Probabilistic models to evaluate effectiveness of steel bridge weld fatigue retrofitting by peening

The purpose of this study was to evaluate, with two probabilistic analytical models, the effectiveness of several alternative fatigue management strategies for steel bridge welds. The investigated strategies employed, in various combinations, magnetic particle inspection, gouging and rewelding, and postweld treatment by peening. The analytical models included a probabilistic strain-based fracture mechanics model and a Markov chain model. For comparing the results obtained with the two models, the fatigue life was divided into a small, fixed number of condition states based on crack depth, similar to those often used by bridge management systems to model deterioration due to other processes, such as corrosion and road surface wear. The probabilistic strain-based fracture mechanics model was verified first by comparison with design S-N curves and test data for untreated welds. Next, the verified model was used to determine the probability that untreated and treated welds would be in each condition state in a given year; the probabilities were then used to calibrate transition probabilities for a much simpler Markov chain fatigue model. Then both models were used to simulate a number of fatigue management strategies. From the results of these simulations, the performance of the different strategies was compared, and the accuracy of the simpler Markov chain fatigue model was evaluated. In general, peening was more effective if preceded by inspection of the weld. The Markov chain fatigue model did a reasonable job of predicting the general trends and relative effectiveness of the different investigated strategies

Tensiones residuales en uniones soldadas por FSW en aluminio 7075-T651

Las tensiones residuales pueden ser un aspecto de relevancia en la integridad estructural de componentes en servicio, pudiendo presentar una importante influencia sobre la vida a la fatiga, entre otros mecanismos de falla. El proceso de soldadura por fricción-agitación (FSW) ha revolucionado en los últimos años el campo de la tecnología de la soldadura. Su mayor aplicación se ha dado en las aleaciones de aluminio, aunque hoy en día se utiliza para prácticamente todos los materiales. Una de las ventajas enunciadas de este proceso es el menor nivel de tensiones residuales resultantes, debido a que se produce en estado sólido por lo que los gradientes térmicos durante la soldadura son menores. Entre las aleaciones de aluminio de uso estructural, las aleaciones termoenvejecibles de la serie 7XXX se utilizan habitualmente en la industria aeronáutica y aeroespacial debido a su alta resistencia mecánica. El objetivo del presente trabajo es analizar el efecto de la velocidad de avance en FSW sobre las tensiones residuales en juntas de aluminio AA7075-T651, mediante la técnica de seccionamiento. Se soldaron probetas de dicha aleación de 150x150x4mm mediante FSW, variando la velocidad de avance entre 51 y 206 mm.min-1. Durante la soldadura se adquirieron los ciclos térmicos. Posteriormente se midieron las tensiones residuales longitudinales a distintas distancias del cordón de soldadura, en cada caso. A partir de los ciclos térmicos adquiridos se obtuvieron los gradientes térmicos en la zona de medición. Las tensiones residuales máximas se encontraron entre 52 y 78 MPa, correspondiente entre 10 y 15 % del límite de fluencia del material. Las mismas aumentaron con la velocidad de avance, consistentemente con un aumento en el gradiente térmico observado. Dichos valores de tensiones residuales son menores que los obtenidos para la soldadura de estos materiales mediante procesos del tipo GMAW.Residual stresses could be a relevant issue in the structural integrity of a component in service and usually have a major influence on their fatigue life, among other failure mechanisms. In recent years Friction-Stir Welding (FSW) has revolutionized the welding technology. Its main application has been given in aluminum alloys, but nowadays can be applicable to different materials. One of the several advantages of this process is a lower level of residual stresses, because the thermal gradients introduced during welding are lower. Among aluminum alloys used for structural applications, 7XXX strain-aged series are usually employed in the aerospace industry, because of their high strength. The aim of this paper is to analyze the effect of welding speed of FSW on residual stresses in aluminum AA7075-T651 joints, using sectioning technique. Coupons were welded AA7075-T651 FSW of 150x150x4 mm by varying the welding speed between 51 and 206 mm.min-1. During the welding thermal cycles were acquired. Subsequently, longitudinal residual stresses measured at different distances from the weld, in each case. Based on the acquired thermal cycling thermal gradients were obtained in the measurement area. Maximum residual stresses ranged from 52 to 78 MPa, corresponding to a range of 10 and 15% of the yield strength. They increased with increasing welding speed, consistent with an increase in the thermal gradient observed. These residual stresses values are lower than those obtained for the welding of these materials by type GMAW processes

Influência do tipo de chanfro, tecimento e sentido de laminação na distorção angular em soldagem GMAW-P robotizada de alumínio

O interesse da indústria em ter um maior controle das deformações provocadas pela soldagem se deve ao fato das tolerâncias dimensionais e geométricas estarem cada vez mais precisas nas especificações de projeto, motivando a engenharia de fabricação a desenvolver processos estáveis e que garantam a rotina de produção. Visando isso, o presente trabalho tem como objetivo analisar o quanto situações rotineiras utilizadas na soldagem automatizada de alumínio podem influenciar nas deformações angulares deste material. Utilizando a liga AA 5052 H34, e a soldagem automatizada no processo GMAW pulsado, foram aplicados três tipos de tecimento ao longo do comprimento da solda, em juntas de topo montadas sem chanfro e com chanfro de 60º, dispostas tanto transversais quanto longitudinais ao sentido de conformação da chapa. A medição das deformações foi realizada por um braço tridimensional, antes e após a soldagem, em três regiões distintas nas placas de teste. O perfil do cordão de solda foi o fator determinante para as diferentes formas das deformações encontradas, assim como revelado pelas análises macrográficas. A junta com chanfro de 60º apresentou maiores amplitudes das deformações que a junta sem chanfro. A oscilação da tocha não foi uma variável de influência estatisticamente significativa nessas amplitudes.The industry's interest in having a greater control of the deformations caused by welding is due to the geometric and dimensional tolerances been more and more precise in the project specifications, motivating the manufacturing engineering to develop stable processes and to ensure routine production. Aiming at it, the main goal of this present work is to analyze how much routine situations used in automatic aluminum welding can influence on the angular deformations of this material. Using the alloy AA 5052 H34, and the automatic welding in pulsed GMAW process, three types of weaving were applied throughout the length of the weld, in butt joints assembled without groove and with 60º single-V-groove, arranged transversely as well as longitudinally to the rolling direction of the plate. The measurement of the deformations was made by a three-dimensional equipment, before and after the welding, in three distinct regions in the specimens. The profile of the weld bead was the main factor for the different types of deformations found, as revealed by macrographical analysis. The 60º single-V-groove had higher amplitudes of deformations as the joint without groove. The torch oscillation wasn`t a variable of statistically significant influence on this amplitudes