LIBRARY ı6ıul 0) - Cranfield University

Table 7.3 - Bead geometry along the welds produced in the stand-off controlled
flat position fillet welding trials
Run Measured feature Position aloe the weld mm Geometry feature
mm 30 65 100 135 170 Min. Required Expected
S2 Le 4.82 4.76 4.51 4.70 5.01 4.00 4.46
Pen, 0.68 0.75 0.78 0.63 0.73 0.32 0.60
Max. Undercut 0.0 0.0 0.0 0.0 0.0 0.0 0.0
S3 Le 5.73 5.72 5.69 5.89 5.75 6.00 6.41
Pence. 1.06 0.97 0.87 0.88 1.04 0.32 1.26
Max. Undercut 0.0 0.0 0.0 0.0 0.0 0.0 0.0
S4 Le 3.77 2.85 3.84 4.38 4.36 4.00 4.54
Pen,,, 1.11 0.98 0.90 1.08 1.06 0.32 1.26
Max. Undercut 0.49 0.55 0.42 0.36 0.28 0.0 0.0
S5 4.67 4.81 4.87 4.79 5.35 5.00 5.40
Pen,,. 1.77 1.72 1.71 1.79 1.67 0.32 1.70
Max. Undercut 0.68 0.45 0.40 0.35 0.30 0.0 0.0
S6 Le 4.70 4.79 4.99 5.30 5.03 5.00 5.43
Pen,,. 2.05 2.01 1.95 1.87 2.04 0.32 1.86
Max. Undercut 0.25 0.21 0.21 0.23 0.15 0.0 0.0
7.4 Tests with both stand-off and voltage control
Some welding trials were carried out in order to test the performance of both
stand-off and voltage controllers acting together. The welding parameters used are
shown in Table 7.4 and were generated for producing the same weld geometry as the
ones shown in Table 7.1 with the difference that a stand-off of 15 mm was considered
for calculation purposes in all the cases. The weld runs were referenced as "SVn"
(n=2,..., 6), in this case.
Table 7.4 - Welding parameters used in the voltage and stand-off controlled flat
position fillet welding trials
Run WFS
m/min
V,., Sw
minim
SO,, rt
mm
SOme
mm
Leg,. q
mm
Legp,. a
mm
Pen..
[mm]
SV2 8.0 22.2 0.6 15 23 4.0 4.46 17.9
SV3 10.0 22.4 0.4 15 23 6.0 6.41 37.9
SV4 11.0 32.9 0.8 15 23 4.0 4.54 39.4
SV5 13.0 33.2 0.7 15 23 5.0 5.40 53.1
SV6 15.0 33.4 0.8 15 23 5.0 5.43 58.0
SO.,,: initial stand-off SO, e:
final stand-off after 200 mm weld length
Leg,. leg length
q: required in the welding parameter generator
Legj: expected average leg length predicted by the welding parameter generator
Pence: expected average penetration predicted by the welding parameter generator
Figures 7.23,7.25,7.27,7.29 and 7.31 show the bead appearances and the
bead profiles obtained from the controlled trials. Figures 7.24,7.26,7.28,7.30 and
7.32 show the variation in the welding voltage and current as well as in the stand-off
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