Manufacturing Technology 2022, 22(3):279-287 | DOI: 10.21062/mft.2022.033
Influence of Energy Ratio of Hybrid Heat Source on Residual Stress Distribution of 7A52 Aluminum Alloy VPPA-MIG Hybrid Welding
- 1 College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, 010051, China
- 2 Materials Forming Key Laboratory, Inner Mongolia University of Technology, Hohhot 010051, China
- 3 Inner Mongolia Key Laboratory of Mechanical & Electrical Control, Hohhot, 010051, China
Variable Polarity Plasma Arc-Metal Inert Gas (VPPA-MIG) welding process is a new hybrid welding process with broad application prospects for aluminum alloy structure in the fields of aerospace manufacturing, transportation and others. The heat source of the hybrid welding process is composed of VPPA heat source and MIG heat source. When the total input energy of VPPA-MIG hybrid heat source is constant, the different energy ratio of VPPA arc and MIG arc affects not only the forming effect of hybrid weld, but also the stress distribution of hybrid welding joint. Hole-drilling method was used to analyze the influence of the ratio of VPPA and MIG arc energy on the distribution of welding residual stress in the process of 10 mm 7A52 aluminum alloy VPPA-MIG hybrid welding. The results show that the peak magnitude of hybrid welding residual stress increases with the increase of the ratio of VPPA arc energy. Considering the appearance of weld forming, VPPA-MIG hybrid welding parameters of 7A52 aluminum alloy are optimized on the basis of the distribution characteristic of residual stress. When the ratio of VPPA arc energy is selected between 35% and 40%, the peak magnitude of transverse residual stress is (in the direction vertical to the weld) no more than 92.0 MPa, and the peak magnitude of longitudinal residual stress(in the direction parallel to the weld) is no more than 234.3 MPa. It shows that the VPPA-MIG hybrid welding with optimized parameters can not only produce weld joint with satisfied macroscopic appearance, but also avoid high peak magnitude of residual stress.
Keywords: ratio of energy, variable polarity plasma arc-MIG hybrid welding, residual stress, appearance of weld forming
Grants and funding:
This work is supported by the natural science foundation of Inner Mongolia (Grant Number: 2019MS05061), scientific research project of Inner Mongolia University of Technology (Grant Number: BS2021033), and the scientific research project of college and university in Inner Mongolia Autonomous Region (Grant Number: NJZY20066).
Received: February 11, 2022; Revised: June 6, 2022; Accepted: June 6, 2022; Prepublished online: June 6, 2022; Published: July 1, 2022 Show citation
References
- CHEN, S.J., JIANG, F., ZHANG J.L., HUANG, N., ZHANG, Y.M. (2013). Principle of weld formation in variable polarity keyhole plasma arc transverse welding of aluminum alloy. Transactions of the China Welding Institution, 34(4):1-6+113.
- WU, D., HUANG, Y., CHEN, H., HE, Y., & CHEN, S. (2017). VPPAW penetration monitoring based on fusion of visual and acoustic signals using t-SNE and DBN model. Materials & Design, 123:1-14. https://doi.org/10.1016/j.matdes.2017.03.033
Go to original source...
- SAHOO, A., & TRIPATHY, S. (2021). Development in plasma arc welding process: A review. Materials Today-Proceedings, 41(Pt 2):363-368. https://doi.org/10.1016/j.matpr.2020.09.562
Go to original source...
- IKRAM, A., & CHUNG, H. (2021). Numerical simulation of arc, metal transfer and its impingement on weld pool in variable polarity gas metal arc welding. Journal of Manufacturing Processes, 64:1529-1543. https://doi.org/10.1016/j.jmapro.2021.03.001
Go to original source...
- CHEN, S.J., LEI, Y., LU, Z.Y., BAI, L.L., ZHANG, H. (2017). Control system of variable polarity plasma arc welding based on soft PLC. Welding & Joining, (7):9-12+69+73.
- YAN, Z., CHEN, S., JIANG, F., TIAN, O., HUANG, N., & ZHANG, S. (2020). Weld properties and residual stresses of VPPA Al welds at varying welding positions. Journal of Materials Research and Technology, 9(3):2892-2902. https://doi.org/10.1016/j.jmrt.2020.01.040
Go to original source...
- JUNG, J. S., LEE, H. K., & PARK, Y. W. (2016). Prediction of Tensile Strength for Plasma-MIG Hybrid Welding Using Statistical Regression Model and Neural Network Algorithm. Journal of Welding and Joining, 34(2):67-72. https://doi.org/10.5781/JWJ.2016.34.2.67
Go to original source...
- SYDORETS, V., KORZHYK, V., KHASKIN, V., BABYCH, O., & BONDARENKO, O. (2017). Electrical Characteristics of the Equipment for the Hybrid Plasma-MIG Welding. 2017 IEEE 58th International Scientific Conference on Power and Electrical Engineering of Riga Technical University (RTUCON), Riga, Latvia, 1-6.
Go to original source...
- GRUZDEV, V.A., ZALESSKY, V.G., GRUSETSKY, I.S. (2019). Plasma electron source for generating electronic beams in material surface welding, modification and hardening applications, has improved-type structure. PATENT: UNIV BELO TECH (UYBT-Non-standard), patent no. BY15662-C1.
- MAMAT, S. B., TASHIRO, S., MASRI, M. N., HONG, S. M., BANG, H. S., & TANAKA, M. (2020). Application of pulse plasma MIG welding process to Al/steel dissimilar joining. Welding in the World, 64(5):857-871. https://doi.org/10.1007/s40194-020-00879-2
Go to original source...
- ANTONOVICH, D. A., GRUZDEV, V. A., & ZALESSKI, V. G. (2021). Features of Electron Optical Systems with the Plasma Emitter Based on Stationary Double Electric Layers in the Plasma. Russian Physics Journal, 63(10):1713-1720. https://doi.org/10.1007/s11182-021-02225-5
Go to original source...
- Kusmiè, D., & Faltejsek, P. (2019). Corrosion Resistance of Low Temperature Plasma Nitrided X12CrMoWVNbN10-1-1 Martensitic Stainless Steel. Manufacturing Technology, 19(4): 619-623. DOI: 10.21062/ujep/344.2019/a/1213-2489/MT/19/4/619
Go to original source...
- Novakova, I., Moravec, J., Svec, M., Kik, T., & Korecek, D. (2019). Influence of the Welding Process on the Change of Mechanical Properties in the HAZ of Welds at Alloy AW 6005 and Possibilities of Their Renewal by Heat Treatment. Manufacturing Technology. 19(5): 823-830 | DOI: 10.21062/ujep/379.2019/a/1213-2489/MT/19/5/823
Go to original source...
- HONG, H.T. (2016). Investigation on heat source characteristics and welding procedure in variable polarity plasma arc-MIG hybrid welding of aluminum alloys. PHD Thesis. Inner Mongolia University of Technology of China.
- HONG, H., HAN, Y., DU, M., & TONG, J. (2016). Investigation on droplet momentum in VPPA-GMAW hybrid welding of aluminum alloys. The International Journal of Advanced Manufacturing Technology, 86(5-8):2301-2308. https://doi.org/10.1007/s00170-016-8381-2
Go to original source...
- JAMES, M. N., HUGHES, D. J., HATTINGH, D. G., MILLS, G., & WEBSTER, P. J. (2009). Residual stress and strain in MIG butt welds in 5083-H321 aluminium: As-welded and fatigue cycled. International Journal of Fatigue, 31(1):28-40. https://doi.org/10.1016/j.ijfatigue.2008.04.010
Go to original source...
- LU, Y.X., SHAN, Q.Q., WANG, C.G., MA, C.P. (2015). Influence of different treatment processes on the residual stress of welded joints in laser-MIG hybrid welding for 6005A aluminum alloy. Electric Welding Machine, 45(10):134-137.
- XU, G.X., GUO, Q.H., HU, Q.X., ZHU, J., LIU, P., PAN, H.C. (2018). Numerical analysis of welding residual stress in Laser + MIG hybrid butt welding of medium-thick aluminum alloy. Journal of Mechanical Engineering, 54(2):77-83.
Go to original source...
- GAN, S.M., HAN, Y.Q., CHEN, F.R. (2018). Analysis on Error Factors of Welding Residual Stress Measured by Hole Drilling Method. Transactions of the China Welding Institution, 39(10):48-53+131.
- GAN, S.M., HAN, Y.Q., CHEN, F.R., LI, X.F. (2019). 7A52 aluminum alloy VPPA-MIG hybrid welding residual stress testing based on elastic modulus variation. Transactions of the China Welding Institution, 40(5):13-17+23+161.
- SUN, Z., HAN, Y., DU, M., HONG, H., & TONG, J. (2018). Numerical simulation of VPPA- GMAW hybrid welding of thick aluminum alloy plates considering variable heat input and droplet kinetic energy. Journal of Manufacturing Processes, 34(Pt A):688-696. https://doi.org/10.1016/j.jmapro.2018.07.011
Go to original source...
- SUN, Z., HAN, Y., DU, M., TONG, J., & HONG, H. (2019). An improved simulation of temperature field in VPPA-GMAW of Al-Cu-Mg alloy. Journal of Materials Processing Technology, 263:366-373. https://doi.org/10.1016/j.jmatprotec.2018.08.017
Go to original source...
- TONG, J.H., HAN, Y.Q., HONG, H.T., SUN, Z.B. (2018). Mechanism of weld formation in variable polarity plasma arc-MIG hybrid welding of high strength aluminium alloy. Transactions of the China Welding Institution, 39(5):69-72+91+132.
- HAN, Y., TONG, J., HONG, H., & SUN, Z. (2019). The influence of hybrid arc coupling mechanism on GMAW arc in VPPA-GMAW hybrid welding of aluminum alloys. The International Journal of Advanced Manufacturing Technology, 101(1-4):989-994. https://doi.org/10.1007/s00170-018-3007-5
Go to original source...
- SUN, Z.B. (2020). Numerical simulation and experimental study on VPPA-MIG hybrid welding of high strength aluminum alloy. PHD Thesis. Inner Mongolia University of Technology of China.
- RENDLER, N. J., & VIGNESS, I. (1966). Hole-Drilling Strain-Gage Method of Measuring Residual Stresses. Experimental Mechanics, 6(12):577-586. https://doi.org/10.1007/BF02326825
Go to original source...
- Rosli, N. A., Alkahari, M. R., Ramli, F. R., Fadzli bin Abdollah, M., Ikhwan Abdul Kudus, S., & Gazali Herawan, S. (2022). Parametric Optimisation of Micro Plasma Welding for Wire Arc Additive Manufacturing by Response Surface Methodology. Manufacturing Technology, 22(1): 59-70. DOI: 10.21062/mft.2022.001
Go to original source...
This is an open access article distributed under the terms of the Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0), which permits non-comercial use, distribution, and reproduction in any medium, provided the original publication is properly cited. No use, distribution or reproduction is permitted which does not comply with these terms.