Materials Science Forum Vol. 1095

Abstract: Hybrid joints between aluminium and steel are used sometimes in case of thin sheets for example for a car body. Resistance welding for this joining challenge is not frequently used, but the resistance welded joints basically have good mechanical properties. During resistance spot joining of these hybrid joints, fusion between the two materials cannot occur, but with the right technological parameters an intermetallic compound (IMC) appears in the joint line. The properties of the IMC have significant effect to the joint properties, because the researchers basically investigate this. The original static mechanical tests can show good, comparable results for the joint properties. If we see the dynamic tests basically really difficult to find results in case of spot welding of steels and joining of hybrid aluminium – steel joints. The aim of this paper to show the dynamic properties of these hybrid joints. During our investigation DP600 dual-phase steel was used as the steel part because this grade is frequently used in a car chassis. For the aluminium part, two types of aluminium were applied: non-heat treatable 5754-H22 alloy, and heat-treatable 6082-T6 alloy. The different aluminium alloys have different properties, so different technological parameter combinations were used. To test the resistance of hybrid joints against dynamic loading, instrumented impact tests were performed. This special impact test is considered as an impact-bending test, because the load is perpendicular to the welded point joint. Force – time diagrams of impact tests were shown too in this paper. The intermetallic compound is necessary for joint, but it is very brittle with very big hardness, but in case of dynamic testing this hardness has no significant effect, so these specimens show good result in case of dynamic loading. The two different aluminium – steel joints show different resistance against dynamic loading, and the fracture modes were different too.

Abstract: Titanium alloys are widely used in aerospace, automotive, biomedical and marine engineering due to their good hot and cold processing properties, fracture toughness, high specific strength and good deformability. Nevertheless, titanium is also characterized by very high production costs, which are approximately 6 times and 30 times higher, respectively, in comparison to those to obtain the same quantity of aluminum or steel relegating titanium to high demanding sectors. One possible way to reduce the cost of titanium is to use cheaper alloying elements instead of vanadium or niobium to stabilize the body-centred-cubic (B.C.C) β-phase. TIG-welding of high-strength low-cost pseudo-β titanium alloys is complicated, primarily due to the high content of alloying elements, such as iron, molybdenum, as well as the use of oxygen as an alloying elements. By the correct choice of welding modes in most cases, it is possible to obtain welded joints of high-strength pseudo-β titanium alloys with good microstructure and mechanical properties. To study the influence of TIG welding on the structure and mechanical properties of low-cost titanium alloy Ti–2.8Al–5.1Mo–4.9Fe, two types of TIG-welding chosen: standard fusion TIG welding and TIG welding on the thin flux layer.

Abstract: In the context of some problems noticed by the business environment regarding the quality and costs of welding aluminum components, some experimental research was carried out on the efficiency of applying MIG spot welding, using improved equipment and working regimes. A new technical solution is proposed for joining thin aluminum plates using MIG spot welding instead of resistance spot welding. Therefore, the research was guided in studying the influence of two main parameters – specific to the MIG welding process – on the quality of welded joints. According to the obtained experimental results, in the paper is highlighted that MIG spot welding could be a viable alternative to resistance spot welding of thin aluminum plates, but just then when some important conditions are fulfilled. The paper also contains some practical recommendations for specialists working in this operational field.

Abstract: An important problem for plastic injection moulding companies is the deterioration of mould nests due to several factors such as wear and tear caused by heavy use, corrosion, misuse, etc. These defects, even small ones, can affect the injection moulded product. To reduce the cost of making a new mould, damaged areas are repaired. TIG welding or laser welding is commonly used. For areas with small defects, laser welding is preferred due to its advantages. The paper presents research on the choice of wire when reconditioning a mould using laser welding.

Abstract: Using austenitic steel in welding structures requires both destructive and non-destructive testing (NDT) to approve the use of intended welding specification, but also testing of material properties, even if they are guaranteed by manufacturer. In this particular case, X2CrNiMo17-12-2 (commercial trademark AISI 316L) is the material that has to be partly replaced by NiCr21Mo (commercial trademark Incoloy 825) in a piece of process equipment exposed to elevated temperature and highly corrosive environment. This research presents an investigation of overmatching V groove welded joint made of these two austenitic steels. Due to materials properties and specific application conditions, low heat input TIG welding was utilized. Mechanical properties of welded joint have been examined to check criteria which guarantees safe work and integrity of welded components. Chemical composition of used filler material was close to the one of NiCr21Mo alloy, providing weld overmatching, which needs to be checked as well. Mechanical testing (tensile, bending, impact, hardness), macro-and microstructure analysis provided detailed insight into welded joint characteristics and a ground for further investigation concerning heterogeneous austenitic welded joint, taking into account overmatching effect.

Abstract: Welding process is very important in numerous industries ranging from automotive and aviation to shipbuilding and pressure vessel production. Nowadays new methods to improve the productivity and quality of various welding techniques are searched. In many industrial applications even small process optimizations may lead to significant cost and energy savings and new applications. Large plate welding is particularly important in shipbuilding industry. It is common to weld multiple times to join thick plates, but this approach is not optimal from energy and time effectiveness and outcome quality is limited. Alternative is single high heat input welding, which causes various problems related to rapid local overheating and the formation of inhomogeneous post-weld microstructure. There are several heat affected zones near the weld pool, which has different properties and microstructure due to different cooling rates and heat flux orientation during solidification. Since welding is a complex multiphysical process there are various parameters such as electric current, oxygen presence, heat flow and weld pool flow which influence the quality of welding joint and efficiency of the process. In this paper we aim to experimentally and theoretically investigate how to modify heat and mass transfer in the weld pool and heat affected zone by static magnetic fields. Electromagnetic force is one of the ways how to affect the weld pool flow and to influence the heat and mass transfer from the weld pool to the base metal. Our research demonstrates that moderate DC magnetic field can cause various effects on the post-weld morphology, depending on the magnetic field direction. Analytical estimates and similarity analysis for high heat input welding on EH36 shipbuilding steel shows that electromagnetic methods, like application of DC magnetic field can be promising approach for improved welding outcome in some cases.

Abstract: Resistance spot welding (RSW) is one of the most common welding methods for steel sheets, as it is mainly used to join the automotive body structure parts. Different types of ultra-high strength steels (UHSS) have become widely used in the automotive body to obtain the required demands such as lower car weight, improving crashworthiness behavior, and enhancing strength–ductility combination. Martensitic UHSS belong to the highest grades width their tensile strength above 1000 MPa. During the lifetime of the vehicle cyclic loading generally occurs, therefore the optimization of welding technology should be performed considering the fatigue resistance of the welded joints. In our research 1 mm thick standardized lap shear sheets of martensitic MS1400 steel were welded by a TECNA 8007 RSW equipment with two different welding parameter combinations. The idea was to analyze the effect of welding and pulsation parameters on joint properties under static and cyclic loading. The welding parameters have been calibrated to produce the same weld nugget size for both technological combinations. Macroscopic, hardness, and tensile-shear tests were carried out to determine the fundamental mechanical characteristics of the RSW joints. The relation between the weld nugget microstructure and mechanical properties was explored. The high cycle fatigue (HCF) tests were performed on an MTS 810.23 universal electro-hydraulic materials testing system. A statistical approach was applied during the preparation and evaluation of the investigations, which increased their reliability. Measured and analyzed data of the lap shear welded joints, prepared by different technological parameters, were compared and discussed. The parameters of the HCF experiments were calculated considering the Japanese testing method (JSME S 002-1981). In most of the samples it was observed from both welding parameter combinations that the fatigue cracks initiate and grow in curvature shape in the softened part of the heat-affected zone towards the base metals in both directions symmetrically. A slight difference was observed in the HCF resistance of the welded joints prepared by different welding parameters.

Abstract: This paper presents the development of numerical models which were used to simulate the behaviour of welded joints containing different combinations of multiple defects under tensile loads. Four representative combinations of defects were selected (including undercuts, incomplete root penetration, misalignments...), based on practical experience. In order to create accurate and functional models, this research involve a number of stages. This paper will focus on the various improvements made to the models, which started in relatively simple form. For this purpose, initial experimental and numerical analyses were carried out on specimens made of low-alloyed low-carbon steel S235, and after their accuracy was verified, the same methodology was applied to specimens made of higher quality material, steel S275. Improvements made to the models involved geometry, different combinations of boundary conditions and loads, and some were based on stress-strain states obtained by a combination of tensile testing and digital image correlation. The final result was a set of detailed numerical models which accurately simulated the behaviour of welded joints with multiple defects in them.

Abstract: In the food industry, food safety largely depends on the quality of the surfaces that meet the food. Their various imperfections can become dangerous areas of contamination. The manufacturer of industrial equipment has imposed rules in this regard. This paper highlights certain violations of these rules in the maintenance interventions, carried out in improper conditions at the food processor's headquarters. Some quality control methods of these welded joints are presented, specifying some correlations of surface imperfections with the risks of contamination of the food product. Some corrective measures contained in the European hygienic design guide are also highlighted, with the particularities imposed on welding technologies.

Abstract: The present work aims to design an artificial neural network (ANN) for controlling the geometry of the fusion zone in different welding conditions. AA5754 aluminium plates with 6 mm thickness were welded in butt configuration by using an Yb-doped fiber laser in continuous wave regime. Laser power, travel speed, beam diameter and shielding gas were considered as process-related factors, while the weld geometry was evaluated in terms of penetration depth and bead width. The accuracy of the model was endorsed by using untrained test data. Results showed a good agreement between the ANN output and the experimental values.