Potential of error for arc welding processes: Where can i make mistakes and how they affect the component?

Abstract

For example, in vehicle or crane production and in the steel construction area, in many areas the weight reduction has a decisive influence on the development of new products. So modern, temperature-sensitive, high-performance materials replace more and more unalloyed structural steels. The processing window for welding these materials is much smaller, so the exact determination and compliance of the t8/5 value (cooling rate) is important. This is why the welding parameters and the exact determination of specific parameters have a great impact on the calculation and determination of the t8/5-value as well as on the resulting mechanical and technological characteristics. Depending on the welding process, a variety of welding parameters, welding seam geometry, the welding position, and the layer structure change the heat input into the component. On the one hand, the efficiency is changed, and on the other hand, they affect the cooling behavior by more than 60%. Various welding processes and parameters are analyzed, as well as different error potentials discussed, and following that, their impact will be illustrated. The summation of the possible errors shows that the compliance with the mechanical and technological characteristics, as well as the theoretical determination of these values, and the calculation and simulation of the resulting sizes, like areas, microstructure, or internal stresses, is practically insufficiently possible. Knowing the sources of error and the use of this knowledge gained at the TU Chemnitz has made a large contribution to improving the quality of welded joints. At the end, recommendations of necessary adaptations of actual standards are visualized.