Effects Of The Flash Welding Process On Mechanical And Microstructural Properties Of Structural Steel Joints Assessed Using Dest

ASTM A529 carbon¿manganese steel angle specimens were joined by flash butt welding and the effects of varying process parameter settings on the resulting welds were investigated. The weld metal and heat affected zones were examined and tested using tensile testing, ultrasonic scanning, Rockwell hardness testing, optical microscopy, and scanning electron microscopy with energy dispersive spectroscopy in order to quantify the effect of process variables on weld quality. Statistical analysis of experimental tensile and ultrasonic scanning data highlighted the sensitivity of weld strength and the presence of weld zone inclusions and interfacial defects to the process factors of upset current, flashing time duration, and upset dimension. Subsequent microstructural analysis revealed various phases within the weld and heat affected zone, including acicular ferrite, Widmanstätten or side-plate ferrite, and grain boundary ferrite. Inspection of the fracture surfaces of multiple tensile specimens, with scanning electron microscopy, displayed evidence of brittle cleavage fracture within the weld zone for certain factor combinations. Test results also indicated that hardness was increased in the weld zone for all specimens, which can be attributed to the extensive deformation of the upset operation. The significance of weld process factor levels on microstructure, fracture characteristics, and weld zone strength was analyzed. The relationships between significant flash welding process variables and weld quality metrics as applied to ASTM A529-Grade 50 steel angle were formalized in empirical process models.

The Modified Direct Analysis Method: an Extension of the Direct Analysis Method

The purpose of this research project is to study an innovative method for the stability assessment of structural steel systems, namely the Modified Direct Analysis Method (MDM). This method is intended to simplify an existing design method, the Direct Analysis Method (DM), by assuming a sophisticated second-order elastic structural analysis will be employed that can account for member and system instability, and thereby allow the design process to be reduced to confirming the capacity of member cross-sections. This last check can be easily completed by substituting an effective length of KL = 0 into existing member design equations. This simplification will be particularly useful for structural systems in which it is not clear how to define the member slenderness L/r when the laterally unbraced length L is not apparent, such as arches and the compression chord of an unbraced truss. To study the feasibility and accuracy of this new method, a set of 12 benchmark steel structural systems previously designed and analyzed by former Bucknell graduate student Jose Martinez-Garcia and a single column were modeled and analyzed using the nonlinear structural analysis software MASTAN2. A series of Matlab-based programs were prepared by the author to provide the code checking requirements for investigating the MDM. By comparing MDM and DM results against the more advanced distributed plasticity analysis results, it is concluded that the stability of structural systems can be adequately assessed in most cases using MDM, and that MDM often appears to be a more accurate but less conservative method in assessing stability.