COMPARATIVE MECHANICAL BEHAVIOUR ANALYSIS

WITH POST WELD HEAT TREATMENT ON EN24

 
 ABSTRACT

Welding operation were carried out on the medium carbon steel followed by heat treating
 
(annealing), the specimen has to be heat treated at the weld zone to a temperature of 550°C using
heat treatment furnace. FCAW butt welding of EN24 steel best tensile strength was obtained and
depth of penetration also good in the Flux Core arc welding process. Comparatively tensile strength
obtained with PWHT process is higher then WOPWHT test plate. During the PWHT process tensile
strength of EN24 steel increased 43%.
 LITERATURE SURVEY:
S.NO Author Title/ Material Volume / Year Discussion
1. Syarul Asraf Procedia Welding speed, Arc The result shown increasing
The Effect of Flux Core
Mohamat Engineering 41 voltage and Current welding current will
Arc Welding (FCAW)
Izatul Aini influenced the value depth of
( 2012 ) 1497 –
Ibrahim processes on different penetration increased
1501
Amalina Amir Parameters/Mild steel
Abdul Ghalib
2. B. Senthilkumar Procedia welding voltage, The developed models can be
Sensitivity analysis of
Engineering 64 wire feed rate used to
T.Kannan flux cored arc welding
welding speed predict and simulate the
( 2013 ) 1030 –
process variables in plate distance influence of the process
1039
Super duplex stainless welding gun angle variables on the responses.
steel claddings./low
carbon
3. A. Aloraier FCAW process to avoid International Welding speed, Arc Examined different
the use of post weld heat Journal of voltage and Current percentages of bead overlaps
R. Ibrahim
treatment Pressure Vessels and studies their effects on the
P. Thomson and Piping mechanical properties as well
as the microstructures
 LITERATURE SURVEY:
S.N Author Title/ Material Volume / Year Discussion
O
4 N.B. Mostafa Optimisation of welding Achievements in Welding speed, Arc The optimization result also
parameters for Materials voltage and Current shows that weld penetration
.
weld penetration in and Nozzle to plate attains its maximum value
FCAW Manufacturing distance when welding current,
Engineering arc voltage , nozzle-to-plate
distance and electrode-to-work
angle are maximum and
welding speed is minimum

5. Li Yajiang Indian Academy Welding current Avoid such welding

Finite element analysis
Wang Juan, of Sciences cracks, the thermal stress in
Chen Maoai Shen of residual stress in the Welding voltage
the weld joint has to be
Xiaoqin Vol. 27, No. 2,
welded zone Weld heat input minimized by controlling the
April 2004
of a high strength steel/ weld heat input.
Thickness`
H130-GRADE
6 J. Dutta Experimental and Journal of Current From the analysis of heat loss
Narendranath S. analytical investigation Mechanical an optimum temperature has
Heat
of thermal parameters Engineering been observed and it is helpful
Developed in high Voltage to define the range of
Vol. ME 44, No.
carbon steel joints convection and radiation heat
2, December 2014 Surface area
formed by GTA welding loss phenomena.
 LITERATURE SURVEY:
S.NO Author Title/ Material Volume / Year Discussion
7. Vishnu V.S IOSR Journal of
Nadeera M Numerical Analysis of Mechanical and welding speed The effects of welding process
, Joy Varghese V.M Effect of Process Civil Engineering parameters (welding speed and
welding current
Parameters on Residual (IOSR-JMCE) e- welding current) in the
Stress in a Double Side TIG ISSN: 2278-1684, p- Heat symmetrical and asymmetrical
Welded Low Carbon Steel ISSN: 2320-334X double-side TIG welding process
Plate PP 65-68 were investigated. d

8. M. Pal Pandi Thermal Analysis on Butt International Journal Voltage a relationship

Dr. R. Kannan Welded Aluminium Alloy of Engineering between welding parameters and
Amp
AA7075 Plate Using FEM Research the responses of single pass
Volume No.3, Issue butt welding are evaluated through
No.2, pp : 116-120 the finite element
01 Feb. 2014 analysis.
(ISSN:2319-6890)
(online),2347-
5013(print)

9. M Sundar, Assessment of residual (ICME2005) 28- 30 Welding parameters Finite Element Method has been
G Nandi, stress and distortion in December 2005 conducted to
A Bandyopadhyay Welding by finite element illustrate the temperature
S C Roy method distribution, distortion and residual
stress field developed in the
weldment.
 LITERATURE SURVEY:
S.NO Author Title/ Material Volume / Year Discussion
10 International Different Groove
N. Akkuş1, Thermomechanical Analysis Congress on angle realize a simulation of arc welding
of Arc Welded Joint by Advances in using Finite Elements Analysis
Finite Element Method Welding Science (FEA).
and Technology for
Construction,
Energy and
Transportation
Systems (AWST -
2011)
 FCAW FEATURE

Metal cored wires have a Higher current density this results in

 Higher deposition rates
 Better penetration
 Better side wall fusion
 EXPERIMENTAL METHODOLOGY
•Selection of base material.
•Identify the importance FCAW welding process parameters.
•Find the upper and lower limits (i.e. range) of the identified process parameters.
•Select the orthogonal array (design of matrix).
•Conduct the experiments as per the selected orthogonal array.
•Record the quality characteristics.
•Find the optimum condition for FCAW welding through TAGUCHI
•Confirmation test & Identify the significant factors
 POST WELDING HEAT TREATMENT

Preheating the steel to be welded slows the cooling rate in the weld area. This may

be necessary to avoid cracking of the weld metal or heat affected zone. The need
for preheat increases with steel thickness, weld restraint, the carbon/alloy content of
the steel, and the diffusible hydrogen of the weld metal.
 OBJECTIVE OF THE PROJECT

PWHT can be used to reduce residual stresses, as a method of hardness control, or

even to enhance material strength. These parameters(welding current, welding voltage,
Bevel angle) are the process variables which control the weld deposition rate and weld
quality. Through this project can be determine the proper input parameter of EN24steel
with the thickness of 6mm with PWHT &with out PWHT
 SCOPE OF WORK

 To reduce or eliminate the cold crack produced during Arc welding procedures such
as Flux Core Arc Welding Process
 To Minimize change the mechanical properties of the steel.
 To investigate the welding strength with and with out PWHT method.
 PROBLEM IDENTIFICATION

Heat input is a relative measure of the energy transferred per unit length of weld. If improper

input parameter leads to maximize the heat input, it will induces, the metallurgical defects.

The thermal expansion and contraction during heating and subsequently cooling as well as

material plastic deformation at elevated temperatures result in inevitable distortions and

residual stresses in the joint and the parent metals, which greatly effects the fabrication

tolerance and quality.

PROJECT METHODOLOGY
 MATERIAL-EN24

(EN24) Specification Chemical composition

Carbon 0.36-0.44%

Silicon 0.10-0.40%

Manganese 0.60-1.00%

Sulphur 0.050 Max

Phosphorus 0.050 Max

APPLICATION
EN24 Material is used in tooling applications requiring a high degree of accuracy in hardening, such as
High strength shafts, Punches die, Drill bushings and Retaining rings.
PROCESS PARAMETER AND THEIR LEVEL

PROCESS PARAMETERS
LEVELS
AMPS VOLT BEVEL ANGLE

1 140 18 60

2 160 20 65

3 180 22 70
INPUT PARAMETER AND THEIR BOTH PROCESS

AMPS VOLT BEVEL θ

140 18 60

160 20 65

180 22 70

140 18 60

160 20 65

180 22 70
 HARDNESS STRENGTH

SAMPLES S1 S2 S3

WOPWHT EN24 86 78 88

PWHT EN24 86 84 85
COMPARISION OF HARDNESS ANALYSIS PWHT AND
WOPWHT
 TENSILE STRENGTH

TEST IDENTIFICATION BEVEL TENSILE

PLATE CURRENT VOLT TENSILE LOAD
ANGLEº STRENGTH
NO
42.18 451.51
1 140 18 60
WOPWHT
34.29 359.66
3 160 20 65
43.19 456.74
5 180 22 70
58.46 624.97
2 140 18 60
WPWHT
51.29 543.44
4 160 20 65
60.26 609.79
6 180 22 70
BEAD GEOMENTRY
COMPARISION OF TENSILE STRENGTH ANALYSIS
PWHT AND WOPWHT
VARIOUS SIZES OF BEAD WIDTH, DEPTH OF
PENETRATION

SAMPLES Area Mean Min Max Angle Length

0.179 110.51 70 192 0 7.754

S1
0.058 127.497 92 163 90 2.492

0.213 105.793 52.333 162.333 0 9.231

S2
0.051 111.795 74.667 151 90 2.215

0.211 76.677 40 107.667 0 9.138

S3
0.049 109.699 70.333 141.333 90 2.123
 RESULT &CONCLUSION
From the investigation the mechanical property of FCAW butt welding of EN24 steel with and without
PWHT, conclusions were summarized as following the tensile strength value. With PWHT process plate was
comparatively satisfied value (140 AMPS VOLT-18 Bevel angle 60º) than without PWHT test plate value. It
also induces high impact strength. Finally we concluded that in this project investigation the 140 AMPS
VOLT-18 Bevel angle 60º is the best parameter for EN24 -6 mm thickness plate for obtain the good weldment
state for the FCAW process with post weld heat treatment plate. Generally bead geometry analysis through
IMAGEJ software the test plate No -1 is achieved maximum depth of penetration and minimum bead width
(WOPWHT). Comparatively tensile strength obtained with PWHT process is higher then WOPWHT test
plate. During the PWHT process tensile strength of EN24 steel increased 43%.
 REFERENCE
1. Syarul Asraf Mohammad, Izatul Aini Ibrahima, Amalina Amira, Abdul GhalibaThe Effect of Flux Core Arc Welding
(FCAW) processes on differentParameters aUniversiti Teknologi Mara (UTM), Faculty of Mechanical Engineering, 40450
Selangor
2. B. Senthilkumara and T.Kannanb Sensitivity analysis of flux cored arc welding process variables in super duplex stainless
steel claddings. Assistant Professor, Department of Mechanical Engineeirng, Kumaraguru College of Technology,
Coimbatore – 641 049, Tamilnadu, India.bPrincipal, SVS College of Engineering, J P Nagar,Arasampalayam, Coimbatore –
641 109
3. A. Aloraier a,*, R. Ibrahim a, P. Thomson FCAW process to avoid the use of post weld heat treatmenta Department of
Mechanical Engineering, Monash University, P.O. Box 197, Caulfield East, Vic. 3145, Australia b School of Physics and
Materials Engineering, Monash University, Box 69M, Clayton, Vic. 3800, Australia
4. N.B. Mostafa, M.N. Khajavi Optimisation of welding parameters forweld penetration in FCAWMechanical Engineering
Department, Shahid Rajaee University, and Tehran, Iran
5. J.S. Seo, H.J. Kim*, H.S. Ryoo Microstructural parameter controlling weld metal cold cracking, Korea Institute of
Industrial Technology, 35-3 HongChonRi, IbJangMyun, ChanAnSi, 330-825, Korea
6. J. Dutta* and Narendranath S. Experimental and analytical investigation of thermal parameters developed in high
carbon steel joints formed by gta welding department of mechanical engineering, national institute of technology
karnataka, surathkal, india *corresponding e-mail:
7. Vishnu V.S, Nadeera M, Joy Varghese V.M Numerical Analysis of Effect of Process Parameters on Residual Stress
in a Double Side TIG Welded Low Carbon Steel Plate Dept. Of CIM, T.K.M College of engg./ Kerala University,
India 3Dept. of ME, SCT College of engg. / Kerala University, India
8. M. Pal Pandi, Dr. R. Kannan Thermal Analysis on Butt Welded Aluminium Alloy AA7075 Plate Using FEM
Department of Mechanical Engineering, PSNA College of Engineering and Technology, Dindigul, India.
9. M Sundar1, G Nandi, A Bandyopadhyay and S C RoyASSESSMENT OF RESIDUAL STRESS AND
DISTORTION IN WELDING BY FINITE ELEMENT METHODSchool of Laser Science & Engineering, Jadavpur
University, Kolkata-7000322
10. N. Akkuş1,a, E. Toptas2,b, O. Topal3 Thermomechanical Analysis of Arc Welded Joint by Finite Element Method
1Gedik University, Cumhuriyet Mahallesi, E-5 Yanyol No:29 Kartal, Istanbul 2Marmara University, High Collage for
Technical Sciences, Goztepe, Istanbul 3Marmara University, Institute of Pure Sciences, Goztepe Campus, Istanbul