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Sharma, Abhay
- Enhancement in Mechanical Properties of Tailored Welded Blanks Due to Pulsed Tig Welding
Authors
1 Bharat Heavy Electrical Limited, Haridwar, IN
2 Institute of Petroleum Technology, Gandhinagar, IN
3 Department of Mechanical and Industrial Engineering, Indian Institute of technology Roorkee, Roorkee, 247 667, IN
Source
Indian Welding Journal, Vol 42, No 4 (2009), Pagination: 38-45Abstract
The present paper reports experimental results on enhancement in mechanical properties of tailored welded blanks due to Pulsed TIG welding. Experimental evaluation of various mechanical properties has been made under the influence of varying peak current, pulse frequency and pulse width. The resulting welds have been checked for ultimate tensile strength, % elongation, hardness, toughness and fatigue life. The mechanical properties of Pulsed TIG welded tailored blanks have further been compared with that produced by conventional TIG welding. It has been observed that the Pulsed TIG welding can successfully be employed to improve the mechanical properties of tailored welded blanks. The results of experiments have been analyzed and related discussion has been presented.
Keywords
Pulsed TIG Welding, Mechanical Properties, Tailored Welded Blanks.
- Impact of Process Modelling on Current Direction of Welding Research and Future Targets
Authors
1 Institute of Petroleum Technology, Gandhinagar - 382 007, IN
2 Indian Institute of Technology Roorkee, Roorkee - 247 667, IN
Source
Indian Welding Journal, Vol 41, No 4 (2008), Pagination: 43-50Abstract
The present paper gives a description of process modelling and its impact on current direction of welding research and future targets. It analyses the research work carried out in the filed of process modelling and presents quantitative analysis. The present work classifies and subsequently quantifies the welding research on the basis of approaches including modelling and simulation, product development, cause-effect analysis and sensor and control. The analysis indicates that modelling based research is primarily reported for existing technologies and existing materials. Research in new technologies using modelling is still is in developing stages and new materials based research is primarily carried out with cause-effect based analysis. The paper also mentions the future targets in welding research and indicates the role of process modelling in achieving the targets.
Keywords
Process Modelling, Welding Research, Future Targets.- A Comparative Study between Linear and Nonlinear Regression Analysis for Prediction of Weld Penetration Profile in AC Waveform Submerged Arc Welding of Heat Resistant Steel
Authors
1 Department of Mechanical & Aerospace Engineering, IIT Hyderabad, Sangareddy, IN
2 Technical Research Institute, Hitachi Zosen Corporation, Osaka, JP
3 Joining & Welding Research Institute, Osaka University, JP
Source
Indian Welding Journal, Vol 52, No 1 (2019), Pagination: 40-48Abstract
Alternating current with square waveform provides better control of weld quality and reduces the effect of the arc-blow in the submerged arc welding process. This paper presents a comparative study in between conventionally used linear regression and newly proposed nonlinear regression analysis for prediction of weld penetration profile, i.e. weld width, penetration and penetration shape factor in the AC waveform welding of heat resistant steel. The comparison is based on second order linear regression and nonlinear regression analysis using Levenberg-Marquardt method. The frequency, electrode negative ratio, welding current, and welding speed are used as input parameters to obtain the models for penetration and width. The models are developed following a design of experiment and extra experiments are conducted to check the adequacy of the models. The results show that the Levenberg-Marquardt method associated with exponential function without considering constant term is more effective as compared to second order linear regression in terms of predictability and accuracy. The significant effect of process variables on the outcomes is analyzed. The investigation shows a new approach to weld penetration profile prediction that can be horizontally deployed to other welding process where predication is difficult because of the complex shape of the weld bead.
Keywords
Weld Bead Geometry, Linear Regression, Process Variable, Nonlinear Regression, Model Adequacy.References
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- Arc Behavior Study Using Welding Current Module and its Impact on Residual Stress and Weld Bead in Anti-Phase Synchronized Twin-Wire Gas Metal Arc Welding
Authors
1 Department of Mechanical & Aerospace Engineering, Indian Institute of Technology, Hyderabad- 502285, IN
Source
Indian Welding Journal, Vol 52, No 1 (2019), Pagination: 64-70Abstract
The importance of twin-wire welding in increasing the deposition rate is known for a long, but its application in gas metal arc welding is limited due to the arc-stability related issues. An unstable welding arc causes irregular weld bead and material loss in the form of spatters. Previous investigations indicate that the problem can be addressed through arc-stability induced by dissimilar twin-arcs as the electromagnetic field concentrates around the arc with higher current. The present study is intended to reduce the twin-arcs' interactions and to improve the arc stability in twin-wire gas metal arc welding by evaluating different conditions at lead and trail wires. Further, their influence on the residual stresses and weld bead geometry is studied. Bead-on-plate-welds are carried out. A data acquisition system is used to capture the electrical signals during welding. The results indicate that the unequal currents at trail and lead wires provide stability to the arc that also results in a shift in residual stresses from compressive to tensile along the weld transverse direction. In addition, the maximum residual stress is located at the weld toe. When the current difference between the trail and lead wire is more, the arc produces stable metal transfer with uniform heating and cooling that results in reduction in stresses and improvement in weld quality.
Keywords
Twin-Wire GMAW, Heat Input, Residual Stresses, Weld Bead Geometry.References
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- Modified Mathematical Models for Melting Rate in Submerged Arc Welding
Authors
1 Institute of Petroleum Technology, Gandhinagar, IN
2 Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee, IN
3 Department of Mechanical and Industrial Engineering, IN
Source
Indian Welding Journal, Vol 40, No 4 (2007), Pagination: 21-32Abstract
Modified mathematical models for melting rate during submerged arc welding with straight and reverse polarities have been proposed. The present work is a result of a critical analysis of existing models and subsequent modification in order to improve the predictability and practicability. The proposed models bridge the gap between less scientific shop-fioor-friendly models and scientifically correct but not so shop-floor- friendly models. Instead of experimental measurement of electrode extension or making the assumption that the electrode extension is equal to contact tube to work-piece distance, the present work models the role of electrode extension during melting by considering the effect of process parameters on it. On the other hand, influence of process parameters on arc heating has also been incorporated. The developed models cover the effect of fundamental parameters like current, voltage, electrode extension and wire diameters.
Simulated annealing has been used to calibrate the proposed models and subsequently the models are validated with data points different from the points used for model calibration. The modified models provide better accuracy than the models that have been constituted with the above stated assumption as well as it is more practical than those models in which actual electrode extension has been experimentally measured. The outcome of investigation has been analyzed in terms of improvement in the predictability, resemblance with physics of the process and generalization capacity of the models. The approach of the present work is applicable for future research in other welding processes.