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Dissimilar welding has been subject of several investigations due to its potential importance in various industrial fields such as transportation, energy generation and management. Dissimilar welding can increase the design efficiency, by the use of complementary alloys with different properties, cost cutting and light weighting structures. The use of different materials within a component or structure to best suit a particular task, requirement or increase its life and performance has always been an ambition of several designers and engineers. This project investigated the joining steel and aluminium for the automotive industry and also stainless steel and titanium to be applied in the civil nuclear energy generation industry. These dissimilar metallic combinations are metallurgically incompatible and the formation of brittle intermetallic phases (IMC) need to be controlled or eliminated. To join steel to Al, laser spot welding process was selected, to avoid the bulk melting of steel and Al at the joint interface that enhance the formation of brittle IMC. This part of the work was focused in controlling the joining process to control the IMC formation of galvanized and uncoated steel to Al and verify if it was possible to have a sound and reliable joint in the presence of an IMC layer. In the second part of this study, stainless steel to titanium joining, a different approach was taken with the application of weld metal engineering to modify or eliminate the IMC formation. Several metals were evaluated as potential interlayers to use and laser welding with a Ni interlayer was evaluated with moderate success, due to the modified IMC with improved mechanical properties and the good compatibility between Ni and the stainless steel. A further improvement was achieved when Cu was brazed between stainless steel and Ti using CMT (Cold Metal Transfer) a low heat input MIG process. The final attempt was to use a different interlayer that was 3D printed and deposited in several layers. This interlayer was composed Cu and Nb that were selected as candidates to avoid the IMC formation between the stainless steel and Ti. With this approach it was possible to build an IMC free component and possibly improve and avoid IMC formation in several other dissimilar metallic combinations.

Submitted by DANIEL FERNANDO DA SILVA null (danielprofessorengemec@gmail.com) on 2018-01-04T13:41:19Z No. of bitstreams: 1 Dissertação - Daniel Fernando - versão final.pdf: 4270080 bytes, checksum: a1076d940ede22de07f7319dd405f059 (MD5) / Approved for entry into archive by Cristina Alexandra de Godoy null (cristina@adm.feis.unesp.br) on 2018-01-04T17:07:06Z (GMT) No. of bitstreams: 1 silva_df_me_ilha.pdf: 4270080 bytes, checksum: a1076d940ede22de07f7319dd405f059 (MD5) / Made available in DSpace on 2018-01-04T17:07:06Z (GMT). No. of bitstreams: 1 silva_df_me_ilha.pdf: 4270080 bytes, checksum: a1076d940ede22de07f7319dd405f059 (MD5) Previous issue date: 2017-07-07 / O presente trabalho estudou a influência do aporte térmico do processo de soldagem GTAW automatizado nas propriedades mecânicas do aço inoxidável austenítico AISI 316L. Esse aço é amplamente utilizado na indústria alimentícia e de petróleo e gás, por ser muito resistente a corrosão. Utilizou-se chapas de 1,0 mm de espessura, soldadas por junta de topo sem chanfro. Os parâmetros de soldagem foram selecionados e ajustados através de pré-testes, pois existem poucas fontes de pesquisa sobre a soldagem de chapas finas de aço inoxidável. Para analisar a influência da variação do aporte térmico, variou-se a velocidade de soldagem na faixa de 375 a 500 mm/min, com incremento de 25 mm/min. O processo de soldagem foi autógeno. Foram realizadas análises macrográficas para avaliar a largura e profundidade do cordão de solda. Foram realizados também ensaios mecânicos de microdureza Vickers e ensaios de tração para avaliar as propriedades mecânicas do cordão de solda formado. Os valores encontrados nestes ensaios foram comparados com o aporte térmico de soldagem, para avaliar a influência do mesmo nas propriedades mecânicas da junta de solda. Os resultados obtidos com os ensaios descritos, mostraram que o controle da energia de soldagem, ou seja, do aporte térmico é essencial na soldagem de chapas finas de aço inoxidável austenítico AISI 316L, gerando juntas de solda livres de descontinuidades e com propriedades mecânicas próximas ao do metal puro. / The present research studied the influence of the thermal input of the automated GTAW welding process on the mechanical properties of AISI 316L austenitic stainless steel. This steel is widely used in the food and oil and gas industry because it is very resistant to corrosion. Panels of 1.0 mm thickness were used, welded by a non-chamfered top joint. The welding parameters were selected and adjusted through pre-tests, as there are few sources of research on the welding of stainless steel thin sheets. In order to analyze the influence of the variation of the thermal input, the welding speed was varied in the range of 375 to 500 mm / min, with an increase of 25 mm / min. The welding process was autogenous. Macrographic analyzes were performed to evaluate the width and depth of the weld bead. Mechanical tests of Vickers microhardness and tensile tests were also performed to evaluate the mechanical properties of the weld bead formed. The values found in these tests were compared with the thermal input of welding, to evaluate the influence of the same on the mechanical properties of the weld joint. The results obtained with the described tests showed that the control of the welding energy, that is, of the thermal input is essential in the welding of thin sheets of AISI 316L austenitic stainless steel, generating solder joints free of discontinuities and with mechanical properties close to the of the pure metal.

Orientador: Vicente Afonso Ventrella / Resumo: O presente trabalho estudou a influência do aporte térmico do processo de soldagem GTAW automatizado nas propriedades mecânicas do aço inoxidável austenítico AISI 316L. Esse aço é amplamente utilizado na indústria alimentícia e de petróleo e gás, por ser muito resistente a corrosão. Utilizou-se chapas de 1,0 mm de espessura, soldadas por junta de topo sem chanfro. Os parâmetros de soldagem foram selecionados e ajustados através de pré-testes, pois existem poucas fontes de pesquisa sobre a soldagem de chapas finas de aço inoxidável. Para analisar a influência da variação do aporte térmico, variou-se a velocidade de soldagem na faixa de 375 a 500 mm/min, com incremento de 25 mm/min. O processo de soldagem foi autógeno. Foram realizadas análises macrográficas para avaliar a largura e profundidade do cordão de solda. Foram realizados também ensaios mecânicos de microdureza Vickers e ensaios de tração para avaliar as propriedades mecânicas do cordão de solda formado. Os valores encontrados nestes ensaios foram comparados com o aporte térmico de soldagem, para avaliar a influência do mesmo nas propriedades mecânicas da junta de solda. Os resultados obtidos com os ensaios descritos, mostraram que o controle da energia de soldagem, ou seja, do aporte térmico é essencial na soldagem de chapas finas de aço inoxidável austenítico AISI 316L, gerando juntas de solda livres de descontinuidades e com propriedades mecânicas próximas ao do metal puro. / Abstract: The present research studied the influence of the thermal input of the automated GTAW welding process on the mechanical properties of AISI 316L austenitic stainless steel. This steel is widely used in the food and oil and gas industry because it is very resistant to corrosion. Panels of 1.0 mm thickness were used, welded by a non-chamfered top joint. The welding parameters were selected and adjusted through pre-tests, as there are few sources of research on the welding of stainless steel thin sheets. In order to analyze the influence of the variation of the thermal input, the welding speed was varied in the range of 375 to 500 mm / min, with an increase of 25 mm / min. The welding process was autogenous. Macrographic analyzes were performed to evaluate the width and depth of the weld bead. Mechanical tests of Vickers microhardness and tensile tests were also performed to evaluate the mechanical properties of the weld bead formed. The values found in these tests were compared with the thermal input of welding, to evaluate the influence of the same on the mechanical properties of the weld joint. The results obtained with the described tests showed that the control of the welding energy, that is, of the thermal input is essential in the welding of thin sheets of AISI 316L austenitic stainless steel, generating solder joints free of discontinuities and with mechanical properties close to the of the pure metal. / Mestre

O objetivo deste trabalho é analisar a influência dos parâmetros de um sistema mecanizado de soldagem, composto por uma tocha TIG e outra MAG em tandem, sobre a geometria do cordão de solda resultante. Os resultados obtidos foram comparados com soldas realizadas pelos processos TIG e MAG operando isoladamente. Os testes foram executados por meio de simples deposição de cordões sobre chapas de aço ao carbono AISI 1010 com espessura de 6,3 mm. Os parâmetros analisados foram: corrente de soldagem e distância da ponta do eletrodo até a peça no processo TIG, velocidade de alimentação de arame e tensão do arco no processo MAG, além de velocidade de soldagem e distância entre as tochas. Os cordões de solda foram executados em um dispositivo de soldagem mecanizado, que permite a variação da velocidade de soldagem, distância da ponta do eletrodo TIG e a distância entre as tochas. Os ajustes de corrente e tensão de soldagem foram feitos em duas fontes de potência separadas, ambas do tipo transformador-retificador, uma para cada tocha, devido às diferentes curvas características de cada processo. Através do projeto de experimento fatorial fracionado, foram avaliados os efeitos de dois níveis, um mínimo e outro máximo, mais quatro réplicas dos seus níveis intermediários, resultando em 20 experimentos para cada processo de soldagem. Os valores dos resultados finais indicam uma diferença ao utilizar uma tocha TIG para pré-aquecer o material base, porém, estatisticamente, essa diferença não é significativa entre os processos TIG e MAG em tandem e MAG convencional para a faixa de parâmetros de soldagem adotada. / This study aims to investigate the influence of process parameters of a mechanized welding system, comprising a GTAW torch and a GMAW torch in tandem configuration, on the geometry of the resulting weld bead, performed using GTAW and GMAW welding processes in tandem. The results were compared with weld beads performed by conventional GTAW and GMAW welding processes. The tests were conducted performing bead-on-plate deposits over AISI 1010 6,3 mm thick carbon steel plates. GTAW current, GMAW wire feed speed, GTAW arc length, GMAW voltage, welding speed and the distance between GTAW and GMAW torches were the analyzed parameters. The weld beads were performed in a mechanized welding bench, which allows the variation of speed, distance between torches and arc length of the GTAW torch. Current and voltage adjustments were made in two separate transformer-rectifier power sources, one for each welding torch, due to their different characteristic curves of each process. Through the fractional factorial design of experiment, the effects of two different levels for each parameter were analyzed, plus four replicates of the average values of these levels, resulting in 20 experiments for each welding process. The results show a difference on the weld bead geometry using a GTAW torch to preheat the base metal, however, this difference is not statistically significant between GTAW and GMAW welding process in tandem and GMAW welding process for the adopted range of welding parameters.

O objetivo deste trabalho é analisar a influência dos parâmetros de um sistema mecanizado de soldagem, composto por uma tocha TIG e outra MAG em tandem, sobre a geometria do cordão de solda resultante. Os resultados obtidos foram comparados com soldas realizadas pelos processos TIG e MAG operando isoladamente. Os testes foram executados por meio de simples deposição de cordões sobre chapas de aço ao carbono AISI 1010 com espessura de 6,3 mm. Os parâmetros analisados foram: corrente de soldagem e distância da ponta do eletrodo até a peça no processo TIG, velocidade de alimentação de arame e tensão do arco no processo MAG, além de velocidade de soldagem e distância entre as tochas. Os cordões de solda foram executados em um dispositivo de soldagem mecanizado, que permite a variação da velocidade de soldagem, distância da ponta do eletrodo TIG e a distância entre as tochas. Os ajustes de corrente e tensão de soldagem foram feitos em duas fontes de potência separadas, ambas do tipo transformador-retificador, uma para cada tocha, devido às diferentes curvas características de cada processo. Através do projeto de experimento fatorial fracionado, foram avaliados os efeitos de dois níveis, um mínimo e outro máximo, mais quatro réplicas dos seus níveis intermediários, resultando em 20 experimentos para cada processo de soldagem. Os valores dos resultados finais indicam uma diferença ao utilizar uma tocha TIG para pré-aquecer o material base, porém, estatisticamente, essa diferença não é significativa entre os processos TIG e MAG em tandem e MAG convencional para a faixa de parâmetros de soldagem adotada. / This study aims to investigate the influence of process parameters of a mechanized welding system, comprising a GTAW torch and a GMAW torch in tandem configuration, on the geometry of the resulting weld bead, performed using GTAW and GMAW welding processes in tandem. The results were compared with weld beads performed by conventional GTAW and GMAW welding processes. The tests were conducted performing bead-on-plate deposits over AISI 1010 6,3 mm thick carbon steel plates. GTAW current, GMAW wire feed speed, GTAW arc length, GMAW voltage, welding speed and the distance between GTAW and GMAW torches were the analyzed parameters. The weld beads were performed in a mechanized welding bench, which allows the variation of speed, distance between torches and arc length of the GTAW torch. Current and voltage adjustments were made in two separate transformer-rectifier power sources, one for each welding torch, due to their different characteristic curves of each process. Through the fractional factorial design of experiment, the effects of two different levels for each parameter were analyzed, plus four replicates of the average values of these levels, resulting in 20 experiments for each welding process. The results show a difference on the weld bead geometry using a GTAW torch to preheat the base metal, however, this difference is not statistically significant between GTAW and GMAW welding process in tandem and GMAW welding process for the adopted range of welding parameters.

O objetivo deste trabalho é analisar a influência dos parâmetros de um sistema mecanizado de soldagem, composto por uma tocha TIG e outra MAG em tandem, sobre a geometria do cordão de solda resultante. Os resultados obtidos foram comparados com soldas realizadas pelos processos TIG e MAG operando isoladamente. Os testes foram executados por meio de simples deposição de cordões sobre chapas de aço ao carbono AISI 1010 com espessura de 6,3 mm. Os parâmetros analisados foram: corrente de soldagem e distância da ponta do eletrodo até a peça no processo TIG, velocidade de alimentação de arame e tensão do arco no processo MAG, além de velocidade de soldagem e distância entre as tochas. Os cordões de solda foram executados em um dispositivo de soldagem mecanizado, que permite a variação da velocidade de soldagem, distância da ponta do eletrodo TIG e a distância entre as tochas. Os ajustes de corrente e tensão de soldagem foram feitos em duas fontes de potência separadas, ambas do tipo transformador-retificador, uma para cada tocha, devido às diferentes curvas características de cada processo. Através do projeto de experimento fatorial fracionado, foram avaliados os efeitos de dois níveis, um mínimo e outro máximo, mais quatro réplicas dos seus níveis intermediários, resultando em 20 experimentos para cada processo de soldagem. Os valores dos resultados finais indicam uma diferença ao utilizar uma tocha TIG para pré-aquecer o material base, porém, estatisticamente, essa diferença não é significativa entre os processos TIG e MAG em tandem e MAG convencional para a faixa de parâmetros de soldagem adotada. / This study aims to investigate the influence of process parameters of a mechanized welding system, comprising a GTAW torch and a GMAW torch in tandem configuration, on the geometry of the resulting weld bead, performed using GTAW and GMAW welding processes in tandem. The results were compared with weld beads performed by conventional GTAW and GMAW welding processes. The tests were conducted performing bead-on-plate deposits over AISI 1010 6,3 mm thick carbon steel plates. GTAW current, GMAW wire feed speed, GTAW arc length, GMAW voltage, welding speed and the distance between GTAW and GMAW torches were the analyzed parameters. The weld beads were performed in a mechanized welding bench, which allows the variation of speed, distance between torches and arc length of the GTAW torch. Current and voltage adjustments were made in two separate transformer-rectifier power sources, one for each welding torch, due to their different characteristic curves of each process. Through the fractional factorial design of experiment, the effects of two different levels for each parameter were analyzed, plus four replicates of the average values of these levels, resulting in 20 experiments for each welding process. The results show a difference on the weld bead geometry using a GTAW torch to preheat the base metal, however, this difference is not statistically significant between GTAW and GMAW welding process in tandem and GMAW welding process for the adopted range of welding parameters.

In gas tungsten arc welding (GTAW), weld pool surface contains crucial information for welding development. In this research, simulate skilled welders to control the welding process and determine the penetration stages based on the weld pool reaction. This study focuses on solving the uncertainty of the liquid weld pool in joint bases. The weld pool penetration process is highly depending on how the weld pool surface shape. To observe the weld pool, reflect the weld pool surface by the laser and image on the shield glass. The experiments show that the penetration can’t be determine by the reflecting grayness due to the variability of base metal. To control the joint bases diversity, fed a tip of the wire after the arc is established. Crate the new pattern of the weld pool penetration. Experiments verified the feasibility of this method.

The surface of the weld pool contains information that can be exploited to emulate a skilled human welder to better understand and control the welding process. Of the existing techniques, the method that uses the pool's specular nature to an advantage and which is relatively more cost effective, and suitable for welding environment is the one that utilizes reflected images to reconstruct 3D weld pool surface by using structured light and image processing techniques. In this thesis, an improvement has been made to the existing method by changing welding direction to obtain a denser reflected dot-matrix pattern allowing more accurate surface measurement. Then, the reflected images, obtained by capturing the reflection of a structured laser dot-matrix pattern from the pool surface through a high-speed camera with a narrow band-pass filter, are processed by a newly proposed algorithm to find the position of each reflected dot relative to its actual projection dot. This is a complicated process owing to the increased density of dots and noise induced due to the harsh environment. The obtained correspondence map may later be used by a surface reconstruction algorithm to derive the three-dimensional pool surface based on the reflection law.

No description available.