Mitigating distortion and residual stress by static thermal tensioning to improve fatigue crack growth performance of MIG AA5083 welds

Ilman, Mochammad Noer; Kusmono, Kusmono; Muslih, Muhamad; Subeki, Nur; Wibowo, Heri Budi

doi:10.1016/j.matdes.2016.03.049

Cited by 39 publications

(19 citation statements)

References 23 publications

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“…Compared with as welded weld joint, fatigue crack propagation of the weld treated using TTT with 200 °C heating is lower. These results seen to be consistent with previous report [6] The Paris constant of C and n can be seen in Table 2. The n value for the weld treated using TTT heated is smaller than that of as welded, suggesting that fatigue crack growth rate is improved.…”

Section: Resultssupporting

confidence: 93%

“…These findings indicate that the temperature distribution, especially temperature gradient (dT/dx) influences the formation of distortion. It can be seen that a low or almost no distortion is observed when the heating temperature of TTT achieves 200 °C [6][7] [8]. TC1 TC3 TC4 TC4 TC1 TC3 TC4 TC3 TC4 TC3 TC2 TC1 TC3 TC2 TC1 Microstructures of the weld metals with and without TTT treatment are shown in Fig.…”

Section: Resultsmentioning

confidence: 99%

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Minimizing Distortion by Transient Thermal Tensioning and Its Effect on Fatigue Crack Growth Behavior of Flux Cored Arc Steel Weld Joints

Subeki¹,

Jamasri²,

Ilman³

et al. 2017

IJET

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Abstract-The need for weight saving and low distortion in structural design such us ship and railway structures is accomplished by the use of welding as a joining technique. This is becouse welding process allows to join thin plates despite the use of thin section material often produces distortion which leads to loss of precision and even structural integrity. One of welding techniques which is widely used for joining steel construction is flux-cored arc welding (FCAW). The aim of this study is to control distortion and improve fatigue performance using transient thermal tensioning (TTT).In this research, welding was conducted with and without TTT treatment. The secondary flame heating temperature for TTT treatments were 100 °C, 200 °C, and 300 °C and during welding process the thermal cycles were measured using a data acquisition. After the welding process was completed, a sequence of an experiment was conducted including chemical, distortion measurement and fatigue crack propagation test. Results show that TTT treatment reduces distortion and improves fatigue crack growth performance with the optimum heating temperature is achieved at 200 °C.Keyword-Thin plate, FCAW weld, TTT weld treatment, distortion, and fatigue. I. INTRODUCTION To date a welding technique plays an important role in design and manufacturing process especially for reducing heavy products, and energy consumption savings [1]. The weld joints are used in pressure vessels, ship structures and offshore buildings. Factors affecting the quality of weld joints include welding technique, electrode, joint designs and weld thermal cycles [2]. Because weld joints are heated locally by the welding heat source, temperatures around the weld joints are not uniform, but they vary with the distance from the weld centerline. Combined effect of local heating and undesirable thermo-physical properties such as high coefficient of expansion and high thermal conductivity can cause buckling distortion and residual stress.Comprehensive studies have been conducted to control buckling distortion and residual stress in thin plates either by post weld treatment or in-process welding. In-process welding includes preheating . Transient thermal tensioning is a technique for controlling the residual stress and distortion by applying secondary heating which moves together with the weld torch (heat source). The secondary heat sources are located at both sides of the weld well in front, beside and behind the weld torch.One of the welding techniques that is widely used to join steel constructions is an arc welding with welding wire containing a flux known as flux-cored arc welding (FCAW). It is easy for operation and it can be operated continuously. The FCAW process involves wire filler which also acts as an consumable electrode and it is a feed continuously. As a result, welding can be performed semi-automatically, it is comfortable to operate and it has high reliability. FCAW is used for welding fillet lengthwise and for connecting the transverse done semi-automatically [12]....

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Section: Resultssupporting

confidence: 93%

Section: Resultsmentioning

confidence: 99%

Minimizing Distortion by Transient Thermal Tensioning and Its Effect on Fatigue Crack Growth Behavior of Flux Cored Arc Steel Weld Joints

Subeki¹,

Jamasri²,

Ilman³

et al. 2017

IJET

View full text Add to dashboard Cite

show abstract

“…It can be seen that a low or almost no distortion is observed when the heating temperature of STT achieves 200°C. These results seem to suggest that distortion could be mitigated with quenching and heating [5].…”

Section: Resultsmentioning

confidence: 83%

“…The use of TTT in welding can reduce the rate of fatigue crack propagation [4]. Recent investigation has shown that STT can reduce distortion, residual stress and rate of fatigue crack propagation [5] However, there has been limited data on the use of STT for reducing distortion and residual stress in FCAW steel welded structures. Therefore it is the subject of the present research.…”

Section: Introductionmentioning

confidence: 99%

The effect of heating temperature in static thermal tensioning (STT) welding on mechanical properties and fatigue crack propagation rate of FCAW in steel A 36

Subeki¹,

Jamasri²,

Ilman³

et al. 2017

AIP Conference Proceedings

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Effect of codoping cobalt and aluminum on enhancing the piezoelectricity properties of fiber-based zinc oxide AIP Conference Proceedings 1788, 030059 (2017); 10.1063/1.4968312Hot-corrosion of AISI 1020 steel in a molten NaCl/Na 2 SO 4 eutectic at 700°C AIP Conference Proceedings 1788, 030066 (2017); 10.1063/1.4968319The influence of surface modification on sound absorption coefficient of albizzia wood absorber AIP Conference Proceedings 1788, 030047 (2017) Abstract. The trend in mechanical design and manufacturing process is marked by the use of thin structures to reduce product weight and fuel savings. It is known that the main problem related to the welding of thin plates is distortion and residual stress which influence fatigue performance of welded structures. The aim of this study is to minimize distortion, improve the mechanical properties and to increase fatigue crack growth resistance of flux-cored arc A 36 steel welded joints using static thermal tensioning (STT) process. In this research, FCAW welding was conducted with and without STT process. The voltage, current, and heat input were 40 Volt, 210 Ampere and 2.184 kJ/mm, respectively. The position of both heaters was 80 mm, and weld with the cooling system was heated near weld center line. During the experiment, the weld metal cycles were measured using data acquisition. After completing the welding process, a sequence of the experiment was conducted including chemical analysis, measurement of distortion, tensile strength and hardness measurement and fatigue tests. Results of this research show that the STT-treat weld joints process performed at temperature of 200 °C produces the highest quality of weld, marked by lowest distortion, high tensile strength, low hardness in weld metal and improvement of fatigue performance

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“…In fact, thermal balance in-process control methods which employ additional heating with and without cooling sources during welding process are more desirable than those based on mechanical techniques 43) . This is because thermal stretching generated by differential heating is more efficient compared to mechanical stretching which requires complex setup and large forces for large structures.…”

Section: Mechanical and Thermal Balancementioning

confidence: 99%

Review on Mitigation of Welding-Induced Distortion Based on FEM Analysis

Kim

2020

Journal of Welding and Joining

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Welding distortion is an unavoidable issue due to localized expansion and contraction during the heating and cooling cycles, and has a negative effect on the fabrication process. However, mitigating weld distortion to meet product requirements is a challenging task, because welding shrinkage can't be prevented, only controlled. This paper provides a comprehensive literature review of various techniques to reduce and optimize the deformation induced by welding in the design stage and manufacturing process. Finite element numerical analysis methods are usually employed to predict welding distortion, and can cost less than actual experiments. The review of these approaches is useful to fully understand the main mechanisms used to mitigate weldinginduced distortion, and for choosing the most suitable method to minimize deformation based on realistic fabrication requirements.

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Mitigating distortion and residual stress by static thermal tensioning to improve fatigue crack growth performance of MIG AA5083 welds

Cited by 39 publications

References 23 publications

Minimizing Distortion by Transient Thermal Tensioning and Its Effect on Fatigue Crack Growth Behavior of Flux Cored Arc Steel Weld Joints

Minimizing Distortion by Transient Thermal Tensioning and Its Effect on Fatigue Crack Growth Behavior of Flux Cored Arc Steel Weld Joints

The effect of heating temperature in static thermal tensioning (STT) welding on mechanical properties and fatigue crack propagation rate of FCAW in steel A 36

Review on Mitigation of Welding-Induced Distortion Based on FEM Analysis

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