ROBUST CONTROL OF GAS TUNGSTEN ARC WELDING SYSTEM

The robust control law for gas tungsten arc welding dynamic process, which is a typical sampled-data system and full of uncertainties, is presented. By using the Lyapunov second method, the robust control and robust optimal control for a class of sampled-data systems whose underlying continuous-time systems are subjected to structured uncertainties are discussed in time-domain. As a result, some sufficient conditions of robust stability and the corresponding robust control laws are derived. All these results are designed by solving a class of linear matrix inequalities (LMIs) and a class of dynamic optimization problem with LMIs constraints respectively. An example adapted under some experimental conditions in the dynamic process of gas tungsten arc welding system in which the controlled variable is the backside width of weld pool and controlling variable pulse duty ratio, is worked out to illustrate the proposed results, it is shown that the sampling period is the crucial design parameter.     

Tensile creep behaviour of NiAl-Cr(Zr) multiphase intermetallic alloy

Abstract

The microstructure of a multiphase NiAl-33.5Cr-0.5Zr intermetallic alloy was examined by SEM with energy dispersive spectroscopy and TEM. The tensile creep behaviour of the hot isostatically pressed NiAl-33.5Cr-0.5Zr alloy was studied. The results of the creep test indicated that all of the creep curves under the present test have similar characteristics: a short primary creep stage, a dominant tertiary creep stage, and nearly identical creep strains (~45%). The apparent stress exponent and the apparent activation energy were analysed and discussed. The mechanism of the creep deformation was also analysed by the observation of TEM.     

Process model for strength of age hardenable aluminium alloy welds

Abstract

An existing process model for hardness prediction in age hardenable aluminium alloy welds is presented and analysed. One of the key criticisms of this model is that its derivation assumes softening is due to precipitate dissolution alone. The influence of precipitate coarsening has been determined by developing an equivalent model for softening owing to coarsening. It is shown that the experimentally derived master curves that form the basis of the model are capable of representing softening by a mixture of precipitate coarsening and dissolution. Methods to predict post-weld natural aging are discussed, and a new method is presented based on direct prediction of the Guinier–Preston zone fraction. The model has been applied to friction stir welding. Model predictions agree well with measured hardness profiles, and the sensitivity of the predictions to temperature is discussed.     

Coupled effect of heat input and beam oscillation on mechanical properties of alloy 718 electron beam weldments

Abstract

Autogenous full penetration electron beam welds were made on alloy 718 with and without beam oscillation technique. Weldments were subjected to two types of post-weld heat treatments: direct aging (DA) and solution treatment at 980°C followed by aging (STA). When the welds were prepared using different heat inputs in the welding processes with and without beam oscillation, the influence of beam oscillation could not be studied in isolation but the coupled effect of heat input and beam oscillation was studied. Laves particles were finer in size and lower in amount in unoscillated welds compared with those in beam oscillated welds subjected to DA condition. δ phase needles were observed around Laves particles in the welds subjected to STA condition. The amount of Laves particles was less and that of δ phase was more in unoscillated welds compared with those in beam oscillated welds subjected to STA condition. Unoscillated weldments exhibited longer fatigue lives compared with beam oscillated weldments in both DA and STA conditions owing to less amount of Laves in the former. Weldments in STA condition had longer lives compared with those in DA condition. The role of δ phase needles in fatigue life could not be identified.     

New structure of automatic torch and new approach for controlling drop transfer in rotating spray welding arc

Abstract

Using computer aided design/computer aided manufacturing technology, an automatic welding system is designed and manufactured for high current, high speed, and high deposition metal arc active gas (MAG) welding. The welding torch structure is evaluated and optimised via the finite element method and practical welding technology experiments. Finally, the process of high deposition MAG welding is investigated, and it is highlighted that on application of a longitudinal magnetic field to the high deposition MAG welding process, a steady metal transfer and drop deposition condition can be achieved, which is suited to the demands of high current, high speed welding technology.     

Welding behaviour,microstructure and mechanical properties of dissimilar resistance spot welds between galvannealed HSLA350 and DP600 steels

Abstract

Resistance spot welding experiments were conducted on dissimilar material combination of HSLA350/DP600 steels. The welds were characterised using optical and scanning electron microscopy. The fusion zone of the dissimilar material spot weld was predominantly martensitic with some bainite. Mechanical properties were also determined by tensile shear, cross tension and fatigue tests. The performance of dissimilar material spot weld was different from that of the similar ones in each of the HSLA350 and DP600 steels and exhibited different heat affected zone hardness. The DP600 weld properties played a dominating role in the microstructure and tensile properties of the dissimilar material spot welds. However, the fatigue performance of the dissimilar welds was similar to that of the HSLA350 welds. Fatigue tests on the dissimilar material spot welds showed that the 5·5 mm diameter nugget exhibited higher fatigue strength than the 7·5 mm diameter nugget.     

Spatter reduction in gas metal arc welding of stainless steel sheets using controlled bridge transfer process

Abstract

In non-pulsed gas metal arc welding (GMAW), spatter can be reduced by controlling the short circuit current to a low level just before the re-arcing. The controlled bridge transfer (CBT) process, which optimises the accuracy of predicting the re-arcing in real time in response to the metal transfer, realises stable, low spatter level. In this research, the methods for controlling short circuit transfers to minimise spatter and realise stable arcs in GMAW of stainless sheet using argon rich shielded gases are investigated. The new CBT process has been developed by applying the specific arc length estimation method that is not affected by abnormal rise in arc voltage. This process can suppress the spatter generation caused by a fluctuation in the vibratory motion of the weld pool or inaccurate prediction of the re-arcing in the succeeding short circuit/re-arcing cycle, and thereby spatter free GMAW in the short circuit transfer mode can be carried out even on stainless steels.     

Measuring and modelling residual stresses in butt welded P91 steel pipe including effects of phase transformations

Abstract

Residual stresses in a circumferentially butt welded steel pipe have been measured and numerically predicted. The pipe, containing the circumferential weld, has an outer diameter of 290 mm and a wall thickness of 55 mm, typical of components in power generation plants. An axisymmetric thermomechanical finite element (FE) simulation has been performed to obtain the residual stress field induced by the fusion welding of the pipe, taking solid state phase transformation effects into account and using temperature dependent material property data. Residual stresses have been measured using the X-ray diffraction and deep hole drilling techniques. Good correlation has been demonstrated with the predictions of the FE model. The paper demonstrates that a mixed experimental and numerical approach is useful for determining the residual stress distribution in welded joints.     

Method for welding highly crack susceptible magnesium alloy ZK60

Abstract

The highly crack susceptible magnesium alloy ZK60 plates of 2 mm thickness were successfully welded by laser beam welding (LBW) with filler strip, which has the advantages of low heat input and capability of adjusting the compositions of weld metal to a less susceptible level. The effects of the compositions of filler strips on the microstructures and mechanical properties of the joints were investigated. Compared with autogenous LBW, LBW with filler strip can produce a narrower joint and avoid the cracks and pits, which severely worsen mechanical properties of the joints. When the filler strip of ZK40 alloy is employed, the grains in fusion zone can be refined, and a high quality joint, with the ultimate tensile strength of 322 MPa up to 90·7% of the base metal, is obtained.     

Applicable conditions of instantaneous source used for welding heat conduction

Abstract

This paper deals with the sufficient conditions under which instantaneous heat source can be considered as welding heat source instead of moving source. Temperature rises calculated by instantaneous source and moving one were compared. The applicable conditions of the instantaneous heat source with errors of 1% and 5% were found. This enables us to select either moving or instantaneous source with information of welding speed, thermal diffusivity and the distance from the weld centre line to the interested location. Approximate equations to determine the maximum temperature rise using a moving source were proposed and the accuracy of their calculation was proved to be ～99%.