Sharif Digital Repository

Joining in the semisolid state is considered a possible method to join alloys to each other. The mechanisms taking part in semisolid stir welding of AZ91 alloys were investigated. Two 7.5 mm-thick AZ91 pieces and a 2 mm-thick Mg-25%Zn interlayer piece were placed in a heating plate. After holding for 3 min at a desired temperature, the weld seam was stirred by a rotational tool. The heating plate was travelled on a trolley at a constant speed of 4.6 cm/min. In addition, one sample was welded without interlayer. Evolution of welding as a function of stirring rate, tool shape and temperature was studied throughout this welding process with scanning electron and optical microscopes. Interlayer... 

In this paper, we present a method to dynamically observe two important variables of a Gas Metal Arc Welding (GMAW) process, i.e. arc voltage and arc length. To do this, we use Kalman filter to estimate these two variables in a high level noisy environment of GMAW process both in open and closed loop modes  

The heat affected zone (HAZ) softening behavior of strain-hardened Al-6.7Mg alloy welded by gas tungsten arc welding (GTAW) process was investigated. Increasing the heat input during welding led to formation of a wider HAZ. Moreover, the size of the precipitates was increased at higher heat inputs. Consequently, by increasing the heat input, lower strength was obtained for the welding joints. At the second stage of the study, pulsed-GTAW (PGTAW) process was employed to improve the strength of the joints. It was observed that the overall strength of the welding joints was improved and the fracture during tensile test was moved from the HAZ to the fusion zone. Moreover, the effect of duration... 

Highly cold worked (HCW) low carbon steel sheets with cellular structure in the range of 200 to 300 nm are fabricated via constrained groove pressing process. Joining of the sheets is carried out by resistance spot welding process at different welding currents and times. Thereafter, failure behavior of these welded samples during tensile-shear test is investigated. Considered concepts include; failure load, fusion zone size, failure mode, ultimate shear stress, failure absorbed energy, and fracture surface. The results show that HCW low carbon steel spot welds have higher failure peak load with respect to the as-received one at different welding currents and times. Also, current limits for... 

A predictive functional controller based on ARMarkov model structure has been designed to control welding current and arc voltage in a GMAW process. The closed loop system performance is investigated through computer simulations and is compared by those achieved from implementing two commonly used controllers i.e. PI and feedback linearization based PID. The local stability of the closed loop system is analyzed in the presence of uncertainties in the linearized model of the process as well as the control parameters. Finally it is shown that the proposed controller performs like a PI controller along with a pre-filter compensator  

Effects of welding current (at the range of 2-4 kA) on the microstructure and mechanical properties of upset resistance welds of AISI-1035 carbon steel to AISI-304L austenitic stainless steel rods were investigated. The results showed that the joint strength first increased by raising the welding current up to 3 kA and then decreased beyond it. Increasing trend was related to more plastic deformation, accelerated diffusion, reduction of defects and formation of mechanical locks at the joint interface. For currents more than 3 kA, decrease in the joint strength was mainly caused by formation of hot spots. Using the optimum welding current of 3 kA, tensile strength of the joint reached to ~76%... 

A new refill friction spot welding process called Threaded Hole Friction Spot Welding (THFSW) was introduced to join AA5052 aluminum to short-carbon-fiber-reinforced polypropylene (PP-SCF) composite sheets. The process was based on filling of the pre-threaded hole by melted and re-solidified polymer. The results showed that THFSW was successful to join aluminum to polymer sheets and the hole was completely filled with melted polymer. Formation of a reaction layer composed mostly of Al, C and O as well as interlocking between the threaded hole and the re-solidified polymer were recognized as main bonding mechanisms. Maximum shear-tensile strength of the joints reached to ∼80 percent of the... 

This paper aims at understanding the role of liquation and solidification phenomena on the tensile properties of arc welded cast AZ91 magnesium alloy. Owing to its refined microstructure, the fusion zone exhibited improved ductility/strength compared to the base metal. It is demonstrated that the partially melted zone (PMZ) which is characterised by constitutional liquation of eutectic β-Mg17Al12 phase is the weakest link in the weldment. The reduced strength and ductility associated with the liquation phenomena are due to the increased volume fraction and thickness of the eutectic β-Mg17Al12 in the PMZ as well as the formation of liquation micro-cracks in a network of brittle intermetallic... 

Wrought aluminum sheets with thickness of 13. mm were square butt-welded by friction stir welding (FSW) and gas tungsten arc welding (GTAW) methods. Corrosion behavior of the welding zone was probed by Tafel polarization curve. Optical metallography (OM) and scanning electron microscopy together with energy dispersive spectroscopy (SEM-EDS) were used to determine morphology and semi-quantitative analysis of the welded zone. FSW resulted in equiaxed grains of about 1-2 μm, while GTAW caused dendritic structure of the welded region. Resistance to corrosion was greater for the FSW grains than the GTAW structure. In both cases, susceptibility to corrosion attack was greater in the welded region... 

Constrained groove pressing as a severe plastic deformation method is utilized to produce ultra-fine grained low carbon steel sheets. The ultra-fine grained sheets are joined via resistance spot welding process and the characteristics of spot welds are investigated. Resistance spot welding process is optimized for welding of the sheets with different severe deformations and their results are compared with those of as-received samples. The effects of failure mode and expulsion on the performance of ultra-fine grained sheet spot welds have been investigated in the present paper and the welding current and time of resistance spot welding process according to these subjects are optimized.... 

This study concentrates on the effects of weld sequence and welding fixtures on distribution and magnitude of induced arc welding residual stresses built up in butt-joint of Gas Tungsten Arc Welding (GTAW) AA5251 plates. Aluminum plates have been welded under different welding conditions and then, longitudinal and transverse residual stresses were measured in different points of the welded plates employing hole-drilling technique. The results indicate that welding sequence significantly alters the distributions of both longitudinal and transverse residual stresses while the changing in the weld sequence leads to 44% decrease in longitudinal residual stress. Besides, both the geometry of weld... 

In this paper, a thermo-mechanical model has been used to predict the temperature history and residual stress distribution in gas tungsten arc welding of AA5251 plates. This model has also been utilized to estimate the residual stresses under different welding sequences, while in the model the effect of temperature on material properties were taken into account. In order to verify the predictions, residual stresses within the welded samples and weld pool geometry were experimentally measured employing hole drilling and macro-examination of weld cross-section, respectively. The comparison between numerical and experimental data shows a reasonable agreement. The predictions show that the... 

The welding of nanostructured low carbon steel sheets produced by severe plastic deformation (SPD) has been considered in the present paper. Constrained groove pressing (CGP) method is used for imposing the severe plastic deformation to the steel sheets as a large pre-strain. The SPDed sheets are joined using resistance spot welding (RSW) process. The results show that severe plastic deformation can effectively increase the electrical resistivity of steel sheets; therefore it can affect the microstructure and mechanical properties of spot welds. Microstructure and mechanical properties of fusion zone, heat affected zone (HAZ), recrystallized zone and base metal of SPDed sheets are... 

The purpose of this work is to assess the effect of welding fixtures on distributions and values of residual stresses during Gas Tungsten Arc Welding (GTAW). The butt-joint GTAW of AA5251 plate is investigated using a transient thermo-mechanical analysis performed by the finite element program, ABAQUS. The model considers two different welding conditions including unconstrained and perfectly constrained conditions while macro examination and residual stress measurements by implementing hole drilling techniques are utilized to evaluate the predictions. The results show that the utilizing of a welding fixture alters the temperature field within the plate being welded and the depth of the weld... 

Joining of commercially pure Ti to 304 stainless steel by fusion welding processes possesses problems due to the formation of brittle intermetallic compounds in the weld metal, which degrade the mechanical properties of the joints. Solid-state welding processes are contemplated to overcome these problems. However, intermetallic compounds are likely to form even in Ti-SS joints produced with solid-state welding processes such as friction welding process. Therefore, interlayers are employed to prevent the direct contact between two base metals and thereby mainly to suppress the formation of brittle Ti-Fe intermetallic compounds. In the present study, friction-welded joints between commercially... 

Microstructure and mechanical properties development of X80 weld metal by addition of different amounts of alloying elements such as Nickel and Manganese to the covering of electrodes were investigated. For this reason samples were welded with electrodes that Ni value changed between 0.8%- 3.5% in tow critical amounts of Mn: 0.7 and 1.6. Tensile test and microhardness results indicated the suitable ranges of Ni and Mn for acceptable mechanical properties. In addition, optical microscopy and scanning electron microscopy were applied to link the microstructure with mechanical properties. The hardness of weld metals were found to increase linearly with Mn and Ni, which was attributed mainly to... 

A three-dimensional model is utilized to predict temperature distribution and fluid flow during the process of gas tungsten arc welding (GTAW). In order to evaluate the effect of the heat flux model on the accuracy of predictions, two types of heat sources - with different natures based on Gaussian surface heat flux and volumetric Goldak's double-ellipsoid heat flux distributions - are taken into account. These heat flux schemes are input into a model simulation of GTAW of AA1050. In the next stage, the transient temperature distribution within the metal being welded is predicted for each heat flux model using FLUENT computational fluid dynamics software. The fusion and heat-affected zones... 

In the present research, weld pool geometry, thermal cycle, temperature and velocity fields during gas tungsten arc welding of aluminum alloys were predicted by solving three-dimensional equations of conservation of mass, energy and momentum under steady-state conditions. Welding experiments were then conducted on several samples with different thicknesses and chemical compositions. The geometries of the weld pools as well as the thermal cycles were measured. It is found that the calculated geometry of the weld fusion zone and the weld thermal cycles are in good agreement with the corresponding experimental results. In addition, the magnitude of the maximum velocities under different... 

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 research, the galvanized steel with thickness of 2 mm was joined to the 5754 aluminum alloy with thickness of 3 mm by the cold metal transfer MIG welding–brazing process. The effect of the filler wires (AlSi3Mn, AlSi5, and AlSi12) and wire feed speeds (4.7, 5, and 5.3 m/min) on metallurgical and mechanical properties have been discussed. According to the experimental results, thickness of intermetallic compound (IMC) layer which was formed along the interface during the MIG welding–brazing was varied by changing of parameters. In addition, the results indicated that by increasing of the wire feed speed, the thickness of IMC layer at first decreased and then increased. Results...