ME i– i10A November i12, i2019

ADVANCED WORKSHOP PRACTICE ASSIGNMENT – 01 i i i i i

RESIDUAL STRESSES IN WELDING (TIG vs. LASER WELDING)

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GROUP iMEMBERS: i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i

 IBRAHIM iBIN iALI iKHAN i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i CMS: i251464

 IRTEZA iALI iAHMED iFARUQI i i iiI CMS: i241836
 AQIB iHABIB i CMS: i266993
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 BILAL iAZIZ i CMS: i255382

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RESIDUAL iSTRESSES iIN iWELDING

The istress ipresent iin ia ibody iin ithe iabsence iof iany iexternal iloadings ior ithermal igradients iis
known ias iresidual istress. iIn iother iwords, iresidual istresses iin ia istructural imaterial ior icomponent
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are ithose istresses, iwhich iexist iin ithe iobject iwithout ithe iapplication iof iany iservice ior iother
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external iloads. iResidual istress ican icause ia isudden isplit iof ithe imetal iin itwo ior imore ipieces iwhen
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a iload iis iapplied. iResidual istress iin iwelding iis imainly ithe iresult iof ithermal iexpansion, iwhich iin
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basic iterms imeans ithat imaterials iexpand ior icontract iwith itemperature. iSince ithe imaterials
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especially imetals itend ito icool ias ithe itemperature igoes idown, ithe iwelding iprocess iresults iin
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numerous idefects ias iit iis ia ihighly ithermal iprocess iwhere isignificant iheat iis iapplied. iThe istresses
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arise idue ito ithe iforce icreated iby ithe inearby imaterial ias iit ipulls iback ithe icooled imetal ito imaintain
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the ibond.
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LASER iWELDING:

The ifocused ilaser ibeam iis ione iof ithe ihighest ipower idensity isources iavailable ito iindustry itoday. i
It iis isimilar iin ipower idensity ito ian ielectron ibeam. iTogether ithese itwo iprocesses irepresent ipart
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of ithe inew itechnology iof ihigh-energy idensity iprocessing. iLBW i(Laser iBeam iWelding) iis ia ihigh
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power idensity iwelding iprocesses iwhich ican ipenetrate ithicker imaterial ior isheet iwith ia isingle
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strike iand idue ito ithis ia ismall iHAZ i(heat iaffected izone), igood iweld iquality iand ilow iheat iinput iper
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unit ivolume iis iobtained. iLaser iwelding ican ibe iobtained iusing idifferent itypes iof ilasers isuch ias
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solid istate ilaser, igas ilaser ior isemi-conductor ilaser i[1]. iSince ithe iweld iis irarely iwide icompared
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with ithe ipenetration, iit ican ibe iseen ithat ithe ienergy iis ibeing iused iwhere iit iis ineeded iin imelting
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the iinterface ito ibe ijoined iand inot imost iof ithe isurrounding iarea ias iwell.
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Residual iStresses iin iLaser iWelding

Residual istress igenerally iare ioriginated iin ilaser iweld imaterials ifrom iuneven iand ifast iheating iand
cooling, iaffecting ithe istrength iand iperformance iof iwelded istructures. iHowever, idue ito ithe
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limitations iof iavailable itesting itechnology iand imethods, ithe iformation imechanism iof ithe
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residual istress iin ilaser iwelding ihas inot iyet ibeen isolved. iThe icommon imethods iof imeasuring
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residual istress iincludes icutting igroove, ihole-drilling, iand iX-ray. iHowever, iall ithe imethods iare
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time-consuming, ilaborious, iand ican idamage imaterials. iResidual istresses imay ibe idesirable ior
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undesirable idepending ion ithe imagnitude iand idistribution. iTo iavoid iresidual istress, iits icauses
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must ibe iknown, iwhich iincludes ithe imechanism iand iprocess iof iwelding iand idifferent iother
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welding iparameters isuch ias iwelding ispeed, iand iwelding ipower ietc.
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A istudy i[2] iof iResidual iStress iin iLaser iwelding ibased ion iUltrasonic iLaser iTechnology idiscusses
the idifferent iparameters iwhich iimpacts ithe iresidual istresses iin iLaser iWelding.
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1. Effect iof iHeat iInput ion iResidual iStress

The iincrease iin iheat iinput ithrough ilaser iwelding iincreases, ithe ienergy iabsorbed iper iunit ilength
increases, iwhich iexpands ithe ihigh itemperature izone igenerating iplastic ideformation, itherefore,
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the itensile iresidual istress iregion iincreases i[3].

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2. Effect iof iWelding iSpeed ion iResidual iStress

As ian iimportant iprocess iparameter iof ilaser iwelding, iwelding ispeed idirectly idetermines ithe
efficiency iof iwelding. iIt iis iseen ithat iwith ithe iincrease iin iwelding ispeed, ithe iresidual istress
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maximum idecreases idue ito ithe idecrease iin ithe ienergy iabsorbed i[3].
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2 TIG iWELDING:

A iwelding iprocess iusing ithe inon-consumable itungsten ielectrode ito icreate ian iarc ion ithe iwork
piece ito ibe iwelded iunder ia ishielding igas iis iknown ias iGas iTungsten iarc iwelding i(GTAW) ior
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Tungsten iInert iGas i(TIG) iwelding. iIt ihas ibecome ia ipopular ichoice iof iwelding iprocess iwhen ia
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high ilevel iof iweld iquality ior iconsiderable iprecision iwelding ioperation iis irequired. iThe imain
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limitation ithat iarises iin ithe iTIG iwelding iis ithe ithickness iof ithe imaterial.
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Residual iStresses iin iTIG iWelding

The inon-uniform idistribution iof ithermal iand iespecially iplastic istrains iin iand iaround ithe iweld
pool iduring ithe iTIG iwelding iprocess, ilarge iamount iof iresidual istress iand ideformations iare
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present iin ithe iwelded istructures. iThere iare imany ifactors iaffecting ithe iresidual istresses idue ito
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TIG iwelding, isuch ias imechanical iand ithermal iproperties iof ithe iwelded imaterials, imechanical
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properties iof ithe imaterials ito ibe ijoined, ithe igeometry iand idimensions iof ithe imaterial, ithe iheat
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input iand inumber iof ipasses iof ithe iwelding iprocess i(Deng iet ial. i2008). iHowever, ithe istudy iof
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residual istresses iis iextremely iimportant ifor ievaluating ithe irisk iof ifatigue icrack ipropagation i[4]. iIn
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fact, ithe iresidual istresses iintroduced iby ithe iTIG iwelding iprocess ican igreatly iincrease ithe inet
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stress ivalues iapplied ibeyond ithe idesign iloads, icausing ifatigue icrack ipropagation iresulting iin ithe
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weakness iof ithe iwelded iparts. iTherefore, ito iprevent ithe ioccurrence iand igeneration iof iresidual
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stresses, ithe icommon ipractice iis ito icarry iout istress-relief itreatments, iwith ithe iobjective ito
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reduce iand iminimize ithe iadverse ieffects iof iresidual istresses; iotherwise, ithe iwelded istructure
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tends ito icollapse iwhen isubjected ito iloading ilevels imuch ilower ithan ithose iused iat ithe idesign
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stage. iCurrently, iit iis ipossible ito idetermine ithe imagnitude iof iresidual istresses iby ivarious
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methods, iand isome iof ithese itechniques iare iof idestructive itype i[5]. i
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References

1. Honey iGoel, iProf. iS.K. iSahoo, iResidual iStress iDevelopments iduring iLaser iWelding iof
Commercially iPure iTitanium iSheets, iNIT, iRourkela, i2005.
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2. Yu iZhan, iEnda iZhang, iYiming iGe, iResidual iStress iin ilaser iwelding ibased ion iultrasonic
laser itechnology, iAppl. iSci. i2018, i8, i1997.
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3. Wang, iS.H., iWei, iM.D., iTsay, iL.W., iMaterials. iLetters iVol. i57, i2003, ipp.1815–1823.
4. Yunlian, iQ., iJu, iD., iQuan, iH., iLiying, iZ., iMaterial iScience iEngineering iA i280, i2000, ipp.177–
181.
5. W. iZinn, iB. iScholtes, iHandbook iof iresidual istress iand ideformation iof isteel, i391(2013).
6. C.M. iChen, iRs. iKovacevic, iMachine iTools i& iManufacture i43, i1319 i(2003).