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<p>Angular distortion is a critical issue in thick plate welding, affecting dimensional accuracy, assembly precision, and mechanical performance, particularly in large-scale manufacturing industries such as shipbuilding and heavy machinery. This study investigates the evolution of angular distortion in multi-layer multi-pass thick plate welding with double-U and X-grooves and explores the effects of flip welding, gravity, and heat input on distortion control. Narrow gap TIG welding experiments were conducted under different heat inputs (1.31–5.63 kJ/mm), with welding currents ranging from 150–300 A, voltages 12.5–18.0 V, and welding speeds 50–100&#xa0;mm/min. A three-stage angular distortion evolution model is proposed, comprising (1) an initial minimal distortion phase, (2) a rapid distortion growth phase, and (3) a stabilization phase. Results indicate that flip welding effectively reduces angular distortion, with a negative correlation between the number of flips and final distortion magnitude. Additionally, gravity delays the onset of distortion in the early stages, and when the filler thickness exceeds 60% of the plate thickness, distortion growth significantly slows due to increased weld stiffness. To mitigate distortion, a set of practical control strategies-including clamping, dynamic heat input regulation, flip welding, and preset reverse distortion is proposed. These findings enhance the understanding of angular distortion mechanisms and provide practical solutions for minimizing welding distortion, contributing to improved weld quality and production efficiency in industrial applications.</p>

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Effect of flipping and gravity on angular distortion evolution and control strategies in thick plate welding: insights from experimental findings

  • 期刊论文

  • 发表日期：

    2025年4月29日

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  • Zhuoyong Liang,
  • Leilei Wu,
  • Song Zhang,
  • Yonghua Shi,
  • Maimaitiyiming Maimaiti

摘要

Angular distortion is a critical issue in thick plate welding, affecting dimensional accuracy, assembly precision, and mechanical performance, particularly in large-scale manufacturing industries such as shipbuilding and heavy machinery. This study investigates the evolution of angular distortion in multi-layer multi-pass thick plate welding with double-U and X-grooves and explores the effects of flip welding, gravity, and heat input on distortion control. Narrow gap TIG welding experiments were conducted under different heat inputs (1.31–5.63 kJ/mm), with welding currents ranging from 150–300 A, voltages 12.5–18.0 V, and welding speeds 50–100 mm/min. A three-stage angular distortion evolution model is proposed, comprising (1) an initial minimal distortion phase, (2) a rapid distortion growth phase, and (3) a stabilization phase. Results indicate that flip welding effectively reduces angular distortion, with a negative correlation between the number of flips and final distortion magnitude. Additionally, gravity delays the onset of distortion in the early stages, and when the filler thickness exceeds 60% of the plate thickness, distortion growth significantly slows due to increased weld stiffness. To mitigate distortion, a set of practical control strategies-including clamping, dynamic heat input regulation, flip welding, and preset reverse distortion is proposed. These findings enhance the understanding of angular distortion mechanisms and provide practical solutions for minimizing welding distortion, contributing to improved weld quality and production efficiency in industrial applications.