STRESS ANALYSIS AND NUMERICAL SIMULATION STUDY OF COLD METAL TRANSFER WELD HEAD
Keywords:
cold metal transfer welding, Q235 steel plate, stress analysis, numerical simulation, weld parameter
Abstract
In order to study stress and deformation during welding, the macroscopic and microscopic morphologies of the welded joints were recorded to obtain the best welding parameters. Taking a Q235 steel plate as the specimen, six groups were welded under different welding parameters using the cold metal transfer method. The stress field and deformation field in the welding process were simulated using the finite element method. The simulation results were used to further explain the experimental findings and to compare them with the experimental data. The results show that an excessive welding current aggravates the stress concentration of the joint and reduces the fatigue strength of the joint. If the welding current is too small, the stress of the base metal after welding is small, and there are defects including incomplete penetration and undercut. By comparison, the optimal welding parameters are identified as a current of 180 A, a voltage of 14.0 V, a welding speed of 600 mm/min, and a wire feeding speed of 5.5 m/min, under which good weld formation is achieved, and both stress and deformation are relatively low. The experimental results are basically consistent with the numerical simulation results.
References
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[2] Y. H. Sun, Y. Z. Liu, C. J. Luan, et al. The effect of welding heat input on the structure and properties of CMT backing welding joint[J]. Metal processing (hot working), 2023(11): 22-26.
[3] M. Liu. Study on technology and mechanical properties of joint of dissimilar AZ31B Mg/6061 Al alloys by CMT welding[D]. Zhenjiang: Jiangsu University of Science and Technology, 2017.
[4] H. K. Yuan, B. Q. Wei, T. K. Guo, et al. Comparison of Aluminum Alloy Welding Quality Between CMT and MIG[J]. Aluminum processing, 2018(01): 56-60.
[5] Q. l. Chu, Q. L. Cao, Z. G. Xie, et al. Microstructure and Properties of 1J50 and 0Cr18Ni9 Welding Joints under Different Welding Methods[J]. Welded tube, 2023, 46(10): 21-27. doi:10.19291/j.cnki.1001-3938.2023.10.004.
[6] C. Zhang. Study on microstructure and properties of Al alloy and steel CMT welding-brazing [D]. Zhenjiang: Jiangsu University of Science and Technology, 2024.
[7] Q. L. Meng. Study on the Welding Process of Stainless Steel Sheet by Cold Metal Transfer (CMT)[D]. Changchun: Jilin University, 2015.
[8] LUO S, WU Z, WANG D, et al. Solidification microstructures and softening behavior of laser welded 6082-A356 aluminum alloy dissimilar butt joints[J]. Materials Today Communications, 2024, 38: 108411-108413.
[9] KUBOKI T, NISHIDA K, SAKAKI T, et al. Effect of plug on levelling of residual stress in tube drawing[J]. Journal of Materials Processing Technology, 2008, 204(1): 162-168.
[10] KIM Y K, SONG M H. Effects of expanding methods on residual stress of expansion transition area in steam generator tube of nuclear power plants [J]. Academic Conference of Korea Energy Society, 2012, 21(4): 362-372.
[11] Y.F. Zhang, D. J. Li, Y. Xiong, et al. Analysis on difference of collapse strength of two kinds of expansion tubes after expansion[J]. Journal of Material Heat Treatment, 2022, 43(11): 190-196. doi:10.13289/j.issn.1009-6264.2022-0179.
[12] G. Mu. Interfacial organization regulation and properties of CMT welded joints made of TC4/304L dissimilar materials[D]. Shanghai: Shanghai Jiao Tong University, 2022.
[13] X. Zhang. Study on microstructure and properties of CMT additive repair of 2A12 aluminum alloy[D]. Nanchang: Nanchang Aviation University, 2022.
[14] HAN Y, ZHONG S, TIAN L, et al. Welding heat input for synergistic improvement in toughness and stress corrosion resistance of X65 pipeline steel with pre-strain[J]. Corrosion Science, 2022, 206: 1-15.
[15] HAN Y, ZHONG S, PENG C, et al. Fatigue behavior of X65 pipeline steel welded joints prepared by CMT/GMAW backing process[J]. International Journal of Fatigue, 2022, 164: 1-14.
[16] C. Wang, S. K. Wang, S. G. Xu. Effect of forming temperature on strength of monohole expandable tubular with thread connection[J]. Journal of Plastic Engineering, 2017, 24(03): 50-56.
[17] SABER M, CHOUIKHI H. Development of the bicone mandrel ring expansion test to evaluate the hoop stress in extruded aluminum tubes[J]. Experimental Mechanics, 2021, 61(2): 791-802.
[18] J. B. Zhang, D. T. Kong, C. Y. Jiang, et al. Effect of tool cone angle on circumferential residual stress of expansion casing[J]. Journal of Plastic Engineering, 2022, 29(01): 155-161.
[19] PODUSKA J, KUCERA J, HUTAR P, et al. The Effect of Specimen Size on the Determination of Residual Stress in Polymer Pipe Wall[J]. Key Engineering Materials, 2014, 627: 141-144.
[20] WOJDAT T, KUSTRON P, MARGIELEWSKA A, STACHOWICZ M. Microstructure and Mechanical Properties of Braze Welded Joints of Copper with Austenitic Steel Made by CMT Method[J]. Archives of Metallurgy and Materials, 2019, 64(4): 1411-1420.
[21] W. Z. Luo, H. M. Cheng, H. Y. Liu, et al. Numerical Simulation of Residual Stress and Welding Deformation for High Strength Steel Q960E Butt-welded Joints[J]. China Mechanical Engineering, 2023, 34(17): 2095-2105.
[22] MURANSKY O, HAMELIN CJ, SMITH M C, et al. The effect of plasticity theory on predicted residual stress fields in numerical weld analyses[J]. Computational Materials Science, 2012, 54: 125-134.
[23] CHEN Y, YANG Z, SHI C, et al. Laser-CMT Hybrid Welding-Brazing of Al/Steel Butt Joint: Weld Formation, Intermetallic Compounds, and Mechanical Properties[J]. Materials, 2019, 12(22): 3651-3652.
[24] C. Liu. Study on 2205 Duplex Stainless Steel with Twin-CMT Welding and Numerical Simulation[D]. Chongqing: Chongqing Institute of Science and Technology, 2020.
[25] Y. H. Zhu, Z. Q. Geng. Limitation of sheet metal welding------CMT cool metal transition technique[J]. Electric welding machine, 2011(41): 78-80 + 84.
Published
2026-06-04
How to Cite
1.
Li M, Yang F, Wei X, Jia Z. STRESS ANALYSIS AND NUMERICAL SIMULATION STUDY OF COLD METAL TRANSFER WELD HEAD. MatTech [Internet]. 2026Jun.4 [cited 2026Aug.10];60(3):311–318. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1520
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