Simulation of Three Different Types of Welding using Three Different Weld Materials - Stainless Steel, Aluminium Alloy, & Bronze using ANSYS WorkBench.

Objective: Simulate three different types of welding using three different weld materials

Case 1. Stainless Steel: In this case, the material of the plates must also be the same. Use Stainless steel for both weldments and plates.

Case 2. Aluminium Alloy: The material to be chosen for this case is Aluminium alloy. [Plate material to be used is stainless steel]

Case 3.Bronze: In order to simulate "Brazing", you should be using bronze as the weld material. Assign Stainless Steel to both plates and Copper to the "Ribs".

Run the simulation for a load of 15000N that is to be applied at the rectangular hole in the small plate

Theory: Stainless steel is divided into one of four groups.

1. Austenitic: Austenitic steels are renowned for their extreme weld-ability and malleability. Commonly used for kitchen cutlery and storage components.

2. Ferritic: Ferritic stainless steels are magnetic, and are used commonly for their resistance to stress corrosion cracking

3. Duplex: Duplex stainless steels are essentially combinations of ferritic and austenitic stainless steels. Stronger than both ferritic and austenitic stainless steels. Duplex stainless steel is

used heavily in the underwater oil industry. This is due mainly to its corrosion resistance capabilities, which allow it to withstand the corrosive nature of saltwater over long periods of time.

4. Martensitic: Martensitic steels have very high yield strength and an extremely high tensile strength. Martensitic steel has good draw ability and good edge stretching properties.

It is also good in welding.

• Brazing is a widely used joining process because it can join almost all metal except aluminium and magnesium. It is used for electrical components, pipe fittings. Metals having uneven thickness can be joined by brazing. Provide excellent sealing as compared to spot welding, riveting and bolt fastening.

• Welding Bronze requires a lot more amperage than steel because it transfers heat away so quickly. Bronze welds are not effective at the higher temperature.

The factor of safety: The factor of safety is the ratio of the allowable stress to the actual stress: A factor of safety of 1 represents that the stress is at the allowable limit. A factor of

safety of less than 1 represents likely failure. A factor of safety of greater than 1 represents how much the stress is within the allowable limit.

Setting up a model for simulation:

Model Given:

Material Used:

Aluminium Alloy:

Meshing:

Loads:

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Case1: Stainless Steel: In this case, the material of the plates must also be the same. Use Stainless steel for both weldments and plates.

Directional (Y-axis) Deformation:

Equivalent Stress:

Equivalent Strain:

Stress at weld joints:

Safety Factor - Stainless Steel

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Case2: Aluminium Alloy: The material to be chosen for this case is Aluminium alloy. [Plate material to be used is stainless steel]

Directional (Y-axis) Deformation:

Equivalent Stress:

Strain at ribs:

Stress at weld joints:

Safety Factor-Aluminium Alloy:

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Case3: Bronze: In order to simulate "Brazing", you should be using bronze as the weld material. Assign Stainless Steel to both plates and Copper to the "Ribs".

Directional Deformation:

Equivalent Stress:

Strain at ribs:

Stress at welds:

Safety Factor - Cast Bronze:

Results and Conclusion:

	Case 1(Stainless Steel)	Case 2 (Al Alloy)	Case 3 (Cast Bronze)
Deformation (mm)	0.338	0.830	0.74
Stress (Mpa)	350.5	345.08	335.36
Strain at ribs (mm/mm)	0.00072	0.0020	0.0014
Stress at weld joints (Mpa)	304.51	305.29	322.01
Safety factor	0.713	0.917	0.19

Firstly, Stress at weld joints in cast bronze is highest and also the factor of safety is much below the required numbers. Secondly, stainless steel and aluminium alloy don't have high differences in values of stresses also the factor of safety is close.

So, for this particular case, we will consider aluminium alloy because of the low stress at weld joints and the highest factor of safety.