Computational modeling of fatigue crack propagation in butt welded joints subjected to axial load.

This article addresses the study of crack behavior elicited on axial fatigue in specimens joined by butt weld made of steel ASTM A36 by using fracture mechanics and simulation software of finite elements (Ansys APDL, Franc3D). The computational model was initially to define the geometry model by using CAD software. Specimens with Weld Reinforcement of 2 mm and 3mm were simulated. Subsequently, the type of element for the mesh, the information inclusion concerning material mechanical properties and load conditions were selected. By using Franc3D software, the crack propagation phenomenon is analyzed, and its growth parameters have been established. In this way, it is possible to calculate the magnitude of stress intensity factor (SIF) along the crack front. It is concluded that the stress located in the weld toe is maximized proportionately to the size of the weld reinforcement due to the concentration effect of geometric stress. In addition, it is observed that the propagation rate obtained from Paris law has a similar behavior for the studied weld reinforcements; the latter as there were short cracks.

Evaluation of operational parameters role on the emission of fumes.

Electric arc welding is a routine operation in the construction of metallic structures, but the fumes generated during the welding process can threaten the health of welders. Fumes are undesirable products of the majority of welding operations and may have various detrimental effects on health. The purpose of this study was to investigate the effect of operational parameters of the shielded metal arc welding (SMAW) process on the emission of fumes. A dust monitor was used to measure the number and mass concentration of fumes generated by SMAW. Measurements were made at the distances of 23 cm (hood inlet) and 41 cm (welder's breathing zone) from the weld point, with different values assigned to three operational parameters, namely current intensity, travel speed, and heat input (HI). Number concentration (NC) decreased with the increase in particle size. The highest mass concentrations (MC) were observed for MC1 (0.35-0.5 µm) and MC8 (Larger than 6.5 µm). For reducing exposures to fumes, welders are recommended to use the lowest voltage and amperage and the highest travel speed to the extent that does not compromise in the quality of welds. For assessment of exposure to airborne particles in industrial workplaces and specially in welding operations, it is thought that taking, solely, mass concentration in to consideration and lack of attention to number concentration would not be able to reflect accurate assessment of the adverse effects of particles on the body organs.

Mitigation measures of electromagnetic field exposure in the vicinity of high frequency welders.

BACKGROUND: Presented information about the welding process and equipment, focusing on the emission of electromagnetic field (EMF) with levels significant in terms of the labor safety regulations in force in Poland - the ordinances of the Minister of Family, Labour and Social Policy that came into force on June 27, 2016 and June 29, 2016 - emerged due to harmonization with European Union directive 2013/35/EU of 26 June 2013 of the European Parliament and the Council. They presented methods of determination of the EMF distribution in the welding machine surroundings and analyzed the background knowledge from the available literature. MATERIAL AND METHODS: The subject of the analysis included popular high frequency welders widely used in the industry. Electromagnetic field measurements were performed in the welder operating place (in situ) during machine normal operations, using measurement methods accordant with labor safety regulations in force in Poland and according to the same guidelines, the EMF distributions and parameters having been described. RESULTS: They presented various scenarios of particular, real examples of excessive exposure to EMF in the dielectric welder surroundings and showed solutions, ranging from simple and costless and ending on dedicated electromagnetic shielding systems, which allowed to reduce EMF exposure in some cases of more than 80% (protection zone ranges) or eliminate dangerous zone presence. CONCLUSIONS: It has shown that in the dielectric welders surrounding, significant EMF strength levels may be the result of errors or omissions which often occur during development, installation, operation or modification of welding machines. It has allowed to present the measures that may significantly reduce the exposure to EMF of workers in the welder surroundings. The role of accredited laboratories in helping in such cases was underlined. Med Pr 2017;68(6):693-703.

Determination of "safe" and "critical" nanoparticles exposure to welders in a workshop.

The present study examined consequences of "safe" versus "critical" exposure to nanoparticles (NP) released during welding operations. With this aim in mind, a set of measurements regarding NP emissions was undertaken in a workshop during welding by metal active gas of carbon steel using different mixtures of argon (Ar) and carbon dioxide (CO2) as well as different process parameters which might influence emission of (NP). If these measurements were conducted in several locations away from the welding sources, the graphical representation of the obtained observations with time enabled definition of "safe" and "critical" regions within a welding workshop in terms of welder's exposure. This information may be combined with the results of risk analysis derived by control banding and helps to categorize the sites where regulatory measures such as operation containment or dedicated exhaust ventilation need to be implemented.

Computer aided weld defect delineation using statistical parametric active contours in radiographic inspection.

A perfect knowledge of a defect shape is determinant for the analysis step in automatic radiographic inspection. Image segmentation is carried out on radiographic images and extract defects indications. This paper deals with weld defect delineation in radiographic images. The proposed method is based on a new statistics-based explicit active contour. An association of local and global modeling of the image pixels intensities is used to push the model to the desired boundaries. Furthermore, other strategies are proposed to accelerate its evolution and make the convergence speed depending only on the defect size as selecting a band around the active contour curve. The experimental results are very promising, since experiments on synthetic and radiographic images show the ability of the proposed model to extract a piece-wise homogenous object from very inhomogeneous background, even in a bad quality image.

Evaluation of human exposure to complex waveform magnetic fields generated by arc-welding equipment according to European safety standards.

In this paper, a procedure is described for the assessment of human exposure to magnetic fields with complex waveforms generated by arc-welding equipment. The work moves from the analysis of relevant guidelines and technical standards, underlining their strengths and their limits. Then, the procedure is described with particular attention to the techniques used to treat complex waveform fields. Finally, the procedure is applied to concrete cases encountered in the workplace. The discussion of the results highlights the critical points in the procedure, as well as those related to the evolution of the technical and exposure standards.

Evolution of microstructure and residual stress under various vibration modes in 304 stainless steel welds.

Simultaneous vibration welding of 304 stainless steel was carried out with an eccentric circulating vibrator and a magnetic telescopic vibrator at subresonant (362 Hz and 59.3 Hz) and resonant (376 Hz and 60.9 Hz) frequencies. The experimental results indicate that the temperature gradient can be increased, accelerating nucleation and causing grain refinement during this process. During simultaneous vibration welding primary δ -ferrite can be refined and the morphologies of retained δ-ferrite become discontinuous so that δ-ferrite contents decrease. The smallest content of δ-ferrite (5.5%) occurred using the eccentric circulating vibrator. The diffraction intensities decreased and the FWHM widened with both vibration and no vibration. A residual stress can obviously be increased, producing an excellent effect on stress relief at a resonant frequency. The stress relief effect with an eccentric circulating vibrator was better than that obtained using a magnetic telescopic vibrator.

A laser-based vision system for weld quality inspection.

Welding is a very complex process in which the final weld quality can be affected by many process parameters. In order to inspect the weld quality and detect the presence of various weld defects, different methods and systems are studied and developed. In this paper, a laser-based vision system is developed for non-destructive weld quality inspection. The vision sensor is designed based on the principle of laser triangulation. By processing the images acquired from the vision sensor, the geometrical features of the weld can be obtained. Through the visual analysis of the acquired 3D profiles of the weld, the presences as well as the positions and sizes of the weld defects can be accurately identified and therefore, the non-destructive weld quality inspection can be achieved.

Increased metal concentrations in exhaled breath condensate of industrial welders.

It was the aim of this study to evaluate the effect of different devices on the metal concentration in exhaled breath condensate (EBC) and to prove whether working conditions in different welding companies result in diverse composition of metallic elements. The influence of two collection devices (ECoScreen, ECoScreen2) on detection of metallic elements in EBC was evaluated in 24 control subjects. Properties of ECoScreen and a frequent use can alter EBC metal content due to contamination from metallic components. ECoScreen2 turned out to be favourable for metal assessment. Concentrations of iron, nickel and chromium in EBC sampled with ECoScreen2 were compared between non-exposed controls and industrial welders. Metal concentrations in EBC were higher in 36 welders recruited from three companies. Exposure to welding fumes could be demonstrated predominantly for increased iron concentrations. Concentrations of iron and nickel differed by working conditions, but chromium could not be detected in EBC.

Macular degeneration in an arc welder.

A male welder who had been working in an industrial machine plant for more than 20 years experienced acute intense pain in his left eye with continuous lacrimation while performing arc welding in 1997. Later in 1997, at the age of 39 yr, macular edema was found in his left eye. He was diagnosed with macular degeneration (MD) of the left eye in 2002, and with right eye MD in 2004. Radiation in the visible and near infrared (IR) spectra penetrates the eye and is absorbed by the retina, possibly causing thermal or photochemical damage. Such retinal damage may be permanent and, therefore, sight-threatening. The young age and history of an acute painful eye injury are not consistent with age related macular degeneration (AMD) but rather is likely maculopathy caused by welding arc exposure.

Development of error-compensating UI for autonomous production cells.

This contribution deals with the impact of human error on the overall system reliability in flexible manufacturing systems (FMS). Autonomous production cells are used to illustrate an error-compensating system design on the basis of Sheridan's (1997) paradigm of supervisory control. In order to specify human errors and their effects in terms of system disturbances, a taxonomy of system disturbances is recommended. This taxonomic approach was derived by a value benefit analysis and is based on HEDOMS (Human Error and Disturbance Occurrence in Manufacturing Systems) with slight modifications and Reason's GEMS (Generic Error Modelling System). The taxonomy is used for data acquisition. Next, a risk priority equivalent to FMEA (Failure Mode and Effect Analysis) is introduced to structure the data according to their relevance. Then, Vicente's and Rasmussen's guidelines (1987) for an ecological interface design are related to the paradigm of supervisory control. On the basis of these guidelines four case studies are presented to show their successful applicability for interface design in FMS.

Fatigue life of a Nd:YAG laser-welded metal ceramic alloy.

Fifteen laser-welded Olympia alloy samples were divided into three groups of five samples each, with different gap distances between the welded halves. The first group was welded with a 0.0-mm gap distance. The second and third groups had Olympia shims placed in 0.3- and 1.0-mm gaps, respectively, prior to laser welding. Each of the samples was tested to failure in load fatigue at 30 Hz in a fatigue testing device using an applied stress of 35,000 psi (241.4 MPa). The means and standard deviations for the number of cycles required to produce fatigue failure for each group was 494,618 +/- 118,311 cycles for the group welded with 0.0-mm gap distance, and 242,741 +/- 44,623 and 232,021 +/- 55,877 cycles for the 0.3- and 1.0-mm specimens, respectively. A one-way analysis of variance showed that the 0.0-mm gap specimens had the greatest number of cycles to failure (P < or = 0.05). There was no significant difference between the other two groups. With the exception of two specimens that failed at the weld center, all failures occurred at the edge of the weld.

Three-dimensional distortion of gold alloy castings and welded titanium frameworks. Measurements of the precision of fit between completed implant prostheses and the master casts in routine edentulous situations.

Thirty routine patients, provided with fixed prostheses supported by osseointegrated Brånemark implants in edentulous lower jaws, were arranged into three different groups with regard to design of the metal framework. Ten patients received cast gold alloy frames and the other two groups were provided with two different designs of welded titanium frames. The fit of the completed prostheses was measured in three dimensions (3-D) in relation to the master cast, by means of a photogrammetric technique, prior to insertion. Mean 3-D distortion of the centre point of the gold cylinder was 42 (s.d. 8) microns for the cast framework. The corresponding mean distortion for the two designs of titanium frameworks was 43 (s.d. 16) and 36 (s.d. 10) microns, respectively. Least distortion was observed in vertical direction for all three designs. None of the different designs of metal frames showed a significantly better fit (P > 0.05), but the cast and oldest titanium framework design presented a much wider range of distortion. This indicated a higher risk of sectioning and resoldering during the fabrication of the prostheses as compared to the more consistently fabricated prostheses, with a new titanium framework design.