Investigating the Effects of Process Variables on the Residual Stresses of Weld and Laser Cladding

Schnier, Gladys; Wood, JodiAnne T.; Galloway, Alexander

doi:10.4028/www.scientific.net/amr.996.481

Cited by 10 publications

(5 citation statements)

References 12 publications

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“…At the interface, there is no sharp discontinuity present, as was illustrated in the previous modeling results [52]. Such discontinuity stresses were expected to be exaggerated because of the idealized interface modeled, which did not account for alloying and diffusion due to the weld cladding process [53]. A slight increase in tensile residual stress occurs immediately upon entering the substrate material, prior to a decrease into the compressive region.…”

Section: Resultsmentioning

confidence: 84%

Multiscale Measurements of Residual Stress in a Low-Alloy Carbon Steel Weld Clad with IN625 Superalloy

Benghalia

Rahimi

Wood

et al. 2018

Materials Performance and Characterization

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Fatigue fracture is one of the major degradation mechanisms in the low-alloy 4330 carbon steel pumps that are utilized in the hydraulic fracturing process operating under cyclic loading conditions. A weld cladding technology has been developed to improve the ability of these components to resist fatigue crack initiation by cladding them with a secondary material. This process introduces a residual stress profile into the component that can be potentially detrimental for fatigue performance. The cladding technology under examination is a low-alloy 4330 carbon steel substrate weld that is clad with the nickel-chromium-based superalloy IN625 and is investigated herein using several experimental residual stress measurement techniques. Understanding the magnitude and distribution of residual stress in weld clad components is of the utmost importance to accurately assess the performance of the component in service. This study summarizes the results of residual stress measurements that were determined using X-ray diffraction, i.e., hole drilling based on electronic speckle pattern interferometry, deep-hole drilling, and the contour method, to obtain the residual stress distributions from the surface of the weld clad, through the clad layer, and into the substrate material. The results of deep-hole drilling and the contour method show large-scale tensile residual stress in the clad layer and compressive residual stress in the majority of the substrate. However, the X-ray diffraction and hole drilling methods indicate the presence of short-scale compressive residual stress on the surface and near the surface of the clad layer. It was shown that these Manuscript

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Section: Resultsmentioning

confidence: 84%

Multiscale Measurements of Residual Stress in a Low-Alloy Carbon Steel Weld Clad with IN625 Superalloy

Benghalia

Rahimi

Wood

et al. 2018

Materials Performance and Characterization

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“…Weld-cladding simulations are typically performed by thermomechanical simulation methods, which predict the global thermo-mechanical behavior of the weld. Incorporating thermal material parameters into the model at the melting point and room temperature simplifies this behavior [44]. Lou et al [45] developed a three-dimensional finite element model to examine the influence of a heat source on a heat-affected zone.…”

Section: Reinforcement Of Toolingsmentioning

confidence: 99%

Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding

Israr

Buhl

Härtel

et al. 2022

Metals

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Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters.

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“…Cottam et al [30] investigated the effect of the deposition rate on the residual stresses formed during the laser cladding of Ti-6Al-4V powder onto a Ti-6Al-4V substrate. The above studies are mainly aimed at titanium alloy [31], nickel-based alloy [32,33], stainless steel, and other materials [34], but there are relatively few studies on 12CrNi2 high-performance alloy steel, which plays an important role in the national economy and national defense. At the same time, the research on the temperature and stress field of LMD is mainly based on single-track, thin wall, and plane models.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Study on Residual Stress in the Curved Surface Forming of 12CrNi2 Alloy Steel by Laser Melting Deposition

Cui

Dong³

et al. 2020

Materials

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The performance and service life of the nuclear emergency diesel engine shaft made of 12CrNi2 alloy steel is very important for the safety of nuclear power. Laser melting deposition (LMD) is a challenging camshaft-forming technology due to its high precision, rapid prototyping, and excellent parts performance. However, LMD is an unsteady process under the local action of laser, especially for curved surface forming, which is more likely to generate large residual stress on components, resulting in cracks and other defects. At present, the stress research on LMD curved surface forming is relatively insufficient. In the present paper, material parameter testing, high-temperature mechanical properties analysis, single-track sample preparation, and heat source checks are conducted. At the same time, the ABAQUS software and the DFLUX heat source subroutine are used to compile the curved double-ellipsoidal moving heat source, and the effects of the temperature-dependent thermophysical parameters and phase change latent heat on the temperature field are considered. A three-dimensional finite element model is established to analyze the thermal stress evolution and residual stress distribution of multi-track multi-layer on a curved surface by LMD, and the effect of the scanning method and interlayer cooling time on the residual stress of the formed components is studied. The results show that with the increase in temperature, the strength of the material reduces, and the fracture morphology of the material gradually transitions from ductile fracture to creep fracture. The material parameters provide a guarantee for the simulation, and the errors of the width and depth of the melt pool are 4% and 9.6%, respectively. The simulation and experiment fit well. After cooling, the maximum equivalent stress is 686 MPa, which appears at the junction of the substrate and the deposited layer. The larger residual stress is mainly concentrated in the lower part of the deposited layer, where the maximum circumferential stress and axial stress are the tensile stress. Compared with the axial parallel lap scanning method, the arc copying lap scanning method has a relatively smaller maximum thermal stress and residual stress after cooling. The residual stress in the deposited layer is increased to some extent with the increase in the interlayer cooling time.

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Investigating the Effects of Process Variables on the Residual Stresses of Weld and Laser Cladding

Cited by 10 publications

References 12 publications

Multiscale Measurements of Residual Stress in a Low-Alloy Carbon Steel Weld Clad with IN625 Superalloy

Multiscale Measurements of Residual Stress in a Low-Alloy Carbon Steel Weld Clad with IN625 Superalloy

Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding

Numerical Simulation and Experimental Study on Residual Stress in the Curved Surface Forming of 12CrNi2 Alloy Steel by Laser Melting Deposition

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