Sharif Digital Repository

A 2-D numerical model was developed to predict the shape of weld pool in stationary GTA welding of commercial pure aluminium, without considering fluid flow in the weld pool. A Gaussian current density and heat input distribution on the surface of the workpiece were considered. The parameters of Gaussian distribution were modified by comparing calculated results with experimental ones. It was found that these distribution parameters are functions of applied current and arc length. Effects of arc length, applied current and welding time on the geometry of the weld pool were investigated. To check the validity of the model, a series of experiments were also conducted. In general, the agreement... 

In this work, a three-dimensional model has been proposed to predict temperature distribution and weld-pool shape during dissimilar arc welding of low-carbon steel (CK4) and ferritic stainless steel (AISI 409). The model has been developed using the finite-element software ANSYS, while in the analysis, the effects of process parameters, as well as dilution, in the weld pool have been considered. To verify the predictions, welding experiments were conducted under different welding conditions, and the model results were then compared with the measured weld-pool geometry; a reasonable consistency was observed  

In this study, a three-dimensional model has been utilized for predicting thermal responses during tungsten arc welding of AA2024-T4 plates in which double ellipsoidal heat source model was employed to consider the moving torch in the model. Furthermore, tensile and hardness tests and microstructural evaluations have been carried out to investigate the mechanical properties and the microstructures within the welded metal. The results show that there is a region inside the heat-affected zone where hardness increases while in some parts of this region having temperatures higher than 250 C the hardness decreases significantly. Furthermore, natural aging occurs after welding; however, its... 

In the present research, different weld layers were deposited on a 1.2714 steel die by gas tungsten arc (GTA) welding with the weld wire of Udimet 520, and effects of welding parameters on microstructure and mechanical properties of Udimet 520 superalloy were investigated. The results showed Udimet 520 weld with cellular-dendritic and rarely dendritic structure including γ matrix rich of Cr, Mo and W, low percentage associated with order morphology and relative uniform distribution of MC type carbides. Udimet 520 alloy showed high resistance against hot cracking during welding and hot cracking occurred only at high input heat values. Also, cracking during welding occurred at the places that... 

In the welding process, droplet detachment regularity is important for a good welding quality. The frequency of detachment is one of influential indices for assessing the quality of GMAW in the globular transfer mode. In this paper, a relationship is estimated for measuring droplet detachment frequency in the globular GMAW. The droplet detachment frequency is estimated with a curve fitting by the least squares error (LSE) method. By using short time frequency transform (STFT) we can extract the frequency contents from the mass of drop that is one of the states in the welding model  

An adaptive extended Kalman filter is designed to estimate the arc length in a gas metal arc welding system. The simulation results show that the estimated variables track the true variables of the non-linear model with negligible error and are robust against parameters uncertainties. The proposed estimator also operates adequately in a highly noisy welding environment. Because of the low computational requirements and little lag produced in the process dynamic, use of the proposed estimator would be valuable in the design of a controller for the gas metal arc welding system  

In this study, the effect of electromagnetic vibration on joining of aluminum alloy 2024 was investigated. Simultaneously applying a static magnetic field and alternating electrical current passing through a conductor produced electromagnetic vibration. Joining was accomplished using constant electric current (60 A) and the magnetic flux of 75, 110, and 145 mT in the presence of argon gas. After joining, samples were cooled first by argon gas as a shielding gas and then by water. The microstructure and mechanical properties of the welded samples were studied for different electromagnetic vibrations. The optimum microstructure and mechanical properties were obtained when applied... 

Gas metal arc welding (GMAW) process was used to weld plates of strain-hardened Al-6.7Mg alloy. It was observed that HAZ softening issue occurred extensively for the current material using the GMAW process. So, as a solution, pulsed current was employed and the plates were welded by pulsed GMAW (PGMAW) process. The effects of peak current (93, 120, 140, and 160 A) and pulse frequency (0.5, 2.0, and 5.0 Hz) on the strength of the weldments were investigated. For high peak currents (160 A), catastrophic defects were formed in the weld metal. It was observed that for the lowest pulse frequency (0.5 Hz), increasing the peak current increased the weld strength. The peak current did not change the... 

Since the mechanical properties and the integrity of the weld metal depend on the solidification behaviour and the resulting microstructural characteristics, understanding weld pool solidification is of importance to engineers and scientists. Thermal and fluid flow conditions affect the weld pool geometry and solidification parameters. During solidification of the weld pool, a columnar grain structure develops in the weld metal. Prediction of the formation of the microstructure during welding may be an important and supporting factor for technology optimization. Nowadays, increasing computing power allows direct simulations of the dendritic and cell morphology of columnar grains in the... 

Al-Mg aluminum alloy was lap joined to aluminum clad steel sheet using pulsed gas tungsten arc welding process and Al-Si filler metal. The effects of the welding heat-input were investigated on the joint microstructure and mechanical properties. Weld metal microstructure, formation of intermetallic compounds (IMCs) at the joint interface and the fracture locations were studied using stereo, optical and scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS). The joint strength of the welds was evaluated by shear-tensile test. The results showed that presence of a thin aluminum clad layer with 350 μm thickness drastically decreased the Al-Fe intermetallic... 

In the present study, the temperature and the velocity fields during gas tungsten arc welding of commercial pure aluminum were simulated using the solution of the equations of conversation of mass, energy and momentum in three dimensions and under steady-state heat transfer and fluid flow conditions. Then, by means of the prediction of temperature and velocity distributions, the weld pool geometry, weld thermal cycles and various solidification parameters were calculated. To verify the modeling results, welding experiments were conducted on two samples with different thicknesses and the geometry of the weld pool was measured. It is found that there is a good agreement between the predicted... 

A mathematical model is developed to assess the solidification behaviour of the weld pools. To do so, during gas tungsten arc welding of commercial pure aluminium, equations of conversation of mass, energy and momentum are numerically solved considering three-dimensional steady state heat transfer and fluid flow conditions. The weld pool geometry, weld thermal cycles and various solidification parameters are calculated using temperature and velocity fields acquiring from the utilised model. The solidification behaviour of the weld pool at the weld centreline and the fusion line is then studied using the solidification parameters including temperature gradient G, solidification rate R and the...