Search Results (925)

Abstract: Aluminium and its composites are widely used in production to enhance the strength of lightweight objects. In this study, an AA7075/SiC composite was fabricated using a stir casting route. Multi-objective optimization and finite element analysis were performed with various process parameters on a manufactured aluminium composite (AA7075 + SiC) undergoing a laser beam welding process. Four welding parameters, i.e., pulse frequency, power, welding speed (transverse), and wire size were taken for laser welding as per the L-9 orthogonal array for experimental study. Tensile strength, deflection, temperature distribution, Rockwell hardness (fusion zone), and Rockwell hardness (heat affected zone) were taken as output parameters after welding. The standard deviation objective weighting–grey relational optimization method optimized the process parameter. ANSYS APDL 23 software was utilized to simulate the entire laser welding method with a cylindrical heat source to predict the temperature distribution in the butt-welded plates. This software uses finite element analysis and gives a deviation of only 5.85% for temperature distribution with experimental results. This study helps to understand the effect of various parameters on the welding strength of the aluminium composite. Full article

This paper introduces an optimization method for multi-robot automated control welding based on a Particle Swarm Genetic Algorithm (PSGA), aiming to address issues such as high costs, large footprint, and excessive production cycles in multi-robot welding production lines. The method first constructs a multi-axis robotic kinematic model to provide constraint conditions. Then, the PSO (particle swarm optimization) algorithm, which integrates penalty functions into the fitness evaluation, is used to determine the optimal welding path by simulating collective behavior within a group. The GA (genetic algorithm) encodes the position of the welding robot bases into chromosomes to find the optimal layout for coordinated control of multiple robots. The entire process is optimized according to welding standards and requirements. Additionally, a comprehensive production line performance estimation model was used to quantitatively analyze the new scheme. The results show that the optimized production line’s balance rate increased by 10%, the balance loss rate decreased by 10%, the smoothness index increased by 37.8%, the space costs reduced by 44.4%, the equipment demand reduced by 41.1%, the labor demand reduced by 50%, the total costs reduced by 10%, and the average product cycle time was reduced by 5.07 s. Finally, we tested the algorithm in various complex scenarios and compared its performance against mainstream algorithms within the context of this study. The results demonstrated that the optimized production line significantly improved efficiency while maintaining safety standards. Full article

In order to study the corrosion resistance of 904L composite plate pressure vessels under a high-temperature and high-pressure gas field environment, the pitting corrosion and stress corrosion cracking resistance of a 904L composite plate body and weld material were compared with those of a 2205 composite plate and 825 composite plate, which are used in high-temperature and high-pressure gas field environments. The results showed that the pitting resistance of the 904L composite plate was lower than that of the 825 composite plate and higher than that of a 2205 solid-solution pure material plate and a 2205 composite plate. The corrosion resistance of the 625 welding material is higher than that of the E385 welding material. In the simulation of the corrosion environment of a high-temperature and high-pressure gas field, the corrosion rates of the 904L composite plate body, welding seam, and surfacing welding were all less than 0.025 mm/a, indicating slight corrosion, and the sensitivity coefficient of chloride stress corrosion cracking was less than 25%, indicating low sensitivity. The 904L composite plate met the requirements of corrosion resistance for pressure vessel materials in a high-temperature and high-pressure gas field environment. Full article

The solidification of alloys is a key physical phenomenon in advanced material-processing techniques including, but not limited to, casting and welding. Mastering and controlling the solidification process and the way in which microstructure evolution occurs constitute the key to obtaining excellent material properties. The microstructure of a solidified liquid metal is dominated by dendrites. The growth process of these dendrites is extremely sensitive to temperature changes, and even a small change in temperature can significantly affect the growth rate of the dendrite tip. Dendrite remelting is inevitable when the temperature exceeds the critical threshold. In this study, a temperature-induced-dendrite remelting model was established, which was implemented through the coupling of the phase field method (PFM) and finite difference method (FDM). The transient evolution law of dendrite remelting was revealed by simulating dendritic growth and remelting processes. The phase field model showed that the lateral dendrites melt first, the main dendrites melt later, and the main dendrites only shrink but do not melt when the lateral dendrites have not completely melted or the root is not broken. The long lateral branches break into fragments, while the short lateral branches shrink back into the main dendrites. The main dendrites fracture and melt in multiple stages due to inhomogeneity. Full article

Laser welding on thin plates of high-strength steel is increasing in various industrial applications. The mechanical behavior of welded joints depends on their local properties, which in turn depend on the welding parameters applied to join the base material. This work characterizes the local properties of butt-welded joints of thin plates of high-strength–low-alloy (HSLA) steel. This study focuses on the effect of welding parameters on the microstructure, tensile response, microhardness, and weld bead profile. For this purpose, a factorial experimental design was formed, covering a heat input range from 53 to 75 J/mm. This study identified the main effects and interactions of welding speed and laser power on the weld bead profile and on its width. The microstructure, weld bead width, hardness, and tensile mechanical properties were significantly influenced by heat input. Furthermore, numerical simulations on real weld bead profiles revealed high values of the stress concentration factor and suggested a correlation with heat input. Full article

This article presents issues related to the methodology of the correct definition of the heat source model in the numerical analyses of welding processes. The problem of determining the input data for the stage of a heat source model definition, obtaining input data from experiments, and their proper interpretation and use in defining the numerical model was discussed. Particular attention is paid to the specificity of the problem of defining the heat source model, the way of interpreting the results of the analyses and the way of comparing them with the results of real experiments. The basic problems related to the mapping of the complex geometry of the molten metal pool and the ways to solve them were indicated. The solutions and guidelines presented in the article allow to improve the accuracy and quality of the obtained results of numerical analyses, as well as to shorten the time of preparation of computational models by reducing the number of computational iterations related to the search for the maximum consistency of the compared values and temperature cycles. Full article

This study delves into the exploration of the fatigue performance of a structure that has been spot-welded and is being loaded with torsional fatigue. The extended finite element method (XFEM) was applied to simulate the intricate interaction of spot welds in response to cyclic loading. The developed model was validated through experiments. The influences of different parameters, such as the number of spot welds used to join the adherends, the diameters of the spot welds, and the load ratio applied, on the fatigue performance of the box were investigated. The first two parameters studied had a significant influence on the extent of the fatigue failure-affected spot welds, where the crack propagation rate can be decreased by more than 700%. Full article

The wetting behaviors of Al-Si-Cu-Mg-Zn brazing materials on 5083 aluminum alloy substrate were investigated through changing the proportion of Mg from 0 to 2 wt.%. The experimental results showed that the welding process goes through the three following stages: slow spreading, fast spreading, and stabilizing. The wettability of the brazing material was improved effectively, and the porosity of the interfacial layer was reduced, with the addition of Mg. With Mg content at 1 wt.%, the wetting diameter reached a maximum value of 20.46 mm. The reaction mechanism of the wetted interfacial layer between the brazing material and substrate alloy was illustrated with dynamic data, provided through experimentation and simulated thermodynamic calculation, and showed that the wetting behavior of the resultant Al-7.5Si-15Cu-1Mg-5Zn brazing material was dominated primarily by a diffusion reaction from elemental magnesium. Full article

Finite element (FE) analysis of the tensile test of TWB-HPF 22MnB5 steel was performed and compared with the experimental results. To improve the accuracy of the simulation, the damage theory of FLD and ductile damage theory were used in 2D and 3D simulations. The tensile strength of 22MnB5 steel was determined under various welding heat inputs for FE simulation. Crack propagation of the welded region indicated that the fracture was observed in the base metal under normal welding conditions. Also, the crack propagated along the HAZ region due to higher heat input of the welding, and lead fractures have been highlighted as a potential complication. Full article

In recent years, high-performance lightweight and multifunctional aluminum foam sandwiches (AFSs) can be successfully applied to spacecraft, automobiles, and high-speed trains. Friction stir welding (FSW) has been proposed as a new method for the preparation of AFS precursors in order to improve the cost-effectiveness and productivity of the preparation of AFS. In this study, the AFS precursors were prepared using the FSW process. The distribution of foaming agents in the AFS precursors and the structure and morphology of AFS were observed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray energy dispersive spectroscopy (EDS). The effects of the temperature and material flow on the distribution of the foaming agent during the FSW process were analyzed through experimental study and numerical simulation using ANSYS Fluent 19.0 software. The results show that the uniform distribution of the foaming agent in the matrix and excellent densification of AFS precursor can be prepared when the rotation speed is 1500 r/min, the travel speed is 25 mm/min, the tool plunge depth is 0.2 mm, and the tool moves along the retreating side (RS). In addition, the experimental and numerical simulations show that increasing the welding temperature improves the uniformity of foaming agent distribution and the area of AFS precursor prepared by single welding, shortening the thread length inhibits the foaming agent from reaching the upper sandwich plate and moving along the RS leads to a more uniform distribution of the foaming agent. Finally, the AFS with porosity of 74.55%, roundness of 0.97, and average pore diameter of 1.192 mm is prepared. Full article

Friction stir welding has been extensively applied for the high-quality bonding of Mg alloys. The welding temperature caused by friction and plastic deformation is essential for determining the joint characteristics, especially the residual stress and weld microstructure. In this work, a modified moving heat source model was proposed by considering the variations in heat generation caused by friction shear stress at both the side and bottom surfaces of the tool. The application of this model was further extended to the entire welding process, especially in the plunging stage. The relative errors between the experimental and simulated peak temperatures at characteristic points were small, with a maximum of 10%, thereby validating the model for accurate temperature prediction. Furthermore, the influence of welding and rotational speed on temperature fields was systematically investigated. At relatively low welding and rotational speeds, the welding temperature increased significantly with either an increase in rotational speed or a decrease in welding speed. However, this effect gradually diminished at higher welding and rotational speeds. These results provide some valuable guidelines for controlling heat generation to improve the quality of Mg alloy welds. Full article

Corrosive environments can adversely affect the fatigue performance of bridges and other building structures. In order to determine the influence of corrosion on the fatigue failure of concrete composite girders with a corrugated web on a steel bottom plate (hereinafter referred to as CGCWSB), a scaled model test was conducted on a CGCWSB with a span of 30 m, which served as the structural prototype. Through the model test, theoretical analysis, and numerical simulation, the influence of uniform corrosion and pitting corrosion on the fatigue failure of the CGCWSB was determined, and the propagation law of pitting fatigue crack was determined. The results show that (1) the uniform corrosion caused the stress of the CGCWSB to become larger and the performance of the CGCWSB was reduced, the stress growth of the test girder after corrosion was about 10%, the corrosion rate was 9%, the pitting unevenness coefficient was 1.25, and the relative corrosion life was 26.34 years; (2) the fatigue failure of the non-corroded girder belongs to the weld fatigue failure, and the fatigue failure of the corroded girder was the coexistence of weld fatigue failure and pitting fatigue failure; (3) uniform corrosion did not create a new fatigue source, but it did result in the test girder’s fatigue failure ahead of time. Pitting corrosion did, however, create a new fatigue source; (4) an exponential correlation was present between the propagation length of a pitting crack and the number of equal load cycles. The ultimate failure mode of a pitting fatigue crack was when the crack length reached the thickness of the plate and the component was torn and destroyed; (5) following corrosion, the fatigue life of the test girder was found to be reduced by 10.65%, which suggests that salt corrosion had a significant impact on the fatigue life of the composite girder. This research work can provide a reference for the design and promotion of the use of the CGCWSB. Full article

Double-wire arc welding involves simultaneously feeding two wires into a molten pool, improving the efficiency and flexibility of traditional welding techniques. However, the interactions between the two wires and the molten pools are complex, which increases the difficulties in process and composition control. This work focuses on the weld pool flow characteristics in double-wire TIG arc welding. A CFD model incorporating a liquid bridge transfer model was developed to simulate the fluid flow phenomenon. Results show that the bead-forming appearances and flow characteristics of double-wire arc welding show no significant differences from single-wire arc welding. Welding current and welding speed have significant effects on the weld bead dimensions, while only welding current has effects on the flow characteristics. Wire feed XOZ angles show no significant influences on weld bead forming appearances and molten pool flow characteristics. Wire feed XOY angles influence the symmetry of the weld bead and the fluid flow. In 5B71/7055 heterogeneous double-wire arc welding, achieving a uniform distribution of alloy elements is difficult due to the complex convection patterns within the molten pool. Full article

This paper proposes a procedurefor multi-criteria calibration of a thermo-mechanical model for numerical simulation of welding in the space vacuum. A finite-element model of a steel plate is created. Experimental and computational data are obtained. An inverse problem is formulated for the vector identification of five calibration parameters from the heat-flow model. They are evaluated for adequacy with controlled accuracy according to four criteria. An optimization problem is solved using a two-step interactive procedure. The parameter space studying method (PSI) has been applied to the study of multidimensional regions by means of quasi-uniform sounding. A Pareto-optimal set is defined. It is used to determine reduced ranked Pareto subsets by μ-selection. Salukvadze optimum is also determined. Full article

Ship welding is a crucial part of ship building, requiring higher levels of robot coordination and working efficiency than ever before. To this end, this paper studies the coordinated ship-welding task, which involves multi-robot welding of multiple weld lines consisting of synchronous ones to be executed by a pair of robots and normal ones that can be executed by one robot. To evaluate working efficiency, the objectives of optimal lazy robot ratio and energy consumption were considered, which are tackled by the proposed dynamic Kuhn–Munkres-based model-free policy gradient (DKM-MFPG) reinforcement learning algorithm. In DKM-MFPG, a dynamic Kuhn–Munkres (DKM) dispatcher is designed based on weld line and co-welding robot position information obtained by the wireless sensors, such that robots always have dispatched weld lines in real-time and the lazy robot ratio is 0. Simultaneously, a model-free policy gradient (MFPG) based on reinforcement learning is designed to achieve the energy-optimal motion control for all robots. The optimal lazy robot ratio of the DKM dispatcher and the network convergence of MFPG are theoretically analyzed. Furthermore, the performance of DKM-MFPG is simulated with variant settings of welding scenarios and compared with baseline optimization methods. Compared to the four baselines, DKM-MFPG owns a slight performance advantage within 1% on energy consumption and reduces the average lazy robot ratio by 11.30%, 10.99%, 8.27%, and 10.39%. Full article