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Shome, Mahadev
- Transforming India–Few Significant Developments and Prospects in Welding Technology
Abstract Views :335 |
PDF Views:13
Authors
Affiliations
1 Materials Characterization & Joining, R&D, Tata Steel, Jamshedpur, IN
1 Materials Characterization & Joining, R&D, Tata Steel, Jamshedpur, IN
Source
Indian Welding Journal, Vol 51, No 2 (2018), Pagination: 51-56Abstract
I feel humbled in being considered to deliver the revered Keith Hartley Memorial lecture of the Indian Institute of Welding, and am really grateful to the Jamshedpur Branch for nominating me and the jury who found me deserving. Given this opportunity, it's an honor to share with you some of my work and contributions made in the field of 'welding and joining' engineering. I would also like to take this opportunity to salute late Mr. Keith Hartley, who laid the foundation of the Indian Institute of Welding with a vision to make quantum progress through cooperative efforts of professionals, and the success story of the manufacturing industry in the country in the last 20 years stands testimony to a mission partly accomplished and progressing rapidly to attain new heights.
- Shear Tensile and High Cycle Fatigue Performance of MIG Brazed DP600-GI Steel Sheet Joint
Abstract Views :338 |
PDF Views:9
Authors
Affiliations
1 Metallurgical and Material Engg. Dept., Jadavpur University, Kolkata - 700 032, IN
2 Material Characterization & Joining Group, R & D, Tata Steel, Jamshedpur - 831 007, IN
1 Metallurgical and Material Engg. Dept., Jadavpur University, Kolkata - 700 032, IN
2 Material Characterization & Joining Group, R & D, Tata Steel, Jamshedpur - 831 007, IN
Source
Indian Welding Journal, Vol 51, No 3 (2018), Pagination: 42-53Abstract
MIG brazing is a potential process for joining coated automotive steel sheets over conventional fusion welding process such as gas metal arc welding (GMAW). However, understanding the process variables on the joint performance is not yet clear. This paper deals with details study on the effect of process parameters and two different modes of operation (push and pull) on bead geometry, microstructure, shear tensile strength and high cycle fatigue behavior of MIG brazed lap joint of 1.4 mm thick galvanized DP600 steel sheet using solid CuAl8 filler wire. It has been possible to obtain 98% joint efficiency due to dispersion hardening effect of fusion zone consisting of dispersed iron from base metal in copper matrix. Also, an interface region formed (~6 μm) inbetween fusion zone and steel substrate has been characterized. High cycle fatigue test of all MIG brazed joints showed fatigue endurance (2 million cycles) at 10% of tensile load and fatigue life increased with increasing heat input. Interestingly, three different fatigue failure paths were observed with different loading cycle, such as interfacial failure; fusion zone failure and fine grain heat affected zone failure where the bead geometry played an important role in brazed joint under dynamic loading condition.Keywords
Galvanized Dual Phase Steel, MIG Brazing, Push and Pull Mode, Bead Geometry, Microstructure, High Cycle Fatigue.References
- Bhattacharya D (2011); Metallurgical perspectives on advanced sheet steels for automotive applications, Advanced Steels, pp.163-175.
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- Chovet C and Guiheux S (2006); Possibilities offered by MIG and TIG brazing of galvanized ultra high strength steels for automotive applications, La Metallurgia Italiana, 7-8, pp.47-54.
- Dilthey U amd Stein L (2006); Multimaterial car body design: challenge for welding and joining, Science and Technology of Welding and Joining, 11, pp.135-142.
- Fatih H and Sevim I (2012); The effect of welding parameters on fracture toughness of resistance spotwelded galvanized DP600 automotive steel sheets, International Journal of Advance Manufacturing Technology, 58, pp.1043-1050.
- Wen-feng Zhu, Xu C and Zeng L (2010); Coupled finite element analysis of MIG welding assembly on auto-body high-strength steel panel and door hinge, International Journal of Advance Manufacturing Technology, 51, pp.551-559.
- Guimaraes AS, Mendes MT, Costa HRM, Machado JDS and Kuromoto NK (2007); An evaluation of the behaviour of a zinc layer on a galvanised sheet, joined by MIG brazing, Welding International, 21, pp.271-278.
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- Basak S, Pal TK, Shome M and Maity J (2013); GMA brazing of galvannealed interstitial-free steel, Welding Journal, 92, pp.29s-35s.
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- Stabilizing Flash Butt Welding of Varied Chemistry Steels during End-To-End Coil Joining
Abstract Views :213 |
PDF Views:7
Authors
Nikhil Shajan
1,
Kanwer Singh Arora
1,
Mahadev Shome
1,
Atanu Roy
2,
US Patnaik
2,
Niranjan Behera
3,
V. Santhanagopalan
3
Affiliations
1 Research and Development, TATA Steel, Jamshedpur- 831001, IN
2 PLTCM, TATA Steel, Jamshedpur- 831001, IN
3 Product Technology Group, TATA Steel, Jamshedpur- 831001, IN
1 Research and Development, TATA Steel, Jamshedpur- 831001, IN
2 PLTCM, TATA Steel, Jamshedpur- 831001, IN
3 Product Technology Group, TATA Steel, Jamshedpur- 831001, IN
Source
Indian Welding Journal, Vol 53, No 3 (2020), Pagination: 64-69Abstract
Flash butt welding (FBW) is extensively used for joining front end of incoming hot rolled coil to the tail end of the previous coil in pickling and tandem cold rolling mill (PLTCM). Improper welding causes failure in the cold rolling strands in the later stages. Hence, it is of paramount importance to establish a sound weld line by selecting the right welding process parameters. Optimizing the process parameters largely depends on the thickness and chemistry of the steels because slight variations in steel chemistry can cause weld failures. Recently, during flash butt welding of hot rolled Interstitial Free (IF) steel from TSK (Steel A) in the cold rolling mill (CRM) of TSJ (Steel B), adjustments had to be made in the welding parameters to enable smooth cold rolling. The flash butt welded TSK coils showed oxides of Fe, Mn, Al and Ti on fractured surfaces with the standard TSJ welding parameters. Back up study suggested that higher Mn, Al and Ti levels in the TSK coils were possibly responsible for greater volume fraction of oxides at the weld zone. Since, flash butt welding is done without the use of shielding gas, oxidation of the molten pool happens at the abutting edges. Improper process parameters can lead to the entrapment of oxides at the fusion line causing failure initiation. Therefore, this called for a change in welding parameter from the set value. Increasing the flashing length and upset length enabled in removing the excessive oxides formed during the flashing stage and prevented failure of the welds. The downstream end has hence been stabilized.Keywords
Flash Butt Welding, Oxidation, Interstitial Free Steel, Cold Spot/penetrators.References
- Mansouri H and Monshi A (2004); Microstructure and residual stress variations in weld zone of flash-butt welded railroads, Science and Technology of Welding and Joining, 9(3), pp.237-245.
- Tawfik D, Mutton PJ and Chiu WK (2006); Transient thermal stress analysis on rapid post-weld heat treatments applied to flash butt welded rails, Science and Technology of Welding and Joining, 11 (3), pp.326-336.
- Xu Z, Lu P and Shu Y (2016); Microstructure and fracture mechanism of a flash butt welded 380CL steel, Engineering Failure Analysis, 62, pp.199-207.
- Ziemian CW, Sharma MM and Whaley DE (2012); Effects of flashing and upset sequences on microstructure, hardness, and tensile properties of welded structural steel joints, Materials & Design, 33, pp.175-184.
- Lu P, Xu Z, Jiang K, Ma F and Shu Y (2017); Influence of flash butt welding parameters on microstructure and mechanical properties of HSLA 590CL welded joints in wheel rims, Journal of Materials Research, 32(4), pp.831-842.
- Xi C, Sun D, Xuan Z, Wang J and Song G (2016); Microstructures and mechanical properties of flash butt welded high strength steel joints, Materials & Design, 96, pp.506-514.
- Arabaci U, Çetînkaya C and Akay A (2007); An investigation of effects of upsetting current time and normalization heat treatment on mechanical properties of X40CrMoV5 1 and Ç1030 steels joined by flash butt welding, Materials & Design, 28(8), pp.2351-2360.
- Çetinkaya C and Arabaci Uu (2006); Flash butt welding application on 16MnCr5 chain steel and investigations of mechanical properties, Materials & Design, 27(10), pp.1187-1195.
- Ichiyama Y and Saito T (2004); Factors affecting flash weldability in high strength steel- a study on toughness improvement of flash welded joints in high strength steel, Welding International, 18(6), pp.436-443.
- Räsänen AN and Martikainen J (2011); Experimental review of metallurgical flash weld defects in welded joints: essence of flat spots, penetrators and oxide inclusions, Science and Technology of Welding and Joining, 16(6), pp.471-476.
- Bhattacharyya S, Adhikary M, Das MB and Sarkar S (2008); Failure analysis of cracking in wheel rims-material and manufacturing aspects, Engineering Failure Analysis, 15(5), pp.547-554.
- Shajan N, Arora KS, Sharma V and Shome M (2017); Effect of upset pressure on texture evolution and its correlation to toughness in flash butt joints, Science and Technology of Welding and Joining, 23(5), pp.1-7.
- Shajan N, Arora KS and Shome M (2019); Correlation between grain misorientation, texture and impact toughness across a flash butt weld of HSLA steel, Materials Letters, 236, pp.436-439.
- Shajan N, Arora KS, Asati B, Sharma V and Shome M (2018); Effects of post-weld heat treatment on the microstructure and toughness of flash butt welded high-strength low-alloy steel, Metallurgical and Materials Transactions A, 49(4), pp.1276-1286.
- Suzuki M and Endo S (1991); Effect of PWHT on TMCP steel flash butt welded joints, Welding International, 5(4), pp.271-276.
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- Gas Metal Arc Welding – Simplified Perspective of Power Sources (Part I)
Abstract Views :214 |
PDF Views:4
Authors
Affiliations
1 Freelance Consultant in Materials & Welding, IN
1 Freelance Consultant in Materials & Welding, IN
Source
Indian Welding Journal, Vol 55, No 2 (2022), Pagination: 47-52Abstract
Gas Metal Arc Welding (GMAW), also known as Metal Inert Gas (MIG) Welding, has evolved over the years and a significant volume of welding is carried out by this process. The AC/DC transformer-rectifier with different control systems have been the most sought-after power sources and has served majority of the manufacturing requirements in recent times. The latest inverter based GMAW power sources with enhanced features have led to more advancements in welding technology, be it functional efficiency or welding of relatively difficult materials, joint configurations, and weld positions. This article intends to give a clarity about some of the modern power sources, their design and characteristics, and some special features that are aligned to industry needs. Part I of the article would essentially cover welding machine systems, while the subsequent parts would delve with the benefits that modern welding machines provide in to address material and manufacturing issues.Keywords
GMAW, Power Sources, Transformer-Rectifier, Flat Characteristics, Metal Transfer.References
- TWI (2015); https://www.twi-global.com/technicalknowledge/ job-knowledge/mig-mag-developments-inlow-heat-input-transfer-modes-133, October 2015.
- Norrish J (2006); Advanced Welding Processes, Woodhead Publishing.
- Biswas P (2019); Welding Power Sources, https://freevideolectures.com/course/4283/nptel-fundamentalwelding-science-technology/8, Swayam-NPTEL, IIT Guwahati, February 2019.
- Li C, Du C, Xu H and Luo Y (2011); The design and study of GMAW inverter power based on DSCCS, Procedia Engineering, 15, pp.1098–1102.
- Mathers G (2015); Power Source Characteristics, https://www.twi-global.com/technical-knowledge/jobknowledge/power-source-characteristics-121, Oct 2015
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- Mathison J (2008); Understanding transfer modes for GMAW, The Fabricator, Dec 2008
- Naidu D S, Ozcelik S and Moore K L (2003); Modeling, Sensing and Control of Gas Metal Arc Welding (Book),Elsevier Publication.
- Mvola B, Kah P, Martikainen J and Hiltunen E (2013); Applications and benefits of adaptive pulsed GMAW, Mechanika, 19(6), pp.694-701.
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- Gas Metal Arc Welding – Temperature characteristics (Part II)
Abstract Views :120 |
PDF Views:3
Authors
Affiliations
1 Freelance Consultant in Materials & Welding, IN
1 Freelance Consultant in Materials & Welding, IN
Source
Indian Welding Journal, Vol 55, No 4 (2022), Pagination:Abstract
.Temperature distribution in the workpiece during gas metal arc welding are valuable information that can help diagnose the weld joint quality and take corrective measures by fine tuning the welding parameters. The temperature isotherms and temperature-time plots of specific locations in the weld joint are predicted using mathematical models, wherein the heat of welding is a major input. The heatinput can be derived from the current and voltage waveforms of power sources and can be used to predict the temperature distribution and time-temperature profile. Modern power sources have addressed short comings related to burn-through and spattering by controlling current and voltage waveforms without any instantaneous heat spikes and maintaining steady heat-input throughout the process. The temperature maps are indicative of heat variation during welding.Keywords
GMAW, heat-input, temperature-time plot, weld, HAZ, short-circuit, waveform.References
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