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![Schematic of hybrid laser-arc welding process. Adapted from [10]](publication/341114152/figure/fig1/AS:887334388125697@1588568412793/Schematic-of-hybrid-laser-arc-welding-process-Adapted-from-10.png)
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![Schematic of hybrid laser-arc welding process. Adapted from [10]](publication/341114152/figure/fig1/AS:887334388125697@1588568412793/Schematic-of-hybrid-laser-arc-welding-process-Adapted-from-10_Q320.jpg)
![Schematic of the measurement of angular distortion. Adapted from [3]](publication/341114152/figure/fig2/AS:887334388113410@1588568412879/Schematic-of-the-measurement-of-angular-distortion-Adapted-from-3_Q320.jpg)
Hybrid laser-arc welding (HLAW) is a joining process that simultaneously combines arc and laser welding in the same weld pool. The basic concept is to reduce the drawbacks and maximize the advantages of each individual welding process. In the present work, low-alloy steel NK: KD36 plates were welded by HLAW with the following thickness: 7, 9, 14, a...
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Citations
... The amount and distribution of heat energy in the HLAW process determine the temperature field in the material. The coupled laser beam and electric arc define the heat transfer and motion of liquid steel in the FZ; as a result, the shape and size of the welded joint are determined [19][20][21][22]. An important issue in the HLAW model is the proper distribution of heat source power, reflecting the real process conditions as closely as possible. ...
... Heat transfer mostly depends on convection and conduction. In the HLAW process, two heat sources cooperate in a single welding pool [22,25]. Fluid flow in the fusion zone is generated by electromagnetic force, Marangoni shear stress, arc forces, recoil pressure, surface tension, buoyancy forces, etc. [26][27][28]. ...
This paper focuses on the mathematical and numerical modeling of the electric arc + laser beam welding (HLAW) process using an innovative model of the Yb:YAG laser heat source. Laser energy distribution is measured experimentally using a UFF100 analyzer. The results of experimental research, including the beam profile and energetic characteristics of an electric arc, are used in the model. The laser beam description is based on geostatistical kriging interpolation, whereas the electric arc is modeled using Goldak’s distribution. Hybrid heat source models are used in numerical algorithms to analyze physical phenomena occurring in the laser–arc hybrid welding process. Thermal phenomena with fluid flow in the fusion zone (FZ) are described by continuum conservation equations. The kinetics of phase transformations in the solid state are determined using Johnson–Mehl–Avrami (JMA) and Koistinen–Marburger (KM) equations. A continuous cooling transformation (CCT) diagram is determined using interpolation functions and experimental research. An experimental dilatometric analysis for the chosen cooling rates is performed to define the start and final temperatures as well as the start and final times of phase transformations. Computer simulations of butt-welding of S355 steel are executed to describe temperature and melted material velocity profiles. The predicted FZ and heat-affected zone (HAZ) are compared to cross-sections of hybrid welded joints, performed using different laser beam focusing. The obtained results confirm the significant influence of the power distribution of the heat source and the laser beam focusing point on the temperature distribution and the characteristic zones of the joint.
... If the cooling rate is too fast, it can cause excessive shrinkage and lead to distortion and cracking, while, if it is too slow, it can cause excessive expansion and contraction, leading to warping and distortion. In conclusion, it is necessary to perform a statistical analysis using the Taguchi method in order to obtain the optimal parameters [55][56][57]. The arc current and filler feed rate are directly related to the amount of heat input into the weld, which, in turn, affects the amount of distortion. ...
... The relationship between angular distortion and transverse shrinkage was direct, with increasing angular distortion leading to an increase in transverse shrinkage, as shown in Figure 10. Moreover, the same results were observed in a study by Fernandes et al. [56]. ...
... The relationship between angular distortion and transverse shrinkage was direct, with increasing angular distortion leading to an increase in transverse shrinkage, as shown in Figure 10. Moreover, the same results were observed in a study by Fernandes et al. [56]. The bead width is an important factor in welding that affects transverse shrinkage. ...
This study investigates the impact of gas metal arc welding (GMAW) parameters on the bead geometry and material distortion of AISI 316L. Three parameters—arc current in ampere (A), filler feed rate (m/min), and gas composition—were modified at varying levels in order to examine their effects. This study sheds new light on MAG welding lines’ physical properties and behavior and highlights the influence of quaternary shielding gas compositions. Taguchi analysis, which includes signal-to-noise (S/N) ratio and analysis of variance (ANOVA), was utilized to analyze and optimize the welding parameters. This study found that arc current significantly impacts bead geometry, while the shielding gas composition has the most significant effect on angular distortion and transverse shrinkage. The optimal welding parameters for achieving the best bead height and width are 160 A, 3.5 m/min, G1, with a bead height of 4.89 mm, and 120 A, 3 m/min, G2, with a bead width of 6.69 mm. Moreover, the optimal welding parameters for minimizing both angular distortion and transverse shrinkage are 120 A, 4 m/min, G2, resulting in an angular distortion value of 0.0042° and a transverse shrinkage value of 0.0254 mm. This research has practical implications for improving welding performance and can contribute to the advancement of MAG and MIG welding in manufacturing applications.
... In recent years, inexpensive but high-performance laser oscillators have been developed, and the practical application of joining technology using a laser heat source for large steel structures is increasing [7][8][9]. When LAHW is applied to thick plate structures, most joints are butt joints processed in the flat position or T-joints in a fillet weld [10][11][12][13][14]. However, it is desirable to be able to use LAHW for various joint types and positions to expand the application range of the high-quality welded joints obtained by LAHW and achieve cost-effectiveness in terms of equipment installation. ...
Laser–arc hybrid welding (LAHW) is an advanced welding method that combines arc welding and laser welding and can achieve deep penetration and the reduction of welding deformation compared with conventional arc welding. As with other welding techniques, it is common to target the flat position (PA) as the welding position. However, the expansion of the applicable positions enables the application of high-quality welded joints fabricated by LAHW to many welded joints in large steel structures. This study used the LAHW system with a robot manipulator to establish weldability in the horizontal position (PC) and the vertical-up position (PF) to expand the applicable range of LAHW in large steel structures. Suitable LAHW conditions for fabricating the butt-welded joint with a welding length of 1,000 mm for these positions were established through various investigations, including molten pool observation. Finally, the quality of these joints was evaluated in accordance with the laser–arc hybrid welding guidelines (ClassNK) of Nippon Kaiji Kyokai, and it was confirmed that the joints satisfy the required standards.
... In the early 1980s, Steen proposed a laser-arc hybrid welding technology that integrates the merits of both welding technologies, while making up for each one's shortcomings [1]. This welding method exhibits huge laser fluence [2], high welding velocity [3], large aspect ratio weld [4,5], small heat-affected zone [6,7], small heat distortion [8], and strong gap bridging ability [9]. In laser-gas metal arc welding (GMAW) hybrid welding, the metallurgical effect of welding wire and the base metal is beneficial to enhance the mechanical property of the weld and decrease the tendency of welding defects. ...
Real-time monitoring of laser-metal inert gas (MIG) hybrid welding plays a significant role in modern automatic production. In this paper, an innovative prediction model is proposed for laser-MIG hybrid welding process monitoring and weld defect detection. Specifically, the status of laser-MIG hybrid welding was monitored using a high-speed imaging system that could observe the visual information from the top and bottom of the weldment simultaneously. Then, the morphological features were extracted by image process algorithm. Furthermore, the empirical mode decomposition (EMD) was employed to analyze the time series of visual features, and the decomposed component intrinsic mode functions (IMFs) and residue were inputted to the support vector machine (SVM) classification model. Finally, the EMD-SVM model was employed to evaluate the welding status of four weld formations, including sound weld, root humping, incomplete penetration and burn through. Experimental results demonstrate the superiority of the proposed method in terms of accuracy and robustness compared with traditional methods such as the backpropagation (BP) neural network, SVM, wavelet packet decomposition (WPD)-BP, WPD-SVM, and EMD-BP. This proposed method provides a novel and accurate approach to perform laser-MIG welding process monitoring and online defects detection.
... In the manufacturing process, fusion welding is the most common joining method due to its advantages of production flexibility, costs saving, and performance improvement (Ref 2). However, serious distortion often inevitably occurs in thin-plate structures during the welding process due to the rapid heating and cooling rate (Ref 3), and this can result in the degradation of dimensional accuracy, structural performance, and productivity ( Ref 4,5). Thus, predicting and controlling the welding deformation has an extreme significance in improving the product quality and saving the production cost. ...
In the past decades, thin-plate weldments have been increasingly used in various engineering structures to meet the requirements of lightweight. However, deformation induced by welding process has a negative effect on assembly accuracy and structural integrity. Therefore, it is critical to predict welding deformation and then to control or reduce the total deformation. Because the thermal elastic plastic FEM has the advantage of high computational accuracy, an attempt was made to predict the welding deformation of a large-scale thin-plate welded structure in this study. Based on the commercial software MSC. Marc, a thermal elastic plastic FEM with the consideration of material nonlinearity, geometrical nonlinearity, and boundary nonlinearity was developed to simulate the welding deformation of large-scale welded structures. The effectiveness of the developed computational approach was verified by the experimental measurements. Moreover, the mechanism of buckling distortion in a large-scale stiffened panel structure was investigated based on the simulated results. In addition, the influences of heat input, welding procedures, and constraint condition on welding deformation were also examined numerically.
Nowadays, computer-aided inspection (CAI) is used to cope with increasing complexity in part manufacturing and the difficulty of physical access to certain workplaces. Therefore, manufacturing companies adopt automated CAI methods to increase the efficiency of the control quality activities. This study aims to capture the current state of the art of literature related to rigid and non-rigid inspection with a focus on the intelligent factory based on CAI. This investigation is a road map of different methods developed and how precise this kind of inspection can be. This paper presents a systematic literature review in the computer-aided inspection field with an extensive assessment of the included studies. After analyzing the relevant papers and industrial documents in detail, we derive deep insights into the different methods developed to inspect parts based on their physical aspects. This study will contribute to the computer-aided inspection field providing methodologies that will make the human intervention useless at one point. Finally, the digital twins’ model has been proposed for an industrial application based on Industry 4.0.KeywordsGeometric inspectionRigid partsDigital twinsGD&TIndustry 4.0Sustainable inspection
A 10 mm 316 L stainless steel, filled by 1.2 mm 316 LSi, was joined using multi-layer laser-GMAW in the presence of a constant magnetic field. Results suggested that the addition of a 18 m T magnetic field resulted in an optimized weld bead formation with asymmetrical fusion line and grain growth by stabilizing the arc morphology and droplet transfer in the narrow gap. The interaction of arc current and magnetic field differed in central and columnar zones with a moving heat source such that refinement was relatively obvious in the columnar zone. These two zones were dominated by high angle grain boundaries (HAGBs: 15°-60°) and the magnetic field potentially strengthen both the fraction and density. Due to the induced rotation and deflection behavior in austenite (γ) grain growth, the applied magnetic field progressively decreased the texture density of (010)[101] in columnar zones while altered (051)[61-5], (032)[62-3] and (011)[32-2] to (001)[31-0] and (001)[12-0] in central zones. Refinement of γ grains was attributable to the fragment, rotation and deflection of ferrite and associated γ assemblies under axial torques induced by the magnetic field and arc current. Also, γ grain refinement and texture alternation of the central and columnar zones decrease the notch sensitivity of the weld bead. These results and findings suggested a novel means for improving the weld quality of thick plates with favorable microstructure and microtexture using an external magnetic field.
