Predictive control based double-electrode submerged arc welding for filet joints

Lu, Yi; Chen, Jinsong; Zhang, Yuming; Kvidahl, L.

doi:10.1016/j.jmapro.2014.05.001

Cited by 20 publications

(3 citation statements)

References 11 publications

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“…In all cases, desirable spray transfer is much easily obtained and guaranteed at low base metal currents and the process is thus suitable also sheet metal welding that often requires short-circuiting transfer based processes which are not always preferred due to the lower productivity [94]. Efforts have been made to provide robust controls to assure process stability [95][96][97] and desired separate controls of the heat input and wire melting speed.…”

Section: Filling Processesmentioning

confidence: 99%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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Welding is a major manufacturing process that joins two or more pieces of materials together through heating/mixing them followed by cooling/solidification. The goal of welding manufacturing is to join materials together to meet service requirements at lowest costs. Advanced welding manufacturing is to use scientific methods to realize this goal. This paper views advanced welding manufacturing as a three step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the welding parameters by adjusting the welding parameters based on such real-time sensing and feedback control. The paper analyzes how these three steps depend on process properties/capabilities, process innovations, predictive models, numerical models for fluid dynamics, numerical models for structures, real-time sensing, and dynamic control. The paper also identifies the challenges in obtaining ideal solutions and reviews/analyzes the existing efforts toward better solutions. Special attention and analysis have been given to (1) gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) as benchmark processes for penetration and materials filling; (2) keyhole plasma arc welding (PAW), keyhole-tungsten inert gas (K-TIG), and keyhole laser welding as improved/capable penetrative processes; (3) friction stir welding (FSW) ......

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Section: Filling Processesmentioning

confidence: 99%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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“…The appropriate size of nonmetallic inclusions for AF nucleation stated in the literature is 1.1 μm. Besides, the minimum inclusion size for nucleation is 0.2 μm [20,21]. Tae-kyu et al [22] examined low-carbon steel WM and classi ed the inclusions into two groups of the non-nucleant and the nucleant.…”

Section: Introductionmentioning

confidence: 99%

Microstructural and mechanical evaluations of SAW by manufactured granular basic bonded Cr, Mo, and Cr–Mo active fluxes on ST37 low carbon steel

Alishavandi

Mohammadmirzaei

Ebadi

et al. 2022

Int J Adv Manuf Technol

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Bead-on-plate submerged arc welding was conducted on St37 steel by manufactured Cr, Mo, and Cr-Mo active basic uxes produced via the unfused bonded method. The base metal heat-affected zone and weld metal (WM) microstructures were identi ed and characterized by optical microscopy and scanning electron microscopy. Then, the ferrite morphologies volume fraction of WMs were measured. Moreover, the chemical analysis of slag and inclusions was evaluated by point scan energydispersive X-ray spectroscopy and extensively discussed. Inclusions number density and size and their effects on the formation of AF were also elaborated. Then, the WMs' longitudinal tensile strength and Vickers hardness were measured.Finally, the Charpy V-notch test was conducted to determine the impact toughness; the fracture surfaces were investigated, as well.

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“…Cho et al (2013; studied the molten pool behavior in the tandem submerged arc welding process using computational fluid dynamics. To minimize the resultant variations in currents and resultant welds, Lu et al (2014a;2014b) modeled the double electrode submerged arc welding process and a multivariable predictive control algorithm was developed to control the process variables at desired levels. The effect of external load on angular distortion in submerged arc welded fillet joints were studied by Park et al (2012).…”

Section: Introductionmentioning

confidence: 99%

Influence of tacking sequence on residual stress and distortion of single sided fillet submerged arc welded joint

Mondal

Biswas

Bag

2015

J. Marine. Sci. Appl.

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Submerged arc welding (SAW) is advantageous for joining high thickness materials in large structure due to high material deposition rate. The non-uniform heating and cooling generates the thermal stresses and subsequently the residual stresses and distortion. The longitudinal and transverse residual stresses and angular distortion are generally measured in large panel structure of submerged arc welded fillet joints. Hence, the objective of this present work is to quantify the amount of residual stress and distortion in and around the weld joint due to positioning of stiffeners tack. The tacking sequence influences the level of residual stress and proper controlling of tacking sequences is required to minimize the stress. In present study, an elasto-plastic material behavior is considered to develop the thermo mechanical model which predicts the residual stress and angular distortion with varying tacking sequences. The simulated result reveals that the tacking sequence heavily influences the residual stress and deformation pattern of the single sided fillet joint. The finite element based numerical model is calibrated by comparing the experimental data from published literature. Henceforth, the angular distortions are measured from an in-house developed experimental set-up. A fair agreement between the predicted and experimental results indicates the robustness of the developed numerical model. However, the most significant conclusion from present study states that tack weld position should be placed opposite to the fillet weld side to minimize the residual stress.

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Predictive control based double-electrode submerged arc welding for filet joints

Cited by 20 publications

References 11 publications

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Microstructural and mechanical evaluations of SAW by manufactured granular basic bonded Cr, Mo, and Cr–Mo active fluxes on ST37 low carbon steel

Influence of tacking sequence on residual stress and distortion of single sided fillet submerged arc welded joint

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