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Eingeladener Vortrag
- nein (41)
In the last decade, high-strength fine grained steels and welding consumables have gained a strong raise of application ranging from mobile cranes to bridge constructions. However, the cracking susceptibility of these steels increases significantly in correspondence with the achieved improvements in yield strength and the loss in plastic deformation reserves.
In order to determine this behavior a series of different standardized cold cracking tests has been developed. One remaining major problem of these tests is the uncertainty about the quantitative intensity of the restraint conditions as well as the corresponding welding residual stresses.
Consequently, the comparison of different tests and welding conditions as well as the transferability of the results onto real parts is difficult at best. The main topic of this paper is the analysis of the restraint conditions and their link with the welding induced residual stresses. The importance of the given standardized selfrestrained tests and first results about the transferability of
results onto real parts are discussed. The influence of the test specimen geometry on the restraint conditions of the test is investigated for a selected test with numerical Simulation using commercial FEA software. Additionally, the residual stresses caused by the welding process are measured and linked with the restraint conditions which are defined mainly by the geometry parameters.
Finally the transferability of the selected cold cracking test results is validated experimentally. The test results of a multilayer weld on high-strength fine grained steel of real size weldments are investigated. For these experiments a 16 MN large scale testing facility is used which is capable of applying the high reaction forces and clamping conditions found at large scale demonstrator parts.
The results show the importance of the quantitative knowledge of the restraint conditions and the welding residual stresses on the cold cracking resistance.
Ultrasonic vibration enhanced friction stir welding (UVeFSW) is a recent modification of conventional friction stir welding (FSW), which transmits ultrasonic vibration directly into the localized area of the workpiece near and ahead of the rotating tool. In this study, a high strength aluminium alloy (2024-T4) was welded by this process and conventional FSW, respectively. Then tensile tests, microhardness tests and fracture surface analysis were performed successively on the welding samples. The tests results reveal that ultrasonic vibration can improve the tensile strength and the elongation of welded joints. The microhardness of the stir zone also increases.
Mechanische Eigenschaften der laserhybridgeschweißten Schweißverbindungen von hochfesten niedriglegierten Stählen erfüllen die Anforderungen der geltenden Normen
Eindringtiefe des Zusatzwerkstoff bis ca. 12 mm
Halborbitales Schweißen an 36” Rohren mit einer Wandstärke von 16 mm bei einer Schweißgeschwindigkeit von bis zu 2,2 m/min und Laserleistung von 19 kW technisch möglich
Rissfreie Schweißverbindungen an Präzisionsrohren können durch eine geeignete Schweißparameterauswahl mittels Laser-Hybridverfahren hergestellt werden
The influence of two different weld imperfections (gap/crack) on the fatigue behaviour of spot welded joints was tested
Surface cracks havenoinfluenceon thefatiguelife
Samples with cracks in the electrode indentation /HAZ where tested
Stiffness curves are not significantly influenced by surface cracks
3D FE-Simulation demonstrate no changes of stress due to surface imperfections
Drop-out of molten material was avoided by EM pressure
Compensation of the hydrostatic pressure of up to 20 mm thick
aluminum and stainless steel (experiment and FEM)
Mitigation of the weld bead dynamics
Significant changes in the velocity distributions in the weld pool
Weld pool geometry shape changes due to Hartmann effect
Significant porosity reduction
Surface quality improvements
Drop-out of molten material was avoided by EM pressure
Compensation of the hydrostatic pressure of up to 20 mm thick
aluminum and stainless steel (experiment and FEM)
Mitigation of the weld bead dynamics
Significant changes in the velocity distributions in the weld pool
Weld pool geometry shape changes due to Hartmann effect
Significant porosity reduction
Surface quality improvements
Solidification cracking phenomena taking place under Controlled Tensile Weldability (CTW) test conditions have already been investigated both experimentally and numerically via FEA in order to get a better understanding of the mechanisms of hot crack formation during laser beam welding of austenitic steel grades. This paper develops a three dimensional finite element model employing the contact elements technique to simulate the formation and propagation of solidification cracks during laser full penetration welding of fully austenitic stainless steel 1.4376. During the experimental procedure the resulting strain and displacement directed to the laser beam in the Close vicinity of the weld pool was measured at the surface of the workpiece using a Digital Image Correlation (DIC) technique with an external diode laser as an illuminating source. Local strain fields, global loads and crack lengths predicted by the model are in good Agreement with those observed in experiments.
Laser welding is a widely established manufacturing process in many industry sectors. Solidification cracking represents one of the most inadequately solved problems in welding and has major economic implications. The avoidance of hot crack forms for most fusion welding processes poses a key challenge for an important range of metallic construction materials and affects not only the manufacturers of welding equipment and material manufacturers, but also a large number of customers using welding technologies, as well as welding technical standardization and research. Solidification cracking susceptibility was examined with the help of the Controlled Tensile Weldability Test (CTW) developed by Federal Institute for Materials Research and Testing (BAM), Berlin. The test is based on the fact that hot crack formation depends on a critical strain that emerges within a critical temperature range, the so called brittle temperature range (BTR). Using this test and defined investigation programme a centreline solidification crack was generated. By controlling the applied strain during the laser beam welding process, it was possible to determine the critical strain and strain rate that led to solidification cracking formation. The hot cracking susceptibility of the tested stainless steels was qualified and quantified. The results demonstrate that the crack length increases with increasing applied strain. Furthermore, the strain rate has a significant influence on the formation of the solidification crack.
Laser welding is a widely established manufacturing process in many industry sectors. Solidification cracking represents one of the most inadequately solved problems in welding and has major economic implications. The avoidance of hot crack is for most fusion welding processes a key challenge for an important range of metallic construction materials and affects not only the manufacturers of welding equipment and material manufacturers, but also a large number of customers using welding technologies, as well as welding standardization and research. In this study a new investigation programme has been developed to qualify the hot cracking susceptibility of a variety of austenitic stainless steels. The results show the possibility of using this technique to determinate the critical values that occur with initiation of solidification cracking during laser beam welding
The numerical simulations of high power laser keyhole welding at different welding positions are performed by using Volume-Of-Fluid (VOF) method. The main material is SS400. The multi-physics phenomenon is considered using several models, such as the heat flux of Gaussian heat source, the recoil pressure with Clausisus-Clapeyron equation, the Marangoni flow considering temperature gradient, the buoyancy force with Boussinesq approximation, the additional shear stress and heat source due to metallic vapor ejected through keyhole entrance, the bubble formation assumed as adiabatic bubble, and the multiple-reflection by solving proper discriminant, are used. To analyze the fluid flow pattern, the concept of streamline formed by reconstructing the value of the velocity vector is applied.
Partial and full penetration cases at different welding positions are considered. The welding position seems to have only a minor influence on bead formation characteristics in both cases. This is probably due to the fact that the recoil pressure has a major influence when compared to other driving forces. The flow characteristics and fluid velocity in weld pool are analyzed to compare the gravity direction effect at different welding positions. It is observed that the clockwise flow pattern is mainly formed by the recoil pressure on the keyhole surface in the case of partial penetration. The laser energy can't maintain the whole weld pool when the weld pool size becomes too large. And then the solidification starts from the middle part of weld pool and a necked weld pool shape is formed. In the full penetration welding, the weld pool flow patterns are affected by the leakage of laser power through the full penetration keyhole and also by surface tension. Furthermore, the numerical simulation of full penetration welding with AISI316L is also performed to analyze the effect of material properties. The weld bead shapes obtained by simulations were compared with the corresponding experimental results to confirm the validity of the process models adopted and the CFD simulation tool.