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    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment by Plasma-MAG Hybrid Welding Process

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    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment by Plasma-MAG Hybrid Welding Process

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    Kaushik Sengupta
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    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment by Plasma-MAG Hybrid Welding Process

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    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment by Plasma-MAG Hybrid Welding Process

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    44 views5 pages

    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment by Plasma-MAG Hybrid Welding Process

    Uploaded by

    Kaushik Sengupta
    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment by Plasma-MAG Hybrid Welding Process

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 5

    5th International Conference on Information Engineering for Mechanics and Materials (ICIMM 2015)

    Residual Stress and Deformation of Bogie Frame Steel Plate Weldment


    By Plasma-MAG Hybrid Welding Process
    Xiangyang Wu1, a, Zhiyi Zhang1, b, Weichuang Qi1, c,Renyong Tian2, d
    1
    CSR Qingdao Sifang Locomotive and Rolling Stock Co.,Ltd.,Qingdao 266111,China
    2
    Dalian Jiaotong University,Dalian 116028
    a
    sfxiangyangw@163.com, yefan_0954@163.com, cqwc5137@163.com, dtianrenyonghj@163.com
    b

    Keywords: plasma-MIG hybrid welding process; residual stress; welding deformation; bogie frame

    Abstract. The residual stress and welding deformation were measured for the bogie frame steel
    plate SMA490BW butt joint welded by using the plasma-MIG hybrid welding process and the
    general MAG welding process respectively, as well as in different groove angle conditions. The
    results indicate that the plasma-MAG hybrid welding can effectively reduce the residual stress and
    the welding deformation compared with the classic MAG welding. With the decrease of groove
    angles, the residual stress and welding deformation reduced accordingly. From the angle of
    reducing the residual stress and the deformation, the plasma-MAG hybrid welding process should
    be adopted in the way of narrow groove.

    Introduction
    The bogie frame is the main constructional part of weight bearing for the high-speed train. It is
    not only supporting the train body and every kind of components, but also transporting every kinds
    of loading. During the train body is manufactured the MAG welding process is mainly used for the
    welding of bogie frame, but as the structure of frame is complicated, the distribution density of
    welding line is large and the MAG welding process is possessed of itself characters, the
    complicated residual stress and welding deformation will be produced after welding of the frame.
    So there are bad influences to the bogie frame’s breakage, fatigue strength, and the accuracy of
    shape dimension and the stability of the structure. And the residual stress is the main reason to the
    welding deformation and fatigue damage [1-3]. Consequently, how to effectively reduce the residual
    stress and the welding deformation is the main problem in the welding and producing process of the
    bogie frame.
    The impact elements of the residual stress and welding deformation are many and complicated,
    which is caused by the nonuniform elastic-plastic strain during the nonuniform heating and cooling
    in the welding process of the frame. The welding technique, joint type, welding heat imput,
    assembling and welding sequence, the number of plies, the restrain intensity of frock and the fit-up
    gap and so on directly influence on the residual stress and welding deformation of the frame [3,4].
    The plasma-MAG hybrid welding is a new kind of welding technique which combines two
    different welding techniques, Plasma welding and MAG welding . By complementing each other’s
    advantages of these two welding heat sources, it can improve the welding quality and welding
    efficiency. Compared with the classic MAG welding, the plasma-MAG hybrid welding can reduce
    the welding heat input, concentrate on the welding energy and reduce the HAZ size, so it is hard to
    produce deformation of the components and parts [5,6].
    Therefore, this article respectively takes the butt weldments of SMA490BW steel for the bogie
    frame to investigate the different welding techniques and groove angle conditions’ efforts to the
    residual stress and welding deformation. And it provides the experimental basic theory for the
    plasma-MAG hybrid welding process to be used in the frame welding.

    © 2015. The authors - Published by Atlantis Press 712


    Test materials and methods
    Test materials
    The SMA490BW steel plate (thickness of 12 mm) was slected for the test materials, and the size
    of test plate is 350mm*150 mm. The welding wire choosed is CHW-55CNH solid core wire
    (diameter of 1.2mm). The welding protective gas is 80% Ar +20%CO 2 mixed gases.

    Test method
    Welding procedure method
    The MAG welding and the plasma-MAG hybrid welding, and the single v-shaped groove
    multilayer multichannel welding process was used respectively. The joint type is butt joint,
    welding’s groove angle is 60° for the MAG, and the plasma - MAG hybrid welding’s groove angle
    is 30° and 60° respectively. The blunt edge and the gap is 1 mm. During the welding process, the
    weldment keeps unconstrained state. The welding process parameters are listed in table 1.

    Table.1 Welding process parameters


    wroove plasma plasma MIG MIG welding plasma gas
    welding weld
    angle current voltage current voltage speed flow
    process pass
    /° /A /V /A /V /cm·min-1 /L·min-1
    1 180 27.2 190-200 20.6 60 6
    30
    2 100 23 260-270 27.7 40 3
    Plasma-MAG
    1 120 24.6 180-190 19.4 60 5
    60
    2~3 80 22 255-260 26.3 35 3
    1 / / 110-115 20.5 20 /
    MAG 60
    2~3 / / 265-270 28.1 30 /

    Residual stress measurement


    Residual stress measurement reference CB3395-92 using the blind hole method. The position of
    the stress measuring point is shown in figure 1,weld residual stress along the direction of weld
    direction is the longitudinal residual stress, expressed with sigma x, weld residual stress of
    perpendicular to the direction is the transverse residual stress, with sigma y said. The distance
    between the residual stress test point is not less than 30 mm.

    Fig. 1 The location of residual stress measuring point Fig. 2 The scene of residual stress measurement

    When it is measured, a resistance strain gage which model is BE120-2CA–K is pasted on the
    position to be measured, the sensitive coefficient is 2.16. The CCZ-1 test drilling equipment is
    adopted to drill a blind hole with diameter of 2 mm and 2 mm deep. According to the released
    strains obtained throuth YJ-25 type strain gauge, the residual stress of the position is calculated by
    713
    means of elastic theory. The scene of residual stress measurement is shown in figure 2.
    Welding deformation measurement
    Using Hexagon three-dimentional coordinate measuring machine, the welding residual
    deformation was precisely measured based on triggering and scanning technology. Welding
    deformation test points are shown in figure 3.
    When the deformation measured, the weldment was firstly fixed on the worktable, and then the
    one side of the weldment was tightly pressed, the other side of the weldment appeared a free state.
    Selected zero position as a benchmark, the three-dimentional space coordinates of each measuring
    point of the welding pieces were measured, and then according to the corresponding coordinate
    values of the two points, the angular deformation was calculated by the pythagore’an theorem. The
    scene of welding deformation measurement is shown in figure 4.

    Fig. 3 The location of welding deformation Fig. 4 The scene of welding deformation
    measuring point measurementt

    The test results and analysis


    Residual stress
    Welding residual stress distribution is shown in figure 5. Can be seen from figure 5, both MAG
    welding and plasma-MAG hybird welding, longitudinal residual stress σ x of the weld seam and its
    nearby regions are in tensile stress state, the stress value is close to or achieves the yield limit of
    SMA490BW steel. With the increase of distance from the weld centerline, σ x gradually change
    from tensile residual stress to compression residual stress. Compared with the longitudinal residual
    stress σ x , transverse residual stress σ y is in lower stress levels.
    Compared with the traditional MAG welding, under the conditions of the same welding process,
    the longitudinal residual stress σ x and transverse residual stress σ y are all down to a certain extent
    by using the plasma-MAG hybird welding, and among them the σ x reduce about 7.5% at the weld
    seam and 18.1% at the near seam area. The main reason for residual stress decline with
    plasma-MAG hybrid welding is the heat energy of plasma-MAG hybrid welding is more
    concentrated than traditional MAG welding, heating range is shrink, and welding speed is rapid,
    welding heat input is reduced, so as to reduce high temperature thermoplastic area to reduce
    residual stress.
    Using plasma-MAG hybrid welding method and at the same time the other welding process
    conditions unchanged, with reduction of the weld groove angle, the welding residual stress also
    reduced accordingly. Compared with the commonly used 60° groove angle, the σ x of weld area
    reduces 6.7%, and the near seam regions the σ x declins 19.6% when the angle of 30° groove is
    selected. Obviously, the groove angle is smaller, the weld beads and filler metals are less, and the
    welding heat input is more reduced, so that the residual stress of joint is reduced.
    Compared with the traditional MAG welding, choosing plasma-MAG hybrid welding process, or
    reducing the weld groove angle, can all reduce the residual stress of near weld seam regions and
    weld seam area, in the nearly seam area the effect of residual stress decrease is more obvious.

    714
    a) Longitudinal residual stress b) Transverse residual stress
    Fig. 5 The residual stress distribution of weldments

    The welding deformation


    The results of welding deformation measurement are shown in figure 6. In the same groove angle
    with 60°, the angular distortion of plasma-MAG welding is smaller than MAG welding, the average
    angular distortion θ reduced from 3.14°to 2.69° ,decrease about 14.3%. Plasma-MAG welding
    deformation is smaller than MAG welding, the main reason is the welding heat input is relatively
    small.
    With the welding method of plasma-MAG welding, the groove reduced from 60° to 30°, the
    average angular distortion θ reduced from 2.69° to 2.50°, reduced 7.1%. Welding groove angle is
    small, the filler metal and weld cross-sectional area is small, the contraction deformation is little
    after cooling. In addition, the narrower the groove angle, the lower the difference from top to
    bottom of the weld section, the smaller the bending deformation of wendment.
    In the case of other welding conditions unchanged, with the plasma-MAG hybrid welding and
    narrow groove welding technology the welding deformation can effectively reduce. Compared with
    the effect of reducing the deformation by reducing groove angle, the effect of using plasma-MAG
    hybrid welding instead of MAG welding to decrease welding deformation is better.

    Fig. 6 The welding deformation of weldments

    Summary
    (1) Compared with the traditional MAG welding, the residual stress of SMA490BW weldment is
    decreased obviously when the plasma-MAG hybrid welding process is adoped. At the same time,
    with the decrease of the weld groove angle, the residual stress reduced accordingly.
    (2) In the case of other welding conditions unchanged, by using plasma-MAG hybrid welding
    instead of MAG welding, or by reducing weld groove angle, the welding deformations can all be
    reduced.
    (3) Plasma-MAG hybrid welding technology with narrow groove of weldment can reduce the

    715
    welding residual stress and deformation more effectively.

    References
    [1] Xinglong Liu, Xiaoyan Li.The study of bogie frame welding residual stress and deformation .
    Journal of locomotive vehicle technology, 2006 (1) : 9-11
    [2] Wei Zhuang. Bogie frame welding residual stress and deformation of control. Journal of
    locomotive vehicle technology, 2013 (1) : 25-26
    [3] Jie Zhou. The influence of welding residual stress for the structure fatigue strength. Southwest
    jiaotong university, 2010, 1
    [4] Huanjun Liu. Bogie side beam welding residual stress and deformation of the study. Southwest
    jiaotong university,2012,5
    [5] Changchun Wang, Du Bing. Composite heat source plasma-MIG/MAG welding technology
    research Investigate and application . Welding, 2009, 10 (12) : 62-64.
    [6] Juefu Heng Zhenmin Wang. The research progress of plasma-MIG welding. Electric welding
    machine, 2013, 43 (3) : 28 to 30

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