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Methodology to Reduce Distortion Using a Hybrid Thermal Welding Process.

Javier Souto1, Enrique Ares2, Paulino Alegre3

  • 1Calculus and Simulation Unit at AIMEN Technology Center, C/Relva 27A Torneiros, 36410 Porriño-Pontevedra, Spain. javier.soutogrela@outlook.com.

Materials (Basel, Switzerland)
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Summary

This study introduces a line-heating process during welding to minimize structural distortions. The advanced high-temperature thermal transient tensioning (htTTT) method effectively reduces manufacturing defects in welded components.

Keywords:
FEMLSND (low stress no distortion)htTTTmodel validationwelding distortion

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Computational Mechanics

Background:

  • Welding generates high strains and stresses, leading to material phase changes and significant structural distortions.
  • These distortions pose a critical challenge in the design and manufacturing of welded structures.
  • Minimizing distortion is crucial for ensuring the integrity and functionality of welded components.

Purpose of the Study:

  • To investigate and develop a line-heating-based forming process integrated with welding.
  • To minimize distortion in welded structures through a novel thermal process.
  • To present a computational framework for simulating and optimizing this process.

Main Methods:

  • Utilized a finite element method (FEM) with a thermo-elastoplastic approach for simulation.
  • Calibrated the computational model through three stages: heatline forming, flame heat source, and weld process.
  • Developed and simulated a hybrid high-temperature thermal transient tensioning (htTTT) process.

Main Results:

  • The calibrated FEM model accurately simulates the thermo-mechanical behavior during welding and forming.
  • The htTTT process demonstrated effectiveness in minimizing distortion for large T-welded components.
  • Optimization of the htTTT process led to significant reductions in final component distortion.

Conclusions:

  • Line-heating-based forming integrated with welding is a viable strategy for distortion control.
  • The developed FEM model and htTTT process provide a robust solution for minimizing welding-induced distortions.
  • This approach offers a pathway to improved design and manufacturing of high-quality welded structures.