Evaluation of Residual Deformations of a Welded Joint Generated by Various Welding Methods

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Abstract

This paper presents the comparison results of laser and arc welding methods. The modes for laser welding, hybrid laser-arc welding and laser welding with filler wire for the St3 plates with the thickness of 10 mm were developed. Three test joints were welded by each welding method using the developed modes. The metallographic studies were conducted demonstrating stable formation of the welded joint and absence of internal defects. The residual deformations were assessed for the following types of welding: laser welding, hybrid laser-arc welding, laser welding with filler wire, single-sided and double-sided manual arc welding, single-sided and double-sided mechanized welding in the active gases and mixtures. The test samples for each welding type were analyzed in terms of the level of residual deformations after welding by comparing geometric dimensions and using the 3D scanning procedure. A comparative technical and economic analysis of welding methods was performed.

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About the authors

Mikhail V. Kuznetsov

Peter the Great St. Petersburg Polytechnic University

Author for correspondence.
Email: kuznetsov_mich@mail.ru
ORCID iD: 0000-0002-9981-1078

Ph.D. in technical sciences, Head of the Research Laboratory “Laser and Additive Technologies”, Director of the Russian-German Center for Laser Technologies, Institute of Mechanical Engineering, Materials and Transport

Russian Federation, Saint-Petersburg

Maksim V. Larin

Peter the Great St. Petersburg Polytechnic University

Email: kuznetsov_mich@mail.ru
ORCID iD: 0000-0002-6382-7561

engineer of the research laboratory “Laser and Additive Technologies”, junior researcher of the Russian-German Center for Laser Technologies, Institute of Mechanical Engineering, Materials and Transport

Russian Federation, Saint-Petersburg

Daria A. Kuznetsova

Peter the Great St. Petersburg Polytechnic University

Email: kuznetsov_mich@mail.ru
ORCID iD: 0009-0003-3938-5710

engineer of the research laboratory “Laser and Additive Technologies”, junior researcher of the Russian-German Center for Laser Technologies, Institute of Mechanical Engineering, Materials and Transport

Russian Federation, Saint-Petersburg

Anatoly A. Popovich

Peter the Great St. Petersburg Polytechnic University

Email: kuznetsov_mich@mail.ru
ORCID iD: 0000-0002-5974-6654

Doctor of Technical Sciences, professor, director of the Institute of Mechanical Engineering, Materials and Transport

Russian Federation, Saint-Petersburg

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Supplementary files

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2. Fig. 1. External appearance of the RPS HLAW

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3. Fig. 2. Results of beam quality measurements at the output of the 100 / 500 mm optical head (optical cable with the length of 15 m). The measurements were performed using the Primes device (the measured parameter BPP = 4.1 mm ∙ mrad)

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4. Fig. 3. Geometric parameters of the cut for MMA and MSW: a) – for single-sided welding; b) – for double-sided welding

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5. Fig. 4. Geometric parameters of the cut: a) – for LW and HLAW; b) – for LBW-W

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6. Fig. 5. Drawing of the plate for welding

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7. Fig. 6. Plates assembled for welding in the tooling

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8. Fig. 7. Sizing scheme for residual deformation analysis

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9. Fig. 8. End view of the welded joints obtained by: a) – MMA1; b) – MMA2; c) – MSW1; d) – MSW2

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10. Fig. 9. End view of the welded joints on the welded samples obtained by: a) – LW; b) – HLAW; c) – LBW-W

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11. Fig. 10. Macrosections of the cross-section of welded samples (50x): a) – LW; b) – HLAW; c) – LBW-W; d) – MMA1; e) – MMA2; f) – MSW1; g) – MSW2

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12. Fig. 11. Microstructure of the base metal: a) 100x magnification; b) 1000x magnification

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13. Fig. 12. Microstructure of the welded joints: a) – LW; b) – HLAW; c) – LBW-W; d) – MMA1; e) – MMA2; f) – MSW1; g) – MSW2 (100x)

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14. Fig. 13. Deviation maps of the welded samples obtained by the following methods: a) – LW; b) – HLAW; c) – LBW-W

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15. Fig. 14. Scheme of size comparison during the 3D scanning procedure

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16. Fig. 15. Comparison chart for welding methods

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Copyright (c) 2025 Kuznetsov M.V., Larin M.V., Kuznetsova D.A., Popovich A.A.