Article
Materials Science, Multidisciplinary
Harinadh Vemanaboina, M. Mohan Babu, Inguva Chinmaya Prerana, Edison Gundabattini, Balram Yelamasetti, Kuldeep K. Saxena, Karrar Hazim Salem, Muhammad Ijaz Khan, Sayed M. Eldin, Manoj Kumar Agrawal
Summary: Laser welding is used for critical component production with tight tolerances. It provides benefits such as lower heat input, smaller heat affected zone, lower residual stresses, minimum distortions, and better mechanical joint characteristics compared to conventional welding. In this study, a Gaussian heat source model was used to simulate the laser welding process on SS316L plates. The model was developed and simulated using ANSYS with APDL coding. The thermal profiles at the joint cross sections and the interface across joints were analyzed. The maximum temperature was observed at the fusion zone and associated zones. The residual stresses were analyzed and found to be within the safe limits of the base material. The predicted and experimentally measured residual stresses were in close agreement with a difference of 10%.
MATERIALS RESEARCH EXPRESS
(2023)
Article
Engineering, Manufacturing
M-N Avettand-Fenoel, T. Sapanathan, T. Pirling, G. Racineux, A. Simar, J-M Drezet
Summary: Residual stresses in a dissimilar AA1050-DP450 steel magnetic pulse weld were investigated using neutron diffraction for the first time. Tensile residual stresses were observed in the Al sheet and compressive residual stresses in the steel sheet, with different distributions at the joint interface. The asymmetrical shape of the rectangular joint line resulted in lower magnitude of residual stresses along the short side of the weld.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Materials Science, Multidisciplinary
Mato Peric, Ivica Garasic, Mislav Stefok, Kresimir Osman, Ante Cikic, Zdenko Tonkovic
Summary: This study conducted numerical and experimental research on residual stresses of an I-profile structure model welded using Metal-cored Arc Welding technique. The longitudinal stresses in the weld and its immediate surroundings were found to be tensile, while compressive stresses were observed towards the ends of the model. Transversal residual stresses mainly existed around the weld and its immediate surroundings, gradually decreasing towards the ends of the model. The numerical and experimental results showed a high level of agreement.
Article
Engineering, Manufacturing
Jiamin Sun, Klaus Dilger
Summary: Generally, as-received steel components before welding undergo various manufacturing processes, leading to the presence of initial residual stresses (IRS). The relationship between IRS and welding residual stresses (WRS) is still unclear, particularly in ultra-high strength steels (UHSS). This study aims to investigate the influence of IRS on WRS in ultra-high strength steel S960 using X-ray diffraction (XRD) measurements. The results indicate that IRS in the weld area are completely eliminated and have no impact on WRS due to the metallurgical and mechanical melting effect. In the heated zone outside the weld area, the initial longitudinal residual stress (σLRS) affects WRS significantly only when it is in tension. In the cold area, WRS are a combination of IRS and welding-induced residual stresses (WIRS), with IRS playing the dominant role in general and having minimal impact on WRS in the weld area.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Mathematics, Applied
Sandipan Baruah, Subrato Sarkar, I. Singh, B. K. Mishra
Summary: This work presents a computational framework based on finite element analysis, machine learning, and genetic algorithm to accurately estimate and minimize residual stresses in welding. By utilizing an optimization process, the framework can obtain an accurate phase-change model and a set of welding operating conditions that reduce residual stresses.
FINITE ELEMENTS IN ANALYSIS AND DESIGN
(2022)
Article
Chemistry, Physical
Yuan Fang, Chunwei Ma, Guangkai Zhang, Yuli Qin, Wentao Cao
Summary: In this paper, a new narrow gap oscillation calculation method is developed in ABAQUS thermomechanical coupling analysis to study the distribution trend of residual weld stresses. The reliability of the prediction experiment is verified using the blind hole detection technique and thermocouple measurement method. The results show a high degree of agreement between the experimental and simulation results. The use of high-energy single-layer welding instead of multi-layer welding not only optimizes the weld quality but also significantly reduces the time cost.
Article
Thermodynamics
Weifeng Xie, Chenglei Fan, Chunli Yang, Yu Liu
Summary: This study compares the weld deformation and residual stress distribution of dual phase steel thin plate joints welded using Gas Tungsten Arc (GTA) and Ultrasonic-wave-assisted Gas Tungsten Pulsed Arc (U-GTPA) welding. The results show that using U-GTPA welding can reduce weld deformation and achieve narrower longitudinal tensile stress range.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2023)
Article
Engineering, Manufacturing
Charles R. Fisher, Kelly E. Nygren, Armand J. Beaudoin
Summary: The shipbuilding industry is focusing on developing digital twin technology, but the lack of material processing data in simulations affects the accuracy of structural performance. Integrated Computational Materials Engineering (ICME) techniques link digital information across multiple length scales to reduce the time and cost of physical testing needed for validation. This study validates the materials-informed digital twin method through physical specimen selection, finite-element analysis (FEA) based welding simulations, and comparison of predicted strain data with experimental results using energy dispersive diffraction (EDD) techniques.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Chemistry, Physical
Kasireddy Usha Rani, Rajiv Kumar, Manas M. Mahapatra, Rahul S. Mulik, Aleksandra Swierczynska, Dariusz Fydrych, Chandan Pandey
Summary: Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on arc welding that has gained attention in industrial production due to its cost and speed advantages. The gas metal arc welded (GMAW) based WAAM process provides higher deposition rates and is suitable for manufacturing mild steel and stainless steel samples. Microstructure characterization, hardness testing, and residual stress measurement were conducted to evaluate the quality of the samples produced using the WAAM technique.
Article
Engineering, Mechanical
Harinadh Vemanaboina, Suresh Akella, A. C. Uma Maheshwer Rao, Edison Gundabattini, Ramesh Kumar Buddu
Summary: In this study, simulation and experimental analysis were conducted for multipass Gas tungsten Arc Welding of SS316L, showing temperature and residual stress variations in different regions. Results indicated a good agreement between simulated and measured temperatures, with slightly lower consistency in residual stresses.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2021)
Article
Engineering, Mechanical
Raffaele Sepe, Alessandro De Luca, Alessandro Greco, Enrico Armentani
Summary: This paper presents a novel numerical model based on the finite element method for simulating residual stresses and distortions in a welding process, using the 'element birth and death' technique for weld filler supply simulation. Advancements include simulating plate interaction and using a more efficient method for supplying heat to FEs.
FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES
(2021)
Article
Materials Science, Multidisciplinary
Yu Su, Xiawei Yang, Dong Wu, Tingxi Meng, Wenya Li, Wuyuan Feng, Wenwei Zhao, Achilles Vairis
Summary: This study experimentally and numerically investigated the welding deformation and residual stress optimization of an Invar steel TIG welded butt joint. The results showed that deformation could be effectively controlled with the appropriate welding sequence. Segmental bidirectional welding could avoid the highest deformation area, and welding heat treatment improved residual stresses.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
Jiamin Sun, Thomas Nitschke-Pagel, Klaus Dilger
Summary: This study investigates the reasons and mechanisms behind the generation and distribution of welding-induced residual stresses (WIRS) through experiments and numerical simulations. The results show that thermal shrinkage and phase transformation are the main sources of longitudinal residual stresses, while quenching process is another source of transverse residual stresses. It is also found that the distribution of residual stresses varies in shape depending on the transforming property of the materials.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Civil
Mehran Ghafouri, Antti Ahola, Joseph Ahn, Timo Bjork
Summary: This study investigates the influence of welding sequences and external constraints on angular distortion and residual stresses in short fillet welds made of high strength steel. The findings show that external constraint has a larger impact than welding sequence on the development of angular distortion and peak residual stresses. Furthermore, the results demonstrate that short fillet welds have larger peak magnitudes of localized transverse residual stress fields compared to continuous fillet welds. The stiffness of external constraint has a greater influence on preventing angular distortion in continuous fillet welds than in short fillet welds.
ENGINEERING STRUCTURES
(2022)
Article
Engineering, Marine
M. Hashemzadeh, Y. Garbatov, C. Guedes Soares
Summary: This study estimates the residual stresses and distortions induced by hybrid laser welding of a ship deck panel using a 3-D finite element analysis. A numerical model is developed to estimate the post-weld-induced distortions and residual stresses, and it is validated and compared with experiments. The developed model can be directly implemented in fatigue and ultimate strength structural analysis.
Article
Engineering, Mechanical
Dileep Kumar Ganji, Rajyalakshmi Gajjela
Summary: The present work focuses on developing nickel-based superalloys by studying the impact of alloying elements on their physical and mechanical characteristics. Computationally developed materials have the potential to meet the needs of materials engineers and are now being integrated into the planning process.
AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING
(2023)
Review
Engineering, Mechanical
G. Ranjith Kumar, M. Sathishkumar, M. Vignesh, M. Manikandan, G. Rajyalakshmi, R. Ramanujam, N. Arivazhagan
Summary: Metal additive manufacturing (AM) has matured and gained wide applications in the aerospace industry. With the introduction of new processes, materials, and cost-efficiency, AM has become a more versatile, common, and safer manufacturing technology. This article focuses on the use of AM in the aerospace industry, discussing its advantages and challenges.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Materials Science, Multidisciplinary
Sreenivasulu Bezawada, Rajyalakshmi Gajjela
Summary: In this investigation, Hastelloy C276 and 316L stainless steel were joined using the PCGTAW process. The welded joints were characterized using optical microscopy and SEM with EDS. The results showed that PCGTAW is an appropriate welding technique for making sound welded joints between Hastelloy C276 and 316L stainless steel.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Materials Science, Multidisciplinary
Harinadh Vemanaboina, M. Mohan Babu, Inguva Chinmaya Prerana, Edison Gundabattini, Balram Yelamasetti, Kuldeep K. Saxena, Karrar Hazim Salem, Muhammad Ijaz Khan, Sayed M. Eldin, Manoj Kumar Agrawal
Summary: Laser welding is used for critical component production with tight tolerances. It provides benefits such as lower heat input, smaller heat affected zone, lower residual stresses, minimum distortions, and better mechanical joint characteristics compared to conventional welding. In this study, a Gaussian heat source model was used to simulate the laser welding process on SS316L plates. The model was developed and simulated using ANSYS with APDL coding. The thermal profiles at the joint cross sections and the interface across joints were analyzed. The maximum temperature was observed at the fusion zone and associated zones. The residual stresses were analyzed and found to be within the safe limits of the base material. The predicted and experimentally measured residual stresses were in close agreement with a difference of 10%.
MATERIALS RESEARCH EXPRESS
(2023)
Article
Materials Science, Multidisciplinary
Balram Yelamasetti, P. Naveen Kumar, G. Venkat Ramana, Kuldeep Kumar Saxena, Devender Singh, Amardeep Singh Kang, Kahtan A. Mohammed
Summary: Surface modification of aluminium alloy 6061 was conducted through friction stir processing with B4C particle embedding. Three different samples (sample 1, sample 2, and sample 3) were developed to investigate the wear, corrosion, and microstructural properties. The modified surfaces were characterized using optical and scanning electron microscopes. Pin-on disc method was used to study the wear rate, while corrosion behavior was evaluated in a 3.5 wt.% NaCl solution. Microstructural analysis revealed distinct characteristics in sample 2 and sample 3. The wear rate was highest in sample 1, and sample 2 exhibited improved corrosion resistance compared to sample 1 and sample 3.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
(2023)
Article
Materials Science, Multidisciplinary
G. Ranjith Kumar, G. Rajyalakshmi, S. Swaroop, M. Vignesh, M. Satish Kumar, Jia Deng
Summary: In this article, the effect of hydrogen on the mechanical properties of laser peened hydrogen charged Ti6Al4V samples was analyzed using the slow strain rate tensile (SSRT) test. The microstructural analysis using TEM and EBSD revealed the formation of new grain boundaries, slip bands, and hexagonal networks, as well as the occurrence of beta/alpha ' martensitic transformation. Laser peening played a crucial role in preserving the mechanical properties, even after hydrogen charging. The experimental results showed that laser peening significantly protected the mechanical properties of Ti6Al4V alloy from the detrimental effects of hydrogen.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Engineering, Manufacturing
G. Vijay Kumar, P. Gopalakrishnaiah, M. Radha Devi, T. Vishnu Vardhan, Balram Yelamasetti
Summary: This research paper investigates the optimization of the milling process for S-GFRP composites by adjusting spindle speed, cutting depth, and feed rate. The study uses the Taguchi method and a unique Orthogonal Array L9 design to analyze the effects of different parameter combinations on cutting force, surface roughness, and delamination. The results highlight the significant influence of spindle speed, with a contribution of 66.64% on all three responses, followed by feed rate at 26.12% and cutting depth at 5.78%. This research provides valuable insights for improving the milling processes of S-GFRP composite materials, leading to enhanced performance and quality in machined parts.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
P. Bridjesh, N. K. Geetha, Balram Yelamasetti
Summary: This article investigates the influence of pores on functionally graded materials, finding that the distribution of pores affects the Young's modulus and tensile strength. It also studies 2D-functionally graded porous beams under different boundary conditions.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
Ajit Kumar Yadav, Manoj Kr. Agrawal, Kuldeep K. Saxena, Balram Yelamasetti
Summary: This research paper predicts the thermal and residual stresses in dissimilar welds of AA5083 and AA6082 using ANSYS (R). The combination of different materials is widely used when high corrosion resistance and good mechanical properties are required. A 3-Dimensional Goldak ellipsoidal model was developed to predict the thermo-mechanical properties. Accurate results in the welded structures were obtained by applying suitable boundary conditions during simulation. The stress formation along welding and transverse direction was predicted by considering the FE results obtained from the thermal model.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
Sagar Shelare, Pramod Belkhode, Keval Chandrakant Nikam, Balram Yelamasetti, Trupti Gajbhiye
Summary: Unmanned aerial vehicles, or drones, are a popular technology that will have significant practical uses in the future, especially for mapping and monitoring remote areas. The main challenge with using drones is carrying heavy payloads, which requires careful selection and design optimization of multi-rotor drones.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
Ajit Kumar Yadav, Manoj Kr. Agrawal, Kuldeep K. Saxena, Balram Yelamasetti
Summary: The study aimed to develop dissimilar components for aerospace industries with high corrosion resistance and good mechanical properties using dissimilar plates of AA5083 and AA6082. TIG welding with ER4043 filler rod was used to join the dissimilar joints. Mechanical testing, including tensile test, Izod test, and Brinell hardness test, was conducted on the welded samples. ANOVA analysis showed that welding speed had the most significant effect on the responses, followed by weld current and filler diameter.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Mechanical
Narayanan Kannaiyan Geetha, Pappula Bridjesh, Balram Yelamasetti, Kuldeep K. Saxena, Nakul Gupta
Summary: Pores play a crucial role in shaping the features of functionally graded materials. A new method is proposed to analyze the bending response of porous beams, considering both even and uneven porosity distributions. By modifying the material properties with a power law, the properties of functionally graded materials can be adjusted. The results show that the dimensionless deflections and stresses are influenced by gradient exponents, porosities, and aspect ratios.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Engineering, Manufacturing
P. Thejasree, Manikandan Natarajan, Muhammed Anaz Khan, Sai Vempati, Balram Yelamasetti, Abhishek Dasore
Summary: There has been an increase in the utilization of laser sources, resulting in decreased expenses and increased efficiency. This phenomenon is due to advancements in procedures and machinery, such as laser beam welding systems. A thorough investigation of welding techniques for dissimilar metals, specifically SS304 and Inconel 718, is crucial. The research using the Taguchi design methodology found that laser power significantly impacts the width of welding sections, and welding velocity influences the rate of penetration. Optimal penetration can be achieved through combinations of higher peak power and pulse duration with lower weld speed.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
Abhishek Saxena, Kuldeep K. Saxena, Bharat Singh, S. K. Rajput, Balram Yelamasetti
Summary: In this study, experimental measurements of temperature profiles and residual stresses were conducted to validate the predicted temperature gradients and thermal stresses in dissimilar gas tungsten arc weldments of AA 6082 and AA 7075. The analysis took into account temperature-dependent thermo-mechanical properties and considered convective and radiation boundary conditions. SOLID 90 and SOLID 185 elements were used for the analysis. The predicted thermal fields and stresses were experimentally validated using Infra-Red (IR) Thermography and X-Ray diffraction techniques, showing a deviation of only 7.5% between the predicted and measured thermal fields.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Engineering, Manufacturing
K. Srinivasulu Reddy, Harinadh Vemanaboina, B. Vishnu Vardhana Naidu, Balram Yelamasetti, P. Bridjesh, Sagar Dnyaneshwar Shelare
Summary: Gas tungsten arc welding employs the Taguchi method to reduce thermal distortions in welded structures. The study found that the welding parameters significantly influence the weld distortion, with higher welding current and gas flow rate resulting in lower thermal strain values. Controlling welding speed and root gap is crucial for producing a reliable design.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
