Article
Engineering, Multidisciplinary
Nikhil Shajan, Brajesh Asati, Suman Patra, Mohommed Aamir, Kanwer Singh Arora, Rhushikesh R. Mane
Summary: Failure of flash butt welds due to oxide entrapment is a common cause of wheel rim failures. The initial jaw distance and number of preheating pulses have a critical impact on the quality of the welds. Sufficient upset length is necessary to remove oxides and cold spots formed during welding for defect-free joints. Increasing the number of preheating pulses helps improve edge quality and reduce defects.
SADHANA-ACADEMY PROCEEDINGS IN ENGINEERING SCIENCES
(2022)
Article
Materials Science, Multidisciplinary
Jun Wang, Cheng Ma, Jian Han, Zhengyi Jiang, Valerie Linton
Summary: In this study, the flash butt welding (FBW) of high-strength low-alloy steel was physically simulated, and it was found that a moderate increase in upset allowance (Δu) can enhance the microstructural and mechanical properties of the welds, leading to excellent strength and plasticity compatible with the base metal. These findings will provide valuable guidance for practical FBW processes.
Article
Engineering, Mechanical
Yong Pang, Nicolo Grilli, Hang Su, Wencheng Liu, Jun Ma, Siu Fung Yu
Summary: In this study, the weldability of mobile flash-butt welded joints was investigated in terms of microstructures, mechanical properties, and residual stresses. The results showed that the heat-affected zone (HAZ) experienced significant reductions in hardness and underwent plastic strain with lattice reorientation. The bond strength of the weld was inversely correlated with the HAZ width. Shrinkage cracks, inclusions, and flat spots in the rail web were the main cause of early failure. FBW introduced high residual stresses in the rail web.
ENGINEERING FAILURE ANALYSIS
(2022)
Article
Automation & Control Systems
Jun Wang, Yao Lu, Jian Han, Jianjun Qi, Li Sun, Zhengyi Jiang, Cheng Ma, Valerie Linton
Summary: This study simulated the FBW process of 440CL high-strength-low-alloy steel and systematically evaluated the influence of flash parameters on the weld joint. The results showed that the width of heat affected zone increased with accumulated flash allowance while declined with accelerated flash speed. The recrystallization level would be intensified with increased accumulated flash allowance, and the acceleration in flash speed populated the weld zone with a more homogeneous microstructure.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Chemistry, Physical
Andrzej Kubit, Lukasz Lenart, Tomasz Trzepiecinski, Andrzej Krzysiak, Wojciech Labunski
Summary: The research analyzed the effect of surface treatment methods on the static and fatigue strength of flash butt welded bandsaw blades, finding that sandblasting the weld surface increased the repeatability of load capacity and extended the time before fatigue cracks initiate.
Article
Optics
Xiaoya Li, Rui Ma, Xin Liu, Qibing Lv, Xiao Wang, Zeng Tian
Summary: This study examines the effect of laser shock peening (LSP) treatment on the bending fatigue performance of rail-welded joints. It was found that LSP treatment increases the fatigue life of the joints and enhances resistance to fatigue crack growth.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Kotchaporn Thadsoongnoen, Anat Hasap, Nitikorn Noraphaiphipaksa, Chaosuan Kanchanomai
Summary: Flash-butt welding is used for joining railway rails, but it can result in residual stress formation in the welded joint, which affects the performance and reliability of the rail. In this study, the mechanisms of residual stress formation and the influence of upsetting force were investigated through finite element analysis. The calculation results were found to be in good agreement with the measured results, and compressive residual stresses were observed at the rail head and foot, while tensile residual stresses were observed at the rail web. The investigated upsetting force had minimal impact on the formation of residual stress.
Article
Materials Science, Multidisciplinary
Shih-Chen Shi, Wei-Cheng Wang, Dun-Kai Ko
Summary: Flash butt welding is an efficient welding technology widely used in industrial development. Inclusions generated during the process can significantly affect the welding quality. This study investigated the impact of different upset distances on the number of inclusions, while fixing the flash welding time. Statistical analysis of the experimental data revealed a relationship between upset distance and the number of inclusions, with the total number of inclusions negatively impacting the product's strength.
Article
Materials Science, Multidisciplinary
Henrique Varella Ribeiro, Milton Sergio Fernandes Lima, Jose Benedito Marcomini, Filipe Correa Pinto, Carlos Antonio Reis Pereira Baptista
Summary: This paper evaluates the fatigue crack growth in HSLA steel plates welded by flash butt welding and laser beam welding. Different welding processes result in distinct microstructures, which significantly affect hardness but not fatigue crack growth. Furthermore, weld beads show higher resistance to fatigue crack growth compared to the base metal.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Materials Science, Multidisciplinary
Xi Zhang, Tingting Liao, Qibing Lv, Guoqing Gou
Summary: This study investigates the effect of normalisation process on the electrochemical behavior of U75V rail-welded joints. The results show that normalisation leads to finer and more homogeneous grains within the joints, resulting in lower corrosion rate and higher corrosion resistance. The formation of denser passivation films is also observed, contributing to the improved corrosion resistance of the welded joints.
Article
Materials Science, Multidisciplinary
YuanBo Bi, Zhen Luo, Jing Guo, Yue Yang, Jie Su, Yixuan Zhang
Summary: AA 5754 aluminum alloy sheets were successfully joined by resistance spot welding in butt configuration, resulting in irregular ellipsoidal-shaped nuggets. The microstructures and mechanical properties of the butt joints were investigated, and it was found that butt joints had larger shear force compared to lap joints, with a maximum shear force of 2888 N at the interface zone.
Article
Nanoscience & Nanotechnology
Lei Zhou, Pingwei Xu, Tingyi Lin, Xueru Zhu, Yilong Liang, Yu Liang
Summary: This paper investigates the evolution of microstructure and mechanical properties of Inconel 718 flash-butt welded joints after post-weld heat treatment at different solution temperatures. The results show that the treatment at 980 degrees C produces gradient grains that improve ductility without compromising strength.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Nanoscience & Nanotechnology
Lei Zhou, Tingyi Lin, Pingwei Xu, Yilong Liang, Yu Liang
Summary: Flash-butt welded IN718 alloy joint obtains higher strength and ductility due to an improved heterogeneous microstructure distribution achieved by adjusting the upsetting deformation. Finer grains and more residual stress in the heat affected zone (HAZ) lead to increased strength and hardness. The coordination between the HAZ and the matrix enhances the ductility, resulting in a welded sample achieving the same high strength and ductility as the base material.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Materials Science, Multidisciplinary
Kun Gao, Shengwei Zhang, Mounarik Mondal, Soumyabrata Basak, Sung-Tae Hong, Heechan Shim
Summary: Friction stir spot welding of dissimilar S45C steel and 6061-T6 aluminum alloy in a butt configuration was experimentally investigated, showing that increasing the tool rotational speed can improve the thickness of the IMC layer and tensile strength. The performance of the joint is closely related to the IMCs at the joint interface, as shown by tensile tests and microstructural analysis.
Article
Engineering, Mechanical
Bin Rong, Shaopeng Liu, Qiuping Li, Jinfang Peng, Mingxue Shen
Summary: Flash-butt welded rail is widely used in railway transportation, but the welded joint can become vulnerable after a long time of service. In this study, mechanical and tribological behaviors between the welded joint and the base metal of a U75VG rail were analyzed through tests. The results showed that flash-butt welding promotes the transformation of pearlite into ferrite, resulting in lower hardness but higher plasticity. Additionally, the all-weld-metal specimen had lower yielding and strength compared to the base metal specimen. The wear mechanism of the U75VG rail also changed from adhesive wear and oxidation to fatigue wear and slight oxidation.
