Influence of Innovative Post-Weld Finishing Method on Bead Surface Quality

Area of Science:

• Materials Science and Engineering
• Manufacturing Technology

Background:

• Post-weld surface finishing is critical for structural integrity and performance.
• Conventional methods for weld bead removal can be time-consuming and may introduce undesirable stresses.
• Heterogeneous hardness of post-weld surfaces presents challenges for machining.

Purpose of the Study:

• To present an innovative single-pass cutting method for post-weld surface finishing of butt welds.
• To evaluate the effectiveness of this method on surface roughness and residual stress.
• To analyze the influence of the finishing method on the surface quality of welded steel.

Main Methods:

• Development and application of a specialized cutting tool with linearly arranged, height-increasing teeth.
• Machining of weld bead height in one pass on S235JR steel butt welds (MMA, MIG, TIG).
• Surface roughness analysis using optical methods (2D profile and 3D stereometric characteristics).
• Residual stress analysis using X-ray diffraction.

Main Results:

• The innovative cutting tool successfully removed weld bead height in a single pass, creating a flush surface.
• Significant improvements in surface quality, characterized by reduced roughness parameters, were observed.
• Residual stress analysis indicated a favorable influence of the finishing method on surface layer stresses.

Conclusions:

• The developed post-weld finishing method offers an efficient and effective solution for improving the surface quality of butt welds.
• The unique tool geometry allows for finishing heterogeneous surfaces with increased hardness.
• This technique has the potential to enhance the performance and reliability of welded structures.