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1
Content available remote

Fume Formation Rate Analysis of Shipbuilding Steel with SMAW Using Taguchi Design and ANOVA

100%
Mert T., Ekinci S.
Acta Physica Polonica A
|
2017
|
vol. 131
|
issue 3
495-499
EN
Shipbuilding industry grows rapidly due to the increasing growth of economies and thus, the need for new and bigger ships emerge. Manufacturing of ships in shipyards includes harmful processes, such as welding, which impact the workers and the environment. As a consequence of increase in demand for new ships, deleterious welding fume and emissions all over the world increase year by year. Welding fume includes hazardous micro and sub-micro sized metal particulates and in addition to welding fume, welding emissions consist of detrimental gaseous wastes as well. In this study, a set of experiments was designed by Taguchi method. These experiments were realized by two welders using two different types of covered electrodes (rutile and cellulosic), welding speeds and currents on Grade A shipbuilding steel, which is one of the most common steels in shipbuilding. After the experiments, fume formation rate was measured and it was observed that the contributions of the factors are 92.47%, 5.42% and 1.66% for electrode type, current and welder, respectively. The results were assessed using Taguchi and ANOVA and evaluated in terms of environment and occupational health and safety.
2
Content available remote

The Response of the Heat Affected Zone to Natural Aging in Friction Welded Al-Mg-Si-T6 Alloy

100%
Abudaia F., Marwan K.
Acta Physica Polonica A
|
2014
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vol. 125
|
issue 2
208-210
EN
In this work, it is aimed to study the effect of welding parameters on the response of the fully reverted zone of the heat affected zone in Al-Mg-Si-T6 alloy to natural aging. The study takes in consideration the effect of welding time which usually receives less attention than other parameters. Rods of 25 mm diameter were friction welded at varying welding times and forge pressures. The highest hardness recovery in the fully reverted zone was obtained by a combination of a high heat input with a short welding time. These welding conditions produced a thermal welding cycle with higher cooling rate with a relatively longer time at the peak temperature. The high cooling rate is important to avoid the formation of the non-hardening Mg_2Si precipitates which do not contribute to the hardness. The longer hold time at peak temperature permits more precipitate dissolution to increase the solute concentration in the solution before the rapid cooling.
3
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Soda Lime Silicate Glass-Copper Metal Joining by Controlled Heat Treatments in Air

100%
Telli M.
Acta Physica Polonica A
|
2016
|
vol. 129
|
issue 4
482-484
EN
Metal-glass joints are needed to improve efficiencies of heat collecting units used in linear parabolic sun collector systems. Soda lime silicate glass-copper metal joints were prepared at 800°C for 5, 10 and 20 min by furnace treatment in air. Cu is rapidly oxidized with heat treatment in air, reacted with glass and formed some bubbles at reaction interface. Scanning electron microscope investigation suggested copper oxide formation at copper interface, reaction between copper oxide and glass and formation of bubbles at joining interface and some microcracking for the studied glass disk on Cu disk sample profiles. ANSYS14 software simulations suggested joined glass experienced complicated and high residual stress levels due to big thermal expansion coefficient difference and bubble formation at the joining interface. The residual minimal principal stress levels were at the order of -400 MPa for joined glass at interface produced microcracking in glass starting from joined interface growing into glass layer.
4
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Effect of Welding Current on Mechanical Properties of Welding Joints in SPA-C Steel Sheets in Resistance Spot Welding

100%
Akkas N., Ilhan E.
Acta Physica Polonica A
|
2014
|
vol. 125
|
issue 2
497-499
EN
This paper presents an experimental study on resistance spot welding of SPA-C steel sheets used in side wall and roof in rail vehicles. SPA-C steel sheets having 2.3 mm thicknesses were joined by using resistance spot welding as lap joint. A timer and current controlled resistance spot welding machine having 120 kVA capacity and a pneumatic application mechanism with a single lever was used to prepare the specimens. Welding periods were chosen as 5, 10, 15, 20, 25, and 30 cycles and also welding currents were increased from 6 kA up to 14 kA by rise of 0.5 kA. The electrode force was kept constant at 6 kN. The prepared welding specimens were exposed to tensile-shear and tensile-peel tests and the obtained results were supported by diagrams and, finally, appropriate welding parameters were advised to the users.
5
Content available remote

Effect of Welding Current on Mechanical Properties of Welding Joints in S235JR(Cu) Steel Sheets in Resistance Spot Welding

100%
Akkas N., Varol F., Ferik E., Ilhan E., Ozsarac U., Aslanlar S.
Acta Physica Polonica A
|
2014
|
vol. 125
|
issue 2
500-502
EN
This paper presents an experimental study on resistance spot welding of S235JR(Cu) steel sheets used in side wall and roof in rail vehicles. S235JR(Cu) steel sheets having 2.0 mm thicknesses were joined by using resistance spot welding as lap joint. A timer and current controlled resistance spot welding machine having 120 kVA capacity and a pneumatic application mechanism with a single lever was used to prepare the specimens. Welding periods were chosen as 10, 15, 20, 25 and 30 cycles and also welding currents were increased from 6 kA up to 14 kA by rise of 1 kA. The electrode force was kept constant at 6 kN. The prepared welding specimens were exposed to tensile-shear and tensile-peel tests and the obtained results were supported by diagrams and, finally, appropriate welding parameters were advised to the users.
6
Content available remote

Welding Time Effect on Mechanical Properties in Resistance Spot Welding of S235JR(Cu) Steel Sheets Used in Railway Vehicles

100%
Akkaş N., İlhan E., Varol F., Aslanlar S.
Acta Physica Polonica A
|
2016
|
vol. 129
|
issue 4
541-543
EN
In this paper, S235JR(Cu) steel sheets were welded by electrical resistance spot welding method. Their thickness was 2 mm and joints were prepared in overlap joint form. A timer and current controlled resistance spot welding machine having 120 kVA capacity and a pneumatic application mechanism with a single lever was used to prepare the specimens. Welding periods were chosen as 5, 10, 15, 20, 25, and 30 periods and also welding currents were increased from 6 kA up to 14 kA by rise of 0.5 kA. The electrode force was kept constant at 6 kN. The obtained welding joints were exposed to tensile-peel and tensile-shear tests. As a result of these experiments, the maximum tensile-shear and tensile-peel strength are obtained in 30 period welding time for 8.5 kA welding current.
7
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Joining of Soda Lime Silicate Glass TO TI6AL4V Alloy in Air by Controlled Heat Treatments

100%
Telli M.
Acta Physica Polonica A
|
2015
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vol. 127
|
issue 4
972-975
EN
Soda lime silicate glass was joined to Ti6Al4V alloy in air by heat treatment at 800°C for 10, 20 and 30 min and by subsequent cooling to room temperature with a controlled cooling rate. Stresses, due to thermal expansion mismatch, have developed at glass-metal interface after high temperature joining and cooling down to room temperature. The finite element calculations, performed using ANSYS 14 software, suggested that the glass-metal interface was experiencing rather low maximal and minimal principal stresses due to joining. Highest maximal principal stress level was about 25 MPa and lowest minimal principal stress level was about -40 MPa for used sandwich sample profiles. Heat treatment duration affected tensile bonding strength and interfacial reaction between the glass and the Ti alloy. Scanning electron microscope analysis of glass-alloy joining interface showed that a secondary K, Ca, Ti rich sodium silicate phase was forming in glass, starting at glass alloy interface and that it was growing with the increase in heat treatment duration. Low joining stress levels at the glass-alloy interface for used sandwich sample profile and good bonding between the soda lime silicate glass and Ti6Al4V alloy resulted in creation of successful soda lime silicate glass-Ti6Al4V joints.
8
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A Study on Hardfacing Alloy Using Fe-Cr and Fe-B Powders

100%
Karip E., Aydin S., Muratoğlu M.
Acta Physica Polonica A
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2015
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vol. 128
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issue 2B
B-160-B-163
EN
The aim of this study is the investigation of the effect of ferroboron and ferrochromium with massive wire based hardfacing alloys. Mixture of Fe-Cr and Fe-B powders was added to massive wire during welding process. Hardface layers were obtained by three different powder mixture and three different powder/massive wire proportions. Hardfacing was applied to two AISI 1020 steel substrates by open arc welding. Hardness test, scanning electron microscope and X-ray diffraction analysis were made to the samples. Test results showed that increasing ferroboron content and increasing powder mixture amount enhanced the microhardness of the specimens.
9
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Application of Taguchi Method to Investigate the Effect of Nucleus Diameter on Mechanical Properties of Automotive Sheets in Electrical Resistance Spot Welding

100%
Savaş Ö.
Acta Physica Polonica A
|
2015
|
vol. 127
|
issue 4
921-924
EN
In this study, the effects of nucleus diameter on tensile-peel strength in electrical resistance spot welding were investigated. Taguchi design approach has been employed to the experimental planning, the L_{27}(3^{13}) orthogonal array. The larger-the-better and the nominal-the-best response criteria were selected to obtain the optimum conditions for nucleus diameter and tensile-peel strength, respectively. In addition, the effects of five parameters, electrode pressure, clamping time, welding current, welding time, and holding time, were examined in this way. Results showed that the tensile-peel strength was related with nucleus diameter, and that welding current and welding time were the most effective parameters for improvement of the strength of weld joints.
10
Content available remote

Soda Lime Silicate Glass-to-Titanium Joining by Controlled Heat Treatments in Air

100%
Telli M.
Acta Physica Polonica A
|
2017
|
vol. 131
|
issue 3
414-416
EN
Glass-to-metal joining is important for improving efficiencies of heat collecting units, employed in parabolic solar collecting systems. In this study, soda lime silicate glass was joined to titanium in air at 700, 800 and 900°C for 5 min by controlled heat treatments. Glass-to-titanium bonding was good and no delamination or macro cracking in glass was observed. During heat treatment, titanium is oxidized in air prior to the reaction with glass. The reaction between oxidized titanium and glass results in bubble formation at joining interface. Bubble formation was found to be decreased with decreasing joining temperature. Thermal stresses developed at glass-titanium junction were modeled by employing ANSYS 14 multiphysics simulation software. For the studied sample profile, soda lime silicate glass, close to the joining interface, experienced rather low residual stresses of the order of 10 MPa maximum and -40 MPa minimum principal stress levels. Good glass-to-titanium bonding and low thermal residual stress are mainly due to similar thermal expansion coefficients of these materials, which was found to be important for achieving successful joining in air.
11
Content available remote

Welding Time Effect of Welding Joints in Micro Alloyed and TRIP 800 Steels in Resistance Spot Welding

100%
Onar V., Aslanlar S.
Acta Physica Polonica A
|
2017
|
vol. 131
|
issue 3
389-391
EN
This paper presents an analysis of resistance spot welds between micro alloyed steel sheets having 1 mm thickness and TRIP 800 (transformation-induced plasticity) steel sheets having 1.5 mm. TRIP 800 steel and micro alloyed steel sheets are used in automobile chassis and automobile body parts, respectively. In this study, resistance spot-welding method was used for joining steel pairs to be lap joint. A time and current controlled resistance spot welding machine having 120 kVA capacity, and pneumatic application mechanism were used in the experiments. Specimens prepared for spot welding operations were joined with different welding time ranging from 5 to 30 periods (1 period = 0.02 s) and different weld currents, ranging from 8.5 to 16.5 kA in 0.5 kA steps. The electrode force was kept constant at 6 kN. Tensile-peel tests were applied to the welded specimens. The effect of welding time parameter on tensile-peel properties was analyzed. The highest tensile-peel load was obtained using 15 periods.
12
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Investigation of Mechanical Properties of Metal Inert Gas-Brazed TRIP800 Steel Joints Using Different Shielding Gas Flow Rate

100%
Akkas N., Varol F., Ferik E., Ilhan E., Ozsarac U., Aslanlar S.
Acta Physica Polonica A
|
2014
|
vol. 125
|
issue 2
473-474
EN
In this study, TRIP 800 (transformation induced plasticity) steel plates having 1.5 mm thickness were joined by copper-based (CuAl8) wire in gas metal arc brazing technique. Specimens were prepared in joining forms as butt joint. Brazing operations were done with five different shielding gas flow rates of 8, 10, 12, 14, and 16 L/min. CuAl8 wire composed mostly of copper serves as the filler metal. Having accomplished the brazing operations, tensile properties of joints were detected, and micro- and macrostructures of joints were investigated in order to see the joinability of TRIP 800 steel by gas metal arc brazing technique.
13
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The Effect of Welding Current on Nugget Sizes in Resistance Spot Welding of SPA-C Steel Sheets Used in Railway Vehicles

63%
Akkaş N., Ferik E., İlhan E., Aslanlar S.
Acta Physica Polonica A
|
2016
|
vol. 130
|
issue 1
142-144
EN
This paper presents an experimental study on resistance spot welding of SPA-C steel sheets used in side wall and roof in rail vehicles. SPA-C steel sheets having 2.3 mm thicknesses were joined by using resistance spot welding as lap joint. A timer and current controlled resistance spot welding machine having 120 kVA capacity and a pneumatic application mechanism with a single lever was used to prepare the specimens. Welding periods were chosen as 10, 15, 20, 25 and 30 periods and also welding currents were increased from 6 kA up to 11.5 kA by rise of 0.5 kA. The electrode force was kept constant at 6 kN. The nugget sizes of prepared welding specimens were calculated by means of an optical microscope and the obtained results were supported by diagrams and, finally, appropriate welding parameters were advised to the users.
14
Content available remote

Investigation of Mechanical Properties of Butt Joints of DP800 Thin Zinc-Coated Steel Plates, CMT-Brazed Using Different Current Intensities

63%
Acar İ., Sıksık V., Varol F., Aslanlar S.
Acta Physica Polonica A
|
2017
|
vol. 132
|
issue 3
849-851
EN
In this study, DP800 (dual phase) steel plates, having 1 mm thickness were joined by copper-based (CuAl8) wire using CMT-brazing (cold metal transfer) technique. Specimens were prepared in joining forms in butt joint configuration. CMT-brazing operations were done under nine different CMT-brazing current intensities of 40, 45, 50, 55, 60, 65, 70, 75 and 80 A. CuAl8 wire, composed largely of copper, was used as the filler metal. Having accomplished the CMT-brazing operations, the tensile properties of joints, and micro- and macro-structures of joints were investigated in order to test the joinability of DP800 steel by CMT-brazing technique.
15
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Welding Time Effect on Tensile-Shear Loading in Resistance Spot Welding of SPA-H Weathering Steel Sheets Used in Railway Vehicles

63%
Akkaş N.
Acta Physica Polonica A
|
2017
|
vol. 131
|
issue 1
52-54
EN
This paper presents an experimental study on the resistance spot welding of SPA-H weathering steel sheets used in side wall and roof application of rail vehicle bodies. A timer and current controlled resistance spot welding machine having 120 kVA capacity and a pneumatic application mechanism with a single lever were used to prepare the specimens. Welding periods were chosen as 10, 15, 20, 25, and 30 periods (1 period = 0.02 s) and also welding currents were increased from 6 kA up to 11 kA by rises of 0.5 kA. The electrode force was kept constant at 4 kN. The prepared welding specimens were exposed to tensile-shear test and the obtained results were supported by diagrams and, finally, appropriate welding parameters were advised to the users.
16
Content available remote

Weldability of CuZn30 Brass/DP600 Steel Couple by Friction Stir Spot Welding

63%
Barlas Z.
Acta Physica Polonica A
|
2017
|
vol. 132
|
issue 3
991-993
EN
This study deals with the weldability and assessment of the friction stir spot welding of dissimilar CuZn30 brass/DP600 steel couple. The effects of axial tool load and tool hold time were evaluated in the joining experiments. The tool load forces of 3.2-4.8 kN and the tool hold times of 8 s and 12 s were applied to brass/steel bimetal sheets. Tensile-shear test was employed to investigate the mechanical properties of the joint. Optical and scanning electron microscopies were utilized to characterize the microstructure of the joint having the better mechanical performance, as well as the microhardness test. Temperature measurements were also performed between the lapped sheet faces. The results show that the vertical tool load value has reached more significant influence than the tool hold time. Furthermore, the tensile-shear failure load has increased with increasing tool load and hold time and has reached the highest value of 4.6 kN. The EDS analyses on the fractured surface depict that the copper and zinc concentrations are similar to those of CuZn30 base metal. A peak temperature of 607°C was measured in the weld centre of this joint. No significant microstructural change was observed in the steel sheet, while the fine grains with onion rings were revealed in the brass. Different hardness values were measured depending on microstructural change in the weld zone. Although the onion rings made a contribution to the microhardness, a softened stir zone (129.8 HV), with regard to the brass base metal (149.1 HV), was observed.
17
Content available remote

The Effect of Nugget Sizes on Mechanical Properties in Resistance Spot Welding of S235JR(Cu) Steel Sheets Used in Railway Vehicles

63%
Akkaş N., Ferik E., İlhan E., Aslanlar S.
Acta Physica Polonica A
|
2016
|
vol. 130
|
issue 1
60-63
EN
This paper presents an experimental study on the resistance spot welding of S235JR(Cu) steel sheets used in side walls and roofs of rail vehicle bodies. A timer and current controlled resistance spot welding machine having 120 kVA capacity and a pneumatic application mechanism with a single lever were used to prepare the specimens. Welding duration was chosen to be 5, 10, 15, 20, 25 and 30 periods (1 period = 0.02 s) and also welding currents were increased from 6 kA up to 14 kA in steps of 0.5 kA. The electrode force was kept constant at 6 kN. The obtained welding joints were exposed to tensile peel and tensile shear tests and their nugget sizes were measured by means of an optical microscope. The effect of nugget sizes on tensile peel strength and tensile-shear strength was determined using weld lobe diagrams. Based on this data the optimum welding currents and times were advised.
18
Content available remote

Structural Studies of Welds in Wear-Resistant Steels

63%
Bramowicz M., Kulesza S., Lewalski P., Szatkowski J.
Acta Physica Polonica A
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2016
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vol. 130
|
issue 4
963-965
EN
The work presents results of the research on changes in microstructural, and mechanical properties of the structural XAR 400 wear-resistant steel caused by the welding procedure. Metallographic and microhardness studies revealed complex microstructure of the welds that turned out to vary with the distance from the weld axis: predominance of the acicular ferrite (ACF) structures in the weld itself, quasi-polygonal ferrite (QPF) crystals with precipitates of troostite (T) in the heat-affected zone, and the bainitic ferrite (BF) structures in the heat-partially-affected zone.
19
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The Influence of Tool Tilt Angle on 1050 Aluminum Lap Joint in Friction Stir Welding Process

63%
Barlas Z.
Acta Physica Polonica A
|
2017
|
vol. 132
|
issue 3
679-681
EN
In this paper, the effect of tool tilt angle on tensile-shear failure load and weld zone properties for 1050 aluminum plates, welded by friction stir lap welding, were investigated. For this purpose, tool tilt angle was varied from 0° to 5° under the constant other parameters, such as tool geometry, tool rotation speed of 1200 rpm and tool travel speed of 30 mm/min. The tensile-shear test was employed to test the mechanical properties of the joint. Optical microscope examinations, microhardness and temperature measurements were also performed in weld zone of lap joints. According to overall results, the tool tilt angle has a reasonable influence on the joint soundness and weld defect formation. If the tool axis was perpendicular to plate surface or a larger tool tilt angle was used, such configurations had harmful effect for the weld zone. In such case the tensile-shear failure load dropped from 4853 N to 2799 N. Recorded peak temperatures varied from 381°C to 438°C in the weld center. The measured mean hardness values of the stir and heat-affected zones were 31.5 HV and 28.3 HV, respectively, which are lower than that of aluminum 1050 base metal (40.7 HV).
20
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Investigation of Mechanical Properties of Microalloyed Steels Joined by GMAW and Electrical Arc Welding

51%
Ekici M., Ozsarac U.
Acta Physica Polonica A
|
2013
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vol. 123
|
issue 2
289-290
EN
In this study, micro-alloyed steel samples were exposed to gas metal arc welding process by two welding wires coded ER100 SG and SG 3. Protection gases compositions were selected as 100% argon (Ar), 15% CO_2 + 85% argon (MIG/MAG-1) and 25% CO_2 + 75% argon (MIG/MAG-2) in three different types in order to investigate the CO_2 effect on mechanical properties. In addition, an electric arc welding electrode coded Fox EV 85 was selected for arc welding applications to research the effect of welding method in mechanical properties. Welded joint were prepared at 130 A, 20 V; 150 A, 22 V and 170 A, 24 V welding parameters. All welded joint specimens were exposed to tensile tests, Charpy impact tests to evaluate the yields strength, maximum tensile stress, fracture stress, % elongation values and ductile-to-brittle transition temperatures values. Micro and macrostructure photos and scanning electron microscopy micrographs of specimens were obtained. The optimum parameters were advised to users at the end of this study.
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