Article
Engineering, Chemical
Jin Zhang, Qiong Xu
Summary: This study investigates the element transfer behavior of Cr2O3-bearing agglomerated fluxes in submerged arc welding. The gas-slag-metal equilibrium consideration is shown to qualitatively analyze the transfer behaviors, and a thermodynamic approach to predict element transfer levels is proposed.
Review
Thermodynamics
Jie Yang, Shichang Xu, Chuanbao Jia, Yanfei Han, Sergii Maksymov, Chuansong Wu
Summary: In this paper, a non-axisymmetric three-dimensional numerical model was developed to simulate the typical globular repelled transfer process with large droplets in underwater wet flux-cored wire arc welding. The results showed that the droplet movement was affected by multiple forces, including gravity, surface tension, self-induced electromagnetic force, gas flow, and force from metal evaporation. The simulated values from the numerical model were in good agreement with the experimental ones.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2023)
Article
Thermodynamics
Xiaochao Liu, Zhen Sun
Summary: The underlying mechanism of heat and mass transfer in vortex-friction stir welding (VFSW), which utilizes a tool made of identical materials as workpieces, was investigated in this study. Computational fluid dynamics analysis was used to model the spatial heat transfer and three-dimensional visco-plastic flow in VFSW. The results showed that the heat for welding mainly comes from plastic deformation work and is greatly influenced by the tool's rotating speed. The high-temperature region in VFSW is larger than that in conventional friction stir welding (FSW), and the vortex shape decreases in size as the distance from the workpiece surface decreases.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2022)
Review
Automation & Control Systems
Junyan Miao, Yiwen Li, Bowen Ren, Zhihai Dong, Wenfeng Zou, Chenhe Chang, Yunlong Chang
Summary: The heat and mass transfer behavior of droplet transfer in the CO2 welding process plays a decisive role in weld formation, joint microstructure, and service performance. Studying the process of droplet transfer is of great significance for welding metallurgical analysis, stress deformation analysis, process control, and process optimization. In recent years, welding scholars have devoted themselves to the theoretical analysis of the dynamic information of droplet transfer through numerical simulation and combined with experimental research, so that the welding process has changed from qualitative analysis to quantitative analysis, and the theoretical research and experimental research have been upgraded to scientific research.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Chemistry, Physical
Dawid Stanisz, Tomasz Machniewicz, Slawomir Parzych, Grzegorz Jez, Leonid Dvorkin, Marek Hebda
Summary: This paper compares the properties of different joining processes for thin-walled sheets. The results show that manual laser welding and butt welding have the best weld shape, smallest joint width, and greater grain refinement, while robotic welding CMT has the widest zone of hardness increase and largest heat-affected zone.
Article
Optics
Liming Liu, Xingkong Tao, Huanyu Yang
Summary: In this study, the effects of workpiece inclination angles and distance between laser spot and wire tip on arc morphology, droplet transfer characteristics, and stability were investigated. The results showed that the laser plasma compressed the arc, which increased the electromagnetic resistance of droplet transfer and improved its stability. This research provides a theoretical basis for the popularization and application of laser-induced MAG all-position hybrid welding technology.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Ke Yang, Fei Wang, Hongbing Liu, Peng Wang, Chuanguang Luo, Zhishui Yu, Lijun Yang, Huan Li
Summary: A novel double-pulse, triple-wire MIG welding process was proposed for welding 6082-T6 aluminum alloy, showing that a proper double-pulse frequency could improve weld quality significantly. The joint's tensile strength reached 64% of the base material's tensile strength, with a fracture occurring in the heat-affected zone, indicating the great potential of this new welding method in aluminum alloy welding.
Article
Materials Science, Multidisciplinary
Ritsu Nishimura, Sendong Ren, Maho Suefusa, Kunio Narasaki, Ninshu Ma
Summary: This study employed cold metal transfer (CMT) lap welding to join TS1500 and SPC1180 dissimilar metals. A thermal-mechanical coupled model was developed using the in-house FE code JWRIAN-Hybrid to efficiently reproduce the behaviors that occurred in the CMT process. The experimental verification showed good agreement with the predicted temperature field, residual stress distribution, and welding deformation. The study also clarified the high-temperature material properties of TS1500 and gauged the critical phase transformation temperatures. It was found that the strength grade of the steel couple had a significant effect on welding deformation in the UHSS CMT welded lap joint.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Engineering, Industrial
Weiwei Ge, Hongcheng Li, Xuanhao Wen, Chengchao Li, Huajun Cao, Bin Xing
Summary: This paper studies the mathematical modeling of carbon emissions and process parameters optimization for laser welding cells. It analyzes the carbon emission characteristics of the laser welding system and establishes a carbon emission model considering welding features and transfers. Additionally, a process parameters optimization model is developed and a combinatorial algorithm based on Culture Algorithm and Ant Colony Algorithm is proposed to obtain optimal welding sequence and transfer speed. A case study is performed to verify the feasibility and reliability of the model, and the proposed solution algorithm outperforms the Ant Colony Algorithm in terms of convergence speed and optimization accuracy. This study lays a theoretical foundation for carbon emission modeling of laser welding cells and can support automobile enterprises in selecting processing parameters for laser welding lines during the design stage.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2023)
Article
Automation & Control Systems
Anand Mohan, Pasquale Franciosa, Dariusz Ceglarek, Michael Auinger
Summary: Remote Laser Welding (RLW) of Aluminium alloys is important for lightweight manufacturing and understanding the physical processes during welding is critical for the mechanical performance of joints. A transient three-dimensional Finite Element (FE) based Multiphysics model was developed and validated to investigate the influence of beam oscillation on heat transfer, fluid flow, and material mixing. The study found that beam oscillation during welding creates an additional vortex, and increasing oscillation amplitude widens the welds but decreases penetration depth. Higher oscillation frequency increases the flow rate of molten metal, indicating increased mixing due to the churning action of the oscillating beam. Material mixing depends on diffusion and convection.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Mathematics, Applied
H. I. Seker, S. Kacar, O. Castillo, S. Uzun, I. Pehlivan, Z. Tatli
Summary: Welding quality is crucial for product performance, quality, and strength. Detecting weld quality and defects is important in industrial production. This study uses transfer learning networks to detect welding faults in resistance spot welding machines, achieving classification accuracies ranging between 89% and 100%.
APPLIED AND COMPUTATIONAL MATHEMATICS
(2023)
Article
Automation & Control Systems
Mitchell Cullen, Sipei Zhao, Jinchen Ji, Xiaojun Qiu
Summary: Gas metal arc welding is a crucial welding process where identifying metal transfer modes is essential for monitoring and controlling the welding process effectively.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Computer Science, Artificial Intelligence
Meng Xiao, Bo Yang, Shilong Wang, Yongsheng Chang, Song Li, Gang Yi
Summary: This paper proposes two methods based on deep learning to recognize the appearance of welding spots. Experimental results show that the accuracies of these two models are higher than existing models, with RswNet model achieving higher accuracy and reducing parameters by more than 56% compared to existing models.
JOURNAL OF INTELLIGENT MANUFACTURING
(2023)
Article
Automation & Control Systems
Jiafu Zhou, Dianwu Zhou, Jinshui Liu
Summary: The three-dimensional numerical model established the effect of a stable longitudinal magnetic field on magnesium/aluminum laser welding molten pool. The experimental results showed deeper penetration of the molten pool, symmetrical welding pool shape, and increased density of Al element distribution under the influence of magnetic field.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Optics
Wei Sun, Shushuai Liu, Fuqiang Guo, Dongting Wu, Yongang Zhang, Yong Zou
Summary: This paper comparatively investigated the droplet transfer behavior between flux-cored arc welding and laser-flux cored arc hybrid welding, proposing a new parameter to evaluate welding stability and identifying different droplet transfer modes. The laser influenced droplet transfer but did not significantly impact the process stability between hybrid welding and FCAW.
OPTICS AND LASER TECHNOLOGY
(2022)
