CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application does not claim priority from any patent application.
TECHNICAL FIELD
[002] The present disclosure in general relates to a method for welding a component according to optimized weld sequence. More particularly, the present subject matter relates to welding of the component using heat balance technique to reduce distortion of component.
BACKGROUND
[003] Generally, welding operations are required in a variety of manufacturing applications, e.g., while fabricating components of a mechanical structure or while joining existing components. The welding operations, however, cause various undesirable side effects on the welded components. For example, distortions may build up from the intense heat being involved in the welding operations. Distortion in a weld results from the expansion and contraction of the weld metal and adjacent base metal during the heating and cooling cycle of the welding process. Doing all welding on one side of a part will cause much more distortion than if the welds are alternated from one side to the other. During this heating and cooling cycle, many factors affect shrinkage of the metal and lead to distortion, such as physical and mechanical properties that change as heat is applied. Therefore, the resultant component may not maintain the desired shape when welding is completed. Although distortion of components can be sometimes resolved by operations, such as straightening operations and top level machining, these operations are limited to resolve simple distortions like flatness. But for large complex components, the restoration of deformed size to original size and specification may become difficult. Further, the distortion of components may also have a negative effect on the performance or functioning of the component.
[004] Thus, there is a need to devise a weld sequence for welding a component that can prevent distortion of the component.
SUMMARY
[005] Before the present subject of a method for welding a component according to optimized weld sequence is described, it is to be understood that this application is not limited to a particular type of method for welding a component according to optimized weld sequence, as there may be multiple possible embodiments, which are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular implementations, versions, or embodiments only, and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a method for welding a component according to optimized weld sequence. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[006] In one embodiment, a method for welding a component according to an optimized weld sequence is described. The method comprises the steps of intermittently welding the component along the inner longitudinal edge, outer longitudinal edge and the lateral edge using a heat balance technique for preventing distortion of the component.
BRIEF DESCRIPTION OF DRAWINGS
[007] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present subject matter, an example of construction of the present subject matter is provided as figures; however, the present subject matter is not limited to the specific method for welding a component according to an optimized weld sequence to reduce distortion disclosed in the document and the figures.
[008] The present subject matter is described in detail with reference to the accompanying figures along with reference numbers. The same reference numbers are used throughout the figures to refer various features of the present subject matter.
[009] Figure 1 illustrates a base plate to be welded with side plates, in accordance with an embodiment of the present subject matter.
[0010] Figure 2 illustrates welding of a base plate with an optimized weld sequence, in accordance with an embodiment of the present subject matter.
[0011] Figure 3 illustrates a predicted distortion mapping after optimization of welding sequence, in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION
[0012] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any method for evaluating optimized weld sequence to reduce distortion during fabrication of protection plate and, similar or equivalent to those described herein may be used in the practice or testing of embodiments of the present disclosure, the exemplary, method for welding a component according to an optimized weld sequence to reduce distortion is now described.
[0013] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments described, but is to be accorded the widest scope consist in this regard, in a generic sense.
[0014] As described, while fabricating components of a mechanical structure or while joining existing components, the welding operations cause various undesirable side effects on the welded components such as distortions. Distortion in a weld results from the expansion and contraction of the weld metal and adjacent base metal during the heating and cooling cycle of the welding process. Doing all welding on one side of a part will cause much more distortion than if the welds are alternated from one side to the other. During this heating and cooling cycle, many factors affect shrinkage of the metal and lead to distortion, such as physical and mechanical properties that change as heat is applied. Therefore, the resultant component may not maintain the desired shape when welding is completed. Although distortion of components can be sometimes resolved by operations, such as straightening operations and top level machining, these operations are limited to resolve simple distortions like flatness. But for large complex components, the restoration of deformed size to original size and specification may become difficult. Further, the distortion of components may also have a negative effect on the performance or functioning of the component. Furthermore, the use of stiffeners and intermittent welding sequence during fabrication helps to reduce the distortion, but fails to aid in achieving optimized distortion parameters.
[0015] The present invention discloses a method for welding a component according to an optimized weld sequence is described. The method comprises the steps of intermittently welding the component along the inner longitudinal edge, outer longitudinal edge and the lateral edge using a heat balance technique for preventing distortion of the component.
[0016] Now referring to the figures, Figure 1 discloses a base plate to be welded with side plates, in accordance with an embodiment of the present subject matter. Conventionally, side plates are fillet welded with base plate by continuous welds that extend along the edges of the base plate. Further, the continuous welding is carried out on one edge of the base plate and then is continued on other edges of the base plate. When the continuous weld is laid on a first edge of the base plate, it is molten metal state and therefore hot. Further, the continuous welding is carried out on a second edge of the base plate. By the time, the continuous welding on the second edge of the base plate is completed, the hot weld weld on the first edge of the base plate cools down. The cooling of the continuous weld results in shrinkage of the base plate and imposes stresses in the base plate. Hence, continuous welding results in distortion of the base plate and is not recommended.
[0017] Referring next figure, Figure 2 illustrates welding of a base plate with an optimized welding sequence, in accordance with an embodiment of the present subject matter. As distortion and shrinkage are the inevitable results of welding, a good weld design requires minimum amount of weld length as well as minimum amount of weld deposition. Thus, intermittent welding is very advantageous to achieve a good weld design as compared to continuous weld for component fabrication. Placing and balancing of weld are important in designing for minimum distortion. The number of welds in the intermittent weld sequence may vary as per the size and shape of the component to be welded. Further, the length of the weld in the intermittent weld sequence may vary as per the size and shape of the component to be welded. Furthermore, the length of the weld in intermittent weld sequence may vary based on the thickness of the component to be welded. The weld sequence designed is positioned closer to the neutral axis of component and proceeds outwards towards the edges of the component. When the weld sequence commencement is closer to the neutral axis of fabrication, the leverage effect of shrinkage forces and the final distortion is lower. Further, the welds of short lengths are deposited away from the neutral axis and on the opposite side of the neutral axis in an alternating manner. Thus, the shrinkage force of an individual weld is balanced by another weld on the opposite side of the neutral axis to reduce distortion. Fillet welding technique refers to the process of joining two pieces of metal together when they are placed perpendicular or at an angle to each other. Shielded metal arc welding (SMAW) is a manual arc welding process that uses a consumable and protected electrode. As the electrode melts, a cover that protects the electrode melts and protects the weld area from oxygen and other atmospheric gases. The base plate is welded to the side plates using a fillet welding technique by a shielded metal arc welding process.
[0018] Figure 2 discloses a method for welding a component according to an optimized weld sequence. The component has a longitudinal neutral axis parallel to the length of the component and passing through a centre of the component. Further, the component has a lateral neutral axis perpendicular to the length of the component and passing through the centre of the component. The longitudinal and lateral axis may vary according to the shape of the component to be welded. A first side of the lateral neutral axis refers to the region on the left side of the neutral lateral axis till the lateral edge of the component. A second side of the lateral neutral axis refers to the region on the right side of the neutral lateral axis till the lateral edge of the component. A first side of the longitudinal neutral axis refers to the region on the upper side of the longitudinal neutral axis till the longitudinal edge of the component. A second side of the longitudinal neutral axis refers to the region below the longitudinal neutral axis till the longitudinal edge of the component. The component is welded using an intermittent weld sequence of pre-determined weld lengths. The component is first welded along the inner longitudinal edge, then on the outer longitudinal edge and eventually along the lateral edge. The welding of the component commences from the inner side of the component via a first intermittent inner welding (1). The first intermittent inner welding (1) is located at a point proximate to and on first side of a lateral neutral axis of the component. After completing the first intermittent inner welding (1), a second intermittent inner welding (2) is commenced from the inner side of component. The second intermittent inner welding (2) is located at a point proximate to and on second side of the lateral neutral axis of the component on opposite side of the component on which the first intermittent inner welding (1) is carried out. Further, a third intermittent inner welding (3) is commenced from the inner side of the component. The third intermittent inner welding (3) is located on second side of the lateral neutral axis of the component and adjacent to the first intermittent inner welding (1). Furthermore, a fourth intermittent inner welding (4) is commenced from inner side of the component. The fourth intermittent inner welding (4) is located at a point proximate to and on first side of the lateral neutral axis and adjacent to the second intermittent inner welding (2). In order to complete the welding along the longitudinal inner edge of the component, the welding sequence commencing from the first intermittent inner welding (1) till the fourth intermittent inner welding (4) is repeated. The welding sequence is repeated until the intermittent welds reaches the longitudinal outer edges on both sides of the lateral neutral axis of the component. Once the inner longitudinal edge of the component is completely welded, then welding of the outer longitudinal edge of the component is commenced from a first intermittent outer welding (17). The first intermittent outer welding (17) is located at a point proximate to and on second side of the lateral neutral axis of the component. Further, a second intermittent welding (18) commences from outer side of the component and at a point proximate to and on second side of the lateral neutral axis and on the opposite side of the component on which the first intermittent outer welding (17) is carried out. After completion of the second intermittent outer welding (18), a third intermittent outer welding (19) is carried out. The third intermittent outer welding (19) commences from outer side of the component and on first side of the lateral neutral axis of the component and adjacent to the first intermittent outer welding (17). Further, a fourth intermittent outer welding (20) commences from outer side of the component and at a point proximate to and on second side of the lateral neutral axis and adjacent to the second intermittent outer welding (18). In order to complete the welding along the longitudinal outer edge of the component, the welding sequence commencing from the first intermittent outer welding (17) till the fourth intermittent outer welding (20) is repeated. The welding sequence is repeated until the intermittent welds reaches the longitudinal outer edges on both sides of the lateral neutral axis of the component. Once the outer longitudinal edge of the component is completely welded, then welding of the lateral edge of the component is commenced from a first intermittent welding (35). The first intermittent welding (35) is located at a point proximate to and on first side of a longitudinal neutral axis of the component. After completion of the first intermittent welding (35), a second intermittent welding (36) is commenced. The second intermittent welding (36) commences on lateral edge of the component and at a point proximate to and on second side of the longitudinal neutral axis and on the opposite side of the component on which the first intermittent welding (35) is carried out. Further, a third intermittent welding (37) commences on lateral edge of the component and at a point proximate to and on first side of the longitudinal neutral axis and is one but adjacent to the first intermittent welding (35). Furthermore, a fourth intermittent welding (38) commences on lateral edge of the component and at a point proximate to and on second side of the longitudinal neutral axis and is one but adjacent to the second intermittent welding (36). In order to complete the welding along the lateral edge of the component, the welding sequence commencing from the first intermittent welding (35) till the fourth intermittent welding (38) is repeated. The welding sequence is repeated until the intermittent welds reaches the lateral outer edges on both sides of the longitudinal neutral axis of the component. Further, a fifth intermittent welding (43) on the one but adjacent gap on lateral edge of the component is carried out on the first side of the longitudinal neutral axis. Furthermore, a sixth intermittent welding (44) on the one but adjacent gap on lateral edge of the component and on the opposite side of the component on which the fifth intermittent welding (43) is carried out on the second side of the longitudinal neutral axis. In order to complete the welding along the lateral edge of the component, the welding sequence commencing from the fifth intermittent welding (43) till the sixth intermittent welding (44) is repeated. The welding sequence is repeated until the intermittent welds reaches the lateral outer edges on both sides of the longitudinal neutral axis of the component
[0019] Further, Figure 3 illustrates, predicted distortion mapping after optimization of welding sequence, in accordance with an embodiment of the present subject matter. The SYSWELD platform is configured to output a distortion mapping by applying thermos-elastic-plastic analysis based on the weld sequence fed to the SYSWELD platform.
[0020] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include the following:
[0021] Some embodiments of the present subject matter disclose a method to drastically reduce weld volume.
[0022] Some embodiments of the present subject matter disclose a method to optimized weld sequence to reduce distortion.
[0023] Some embodiments of the present subject matter disclose a dummy bar pit sump sensor capable to eliminate dry running of pump.
[0024] Some embodiments of the present subject matter prevents use of stiffeners.
[0025] Some embodiments of the present subject matter disclose a method to simulate the weld sequence to evaluate mapping of distortion.

Claims:

1. A method for welding a component according to an optimized weld sequence comprising the steps of:
i. welding of the component configured with intermittent weld sequence of pre-determined weld lengths, wherein a first intermittent inner welding (1) commences from inner side of the component and at a point proximate to and on first side of a lateral neutral axis of the component;
ii. a second intermittent inner welding (2) commences from inner side of the component and at a point proximate to and on second side of the lateral neutral axis and on the opposite side of the component on which the first intermittent inner welding (1) is carried out;
iii. a third intermittent inner welding (3) commences from inner side of the component and on second side of the lateral neutral axis of the component and adjacent to the first intermittent inner welding (1);
iv. a fourth intermittent inner welding (4) commences from inner side of the component and at a point proximate to and on first side of the lateral neutral axis and adjacent to the second intermittent inner welding (2);
v. repeating the above welding sequence of steps i to iv from the inner side of the component till it reaches the longitudinal outer edges on both sides of the lateral neutral axis of the component;
vi. welding of the component configured with intermittent weld sequence of pre-determined weld lengths, wherein a first intermittent outer welding (17) commences from outer side of the component and at a point proximate to and on second side of a lateral neutral axis of the component;
vii. a second intermittent outer welding (18) commences from outer side of the component and at a point proximate to and on second side of the lateral neutral axis and on the opposite side of the component on which the first intermittent outer welding (17) is carried out;
viii. a third intermittent outer welding (19) commences from outer side of the component and on first side of the lateral neutral axis of the component and adjacent to the first intermittent outer welding (17);
ix. a fourth intermittent outer welding (20) commences from outer side of the component and at a point proximate to and on second side of the lateral neutral axis and adjacent to the second intermittent outer welding (18);
x. repeating the above welding sequence of steps vi to ix from the outer side of the component till it reaches the longitudinal outer edges on both sides of the lateral neutral axis of the component;
xi. welding of the component configured with intermittent weld sequence of pre-determined weld lengths, wherein a first intermittent welding (35) commences from lateral edge of the component and at a point proximate to and on first side of a longitudinal neutral axis of the component;
xii. a second intermittent welding (36) commences on lateral edge of the component and at a point proximate to and on second side of the longitudinal neutral axis and on the opposite side of the component on which the first intermittent welding (35) is carried out;
xiii. a third intermittent welding (37) commences on lateral edge of the component and at a point proximate to and on first side of the longitudinal neutral axis and is one but adjacent to the first intermittent welding (35);
xiv. a fourth intermittent welding (38) commences on lateral edge of the component and at a point proximate to and on second side of the longitudinal neutral axis and is one but adjacent to the second intermittent welding (36);
xv. repeating the above welding sequence steps xi to xiv till it reaches the lateral outer edges of the longitudinal neutral axis;
xvi. repeating the above welding sequence steps xi to xv on other sides of the longitudinal neutral axis of the component;
xvii. welding of the component configured with intermittent weld sequence of pre-determined weld lengths, wherein a fifth intermittent welding (43) on the one but adjacent gap on lateral edge of the component is carried out on the first side of the longitudinal neutral axis;
xviii. a sixth intermittent welding (44) on the one but adjacent gap on lateral edge of the component and on the opposite side of the component on which the fifth intermittent welding (43) is carried out on the second side of the longitudinal neutral axis;
xix. repeating the above welding sequence steps xvii to xviii till it reaches the lateral outer edges of the longitudinal neutral axis;
xx. repeating the above welding sequence steps xvii to xix on other sides of the longitudinal neutral axis of the component.
2. The method as claimed in claim 1, wherein the longitudinal and lateral axis may vary according to the shape of the component to be welded.

3. The method as claimed in claim 1, wherein length of weld in said intermittent welding is configured to vary as per the size and shape of the components to be welded.

4. The method as claimed in claim 1, wherein number of intermittent welds is configured to vary as per the size and shape of the components to be welded.

5. The method as claimed in claim 1, wherein length of weld in said intermittent weld sequence is configured to vary based on the thickness of the components to be welded.

6. The method as claimed in claim 1, wherein shrinkage force of individual intermittent weld is balanced by another weld on the opposite side of the neutral axis to reduce distortion.

7. The method as claimed in claim 1, wherein said weld sequence is configured on heat balance technique of the welding.

8. The method as claimed in claim 1, wherein said welding of component is carried out using fillet welding.

9. The method as claimed in claim 1, wherein said welding of component is carried out by shielded metal arc welding (SMAW) process