In this study, thermal elasto-plastic finite element analysis was conducted to derive the optimal welding sequence to minimize overlay welding deformation on the water wall panels of an SRF (solid refuse fuel) boiler. The water wall panels of an SRF...
Aluminum hulls, which are preferred in the marine industry due to their durability, corrosion resistance, and lightweight properties, face serious challenges due to thermal deformation during welding. This study aims to predict and minimize transvers...
Welding stands as a critical focus for the intelligent and digital transformation of the machinery industry, with automated laser welding playing a pivotal role in the sector’s technological advancement. The management of welding deformation in...
In this study, an effective numerical model was developed for the calculation of the deformation of laser-welded 3 mm 304L stainless steel plates with different gaps (0.2 mm, 0.5 mm, and 1.0 mm). The welding deformation would become larger when the w...
Welding deformation occurs due to non-uniform thermal expansion, thermal contraction, restraint, and phase transformation in a metal by a local welding heat source. This causes problems such as low buckling strength and the reduced workability of the...
To effectively use aluminum, which is inherently weak under heat, as a material for hull construction, it is crucial to precisely predict the thermal deformation in the weld zone. Most studies employing finite element (FE) methods to predict thermal...
In this study, we propose a method for predicting welding deformation caused by multi-pass welding using the thermal elastic–plastic finite element method (TEP-FEM) by considering the interpass temperature. This method increases the interpass t...
In the domain of new energy vehicles, the control of welding deformation in aluminum alloy battery systems poses substantial challenges. The existing methodologies for diminishing welding deformation, such as laser segmented skip welding, alteration...
In a car body, there exist thousands of resistance spot welds, which may induce large deformation during the manufacturing process. Therefore, it is expected that automotive industries will develop a method and a computing system for the fast and sim...
This article proposes a novel method for analyzing residual stress and deformation in butt welding on 6 mm SUS304 stainless steel plates, using MSC.MARC, a commercial finite element method software, to find the best location for jig fixtures that wil...
Numerical simulation of the welding process is critical for predicting and controlling structural deformation. Previous numerical studies have predominantly focused on investigating the welding deformation of simple structures. However, actual engine...
In this paper, the best fixture scheme for the TIG welding torch of nickel-base solid solution superalloy GH3536 in the welding process is explored. First of all, to meet the extremely high-dimensional accuracy requirements of the flame cylinder, a m...
As the environmental pollution issue has recently become significant, environmental regulations in Europe and the United States are being strengthened. Thus, there is a demand for the quality improvement of emission after-treatment systems to satisfy...
Welding is widely used to manufacture and repair steel structures such as piping and pressure vessels. Welding induces deformation and residual stress, which influences the mechanical performance of the structural members. Noting patch welding, which...
Fusion welding causes joint deterioration when joining aluminum alloys, which limits the use of aluminum alloy components in high-end equipment. This paper focuses on an overview of how to achieve high-strength aluminum alloy welded joints using weld...
The welding process, which accounts for about 60% of the shipbuilding process, inevitably involves weld deformation. Considering this, productivity can be significantly increased if weld deformation can be predicted during the design phase, taking in...
The China Fusion Engineering Test Reactor vacuum vessel has strict tolerances requirements and a large number of fully penetrated joints in the manufacturing and assembly processes. As the most complicated component of vacuum vessel, port stubs have...
The influence of temperature on the precipitation evolution in different zones of friction stir welded (FSW) heat-treatable aluminum alloys has been well investigated. However, the role of plastic deformation in affecting precipitation transformation...
With the rise of electric vehicles, the use of battery modules, which are key units that drive vehicles, is increasing. The battery housing is the final form of a battery system mounted on electric vehicles, and is generally made of aluminum alloys,...
The existing inherent strain method is improved in this paper to address the shortcomings of the existing inherent strain method in the process of loading inherent strain. Unlike the traditional inherent strain method, which uses one-step loading inh...
To observe the evolution mechanism of physical fields in the welding deformation rectification process by a traveling induction heating, research on simulation models of welding—induction heating continuous process were carried out. High-streng...
This paper analyzes pitting corrosion at the weld zone and at the heat affected zone (HAZ) in AISI 304 rolled stainless steel welds. As the aforementioned material is one of the most frequently used types of stainless steel, it is needful to be aware...
Surfacing on the surface of thin metal bending plates will cause significant deformation, and current numerical simulation and experimental methods cannot fully and truly reflect the deformation state of the bending plate. In this paper, a non-contac...
Thermal cycles and deformations during high-speed micro friction stir welding (μFSW) under different welding conditions were studied by experimental methods. The results show that the peak temperature and elevated-temperature exposure time (t150)...
The 2024 aluminum alloy is one of the high-quality lightweight materials. Friction stir welding (FSW) has shown advantages in reducing welding defects and improving welding quality in 2024 aluminum alloys. Currently, the research regarding FSW joint...
Finite element (FE) analysis of welding residual stress and deformation is one of the essential stages in the manufacturing process of mechanical structures and parts. It aids in reducing the production cost, minimizing errors, and optimizing the man...
Ultra-thin ferritic stainless steel, essential for applications such as proton exchange membrane fuel cells, presents challenges during pulsed laser welding due to thermal stresses causing deformation. This study explores the effects of welding param...
The increasing burden on shipowners and shipping companies due to environmental regulations imposed by the International Maritime Organization (IMO) has led to the adoption of various compliance strategies, including the use of low-sulfur fuel, insta...
The external floating roof of a large storage tank directly covers the liquid surface as the liquid level rises and falls, enhancing the tank’s safety and environmental performance. It is fabricated from thin SA516 Gr.70 steel plates, with a ca...
In a shipyard, large numbers of temporary pieces are used to align welding lines of a block joint and prevent welding deformations in the block assembly stage. The use of many temporary pieces requires a great number of working man-hours, causing low...
The paper presents a numerical model based on the finite element method (FEM) to predict deformations and residual stresses in socket welding of different diameter stainless steel pipes made of X5CrNi18-10 steel. The next part of the paper concerns t...
To reduce the residual stress and deformation of the copper alloy sheet after welding, and improve the welding quality of the copper alloy sheet, the finite element method (FEM) research on welding thermal deformation and welding sequence optimizatio...
High-manganese steel (high-Mn) is valuable for its excellent mechanical properties in cryogenic environments, making it essential to understand its deformation behavior at extremely low temperatures. The deformation behavior of high-Mn steels at extr...
The power spinning of tailor-welded blank (TWB) provides a feasible way to form the large-scale curved heads of aluminum alloy. However, the inhomogeneous material property of TWB produces different and more complex spinning behaviors compared with t...
The paper concerns the numerical analysis of the influence for three different of welding heat source inclinations on the weld pool shape and mechanical properties of the resulting joint. Numerical analysis is based on the experimental tests of singl...
Ultrasonic metal welding (USMW) is widely used in assembling lithium-ion (Li-ion) battery packs due to its advantages in joining dissimilar and conductive materials in the solid state. However, the welding process and mechanisms are not yet clearly u...
Welding deformation in large thick-plate structures can severely compromise manufacturing quality, making its prediction and control a critical engineering challenge. This study focuses on an engineering vehicle frame, for which a finite element mode...
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 th...
Friction stir welding (FSW) of aluminum alloys is an advanced manufacturing technology to realize lightweight bodywork. However, most studies only focus on the mechanical properties and corrosion behaviors of the welded joints. The effect of deformat...
Heat input is a crucial parameter in the process of welding thin plates. It has a direct impact on the quality of the weld and the degree of deformation caused during welding. This study investigates the impact of heat input on the deformation of a t...
Aiming at the inward shrinkage between the frame and the bottom plate of the power battery enclosure after MIG (melt inert-gas) welding, a welding clamping scheme with hook-pull devices was designed. By adjusting the clamping force of the hook-pull d...
The interactive effects between additives and weld lines, which are frequent injection-moulding defects, were studied in high-density polyethylene (HDPE) and compared to weld-line-free reference samples. These materials were formulated around a D- an...
Complex multiphase flow in oil and gas pipelines raises safety risks. Magnetic flux leakage (MFL) detection effectively identifies pipeline defects. However, the high-speed movement of MFL inspection tools induces motion-induced eddy currents (MIECs)...
To reduce the computational cost associated with traditional moving heat source methods, a segmented approach is proposed for simulating the welding process of T-joints in large-scale infrastructure steel modules. Firstly, the hole-drilling method wa...
Due to various environmental regulations, the demand for natural gas, i.e., a clean energy, is expected to increase continuously. In terms of efficient storage and transportation of natural gas, liquefied natural gas has an advantageous volume of 1/6...
Heavy plate welding has been widely used in the construction of large projects and structures, in which the residual stress and deformation caused by the welding process are the key problems to address to reduce the stability and safety of the whole...
As an innovative technique, laser–GMAW hybrid welding manifests significant superiority in enhancing welding productivity and quality, albeit the optimization of process parameters poses a challenge for practical application. The present manusc...
The experimental evaluation of welding-induced distortion is a topic of great interest to both the scientific and industrial communities. With the aim of addressing a specific need in an industrial context, this paper investigates the capabilities of...
To control the welding residual stress and deformation of metal inert gas (MIG) welding, the influence of welding process parameters and preheat parameters (welding speed, heat input, preheat temperature, and preheat area) is discussed, and a predict...
A 3D thermal elastic-plastic welding analysis ACT (Application Customization Toolkit) was developed in ANSYS, making welding analysis more accessible. The welding analysis was performed using a decoupled method, separated into thermal and structural...
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