Connection Mechanism of Molten Pool during Laser Transmission Welding of T-Joint with Minor Gap Presence

Xu, Ke; Cui, Haichao; Li, Fuquan

doi:10.3390/ma11101823

Cited by 5 publications

(3 citation statements)

References 11 publications

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“…To date, welding simulations are validated and employed in industrial applications to study macro-level product deformation (distortion) and residual stresses. However, the simulation of other aspects of weld quality such as weld bead geometry, microstructure, and formation of metallurgical discontinuities such as cracks and pores are at a research stage [29][30][31][32][33]. Additional aspects of welding simulation that are under investigation are the effects of welding set-up parameters such as gun-to-workpiece distance and beam incident angle [34,35].…”

Section: Methodsmentioning

confidence: 99%

A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

et al. 2019

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During multidisciplinary design of welded aircraft components, designs are principally optimized upon component performance, employing well-established modelling and simulation techniques. On the contrary, because of the complexity of modelling welding process phenomena, much of the welding experimentation relies on physical testing, which means welding producibility aspects are considered after the design has already been established. In addition, welding optimization research mainly focuses on welding process parameters, overlooking the potential impact of product design. As a consequence, redesign loops and welding rework increases product cost. To solve these problems, in this article, a novel method that combines the benefits of design of experiments (DOE) techniques with welding simulation is presented. The aim of the virtual design of experiments method is to model and optimize the effect of design and welding parameters interactions early in the design process. The method is explained through a case study, in which weld bead penetration and distortion are quality responses to optimize. First, a small number of physical welds are conducted to develop and tune the welding simulation. From this activity, a new combined heat source model is presented. Thereafter, the DOE technique optimal design is employed to design an experimental matrix that enables the conjointly incorporation of design and welding parameters. Welding simulations are then run and a response function is obtained. With virtual experiments, a large number of design and welding parameter combinations can be tested in a short time. In conclusion, the creation of a meta-model allows for performing welding producibility optimization and robustness analyses during early design phases of aircraft components.

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Section: Methodsmentioning

confidence: 99%

A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

et al. 2019

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“…However, it is sometimes impractical to weld T-joints using conventional fillet welds due to the shielding of the face panels. Instead, the welding must be achieved from the face panel side to connect the face panel to the core panels (Figure 1) [5,6]. Many researchers have concerned the welded T-joints from the face panel side.…”

Section: Introductionmentioning

confidence: 99%

Research on the Weld Position Detection for the T-Joints in Web-Core Sandwich Panels Based on Eddy Current Technology

Wei

Chang

Meng

et al. 2020

Sensors

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Web-core sandwich panels have gained the popularity in various fields, especially aviation and shipbuilding, etc. Penetration welding was considered as an effective process to manufacture such a structure through a T-joint. To ensure the formation quality and mechanical properties of weld, the welding torch needs to be aligned with the T-joint position. However, it is difficult to locate the T-joint position (i.e., the position of core panel) because of the shielding of the face panels. This paper investigated the detection of T-joint position from the face panel side in web-core sandwich panels based on eddy current technology. First, we designed an experimental system for the weld position detection of T-joints from the face panel side. The relationships are investigated between the characteristics of the eddy current detection signal and the primary parameters of the detection system (including excitation frequency, coil outer diameter, and lift off distance) and the T-joint (including thickness of the core panel, gap distance, and thickness of the cover panel). Corresponding experiments were carried out with variable primary parameters, and the influence mechanism of the primary parameters on the detection results in terms of sensitivity and dynamic performance was elaborated to set up the theoretical basis for the detection. Finally, weld position detection experiments were carried out on TC4 titanium alloy T-joint specimens with 3 mm-thick face panel and 5 mm-thick core panel. Results showed that the maximum detection error was 0.482 mm, and the average error was 0.234 mm. This paper provided a possible technical solution to the automatic tracking problem for the welding of T-joints in the web-core sandwich panels.

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“…Considering the structural characteristics of the sandwich panels, it is sometimes impractical to weld such T-joints using conventional fillet welds, which is implemented from the core panel side. Instead, the welding must be implemented from the face panel side (backside of the fillet T-joint) to join the face panel to the core panels [5,6]. Many researchers have conducted in-depth studies of the influence of welding from the face panel side on the sandwich structure.…”

Section: Introductionmentioning

confidence: 99%

Research on the Weld Position Detection Method for Sandwich Structures from Face-Panel Side Based on Backscattered X-ray

Wei

Chang

Xue

et al. 2019

Sensors

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Web-core sandwich panels are a typical lightweight structure utilized in a variety of fields, such as naval, aviation, aerospace, etc. Welding is considered as an effective process to join the face panel to the core panel from the face panel side. However, it is difficult to locate the joint position (i.e., the position of core panel) due to the shielding of the face panel. This paper studies a weld position detection method based on X-ray from the face panel side for aluminum web-core sandwich panels used in aviation and naval structures. First, an experimental system was designed for weld position detection, able to quickly acquire the X-ray intensity signal backscattered by the specimen. An effective signal processing method was developed to accurately extract the characteristic value of X-ray intensity signals representing the center of the joint. Secondly, an analytical model was established to calculate and optimize the detection parameters required for detection of the weld position of a given specimen by analyzing the relationship between the backscattered X-ray intensity signal detected by the detector and the parameters of the detection system and specimen during the detection process. Finally, several experiments were carried out on a 6061 aluminum alloy specimen with a thickness of 3 mm. The experimental results demonstrate that the maximum absolute error of the detection was 0.340 mm, which is sufficiently accurate for locating the position of the joint. This paper aims to provide the technical basis for the automatic tracking of weld joints from the face panel side, required for the high-reliability manufacturing of curved sandwich structures.

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Connection Mechanism of Molten Pool during Laser Transmission Welding of T-Joint with Minor Gap Presence

Cited by 5 publications

References 11 publications

A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

Research on the Weld Position Detection for the T-Joints in Web-Core Sandwich Panels Based on Eddy Current Technology

Research on the Weld Position Detection Method for Sandwich Structures from Face-Panel Side Based on Backscattered X-ray

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