Welding Metallurgy of
01 Jan 1987-
About: The article was published on 1987-01-01 and is currently open access. It has received 991 citations till now. The article focuses on the topics: Welding.
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TL;DR: In this paper, the correlation between weld bead geometry and welding parameters for bead-on-plate in 1G position was studied. And the results showed that the deviation between predicted data and experimental measurement on actual welding is less than 1mm, while the Mean Absolute Deviation was less than 0.6mm.
Abstract: Flux Core Arc Welding (FCAW)is a popular choice for metal fabrication. Correct welding parameter and bead geometry are required before a robot can perform quality welding. An experiment was conducted to study the correlation between weld bead geometry and welding parameter for bead-on-plate in 1G position, and subsequently to develop a tool that can support the input requirement of the robot without resorting to unproductive trial and error. Coupons of quality weld deposit were produced experimentally by FCAW process and the bead geometry is measured and tabulated. The correlation of Heat Input and weld bead geometry is best represented by their trend-line equations. Incorporating these equations into a calculator format, the weld bead geometry and welding parameters can be predicted to produce a wide range of bead geometry. The deviation between predicted data and experimental measurement on actual welding is less than 1mm, while the Mean Absolute Deviation is less than 0.6mm.
2 citations
Cites background from "Welding Metallurgy of"
...The market for the machine, consumable and product of FCAW will be expected increased by many folds [6], [7]....
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01 Jun 2019
TL;DR: In this paper, a thorough metallographic analyses using optical and scanning electron microscopy were carried out to observe Al-5%Si interface and ultrasonic measurements by immersion and scanning acoustic microscopy are made to characterise the bond at Al-Steel interface.
Abstract: Aluminum filler (Al-5%Si) is bonded on steel substrate by gas tungsten arc welding process under different current setting conditions. After welding a thorough metallographic analyses using optical and scanning electron microscopy were carried out to observe Al-Steel interface. Ultrasonic measurements by immersion and scanning acoustic microscopy were made to characterise the bond at Al-Steel interface. The ultrasonic wave reflected from the Al-Steel interface clearly indicated the more debonded area when the welding current is changed from direct current straight polarity (DCSP) mode to alternate current high frequency (ACHF) or the welding current in case of current for DCSP mode is reduced. This may be attributed either adequate amount of oxides along with intermediate phase make the bond interface rough and uneven due to introduction of ACHF mode or debonded areas are higher due to lower heat input when the current reduced to 125 amps from 150 amps in DCSP mode. Whereas smooth and even bond interface due to uniform heat input resulted stable Al-Steel interface and the mapping of bonded area by ultrasonic measurement showed spectrum of minimum peak for using current of 150 amps in DC mode. Thus the non-destructive assessments of interface between dissimilar materials through ultrasonic measurements could be important tools for evaluating the state of the bond.
2 citations
TL;DR: In this paper , an open-access article distributed under the terms of the Creative Commons Attribution-NonCommercial License (CC BY-NC 4.0/deed) is presented. But no modifications or adaptations are made.
Abstract: © 2020. The Author(s). This is an open-access article distributed under the terms of the Creative Commons Attribution-NonCommercial License (CC BY-NC 4.0, https://creativecommons.org/licenses/by-nc/4.0/deed.en which permits the use, redistribution of the material in any medium or format, transforming and building upon the material, provided that the article is properly cited, the use is noncommercial, and no modifications or adaptations are made. Arch. Metall. Mater. 65 (2020), 3, 1147-1156
2 citations
01 Jan 2015
TL;DR: In this article, a new welding process for a company in the Oil & Gas industry, ensuring method consistency and performance quality of their steel drill bit while increasing overall production is presented.
Abstract: This report looks at designing a new welding process for a company in the Oil & Gas industry, ensuring method consistency and performance quality of their steel drill bit while increasing overall production. The current product is welded manually with a flux core wire, resulting in high cycle times and numerous cases of required rework. The use of automation systems will be analyzed for their increased consistency, quality, safety, and production estimates. Specifically robotic cell design will be considered, since it can work on more parts with fewer operators, adding efficiency and flexibility to the production floor. Other areas of researched covered in this report include welding parameters and methods, fixture use in relation to automation, preheating and material properties of steel, and investment justification of automated systems. The design will be modeled and simulated in a 3D environment, and analyzed with economic considerations in the form of payback period and return on investment. All calculations, given values and assumed values will be stated and explained. Results include an estimated payback period of 2.14 years, a 34% ROI, and savings of $ 13,140.00 per year from the robot alone, with capacity for additional savings analysis based on use of the design. Recommendations to go forward with prototype testing on actual weld quality and efficiency improvements as well as cell design finalization.
2 citations
22 Jul 2019
TL;DR: An acquisition methodology for generating a weld image dataset, as well as a software tool that makes possible to analyze, process and visualize each frame from recorded linear welding, providing per sample statistics and a framework to draw annotations of the due video are presented.
Abstract: The Electric-Arc Welding process is affected by several physical phenomena which have a direct impact on the final product quality. To understand and improve weld deposition is a key challenge to upgrade the overall metallic welding process. However, controlling the welding process of continuously fed melting wire electrode is still an open problem, which has not yet been solved. In order to study the phenomenon involved in the metallic transfer in linear welding, we employ a high-speed camera and laser lighting equipment to record the deposition images using two distinct imaging setups. Combining the image acquisition setup with voltage, current and wire speed data, we are able to obtain a dataset of distinct welding conditions, which allow us to observe critical aspects of the deposition. We present an acquisition methodology for generating a weld image dataset, as well as a software tool that makes possible to analyze, process and visualize each frame from recorded linear welding, providing per sample statistics and a framework to draw annotations of the due video. Through visual information and inferential statistics, we are able to identify how each parameter influences the weld of thick steel plates. Furthermore, we believe the tools provided will enable researchers to evaluate the deposition process and, thus, foster the development of hardware, software, and control techniques related to the field.
2 citations
Cites background from "Welding Metallurgy of"
...[1] lists three major types of fusion welding processes: i....
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References
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