Elena Scutelnicu

Influence of heating source position and dilution rate in achieving overmatched dissimilar welded joints

Abstract The investigation addresses the overall performance of black and white joints (BWJ) of low carbon steel (LCS) and stainless steel thin sheets achieved by laser hybrid welding. Assuming that the structural integrity is directly influenced by the processing temperature, a thermal simulation of BWJ of thin sheets was developed. Afterwards, the base metals apportionment at joint formation, namely their distinct dilution rate, was originally estimated from the top surface temperature variation. Defect-free laser hybrid dissimilar welds were experimentally obtained using the selected filler metal and the energetic input from the process simulation, even for a critical analysed case of heat source displacement from the weld gap centreline towards LCS. Detailed macro and microstructural examination of the BWJ and related microhardness analysis results are presented. The tensile tests results indicate that in the case of transversally loaded BWJ, the positive difference in yield between the weld metal and the base materials protects the weld metal from being plastically deformed; the flat transverse tensile specimens loading up to failure reveals large strains in LCS, far away from the weld.

FEM model of butt cold welding

Abstract Butt cold pressure welding is a solid state manufacturing process with several important applications, but with a gap in its fundamentals. This paper presents a new approach of the research in the field, bringing both theoretical and practical original contributions to the knowledge and creating the bases for the development of new processes addressing modern materials. First, an overview of finite element method (FEM) used in butt cold welding is presented. Correlation between stresses and material deformation is further addressed. Original indicators related to cold welding process initiation are introduced: critical deformation, welding critical stress and welding critical radius. The paper brings an original interpretation of cold welding process based on FEM model and on microstructural considerations. Results of mechanical tests and of macro- and microscopic analysis are provided to validate the model.

Specific properties of ferritic/austenitic Dissimilar Metals Welded Joints

This paper addresses several peculiar properties of ferritic/austenitic welded joints (Black and White Joints-BWJ) of thin sheets, which are emerging nowadays due to cost saving and satisfactory service performance. Starting from 3D thermal field modelling approached by considering Goldak’s double ellipsoidal heat source, together with a contribution of the authors, a 2D FEM-based model was used for arc welding of low carbon steel (CS) and stainless steel (SS) of thin sheets (3 mm). Conclusion helped to conduct experiments of BWJ arc welding (MMA and TIG), and laser-GMA hybrid welding, whilst infrared thermographic measurements were compared with the FEM results. Besides microstructural examination and mechanical characterization (hardness and tensile), fracture toughness and stress corrosion tests were performed on the BWJ laser hybrid welded. Whilst the model has offered important qualitative information about the asymmetric thermal field and the heat apportionment on the molten metal pool formation, the experiments have shown inadequate microstructures and constitutions of the welds for MMA and TIG welding, with respect to laser-GMAW hybrid joints. The description of the experimental program focused on B&W laser-GMA hybrid welding of thin plates aiming a characterization procedure using fracture mechanics methods is briefly presented.

Laser shock processing influence on constitutive behaviour of graded structures produced by laser welding of ferritic to austenitic stainless steel

Abstract The main objective of the present investigation was to assess the constitutive behaviour of the graded structures produced by laser shock processing (LSP) on laser welded joints made between thin sheets of ferritic and austenitic stainless steel. First, the evolution of surface strain patterns during uniaxial loading of the as welded and LSP treated joints was experimentally obtained by using a video-image correlation technique. Overall and local constitutive behaviour across the weld, heat affected zone and parent metals resulted by coupling the applied load level with the corresponding strain average of each zone. The differences found in mechanical resistance of the LSP treated zones when comparing with the as welded ones were due to the processing features, namely the generation of compressive stresses and the development of graded surface structures. Special attention was paid on changes occurred in the ferritic steel side of the joint, which acts as a mechanical cut-out fuse in structures working in energy related applications. Then, by extrapolating the fatigue fracture behaviour of macroscopic notches to the surface cavities and irregularities from which surface topography results it was found that LSP improves the ferritic steel side fatigue resistance. Additionally, the growth of eventual surface flaws is delayed by the compressive stress state induced by LSP, as indicated by in-depth X-ray measurements.