Parametric Study and Optimization for Welding Processes Using Machine Learning

Optimization facilitates in attainment of maximum strength, efficiency, reliability, productivity and longevity. In this work, data from three material joining processes - Ultrasonic welding of polymers, arc welding as Metal Inert Gas and Tungsten Inert Gas are analysed for establishing quantitative relationship between the process parameters and for prediction of weld features using Multivariate Linear Regression algorithm. The various dependency coefficients and characteristics generated with the ML algorithms are in agreement with the inherent dependency as obtained from experimental data and simulation results. This investigation is a preliminary attempt with a limited set of data to manifest the suitability of machine learning techniques; nevertheless, the results are far from conclusive owing to small data set and hence may be extended to precisely model joining processes with higher number of process parameters, degree of freedom and responses

Simulation Study of Critical Aspects of MIAB Welding for Analysis of Potential Factors Governing the Performance of Weld Formation

Magnetically Impelled Arc Butt (MIAB) welding, is a solid-state welding technique. The magnetic system of this technique is pivotal for the generation of the Lorentz force, which impels an arc to rotate along the periphery of the weld tubes and thus facilitates the heating of faying surfaces. The magnetic arrangement and the arc dynamics significantly impact the effectiveness of the welding process, eventually dictating the efficiency. This study case investigates the impact of the magnetic arrangement on the arc rotation and possible factors that cause irregularities in the (MIAB) welding through COMSOL simulation. The COMSOL simulation has served as a powerful tool to comprehensively analyse various arc dynamics and magnetic systems and extrapolate the observations to analyse the arc dynamics and magnetic systems involved in MIAB welding. By employing simulation studies, the research aims to unravel critical insights for an efficient design of the MIAB welding system. This work includes a study of the effect of magnetic forces on arc dynamics using various models and attempts to develop an analogy to the MIAB welding process. This is further utilized to explain the process variations in the form of arc displacement, electric potential distribution, and the possibility of self-demagnetization of AlNiCo magnets. Thus, it provides a foundation for advancing the technological aspects of MIAB welding to overcome the limitations and irregularities. This research is instrumental in enhancing the understanding of magnetic interactions involved in the MIAB process, which can further pave the way for improved welding machine designs and consequently, enable research on these lines that can help in establishing an optimized parametric window

Non-Destructive Testing of Magnetically Impelled Arc Butt Welding of Mild Steel Tubes

This paper presents the results of Non-Destructive Testing on Magnetically Impelled Arc Butt (MIAB) welded mild steel tubes of 27mm OD and 1.5mm thickness. As part of this work, the tests covered were radiography, liquid penetrant, and magnetic particle testing. The testing results indicate that porosity, penetration levels and the defects found are within acceptable limits as per standard. For this experimental work, the selection of parameters was based on trial and error adopted in preliminary trials. The irregularities found in the non-destructive testing samples have enabled the fine-tuning of process parameters. The optimum values of hydraulic pressure, weld time and weld current are assessed to be 30-35bar, 5.5s and 150 A, respectively 270 A for this dimension of tubes. This work focuses on the experimental observations of MIAB welding and Non-destructive testing results for MS tubes of the selected dimension, which have not been reported in the existing literature. The achieved input forms the database for the parametric study of this process. The optimum parametric ranges obtained from the results can be extrapolated to be used for joining tubes of different dimensions and can also form the inputs for reaching parameter and response dependency equations

Experimental studies and finite element simulation of ultrasonic welding of Cu alloy

This research study aims to investigate the mechanical and metallographical aspects of ultrasonic welding of Cu-Cu wires. Experimental trials have been conducted and observations have been recorded as a database that collates parametric, quality and strength aspects of various weldments. Destructive testing and metallurgical characterizations have been carried out to examine the strength and integrity of the weldment. The key focus of this research attempt is laid on determining and evaluating the factors that governs the strength of the weldment. Metallurgical characterizations reveal vital information on the weld integrity and the extent of grain distribution. Further, FEM is employed to understand the deformation and thermal aspects involved in Cu-Cu welding using ultrasonics. The numerical model may provide an insight into the thermal phenomenon governing the joining process and subsequently estimation of the impact. Response surface methodology is employed to identify the parametric interdependencies and subsequently determine the optimized range

Experimental investigations on aluminum based metal matrix composites with B4C, SiC and Mg

This research study is framed with an objective to fabricate AlMMC reinforced with varying percentage of SiC, B4C and Mg and evaluate their strength, quality and metallurgical integrity through destructive and non-destructive tests. The specimens indicate higher strength and bond integrity with increase in B4C percentage. The outcome reveals that this AlMMC is an effective alternative to other materials owing to its cost effectiveness and mechanical strength and stability

Investigations on thermal properties, stress and deformation of Al/SiC metal matrix composite based on finite element method

AlSiC is a metal matrix composite which comprises of aluminium matrix with silicon carbide particles. It is characterized by high thermal conductivity (180-200 W/m K), and its thermal expansion are attuned to match other important materials that finds enormous demand in industrial sectors. Although its application is very common, the physics behind the Al-SiC formation, functionality and behaviors are intricate owing to the temperature gradient of hundreds of degrees, over the volume, occurring on a time scale of a few seconds, involving multiple phases. In this study, various physical, metallurgical and numerical aspects such as equation of continuum for thermal, stress and deformation using finite element (FE) matrix formulation, temperature dependent material properties, are analyzed. Modelling and simulation studies of Al/SiC composites are a preliminary attempt to view this research work from computational point of view