Analysis of weld characteristics of micro-plasma arc welding and tungsten inert gas welding of thin stainless steel (304L) sheet

Batool, Sadaf; Khan, Mushtaq; Jaffery, Syed Husain Imran; Khan, Ashfaq; Mubashar, Aamir; Ali, Liaqat; Khan, Nawar; Anwar, Muhammad Ayaz

doi:10.1177/1464420715592438

Cited by 18 publications

(9 citation statements)

References 26 publications

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“…In this stage, most of the heat input is supplied for the SUS430 material and a minor amount of the heat input is supplied for the surface of SS400 material. Next, the heat input causes melting of both materials with a larger amount of melted metal on the SUS430 side, but they are still not penetrated fully, as indicated in 3 . Finally, both materials reach full penetration as in 4 .…”

Section: Formation Of Blowholementioning

confidence: 99%

“…On the other hand, for in welding in the vertical position, due to the critical influence of gravity force and the difficult set-up experimental process, no reports were found in the case of thin sheets. Only a few papers were published recently for joining thin plates by a micro-tungsten inner gas (TIG) welding process [1], micro-Plasma welding [2,3], and laser welding [4] in the plat position. For the laser welding process, because of the complexity in set-up, high cost and restricted safety conditions, it is difficult to apply in factories rather than laboratories and universities.…”

Section: Introductionmentioning

confidence: 99%

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Research and Development of a Novel TIG Welding Torch for Joining Thin Sheets

et al. 2019

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This paper aims to develop a novel tungsten inner gas (TIG) welding torch in order to join thin sheets efficiently. Using a narrowing nozzle (constricted nozzle) inside a conventional TIG torch can critically improve the position accuracy of the tungsten electrode and also the arc plasma characteristics and heat input density. In order to evaluate the efficiency of this new torch, weld bead appearance and cross-section images were examined by an optical microscope, scanning electron microscope (SEM), and electron back scatter diffraction patterns (EBSD). The results showed that in all cases, the weld bead profile was stable without undercut and burn-through. Full penetration weld was seen. The width of weld bead on the bottom surface was increased much in comparison to conventional TIG welding. However, the results from SEM and EBSD images indicated that in the case of low welding current, the blowholes were found out on the side of the thinner material (SS400). The penetration of SUS430 material to SS400 material was not good. It seems that no fusion of SUS430 material to SS400 at the bottom surface can be seen. Meanwhile, no blowholes were seen in the case of high welding current. The penetration was better, and the fusion was reached on the bottom surface.

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Section: Formation Of Blowholementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Research and Development of a Novel TIG Welding Torch for Joining Thin Sheets

et al. 2019

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“…Edge joint weld is a type of welding joint that is commonly used in ultra-thin-walled (thickness ≤ 0.15 mm) precision metal parts and components in industries of aircraft, aerospace, nuclear power, petrochemical, metallurgy, etc., such as the bellows-type accumulator in launch vehicle [ 1 , 2 , 3 ]. These welds are generally welded by precision welding, like micro-plasma arc welding (MPAW), micro-tungsten inert gas welding, or laser welding, which have concentrated energy distributions and narrow heat affected zones [ 4 , 5 , 6 ]. For many key welds, MPAW is preferred.…”

Section: Introductionmentioning

confidence: 99%

In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision

Hong

Chang

Peng

et al. 2018

Sensors

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Lack of fusion can often occur during ultra-thin sheets edge welding process, severely destroying joint quality and leading to seal failure. This paper presents a vision-based weld pool monitoring method for detecting a lack of fusion during micro plasma arc welding (MPAW) of ultra-thin sheets edge welds. A passive micro-vision sensor is developed to acquire clear images of the mesoscale weld pool under MPAW conditions, continuously and stably. Then, an image processing algorithm has been proposed to extract the characteristics of weld pool geometry from the acquired images in real time. The relations between the presence of a lack of fusion in edge weld and dynamic changes in weld pool characteristic parameters are investigated. The experimental results indicate that the abrupt changes of extracted weld pool centroid position along the weld length are highly correlated with the occurrences of lack of fusion. By using such weld pool characteristic information, the lack of fusion in MPAW of ultra-thin sheets edge welds can be detected in real time. The proposed in-process monitoring method makes the early warning possible. It also can provide feedback for real-time control and can serve as a basis for intelligent defect identification.

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“…Buste et al 9 measured the residual deformation of aluminum alloy laser welding by different process parameters. Batool et al 10 found that the joint produced by micro-plasma arc welding exhibited higher tensile strength, higher ductility, smaller dendrite size and a narrow heat-affected zone. Ji and Zhou 11 studied the effect of electrode pressure and displacement on welding deformation of sheet metals.…”

Section: Introductionmentioning

confidence: 99%

Welding deformation analysis of aluminum alloy and steel sheet metal parts based on resistance spot welding

Xing

Wang

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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Auto-body lightweight is becoming an important trend of energy saving and emission reduction. Various materials assembled together would be used to fabricate the auto-body to satisfy this demand. However, the assembly dimensional quality is difficult to be controlled in the real processing due to the huge differences in material properties. Therefore, it is necessary to control and analyze the welding deformation of aluminum alloy and steel. In this work, the orthogonal design experiment has been adopted to analyze the welding deformation of steel–aluminum sheet parts. Subsequently, the response surface model is proposed to establish the relationship between welding deformation and welding parameters by finite element analysis, which is verified by physical experiments again. Meanwhile, the anti-deformation method is also used to decrease the assembly deformation successfully. And the case of Z-shaped planes is applied to further illustrate the proposed method of this work. Finally, the results show that both the methods have a good simulation effect and a high prediction accuracy for the assembly dimensional quality.

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Analysis of weld characteristics of micro-plasma arc welding and tungsten inert gas welding of thin stainless steel (304L) sheet

Cited by 18 publications

References 26 publications

Research and Development of a Novel TIG Welding Torch for Joining Thin Sheets

Research and Development of a Novel TIG Welding Torch for Joining Thin Sheets

In-Process Monitoring of Lack of Fusion in Ultra-Thin Sheets Edge Welding Using Machine Vision

Welding deformation analysis of aluminum alloy and steel sheet metal parts based on resistance spot welding

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