by Hiller et al. [5] of ThyssenKrupp Automotive Systems. Jenicek
and Cramer [6] demonstrated that tubular hollow bodies such as
nuts, sleeves and bushes could be fastened to sheets using a process
with particular economic viability, i.e., an advanced variant of
magnetically impelled arc butt welding-bush or nut welding. With
extended drawn-arc stud welding devices, aluminum components
with an internal thread between M8 and M24 were welded on to
perforated sheets made of ENAW-AlMg3 and ENAW-AlMgSi1. Mori
and Yasuda [7] evaluated the feasibility of the MIAB welding process
with aluminum and aluminum–copper joints. In this set up,
it was a challenge to achieve the required flux density at the joint
with non-ferrous materials vs. ferrous materials. Hence, an iron
core was often inserted inside the pipe. The study reported a MIAB
welding method developed for welding non ferro-magnetic metals
and examined the welding conditions and procedures of butt
welding small diameter pipes of aluminum to aluminum (Al–Al)
and to copper (Al–Cu), for obtaining good properties of joint. Arungalai
Vendan et al. [8] have presented Finite Element Models for
predicting electromagnetic flux and electromagnetic force distribution
that governs the arc impelling in MIAB welding process.
This facilitates effective design of magnetic set up in MIAB welding
process.
There are no available literatures pertaining to MIAB welding of
pressure parts. Further, radiography tests on MIAB have not been
reported in any of the literatures. Hence, an attempt is being made
in this research paper to address these issues.
2. Experimental set up
MIAB machine (MD1) available at Welding Research Institute
(WRI), BHEL, is employed for welding alloy steel tubes used in
pressure parts.
MD1 MIAB machine consists of a power converter, pump station,
control box, welder unit and the remote control as major blocks as
shown in Fig. 1. The input to the power converter is 3 hp, 50 Hz,
400 V.
3. Experimental procedure
Several welding trials are conducted with alloy steel tubes (T11)
of 47.6 mm outer diameter and 6.6–7 mm thickness using MD1
MIAB machine with different sets of input parameters. Horizontal
position is being considered for all the experimental trials. Material
specifications include the chemical composition and the tensile
requirements for MIAB as provided in Table 1.
MIAB being a relatively new welding process and due to inadequate
availability of literature, initially, trial and error method is
by Hiller et al. [5] of ThyssenKrupp Automotive Systems. Jenicek
and Cramer [6] demonstrated that tubular hollow bodies such as
nuts, sleeves and bushes could be fastened to sheets using a process
with particular economic viability, i.e., an advanced variant of
magnetically impelled arc butt welding-bush or nut welding. With
extended drawn-arc stud welding devices, aluminum components
with an internal thread between M8 and M24 were welded on to
perforated sheets made of ENAW-AlMg3 and ENAW-AlMgSi1. Mori
and Yasuda [7] evaluated the feasibility of the MIAB welding process
with aluminum and aluminum–copper joints. In this set up,
it was a challenge to achieve the required flux density at the joint
with non-ferrous materials vs. ferrous materials. Hence, an iron
core was often inserted inside the pipe. The study reported a MIAB
welding method developed for welding non ferro-magnetic metals
and examined the welding conditions and procedures of butt
welding small diameter pipes of aluminum to aluminum (Al–Al)
and to copper (Al–Cu), for obtaining good properties of joint. Arungalai
Vendan et al. [8] have presented Finite Element Models for
predicting electromagnetic flux and electromagnetic force distribution
that governs the arc impelling in MIAB welding process.
This facilitates effective design of magnetic set up in MIAB welding
process.
There are no available literatures pertaining to MIAB welding of
pressure parts. Further, radiography tests on MIAB have not been
reported in any of the literatures. Hence, an attempt is being made
in this research paper to address these issues.
2. Experimental set up
MIAB machine (MD1) available at Welding Research Institute
(WRI), BHEL, is employed for welding alloy steel tubes used in
pressure parts.
MD1 MIAB machine consists of a power converter, pump station,
control box, welder unit and the remote control as major blocks as
shown in Fig. 1. The input to the power converter is 3 hp, 50 Hz,
400 V.
3. Experimental procedure
Several welding trials are conducted with alloy steel tubes (T11)
of 47.6 mm outer diameter and 6.6–7 mm thickness using MD1
MIAB machine with different sets of input parameters. Horizontal
position is being considered for all the experimental trials. Material
specifications include the chemical composition and the tensile
requirements for MIAB as provided in Table 1.
MIAB being a relatively new welding process and due to inadequate
availability of literature, initially, trial and error method is
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