Fatigue optimization of 4140/a36 dissimilar steel welds using robotic induction welding
DOI:
https://doi.org/10.22399/ijcesen.5541Keywords:
Dissimilar welding, AISI 4140, ASTM A36, Fatigue optimization, Robotic induction welding, Residual stressAbstract
Dissimilar steel welds are prone to fatigue failure, a major concern due to disparities in thermal expansion, microstructure, and residual stress. The paper under research investigates fatigue optimization of AISI 4140-ASTM A36 dissimilar steel joints in robotic induction welding. To reduce thermal gradients during welding, a controlled robotic system with induction heating is used to obtain uniform heat input. The optimal process parameters are determined using experimental design techniques, including heating temperature, welding speed, and cooling rate. Fatigue testing and mechanical characterization are conducted to assess the weld's performance, with microstructural analysis of the heat-affected zone. The findings reveal a significant increase in fatigue life and a decrease in residual stress compared with traditional welding methods. The suggested methodology demonstrates the potential of robotic automation and induction welding to be used together to enhance structural integrity in dissimilar-metal joints, providing a scalable solution for state-of-the-art manufacturing.References
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