Experimental and numerical study to minimize the residual stresses in welding of 6082-T6 aluminum alloy

Costa, S.; Souza, Maria Sabrina; César, Manuel B.; Gonçalves, José; Ribeiro, José Carlos Rabelo

doi:10.3934/matersci.2021018

Cited by 9 publications

(6 citation statements)

References 31 publications

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“…25 In most cases, tensile residual stresses are apparent. 26 Based on these discussions, higher tensile residual stresses can be produced at lower printing speeds (i.e., longterm process), which may reduce the mechanical resistance of the manufactured parts. 27 Therefore, it can be expected that the 40 mm/s printing speed resulted in the lower failure loads, and the 80 mm/s printing speed induced the highest value of failure loads, but the obtained results were completely vice-versa.…”

Section: Printing Speedmentioning

confidence: 99%

Printing strategies to fabricate a disk through the fused deposition modeling method

Yousefi

Hashemi

Sedighi

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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The fused deposition modeling (FDM) technique is widely used in different industries due to its low cost and ability to produce complex geometries from polymers. In this technique, some manufacturing parameters are essential because of their effects on the mechanical performance of the final fabricated part. The current study investigated the impact of path strategy and printing speed, two key manufacturing factors, on the mechanical performance of printed disks. Six types of path strategies of rasters corresponding to the loading direction, namely unidirectional-vertical, unidirectional-horizontal, unidirectional-45, cross, cross-45, and concentrate, were used for printing some disks, and compressive tests were done on them. The results showed that these path strategies’ average compressive failure loads were 2955, 4957, 2342, 4640, 3971, and 5893 N, respectively. The lower compressive strength of the unidirectional path pattern was due to the weak zones that were located between the printed layers and rasters. Besides, three printing speeds of 40, 60, and 80 mm/s were considered to fabricate the disks with a concentrate path pattern, and compressive experiments were performed. The results showed that the 40 mm/s printing speed conducted a compressive failure load of 4544 N, while 60 and 80 mm/s resulted in 3008 and 2828 N, respectively. Finally, inter-layer strength as a major factor in controlling the compressive strength of the disks was comprehensively discussed.

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Section: Printing Speedmentioning

confidence: 99%

Printing strategies to fabricate a disk through the fused deposition modeling method

Yousefi

Hashemi

Sedighi

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…Therefore, the development of corresponding control technology based on numerical simulation becomes imperative. Numerical simulations enable the effective prediction of the distribution of the welding temperature field and welding stress field [ 3 , 4 , 5 ], facilitating the optimization of welding process parameters [ 6 , 7 , 8 , 9 , 10 ]. This optimization enhances welding quality, reduces production costs, and enhances production efficiency in the welding process.…”

Section: Introductionmentioning

confidence: 99%

Tungsten Inert Gas Welding of 6061-T6 Aluminum Alloy Frame: Finite Element Simulation and Experiment

Hu,

Pei,

et al. 2024

Materials

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In order to address the irregularity of the welding path in aluminum alloy frame joints, this study conducted a numerical simulation of free-path welding. It focuses on the application of the TIG (tungsten inert gas) welding process in aluminum alloy welding, specifically at the intersecting line nodes of welded bicycle frames. The welding simulation was performed on a 6061-T6 aluminum alloy frame. Using a custom heat source subroutine written in Fortran language and integrated into the ABAQUS environment, a detailed numerical simulation study was conducted. The distribution of key fields during the welding process, such as temperature, equivalent stress, and post-weld deformation, were carefully analyzed. Building upon this analysis, the thin-walled TIG welding process was optimized using the response surface method, resulting in the identification of the best welding parameters: a welding current of 240 A, a welding voltage of 20 V, and a welding speed of 11 mm/s. These optimal parameters were successfully implemented in actual welding production, yielding excellent welding results in terms of forming quality. Through experimentation, it was confirmed that the welded parts were completely formed under the optimized process parameters and met the required product standards. Consequently, this research provides valuable theoretical and technical guidance for aluminum alloy bicycle frame welding.

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“…In the simulation research of welding residual stress, Ghafouri et al 4 analyzed the welding residual stress of high-strength steel (HSS) S700 by ABAQUS software. Costa S et al 5 obtained baseline data by measuring and analyzing the temperature and residual stresses during the welding process. They then conducted experiments using different welding parameters and techniques to compare the distribution and magnitude of residual stresses under different conditions.…”

Section: Introductionmentioning

confidence: 99%

Influence of welding residual stress and welding method on fracture properties of welded joints

Luo

Tan

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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To investigate the influence of residual stress on the fracture performance of T-joint welded joints in 6063 aluminum alloy, ABAQUS simulation was utilized to obtain the post-weld residual stress fields for different welding methods. A finite element model for toughness fracture of T-joints was established using the Johnson-Cook constitutive and damage models, aiming to analyze the impact of welding residual stress on fracture performance. The results indicate that under the same tensile rate, residual stress can lead to earlier fracture occurrence in the welded joints, thereby reducing the overall fracture performance. Among the different welding methods, the double-sided corner weld exhibits the best fracture performance, while the butt joint with a backing plate can effectively mitigate the influence of post-weld residual stress on fracture performance. Through the comparison of experiments and simulations, the material constitutive and damage parameters of each welding zone are verified, and the hardness test is carried out. The results indicate that the average hardness in the weld zone is approximately 63.8 HV, which is higher than the average hardness of 60.2 HV in the heat-affected zone. However, both the weld zone and the heat-affected zone have lower hardness values compared to the average hardness value of 81.5 HV in the base metal zone. Furthermore, it is observed that residual tensile stresses are predominantly distributed in the weld zone, which is one of the reasons contributing to the lower hardness at the center of the weld.

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Experimental and numerical study to minimize the residual stresses in welding of 6082-T6 aluminum alloy

Cited by 9 publications

References 31 publications

Printing strategies to fabricate a disk through the fused deposition modeling method

Printing strategies to fabricate a disk through the fused deposition modeling method

Tungsten Inert Gas Welding of 6061-T6 Aluminum Alloy Frame: Finite Element Simulation and Experiment

Influence of welding residual stress and welding method on fracture properties of welded joints

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