Sequentially combined thermo-mechanical and mechanical simulation of double-pulse MIG welding of 6061-T6 aluminum alloy sheets

Wang, Jianbo; Chen, Xin; Yang, Lifei; Zhang, Guanchen

doi:10.1016/j.jmapro.2022.03.046

Cited by 20 publications

(11 citation statements)

References 36 publications

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“…However, in the case of the smooth specimen Figure 1(b), the fracture morphology is not uniform, showing that it is characterized by transgranular and intergranular fracture. In addition to this, the variation in the pattern of fracture is attributed to the locations of the fracture [16]. On the part of the morphologies of the dimples figure 1b, it could be observed that the reinforced specimens are a mixture of elongated and equiaxed dimples in which the dimples are elongated the direction of the shear stress which are shallow, large, and distributed randomly.…”

Section: Residual Stresses In Mig Welding Processmentioning

confidence: 92%

“…In a study by Wang et al [16], it was reported that the residual stresses and distortion of the welded joints could be analysed via a numerical simulation approach. Thus, the study proposed a sequentially combined thermo-mechanical and mechanical simulation to characterize the mechanical properties of the welded joint using a finite element approach.…”

Section: Residual Stresses In Mig Welding Processmentioning

confidence: 99%

See 1 more Smart Citation

Residual Stress Prediction during TIG and MIG Welding Process of Steel - A Review

Lawal,

Afolalu

2024

IOP Conf. Ser.: Earth Environ. Sci.

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In this study, a forensic review of residual stress predictions and its impact on welded joints especially the steel pipes during the Tungsten inert gas welding and metal inert gas welding processes were reviewed. It was established that in the case of MIG welding, the effect of residual stress can be reduced after treatment. In the case of TIG welding process, increase in current will lead to deformation and residual stresses. Estimating the residual stress is a challenging task. It is common to predict residual stress using a notch stress intensity factor, a numerical simulation approach coupled with a thermal-mechanical finite element model. Thus, adequate design in welding parameters will help in the optimization of the process to achieve a safe and reliable welded joint during TIG and MIG welding process.

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Section: Residual Stresses In Mig Welding Processmentioning

confidence: 92%

Section: Residual Stresses In Mig Welding Processmentioning

confidence: 99%

Residual Stress Prediction during TIG and MIG Welding Process of Steel - A Review

Lawal,

Afolalu

2024

IOP Conf. Ser.: Earth Environ. Sci.

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“…High-strength Al-Cu-Mg-Zn aluminum alloys are susceptible to solidification cracking owing to their high linear expansion and wide semi-solid temperature gap [ 7 , 8 ]. Metal inert gas welding (MIG welding) is a typical fusion welding method for aluminum alloys, and it is widely used due to its high productivity [ 9 , 10 ]. In common MIG welding mode, Al-Cu-Mg-Zn aluminum alloy welds exhibit large deformation and high solidification cracking susceptibility.…”

Section: Introductionmentioning

confidence: 99%

Solidification Cracking Restraining Mechanism of Al-Cu-Mg-Zn Alloy Welds Using Cold Metal Transfer Technique

Wang

et al. 2023

Materials

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Aluminum alloy 7075 (with 7055 and 7150 filler wires) was welded using a digital welding machine that can switch arc mode between MIG, CMT and CMT+P modes. The transverse-motion weldability test of joints welded under different arc modes showed that the solidification cracking susceptibility was lower in CMT-technique-based welds than in MIG welds. The temperature cycle of the welding pool under different arc modes was recorded using mini-thermocouples, which showed that the cooling rate was lower in CMT welded samples than in MIG welded samples. The low cooling rate promoted the growth of α-Al dendrites through the back diffusion effect. Electron probe micro-analysis showed that micro-segregation of the α-Al dendrites was lower in the CMT welded samples than in the MIG welded samples. The T-(fAl)1/2 curve of each weld was calculated, which showed that CMT-based welding enhanced the bridging of adjacent α-Al dendrites, reducing the tendency for solidification cracking.

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“…Tandem MIG welding is considered to have high production effectiveness that can be achieved with high welding speeds [ 12 ]. It consists of two independent electrodes (early electrode and delayed electrode) positioned parallel to the weld line and controlled individually under distinct welding conditions (current and voltage) [ 13 ]. The main advantages of the tandem MIG welding method are its extremely high efficiency, low heat input, improved weld seam integrity, and extremely high deposition rate.…”

Section: Introductionmentioning

confidence: 99%

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

et al. 2023

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The tandem metal inert gas (MIG) process uses two wires that are continuously fed through a special welding torch and disbursed to form a single molten pool. Within the contact tip of the modern approach, the wires are electrically insulated from one another. This study identified the effect of welding electrode spacing on the distortion of AA5052 aluminum plates and different mechanical properties including hardness and thermal cycle using grey relational analysis. Plate distortion was subsequently predicted using the grey prediction model GM (1, 6). This research used a pair of 400 mm × 75 mm × 5 mm of AA5052 plates and electrode distances of 18, 27, and 36 mm. The welding current, voltage, welding speed, and argon flow rate were 130 A, 23 V, 7 mm/s, and 17 L/min, respectively. The temperature was measured using a type-K thermocouple at 10, 20, 30, and 40 mm from the center of the weld bead. The smallest distortion at an electrode distance of 27 mm was 1.4 mm. At an electrode distance of 27 mm, the plate may reach a proper peak temperature where the amount of heat input and dissipation rate are similar to those for electrode distances of 18 mm and 36 mm. The highest relative VHN of 57 was found in the BM, while the lowest, 46, was found in the WM, showing good agreement with their respective grain sizes. Six parameters were designed using grey relational analysis (GRA) and subsequently employed in the grey prediction model GM (1, 6). Process evaluation results show that predictions for welding distortions are consistent with actual results, thus, the GM (1, 6) model can be used as a predictive model for welding distortions of 5052 aluminum plates.

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Sequentially combined thermo-mechanical and mechanical simulation of double-pulse MIG welding of 6061-T6 aluminum alloy sheets

Cited by 20 publications

References 36 publications

Residual Stress Prediction during TIG and MIG Welding Process of Steel - A Review

Residual Stress Prediction during TIG and MIG Welding Process of Steel - A Review

Solidification Cracking Restraining Mechanism of Al-Cu-Mg-Zn Alloy Welds Using Cold Metal Transfer Technique

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

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