Journal of Manufacturing and Materials Processing

Research

14 pages, 63158 KiB

Open AccessArticle

Development of Multi-Part Field-Shapers for Magnetic Pulse Welding Using Nanostructured Cu-Nb Composite

by Evgeny Zaytsev, Vasiliy Krutikov, Alexey Spirin and Sergey Paranin

J. Manuf. Mater. Process. 2024, 8(3), 97; https://doi.org/10.3390/jmmp8030097 - 5 May 2024

Viewed by 394

Magnetic pulse welding (MPW) employs a strong pulsed magnetic field to accelerate parts against each other, thus forming an impact joint. Single-turn tool coils and field-shapers (FSs) used in MPW operate under the most demanding conditions, such as magnetic fields of 40–50 T [...] Read more.

Magnetic pulse welding (MPW) employs a strong pulsed magnetic field to accelerate parts against each other, thus forming an impact joint. Single-turn tool coils and field-shapers (FSs) used in MPW operate under the most demanding conditions, such as magnetic fields of 40–50 T with periods lasting tens of microseconds. With the use of conventional copper and bronze coils, intense thermo-mechanical stresses lead to the rapid degradation of the working bore. This work aimed to improve the efficiency of field-shapers and focused on the development of two- and four-slit FSs with a nanocomposite Cu 18Nb brazed wire acting as an inner current-carrying layer. The measured ratios of the magnetic field to the discharge current were 56.3 and 50.6 T/MA for the two- and four-slit FSs, respectively. FEM calculations of the magnetic field generated showed variations of 6–9% and 3% for the two- and four-slit FSs, respectively. The ovality percentages following copper tube compression were 27% and 7% for the two- and four-slit FSs, respectively. The measured deviations in the weld-joining length were 11% and 1.4% in the two- and four-slit FSs, respectively. Compared to the previous experiments on an entirely steel inductor, the novel FS showed significantly better results in terms of its efficiency and the homogeneity of its magnetic field. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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14 pages, 4900 KiB

Open AccessArticle

The Effect of Niobium Addition on the Operational and Metallurgical Behavior of Fe-Cr-C Hardfacing Deposited by Shielded Metal Arc Welding

by Jaime Perez, Jesus Gutierrez, Jhon Olaya, Oscar Piamba and Americo Scotti

J. Manuf. Mater. Process. 2024, 8(1), 38; https://doi.org/10.3390/jmmp8010038 - 10 Feb 2024

Viewed by 1350

Abstract

Hardfacing is commonly used in parts recovery and in obtaining surfaces with improved properties. Within this field, it is important to analyze the effect of alloying elements on the properties of the deposited layers. One of the critical parameters affecting alloying performances in [...] Read more.

Hardfacing is commonly used in parts recovery and in obtaining surfaces with improved properties. Within this field, it is important to analyze the effect of alloying elements on the properties of the deposited layers. One of the critical parameters affecting alloying performances in SMAW is improper arc length. This article examines the effect of the addition of niobium in different quantities (0, 2, 4, 6, and 8% by weight) to the electrode coating in Fe-Cr-C shielded metal arc welding (SMAW), with short and long arc lengths, on the operational process efficiency, dilution, arc energy, microstructure, and microhardness of the deposited layers. A decrease in operational process efficiency and dilution was found with increases in niobium content. On the other hand, it was found that adding niobium leads to a refinement in chromium carbide sizes, directly affecting the hardness of the obtained deposits. There is a direct relationship between the arc energy, with both short and long arc lengths, leading to a tendency to decrease the dilution in the obtained hardfacing. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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18 pages, 6628 KiB

Open AccessArticle

Possibilities of Artificial Intelligence-Enabled Feedback Control System in Robotized Gas Metal Arc Welding

by Sakari Penttilä, Hannu Lund and Tuomas Skriko

J. Manuf. Mater. Process. 2023, 7(3), 102; https://doi.org/10.3390/jmmp7030102 - 23 May 2023

Cited by 2 | Viewed by 1662

Abstract

In recent years, welding feedback control systems and weld quality estimation systems have been developed with the use of artificial intelligence to increase the quality consistency of robotic welding solutions. This paper introduces the utilization of an intelligent welding system (IWS) for feedback [...] Read more.

In recent years, welding feedback control systems and weld quality estimation systems have been developed with the use of artificial intelligence to increase the quality consistency of robotic welding solutions. This paper introduces the utilization of an intelligent welding system (IWS) for feedback controlling the welding process. In this study, the GMAW process is controlled by a backpropagation neural network (NN). The feedback control of the welding process is controlled by the input parameters; root face and root gap, measured by a laser triangulation sensor. The NN is trained to adapt NN output parameters; wire feed and arc voltage override of the weld power source, in order to achieve consistent weld quality. The NN is trained offline with the specific parameter window in varying weld conditions, and the testing of the system is performed on separate specimens to evaluate the performance of the system. The butt-weld case is explained starting from the experimental setup to the training process of the IWS, optimization and operating principle. Furthermore, the method to create IWS for the welding process is explained. The results show that the developed IWS can adapt to the welding conditions of the seam and feedback control the welding process to achieve consistent weld quality outcomes. The method of using NN as a welding process parameter optimization tool was successful. The results of this paper indicate that an increased number of sensors could be applied to measure and control the welding process with the developed IWS. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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21 pages, 18338 KiB

Open AccessArticle

Linear Friction Welding of Abrasion Resistant CPM 15V Tool Steel to an Alloyed Carbon Shovel-Tooth Steel

by Oscar A. Zambrano, Javad Gholipour, Priti Wanjara and Jiaren (Jimmy) Jiang

J. Manuf. Mater. Process. 2023, 7(2), 51; https://doi.org/10.3390/jmmp7020051 - 21 Feb 2023

Cited by 3 | Viewed by 1729

Abstract

Alloyed carbon steels used in ground engaging tools (GETs), such as shovel-teeth, can withstand high working loads, but their wear resistance is inadequate for abrasive operations in the mining industry. Different approaches to engineer protective surfaces on GETs for improving wear resistance have [...] Read more.

Alloyed carbon steels used in ground engaging tools (GETs), such as shovel-teeth, can withstand high working loads, but their wear resistance is inadequate for abrasive operations in the mining industry. Different approaches to engineer protective surfaces on GETs for improving wear resistance have been developed over the years, but the effectiveness of the applied abrasive resistance layer has been limited by the maximum thickness that can be realized reliably. Considering wear requirements for GETs to reach end-of-life without requiring unscheduled maintenance for after-failure repairs, a minimum thickness of 25 mm has been postulated for the abrasive resistance surface layer, which is roughly four times greater than the thickness of overlays currently manufacturable by weld deposition technologies. Thus, in this study, a novel approach for conceiving thick abrasive surface protection layers—that are unlimited in thickness—on GETs is presented. The method involves applying solid-state linear friction welding and was demonstrated to be feasible for joining abrasive-resistant CPM 15V tool steel to an alloyed carbon steel (extracted from a shovel-tooth). After welding, the integrity of the joints was examined microscopically using optical and scanning electron microscopy to understand the microstructural characteristics, as well as through microhardness and tensile testing to evaluate the performance. A high frequency welding condition was identified that provided integral bonding (i.e., without voids and cracking) at the interface between the CPM 15V tool steel and alloyed carbon shovel-tooth steel. In the as-welded condition, the measured hardness profiles across the joints showed minor softening of both base materials in the heat-affected zone just adjacent to the weld center; this was attributed to over aging of the tempered martensite structures of CPM 15V tool steel and alloyed carbon shovel-tooth steel. The maximum tensile strength of the joint (553 MPa) provides evidence for the viability of linear friction welding technology for joining protective surface materials on GETs. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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15 pages, 5410 KiB

Open AccessArticle

Introduction of a New Test Methodology for Determining the Delayed Cracking Susceptibility

by Anton Hopf, Moritz Klug, Kürşat Durmaz, Klaus Goth and Sven Jüttner

J. Manuf. Mater. Process. 2023, 7(1), 26; https://doi.org/10.3390/jmmp7010026 - 18 Jan 2023

Cited by 2 | Viewed by 2041

Abstract

A missing test methodology that allows for the determination of delayed cracking susceptibility of laser welds of high-strength sheet steel is presented. Unlike other cold crack testing methods, this test is based on a self-restraint testing of specimens welded from thin sheet materials [...] Read more.

A missing test methodology that allows for the determination of delayed cracking susceptibility of laser welds of high-strength sheet steel is presented. Unlike other cold crack testing methods, this test is based on a self-restraint testing of specimens welded from thin sheet materials without welding consumables and external loading. The potential test procedure with sample geometry, clamping device and documentation of the cracks is described. It is shown that the position of the weld on the specimen is a critical parameter and the susceptibility to cold cracking increases with increasing edge distance. The test methodology in combination with the most critical seam position is successfully used to rank two different steels regarding their susceptibility to delayed cracking. Further investigations are conducted evaluating the cold cracking susceptibility at different energy levels and lubricating conditions. It is proven that the lubrication has a significant influence on the susceptibility to cold cracking. Nevertheless, a narrow but safe process window is found. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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18 pages, 8529 KiB

Open AccessArticle

Influence of the Process Parameters on the Properties of Cu-Cu Ultrasonic Welds

by Koen Faes, Rafael Nunes, Sylvia De Meester, Wim De Waele, Felice Rubino and Pierpaolo Carlone

J. Manuf. Mater. Process. 2023, 7(1), 19; https://doi.org/10.3390/jmmp7010019 - 7 Jan 2023

Cited by 7 | Viewed by 2118

Abstract

Ultrasonic welding (USW) is a solid-state welding process based on the application of high frequency vibration energy to the workpiece to produce the internal friction between the faying surface and the local heat generation required to promote the joining. The short welding time [...] Read more.

Ultrasonic welding (USW) is a solid-state welding process based on the application of high frequency vibration energy to the workpiece to produce the internal friction between the faying surface and the local heat generation required to promote the joining. The short welding time and the low heat input, the absence of fumes, sparks or flames, and the automation capacity make it particularly interesting for several fields, such as electrical/electronic, automotive, aerospace, appliance, and medical products industries. The main problems that those industries have to face are related to the poor weld quality due the improper selection of weld parameters. In the present work, 0.3 mm thick copper sheets were joined by USW varying the welding time, pressure, and vibration amplitude. The influence of the process variables on the characteristics of the joints and weld strength is investigated by using the analysis of variance. The results of the present work indicate that welding time is the main factor affecting the energy absorbed during the welding, followed by the pressure and amplitude. The shear strength, on the other hand, resulted mostly influenced by the amplitude, while the other parameters have a limited effect. Regardless the welding configuration adopted, most welds registered a failure load higher than the base material pointing out the feasibility of the USW process to join copper sheets. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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13 pages, 5150 KiB

Open AccessArticle

Improved Coil Design for Magnetic Pulse Welding of Metallic Sheets

by Rishabh Shotri, Koen Faes, Guillaume Racineux and Amitava De

J. Manuf. Mater. Process. 2022, 6(6), 144; https://doi.org/10.3390/jmmp6060144 - 16 Nov 2022

Cited by 2 | Viewed by 1578

Abstract

Magnetic pulse welding of overlapping dissimilar metallic sheets is an emerging technique and usually employs flat electromagnetic coils with rectangular-, H-, I-, and E-shaped cross-sections. The asymmetric cross-section of these coils results in a non-uniform electromagnetic field and in a non-uniform connection in [...] Read more.

Magnetic pulse welding of overlapping dissimilar metallic sheets is an emerging technique and usually employs flat electromagnetic coils with rectangular-, H-, I-, and E-shaped cross-sections. The asymmetric cross-section of these coils results in a non-uniform electromagnetic field and in a non-uniform connection in the interface between the overlapping sheets. In this article, the use of a novel O-shaped flat coil is proposed to join an aluminium flyer sheet with a target steel sheet. A finite element-based numerical model is developed to calculate the electromagnetic field, flyer velocity, and its gradual impact onto the target, and the deformations of the sheet assembly. The calculated results with the O-shaped coil show a high-intensity electromagnetic field, the concentration of which decreases radially outwards in a uniform manner. The numerically computed and experimentally measured flyer velocity are found to be in fair agreement. The calculated results show a regularly decreasing impact behaviour between the flyer and target and their resulting deformation. The measured results show the formation of an annular ring-shaped joint profile that is generally found to be stronger compared to that obtained with flat coils with a rectangular cross-section. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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14 pages, 5449 KiB

Open AccessArticle

A Comparative Study of Mechanical and Microstructural Behavior for Metal Active Gas and Friction Stir Welded Micro-Alloyed Structural Steel

by Davide Campanella, Harikrishna Rana, Toni Lupo and Rosa Di Lorenzo

J. Manuf. Mater. Process. 2022, 6(5), 104; https://doi.org/10.3390/jmmp6050104 - 16 Sep 2022

Cited by 2 | Viewed by 1713

Abstract

Manufacturing tiny components into gigantic structures seems unimaginable without welding connections, whether it is for materials, parts, structures, or equipment. In the recent competitive market scenario, manufacturing industries are desperately looking for a viable alternative to fusion-based conventional material joining technologies, to improve [...] Read more.

Manufacturing tiny components into gigantic structures seems unimaginable without welding connections, whether it is for materials, parts, structures, or equipment. In the recent competitive market scenario, manufacturing industries are desperately looking for a viable alternative to fusion-based conventional material joining technologies, to improve upon cost-effectiveness along with performance. The present investigation is to evaluate the performance of structural steel thick plate joints prepared by advanced solid-state friction stir welding (FSW) over conventional metal active gas welding (MAG). The FSW experiments were carried out with different tool designs and configurations. The outcomes were evaluated in terms of microstructural integrity and mechanical joint resistance. Impressive results were obtained with FSW joints, characterized by an almost defect-free microstructure with a leaner heat-affected zone and higher joint resistance as compared to conventional MAG-welded joints. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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11 pages, 4164 KiB

Open AccessEditor’s ChoiceArticle

Joining 30 mm Thick Shipbuilding Steel Plates EH36 Using a Process Combination of Hybrid Laser Arc Welding and Submerged Arc Welding

by Sergej Gook, Ahmet Midik, Max Biegler, Andrey Gumenyuk and Michael Rethmeier

J. Manuf. Mater. Process. 2022, 6(4), 84; https://doi.org/10.3390/jmmp6040084 - 4 Aug 2022

Cited by 2 | Viewed by 3283

Abstract

This article presents a cost-effective and reliable method for welding 30 mm thick sheets of shipbuilding steel EH36. The method proposes to perform butt welding in a two-run technique using hybrid laser arc welding (HLAW) and submerged arc welding (SAW). The HLAW is [...] Read more.

This article presents a cost-effective and reliable method for welding 30 mm thick sheets of shipbuilding steel EH36. The method proposes to perform butt welding in a two-run technique using hybrid laser arc welding (HLAW) and submerged arc welding (SAW). The HLAW is performed as a partial penetration weld with a penetration depth of approximately 25 mm. The SAW is carried out as a second run on the opposite side. With a SAW penetration depth of 8 mm, the weld cross-section is closed with the reliable intersection of both passes. The advantages of the proposed welding method are: no need for forming of the HLAW root; the SAW pass can effectively eliminate pores in the HLAW root; the high stability of the welding process regarding the preparation quality of the weld edges. Plasma cut edges can be welded without lack of fusion defects. The weld quality achieved is confirmed by destructive tests. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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