Challenges towards Structural Integrity and Performance Improvement of Welded Structures

Welding is a fabrication process that joint materials, is extensively utilized in almost every field of metal constructions. Heterogeneity in mechanical properties, metallurgical and geometrical defects, post-weld residual stresses and distortion due to non-linear welding processes are prime concerns for performance reduction and failures of welded structures. Consequently, structural integrity analysis and performance improvement of weld joints are important issues that must be considered for structural safety and durability under loading. In this study, an extensive experimental program and analysis were undertaken on the challenges towards structural integrity analysis and performance improvement of different welded joints. Two widely used welding techniques including solid-state “friction- stir- welding (FSW)” and fusion arc “gas tungsten arc welding (GTAW)” were employed on two widely utilized materials, namely aluminum alloys and structural steels. Various destructive and non-destructive techniques were utilized for structural integrity analysis of the welded joints. Furthermore, various “post-weld treatment (PWT)” techniques were employed to improve mechanical performances of weld joints. The work herein is divided into six different sections including: (i) Establishment of an empirical correlation for FSW of aluminum alloys. The developed empirical correlation relates the three critical FSW process parameters and was found to successfully distinguish defective and defect-free weld schedules; (ii) Development of an optimized “adaptive neuro-fuzzy inference system (ANFIS)” model utilizing welding process parameters to predict ultimate tensile strength (UTS) of FSW joints; (iii) Determination of an optimum post-weld heat treatment (PWHT) condition for FS-welded aluminum alloys; (iv) Exploration on the influence of non-destructively evaluated weld-defects and obtain an optimum PWHT condition for GTA-welded aluminum alloys; (v) Investigation on the influence of PWHT and electrolytic-plasma-processing (EPP) on the performance of welded structural steel joints; and finally, (vi) Biaxial fatigue behavior evaluation of welded structural steel joints. The experimental research could be utilized to obtain defect free weld joints, establish weld acceptance/rejection criteria, and for the better design of welded aluminum alloy and steel structures. All attempted research steps mentioned above were carried out successfully. The results obtained within this effort will increase overall understanding of the structural integrity of welded aluminum alloys and steel structures

Thermomechanical modeling and optimization of friction stir welding

This thesis research implemented an existing thermomechanical model of friction stir welding process, and studied the surrogate model-based optimization approach to obtain optimal process parameters for the modeled friction stir welding process. As an initial step, the thermomechanical model developed by Zhu and Chao for friction stir welding of 304L stainless steel was replicated using ANSYS. The developed model was then used to conduct parametric studies to understand the effect of various input parameters like total rate of heat input, welding speed and clamping location on temperature distribution and residual stress in the workpiece. With the data from the simulated model, linear and nonlinear surrogate models were constructed using regression analysis to relate the selected input process parameters with response variables. Constrained optimization models were formulated using surrogate models and optimization of process parameters for minimizing cost and maximizing throughput was carried out using improved harmony search algorithm. To handle the constraints, Deb’s parameter-less penalty method was used and implemented in the algorithm. It is learned from this research that: (1) heat input is mainly constrained by the lower bound of the temperature for making good welds; (2) the optimal welding speed must balance the loss of heat input and the gain in productivity; (3) clamping closer to the weld is better than away from the weld in terms of lowering the peak residual stresses. Moreover, the nonlinear surrogate models resulted in a slightly better optimal solution than the linear models when wide temperature range was used. However, for tight temperature constraints, optimization on linear surrogate models produced better results. The implemented improved harmony search algorithm seems not able to converge to the best solution in every run. Nevertheless, the non-converged solution it found was very close to the best