Experimentally validated numerical prediction of laser welding induced distortions of Al alloy parts for railcar body by inherent strain method combined with thermo-elastic-plastic FE model

References

• Sun X, Han X, Dong C, et al. Applications of aluminium alloys in rail transportation. In: Dobrzanski LA, editor. Advanced Aluminium Composites and alloys. London (UK): IntechOpen; 2021.
   Google Scholar
• Katayama S. Fundamentals and details of laser welding. Berlin (Germen): Springer Science & Business Media; 2020.
   Google Scholar
• Katayama S. Handbook of laser welding technologies. Sawston Cambrige (UK): Woodhead Publishing; 2013.
   Google Scholar
• Ueda Y, Murakawa H, Ma N. Welding deformation and residual stress prevention. New York: Elsevier; 2012.
   Google Scholar
• Zhao H, White D, Debroy T. Current issues and problems in laser welding of automotive aluminium alloys. Int Mater Rev. 1999;44(6):238–266. doi: 10.1179/095066099101528298
   Web of Science ®Google Scholar
• Deng A, Chen H, Zhang Y, et al. Effect of filler materials on the porosity formation of aluminium alloy by laser welding with filler wire. Opt Laser Technol. 2023;159:109000. doi: 10.1016/j.optlastec.2022.109000
   Web of Science ®Google Scholar
• Matsunawa A, Mizutani M, Katayama S, et al. Porosity formation mechanism and its prevention in laser welding. Weld Int. 2003;17:431–437. doi: 10.1533/wint.2003.3138
   Google Scholar
• Kawaguchi I, Tsukamoto S, Arakane G, et al. Characteristics of high-power CO2 laser welding and porosity suppression mechanism with nitrogen shielding. Study of high-power laser welding phenomena. Weld Int. 2006;20(2):100–105. doi: 10.1533/wint.2006.3541
   Google Scholar
• Ma D, Jiang P, Shu L, et al. Real-time porosity monitoring during laser welding of aluminum alloys based on keyhole 3D morphology characteristics. J Manuf Syst. 2022;65:70–87. doi: 10.1016/j.jmsy.2022.08.011
   Web of Science ®Google Scholar
• Zhu B, Zhang G, Zou J, et al. Melt flow regularity and hump formation process during laser deep penetration welding. Opt Laser Technol. 2021;139:106950. doi: 10.1016/j.optlastec.2021.106950
   Web of Science ®Google Scholar
• Nisar S, Noor A, Shah A, et al. Optimization of process parameters for laser welding of A5083 aluminium alloy. Opt Laser Technol. 2023;163:109435. doi: 10.1016/j.optlastec.2023.109435
   Web of Science ®Google Scholar
• Chuang T, Lo Y, Tran H, et al. Optimization of butt-join laser welding parameters for elimination of angular distortion using high-fidelity simulation and machine learning. Opt Laser Technol. 2023;167:109566. doi: 10.1016/j.optlastec.2023.109566
   Web of Science ®Google Scholar
• Wan Z, Wang H, Li J, et al. Effect of beam oscillation frequency on spattering in remote laser stitch welding of thin-gage zinc-coated steel with keyhole penetration. J Mater Process Technol. 2022;302:117482. doi: 10.1016/j.jmatprotec.2021.117482
   Web of Science ®Google Scholar
• He Y, Xiong J, Li Y, et al. Process parameter selection for laser welding of aluminium alloy from the perspective of energy effectiveness. Proc Inst Mech Eng B J Eng Manuf. 2022;236(12):1574–1588. doi: 10.1177/095440542210780
   Web of Science ®Google Scholar
• Ramiarison H, Barka N, Amira S. Optimization of parameters in laser welding of aluminum alloy 5052-H32 using beam oscillation technique for mechanical performance improvement. Int J Lightweight Mater Manuf. 2002;5:470–483. doi: 10.1016/j.ijlmm.2022.05.006
   Google Scholar
• Aminzadeh A, Barka N, Ouafi AE, et al. Experimental analysis of overlap fiber laser welding for aluminum alloys: porosity recognition and quality inspection. Opt Lasers Eng. 2024;173:107890. doi: 10.1016/j.optlaseng.2023.107890
   Web of Science ®Google Scholar
• Radaj D. Heat effects of welding, temperature field, residual stress, distortion. Berlin, Heidelberg: Springer; 2012.
   Google Scholar
• Barat K, Kumar CN, Patil G, et al. Defectometry, distortion analysis and metallurgical properties in the keyhole and conduction mode of laser beam welding of Al–Mg–Sc alloy butt joints. Opt Laser Technol. 2023;162:109248. doi: 10.1016/j.optlastec.2023.109248
   Web of Science ®Google Scholar
• Hashemzadeh M, Garbatov Y, Soares CG. Hybrid-laser welding-induced distortions and residual stress analysis of large-scale stiffener panel. Ocean Eng. 2022;245:110411. doi: 10.1016/j.oceaneng.2021.110411
   Web of Science ®Google Scholar
• Kong F, Kovacevic R. 3D finite element modeling of the thermally induced residual stress in the hybrid laser/arc welding of lap joint. J Mater Process Technol. 2010;210(6–7):941–950. [Database] doi: 10.1016/j.jmatprotec.2010.02.006
   Web of Science ®Google Scholar
• Kong F, Lavoie JP, Kleine K, et al. Computational modelling and experimental validations of the heat transfer and residual stresses in the aluminium 6061-T6 plate welded by an adjustable ring mode (ARM) laser. J Light Met Weld. 2020;58:19–25. doi: 10.11283/jlwa.58.19
   Google Scholar
• Derakhshan ED, Yazdian N, Craft B, et al. Numerical simulation and experimental validation of residual stress and welding distortion induced by laser-based welding processes of thin structural steel plates in butt joint configuration. Opt Laser Technol. 2018;104:170–182. doi: 10.1016/j.optlastec.2018.02.026
   Web of Science ®Google Scholar
• Li Y, Wang Y, Yin X, et al. Laser welding simulation of large-scale assembly module of stainless-steel side wall. Heliyon. 2023;9(3):e13835. doi: 10.1016/j.heliyon.2023.e13835
   PubMed Web of Science ®Google Scholar
• Zhang S, Ma J, Wang Z, et al. Research on welding deformation of hollow thin-walled complex structural parts based on plane bending theory of constant section beam. J Manuf Process. 2023;95:330–341. doi: 10.1016/j.jmapro.2023.03.079
   Web of Science ®Google Scholar
• Zhou H, Yi B, Shen C, et al. Mitigation of welding induced buckling with transient thermal tension and its application for accurate fabrication of offshore cabin structure. Mar Struct. 2022;81:103104. doi: 10.1016/j.marstruc.2021.103104
   Web of Science ®Google Scholar
• Dai P, Mi D, Guo B, et al. Bending deformation control in a laser welded long straight structure by elastic pre-bending technique. J Manuf Process. 2023;107:485–495. doi: 10.1016/j.jmapro.2023.10.062
   Web of Science ®Google Scholar
• Guo Y, Wu D, Ma G, et al. Trailing heat sink effects on residual stress and distortion of pulsed laser welded hastelloy C-276 thin sheets. J Mater Process Technol. 2014;214(12):2891–2899. [Database] doi: 10.1016/j.jmatprotec.2014.06.012
   Web of Science ®Google Scholar
• Wu C, Wang C, Kim JW. Welding sequence optimization to reduce welding distortion based on coupled artificial neural network and swarm intelligence algorithm. Eng Appl Artif Intell. 2022;114:105142. doi: 10.1016/j.engappai.2022.105142
   Web of Science ®Google Scholar
• Liang W, Deng D. Investigating influence of external restraint on welding distortion in LAHS steel thin-plate structures by means of integrated computational approach. J Mater Res Technol. 2022;20:2960–2976. doi: 10.1016/j.jmrt.2022.08.048
   Google Scholar
• Huang H, Chen J, Feng Z, et al. Large-scale welding process simulation by GPU parallelized computing. Weld J. 2021;100(11):359–370. doi: 10.29391/2022.101.032
   Web of Science ®Google Scholar
• Dong W, Jimenez XA, To AC. Temperature-dependent modified inherent strain method for predicting residual stress and distortion of Ti6Al4V walls manufactured by wire-arc directed energy deposition. Addit Manuf. 2023;62:103386. doi: 10.1016/j.addma.2022.103386
   Web of Science ®Google Scholar
• Wang J, Lu H, Wei L. Prediction of welding distortions based on theory of inherent strain by FEM and its application. Trans China Weld Inst. 2002;23(6):36–40. doi: 10.3321/j.issn:0253-360X.2002.06.010
   Google Scholar