Search Results (48)

Boron steel welded tubes show strong potential as blanks in the integrated hot gas forming–quenching process for fabricating complex thin-walled automotive parts. Nonetheless, the non-uniform characteristics of the base metal and the weld in the high-heat welded tube can result in uneven deformation during the bulging process. This inconsistency hampers precise predictions of the deformation behavior of the welded tubes at high temperatures. Accordingly, this research explored the flow characteristics and mechanical properties of PHS1500 boron steel welded tubes. This research was conducted at 850 °C and 900 °C, with strain rates of 0.01 s⁻¹–1 s⁻¹. The Johnson–Cook model was modified for both the base metal and the weld using experimental stress–strain data. Meanwhile, to assess the model precisions, the correlation coefficient r and the average absolute relative error (AARE) were employed. Finally, hot gas forming of PHS1500 boron steel welded tubular parts with complex shapes was predicted through a finite element analysis. This research showed a positive correlation of the strain rate with both the yield and tensile strengths in the base metal and the weld. The average yield strength and tensile strength of the weld were 12.8% and 3.9% higher than those of the base metal, respectively. The r and AARE of the modified Johnson–Cook constitutive model for the base metal’s and the weld’s flow stress were 0.99 and 2.23% and 0.982 and 5.31%, respectively. The maximum deviation in the predictions of the distribution of the wall thickness of a typical cross-section of the formed complex-shaped tubular parts was less than 8%. Full article

To address the challenge of achieving an optimal balance between strength and toughness in ultra-high-strength steel welds, this study investigates ultrasonic vibration-assisted laser-arc hybrid welding. The influence of ultrasonic vibrations, applied to the lower surface of laser-arc hybrid welding specimens at powers ranging from 60 W to 240 W, on various aspects of the weld, including macroscopic morphology, porosity, microstructure, and mechanical properties, was systematically examined. Experimental findings reveal that as ultrasonic power increases, weld porosity initially diminishes before rising again. Simultaneously, the fusion ratio of the weld gradually enhances, and the cross-sectional morphology of the weld transforms from a “goblet” shape to an “inverted triangle”, with the transition boundary between the arc zone and laser zone becoming less distinct. Furthermore, an increase in ultrasonic power leads to a gradual rise in the microhardness of the weld, and the mechanical properties of the weld joint exhibit an upward trend. Notably, at an ultrasonic power of 180 W, the weld attains a tensile strength of 1380 MPa and an impact toughness of 10.5 J, highlighting the potential of this technique in optimizing the welding characteristics of ultra-high-strength steel. Full article

In this study, the melt pool formation behavior of high-speed laser-arc hybrid welding of aluminum plates was simulated using finite element analysis (FEA). To evaluate the heat input efficiencies of the laser and arc, standalone laser or arc welding experiments were conducted using the same arc or laser processing parameters as those employed in hybrid welding. These experiments were also simulated using FEA to calibrate the laser and arc heat adsorption parameters. The melt pool shapes were measured from cross-sectional optical microscope (OM) images of the specimens and subsequently used to develop a thermal analysis simulation of the laser and arc welding processes. A simulation model for the laser-arc hybrid welding process was developed by combining the heat input models of the laser and arc welding processes. The FEA model successfully predicted the melt pool shapes observed in the experiments. The accuracy of the developed model was evaluated, yielding average errors in the melt pool sizes of the laser, arc, and hybrid welds of 5.43%, 6.89%, and 4.51%, respectively. Full article

The mast is a critical component of rotary drilling rigs, which has a cross-section consisting of a rectangular shape formed by two web plates and two flange plates. Structural optimization of the mast is necessary to address the issue of excessive weight. The shortcomings of the traditional structural optimization algorithms are summarized as follows: the optimized steel plate thickness is a non-integer, where rounding upwards may increase the cost to a certain extent, but it can ensure the safety of the structure; rounding downwards its load carrying capacity may not satisfy the requirements, and thus a novel Salp Swarm Algorithm is proposed to solve the optimization problem. First, this study improves the initialization and update strategy in the traditional Salp Swarm Algorithm. In order to obtain a solution for engineering, an innovative multi-dimensional running comparison is carried out. Secondly, the optimization model of rotary drilling rigs is established based on the division of the working conditions. The objective function of the optimization model is to minimize the weight of the mast while considering the constraints of strength, stiffness, stability, and welding process. Finally, the proposed optimization algorithm and the established optimization model are applied to optimize the design of the mast for a rotary drilling rig. The empirical results demonstrate that the weight of the mast has been reduced by 20%. In addition, the Improved Salp Swarm Algorithm exhibits higher solution quality, faster iteration capability, and extreme stability in optimizing welded box sections compared to the conventional algorithm. The example shows that the Improved Salp Swarm Algorithm is applicable to the optimization problem of box sections. Full article

Shape memory alloys (SMAs) are becoming a more important factor in actuation technology. Due to their unique features, they have the potential to save weight and installation space as well as reduce energy consumption. The system integration of the generally small-diameter NiTi wires is an important cornerstone for the emerging technology. Crimping, a common method for the mechanical and electrical connection of SMA wires, has several drawbacks when it comes to miniaturization and high-force outputs. For high-force applications, for example, multiple SMA wires in parallel are needed to keep actuation frequencies high while scaling up the actuation force. To meet these challenges, the proposed study deals with the development of a resistance-welding process for manufacturing NiTi wire bundles. The wires are welded to a sheet metal substrate, resulting in promising functional properties and high joint strengths. The welding process benefits from low costs, easy-to-control parameters and good automation potential. A method for evaluating the resistance-welding process parameters is presented. With these parameters in place, a manufacturing process for bundled wire actuators is discussed and implemented. The welded joints are examined by peel tests, microscopy and fatigue experiments. The performance of the manufactured bundle actuators is demonstrated by comparison to a single wire with the same accumulated cross-sectional area. Full article

The present paper is devoted to the seismic design of steel frames constituted by multistep I-shaped cross-section beam elements. The proposed design problem formulation is aimed at protecting the connections among beams and columns. In particular, reference is made to beams welded at their ends to appropriate steel plates connected by bolts to the columns. Therefore, the protection against brittle failure of the beam end sections is ensured by appropriate constraints of the optimal design problem. A useful comparison is made between the adoption of the so-called Reduced Beam Sections (RBS) and the use of multistep beam elements. In particular, the RBS approach here considered is the well-known dogbone technique consisting of reducing the width of the beam cross-sections in correspondence with suitably located beam portions, while the typical multistep beam element is constituted by a factory-made I-shaped uniform piecewise profile. To perform the necessary comparison, reference is made to a three-story, two-span plane steel frame constituted by elastic, perfectly plastic material and subjected to static and seismic loads. The load conditions and the relevant combinations have been imposed in compliance with the Italian structural code. The frame is first studied as constituted by European standard steel profiles on sale, and the related design is obtained using the optimization tool contained in SAP2000 software. A linear dynamic analysis is performed to determine the response of the frame. Later, the same frame, either equipped with dogbone and constituted by multistep beam elements, subjected to serviceability load conditions, is studied in terms of inter-story drifts and beam deflections. The geometry of the multistep beam elements is obtained by the solution to the proposed optimization problem. Furthermore, a nonlinear static analysis is performed to evaluate the capacity curves of the same frames. The results obtained for the frames equipped with the described different devices, compared with those related to the original frame, provide very interesting information on the sensitivity of the seismic response of the structure, showing the full reliability of the multistep beam element approach. Full article

The limit behaviour of I-shaped welded steel cross-sections subjected to axial force, shear, and bending moment is a crucial matter to ascertain the reliability of framed structures constituted by non-standard beam elements. International standards provide an approximate solution to the problem, and other studies have proposed improved approximate formulations to ascertain the real features of the relevant cross-sections. The present paper is devoted to enhancing the problem of the limit behaviour of plane I-shaped welded steel cross-sections subjected to axial force $\left(N\right)$, shear $\left(T\right)$ and bending moment $\left(M\right)$; therefore, new appropriate formulations are proposed in order to define suitable new domains, both in planes $\left(N,T\right)$, $\left(N,M\right)$, and $\left(M,T\right)$ and in the space $\left(N,T,M\right)$. The material is assumed as elastic–perfectly plastic and the Von Mises limit condition is adopted as the resistance criterion. The elastic stresses are described by the Navier formula and the Jourawski formula. The limit stress condition related to the contemporaneous presence of the acting forces is defined as the one that, at each point of the cross-section, fulfils the Von Mises limit condition as equality. The formulation is rigorously devoted to factory-made welded I-shaped steel cross-sections. Some numerical examples are reported in the application stage and useful comparison are carried out, with the results being obtainable by the application of the classical known standard formulae, proving the reliability and effectiveness of the determined domains. Full article

The structural elements of buildings have recently required the development of efficient design solutions due to increased dynamic and thermal loads. The main solution for improving the efficiency of such elements involves creating lightweight non-uniform beam and arch structures from alloyed steel, which has better mechanical characteristics. The most promising approach is the use of welded beams and arches with perforated partitions and composite beams, which are often used together, for instance, as structural elements of cylindrical shells. The development of an effective cross-sectional shape for perforated beams and crane girders is considered, taking into account the strength, local stability, resistance to flat bending, and fatigue deformation. It has been shown that the effective form for perforated beams is a box-shaped structure made of perforated shvellers. Calculations for selecting a rational design from the assortment of hot-rolled shveller profiles have demonstrated that a significant reduction in the weight of the structure can be achieved by using the proposed cross-sectional shape. An evaluation of the fatigue strength of composite metal crane girders operating in harsh conditions has shown the effectiveness of using hot-rolled I-beams as their upper flange, as well as the necessity of using hot-rolled I-beams to ensure strength in their lower part. When choosing the rational parameters of an arch design, multiple recalculations of its bending with respect to technological cutouts in the thickness are necessary; hence, simplified calculation schemes are commonly used. Some authors simplify this process by replacing an arch with a cutout with a solid arch reduced in height by the cutout radius. We have shown that this model does not accurately describe the actual distribution of forces and displacements, leading to inadequate results. We have developed a simplified methodology for the preliminary calculation of a circular arch with a cutout, which includes correction coefficients calculated by us. A calculation of the flat stress–strain state of an elastic circular metal arch with a central semicircular cutout under various ratios of design parameters and uniform external pressure was conducted. A dependence of the stress concentration coefficient at the cutout’s apex on the ratio of the cutout radius and arch thickness was obtained. These results can be generalized for reinforced non-uniform shells and for the fuzzy application of external influences. Full article

Friction stir welding (FSW) is a widely employed welding process, in which advancing and rotational speeds consitute critical parameters shaping the welding outcome and affecting the temperature evolution. This work develops an experimental methodology to identify optimal FSW parameters based on real-time temperature measurement via a thermocouple integrated within the tool. Different rotational and welding speeds were tested on AA5083-H111 and AA6082-T6. Our results underscore the importance of attaining a minimum temperature threshold, specifically 0.65 times the solidus temperature, to ensure high-quality welds are reached. The latter are defined by combining temperature measurements with joint quality information obtained from cross-sectional views. Our research contributes to advancing the efficiency and effectiveness of friction stir welding in industrial settings. Furthermore, our findings suggest broad implications for the manufacturing industry, offering practical insights for enhancing weld quality and process optimization. Full article

This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire feeding speed of 10 m/min on a butt joint with a V-shaped groove using 19 mm thick steel plates. Molten pool stability and defect formation were observed using high-speed imaging and cross-sectional observations. The power consumption and heat input were predicted prior to welding and measured in the experiments. The results indicate that a combination of a welding current of 350–500 A and welding speed of 0.3–0.7 m/min is optimal to avoid defect formation and molten metal precedence using three or four passes. The higher efficiency and lower heat input achieved by hot-wire GMAW results in a weld metal of adequate hardness, narrower heat-affected zone, smaller grain size at the fusion boundary, and lower power consumption than those obtained using tandem GMAW and high-current GMAW. Based on the experimental results, a single bevel groove, which is widely used in construction machinery welding joints, was welded using hot-wire GMAW, and we confirmed that the welding part could be welded in six passes, whereas eight passes were required with GMAW only. Full article

This research aims to show the effects of adding cardinality constraints to limit the number of different cross-sections used in simultaneous sizing and shape optimization of truss structures. The optimal solutions for sizing and shape optimized trusses result in a generally high, and impractical, number of different cross-sections being used. This paper presents the influence of constraining the number of different cross-sections used on the optimal results to bring the scientific results closer to the applicable results. The savings achieved using the cardinality constraint are expected to manifest in more than just the minimization of weight but in all the other aspects of truss construction, such as labor, assembly time, total weld length, surface area to be treated, transport, logistics, and so on. It is expected that the optimal weight of the structures would be greater than when not using this constraint; however, it would still be below conventionally sized structures and have the added benefits derived from the simplicity and elegance of the solution. The results of standard test examples for each different cardinality constraint value are shown and compared to the same examples using only a single cross-section on all bars and the overall optimal solution, which does not have the cardinality constraint. An additional comparison is made with results of just the sizing optimization from previously published research where authors first used the same cardinality constraint. Full article

Formulations of structural optimization problems are proposed in this paper to automatically find the best grouping of columns in 3D steel buildings. In these formulations, the conflicting objective functions, minimized simultaneously, are the weight of the structure and the number of different groups of columns. In other words, the smaller the number of different groups of columns, the greater the weight of the structure, and the greater the number of groups, the smaller the structure’s weight. The design variables are the bracing system configuration, column cross-section orientation, and assigned W-shaped profile indices for columns, beams, and braces. The design constraints are the allowable displacements, strength, and geometric considerations. After solving the multi-objective optimization problem, the result is a Pareto front, presenting non-dominated solutions. Three evolutionary algorithms based on differential evolution are adopted in this paper to solve three computational experiments. Even if preliminary groupings of columns are adopted, considering architectural aspects such as the symmetry of the structure, it is possible to discover other interesting structural configurations that will be available to the decision maker, who will be able to make their choices based on the impacts on manufacturing, cutting, transporting, checking and welding. Full article

This paper investigates the behavior of transverse defects under significant total strain in conditions of complex vortex metal flow implemented through the radial shear rolling (RSR) method. The aim of this study is to assess the applicability of RSR processing for the in-depth transformation of small ingots of special steel into bars, particularly for the manufacturing of structural elements in specialized construction projects such as nuclear power plants. Although a substantial total strain is anticipated to enhance the steel structure and contribute to defect closure, the question of the development or closure of potential casting defects remains unclear. To address this issue, model tests were conducted to simulate the implementation of RSR processing. Defect behavior data under very complex vortex metal flow and high strain conditions were obtained for the first time and have scientific merit. A small steel ingot with a 32 mm diameter, containing a simulated artificial defect in the form of a transverse through-hole with a 5 mm diameter, was employed. During rolling, the workpiece diameter was progressively reduced by 2 mm with each subsequent pass, reaching a final diameter of 20 mm. Additionally, to provide a more detailed visualization of the defect evolution process, the same defect was modeled in an aluminum bar over six passes, and changes in defect volume and shape were analyzed after each pass. A highly detailed 3D visualization of the actual defect evolution was achieved based on cross-sections from experimental workpieces. These data corresponded to the total strain levels obtained by finite element method (FEM) simulation. Notably, a consistent similarity was observed between the test results for both metals, revealing a reduction in defect volume of up to 67.7%. The deformational welding of defects in the outer sections, encompassing one-third of the rod’s radius, occurred in the initial passes. However, defects in the axial zone of the rods remained unclosed, lengthening and gradually decreasing proportionally to the elongation of the rod, akin to conventional rolling. Consequently, the radial shear rolling (RSR) method is unsuitable for ingots with substantial discontinuities in the axial zone post-casting. Nevertheless, the method ensures the total welding of defects located in the outer zones of the ingots, even with minor applied deformations and a slight decrease in the diameter of the deformed ingot. Such data were obtained for the first time and should contribute to future investigations in this field. Full article

Mechanical property changes in friction stir welding can directly affect the rebalance of the stress field in friction stir welding. This means that it reveals a high relevance with the residual states of friction stir welding. Here, we propose a subregion model in which the mechanical property changes are considered to predict the residual states in friction stir welding of dissimilar metals. Results indicate that the accuracy of the predicted distortion can be greatly increased when the different mechanical properties are considered in friction stir welding of 2024-T3 and 6061-T6. The final mechanical property is determined by the mixture of the materials at retreating and advancing sides. The final mechanical property in the stirring zone can be increased to 171 MPa for yield strength and 194 MPa for tensile strength when the strength of the advancing side material is higher. The shrinkage of material in the stirring zone during the cooling stage is the key reason for the formation of the tensile residual stress and the V-shape distortion on the cross-section in the as-weld state. Full article

In this study, butt welds of QP980 steel were produced using small laser spot (0.1 mm) oscillating welding. The effect of beam oscillation with a circular trajectory on weld morphologies, microstructures, and mechanical properties was characterized. As the oscillating amplitude rose, the energy accumulation range enlarged, and the energy peak value was decreased, leading to the appearance of the cross-section changing from a nail-like shape to a cup-cone-like shape and then to a W-type shape. The weld zone is divided into the fusion zone, inner heat-affected zone, and outer soften zone. The fusion zone and inner heat-affected zone are full of typical lath martensite and have the highest hardness. The soften zone is composed of pre-existing martensite, temper martensite, ferrite, and retained austenite and has the lowest hardness. Compared to laser welding, beam oscillation could reduce the pre-existing block martensite to decompose, leading to a narrower width and higher hardness soften zone. Although the width of the fusion zone and soften zone increases with the oscillation amplitude, all welded samples failed at the base metal with 97% joint efficiency. Full article