Roxbin Sem Rep

SEMINAR REPORT
UNDERWATER WELDING OF INCONEL 625
submitted by
ROXBIN J J
Department of
MECHANICAL ENGINEERING
REPORT of
Seventh Semester
SEMINAR (MEQ413)
entitled
UNDERWATER WELDING OF INCONEL 625

Submitted by
ROXBIN J J
Register number –
SJC19ME088 of 2019 -
2023 B batch
Department of
Mechanical Engineering
OCTOBER 2022
Head of Department Seminar Coordinator
Dr. Binoy Baby Mr. Jose Tom Tharappel
Dept. of ME Asst. Prof. - Dept. of ME
Vision
Developing into a world class, pace setting institute of Engineering and
Technology with distinct identity and character, meeting the goals and
aspirations of the society.
● An ISO9001:2015
Certified Educational Institution managed by the Catholic Diocese
. ● of Palai
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AbdulKalam Technological University, Kerala
●
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• To maintain a conducive infrastructure and learning environment for
world class education.
• To nurture a team of dedicated, competent and research-oriented faculty.
• To develop students with moral and ethical values, for their successful
careers, by offering variety of programs and services.
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Department of
Vision
To develop into a center for imparting knowledge and technical skills of international
standards, in Mechanical Engineering.
Mission
• To follow a teaching-learning process, with the support of qualified and
committed faculty, in undergraduate and post graduate Mechanical
Engineering programs.
• To establish an infrastructure and academic ambience for collaborating with
Industry, Academia and Community to serve local and national enterprises.
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individual and collective accomplishments.
Program Educational Objectives (PEOs):

The graduates will:
• Have strong design and analysis skills in the theoretical and practical domains
of Mechanical Engineering.
• Become leading professionals, as individuals, as well as team members, in a
wide range of Mechanical Engineering and related fields.
• Exhibit ethical values and a strong spirit of social commitment to accelerate
societal development.
Program Specific Outcomes (PSOs):

Graduates of the program will be able to:
• Apply Mechanical Engineering knowledge and skills to develop optimum
solutions to problems in the areas of Design, Thermal, Manufacturing,
Industrial Engineering and Management.
• Identify and adopt advancements in Mechanical engineering for academic,
industrial and societal applications.
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Department of
Programme Outcomes (POs)
PO1: Engineering knowledge: Apply the knowledge of mathematics, science,

engineering fundamentals, and an engineering specialization to the solution of
complex engineering problems.
PO2: Problem analysis: Identify, formulate, research literature, and analyse
complex engineering problems reaching substantiated conclusions using the
first principles of mathematics, natural sciences, and engineering sciences.
PO3: Design/development of solutions: Design solutions for complex engineering
problems and system components or processes that meet the specified needs
with appropriate consideration for the public health and safety, and the cultural,
societal, and environmental considerations.
PO4: Conduct investigations of complex problems: Use research-based
knowledge and research methods including design of experiments, analysis
and interpretation of data, and synthesis of the information to provide valid
conclusions.
PO5: Modern tool usage: Create, select, and apply appropriate techniques,
resources, and modern engineering and IT tools including prediction and
modelling to complex engineering activities with an understanding of the
limitations.
PO6: The engineer and society: Apply reasoning informed by the contextual
knowledge to assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional engineering practice.
PO7: Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate
the knowledge of, and need for sustainable development.
PO8: Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
PO9: Individual and team work: Function effectively as an individual, and as a
member or leader in diverse teams, and in multi-disciplinary settings.
PO10: Communication: Communicate effectively on complex engineering activities
with the engineering community and with society at large, such as, being able
to comprehend and write effective reports and design documentation, make
effective presentations, and give and receive clear instructions.
PO11: Project management and finance: Demonstrate knowledge and
understanding of the engineering and management principles and apply these
to one’s own work, as a member and leader in a team, to manage projects and
in multidisciplinary environments.
PO12: Life-long learning: Recognize the need for, and have the preparation and
ability to engage in independent and life-long learning in the broadest context of
technological change.
sjcetpalai.ac.in
TABLE OF CONTENTS
Title Page No.
Acknowledgement ............................................................................................................ i
Executive Summary ......................................................................................................... ii
List of Tables ................................................................................................................... iii
List of Figures ................................................................................................................. iv
1. Introduction ............................................................................................................... 1
1.1. Introduction to underwater welding of
Inconel625 ........................................................ 1
1.1.1. Microstructural analysis and mechanical testes........................ 2
1.1.2. The major challenge encountered in welding of Alloy 625

........................................................2
1.2. The key to obtain high-quality wet welded joints of Inconel 625
all.............................................. 2
2. Experimental procedures .......................................................................................... 5
2.1. Materials ............................................................................................................ 5
2.2. Ultrasonic welding ............................................................................................. 5
2.3. Melt front analysis ............................................................................................. 7
2.4. Energy and power consumption ......................................................................... 8
2.5. Temperature measurement ................................................................................... 8
2.6. Mechanical testing ............................................................................................... 9
3. Result ...................................................................................................................... 10
3.1. Mechanical tests ............................................................................................... 10
3.2. Power and displacement ................................................................................... 12
3.3. Melt front analysis ............................................................................................. 13
3.4. Power, energy and temperature measurement ................................................... 16
4. Discussions ............................................................................................................. 18
5. Conclusion ............................................................................................................... 23
6. References ................................................................................................................ 25
ACKNOWLEGEMENT
First and foremost, I thank God Almighty who gave me the inner strength,
resources and ability to complete my work fruitfully, without his blessings my efforts
would have been in vain. I am extremely happy to mention a great word of gratitude to
Dr. Binoy Baby, Head of Mechanical Dept, St. Joseph’s College of Engineering &
Technology, Palai for providing me with all facilities for the presentation of this paper.
It is my radiant sentiment to place on record my earnest gratitude and regards to

seminar coordinator Mr. Jose Tom Tharappel, Assistant professor, Dept. of Mechanical
Engineering, and seminar guide Ms.Cinu P Elias, Assistant professor, Dept. of
Mechanical Engineering, St. Joseph’s College of Engineering& Technology, Palai for their
careful and precious guidance which were extremely valuable for the seminar.
I also convey my sincere thanks to all other staff for their assistance and
encouragement. I thank all my friends who have helped me during the work with their
valuable suggestions and cooperation. I truly admire my parents for their enduing
support and motivation which made the success of this venture inevitably. I also extend
my gratitude and regards to the authors of different journals and I am much obliged to
all those persons who directly or indirectly had influence on my work
EXECUTIVE SUMMARY
Cost-cutting measures are continually sought after by aircraft producers. As a result,

makers of aircraft are becoming more interested in fiber-reinforced polymer matrix
composites. They enable customization of the mechanical characteristics and can be stiffer
and stronger specifically than metals. As a result, the construction of the aeroplane can be
lighter. Typically, the lower structural weight results in lower operational costs for aircraft,
such as lower fuel usage. This study compared and contrasted static and continuous ultrasonic
welding methods for thermoplastic composites in order to find and understand their
differences and commonalities.
For both types of operations, it was very important to look into the melting of the
interface, consumed power and energy density, temperature evolution at the weld interface,
and ideal welding circumstances. This was done for three different vibrational amplitude and
welding force combinations, which are known to have a big impact on both welding
processes. What follows is our interpretation of the findings from this investigation.
This study's goal was to compare and contrast the static and continuous ultrasonic
welding methods for thermoplastic composites in order to determine how we may use what is
known about static welding to better understand and develop the continuous method.
Experimental comparisons between the two procedures were done for the melting of the
interface, the needed areal energy density and power consumption, the temperature at the
interface, and the impact of welding parameter modifications on the ideal welding conditions.
LIST OF TABLE
No Title Page No.
1. Test matrix for the static and continuous ultrasonic welding .................................. 7
2. Average melt front distances with respect to the front edge of the sonotrode
and position of melt front relative to the pristine ED ............................................... 14
3. Average power and average areal energy density and corresponding standard
deviation ................................................................................................................. 16
4. Time to transform pristine ED into melted ED for static and CUW ..................... 21
LIST OF FIGURES
NO Title Page No.
2.1. In-house developed continuous ultrasonic welding machine. .................................. 6

2.2. Schematic overview of start and end position of the sonotrode .............................. 6
2.3 welding set-up together with five thermocouples. . ....................................................9
2.4 Clamping situation of adherends in static ultrasonic welding set-up .......................9
3.1 Shear strength values obtained in continuous ultrasonic welding process ........... 10
3.2 Fracture surfaces of adherends welded at the optimum welding speeds ............ 11 3.3
Power and vertical sonotrode displacement curves of the continuous
ultrasonic welding process. ........................................................................................ 12
3.4 Power and vertical sonotrode displacement curves of the static ultrasonic
welding process ......................................................................................................... 13
3.5 Fracture surfaces of the melt front positions at optimum welding speeds
after stopping the welding process ............................................................................. 14
3.6 Fracture surfaces of statically welded adherends at different vibration times

.... 15
3.8 Temperature measurements for the static welding process ................................... 17
4.1 Schematic exaggerated interpretation of the CUW process at the interface ........ 18
4.2 Power curves for a normal static weld on 15 mm-wide coupons ......................... 19
4.3 Temperature measurements of the continuous and static welding process ........ 20
4.4 Representative fracture surfaces of continuous welds ........................................... 22

STATIC & COUNTINOUS ULTRASONIC WELDING ON THERMOPLASTIC COMPOSITES
1. INTRODUCTION
The adoption of combined arc welding processes such as double electrode gas
metal inert gas welding (DE- GMAW), tandem tungsten inert gas welding, tandem gas
metal inert gas welding and TIG-MIG hybrid welding has increasingly gained more
attention owing to the ability to improve weld properties. The tandem TIG welding
technique developed by Qin et al. resulted in satisfactory quality welds. But this
technique was of low heat input and low metal deposition rate leading to low
productivity.
The pulsed tandem GMAW process developed by Chen et al. [2] overcame the
low deposition rate problem associated with the tandem TIG welding. However, as this
process required an oxidizing atmosphere for shielding the weld pool, it was not suitable
for joining high strength steel. Improve deposition rate was also achieved by employing
the DE-GMAW. However, the process required a special circuit arrangement. The
aforementioned combined arc processes still had deficiencies associated with the
conventional TIG and MIG processes, especially in weld pool behavior and bead
formation. Consequently, Kanemaru et al. [invented the TIG-MIG hybrid welding
method, which simultaneously combines the high-quality and high-efficiency attributes
of the respective TIG and MIG welding processes in improving weld quality as
appraised by Zhou et al. The TIG-MIG welding process is efficient as it does not require
special circuit and unique power source properties, as highlighted by Zong et al. [5]. The
TIG and MIG arcs can be combined such that the TIG arc is leading while the MIG arc is
trailing written as TIG-MIG or the MIG arc leading while the TIG arc trailing written as
MIG-TIG hybrid welding. Kanemaru et al. [6] alluded that the additional TIG arc
stabilizes the MIG arc even when pure argon gas is used for shielding. Following this,
Ding et al. [7] highlighted that the TIG-MIG hybrid process was capable of welding
dissimilar magnesium and ferritic stainless steel due to arc stability. Besides obtaining a
stable MIG arc that promotes good weld bead formation for similar and dissimilar metal
welds, Cheng et al. [8] reported strong joint connections between copper and stainless
steel plates joined by MIG-TIG double-sided arc welding method.
Dept. of Mechanical Engineering, SJCET Palai

1.1 Introduction to TIG-MIG hybrid welding process
Recent studies have established the improved structural integrity of the TIG-MIG hybrid
welding process compared with the standalone techniques. Despite this advantage of the hybrid
welding method, few authors have compared the evolved properties of the TIG and MIG hybrid
joints against the conventional standalone TIG and MIG joints. For instance, Ye et al. [9]
compared the microstructural and mechanical properties of aluminium/carbon steel joint
produced by MIG-TIG double-sided arc welding-brazing (DSAWB) with the conventional MIG
welding process. The authors reported that the tensile strength of the MIG-TIG process was two
and half times that of the conventional MIG process. It was also noted that the MIG-TIG process
required less heat input to produce a good weld bead, especially at the backside of the weld
compared to that required to produce the same effect using the conventional MIG process. It is
also important to highlight that the lower heat input characteristic of the combined process
limited the thickness of the intermetallic compound formed in the MIG-TIG weld, which
favoured the joint strength. The intermetallic thickness of the combined process was reported to
be 2.03 μm in comparison with 4.20 μm thickness for the conventional MIG process. Similarly,
Chen et al. [10] investigated the influence of low current auxiliary TIG arc on the microstructure
and weld bead formation of mild steel joints during TIG-MIG hybrid welding and compared the
result with the standalone MIG joints.
The authors reported that a leading TIG arc stabilizes the trailing MIG arc and
decentralizes the MIG arc force in the TIG-MIG hybrid process, which causes a reduction in the
impingement of molten droplets and the deceleration of backward fluid flow. The authors claim
that the deceleration of the backward flow provided more time for the molten metal to fill the
weld toe, resulting in suppression of the undercut defect, leading to better weld formation
compared to the standalone MIG process. It was observed that the weld zone’s width of the TIG-
MIG process was greatly reduced compared to that obtained from the conventional MIG welding
process and the microstructural grains of the hybrid process did not deteriorate despite the
increase in heat input in the hybrid process. Zhou et al. [4] also achieved an ideal front and back
weld bead for 24 mm thick mild steel plates by the MIG-TIG hybrid process without using
backing plates. The combined arc interaction was said to have improved the heat distribution at
the root weld because the additional TIG arc introduces more heat at the bottom of the weld
bead, leading to complete fusion.

1.2 Experimental details
1.2.1 Materials and equipment
In this experiment, a Miller 400 A direct current electrode positive (DCEP) MIG
welding machine and a Miller 400 A direct current electrode negative (DCEN) TIG
machine were used in producing the welds. A 3.2 mm diameter tungsten electrode and
2.4 mm diameter ER70S/6 carbon filler rod were used as wire electrode and filler
material. The TIG arc was shielded with the crystal argon gas, while the MIG arc was
shielded with a gas mixture of Argon + O2 + CO2. The welding material was 1008 mild
steel of 6 mm thickness. The elemental composition by weight of the material is Fe -
99.58, C - 0.079, S - 0.0098, Mn - 0.32, and P - 0.0098
1.2.2 Procedures
Butt joint configuration was adopted for this study. The individual MIG and
TIG joints were produced with the machine specification described in section 2.1. The
schematic of the TIG- MIG hybrid method is shown in Fig. 1. The TIG torch proceeded
the MIG torch, and the welding was done in the direction normal to the rolling of the
plates. Prior to welding, the plates were freed from impurities by removing oxide scales
from the surface of the plates and cleaning with acetone. Butt welding experiments were
conducted under the optimized parameters to study and compare the mechanical and
microstructural properties of the welded joints.
Smaller sets of specimens were cut from the welded plates and prepared
according to standard metallographic procedures for microstructural analysis. Test
specimens for mechanical characterization were also machined according to standard
tensile and hardness specifications. The Scanning Electron Microscopy (SEM) and the
Ultima IV X-ray diffractometer were used to analyse the joints’ fracture morphology and
phase composition, respectively.
1.2.3 Process parameters
With weld integrity in mind, the study employed optimum parameters settings of the TIG
and MIG welding processes on the criteria of larger is better for the tensile strength based

on the Taguchi l-9 orthogonal matrix. The input parameters selected in this study for the
three welding processes are the welding current, welding voltage and the gas flow rate.
The levels of input parameters for the TIG welding process were voltage −10,15,20,
Current −140,160,180, gas flow rate −15, 17, 19. The levels of input parameters for the
MIG welding process were voltage - 20,25,30, Current - 220, 250, 280, gas flow rate -
15, 17, 19.
Fig. 1.2.3 (a)The schematic of the TIG- MIG hybrid method.
1.3 Experimental results

1.3.1 Tensile properties and fracture morphology
The tensile properties of the welds produced by the TIG, MIG and TIG-
MIG welding processes were evaluated. Three replicate specimens were tested for each
weld type, and the average values were obtained. All the welded joints failed at the
parent material region, indicating that the weld joints were stronger than the parent
material [15], which is industrially accepted. Fig. 2 shows the fractured specimens for the
three weld types.

A comparative stress-strain plot for one out of the three replicates specimens for each
welding type and the tensile properties for the three welding processes.
Fig 1.3.1 Fractured specimens (a) TIG joint (b) MIG joint (d) TIG-MIG joint
Fig1.3.1 Stress-strain curve for TIG, MIG and TIG-MIG welding processes
The result of the tensile test shows that the TIG-MIG hybrid joint had better tensile
strength, yield strength and percentage elongation compared to the standalone MIG and
TIG welded joints. The MIG welded joint showed better tensile strength and yield
strength compared to the TIG welded joint. However, the percentage elongation of the
TIG welded joint was higher than that of the MIG welded joint. The tensile strength of
the joints determines the load-carrying capacity of the weldments, and the yield strength
determines the limit below which failure will not occur.

It is worthy to state that although the heat input during the TIG-MIG hybrid
process was more than those of the individual TIG and MIG Processes, the tensile
properties did not deteriorate. The SEM fractograph together with the EDS scan. It is
observed that the fracture modes for the joints are different. The TIG weld is
characterized by coarse dimples surrounded by small size dimples. Large tearing ridges
(indicted by the red arrow) and cleavage fracture indicate a brittle fracture mode in the
MIG welds. The brittle mode of fracture may be attributed to the presence of oxide and
impurities as seen in the EDS scan. The fractograph of the TIG-MIG joint is
characterized by uniform fine dimples showing a ductile failure.
1.3.2 Hardness properties
The Vickers hardness distribution for the three welding processes (TIG, MIG and
TIG-MIG hybrid) is illustrated in Fig. 5. The hardness profile reveals that the fusion
zones of the weldments had higher hardness values than the heat-affected zones and the
base material for the three weld types. The microhardness profiling also shows that the
TIG welded joint had the highest hardness property. The hardness of the MIG weld is
also seen to be higher than that of the TIG-MIG hybrid process. The higher hardness
values of the TIG and MIG joints are attributed to the presence of martensite phases, as
seen from the diffractogram obtained from the XRD analysis. The TIG-MIG hybrid
revealed only iron phases accounting for the lower hardness property than the standalone
TIG and MIG processes.
1.3.3 Macrostructure and microstructure
Macrostructural and microstructural evolution occur during and after welding

processes. These evolved properties determine the quality of the welds and the reliability
of the weldments for structural members. The macrographs reveals full penetration joints
produced by all three welding processes. The welds were free from cracks and pores. The
width of the weld bead, the width of the heat-affected zone, the fusion areas of the three
welding processes are seen to be different. The different weld types, input parameters,
heat input, and welding speed accounts for the differences in the geometries. However,
the shapes of the three weld types are somewhat similar.

The dimensions of the width of the weld bead, the width of the heat-affected zone,
the fusion area and the heights of reinforcement are measured by the ImageJ software and
presented in Table 3 The MIG weld bead is much larger than those obtained from the
TIG and TIG-MIG joints. This is due to the higher levels of the input parameters
combination. The fusion area of the TIG-MIG hybrid welded joint (9.182 mm2) is larger
than those of the TIG (6.848 mm2) and MIG (8.361mm2). The TIG-welded joint had the
lowest fusion area. The width of the heat-affected zone of the TIG-MIG hybrid joint is
also seen to be larger than those of the TIG and MIG processes. This is a result of the
relatively higher energy input during the hybrid process. The width of the heat-affected
zone for the TIG joint was also larger than that of the MIG joint. This is attributed to the
fact that TIG welding is a slow welding process; hence, heat is maintained on the
workpiece for a longer time resulting in high heat input. This causes a high-temperature
weld pool and slower cooling rate, resulting in a larger HAZ than the MIG welded joint.
On the other hand, the MIG welded joint is a fast welding process. This allows for low-
temperature per millimetre in the weld pool resulting in faster cooling and solidification.

Fig1.3.3 Fracture morphology for the TIG, MIG and TIG-MIG hybrid welding
processes.
The microstructures of the fusion zones (FZs) and the heat-affected zones (HAZs) of the
three joint types are presented (Fig. 7). The Fusion zone of the TIG welded joint is
characterized by coarse dendritic cementite and lots of fine acicular ferrite, while the
heat-affected zone consists of pearlite and acicular ferrite with more coarse columnar
dendrite structures. The fusion zone of the MIG welded joint is characterized by
Widmanstatten structures, fine acicular and proeutectoid ferrite. Sahasrabudhe and Raut
[13] observed a similar structure. The HAZ of the MIG welded joint exhibited larger
discrete com ponents of cementite and ferrite grains with very scanty pearlite structures.
Widmanstatten ferrite formation in low carbon steel occurs due to sympathetic nucleation
[16]. Sympathetic nucleation is said to occur when an alpha-ferrite nucleus is formed at
the interface between a pre-existing alpha-ferrite precipitate and the parent austenite

phase [17]. The microstructure of the TIG-MIG joint shows the abundant presence of
acicular ferrite with cementite on the boundaries of ferrite grain.
The HAZ of the TIG-MIG joint is characterized by chaotic lenticular acicular ferrite.
Acicular ferrite is known to improve the strength and toughness of steel, as appraised by
Loder et al. [18], Babu [19], Bahu and Bhadeshia [20], Capdevila et al. [21] and Hu et al.
[22]. He and Edmonds [23] also stated that acicular ferrite is desirable in low carbon steel
weldments as it improves the toughness over all other austenite transformation products.
Zhao et al. [24] also affirmed that acicular ferrite microstructure in low carbon steel
improved the strength and toughness. It is worthy to note that the microstructure of the
TIG-MIG joint did not deteriorate despite the higher heat input value. Chen et al. [10]
recorded a similar account. XRD analysis
Fig.1.3.3 Microhardness profiling for TIG, MIG and TIG-MIG hybrid joints

Fig1.3.3 Macrographs of the welded joints (a) TIG (b) MIG (c) TIG-MIG
1.3.4 XRD analysis
The diffractogram of the TIG joint is dominated by martensite phase diffracting at

a peak intensity of 45.24°, 65.65° and 82.79°. However, little iron (Fe) peaks diffracted at
43.76°. The diffractogram of the MIG welded joint shows more iron phases at high-
intensity peaks at 45.38° and 83.07°. Martensites phase also diffracted at a lower
intensity of 65.82°. And lastly, the TIG-MIG welded joint revealed only iron phases,
which accounted for its lowest hardness value. The higher hardness values of the TIG
and MIG joints are attributed to the presence of martensite phases. A similar observation
was reported by Khan et al.

Fig 1.3.4 Microstructures for the TIG, MIG and TIG-MIG welding processes.

Fig 1.3.4 The diffractogram for the TIG, MIG and TIG-MIG joints.

2. MIG welding process with activated flux

In activated MIG the main reason using is its parameter variation affects the weld
penetration and also it’s has impact on the performance of the activating flux. Taguchi’s
design method of optimization is used for identify the optimizing the parameters for the
GMAW process. In activated flux welding process due to marngoni effect arc
constriction happens and HAZ decreases and penetration due low surface tension
potential gradient to higher potential gradient this has major impact on weld penetration
and HAZ area .Then, the activating flux used GMAW steel is analysed in order to get the
effect of activated flux on weld mechanical properties, weld plate distortion and weld
bead geometry
Activated flux made of component of any oxides (MnO2, Cr2O3, MgCO3,

Fe2O3, TiO2, zinc oxide powdered which inorganic form of mixture of powders.
Activated flux mixed with the acetone which is easily evaporated after burning when
welding carried out so it don’t have any effect on weld zone in a liquid solvent in the
range acetone of 5 to 10 ml and flux mixed in order to make its paste uniformly, so that
its ready to apply on joint uniformly .
2.1 STATIC & CONTINUOUS ULTRASONIC WELDING
Up until now, the majority of research in the field of ultrasonic welding of thermoplastic
composites has concentrated on static welding of straightforward single-lap shear
samples. During the static welding process, different stages can be identified that
correspond to heating up and melting of the interface. More specifically, power and
vertical sonotrode displacement could be used to identify these stages and in situ monitor
and control the welding process. it is possible to find combinations of parameters that
consistently result in high strength joints.
Continuous ultrasonic welding has recently emerged as a viable high-speed

welding method for thermoplastic composites made of carbon fibre reinforced
polyphenylene sulphide (CF/PPS). The sonotrode glides over the overlap to be welded
while applying mechanical vibrations and a static welding force in the continuous
welding process.

Fig. 1.3.1 MIG Welding Setup Fig. 1.3.2 MIG Welding
2.2 MIG welding process with activated flux

In activated MIG the main reason using is its parameter variation affects the weld penetration
and also it’s has impact on the performance of the activating flux. Taguchi’s design method of
optimization is used for identify the optimizing the parameters for the GMAW process. In
activated flux welding process due to marngoni effect arc constriction happens and HAZ
decreases and penetration due low surface tension potential gradient to higher potential gradient
this has major impact on weld penetration and HAZ area. Then, the activating flux used GMAW
steel is analysed in order to get the effect of activated flux on weld mechanical properties, weld
plate distortion and weld bead geometry.
Activated flux made of component of any oxides (MnO2, Cr2O3, MgCO3, Fe2O3, TiO2,
zinc oxide powdered which inorganic form of mixture of powders. Activated flux mixed with
the acetone which is easily evaporated after burning when welding carried out so it don’t have
any effect on weld zone in a liquid solvent in the range acetone of 5 to 10 ml and flux mixed in
order to make its paste uniformly, so that its ready to apply on joint uniformly. A coating
generally of 0.1 mm layer thickness of mixture is applied on weld zone with the help of a paint
brush width generally of (10–12 mm) wide before the actual welding is carried out.
2.3 The mechanisms responsible low HAZ and deep penetration
Available literature shows that due to activated flux that is oxides of inorganic
material shows that there is no single theory which is leads to decrease in HAZ and
increase in penetration but some theory which play important shown below.

 Electromagnetic or Lorentz force.

 Marangoni Effect.
 Effect of arc constriction due to negative ions.
 Buoyancy or gravity force.
 Effect of arc constriction due to insulating surface of flux
2.4 Marangoni effect
When dissolved oxides of flux are added in molten weld pool it changes surface
tension in the weld pool properties. The Margonic effect says that flow take place from
lower surface tension gradient to higher surface gradient. When a activated flux is added
in the liquid pool which not in a small but quite significant proportion dc/dT gradient
vary from negative to positive, thus reverse Marangoni effect of convection take pace and
which in turn making the pool of weld much deeper. There are certain type of activated
flux is mention in above point of different flux.
When flux is not present in the cooler liquid metal which is at higher surface
tension at the pool outer surface flow from outer to inner to hot side of liquid pool.Pulls
the warmer liquid metal of lower surface tension near the pool surface outward. In the
presence of an activated flux on the other side, the change in fluid flow due to this
Margonic effect is connected with the Thermal Coefficient of Surface Tension (TCST)
pool of molten metal. If the negative is TCST, the cooler outer regions weld pool will
gives a higher surface tension compared to the centre of weld pool and the flow take
place outside result in shallow depth of penetration [7]. Whereas in positive gradient the
flow of molten metal is reversed to centre direction of the weld pool and at the centre the
flow of molten material flow take place in inner side and that’s why depth of penetration
increase and HAZ decrease. This in turn creates the narrow deeper and deeper weld pool
with small HAZ with same welding parameter and condition.
2.5 Review of literature

Mr. Dinesh Kumar et al. studied the optimization of different welding
parameters with the help of Taguchi method. In Taguchi method they have used L27
array for experimentation and they have found out the optimum parameter for depth of

penetration and Hardness. Taguchi and regression analyses were applied to optimization
of submerged arc welding parameters.
This experiment carried out in semi-automatic S/N mix determines an ideal ratio
from which better parameters are derived. An analysis of variance technique is applied to
measure the percentage contribution of each factor. Father BalaSrinivasan and al. [3] the
study examined the evolution of microstructure and durability changes in a differentiated
welding joint consisting of GTA W’s atenitic stainless steel and ferrite rust (FSS).
Furthermore, in neutral and acidic chloride solutions the various regions of the
resulting solder were examined for general corrosion behavior as well as pitting. The
austenitic stainless steel (ASS) thin section sheet (1,5 mm thickness) corresponds to AISI
316 and the AISI 430. Autogenously welded joints between an austenitic and the FSS
could be formed by the GTAW, since the sold metal has more of mechanical qualities
than the FSS parent material, without the difficulties of heat cracking.
3. Objective
1. The study of effect of activating flux on Tensile strength of Fe410 mild steel is
studied on Metal Inert Gas welding processes and optimum value is find out using
L9 array.
2. To join two dissimilar metals Stainless Steel 304 and mild steel which is in line
with the joining of metals SA-508 grade III and SS-304 LN by conducting
experiment to develop good quality weld by changing the process parameters. To
study the micro structural evaluation of successful weld metal
3.1 Data analysis
The effect of welding parameters on tensile strength and hardness of Fe 410 was
determined by the researchers utilizing activations such as weld current and MgO3 with
different fluxes, such as Fe2O3, FeO and a blend of these two fluxes. The L9 orthogonal
array optimizes these characteristics. Another statistical system, such as ANOVA, is
employed to calculate the proportion contribution of these parameters, and the result is
established by a regression analysis.

2.2. Ultrasonic welding
The continuous ultrasonic welding device that is depicted in Fig. 1a was created
internally. All of the studies involving static and ongoing ultrasonic welding were
conducted using this apparatus. A VE20 SLIMLINE DIALOG 6200 off-the-shelf
ultrasonic welder from Herrmann Ultrasonics and a rigid frame with an X-Y table on a
guiding system that enables automatic translation in its x-direction make up the device.
The welder operates at a 20 kHz frequency. Converter, booster, and sonotrode are the
components of the welding train. The manufacturer specified an 80 m (peak-to-peak)
maximum operational amplitude for the sonotrode. It was a rectangular sonotrode. The
sonotrode's contact surface was 15 mm wide and 30 mm long. In each of the experiments
conducted for this study.
A close-up of the continuous ultrasonic welding setup is shown in Fig. 2.1b

during the welding procedure. Two aluminium bar clamps spaced 70 mm apart from one
another held the CF/PPS top and bottom adherends in place. Between the two adherents
was positioned the mesh energy director. Alignment pins were employed to dependably
guarantee a set overlap width of 12.7 mm between the two adherends. As illustrated in
Fig. 2.2, while the sonotrode delivered the static welding force and the high-frequency
vibrations, the X-Y table moved below the sonotrode over a welding distance of 205
mm. Fig. 1b shows the relative displacement of the sonotrode in relation to the adherends
as a result. Force, amplitude, and translational speed were the continuous welding
process's three main parameters.

Fig. 2.1. (a) In-house developed continuous ultrasonic welding machine and (b) a close-up of the to be
welded parts together with the sonotrode and the bar clamps.
Fig. 2.2. Schematic overview of start and end position of the sonotrode with respect to the to be welded
overlap together with the welding distance.
Table 1 Test matrix for the static and continuous ultrasonic welding experiments for the three parameter
combinations with different welding forces (F) and (peak-to-peak) vibrational amplitudes (A).

2.3. Melt front analysis
A fractographic investigation was carried out around the melt front to understand
how the interface melts and to pinpoint the location of the melt front for the continuous
welding process. The place where the melted ED linked to the adherends was designated
as the melt front's location. To check for consistency over the length of the plate, the
continuous welding process was prematurely stopped at three distinct weld distances of
56 mm, 100 mm, and 144 mm of the leftmost end of the overlap (see Fig. 2.2 for
reference). Up until that weld distance was reached, one continuous weld was made on a
separate pair of adherends (top and bottom). This was done for each combination of
welding force and vibrational amplitude at the optimum welding speed.
For each weld distance a 50 mm-wide sample was cut from the location were the
process was stopped. Each of these samples were mechanically separated, and the
resulting fracture surfaces were analysed using a ZEISS Discovery.V8 SteREO
microscope. For the close-up image of the mesh a Keyence VR one-shot 3D (VR-5000)
microscope was used.
To visualize the melting process during the static ultrasonic welding, four welds
in a single lap shear configuration were welded for each combination of welding force,
vibrational amplitude, and vibration time indicated in Table 1. These welds were then
mechanically tested, and their fracture surfaces were analysed using the ZEISS
Discovery.V8 SteREO microscope.
2.4. Energy and power consumption
Based on the welder's feedback information, the average used power and areal energy
density were calculated. The procedure used the ideal welding speed, while the ideal
vibration time was used for static welding. To determine the amount of energy used for
both processes, the power curve's relationship to time was integrated. By dividing the
whole amount of energy consumed by the total amount of welded area, the energy
density per unit area was calculated. An average was calculated for the static welding
procedure across four welds. Since the initial 15 mm of the continuous process's welded

seam contained non-welded ED, the total amount of welded seam was subtracted from
this measurement to determine the average power and used energy.
2.5. Temperature measurements
Fig. 2.3 shows where the thermocouples were placed for (a) the continuous and (b) the
static welding process. The thermocouples were placed in between the bottom adherend
and energy director. The temperature at the weld interface was measured using K-type
thermocouples supplied by Tempo (product number 2-2200-0004 and description
GG2202K-0). An analog output K-type thermocouple amplifier was used from Adafruit
with product number AD8495 sampling the temperature at 1 kHz. The thermocouples
had a wire diameter of 0.10 mm. A 25 moving average filter (using the filter function in
matlab) was applied to the measured temperature data in order to filter high frequency
fluctuations.
For the continuous process 5 evenly spaced thermocouples were placed along the
overlap as indicated in Fig. 2.3. For the static welding process, 5 additional welds with
thermocouples were made for each combination of force and vibrational amplitude, on
top of the welds used for mechanical testing. The temperature of the weld interface was
measured from the start of the welding process until the optimum vibration time. Per
weld two thermocouples were placed, one (TC1) in the middle of the overlap and a
second one (TC2) approximately 3 mm from the edge as shown in Fig. 2.4
Fig. 2.3. (a) Bottom adherend in the continuous ultrasonic welding set-up together with five
thermocouples.
(b) Side view of adherends for static welding with thermocouple locations

Fig. 2.4. Clamping situation of adherends in static ultrasonic welding set-up
2.6. Mechanical testing
After removing the two sides, the continuously welded 220 mm-long adherends
were divided into six samples for single lap shear testing that were 25.4 mm broad (28.8
mm-wide each). For LSS testing, four welds were created for each vibration period
during the static welding process. A Zwick/Roell 250 kN universal testing machine with
a cross-head speed of 1.3 mm/min was used to physically test the acquired single-lap
shear samples from the continuous and static welding processes. To achieve parallelism
between the entrance of the load and the overlap, the grips were given the necessary
offset. The maximum load was divided by the overlap area to determine the LSS.
3. Results
3.1. Mechanical tests
The results of the single lap shear tests performed on the welded connections made using
the continuous welding procedure are shown in Fig. 3.1. Each point on the graph
indicates the average strength of six samples taken from a panel and welded under a
particular set of force, amplitude, and welding speed variables. It is clear that for all
three force and amplitude combinations, the greatest strength values achieved were in
the range of 28 MPa. Additionally, it can be shown that the ideal welding speed under
these circumstances—approximately 35 mm/s—was determined for the 500 N and 80 m
combination.

A significant drop in strength occurred at either 25 mm/s and 45 mm/s.

Increasing the welding force to 1500 N, while maintaining the amplitude constant (80
μm) resulted in the highest lap shear strength being reached at both 35 and 45 mm/s. It
should be noted that according to ANOVA statistical analysis the average lap shear
strength values obtained for those two speeds are not statistically different (𝑝-value =
0.0709 being not significant at p < 0.05, F = 4.08). However, since degradation of the top
adherend was observed when welding at 35 mm/s, 45 mm/s was chosen as the optimum
speed for this force and amplitude combination. When increasing the speed to 55 mm/s
the strength decreased slightly. The ideal welding speed for the 500 N and 60 m
combination was roughly 15 mm/s. The strength decreased above a 15 mm/s welding
speed. Due to the substantial thermal degradation of the top adherend that was seen
below 15 mm/s, this case's lower speed limit was set at 15 mm/s.
Fig. 3.1. Average single lap shear strength values obtained after mechanical testing for the continuous
ultrasonic welding process. The bars represent plus and minus the standard deviation around the average
(n
= 6)
Fig. 3.2 shows representative fracture surfaces of welds obtained at the optimum
welding speed for each one of the three force and amplitude combinations. The fracture
surfaces have a uniform appearance and no non-welded energy director was present for
any of the welds. However, whitish resin-rich areas containing voids could be observed
for all welds. Failure at the weld interface was the most frequent failure type for the 500
N and 80 μm and 1500 N and 80 μm combinations. However, a portion of the failure
happened in the space between the bottom adherend's first and second layers. The failure
most typically occurred within the adherends for the lowest vibrational amplitude (500 N
and 60 μm combination), with the majority of the top adherend's initial ply staying stuck
to the top adherend following failure.

Fig. 3.2. Fracture surfaces of adherends welded at the optimum welding speeds for the three combinations
of welding force and vibrational amplitude. The arrow indicates a resin rich area containing voids. The
dashed rectangular boxes indicate examples of failures that occurred in between the first and second layer
of the bottom adherend. The circle combinations indicate where the first layer of the top adherend
separated from the top adherend and remained adhered to the bottom adherend.
3.2. Power and displacement curves
The power and displacement curves for the continuous ultrasonic welding
procedure are shown in Fig. 3.3 at the ideal welding rates. At the beginning of the
welding operation, the power immediately increased for all admixtures of welding force
and vibrational amplitude. The power fluctuated throughout the welding process,
hovering around an average power value of around 1600 W for 500 N & 80 mm (Fig.
3.3a), 1900 W for 1500 N & 80 mm (Fig. 3.3b), and 900 W for 500 N & 60 mm (Fig.
3.3c). Power variations were greater near the beginning and conclusion of the weld than
in the middle. The power variations were often less noticeable for the 500 N & 60 m
instance (Fig. 3.3c).

The vertical displacement of the sonotrode did not show a consistent behaviour.
Fig. 3.3. Power and vertical sonotrode displacement curves of the continuous ultrasonic welding process
for the three combinations of force and vibrational amplitude welded at the optimum welding speed.
The power and displacement curves for the three different pairings of vibrational
amplitude and welding force are shown in Fig. 3.4 for the static ultrasonic welding
process. Figure 3.4a, b, and c show that within the first 100 ms in each case, the power
rose sharply. The 1500 N & 80 m combination (Fig. 3.4b) experienced the greatest
power increase, followed by the 500 N & 80 μm (Fig. 3.4a) and the 500 N & 60 m
combinations (Fig. 3.4c). The power stayed between about 800 W and 1500 W for the
500 N & 80 μm combination after the initial increase, and between 1200 W and 1800 W
for the 1500 N &
80 μm combination (Fig. 3.4a) (Fig. 3.4b),
The vertical displacement in Figs. 3.4a, 3.4b, and 3.4c increased steeply within 130 ms
(500 N & 80 μm), 50 ms (1500 N & 80 μm), and 220 ms (500 N & 60 μm) respectively.
This initial steep increase was followed by a plateau in displacement, lasting
approximately 80 ms for 500 N & 80 μm, 60 ms for 1500 N & 80 μm, and 240 ms for
500 N & 60 μm.

Fig. 3.4. Power and vertical sonotrode displacement curves of the static ultrasonic welding process for the
three combinations of force and vibrational amplitude.
3.3. Melt front analysis
For each of the three combinations of force and vibrational amplitude and ideal
welding rates, Fig. 10 depicts example fracture surfaces where the continuous welding
process was abruptly interrupted at 100 mm from the leftmost edge of the overlap. As
seen in Figs. 3.5a, b, and c, the melt front in each of the three cases was closer to the
front edge of the sonotrode, parallel to the rear edge, and under the sonotrode in all three
instances. Behind the melt front, or the welded area, was a rough, resin-rich surface with
sporadic broken fibres (see Fig. 3.5a, b, and c). The resin on the adherends' outer surface
had likely also melted, along with the entire energy director. An energy director who
wasn't welded was present before the melt front. A portion of the non-welded energy
director under and in front of the sonotrode is seen up close in Fig. 3.5d. As can be
observed, the ED was severely flattened and deformed close to the melt front. Far ahead
of the sonotrode, the ED was seen to be completely unaltered.
The process parameters affected where the melt front was in Fig. 3.5. For each set of
processing settings, Table 2 displays the melt front distance—the distance between the
melt front and the front edge of the sonotrode—as well as the melt front distance against

the pristine ED at three distinct places in the overlap With the highest standard deviation
discovered for the 500 N and 60 m combination, it can be shown that the melt front
distance remained largely consistent during the welding operation.
Fig. 3.5. Representative fracture surfaces showing the melt front positions at optimum welding speeds after
stopping the welding process at 100 mm from the leftmost edge of the overlap for (a) 500 N, 80 μm and 35
mm/s, (b) 1500 N, 80 μm, and 45 mm/s, (c) 500 N, 60 μm, and 15 mm/s. (d) Close-up of mainly the
nonwelded energy directing mesh ahead of sonotrode.
Table 2 Average melt front distances with respect to the front edge of the sonotrode and position of melt
front relative to the pristine ED for the three combinations of welding force (F) and vibrational amplitude
(A) welded at the optimum welding speeds (S).
Fig. 3.6 shows representative fracture surfaces of adherends statically welded

under different vibration times for the three combinations of welding force and
vibrational amplitude used in this study. It can be seen that for each combination of
welding parameters the centre of the overlap melted the latest. The area of non-welded
energy director material decreased for increased vibration times. The first vibration times
for which the welds contained no non-welded energy director are 440 ms for 500 N and

80 μm, 335 ms for 1500 N and 80 μm, and 940 ms for 500 N and 60 μm. For most of the
welds obtained under vibration times beyond those values fibre distortion could be
observed at the edges of the overlap.
Fig. 3.6. Representative fracture surfaces of statically welded adherends at multiple different vibration
times for the three combinations of welding force and vibrational amplitude: 500 N and 80 μm, 1500 N
and 80 μm, and 500 N and 60 μm. The white dashed areas indicate the presence of non-welded energy
director
3.4. Power, energy and temperature measurements
Table 3 shows the areal energy density and the average consumed power for both
the static and continuous welding processes at the optimum vibration time and welding
speed, respectively. It can be seen that energy and power were significantly higher for

the continuous welding process. the average power and the energy density in continuous
ultrasonic welding were almost twice as high as those of the static welding process.
Table 3 Average power and average areal energy density and corresponding standard deviation for the three
combinations of force and vibrational amplitude welded at the optimum static vibration times and optimum
continuous welding speeds
Fig. 3.7 shows the temperatures measured during the continuous welding process at five
different locations in the welding interface. The grey shaded areas indicate the time span
during which a specific thermocouple was located under the sonotrode. It can be seen
that the temperature measured by all the thermocouples increased almost instantly to
values between 100 ◦C and 200 ◦C at the beginning of the welding process. Afterwards,
the temperature started to increase more steeply well before the sonotrode reached the
thermocouple until a maximum value was reached coinciding with the point where the
sonotrode moved away from the thermocouple. The maximum temperatures were 474
◦C ± 45 ◦C, 512 ◦C ± 41 ◦C, and 433 ◦C ± 17 ◦C for 500 N & 80 μm (Fig. 3.7a), 1500 N
& 80 μm (Fig. 3.7b), and 500 N & 60 μm (Fig. 3.7c), respectively.
Fig. 3.8 displays typical temperatures recorded at the For the static ultrasonic
welding process, the welding interface. temperature readings at one of the overlap's
edges and in the centre This Figure depicts Figure3.8 a, b demonstrate this. and c
demonstrated a first step in each case's temperature evolution. the temperature quickly
rose from the ambient level to over the melting point. first 50 to 100 milliseconds of the
PPS temperature (280 °C) 50 ms for 1500 N & 80 m, 100 ms for 500 N & 80 m, and 500
N & 60 μm). A second stage could then be seen after that, where Significantly less
temperature rose at a time. This second stage lasted between 50 and 100 ms as well.
During these first and second stages, temperatures at the overlap's centre and periphery

were comparable. Following that, the temperatures at the two places continued to rise but
tended to differ from one another. While the temperature at the edge of the overlap was
often greater than at the centre for the combinations of 1500 N and 80 m (Fig. 3.8b) and
500 N and 60 m (Fig. 3.8c), the reverse behaviour was observed for the combination of
500 N and 80 m (Fig. 3.8a). For the 500 N & 80 μm combination the maximum
temperature amounted to around 450 ◦C (centre of the overlap). For the 1500 N & 80 μm
combination the maximum temperature was around 550 ◦C (edge of the overlap).
Finally, for the 500 N & 60 μm combination the maximum temperature was around 500
◦C (edge of the overlap).
Fig. 3.8. Representative temperature measurements for the static welding process until the optimum
vibration time for the three parameter combinations. TC1 was located in the centre of the overlap and TC2
was located on the edge of the overlap as indicated in Fig. 2.3b
4. Discussion
The fracture surfaces in Figs. 3.5 and 3.6 demonstrate a key distinction between
the continuous and static welding processes with regard to melting of the interface.
While the amount of non-welded region beneath the sonotrode steadily declines in the

static process until it reaches zero, it remains constant in the continuous process. In other
words, while static welding involves going through each step of the welding process
sequentially, the condition of the material beneath the sonotrode steadily changes. On the
other hand, in the continuous welding process, an unchanging condition (a simultaneous
combination of the many stages the material goes through during the welding process, as
schematically shown in Fig. 4.1) can be found under the sonotrode.
In the continuous process, when either the welding force or amplitude increases,
the amount of non-welded area beneath the sonotrode decreases (Fig. 3.5). The
nonwelded energy director will become a welded joint faster as a result of the faster heat
generation. The shape of the power curves is identical in both techniques when it comes
to the power lost during welding (Figs. 3.3 and 3.4). It is thought that these variations,
which have an initial sharp spike and then fluctuate around a particular value, indicate
the various phases the material went through. However, in the continuous process, both
the total power dissipated and the energy density are substantially larger (see Table 3).
Since the power or energy used in ultrasonic welding is usually acknowledged to be
invested in both the creation of the weld and its surrounds, we suppose this is related to
variations in adherend size. In fact, additional studies using the identical adherend and
energy director arrangement as continuous welding and a 15 mm-wide static weld at the
centre demonstrated power dissipation values similar to those seen in continuous
welding (Fig.
4.1).
Fig. 4.1.. (a) Schematic exaggerated interpretation of the CUW process at the interface. (b) Schematic
situation for the static welding process

Fig. 4.2. Power curves for the 500 N & 80 μm combination for a normal static weld on 15 mm-wide
coupons as shown in Fig. 3, and a static welds made in the middle of 220 mm-wide adherends normally
used for continuous welding.
Two phenomena could account for the higher power dissipation in continuous
welding settings as opposed to static welding when the adherends are wider than the
sonotrode. In the beginning, vibrations are conveyed past the material right below the
sonotrode. As seen in Fig. 3.8, at the start of the continuous operation, all the
thermocouples recorded a relatively simultaneous temperature increase to a level
between 100 and 200 C. The occurrence of vibration and subsequent friction between the
thermocouples and adherends along the overlap, rather than just at the precise point of
the sonotrode, might be understood as the cause of this phenomena. Second, the earliest
stages of the welding process begin outside the sonotrode's confines. In the continuous
process, as shown in Fig. 3.5, the mesh energy director undergoes local melting and
flattening before the sonotrode. Additionally, before the sonotrode gets to each
thermocouple point, the temperature there begins the ramp-up associated with the
welding process (Fig. 3.4). The effective area undergoing the various stages of the
welding process can therefore be stated to be larger than the actual imprint of the
sonotrode due to pressure dispersion and amplitude transmission beyond the sonotrode,
which results in increased power requirements.
As previously indicated, before the sonotrode reaches each point, the temperature
in continuous welding begins to ramp up past the pseudo-initial threshold of 100–200 C.
Static welding definitely deviates from this. However, as can be shown in Fig. 4.3, the
highest temperatures reached in both types of processes are essentially within the same
150 C range. Although continuous welding requires a greater thermal energy input due to

longer exposure to high temperatures, melting kinetics at the welding interface are
identical for both the continuous and static processes. The distance between the melt
front and the pristine ED in continuous welding (Fig. 3.5) and the time until the end of
the displacement plateau in static welding are both indicators of how long it takes for
pristine
ED to become melted ED connected to the adherends, and both are similar as shown in
Table 4. Second, the ideal welding rates for continuous welding and static welding have
identical ideal vibration times (Table 4). This suggests that in the specific scenario under
investigation, the results of the static process can be used to establish the ideal welding
speed for the continuous procedure.
Fig. 4.3. Representative temperature measurements for the continuous and the static welding process when
the thermocouple is directly under the sonotrode (grey shaded area) and 300 ms before shown for the three
parameter combinations at the optimum welding speed (continuous) and optimum vibration time (static)
respectivel
This is an important result since it could lead to a considerable reduction of the

effort needed to define optimum welding conditions in continuous ultrasonic welding by
making use of the relatively simple and efficient methods available in literature to define
the optimum vibration time in the static process. Nevertheless, the obvious differences in
temperature evolution between the two processes and their potential impact on the

validity of the relation between vibration time (static) and welding speed (continuous)
need to be further understood. The aforementioned relation may be particularly
challenged by altering the thermal characteristics of the adherends and/or the energy
director's melting behaviour, for as by welding a different composite material. On the
other hand, altering the welding setup (using an ultrasonic welder or a clamping jig) may
modify the absolute values of the vibration duration and welding speed but not their
relationship. This is corroborated by the fact that, while having highly varied absolute
values in each force and amplitude combination, the three combinations utilised in this
investigation demonstrated a comparable relationship between vibration duration and
welding speed.
Table 4 Time to transform pristine ED into melted ED for static and CUW
Finally, compared to statically welded joints, continuous welded joints have a much
lower maximum lap shear strength. We think that this is due to voids weakening the
adhesion interface and, possibly, the neighbouring adherend layers. These voids, which
were clearly visible on the fracture surfaces of the continuous welds , are thought to be
the result of a lack of consolidation during the welding process, specifically since
cooling pressure was not provided.
Lack of consolidation could result from: (i) the continuous welding set-up
missing a consolidation shoe which would enable the welded areas to cool down under
pressure; (ii) uneven thickness and resulting uneven pressure caused by the presence of
non-welded ED under the sonotrode (as indicated in Fig. 4.1). Owing to the fact that
welded joints obtained at 1500 N and 80 μm featured the same maximum LSS as the
other welded joints despite the fact that the melt front was aligned with the front edge of
the sonotrode (Fig. 3.5) points at the absence of a consolidation shoe as the main cause in
the LSS knock down.
Therefore, we anticipate that including a consolidation shoe in the continuous

welding setup will reduce the number of adherend and weld line voids, thereby

increasing the strength of the continuous ultrasonic welds to levels comparable to static
welds. However, we do not anticipate that the addition of a compaction shoe to the
welding setup will have a major impact on the ideal welding speeds identified in the
present investigation. This is based on the fact that the fracture surfaces of samples
welded at welding speeds below and above the optimum featured initial signs of
overheating (fibre distortion, discoloured resin) and areas of not completely molten ED,
respectively (Fig. 4.3). Both overheating and non-molten ED are majorly related to the
heating phase of the welding process and, consequently, we do not expect them to be
affected by whether consolidation pressure is applied or not during the cooling phase.
Fig. 4.4. Representative fracture surfaces of continuous welds for the 500 N and 80 μm parameter
combination obtained at welding speed (a) below and (b) above the optimum welding speed. (a) displays
distorted fibre bundles and discoloured resin at the edges of the overlap, (b) shows areas of non-welded
ED.
Top adherend is shown on the left and bottom adherend is shown on the right.

5. Conclusions
This study's goal was to compare and contrast the static and continuous ultrasonic
welding methods for thermoplastic composites in order to determine how we may use
what is known about static welding to better understand and develop the continuous
method. Experimental comparisons were made between the two processes with regard to
the melting of the interface, the required areal energy density and power consumption,
the temperature at the interface, and the impact of changing welding parameters, such as
vibrational amplitude and force, on the ideal welding conditions. These are the major
findings of this investigation:
• For the continuous process the amount of non-welded area under the sonotrode
remains constant, while for the static process the amount of non-welded area
gradually decreases until it becomes zero. In other words, for the continuous
process there is a constant coexistence of different phases the material goes
through. In the static process, on the other hand, the material sequentially
undergoes all phases of the welding process.
• The morphology of the power curves is similar for both processes. Both featuring
a rapid increase at the beginning followed by fluctuation around a certain value.
However, the overall dissipated power for the continuous process is significantly
higher. This is most likely caused by the larger adherend size in the continuous
process.
• For the continuous welding process the temperature measured at each
thermocouple location starts to ramp before the sonotrode arrives at that specific
location. Therefore, the effective area undergoing the different stages of the
welding process can be said to be bigger than the actual imprint of the sonotrode,
which results in higher power needs. Despite the higher power needs for the

continuous process both the static and continuous process resulted in maximum
temperatures within the same range.
• Because the optimum vibration periods and welding speeds in both processes are
similar, it may be concluded that the kinetics of the melting process are
unaffected by the procedure's use as a static or continuous operation. Through the
use of the relatively straightforward and effective methods described in the
literature to determine the ideal vibration time in the static process, this similarity
has the potential to significantly reduce the labour and material effort invested in
defining the best welding conditions for continuous ultrasonic welding. However,
more research is required to determine how sensitive this result is to variations
in, for example, the composition of the composite material being welded.
• The maximum lap shear strength of the continuous welded joints is significantly
lower than that of the statically welded joints. This is most likely related to the
presence of voids at the continuous welded interface. The voids are believed to
be caused by a lack of consolidation during cooling. Therefore, we expect the
weld quality and the lap shear strength to increase once a consolidation shoe is
implemented into the welding process.

6. REFERENCES
1. Bram Jongbloed,Julie Teuwen, Rinze Benedictus, Irene Fernandez VillegasOn
differences and similarities between static and continuous ultrasonic welding
of thermoplastic composites, 8 October 2022
https://doi.org/10.1016/j.compositesb.2020.108466
2. Bram Jongbloed , Rahul Vinod, Julie Teuwen, Rinze Benedictus, Irene
Fernandez Villegas, Improving the quality of continuous ultrasonically
welded thermoplastic composite joints by adding a consolidator to the
welding setup, 3 January 2022
https://doi.org/10.1016/j.compositesa.2022.106808
3. C. B. G. Brito,J.Teuwen ,C.A.Dransfeld , I. F.Villegas The effects of misaligned
adherends on static ultrasonic welding of thermoplastic composites, 8
January 2022, https://doi.org/10.1016/j.compositesa.2022.106810

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SEMINAR REPORT

UNDERWATER WELDING OF INCONEL 625

UNDERWATER WELDING OF INCONEL 625

Program Educational Objectives (PEOs):

Program Specific Outcomes (PSOs):

PO1: Engineering knowledge: Apply the knowledge of mathematics, science,

Title Page No.

1.1.2. The major challenge encountered in welding of Alloy 625

It is my radiant sentiment to place on record my earnest gratitude and regards to

Cost-cutting measures are continually sought after by aircraft producers. As a result,

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2.1. In-house developed continuous ultrasonic welding machine. .................................. 6

2.3 welding set-up together with five thermocouples. . ....................................................9

2.4 Clamping situation of adherends in static ultrasonic welding set-up .......................9

Power and vertical sonotrode displacement curves of the continuous

ultrasonic welding process. ........................................................................................ 12

welding process ......................................................................................................... 13

after stopping the welding process ............................................................................. 14

3.6 Fracture surfaces of statically welded adherends at different vibration times

3.8 Temperature measurements for the static welding process ................................... 17

4.4 Representative fracture surfaces of continuous welds ........................................... 22

Dept. of Mechanical Engineering, SJCET Palai

1.1 Introduction to TIG-MIG hybrid welding process

Dept. of Mechanical Engineering, SJCET Palai

1.2 Experimental details

1.2.1 Materials and equipment

1.2.3 Process parameters

Dept. of Mechanical Engineering, SJCET Palai

Fig. 1.2.3 (a)The schematic of the TIG- MIG hybrid method.

1.3 Experimental results

Dept. of Mechanical Engineering, SJCET Palai

Dept. of Mechanical Engineering, SJCET Palai

1.3.2 Hardness properties

1.3.3 Macrostructure and microstructure

Macrostructural and microstructural evolution occur during and after welding

Dept. of Mechanical Engineering, SJCET Palai

Dept. of Mechanical Engineering, SJCET Palai

Dept. of Mechanical Engineering, SJCET Palai

Dept. of Mechanical Engineering, SJCET Palai

1.3.4 XRD analysis

The diffractogram of the TIG joint is dominated by martensite phase diffracting at

Dept. of Mechanical Engineering, SJCET Palai

Dept. of Mechanical Engineering, SJCET Palai

Dept. of Mechanical Engineering, SJCET Palai

2. MIG welding process with activated flux

Activated flux made of component of any oxides (MnO2, Cr2O3, MgCO3,

2.1 STATIC & CONTINUOUS ULTRASONIC WELDING

Continuous ultrasonic welding has recently emerged as a viable high-speed

Dept. of Mechanical Engineering, SJCET Palai

Fig. 1.3.1 MIG Welding Setup Fig. 1.3.2 MIG Welding

2.2 MIG welding process with activated flux

2.3 The mechanisms responsible low HAZ and deep penetration

Dept. of Mechanical Engineering, SJCET Palai

 Electromagnetic or Lorentz force.

2.4 Marangoni effect

2.5 Review of literature

Dept. of Mechanical Engineering, SJCET Palai

3.1 Data analysis

Dept. of Mechanical Engineering, SJCET Palai

2.2. Ultrasonic welding

A close-up of the continuous ultrasonic welding setup is shown in Fig. 2.1b

Dept. of Mechanical Engineering, SJCET Palai