Preventing Crack in an Aluminum Alloy Complex Structure during Welding Process Based on Numerical Simulation Technology

被引:6
作者
Zhang, Yuelai [1 ]
Luo, Wenze [2 ]
Zeng, Jiongmeng [2 ]
Li, Xixian [2 ]
Hu, Long [2 ]
Deng, Dean [2 ]
机构
[1] CRRC Zhuzhou Locomot Co Ltd, Zhuzhou 412001, Peoples R China
[2] Chongqing Univ, Coll Mat Sci & Engn, Chongqing 400045, Peoples R China
关键词
aluminum alloy; computational approach; welding crack; instantaneous heat source model; welding-induced stress; WELDED LAP JOINTS; RESIDUAL-STRESS; DISTORTION; DEFORMATION; PREDICTION; FATIGUE;
D O I
10.3390/cryst12121742
中图分类号
O7 [晶体学];
学科分类号
0702 ; 070205 ; 0703 ; 080501 ;
摘要
Aluminum alloy structures are widely used for weight reduction in aviation, shipbuilding, rail vehicles and automotive industries. Fusion welding technology is one of the most important joining methods for lightweight structure assembly due to its advantages such as flexibility in design, high production efficiency, and low cost. However, the local centralized heating during fusion welding inevitably produces residual stress and welding deformation. For actual engineering structures, if the product design is unreasonable or the external restraint is inappropriate, the transient stress or residual stress become a key factor resulting in cracking during the assembly process. In the current study, an effective computational approach was developed based on the MSC Marc software to simulate transient and residual stress fields for complex aluminum alloy structures during the welding process. In the developed computational approach, according to the location and arrangement of welding lines, an instantaneous heat source model was used to replace the traditional moving heat source model, and as a result significanlty improved the calculation efficiency to meet actual engineering needs. The welding stresses, including transient and residual stress, of an A6061 aluminum alloy complex structure were calculated by the developed numerical simulation technology. The simulation results indicated that the cracking was produced by excessive transient stress during welding process. Subsequently, the effect of external restraint intensity on welding stress at the key location was examined numerically. Based on the simulation results, measures to reduce welding stress and cracking risk were put forward based on adjusting the external restraint intensity.
引用
收藏
页数:18
相关论文
共 32 条
[1]  
Brust FW, 2007, PRES VES P, P883
[2]   Comparison of welding residual stress and deformation induced by local vacuum electron beam welding and metal active gas arc welding in a stainless steel thick-plate joint [J].
Feng, Guangjie ;
Wang, Yifeng ;
Luo, Wenze ;
Hu, Long ;
Deng, Dean .
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T, 2021, 13 :1967-1979
[3]  
Feng Z., 2005, PROCESSES MECH WELDI
[4]   A NEW FINITE-ELEMENT MODEL FOR WELDING HEAT-SOURCES [J].
GOLDAK, J ;
CHAKRAVARTI, A ;
BIBBY, M .
METALLURGICAL TRANSACTIONS B-PROCESS METALLURGY, 1984, 15 (02) :299-305
[5]   Neutron diffraction study on full-shape Japanese sword [J].
Harjo, Stefanus ;
Kawasaki, Takuro ;
Grazzi, Francesco ;
Shinohara, Takenao ;
Tanaka, Manako .
MATERIALIA, 2019, 7
[6]  
[胡兴 Hu Xing], 2020, [机械工程学报, Journal of Mechanical Engineering], V56, P38
[7]   Welding deformation and residual stresses in arc welded lap joints by modified iterative analysis [J].
Huang, H. ;
Ma, N. ;
Hashimoto, T. ;
Murakawa, H. .
SCIENCE AND TECHNOLOGY OF WELDING AND JOINING, 2015, 20 (07) :571-577
[8]   High performance computation of residual stress and distortion in laser welded 301L stainless sheets [J].
Huang, Hui ;
Tsutsumi, Seiichiro ;
Wang, Jiandong ;
Li, Liqun ;
Murakawa, Hidekazu .
FINITE ELEMENTS IN ANALYSIS AND DESIGN, 2017, 135 :1-10
[9]   INTERRELATION OF STRUCTURAL STABILITY, STIFFNESS, RESIDUAL-STRESS AND NATURAL FREQUENCY [J].
JUBB, JEM ;
PHILLIPS, IG ;
BECKER, H .
JOURNAL OF SOUND AND VIBRATION, 1975, 39 (01) :121-134
[10]  
KASUYA T, 1993, WELD J, V72, pS107