La simulation numérique du soudage peut être améliorée par une meilleure connaissance des propriétés thermophysiques des métaux à l’état liquide. Un approfondissement de cette connaissance requiert un dispositif capable de conditionner ces métaux à de très hautes températures en vue de les caractériser. Après un état de l’art sur les techniques de caractérisation adaptées à ces échelles de températures (chapitre 1), ce manuscrit détaille les travaux, principalement expérimentaux, dédiés aux développements d’un dispositif capable d’élever des métaux jusqu’à 2 500 °C (chapitres 3 et 4) et d’un pyromètre à cinq longueurs d’onde pour mesurer cette température (chapitres 2, 4 et 5). Le dispositif chauffe par induction une tour en graphite, le creuset étant placé en son centre, et a été dimensionné via une simulation magnéto-thermique 2D axisymétrique à l’aide du logiciel Comsol Multiphysics®. Parallèlement, le pyromètre a été développé dans le but de mesurer simultanément la température et l’émissivité. En l’absence de corps noir à hautes températures, plusieurs expériences ont été menées pour étalonner ce dernier ; elles ont été basées sur la mesure de la température de fusion/solidification de corps purs. En fonction de leur tenue et pour couvrir la plus large gamme de température possible, les métaux choisis sont le fer, le chrome, ou encore le niobium. Les expériences ont montré l’efficacité du pyromètre et la capacité maximale du dispositif hautes températures lors de la fusion du niobium à environ 2 500 °C. Enfin, le pyromètre a été utilisé lors d’une opération de soudage à l’arc, au cours de laquelle la température a été estimée sur une gamme de 1 000°C – 2 500°C. / Welding simulation can be improved by a better knowledge of molten metals thermophysical properties. This improvement requires characterization using a very high temperature apparatus. After portraying a state of the art on characterization technics adapted to this temperature range (chapter 1), this manuscript details works, principally experimental, dedicated to the developments of a device able to heat metals up to 2 500 °C (chapters 3 and 4) and of a five wavelengths pyrometer in order to measure this temperature (chapters 2, 4 and 5). The device heats by induction a graphite tower, the crucible being placed at its center, and has been dimensioned by a magneto-thermal 2D axisymmetric simulation using the Comsol Multiphysics® software. In parallel, the pyrometer has been developed in order to measure both temperature and emissivity. In the absence of a high temperature blackbody, several experiments were carried out for the calibration of it; they were based on the use of the luminance of pure metals at their melting point. In order to cover the largest temperature range possible, chosen metals were iron, chromium, and even niobium. These experiments showed the efficiency of the pyrometer and the maximal ability of the high temperature device during the niobium melting around 2 500 °C. Finally, the pyrometer has been used on an arc welding process, in which temperature has been evaluated over a 1 000 °C – 2 500 °C temperature range.

This thesis discusses on results of experiments carried outwith austenitic, duplex and super duplex stainless steels andTi-6Al-4V. In these it has been seen that the heat cycle duringwelding or weld simulation has a great effect on the propertiesof thematerials. The properties are related to the resultedgrain size after processing, as well as, to the chemicalcomposition of the material. The thesis discusses on the grainsize resulted after hot processing and how the properties areinfluenced by it. Also, it has been seen how large grain sizeinfluences the fracture toughness of the duplex stainlesssteel. The CTOD values become so low that an alternativeproduction method should be used instead of casting. The thesisdescribes the behavior of grain size in the hot processing ofTi-6Al-4V and impact toughness resulted by various weldingprocesses. The thesis shows correlation between grain growthbehavior of metallurgically different materials, i.e. duplexstainless steel, Ti-6Al-4V and quenced and tempered low alloysteel. Keywords:Stainless steel, Duplex Stainless Steel,Titanium Grade 5, Ti-6Al-4V microstructure, mechanicalproperties, welding, welding simulation / <p>QCR 20161026</p>

<p>This thesis discusses on results of experiments carried outwith austenitic, duplex and super duplex stainless steels andTi-6Al-4V. In these it has been seen that the heat cycle duringwelding or weld simulation has a great effect on the propertiesof thematerials. The properties are related to the resultedgrain size after processing, as well as, to the chemicalcomposition of the material. The thesis discusses on the grainsize resulted after hot processing and how the properties areinfluenced by it. Also, it has been seen how large grain sizeinfluences the fracture toughness of the duplex stainlesssteel. The CTOD values become so low that an alternativeproduction method should be used instead of casting. The thesisdescribes the behavior of grain size in the hot processing ofTi-6Al-4V and impact toughness resulted by various weldingprocesses. The thesis shows correlation between grain growthbehavior of metallurgically different materials, i.e. duplexstainless steel, Ti-6Al-4V and quenced and tempered low alloysteel.</p><p><b>Keywords:</b>Stainless steel, Duplex Stainless Steel,Titanium Grade 5, Ti-6Al-4V microstructure, mechanicalproperties, welding, welding simulation</p>

This diploma thesis is focused on the design of a robotic workplace for arc welding and its subsequent virtual commissioning. The summary deals with knowledge from industrial robotics and arc welding, the system analysis is focused on the composition of the workplace and the principle of arc welding, including acting influences. In the practical part, several variants of the solution are proposed, the most suitable variant is processed in the form of a 3D model. This model is then simulated, including all processes, a control program is created, and virtual commissioning of the workplace is demonstrated.

This doctoral thesis is concerned with fatigue life of welded structures. Several topics related to fatigue of welded structures are treated such as; weld defects and their influence on fatigue performance of welded structures, fatigue life prediction using LEFM (Linear Elastic Fracture Mechanics), fatigue testing, welding simulation, residual stress prediction and measurement and their influence on fatigue life. The work that is reported in this doctoral thesis is part results of the Nordic R&amp;D project QFAB (Quality and Cost of Fabricated Advanced Welded Structures) and the Swedish R&amp;D project LOST (Light Optimized Welded Structures). One of the main objectives is to compare different welding processes for the fatigue performance, weld quality and gain understanding of the weld defects, their appearance in different welding processes and their effect on fatigue life. Another main objective is to study welding residual stresses and their effect on fatigue. The design rules are in some cases conservative and especially on the weld root sides the knowledge about the residual stress field may improve the life prediction. The aim is to develop simplified procedures for analysis of residual stresses, their relaxation and influence on fatigue life. Fatigue testing of Hybrid Nd: YAG laser/MAG and MAG welded (tandem arc solid wire, flux cored wire, tandem flux cored wire) non-load carrying cruciform joints was carried out. Four batches were produced, tested and the results were compared. The local weld geometry of the cruciform welded joints was measured and analyzed. Residual stress measurement was carried out close to the toe region using X-ray diffraction. Weld defects, in most cases cold laps, in the cracked specimens were measured. Further fatigue testing, weld defect assessment and residual stress and local weld geometry measurements were carried out on joints welded with flux cored and metal cored arc wires. Two-and three dimensional LEFM crack growth analysis were carried out in order to predict the influence of weld defects, local weld geometry and residual stresses. Residual stresses in multi-pass welded tube-to-plates were studied for two different tubular joint configurations; a three-pass single-U weld groove for maximum weld penetration and a two-pass fillet (no groove) welded tube-to-plates for minimum weld penetration. Torsion fatigue tests were performed in order to study crack propagation from the weld root. Mode III propagation from the lower and upper weld toe on the same tubular joints was also studied. Some tubes were stress relieved (PWHT) and some were fatigue tested with internal static pressure. A three dimensional finite element welding simulation of the multi-pass welded tubular joint was carried out. The calculated temperatures in the transient thermal analysis were compared with measured temperatures. The FE predicted residual stresses in the as-welded conditions were verified with hole drilling strain gage measurements. The residual stresses were used as internal stresses in the finite element model for the torsion fatigue simulation in order to study the cycle by cycle relaxation of the residual stresses in constant amplitude torsion loading. A two dimensional finite element welding simulation procedure was developed in order to predict welding residual stress. The predicted residual stresses were used together with a developed 2D LEFM subroutine to predict the fatigue life, crack path and the effect of residual stresses on weld root defects. The developed simulation subroutines were validated with results found in the literature. Residual stresses measurement, two-and three dimensional welding simulations were carried out in fillet welded joints in order to study the three dimensional effects of the welding process, boundary conditions and modelling technique on the formation of residual stresses. / QC 20100706

Arc welding still requires deeper process understanding and more accurateprediction of the heat transferred to the base metal. This can be provided by CFD modelling.Most works done to model arc discharge using CFD consider the arc corealone. Arc core simulation requires applying extrapolated experimental data asboundary conditions on the electrodes. This limits the applicability. To become independent of experimental input the electrodes need to be included in the arcmodel. The most critical part is then the interface layer between the electrodesand the arc core. This interface is complex and non-uniform, with specific physicalphenomena.The present work reviews the concepts of plasma and arc discharges that areuseful for this problem. The main sub-regions of the model are described, andtheir dominant physical roles are discussed.The coupled arc-electrode model is developed in different steps. First couplingsolid and fluid regions for a simpler problem without complex couplinginterface. This is applied to a laser welding problem using the CFD softwareOpenFOAM. The second step is the modelling of the interface layer betweencathode and arc, or cathode layer. Different modelling approaches available inthe literature are studied to determine their advantages and drawbacks. One ofthem developed by Cayla is used and further improved so as to satisfy the basicprinciples of charge and energy conservation in the different regions of thecathode layer. A numerical procedure is presented. The model, implementedin MATLAB, is tested for different arc core and cathode conditions. The maincharacteristics calculated with the interface layer model are in good agreementwith the reference literature. The future step will be the implementation of theinterface layer model in OpenFOAM.

Es wird ein Überblick über die Bedeutung des Übergangswiderstandes beim Pressschweißen, sowie dessen physikalische Ursachen gegeben. Ausgewählte etablierte und neuere Ansätze der mathematischen Beschreibung des Übergangswiderstandes und deren Charakteristika werden dargestellt und charakterisiert. Im Vergleich wird der empirische Ansatz des KMK-Modells des Übergangswiderstandes dargestellt und dessen Implementierung in das FEM- Programmsystem erläutert. Ein Anwendungsbeispiel belegt die Qualität der mit dem Modell durchführbaren Simulationen, und zeigt daraus resultierende vertiefte Bewertungsmöglichkeiten des Schweißvorganges auf.

This master thesis was carried out at Scania CV AB. The focus for this thesis is the prediction of welding distortions that can cause problems in the manufacturing process of Scania's after-treatment system. The after-treatment system is mainly assembled by sheet metal plates of the ferritic stainless steel EN 1.4509. The plates are welded together. When welding, distortions and residual stresses occur, and they also depend on the sequence in the component was welded together. The distortions and residual stresses can cause tolerance related issues and a lower lifetime for the welded components. Experiments are expensive and therefore it is desirable to simulate the welding process, thereby controlling distortions and optimizing welding sequences. To simulate the welding process and predict the welding distortions a thermo-mechanical FE-model was created for two typical welds found on the after-treatment system. The first scenario was two thin plates welded onto each other in an overlap weld joint and the second scenario was a thin plate welded onto a thick plate in a overlap weld joint. After the FE-model was compared to the experiments. An optimization of the welding sequences was also made on a larger component typically found on the after-treatment system. The FE-model can predict the distortion shape with good accuracy for the T-fillet weld, while the model predicted a more symmetric distortion shape on the overlap weld compared to a more asymmetric shape found on the experiments, but the error is still not very large. The Fe-model can also be used to optimize the welding sequence for bigger components on the after-treatment system within a reasonable time span compared to doing the opimization manually in an experiment. / Detta examensarbete gjordes för Scania CV AB. Fokus for detta examensarbete har varit kvarvarande deformationer efter svetsning som kan skapa problem vid tillverkningen av Scanias avgasefterbehandlingssystem. Avgasefterbehandlingssystemet är till mesta dels konstruerat av stålplåtar av det ferritiska rostfria stålet EN 1.4509, plåtarna är svetsade ihop och då uppstår kvarvarande deformationer. När komponenter svetsas samman uppstår deformationer och restspänningar. Dessa deformationer och restspänningar är också beroende på i vilken sekvens komponenterna har svetsats ihop. Deformationerna och restspänningarna kan skapa problem med toleranser och sänka livslängden för komponenterna som sammanfogats. Experiment är kostsamma och därför är det önskvärt att simulera svetsprocessen, och därav kontrollera deformationerna som uppstår och optimera i vilken sekvens som komponenterna ska svetsas ihop. För att simulera svetsprocessen och prediktera de kvarvarande deformationerna efter svetsning så gjordes termo-mekanisk FE-model för två vanliga svetsscenarion för avgasefterbehandlingssystemet. Det ena scenariot är två tunna plåtar som svetsas ihop i en överlappande position och det andra var en tunn plåt som svetsas på en tjockare plåt. Ett experiment gjordes sedan för båda svetstyperna. Efter att svetstyperna hade jämförts med experimentet så gjordes en optimering av svetssekvensen för en större komponent likt komponenter funna på avgasefterbehandlingssystemet. Den termomekaniska FE-modelen kunde prediktera de kvarnvarande deformationerna och deras form med bra noggrannhet jämfört med experimentet med undantag för en deformationsform på de tunna plåtarna som var mer symmetrisk i FE-modellen jämfört med den asymmetriska formen i experimentet. FE-modellen kunde också användas för att optimera svetssekvensen för den större komponenten inom en rimlig tidsrymd.

Design of robotic cell for welding operations at specific production part including unchangeable process technology. Design of subsystems provides required functions and abilities. Risk management of entire model and its transformation into Siemens Process Simulate simulation software including creation task-cycle simulation.

Millimeterstora och svårupptäckta defekter kan uppstå internt i stora och komplexa gjutgods av Ti-6Al-4V, ibland går dessa oupptäckta tills detaljen genomgått mekanisk bearbetning och en stor kostnad redan har gått in i den. Dessa defekter och andra industriella olyckshändelser leder till ett behov av additiva reparationsmetoder där den för tillfället rådande metoden är TIG-svetsning. Denna metod reparerar defekterna men leder till oacceptabla restspänningar vilka kan åtgärdas med värmebehandling som i sin tur kan orsaka ytdefekten alpha case. Därav finns ett industriellt behov av reparationsmetoder som leder till mindre eller negligerbara restspänningsnivåer i reparerad detalj. Detta arbete utfört hos GKN Aerospace – Engine Products Sweden i Trollhättan analyserar eventuella förhållanden mellan parametrarna Effekt, Spot size, och Svetshastighet och de resulterande restspänningarna i ett lågparameterområde på materialet Ti-6Al-4V. En parameterrymd uppspänd av 17 parameteruppsättningar etablerades, svetsades och analyserades med mikrografi. Ur denna rymd simulerades de 8 yttre parametrarna med hjälpa av Finita Elementmetoden i svetssimuleringsmjukvaran MARC och ett förhållande mellan ingående parametrar och resulterande restspänningar undersöktes. En statistiskt säkerställd trend erhölls för att en minskad Svetshastighet leder till minskade tvärspänningar i mitten på en 20mm lång svetssträng. Detta är applicerbart för svetsar nyttjande start och stopplåtar. Det noterades även att en ökning i Effekt eller Spot size, eller en minskning utav svetshastigheten leder till att det av restspänningar utsatta området ökar i storlek. Detta är har implikationer för efterföljande värmebehandling i avgörandet av form och storlek på området som skall värmebehandlas. / Minute defects may occur in large complex Ti-6Al-4V castings, sometimes these are unnoticed until after machining and a high cost has been sunk into the part. These defect and other potential manufacturing mishaps render a need for additive repair methods. The state of the art method TIG welding can repair the parts but may leave unacceptable residual stresses, where the state of the art solution of Post Weld Heat Treatment might create a surface defect known as alpha case. Therefore there is a need for a repair weld method that results in lesser or negligible residual stresses. This thesis, carried out at GKN Aerospace – Engine Products Sweden, Trollhättan analyses the potential relationships between the laser welding parameters Power, Spot size, and Weld speed and the resulting residual stresses in a low energy parameter area on the material Ti-6Al-4V. A parameter box of 17 parameter sets was established, laid down and analyzed under micrograph, of this box the outer 8 parameter sets were simulated via the Finite Element Analysis welding simulation software MARC and a relationship between the input parameters and their resulting residual stresses was analyzed. A statistically significant trend was found supporting the claim that a decrease in transversal stresses in the center of a 20mm weld line is caused by an increase in Weld speed. This has implications for welds using run-on &amp; run-of plates. It was also noted that an increase in Power or Spot size, or a decrease in Weld speed increases the area under residual stress; both as individual parameters and in synergy. This has implications for Post Weld Heat Treatment in determining the size and shape of the area in need of treatment.