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Process modelling and optimization of keyhole plasma arc welding of thin Ti-6Al-4V

DOI: 10.1177/0309324714524947 DOI Help

Authors: Wei Sun (University of Nottingham) , Mutaz B. Mohammed (Dunlop Oil & Marine Ltd,) , Lei Xu (The Manufacturing Technology Centre Ltd) , Thomas H. Hyde (University of Nottingham) , D. Graham Mccartney (University of Nottingham) , Sean B. Leen (University of Ireland Galway)
Co-authored by industrial partner: Yes

Type: Journal Paper
Journal: The Journal Of Strain Analysis For Engineering Design , VOL 49 , PAGES 410 - 420

State: Published (Approved)
Published: August 2014

Abstract: This article presents a comprehensive piece of research work focused on the development, validation and application of finite element modelling capability for the prediction and optimization of robotic keyhole plasma arc welding of Ti-6Al-4V thin structures. Experimental and computational investigations were carried out to characterize, develop, optimize and validate various aspects of the finite element modelling. The experimental investigations cover the determination of welding parameter envelopes using a robotic welding cell and the measurements of thermal history, distortion, residual stress and weld pool profile. The computational investigations include the development and validation of finite element models as well as the development and validation of a fully automated welding sequence optimization tool using a genetic algorithm approach. The work provides useful guidance and generic methodologies for optimum design of thin and complex lightweight structures and has formed a basis for the development of a framework on structural integrity assessment and component lifing of thin structures fabricated by welding. The optimization tool has significant potential to be conveniently modified to suit other optimization objectives and/or welding processes.

Journal Keywords: Finite element analysis; keyhole plasma arc welding; titanium alloy; distortion; residual stress; optimization

Subject Areas: Engineering, Materials

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Added On: 12/04/2017 09:05

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