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Dissimilar Arc Stud Welding AISI 304/AISI 1008:mechanical Properties

The document summarizes a study on the mechanical properties of dissimilar arc stud welds between AISI 304 and AISI 1008 steel. Experimental welding was conducted with varying current (200-800 AMP) and time (0.2-0.35 sec). Bending and torque tests found the highest strength occurred at 600 AMP and 0.3 sec, producing a torque of 90 Nm. Statistical analysis identified welding time as most influential on weld quality. The conclusions recommend properly selecting current and time to achieve good penetration and weld quality.

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60 views16 pages

Dissimilar Arc Stud Welding AISI 304/AISI 1008:mechanical Properties

The document summarizes a study on the mechanical properties of dissimilar arc stud welds between AISI 304 and AISI 1008 steel. Experimental welding was conducted with varying current (200-800 AMP) and time (0.2-0.35 sec). Bending and torque tests found the highest strength occurred at 600 AMP and 0.3 sec, producing a torque of 90 Nm. Statistical analysis identified welding time as most influential on weld quality. The conclusions recommend properly selecting current and time to achieve good penetration and weld quality.

Uploaded by

Mary marten
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Dissimilar Arc Stud Welding AISI

304/AISI 1008:Mechanical Properties

Asst.Prof. Muzher T.
Firas H.HAJIM
Mohamed

Asst.Prof. Sami A.
Asst.Prof. Jabbar Gattmah
Nawi
Introduction
PRESENTATION Material properties
OUTLINE
Experimental
procedure

Results & Discussions

Conclusions
Introduction
• Arc Stud Welding (ASW) process is generally used for joining fasteners or studs with base
metal . It is widely used in different industries and production areas such as steam boiler
production, bridge, automotive industries …..etc.
• The importance of this study to choose welding parameters (current and time) to produce a good
weld
• The study aims to correlate arc stud welding parameters with the mechanical properties of the
weldments using the bending and torque test.
• The difference between the previous studies and this research is to select welding parameters to
solve problem of tank of transformer produced by general Diyala company.
Material properties
AISI 304 and AISI 1008 were selected as materials of partially threaded studs with
a diameter 10 mm and thickness 6 mm respectively. The chemical composition and
mechanical properties of the materials are put in Tables 1 and 2 respectively
Table 1. Chemical composition of AISI 304 and AISI 1008

Ni Cr S P Mn Si C %Element

8-11 18-20 0.03 0.045 2 1 0.08 AISI 304


--- ---- 0.05 0.04 0.3-0.5 ---- 1 AISI 1008
Table 2. Mechanical properties of AISI 304 and AISI 1008

Percent elongation Yield strength Tensile strength Material type


30% 205 MPa 515 MPa AISI 304

30% MPa 170 MPa 305 AISI 1008


Experimental procedure

For obtaining a high quality for the weld joint, careful attention is important to
select the process parameters and their levels, , two parameters with four different
levels were considered. Arc stud welding machine Dabotek type DT 1000 was used
to join the studs to plates as shown in Fig.1.

Pistol

Figure 1. (DABOTEK) Arc stud welding DT (1000)


To analyze S/N ratio, all data were obtained and fed as input into the design expert. Then, the
value of S/N ratio was used to estimate which any parameter was more statistically significant.
Also, the level of the parameter was identified to show better data quality that represents optimum
parameters values. Table 3 depicts the value of welding parameters and corresponding levels. The
array is with type of (42) and the magnitudes design experiment according to Taguchi approach is
shown in Table 4

Table 3. Stud welding parameters and corresponding levels


4 3 2 1 level

800 800 800 800 600 600 600 600 400 400 400 400 200 200 200 200 Current AMP

0.3 0.3 0.25 0.2 0.35 0.3 0.25 0.2 0.35 0.3 0.25 0.2 0.35 0.3 0.25 0.2 Time Second
Table 4. L16(42) orthogonal array for the stud welding parameters
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 .No
4 4 4 4 3 3 3 3 2 2 2 2 1 1 1 1 Time Second
4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 Current AMP

In order to perform the bending and the torque test, sixteen different
experiments were carried out according of design of experiment layout. Welding
parameters that employed for welding are 200,400, 600, and 800 AMP while
welding time represents 0.2, 0.25, 0.3, and 0.35 second. The bending test was
conducted by the torque wrench to test the samples until the stud bend 30° away
from its axis Fig(2).
Figure 2. Bending test

In the torque test, the stud should be torqued till a pre-specified load is attained or
until the stud fails, and failure occurs in the stud material itself on the thin plate,
then the plug of base metal should be torn out. Fig. 3 presents the torque test with a
simple tensile load to straight-threaded studs.

Figure 3. Torque test


Results and Discussion
1- Bending test results
.
Table 5. Bending test results

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

800 800 800 800 600 600 600 600 400 400 400 400 200 200 200 200 Current AMP

0.35 0.3 0.25 0.2 0.35 0.3 0.25 0.2 0.35 0.3 0.25 0.2 0.35 0.3 0.25 0.2 Time Second

Failure weld No. Weld zone No. Weld zone No. Weld zone Failure weld Fracture location
fract fract fract

-------- pass Failed pass Failed pass Failed ---------- Assessment


2-Torque test results

• Minimum torsional stress of 32 N.m according to the ISO 3506-1,2009


• At current 400 AMP the torque value 35.5 N.m at time 0.2 second and raises to
75 N.m at 0.3 second
• At current 600 AMP the torque is 50 N.m at time 0.2 second and increased to 90
N.m at time 0.3 second
• At current 800 AMP torque is 39 N.m at time 0.2 second
Figure 4. Torque strength and welding current

100

90

80

70

60
Torque (N.m)

50
0.2
40 0.25
0.3
30
0.35
20
MTS
10

0
400 600 800

Welding current(AMP)
3 -Design of experimental (DOE) Taguchi method

• The lowest value of SN ratio gives better data quality as compared


with other levels, After the preparation for stud welding, the
statistical approach of Taguchi was utilized to choose the optimum
condition for stud welding of dissimilar material, The highest value
of torque equals to 90 N.m at 600 AMP and 0.3 Second were chosen
from SN ratio at the best one as illustrated in Fig. 5.
Figure 5. SN ratio and mean torque
Conclusion
 Welding time is the most important parameter in arc stud welding followed by
welding current, proper welding time produces a good weld penetration.

 To get good weld quality both the current and time for the welding must be
chosen properly according to each other.

 The highest value of torque strength was evaluated at 600 AMP and 0.3 second
that reduce with high welding parameters.

 All the fractures in bending tests were noticed in weld zone.

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