Optimisation of laser welding for thin-walled Ti6Al4V glider pressure hull
- Authors: Nel, Matthew Ryan
- Date: 2024-04
- Subjects: Laser welding , Welding , Mechanical engineering
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/64739 , vital:73882
- Description: Laser welding is a type of fusion welding process characterised by deep penetration, low heat input and high welding speed. This dissertation investigates the suitability of this process for the fabrication of an underwater glider buoyancy engine from thin Ti6Al4V alloy sheet. Areas of interest include the effect of process parameters on weld microstructure, static properties (microhardness, tensile and bend tests) and dynamic properties (fatigue tests). The effect of welding speed and laser defocusing were evaluated considering experimental matrices consisting of four different travel speeds and three defocus distances. These were narrowed down to three travel speeds and a single defocus distance, resulting in a final test matrix delivering three different heat inputs. Thereafter, the effect of heat input on static and dynamic properties was investigated. Vickers microhardness tests were carried out to predict weld response during tensile testing, with the expectation being that harder welds would offload more strain. This was confirmed using digital image correlation, which allowed for virtual measurement and visualisation of strain offloading. Bend tests were carried out on parent and welded samples to confirm whether Ti6Al4V could be formed to the correct geometry. Forming Ti6Al4V into a U-shape was the first consideration, since dynamic testing required samples of this geometry with longitudinal weld orientation. A two-stage forming methodology was developed from these experiments. Formed samples were subjected to fatigue tests in a custom designed fatigue platform for testing weld orientation as it would appear in the final component. Prediction of the welded buoyancy engine life was the goal behind these tests. Fracture surfaces were analysed to gain understanding of where crack initiation and final fracture occurred. Porosity served as the primary cause for crack initiation in failed samples. Pore distribution was heaviest in low-heat weldments and decreased with increasing heat input, while pore size increased with increasing heat input. This resulted in medium-heat weldments exhibiting superior performance to that of low- and high-heat ones. It was concluded that the laser welding process is able to produce weldments of sufficient integrity in thin Ti6Al4V sheet-formed components intended for use in glider buoyancy engines. , Thesis (MEng) -- Faculty of Engineering, the Built Environment and Technology, School of Engineering, 2024
- Full Text:
- Date Issued: 2024-04
- Authors: Nel, Matthew Ryan
- Date: 2024-04
- Subjects: Laser welding , Welding , Mechanical engineering
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/64739 , vital:73882
- Description: Laser welding is a type of fusion welding process characterised by deep penetration, low heat input and high welding speed. This dissertation investigates the suitability of this process for the fabrication of an underwater glider buoyancy engine from thin Ti6Al4V alloy sheet. Areas of interest include the effect of process parameters on weld microstructure, static properties (microhardness, tensile and bend tests) and dynamic properties (fatigue tests). The effect of welding speed and laser defocusing were evaluated considering experimental matrices consisting of four different travel speeds and three defocus distances. These were narrowed down to three travel speeds and a single defocus distance, resulting in a final test matrix delivering three different heat inputs. Thereafter, the effect of heat input on static and dynamic properties was investigated. Vickers microhardness tests were carried out to predict weld response during tensile testing, with the expectation being that harder welds would offload more strain. This was confirmed using digital image correlation, which allowed for virtual measurement and visualisation of strain offloading. Bend tests were carried out on parent and welded samples to confirm whether Ti6Al4V could be formed to the correct geometry. Forming Ti6Al4V into a U-shape was the first consideration, since dynamic testing required samples of this geometry with longitudinal weld orientation. A two-stage forming methodology was developed from these experiments. Formed samples were subjected to fatigue tests in a custom designed fatigue platform for testing weld orientation as it would appear in the final component. Prediction of the welded buoyancy engine life was the goal behind these tests. Fracture surfaces were analysed to gain understanding of where crack initiation and final fracture occurred. Porosity served as the primary cause for crack initiation in failed samples. Pore distribution was heaviest in low-heat weldments and decreased with increasing heat input, while pore size increased with increasing heat input. This resulted in medium-heat weldments exhibiting superior performance to that of low- and high-heat ones. It was concluded that the laser welding process is able to produce weldments of sufficient integrity in thin Ti6Al4V sheet-formed components intended for use in glider buoyancy engines. , Thesis (MEng) -- Faculty of Engineering, the Built Environment and Technology, School of Engineering, 2024
- Full Text:
- Date Issued: 2024-04
Induction Heating as an alternative Localised Post Weld Heat Treatment for Friction Taper Hydro-Pillar Welds on thick-walled steam pipes
- Authors: De Klerk, Julien Vincent
- Date: 2022-04
- Subjects: Welding , Friction welding
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/58329 , vital:58984
- Description: Welding procedures regularly require a Post Weld Heat Treatment (PWHT) after the completion of a weld. This PWHT process is principally to mitigate unwanted effects of the welding process which may negatively influence the functional performance of the welded structure. Amongst the unwanted effects that may arise due to welding is the development of unintended metallurgical and mechanical properties. This includes the creation of an un-tempered martensitic structure due to the rapid cooling of the weld region from temperatures above the material’s critical temperature. This typically results in weld regions with high tensile strength and high hardness, but also characterised by low ductility and reduced toughness. In order to improve ductility and toughness a PWHT cycle is often completed on the welded structure. , Thesis (MA) -- Faculty of Engineering, the Built Environment, and Technology, 2022
- Full Text:
- Date Issued: 2022-04
- Authors: De Klerk, Julien Vincent
- Date: 2022-04
- Subjects: Welding , Friction welding
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/58329 , vital:58984
- Description: Welding procedures regularly require a Post Weld Heat Treatment (PWHT) after the completion of a weld. This PWHT process is principally to mitigate unwanted effects of the welding process which may negatively influence the functional performance of the welded structure. Amongst the unwanted effects that may arise due to welding is the development of unintended metallurgical and mechanical properties. This includes the creation of an un-tempered martensitic structure due to the rapid cooling of the weld region from temperatures above the material’s critical temperature. This typically results in weld regions with high tensile strength and high hardness, but also characterised by low ductility and reduced toughness. In order to improve ductility and toughness a PWHT cycle is often completed on the welded structure. , Thesis (MA) -- Faculty of Engineering, the Built Environment, and Technology, 2022
- Full Text:
- Date Issued: 2022-04
Friction stir welding of thin section aluminium extrusions for marine applications
- Authors: Chikamhi, Prince Philhelene
- Date: 2020
- Subjects: Friction welding , Welding
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46030 , vital:39410
- Description: This dissertation focuses on the development of a welding extrusion feeder, tool and schedule for implementation of defect-free butt welds on long, thin and complex-shape aluminium extrusions, as used by the marine industry. Viability of employing Friction Stir Welding (FSW) as a welding technology for joining long extrusions with a short-bed and bolt-on feeder to facilitate onsite fabrication of flat structures in shipbuilding is evaluated. An FSW feeder, tool and process control unit were designed, developed and integrated with an existing FSW platform, to facilitate implementation of continuous welds. Weld data acquired from literature review, experimentation, mechanical testing and metallographic analysis was used in design considerations for the development of a feeder. Subsequently, butt welds were implemented successfully on long 3 mm AA6082-T6 extrusions, during continuous FSW on the feeder. A specially adapted tool, the Floating Bobbin Tool, used with the feeder to implement butt welds was designed and developed from literature tool heuristics and weld trials. The tool eliminated the need for a backing bar and enabled tool-workpiece auto-alignment, beneficial with thin-section extrusions. Effect of rotational and weld speed and tool geometry of two tools (Tool 1 and 2), on weld forces and quality was tested, to establish optimum parameters for attaining high quality welds. Tool geometry had a profound effect on weld forces and integrity; Tool 2 welds exhibited superior and consistent weld quality, meeting maritime rules and standards and proving the adequacy of using FSW for joining long thin extrusions. Feeder process control, automation and optimisation, was implemented by process control unit devices, in addition to force and position control provided by the existing FSW platform. Owing to process control, automation and optimisation during continuous FSW of thin long and complex-shape aluminium extrusions, welding setup times and process variations are minimised and chances for defect-free welds increased, boosting production and cost savings in large panel fabrication in shipbuilding.
- Full Text:
- Date Issued: 2020
- Authors: Chikamhi, Prince Philhelene
- Date: 2020
- Subjects: Friction welding , Welding
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46030 , vital:39410
- Description: This dissertation focuses on the development of a welding extrusion feeder, tool and schedule for implementation of defect-free butt welds on long, thin and complex-shape aluminium extrusions, as used by the marine industry. Viability of employing Friction Stir Welding (FSW) as a welding technology for joining long extrusions with a short-bed and bolt-on feeder to facilitate onsite fabrication of flat structures in shipbuilding is evaluated. An FSW feeder, tool and process control unit were designed, developed and integrated with an existing FSW platform, to facilitate implementation of continuous welds. Weld data acquired from literature review, experimentation, mechanical testing and metallographic analysis was used in design considerations for the development of a feeder. Subsequently, butt welds were implemented successfully on long 3 mm AA6082-T6 extrusions, during continuous FSW on the feeder. A specially adapted tool, the Floating Bobbin Tool, used with the feeder to implement butt welds was designed and developed from literature tool heuristics and weld trials. The tool eliminated the need for a backing bar and enabled tool-workpiece auto-alignment, beneficial with thin-section extrusions. Effect of rotational and weld speed and tool geometry of two tools (Tool 1 and 2), on weld forces and quality was tested, to establish optimum parameters for attaining high quality welds. Tool geometry had a profound effect on weld forces and integrity; Tool 2 welds exhibited superior and consistent weld quality, meeting maritime rules and standards and proving the adequacy of using FSW for joining long thin extrusions. Feeder process control, automation and optimisation, was implemented by process control unit devices, in addition to force and position control provided by the existing FSW platform. Owing to process control, automation and optimisation during continuous FSW of thin long and complex-shape aluminium extrusions, welding setup times and process variations are minimised and chances for defect-free welds increased, boosting production and cost savings in large panel fabrication in shipbuilding.
- Full Text:
- Date Issued: 2020
Study of the interrelationship between weld geometry, process variables and joint intergrity for friction processed AA6082-T6 aluminium
- Authors: Samuel, Darren Alton Graham
- Date: 2014
- Subjects: Friction welding -- Research Pressure welding , Welding
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/48058 , vital:40467
- Description: This work presents a broad overview of the successful development of friction taper stud welding (FTSW) in 25mm thick AA6082-T6 sections. It covers the selection of geometry and process parameters, the development of data logging equipment, energy input results and interpretations. Research was carried out to develop the FTSW process for application in 25mm AA6082-T6 sections. The development and application of the FTSW process addresses the need to fill blind holes in thick aluminium sections for the repair of incorrectly drilled holes, friction stir welding exit holes and defects in critical components. During welding, frictional torque, rotational speed, axial force, near interface temperature of the tapered hole and welding time was recorded. This data was used to calculate energy input and energy input rates throughout a weld, enabling the effect of process parameters to be linked to energy, temperature, microhardness and static joint strength. Results of preliminary experiments are included in the study that were used for the design of a process parameter test window for FTSW in AA6082-T6, as no parameters were available to indicate a starting point for the research. The effect of process parameters on the static joint strength at the base of the tapered hole are presented; using a parallel sided stud and tapered hole configuration. This addresses one of the pressing issues facing FTSW of AA6082-T6, namely the lack of bonding at the bottom of the blind hole. A final process parameter matrix is designed based on the process development welds and is presented and discussed. In addition, the use of a non-consumable heat sink was investigated to prevent the premature collapse of the stud during welding and was shown to be critically important to the FTSW of AA6082-T6. To achieve good sidewall bonding a hole taper angle of 60° is required, this having been shown during visual evaluation of development welds. Stud taper angles between 2° and 5° less than the taper angle of the hole were identified as the range within which good FTSW can be made. With this geometry, at no stage during welding did the body of the stud shear off from the weld interface due to softening, thereby preventing collapse of the stud and formation of poorly bonded regions at the sidewall of the hole. The absence of shearing off of the weld interface during plunge was shown to be a good indicator of appropriate geometry and can be linked to welds made with high hole and stud taper angles and high axial force ramp up rates. The large hole and stud diameter relative to the depth of the hole and the large taper angle of the hole further aid in keeping the weld nugget rotating in the hole, promoting plasticization of the sidewall. Axial force ramp up rate was found to be the main critical success factor in an AA6082-T6 FTSW. Without control of this parameter the body of the stud will heat and detrimentally soften during plunge. It was established that good FTSW in AA6082-T6 cannot be made without the use of preheat to overcome the heat dissipation during welding, and is directly linked to improved energy input characteristics. Energy input as well as energy input rate were directly linked to static tensile strength and softening in the HAZ. The angle of the stud has been related to the energy input rate limit of the stud body, with increasing stud taper angles enabling the stud to withstand a higher energy input rate, allowing the weld interface to propagate up the hole at a slower rate, promoting plasticization of the sidewall. This study has successfully made good FTSW in 25mm thick AA6082-T6, in a 60°, 20mm deep tapered hole. Process parameters and ranges that produce FTSW exhibiting the required characteristics were identified by this study.
- Full Text:
- Date Issued: 2014
- Authors: Samuel, Darren Alton Graham
- Date: 2014
- Subjects: Friction welding -- Research Pressure welding , Welding
- Language: English
- Type: Thesis , Doctoral , DPhil
- Identifier: http://hdl.handle.net/10948/48058 , vital:40467
- Description: This work presents a broad overview of the successful development of friction taper stud welding (FTSW) in 25mm thick AA6082-T6 sections. It covers the selection of geometry and process parameters, the development of data logging equipment, energy input results and interpretations. Research was carried out to develop the FTSW process for application in 25mm AA6082-T6 sections. The development and application of the FTSW process addresses the need to fill blind holes in thick aluminium sections for the repair of incorrectly drilled holes, friction stir welding exit holes and defects in critical components. During welding, frictional torque, rotational speed, axial force, near interface temperature of the tapered hole and welding time was recorded. This data was used to calculate energy input and energy input rates throughout a weld, enabling the effect of process parameters to be linked to energy, temperature, microhardness and static joint strength. Results of preliminary experiments are included in the study that were used for the design of a process parameter test window for FTSW in AA6082-T6, as no parameters were available to indicate a starting point for the research. The effect of process parameters on the static joint strength at the base of the tapered hole are presented; using a parallel sided stud and tapered hole configuration. This addresses one of the pressing issues facing FTSW of AA6082-T6, namely the lack of bonding at the bottom of the blind hole. A final process parameter matrix is designed based on the process development welds and is presented and discussed. In addition, the use of a non-consumable heat sink was investigated to prevent the premature collapse of the stud during welding and was shown to be critically important to the FTSW of AA6082-T6. To achieve good sidewall bonding a hole taper angle of 60° is required, this having been shown during visual evaluation of development welds. Stud taper angles between 2° and 5° less than the taper angle of the hole were identified as the range within which good FTSW can be made. With this geometry, at no stage during welding did the body of the stud shear off from the weld interface due to softening, thereby preventing collapse of the stud and formation of poorly bonded regions at the sidewall of the hole. The absence of shearing off of the weld interface during plunge was shown to be a good indicator of appropriate geometry and can be linked to welds made with high hole and stud taper angles and high axial force ramp up rates. The large hole and stud diameter relative to the depth of the hole and the large taper angle of the hole further aid in keeping the weld nugget rotating in the hole, promoting plasticization of the sidewall. Axial force ramp up rate was found to be the main critical success factor in an AA6082-T6 FTSW. Without control of this parameter the body of the stud will heat and detrimentally soften during plunge. It was established that good FTSW in AA6082-T6 cannot be made without the use of preheat to overcome the heat dissipation during welding, and is directly linked to improved energy input characteristics. Energy input as well as energy input rate were directly linked to static tensile strength and softening in the HAZ. The angle of the stud has been related to the energy input rate limit of the stud body, with increasing stud taper angles enabling the stud to withstand a higher energy input rate, allowing the weld interface to propagate up the hole at a slower rate, promoting plasticization of the sidewall. This study has successfully made good FTSW in 25mm thick AA6082-T6, in a 60°, 20mm deep tapered hole. Process parameters and ranges that produce FTSW exhibiting the required characteristics were identified by this study.
- Full Text:
- Date Issued: 2014
Increasing the gap tolerance in friction stir welded joints of AA6082-T6
- Authors: Oyedemi, Kayode
- Date: 2012
- Subjects: Friction stir welding , Aluminum alloys -- Welding , Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9628 , http://hdl.handle.net/10948/d1012325 , Friction stir welding , Aluminum alloys -- Welding , Welding
- Description: This research project was conducted to increase weld gap tolerance in Friction Stir Welding (FSW) of 8 mm thick aluminum alloy 6082 – T6. Investigation was done on I-STIR PDS platform and a Johnford milling machine. The research project involved tool-pin design with varying re-entrant features and varying parameters as a method of weld gap closing to produce successful welds. Direction of spindle rotation and dwell time were established as part of a preliminary study. Clockwise spindle rotation with 20 seconds dwell time allows sufficient plasticity and improved material flow which assisted in achieving welds with prior 30 percent weld gap of the plate thickness. Final welds were made using three rotational speeds and feed rates with sufficient plunging to prevent root defects. Analysis of the results were detailed which include vickers microhardness test, tensile test and metallographic observation to access the suitability of the weld structure. From the set of tool-pins designed, the flare tool-pin gave a well-defined weld nugget with improved stirring at the weld root. Also, with a concave shoulder, right hand threaded tool-pin and counterclockwise flutes undergoing a clockwise spindle rotation, plasticized material flow was upward which was beneficial in reducing the amount of plate thinning. The right hand thread counter clockwise flute with a flute machined in the foot exhibited superior tensile strength for welds containing 30 percent weld gap.
- Full Text:
- Date Issued: 2012
- Authors: Oyedemi, Kayode
- Date: 2012
- Subjects: Friction stir welding , Aluminum alloys -- Welding , Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9628 , http://hdl.handle.net/10948/d1012325 , Friction stir welding , Aluminum alloys -- Welding , Welding
- Description: This research project was conducted to increase weld gap tolerance in Friction Stir Welding (FSW) of 8 mm thick aluminum alloy 6082 – T6. Investigation was done on I-STIR PDS platform and a Johnford milling machine. The research project involved tool-pin design with varying re-entrant features and varying parameters as a method of weld gap closing to produce successful welds. Direction of spindle rotation and dwell time were established as part of a preliminary study. Clockwise spindle rotation with 20 seconds dwell time allows sufficient plasticity and improved material flow which assisted in achieving welds with prior 30 percent weld gap of the plate thickness. Final welds were made using three rotational speeds and feed rates with sufficient plunging to prevent root defects. Analysis of the results were detailed which include vickers microhardness test, tensile test and metallographic observation to access the suitability of the weld structure. From the set of tool-pins designed, the flare tool-pin gave a well-defined weld nugget with improved stirring at the weld root. Also, with a concave shoulder, right hand threaded tool-pin and counterclockwise flutes undergoing a clockwise spindle rotation, plasticized material flow was upward which was beneficial in reducing the amount of plate thinning. The right hand thread counter clockwise flute with a flute machined in the foot exhibited superior tensile strength for welds containing 30 percent weld gap.
- Full Text:
- Date Issued: 2012
- «
- ‹
- 1
- ›
- »