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ANGULAR DISTORTION IN BUTT ARC WELDING

Year 2018, Volume: 2 Issue: 4, 137 - 144, 28.12.2018

Abstract



The importance of fusion welding
technology has been widely recognized in the manufacturing process of various
steel structures such as ships, bridges, construction machines, power plants,
and automobiles. However, a significant disadvantage of fusion welding is that
it often generates unacceptable levels of geometric imperfections such as
shrinkage and distortion. Angular distortion is a major problem and most
pronounced among different types of distortion in the butt welded plates. This
angular distortion is mainly caused by the non-uniform extension and
contraction through thickness direction due to the temperature gradient. The
principal factors affecting the degree of welding angular distortion are:
material properties (the thermal expansion coefficient, the thermal
conductivity and the specific heat), weld groove geometry, joint type and
welding procedures (welding current, arc voltage,
welding speed, shielding gas chemical composition, gas flow rate, welding gun
angle, time gap between successive passes and number of passes
). All
these factors are explained in the paper.





The importance of fusion welding
technology has been widely recognized in the manufacturing process of various
steel structures such as ships, bridges, construction machines, power plants,
and automobiles. However, a significant disadvantage of fusion welding is that
it often generates unacceptable levels of geometric imperfections such as
shrinkage and distortion. Angular distortion is a major problem and most
pronounced among different types of distortion in the butt welded plates. This
angular distortion is mainly caused by the non-uniform extension and
contraction through thickness direction due to the temperature gradient. The
principal factors affecting the degree of welding angular distortion are:
material properties (the thermal expansion coefficient, the thermal
conductivity and the specific heat), weld groove geometry, joint type and
welding procedures (welding current, arc voltage,
welding speed, shielding gas chemical composition, gas flow rate, welding gun
angle, time gap between successive passes and number of passes
). All
these factors are explained in the paper.

References

  • K. Masubushi, Analysis of Welded Structures, First Edition, Pergamon Press, 1980
  • T. Schenk Modelling of Welding Distortion the Influence of Clamping and Sequencing PhD Thesis, Technische Universiteit Delft (2011)
  • Y. Zhou, Analysis of Welding Distortion Using Qualitative and Semi-Quantitative Techniques: MSc Thesis, University of British Columbia (1995)
  • T. Nagy, Investigation of Thermal Techniques to Mitigate Buckling Distortion in Welded Panels PhD Thesis, Cranfield University (2012)
  • F D S Cordeiro, A Critical Analysis on Weld’s Distortion, MSc Thesis, University of Combria, (2015)
  • A. Kumar, Effect of various parameters on angular distortion in welding, International Journal of Current Engineering and Technology, 1, 132-136 (2011)
  • A.A. Bhatti, Z. Barsoum, H. Murakawa, I. Barsoum, Influence of thermo-mechanical material properties of different steel grades on welding residual stresses and angular distortion, Materials and Design, 65, 878-889. (2015)
  • C.M. Cheng, C.P. Chou, I.K. Lee, H.Y. Lin, Distortion analysis of single V-groove butt welding on heat treatable aluminum alloys, Journal of Materials Science Technology, 21, 738-742 (2005)
  • D. Liu, H. Chen, F. Wong, K. Lee, I. Shiu, J. Wu, Effect of heat affected zone on the mechanical properties of copper bonding wire. Paper was presented IEEE 61st Electronic Components and Technology Conference, May 31-June 3, 2011, Lake Buena Vista, FL, USA
  • C. Heinze, C. Schwenk, M. Rethmeier, Effect of heat source configuration on the result quality of numerical calculation of welding-induced distortion, Simulation Modelling Practice and Theory, 20, 112-123 (2012)
  • D. Deng, FEM prediction of welding residual stress and distortion in carbon steel considering phase transformation effects, Materials and Design, 30, 359-366 (2009
  • H. K. Narang, M. M. Mahapatra, P. K. Jha, PVSS Sridhar, and P. Biswas, Experimental and Numerical Study on Effect of Weld Reinforcement on Angular Distortion of SAW Square Butt Welded Plates, Journal of Welding and Joining, 36, 48-59 (2018)
  • P. Vasantharaja, M. Vasudevan, P. Palanichamy, 2014. Effect of welding processes on the residual stress and distortion in type 316LN stainless steel weld joints, Journal of Manufacturing Processes, 19, 187-193 (2015)
  • P. K. Ghosh, K. Devakumaran, A. K. Pramnick, Effect of Pulse Current on Shrinkage Stress and Distortion in Multipass GMA Welds of Different Groove Sizes, Welding Journal, 89, 43s-53s (2010)
  • F.I. Sattari, M.R. Farahani, Effect of the weld groove shape and pass number on residual stresses in butt-welded pipes. International Journal of Pressure Vessels and Piping, 86, 723–731 (2009)
  • A. Bachorski, M.J. Painter1, A.J. Smailes, M.A. Wahab, Finite-element prediction of distortion during gas metal arc welding using the shrinkage volume approach, Journal of Materials Processing Technology, 92, 405-409 (1999)
  • N.S. Rajkumar, K.R. Varma, S. Gupta, T. Srihari, A study of effect of groove angle on angular distortion and impact strength in butt welds, 4th International Conference on Mechanical Engineering, December 26-28, Dhaka, Bangladesh (2001)
  • C. Rathod, G. K. Reddy, Experimental investigation of angular distortion and transverse shrinkage in CO2 arc welding process, International Journal of Mechanical Engineering, 5, 21-28 (2016)
  • P. Kumar, Parametric optimization og angular distortion on mild steel by using MIG welding. International Journal of Advanced Engineering Technology, 6, 41-46 (2015)
  • B N Sathyanarayana Reddy, G Mahendramani, M.Vishwanath, Experimental investigation for the effect of groove angles on angular distortion in CO2 arc welding, International Journal on Theoretical and Applied Research in Mechanical Engineering(IJTARME), 5, 30-33 (2016)
  • www//http T. Sandor, Comparison of penetration profiles of different TIG process variations
  • S.W. Shyu, H.Y. Huang, K.H. Tseng, C.P. Chou, Study of the performance of stainless steel A-TIG welds, Journal of Materials Engineering and Performance, 17, 193-201 (2008)
  • H. Huang, Effects of shielding gas composition and activating flux on GTAW weldments, Materials and Design, 30, 2404-2409 (2009)
  • S.R. Bhide, P. Michaleris, M. Posada, J. Deloach, Comparison of buckling distortion propensity for SAW, GMAW and FSW, Welding Journal, 85, 189s-195s (2006
  • H.B. Cary, S.C. Helzer, Modern Welding Technology, Prentice Hall, NewYork 2005
  • M.V. Venkatesan, N Murugan, B.M. Prasad, A Manickavasagam, influence of FCA welding process parameters on distortion of 409M stainless steel for rail coach building, Journal of Iron and steel research international, 20, 71-78 (2013)
  • I. Aggarwal, N. Faujdar, A. Das, P. Khanna, Mathematical modeling for predicting angular distortion in TIG welding of stainless steel 409L butt welds, International Journal of Research in Engineering and Technology, 7, 92-97, 2018
  • K.H. Tseng, Development and application of oxide-based flux powder for tungsten inert gas welding of austenitic stainless steels Powder Technology, 233, 72-79 (2013)
  • K.H. Tseng and C.P. Chou, Effect of pulsed gas tungsten arc welding on angular distortion in austenitic stainless steel weldments, Science and Technology of Welding and Joining, 6, 149-153 (2001)
  • P. K. Ghosh, K. Devakumaran, A. K. Pramanick, Effect of pulse current on shrinkage stress and distortion in multipass GMA welds of different groove sizes, Welding Journal, 89, 43s-53s (2010)
  • K.H. Tseng, H. L. Sung, Evaluation study on angular distortion and residual stress of stainless steel pulsed TIG weldment, Advanced Materials Research, 291-294, 905-909 (2011)
  • K.H. Tseng, H. L. Sung, Evaluation study on angular distortion and residual stress of stainless steel pulsed TIG weldment, Advanced Materials Research, 291-294, 905-909 (2011)
  • S. Ramani, V. Velmurugan. Effect of process parameters on angular distortion of MIG welded Al6061 plates, 5th International & 26th All India Manufacturing Technology, Design and Research Conference, December 12th–14th, Guwahati, Assam, India (2014)
  • S.Akella, B. R. Kumar, Distortion control in TIG welding process with Taguchi approach, Advanced Materials Manufacturing and Characterization, 3, 199-205 (2013)
  • Y. Zhao, The effect of shielding gas composition on the weld bead geometry during short-circuit GMA welding of Inconel625 alloy, MSc. Thesis, Delft University of Technology (2016)
  • M. Shoeb, M. Parvez, P. Kumari, Effect of MIG welding parameters on weld bead geometry on HSLA steel, International Journal of Engineering Science and Technology, 5, 200-212 (2013)
  • H.R. Ghazvinloo, A. Honarbakhsh, N.Shadfar, Effect of the electrode to work angle, filler diameter and shielding gas type on weld geometry of HQ130 steel joints produced by robotic GMAW, 3, 1-5 (2010)
  • H. Huang, Effects of shielding gas composition and activating flux on GTAW weldments, Materials and Design, 30, 2404-2409 (2009)
  • B.Y. Kanga, K.D.V. Prasad, M.J. Kang, H.J. Kim, I.S. Kim, The effect of alternate supply of shielding gases in austenite stainless steel GTA welding, Journal of Materials Processing Technology, 209, 4722–4727 (2009)
  • A. Almazrouee, T. Shehatai S. Orabyi, Effect of welding parameters on the weld bead geometry of low alloy steel using FCAW empirical modeling approach, International Journal of Mining, Metallurgy and Mechanical Engineering, 3, 88-92 (2015)
  • V. Murugan, V. Gunaraj, Effects of process parameters on angular distortion of gas metal arc welded structural steel plates, Welding Journal, 84, 165s-171s (2005)C. Adamczuk, I. Machado, J. Mazzaferro, Methodology for predicting the angular distortion in multi-pass butt-joint welding, Journal of Materials Processing Technology, 240, 305-313 (2017)
Year 2018, Volume: 2 Issue: 4, 137 - 144, 28.12.2018

Abstract

References

  • K. Masubushi, Analysis of Welded Structures, First Edition, Pergamon Press, 1980
  • T. Schenk Modelling of Welding Distortion the Influence of Clamping and Sequencing PhD Thesis, Technische Universiteit Delft (2011)
  • Y. Zhou, Analysis of Welding Distortion Using Qualitative and Semi-Quantitative Techniques: MSc Thesis, University of British Columbia (1995)
  • T. Nagy, Investigation of Thermal Techniques to Mitigate Buckling Distortion in Welded Panels PhD Thesis, Cranfield University (2012)
  • F D S Cordeiro, A Critical Analysis on Weld’s Distortion, MSc Thesis, University of Combria, (2015)
  • A. Kumar, Effect of various parameters on angular distortion in welding, International Journal of Current Engineering and Technology, 1, 132-136 (2011)
  • A.A. Bhatti, Z. Barsoum, H. Murakawa, I. Barsoum, Influence of thermo-mechanical material properties of different steel grades on welding residual stresses and angular distortion, Materials and Design, 65, 878-889. (2015)
  • C.M. Cheng, C.P. Chou, I.K. Lee, H.Y. Lin, Distortion analysis of single V-groove butt welding on heat treatable aluminum alloys, Journal of Materials Science Technology, 21, 738-742 (2005)
  • D. Liu, H. Chen, F. Wong, K. Lee, I. Shiu, J. Wu, Effect of heat affected zone on the mechanical properties of copper bonding wire. Paper was presented IEEE 61st Electronic Components and Technology Conference, May 31-June 3, 2011, Lake Buena Vista, FL, USA
  • C. Heinze, C. Schwenk, M. Rethmeier, Effect of heat source configuration on the result quality of numerical calculation of welding-induced distortion, Simulation Modelling Practice and Theory, 20, 112-123 (2012)
  • D. Deng, FEM prediction of welding residual stress and distortion in carbon steel considering phase transformation effects, Materials and Design, 30, 359-366 (2009
  • H. K. Narang, M. M. Mahapatra, P. K. Jha, PVSS Sridhar, and P. Biswas, Experimental and Numerical Study on Effect of Weld Reinforcement on Angular Distortion of SAW Square Butt Welded Plates, Journal of Welding and Joining, 36, 48-59 (2018)
  • P. Vasantharaja, M. Vasudevan, P. Palanichamy, 2014. Effect of welding processes on the residual stress and distortion in type 316LN stainless steel weld joints, Journal of Manufacturing Processes, 19, 187-193 (2015)
  • P. K. Ghosh, K. Devakumaran, A. K. Pramnick, Effect of Pulse Current on Shrinkage Stress and Distortion in Multipass GMA Welds of Different Groove Sizes, Welding Journal, 89, 43s-53s (2010)
  • F.I. Sattari, M.R. Farahani, Effect of the weld groove shape and pass number on residual stresses in butt-welded pipes. International Journal of Pressure Vessels and Piping, 86, 723–731 (2009)
  • A. Bachorski, M.J. Painter1, A.J. Smailes, M.A. Wahab, Finite-element prediction of distortion during gas metal arc welding using the shrinkage volume approach, Journal of Materials Processing Technology, 92, 405-409 (1999)
  • N.S. Rajkumar, K.R. Varma, S. Gupta, T. Srihari, A study of effect of groove angle on angular distortion and impact strength in butt welds, 4th International Conference on Mechanical Engineering, December 26-28, Dhaka, Bangladesh (2001)
  • C. Rathod, G. K. Reddy, Experimental investigation of angular distortion and transverse shrinkage in CO2 arc welding process, International Journal of Mechanical Engineering, 5, 21-28 (2016)
  • P. Kumar, Parametric optimization og angular distortion on mild steel by using MIG welding. International Journal of Advanced Engineering Technology, 6, 41-46 (2015)
  • B N Sathyanarayana Reddy, G Mahendramani, M.Vishwanath, Experimental investigation for the effect of groove angles on angular distortion in CO2 arc welding, International Journal on Theoretical and Applied Research in Mechanical Engineering(IJTARME), 5, 30-33 (2016)
  • www//http T. Sandor, Comparison of penetration profiles of different TIG process variations
  • S.W. Shyu, H.Y. Huang, K.H. Tseng, C.P. Chou, Study of the performance of stainless steel A-TIG welds, Journal of Materials Engineering and Performance, 17, 193-201 (2008)
  • H. Huang, Effects of shielding gas composition and activating flux on GTAW weldments, Materials and Design, 30, 2404-2409 (2009)
  • S.R. Bhide, P. Michaleris, M. Posada, J. Deloach, Comparison of buckling distortion propensity for SAW, GMAW and FSW, Welding Journal, 85, 189s-195s (2006
  • H.B. Cary, S.C. Helzer, Modern Welding Technology, Prentice Hall, NewYork 2005
  • M.V. Venkatesan, N Murugan, B.M. Prasad, A Manickavasagam, influence of FCA welding process parameters on distortion of 409M stainless steel for rail coach building, Journal of Iron and steel research international, 20, 71-78 (2013)
  • I. Aggarwal, N. Faujdar, A. Das, P. Khanna, Mathematical modeling for predicting angular distortion in TIG welding of stainless steel 409L butt welds, International Journal of Research in Engineering and Technology, 7, 92-97, 2018
  • K.H. Tseng, Development and application of oxide-based flux powder for tungsten inert gas welding of austenitic stainless steels Powder Technology, 233, 72-79 (2013)
  • K.H. Tseng and C.P. Chou, Effect of pulsed gas tungsten arc welding on angular distortion in austenitic stainless steel weldments, Science and Technology of Welding and Joining, 6, 149-153 (2001)
  • P. K. Ghosh, K. Devakumaran, A. K. Pramanick, Effect of pulse current on shrinkage stress and distortion in multipass GMA welds of different groove sizes, Welding Journal, 89, 43s-53s (2010)
  • K.H. Tseng, H. L. Sung, Evaluation study on angular distortion and residual stress of stainless steel pulsed TIG weldment, Advanced Materials Research, 291-294, 905-909 (2011)
  • K.H. Tseng, H. L. Sung, Evaluation study on angular distortion and residual stress of stainless steel pulsed TIG weldment, Advanced Materials Research, 291-294, 905-909 (2011)
  • S. Ramani, V. Velmurugan. Effect of process parameters on angular distortion of MIG welded Al6061 plates, 5th International & 26th All India Manufacturing Technology, Design and Research Conference, December 12th–14th, Guwahati, Assam, India (2014)
  • S.Akella, B. R. Kumar, Distortion control in TIG welding process with Taguchi approach, Advanced Materials Manufacturing and Characterization, 3, 199-205 (2013)
  • Y. Zhao, The effect of shielding gas composition on the weld bead geometry during short-circuit GMA welding of Inconel625 alloy, MSc. Thesis, Delft University of Technology (2016)
  • M. Shoeb, M. Parvez, P. Kumari, Effect of MIG welding parameters on weld bead geometry on HSLA steel, International Journal of Engineering Science and Technology, 5, 200-212 (2013)
  • H.R. Ghazvinloo, A. Honarbakhsh, N.Shadfar, Effect of the electrode to work angle, filler diameter and shielding gas type on weld geometry of HQ130 steel joints produced by robotic GMAW, 3, 1-5 (2010)
  • H. Huang, Effects of shielding gas composition and activating flux on GTAW weldments, Materials and Design, 30, 2404-2409 (2009)
  • B.Y. Kanga, K.D.V. Prasad, M.J. Kang, H.J. Kim, I.S. Kim, The effect of alternate supply of shielding gases in austenite stainless steel GTA welding, Journal of Materials Processing Technology, 209, 4722–4727 (2009)
  • A. Almazrouee, T. Shehatai S. Orabyi, Effect of welding parameters on the weld bead geometry of low alloy steel using FCAW empirical modeling approach, International Journal of Mining, Metallurgy and Mechanical Engineering, 3, 88-92 (2015)
  • V. Murugan, V. Gunaraj, Effects of process parameters on angular distortion of gas metal arc welded structural steel plates, Welding Journal, 84, 165s-171s (2005)C. Adamczuk, I. Machado, J. Mazzaferro, Methodology for predicting the angular distortion in multi-pass butt-joint welding, Journal of Materials Processing Technology, 240, 305-313 (2017)
There are 41 citations in total.

Details

Primary Language English
Journal Section Articles
Authors

Ahmet İrfan Yükler

Memduh Kurtulmus

Publication Date December 28, 2018
Published in Issue Year 2018 Volume: 2 Issue: 4

Cite

IEEE A. İ. Yükler and M. Kurtulmus, “ANGULAR DISTORTION IN BUTT ARC WELDING”, IJESA, vol. 2, no. 4, pp. 137–144, 2018.

ISSN 2548-1185
e-ISSN 2587-2176
Period: Quarterly
Founded: 2016
Publisher: Nisantasi University
e-mail:ilhcol@gmail.com