Abstract
Welding is an essential fabrication process in any of the construction or manufacturing industries. Over the years, numerous welding techniques have been developed to fulfil the continuously changing requirements of the manufacturers as well as to keep up with the evolving materials. Any welding operation is associated with a number of input parameters, their interactions with the achievable weld quality and material properties that determine the success of the overall process. Due to time consuming nature of physical experiments and advancements in computing power and theories, in-silico parametric analysis and optimization of welding processes has gained significant attention in recent years. This paper endeavours to provide a timely comprehensive review of the existing literature on finite element modelling, predictive modelling and optimization of the welding processes. Due to numerous welding processes, an exhaustive review of all of them would exceed the limit of a single research paper. Thus, only three widely popular and versatile welding processes, i.e. metal inert gas (MIG) welding, tungsten inert gas (TIG) welding and friction stir welding (FSW) are considered in this review paper. The essence of more than 225 research articles is concisely presented here, which would make this paper an asset to the future researchers and practitioners. Thermo-mechanical finite element analysis of welding processes, and use of traditional experiment design plans, like orthogonal array, Box-Behnken design and central composite design are found to be extremely popular in the literature.
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Abbreviations
- ALE:
-
Arbitrary Lagrangian-Eulerian
- ANFIS:
-
Adaptive Neuro Fuzzy Inference System
- ANOVA:
-
Analysis of Variance
- ANN:
-
Artificial Neural Network
- BA:
-
Bat Algorithm
- BBD:
-
Box-Behnken Design
- BPNN:
-
Back Propagation Neural Network
- BR:
-
Bayesian Regression
- CCD:
-
Central Composite Design
- COPRAS:
-
Complex Proportional Assessment
- CS:
-
Cuckoo Search
- DEMO:
-
Differential Evolution for Multi-Objective
- DF:
-
Desirability Function
- DFA:
-
Dragon Fly Algorithm
- DOE:
-
Design of Experiments
- DT:
-
Decision Tree
- ENR:
-
Elastic Net Regression
- ESWSA:
-
Elephant Swarm Water Search Algorithm
- FCCD:
-
Face-centered Central Composite Design
- FEA:
-
Finite Element Analysis
- FEM:
-
Finite Element Method
- FFD:
-
Full Factorial Design
- FPA:
-
Flower Pollination Algorithm
- FSW:
-
Friction Stir Welding
- GA:
-
Genetic Algorithm
- GPR:
-
Gaussian Process Regression
- GRA:
-
Grey Relation Analysis
- GTM:
-
Grey Taguchi Method
- GWO:
-
Grey Wolf Optimizer
- HAZ:
-
Heat Affected Zone
- HSTA:
-
Heat Transfer Search Algorithm
- IS:
-
Impact Strength
- KNN:
-
K-Nearest Neighbours
- LARS:
-
Least Angle Regression
- LR:
-
Lasso Regression
- MIG:
-
Metal Inert Gas
- ML:
-
Machine Learning
- MLR:
-
Multi-Linear Regression
- MOGA:
-
Multi Objective Genetic Algorithm
- MOORA:
-
Multi Objective Optimization by Ratio Analysis
- MOPSO:
-
Multi Objective Particle Swarm Optimization
- MS:
-
Mild Steel
- MV:
-
Machine Vision
- NN:
-
Neural Network
- NSGA-II:
-
Non-dominated Sorting Genetic Algorithm-II
- OA:
-
Orthogonal Array
- PCA:
-
Principal Component Analysis
- PSO:
-
Particle Swarm Optimization
- RA:
-
Regression Analysis
- RR:
-
Ridge Regression
- RSM:
-
Response Surface Methodology
- SA:
-
Simulated Annealing
- SS:
-
Stainless Steel
- SVM:
-
Support Vector Machine
- TIG:
-
Tungsten Inert Gas
- TLBO:
-
Teaching-Learning-Based Optimization
- TM:
-
Taguchi Methodology
- TOPSIS:
-
Technique for Order Preference by Similarity to Ideal Solution
- XFEM:
-
Extended Finite Element Method
- µ-H:
-
Micro hardness
- A B :
-
Bevel angle
- A G :
-
Groove angle
- A t :
-
Torch angle (referred as tool pin angle in FSW)
- BH:
-
Bead height
- BS:
-
Bending strength
- BW:
-
Bead width
- BBW:
-
Back bead width
- d np :
-
Nozzle-to-plate distance
- d sp :
-
Shoulder plunge depth
- d f :
-
Filler diameter (also referred to as electrode diameter)
- D S :
-
Shoulder diameter
- D tp :
-
Tool pin diameter
- DOP:
-
Depth of penetration (also referred to as bead penetration)
- EEL:
-
Electrode extension length
- f :
-
Feed rate in FSW
- f p :
-
Pulse frequency
- f T :
-
Table feed rate
- f w :
-
Wire feed rate
- F a :
-
Axial force
- F G :
-
Gas flow rate
- FMT:
-
Type of filler material
- H:
-
Hardness
- I :
-
Welding current
- I b :
-
Base current
- I P :
-
Peak current
- I rms :
-
RMS current
- l a :
-
rc length (also referred to as arc gap)
- N :
-
Rotational speed
- P :
-
Power
- P L :
-
Laser power
- PPV:
-
Pulse peak variation
- S w :
-
Welding speed (referred to as traverse speed in FSW)
- T :
-
Pre-heat temperature
- t :
-
Plate or workpiece thickness
- V :
-
Voltage
- V a :
-
Arc voltage
- V b :
-
Back-ground voltage
- V OC :
-
Open circuit voltage
- V rms :
-
RMS voltage
- T on :
-
Pulse-on time
- TPG:
-
Tool pin geometry
- UTS:
-
Ultimate tensile strength
- YS:
-
Yield Strength
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Kalita, K., Burande, D., Ghadai, R.K. et al. Finite Element Modelling, Predictive Modelling and Optimization of Metal Inert Gas, Tungsten Inert Gas and Friction Stir Welding Processes: A Comprehensive Review. Arch Computat Methods Eng 30, 271–299 (2023). https://doi.org/10.1007/s11831-022-09797-6
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DOI: https://doi.org/10.1007/s11831-022-09797-6