding current, the optimum conditions for the depth of penetration, weldability and the geometry of the weld are obtained. The welds showed a cellular structure, and intercellular dendrites in the central region of the weld have been caused due to microsegregations created between the cells. In HAZ, severe recrystallization and grain growth has occurred. Because of the high thermal conductivity of niobium, the HAZ size is relatively large. Based on the 3D Rosenthal’s equation, the recrystallization temperature of alloy was calculated as 713 °C. It is observed that as G × R increases, the grain size in the central line of the weld decreases. The hardness profile shows that the hardness of the weld zone and the HAZ is significantly less than that of the base metal due to elimination of work hardening effect. The tensile strength of the weld for a sample with a current of 30 mA was 281MPa, which is 53% of the tensile strength of the base metal and the weld was broken from the HAZ.
I. Khodai Delouei, H. Sabet , V. Abouei Mehrizi,
Volume 4, Issue 2 (1-2019)
Abstract
Friction Stir Welding is one of the solid-state processes and today it has been used to join different types of materials. Friction stir welding does not have many problems and limitations due to melting and solidification of weld metal and by controlling its variables, the microstructure and desired mechanical properties can be achieved at the joint. Recently, in most industrial areas, due to its lightness and energy saving, much attention has been paid to the joining of aluminum alloys. The present study investigates the microstructure and evaluation of mechanical properties of friction stir welding in AA2024 and AA6061butt welds. A cylindrical threaded tool was used to join 5 mm thick plates at rotational speeds of 800, 1000 and 1200 rpm and traverse speeds of 30, 50, 70, 90 and 110 mm / min. In order to perform the necessary investigations, metallurgical observations were performed by optical microscope and scanning electron microscope equipped with a chemical analysis system of the elements, as well as mechanical tests of tensile strength and micro hardness. The results showed that the difference between the two alloys causes hardness variations in the nugget zone and a large hardness drop at the transition between the zone composed of both alloys and the 6061 zone. By increasing the traverse speed from 30 to 110 mm / min at constant rotational speeds of 800, 1000 and 1200 rpm, due to reduced input heat, the grain size decreases and the hardness and strength increase. Also, the highest tensile strengths and hardness were 221.6 Mpa and 111.05 Vickers, respectively, for a sample welded at a rotational speed of 1000 rpm and a traverse speed of 110 mm / min.
M.saleh Shaikh Meiabadi, A. Kazerooni, M. Moradi,
Volume 4, Issue 2 (1-2019)
Abstract
Laser welding is a novel method for direct joining of metals and polymers, which leads to a mechanical and chemical bond between metal and polymer. In this study, feasibility of dissimilar joining between St12 and polycarbonate is studied theoretically. Then, the ND: YAG laser is implemented to join St12 and Polycarbonate. Empirical results indicate creation of a joint between St12 and polycarbonate. In order to conduct thermomechanical analysis of the welding process, the finite element model has been developed by Abaqus software. In addition, the cylindrical-involution-normal (CIN) heat source model was used to describe the laser power distribution and FORTRAN software has been used to define the thermal model in welding simulation. Comparison of experimental and simulation results shows that the finite element model is capable of predicting weld width, and therefore the results of the finite element model are verified. Therefore, the finite element model is used to predict residual stresses. The results disclose that dissimilar bonding creates residual tension stresses on the metal surface and compressive residual stresses on the polymer surface.
B. Safarbali, M. Shamanian, A. Eslami,
Volume 5, Issue 1 (9-2019)
Abstract
In present study, the effect of heat treatment after friction stir welding dissimilar welds T6-7075 and T4-2024 aluminum alloys were investigated. Friction stir welding was performed at a constant rotation speed of 1140 rpm and welding speed 32 mm/min. After welding samples are taken under various heat treatment processes at different aging temperature and time period. Microstructural observations, phase analysis characterization and mechanical properties were performed on welded before and after heat treatment in cross section of welds joint. The results showed that post-weld heat treatment causes abnormal grain growth turns destructive effect on the mechanical properties, while formation of fine and uniform precipitation recovery strength and ductility of welds joints. It is found heat treatment based on T6-7075 and T6-2024 procedure has highest and lowest impact on the restore of weld strength. Tensile test indicate that fracture occurred on the interface between TMAZ and HAZ in retreating side (7075) at as-weld joint, if that failure happens in the stir zone by applying PWHT. Surface fracture suggested fractures in PWHT samples are predominantly inter-granular, while in as-weld joint the fractures of joints are mostly trans-granular.
M. Abasi Baharanchi , S. B. Askari,
Volume 5, Issue 1 (9-2019)
Abstract
In the present Study, a dissimilar joint of carbon steel sheet EN 10025 with 316 L has been welded by FSW and the welding parameters were optimized by RSM software method. For investigation of mechanical properties and microstructural analysis carried out by using optical, scanning electron microscopes with EDS analysis, tensile and hardness test of different area of joints, SZ, TMAZ, HAZ, their interfaces and Base metal. The optimized result were shown that best of joints within maximum strength (UTS) 312 MPa by rotational speed 950 rpm, transverse speed 90 mm/min and tool angle 3° was achieved. The failures were happened at base metal of EN 10025 to advancing side. Metallographic results were shown that grain size at SZ is 10 to 20 time more reduced caused improved of mechanical properties. Also chemical analysis and hardness result on welded samples by optimized parameters were shown that quite good mixing was happened at SZ.
A. Abdollahzadeh, A. Shokuhfar,
Volume 5, Issue 1 (9-2019)
Abstract
In this study, friction stir butt welding of Mg and Al alloys with applying Zn interlayer was performed. To obtain optimum condition, a combination of two travel and three rotation speeds were selected. Mg-Zn and Mg-Al-Zn IMCs, Al solid solution and residual Zn, were the most common phases in the stirred zone, which eliminated the formation of Al-Mg intermetallics. The maximum mechanical properties were achieved for the joint fabricated at 35 mm/min and 600 rpm, caused to 24% improvement in tensile strength and around 3 times enhancement of elongation compared with Zn free sample FSWed at the same conditions. The fracture micrographs were consistent with corresponding ductility results. Fracture surfaces of Zn-added samples presented a fine texture with a mixture of brittle and ductile fracture feature, which was different from the coarse cleavage plane and fully brittle fracture of the joint without Zn interlayer.
J. M. Milani, T. Saeid,
Volume 5, Issue 1 (9-2019)
Abstract
In the present study, effect of inclusions characteristics changing on the formation of acicular ferrite in submerged arc welding of API5l-X65 low alloy steel was investigated. Three different welding fluxes with different chemical composition and basicity index of 0.72, 0.82 and 0.99, and two different welding heat inputs of 1.6 kJ / mm and 2.4 kJ / mm were used to create inclusions with different characteristics such as chemical composition and size. The results indicate that inclusions acting as acicular ferrite nucleation sites and improvement of the microstructure and resulted mechanical properties, can be observed in welding conditions in which the welding flux with lowest basicity index and higher welding heat input. Under these conditions, the percentage of inclusions with a high titanium oxide value and size range of 0.5 to 1.5 micrometers is increased, which increases the amount of acicular ferrite in the microstructure. However, in other welding conditions, formation of grain boundary ferrite reduces amount of acicular ferrite and weakens mechanical properties of weld metal compared to the base metal.
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Volume 5, Issue 1 (9-2019)
Abstract
In this paper experimentally, the friction-stir welding of the polypropylene sheets with 40% glass fiber has been investigated. Comparison to other welding methods, the strength of the joint is the most important feature in this process. Many parameters such as tool geometry, rotational speed, linear velocity, and tilt angle are very important as input parameters in this type of welding. Therefore, in the present study, the effect of these parameters on the friction-stir welding of the polypropylene composite sheets have been extracted. Experiments are based on the Taguchi method and the orthogonal L9 array that are suitable for three-level designs. Statistical analysis have been performed as variance (ANOVA) and signal-to-noise ratio. Based on the results, the tool with a screw cone-cylindrical pin has a better apparent quality and higher tensile-shear strength. Results analyze show the rotational speed has the most significant effect on the tensile-shear strength and appearance of the weld. The joint with maximum tensile strength is obtained at rotational speed of 1000 rev/min, welding speed of 20 mm/min and tilt angle of 1 degree.
R. Narimani, M. Eliasi, M. Hosseinzadeh, H. Aghajani Derazkola,
Volume 5, Issue 1 (9-2019)
Abstract
Dissimilar joint with good quality and mechanical properties is one of the major problems the industries. One of the most commonly used methods to solve this problem is friction stir welding process. In this paper two different tool pin with simple cylindrical and screwed profile were used to finding optimization of friction stir welding parameters to reach best mixing flow, composite structure and maximum tensile strength in dissimilar joint between AA6065 aluminum alloy and pure copper. In this research 1130 rpm tool rotation, 24, 40 and 65 mm/min travelling speed, 0.3 mm plunge depth and 3o tool tilt angle were carried out. The results shows that internal material flow that produced with screw pin was better than simple cylindrical in constant process parameters. According to the results, at lower tool travelling speed the strength of joint increases. The tensile test results revealed the maximum strength of joint of screw pin was 345MPa with 2.6mm elongation and simple cylindrical pin was 272MPa with 2.2mm elongation which welded with 1130 rpm and 24 mm/min travelling speed.
R. Tamasgavabari, A. Ebrahimi, S. M. Abbasi, A. Yazdipour ,
Volume 5, Issue 1 (9-2019)
Abstract
In this research, the effect of vibration at the resonant range (75 Hz) on the hardness and tensile strength of AA-5083-H321 aluminum alloy, were welded by gas metal arc welding (GMAW) investigated. Vibration forces were ranged from 850 N to 2200 N, under identical welding parameters. Tensile strength and hardness testing of welded samples were performed. After mechanical tests, the fracture surfaces of welds were examined using scanning electron microscope (SEM) and discussed. The results showed that with increasing vibration force, the tensile strength and fracture strength of the specimens were welded during vibration, were increased by about 3 and 9 percent, respectively, compared to the non-vibrated weld sample. However, no significant change was observed in the hardness of the welded specimens. Mean grains size and heat affected zone of the sample was welded was welded with conventional GMAW, were about 200 μm and 1800 μm, but due to inducing vibration, as vibration force increased from 850 N to N 2200 N, Mean grains size was reduced to about 75 μm and HAZ was reduced from about 1000 μm to 700 μm, that is, about 44 to 61%.
N. Marchin, A.r. Soltanipoor, K. Farmanesh,
Volume 5, Issue 2 (1-2020)
Abstract
In this study, the effect of tool's advance velocity on the mechanical behavior of the Al-7075 alloy during friction stir welding was simulated. In this simulation, the Lagrangian method with rigid-Visco-plastic material was used. The results of the process temperature obtained by the simulation method were verified by the experimental welding test. Using the characteristic stress, strain and temperature relationships in the Al-7075 alloy, the changes and the relationship between the material strength during the welding process by simulation was studied. The generated simulation defects was verified by experimental test.
S. Emami, T. Saeid,
Volume 5, Issue 2 (1-2020)
Abstract
Friction stir welding (FSW) was conducted on AISI 304 austenitic stainless steel plate with 2 mm thickness. The FSW was performed at a welding and rotational speeds of 50 mm/min and 400 rpm, respectively. Microstructure observations by the optical microscopy showed that a severe grain refinement occurred in the stir zone (SZ). Electron backscattered diffraction analysis (EBSD) results indicated that high fraction of low angle grain boundaries (LAGBs) developed in the thermo-mechanically affected zone (TMAZ) through the occurrence of the dynamic recovery. Moreover, in the path from the TMAZ towards the SZ, the fraction of high angle grain boundaries (HAGBs) increased with decreasing the fraction of LAGBs through the occurrence of continuous dynamic recrystallization (CDRX). 100 Pole figure showed the formation of shear texture components of A*1 and A*2 in the SZ which implied the occurrence of CDRX mechanism.
S. Shadkam, E. Ranjbar Nodeh, M. Iranmanesh,
Volume 5, Issue 2 (1-2020)
Abstract
Increasingly, Welding is used in industry for assembled various products, such as ships, cars, trains and bridges. Welding distortion often results such as lack of accuracy during assembly and will have increases manufacturing costs. So, predict and reduce welding distortion is very important to improve the quality of welded structures. In this study, firstly, a prediction method of welding distortion, which merges thermo-elastic-plastic finite element method (FEM) and large deformation elastic FEM based on inherent strain theory, was developed. Secondly, the inherent deformations of weld joints in a large thin plate panel structure were calculated using the thermo-elastic-plastic FEM and their specifications were also examined. Then, using the obtained inherent deformations, the usefulness of the proposed elastic FEM was demonstrated through the prediction of welding distortion in the large thin plate panel structures. Finally, the influences of welding sequence on distortion were investigated. The results of elastic analysis shows distortion in edges and interior parts of the panels, that can be reduced by changing welding sequence to symmetrical welding sequence.
N. Habibi, H. Eskandari,
Volume 5, Issue 2 (1-2020)
Abstract
Welded tubular joints are widely used in various industry structures for high efficiency subjected to pressure, bending and twisting.Welded structures are the main parts of structures, buildings, bridges, gas pipes, pressure vessels and power transmission equipment in the ship building, construction, oil, gas, petrochemical industries and power plants.A sample of pipe-welded joints is a X-tubular joint that has been investigated in this study.The main objective of the present work is to investigate the heat transfer and residual stress caused by the three-stage welding process in X-tubular joint made of St52 using Simufact Welding software.The welding process involves three welding steps using arc welding. The finite element model contains the thermal and mechanical properties of base metal and welding metal as a function of temperature.Also, advanced modeling tools such as mesh adaptation during the process and meshing compatible with the welding site, the birth and death technique of the element and the source of heat transfer have been used.Welding simulation showed that significant residual stresses were created in the joint after welding. Comparison of the results shows that the numerical results and empirical measurements are in good agreement with each other and the existing model can provide a good prediction of temperature distribution and stress control in this welding process.
M. Chiani, M. Atapour,
Volume 5, Issue 2 (1-2020)
Abstract
In this study, corrosion behavior of Ti-6Al-4V titanium alloy joint by friction stir welding with a rotational speed of 375 rpm and a travel speed of 100 mm/min was investigated. The welding procedure was carried out under β-transus temperature that was consisted of equiaxed grains in the stir zone. The corrosion behavior of the welded joint was investigated in 3.5% NaCl solution at temperatures of 25, 37 and 80 . Microstructure investigation of sample surfaces after electrochemical experiments was conducted using SEM. results revealed that the β phase was mainly corroded at all three testing temperatures, however the corrosion in the sample tested at 80 °C was more considerable.
S. Asadi, T. Saeid, A. Valanezhad, J. Khalil Allafi,
Volume 5, Issue 2 (1-2020)
Abstract
In this research, dissimilar welding of NiTi shape memory alloy to AISI 304 austenitic stainless steel Archwires was investigated. For this purpose, common straight orthodontic archwire with rectangular cross-section and dimensions of (0.635 × 0.432 mm) were selected and the laser welding technique was used to connect the wires. The microstructure, chemical composition and phasesin the weld zone of the joints werestudied with Optical microscopy (OM), Scanning electron microscopy (SEM) equipped with EDS analysis system, focused X-ray diffraction (Micro-XRD).Also, the mechanical properties of the weld zone were investigated by using Vickers microhardness test. Microstructure investigation showed that the obtained microstructure from the laser weld of these alloys has a dendritic and non-homogeneous structure. According to XRD analysis, brittle intermetallic compounds such as Fe2Ti, Cr2Ti, TiNi3, and Ti2Ni wereformed during laser welding in the weld zone. Formation of these brittle intermetallics caused increasing the hardness of the weld zoneabout 800 HV. and decreasing the mechanical properties. Also, Fe2Ti intermetallic particles mainly formed in the weld region near the NiTi fusion zone which results in stress concentration, micro-cracks formation and dropping joints mechanical properties. Therefore, a suitable modification process is required to control the chemical composition of the weld zone and improving the joint properties of dissimilar laser welded archwires of these alloys.
M. Sabokrouh ,
Volume 5, Issue 2 (1-2020)
Abstract
In this article the effects of carburizing heat treatment on girth weld with containing titanium oxide and titanium carbide nanoparticles (X-65 grade of gas pipeline) is evaluated. The charpy results show that in the carburized sample containing titanium oxide and titanium carbide nanoparticles compared to the no heat treatment sample (containing titanium carbide and titanium carbide nanoparticles), has been respectively increased by 6% and 42%. Also, the ultimate strength carburized sample containing titanium oxide nanoparticles and titanium carbide nanoparticles compared to the no heat treatment sample (containing titanium oxide and titanium carbide nanoparticles) has been respectively increased by 20% and 28%. The results show that the fatigue life in both carburized nano-alloy samples has been increased. The fatigue life in the carburized sample of titanium carbide nanoparticles has increased more than that of titanium oxide nanoparticles. The fatigue test results show that in the carburized sample containing titanium carbide nanoparticles compared to the tempered sample containing titanium oxide nanoparticles, fatigue life (150-N force) has been increased by 20%. In this loading the fatigue life (tempered sample containing titanium carbide nanoparticles compared to the no heat treatment sample) has been increased by 31%. The results show that the residual stress in both carburized nano-alloy samples has been decreased The hole drilling strain gage results show that in the tempered sample containing titanium oxide oxide nanoparticles and titanium carbide nanoparticles compared to the no heat treatment sample (containing titanium oxide nanoparticles and titanium carbide nanoparticles), hoop residual stresses has been respectively decreased by 9% and 6%.
M. Belbasi, M. Rezae,
Volume 5, Issue 2 (1-2020)
Abstract
Today in addition to Join by friction stir welding, the composite fabrication process is also performed simultaneously. The main purpose of the present research is to investigate the effect of pin geometry on the property of Aluminum 6061- alumina nanocomposite created by friction stir welding. For this purpose friction stir welding was carried out by selecting five types of pin geometries on Aluminum 6061 in which Al2O3 particles were deposited and the samples were examined by tensile and hardness tests, optical and electron microscope. Samples were investigated by tensile and hardness test, optical and electronic microscopy. Regular hexagonal pins due to having six smooth face and impulsive movement during rotation, caused a good perturbation which resulted in maximum tensile strength and elongation percentage of 198 MPa and 10.25 and minimum grain size of 13.3 micron, respectively. In the sample welded by a threaded cylindrical pin due to non-impact during rotation, inappropriate flow of reinforcing particles and its accumulation at perturbation the lowest tensile strength and elongation percentage of 133.5 MPa and 1.95%, respectively, were observed.
Ramin Delir Nazarlou, Dr Faraz Omidbakhsh, Dr Javad Mollaei Milani,
Volume 6, Issue 1 (8-2020)
Abstract
Friction stir welding (FSW) is an economic and high quality technique at aluminum welding and joining methods. The most important factor in the soundness of this type of welding, is the mechanism of material transfer in each tool rotation. The materials transfer during the welding process involves horizontal and vertical movement that caused by extrusion process and forging force (the tilt angle due to forging force and on the other hand, shape of pin due to the extrusion process). One of the most important parameters in FSW process is the effect of rotational speed in the welded zone. In this study, the effect of rotational speed at constant welding speed, in the butt joint of pure commercial aluminum, was investigated. The results of the study showed that, increasing the rotational speed due to increases the amount of material transfer in the weld zone. The welded zone was investigated by appearance weld zone experiments and using radiography tests. Also weld zone was investigated in macro and microstructure by using cross section. Then the micro hardness testing has been used by cross section at welded zone. In order to investigate the mechanism of materials transfer during the process, the electrical resistivity test has been used to analyses the amount of materials transfer in the weld zone. Results shows that, increasing rotational speed due to increasing the amount of materials transfer in the weld zone and decreasing the amount of defects in the weld zone.
M. Hajizadeh, S. Emami, T. Saeid,
Volume 6, Issue 1 (8-2020)
Abstract
Friction stir welding was conducted on AISI 304 austenitic stainless steel sheet with dimensions of
100 mm × 100 mm × 2 mm. The FSW was performed at a welding speed of 150 mm/min and rotational speeds of 400 and 800 rpm. The results showed that high frequency of low angle grain boundaries (LAGBs) were formed through dynamic recovery in the thermo-mechanically affected zone (TMAZ). Higher amount of LAGBs were developed in the TMAZ of welded sample with 800 rpm due to the higher amount of strain and heat generated. High fraction of high angle grain boundaries were formed in the stir zone (SZ) of the welded samples through the occurrence of continuous dynamic recrystallization (CDRX). A very fine microstructure developed in the sampled welded with lower rotational speed. Analysis of texture using {111} Pole figures showed the formation of shear texture components in the SZ of both welded samples. The intensity of the obtained texture for the sample welded with 800 rpm was greater. The formation of shear texture components in the SZ of both samples implied the occurrence of CDRX mechanism
