Controlling Welding Residual Stress and Distortion of High-Strength Aluminum Alloy Thin Plates by a Trailing Hybrid High-Speed Gas Fluid Field
Abstract
:1. Introduction
2. Modeling of the Welding of the Trailing of the Hybrid High-Speed Gas Fluid Field
2.1. Theoretical Fundamentals
2.2. The Principle of Controlling the Distortion of Thin Plate Welding with High-Speed Welding
2.3. Parametric Characterization of the Aerodynamic Load
3. Numerical Simulation of Welding with the Trailing of the Hybrid High-Speed Gas Fluid Field
3.1. Finite Element Modeling
3.2. Development and Compilation of the Aerodynamic Load Subroutines
3.3. Temperature Field with the Action of Welding with the Trailing of the Hybrid High-Speed Gas Fluid Field
3.4. Determination of the Aerodynamic Load Action Distance Range
3.5. Variations in the Welding Residual Stress under an Aerodynamic Load
3.6. Analysis of the Welding Deflection Distortion under an Aerodynamic Load
4. Welding Test with the Trailing of the Hybrid High-Speed Gas Fluid Field
4.1. Welding Test
4.2. Longitudinal Residual Stress Test under a High Speed Gas Fluid Field during Welding
4.3. Flexural Distortion Test under a High-Speed Gas Fluid Field during Welding
5. Conclusions
- (1)
- A new method was proposed to control the welding distortion of high-strength aluminum alloy sheet by “welding with a trailing hybrid high-speed gas fluid field”. It was based on the original perspectives of mechanical mechanisms and the concept of “flexible” control. Otherwise, a welding distortion control model was established with a trailing hybrid high-speed gas fluid field, which was also parametrically characterized;
- (2)
- Through the numerical simulations of the temperature field of the welding process under conditions of welding with a trailing hybrid high-speed gas fluid field, the effective action distance (d) between the aerodynamic load and the heat source was determined to range from 12 to 32 mm. Various aerodynamic loads were set according to the corresponding loading distance (d). The longitudinal residual stresses in the mid-length section were measured at an aerodynamic load loading distance of 20 mm and a gas pressure of 30 MPa;
- (3)
- The aerodynamic load applied to the weld could effectively reduce the residual stress of the weld. The control effect was good when the loading distance was 20–28 mm and the aerodynamic load was 30 MPa. The maximum tensile residual stress under a high-speed gas flow field condition was 61.02 MPa, which decreased by 77.73% over that of conventional welding, and the peak residual compressive stress was −24.87 MPa, which decreased by 69.23%.
- (4)
- The maximum deflection of LY12 aluminum-alloy-welded parts under conditions of welding with a trailing hybrid high-speed gas fluid field was 1.79 mm, which was 83.76% lower than the 11.02 mm of conventional welding.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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T/°C | E/GPa | α/(10−6 °C−1) | σs/MPa | c/(J·kg−1 °C−1) | K/(W·m−1 °C−1) |
---|---|---|---|---|---|
20 | 70.0 | 22.8 | 300 | 900 | 117 |
100 | 60.8 | 23.1 | 280 | 921 | 121 |
200 | 54.4 | 24.7 | 240 | 1005 | 126 |
300 | 43.1 | 25.5 | 160 | 1047 | 130 |
400 | 32.0 | 26.5 | 113 | 1089 | 138 |
Loading Distance (mm) | Aerodynamic Load Range (MPa) |
---|---|
12 | 5–15 |
16 | 5–25 |
20 | 5–35 |
24 | 10–40 |
28 | 10–80 |
32 | 10–120 |
Mg | Si | Cu | Cr | Fe | Zn | Mn | Al |
---|---|---|---|---|---|---|---|
0.8 | 0.4 | 0.15 | 0.04 | 0.7 | 0.25 | 0.15 | Remaining |
Plate Thickness (mm) | Tungsten Pole Diameter (mm) | Welding Current (A) | Arc Voltage (V) | Welding Speed (mm·s−1) | Argon Gas Flow (L/Min) |
---|---|---|---|---|---|
1 | 1.6 | 70 | 12–15 | 4 | 14 |
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Zhou, G.; Liu, B.; Song, W.; Li, H.; Kuang, J.; Qiu, M. Controlling Welding Residual Stress and Distortion of High-Strength Aluminum Alloy Thin Plates by a Trailing Hybrid High-Speed Gas Fluid Field. Materials 2022, 15, 6451. https://doi.org/10.3390/ma15186451
Zhou G, Liu B, Song W, Li H, Kuang J, Qiu M. Controlling Welding Residual Stress and Distortion of High-Strength Aluminum Alloy Thin Plates by a Trailing Hybrid High-Speed Gas Fluid Field. Materials. 2022; 15(18):6451. https://doi.org/10.3390/ma15186451
Chicago/Turabian StyleZhou, Guangtao, Biao Liu, Wei Song, Huachen Li, Jingzhen Kuang, and Mingwang Qiu. 2022. "Controlling Welding Residual Stress and Distortion of High-Strength Aluminum Alloy Thin Plates by a Trailing Hybrid High-Speed Gas Fluid Field" Materials 15, no. 18: 6451. https://doi.org/10.3390/ma15186451