A problem hindering intense industrial use is the occurrence of weld hot cracking, when the thickness of the weld exceeds 10 mm. Substitution of chipping for a welding process may help to save time and material, especially when high wall thicknesses need to be processed and/or high precision is demanded as for example, in the production of hydraulics, a beam welding process is beneficial (see for details). Another identified factor having an influence on high stress localization is bulging of the weld. In partial penetration welding, they were caused by the prevention of weld shrinkage due to the cold and strong material below the joint. High stresses emerged in the models in regions which showed cracking during experiments. ![]() ![]() To explain the observed phenomena and support further optimization of manufacturing processes, a computational model was developed, which used a sophisticated strategy to model the material. In welding experiments conducted on heavy wall pipes, the penetration mode (full or partial penetration) occurred to be a significant factor influencing appearance of solidification cracks.
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