Development of a process envelope for friction stir welding of DH36 steel : a step change

Friction stir welding of steel presents an array of advantages across many industrial sectors compared to conventional fusion welding techniques. However, the fundamental knowledge of the friction stir welding process in relation to steel remains relatively limited. A microstructure and property evaluation of friction stir welded low alloy steel grade DH36 plate, commonly used in ship and marine applications has been undertaken. In this comprehensive study, plates of 2000 x 200 x 6 mm were butt welded together at varying rotational and traverse speeds. Samples were examined microscopically and by transverse tensile tests. In addition, the work was complemented by Charpy impact testing and micro-hardness testing in various regions of the weld. The study examined a wide range of process parameters; from this, a preliminary process parameter envelope has been developed and initial process parameter sets established that produce commercially attractive excellent quality welds through a substantial increase in the conventionally recognised weld traverse speed

Cooperative Relaying in Wireless Networks under Spatially and Temporally Correlated Interference

We analyze the performance of an interference-limited, decode-and-forward, cooperative relaying system that comprises a source, a destination, and $N$ relays, placed arbitrarily on the plane and suffering from interference by a set of interferers placed according to a spatial Poisson process. In each transmission attempt, first the transmitter sends a packet; subsequently, a single one of the relays that received the packet correctly, if such a relay exists, retransmits it. We consider both selection combining and maximal ratio combining at the destination, Rayleigh fading, and interferer mobility. We derive expressions for the probability that a single transmission attempt is successful, as well as for the distribution of the transmission attempts until a packet is transmitted successfully. Results provide design guidelines applicable to a wide range of systems. Overall, the temporal and spatial characteristics of the interference play a significant role in shaping the system performance. Maximal ratio combining is only helpful when relays are close to the destination; in harsh environments, having many relays is especially helpful, and relay placement is critical; the performance improves when interferer mobility increases; and a tradeoff exists between energy efficiency and throughput

Packet Travel Times in Wireless Relay Chains under Spatially and Temporally Dependent Interference

We investigate the statistics of the number of time slots $T$ that it takes a packet to travel through a chain of wireless relays. Derivations are performed assuming an interference model for which interference possesses spatiotemporal dependency properties. When using this model, results are harder to arrive at analytically, but they are more realistic than the ones obtained in many related works that are based on independent interference models. First, we present a method for calculating the distribution of $T$. As the required computations are extensive, we also obtain simple expressions for the expected value $\mathrm{E} [T]$ and variance $\mathrm{var} [T]$. Finally, we calculate the asymptotic limit of the average speed of the packet. Our numerical results show that spatiotemporal dependence has a significant impact on the statistics of the travel time $T$. In particular, we show that, with respect to the independent interference case, $\mathrm{E} [T]$ and $\mathrm{var} [T]$ increase, whereas the packet speed decreases

Fatigue and bending behaviour of friction stir welded DH36 steel

Friction stir welding presents many advantages over conventional welding techniques; however, there is limited published data with regards to the fatigue and bending performance of friction stir welded steels. Hence, this investigation aims to evaluate friction stir welded DH36 steel subjected to these loading conditions. A comprehensive fatigue and bending programme has been implemented to assess the impact of process related features, such as weld root flaws, on the welds’ performance. Strain gauges located on the top and bottom surfaces of fatigue samples allowed the secondary bending stresses to be quantified when clamped in the fatigue test machine. Bend test samples were completed to a 180° U-bend for as-welded and ground samples. The bend testing programme demonstrated satisfactory performance of friction stir welded DH36 steel. Despite the presence of surface flaws, cracks did not propagate in bending indicating adequate levels of toughness. Fatigue performance was poor in comparison with results from similar welds however, it was found to be acceptable in terms of class recommendations for fusion welding. This lower performance was predominantly attributed to a weld root flaw. Strain gauge measurements indicated that the local stress at the weld root was up to 25% lower than the nominal stress determined prior to testing, thus artificially improving fatigue performance. Welds of good quality and refined microstructure were found, however process related flaws on the top and bottom surface emphasise the need for optimisation of the tool material and welding parameters

Advances in friction stir welding of steel : Project HILDA

A microstructure and property evaluation of friction stir welded DH36 6mm plate has been undertaken. The study examined a wide range of process parameters and, from this, a process parameter envelope has been developed and an initial process parameter set established that gives good welding properties. Thermo-mechanical deformation studies were developed to generate flow stress regimes over a range of stain rates and temperatures and these data will support the on-going local numerical modelling development. A preliminary thermo-fluid model has been developed to predict temperature and material flow during the FSW of steel grade DH36. In this model, materials are considered as highly viscous incompressible fluid. The welded material is flowing around the rotating tool thanks to the modelling of the friction at tool/workpiece interface. In parallel, a global numerical model is being developed to predict the inherent residual stresses and distortion of FSW butt welded assemblies often in excess of 6m long plate

Defect tolerance of friction stir welds in DH36 steel

Friction stir welding of steel is in the early stages of development. The aim to commercialise this process creates a trade-off between welding time, cost and quality of the joint produced. Therefore, it becomes critical to analyse the lower quality bound of steel friction stir welds in conventional square edge butt welding configuration. Work has been undertaken to evaluate the microstructure and fatigue performance of 6 mm thick DH36 steel plates friction stir welded with sub-optimal process conditions, resulting in the development of embedded and surface breaking flaws. The defective weldments were characterised to understand the nature of the flaws and a programme of mechanical testing was undertaken (including fatigue assessment) to determine the relationship between the flaw geometry, location and weld quality. A number of characteristic flaws were identified and seen to interact with the samples’ fatigue fracture mechanisms. Samples with wormholes at the weld root produced the lowest fatigue performance. Fracture from incomplete fusion paths at the retreating side of the welds’ top surface was seen to correspond to the highest recorded fatigue lives. The work provides an insight into the complex nature of characteristic flaws in steel friction stir welds and their interaction with fatigue behaviour

Recent developments in steel friction stir welding : Project HILDA

Friction stir welding of steel presents an array of advantages across many industrial sectors compared to conventional fusion welding techniques. Preliminary studies have identified many positive effects on the properties of welded steel components. However, the fundamental knowledge of the process in relation to structural steel remains relatively limited, hence industrial uptake has been essentially non-existent to this date. The European-funded project HILDA, the first of its kind in terms of breadth and depth, is concerned with enhancing the understanding of the process on low alloy steel, establishing its limits in terms of the two more significant parameters which can be directly controlled, tool traverse and rotational speed, thus improving its techno-economic competitiveness to fusion welding. A detailed study investigated the effect of process parameters on the evolved microstructure. In parallel, a full programme of mechanical testing was undertaken to generate data on hardness, impact toughness and fatigue. From this, it has been established that friction stir welding of steel produces high integrity joints that exhibit excellent fatigue properties. From a simulation perspective, a local microstructural numerical model has been developed to predict the microstructural evolution within the weld zone during friction stir welding of low alloy steel. This model concentrates on predicting grain size evolution due to dynamic recrystallization with respect to tool traverse and rotational speed. Furthermore, a computational efficient local-global numerical model capable of predicting the thermal transients, stir and heat affected zone, residual stresses and distortion produced by friction stir welding of DH36 plates is presented

Numerical optimisation of laser assisted friction stir welding of structural steel

Significant progress has been made on the implementation of friction stir welding (FSW) in the industry for aluminium alloys. However, steel FSW and other high-temperature alloys is still the subject of considerable research, mainly because of the short life and high cost of the FSW tool. Different auxiliary energies have been considered as a means of optimising the FSW process and reducing the forces on the tool during the plunge and traverse stages, but numerical studies on steel are particularly limited. Building on the state-of-art, laser-assisted steel FSW has been numerically developed and analysed as a viable process amendment. Laser-assisted FSW increased the traverse speed up to 1500 mm min −1, significantly higher than conventional steel FSW. The application of laser assistance with a distance of 20 mm from the rotating tool reduced the reaction force on the tool probe tip up to 55% when compared to standard FSW

Thermomechanical deformation behaviour of DH36 steel during friction stir welding by experimental validation and modelling

Friction stir welding is a solid state thermo-mechanical deformation process from which the plasticisation behaviour of the stirred material can be evaluated throuh the study of flow stress evolution. Flow stress data also supporting the development of a local microstructural numerical model have been generated. Hot compression testing of DH36 steel has been performed at a temperature range of 700ºC-1100ºC and strain rates from 10-³ s-¹ to 10² s-¹ to study the alloy's thermo-mechanical deformation behaviour in conditions which simulate the actual friction stir welding process. It has been found that the evolution of flow stress is significantly affected by the test temperature and deformation rate. The material's constitutive equation and constants have been calculated after analysis of these data. Preliminary numerical analysis results are in good agreement with experimental observations