Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding

Area of Science:

• Materials Science
• Mechanical Engineering
• Computational Modeling

Background:

• Multi-layer welding requires significant time and resources for deformation prediction via experimentation or numerical analysis.
• Predicting transverse angular distortion in multi-layer butt welding is crucial for structural integrity and manufacturing efficiency.

Purpose of the Study:

• To develop a systematic and efficient method for predicting transverse angular distortion in multi-layer butt welding.
• To reduce the computational time and effort associated with traditional deformation prediction techniques.

Main Methods:

• Established a database from bead-on-plate welding experiments correlating welding conditions, bead geometry, material thickness, and angular distortion.
• Developed a calculation method using geometric principles and the database to predict angular distortion per pass for arbitrary joint shapes and welding conditions.
• Verified prediction curves with experimental results from V-groove welding.

Main Results:

• The proposed method accurately predicts transverse angular distortion in multi-layer butt welding.
• Angular distortion is shown to be a function of the number of passes and groove geometry.
• The algorithm leverages databases and geometric principles for a computationally efficient numerical approach.

Conclusions:

• The developed systematic method provides an efficient solution for predicting transverse angular distortion in multi-layer butt welding.
• The algorithm's reliance on databases and geometric principles makes it suitable for industrial applications, saving significant computational time.
• Understanding the relationship between welding parameters, joint geometry, and distortion is key for effective multi-layer welding process control.