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This course will address fundamental aspects that engineers should know when designing welded joints. It will incorporate key findings from the most recent research developments in analytical and computational modelling of welded joints and welding processes. Proper design and cost- effective construction of welded connections require considerations of some of the unique issues associated with welding, in addition to specific loading environments.
This course will delve into how residual stresses and distortions are developed during fusion and solid-state welding, and related manufacturing processes, including metal 3D printing and additive manufacturing. Simple analytical models will be used to describe the underlying mechanisms, and computational modeling results will then be used to demonstrate the relevance of these analytical results for deriving effective solutions to various residual stress and distortion problems experienced by various industry sectors, including aerospace, automotive, heavy equipment and shipbuilding.
Then, the principles for residual stress and distortion mitigation techniques will be discussed and illustrated with various real-world applications. In addition, how residual stresses and distortions affect components' structural performance (such as fatigue capacity) will be discussed, including how to effectively treat their effects in structural integrity evaluation, based on the most recent research findings.
The course is designed: (1) to cover residual stress treatment in design analysis and fatigue design methods in all major international codes and standards (AS 4100 is very similar to certain European Codes) rather than a single Code or Standard for a broader audience; (2) provide common technical basis for how to interpret some of the code provisions and their limitations; (3) introduce proven procedures for dealing with some situations where existing codes may be difficult to apply.
·
Simple
descriptions on how residual stress is generated in thermal manufacturing, e.g.
welding and metal additive manufacturing
·
How
are distortions related to residual stress?
·
Simplified
residual stress and distortion calculation methods
·
How
to quantify the importance of residual stresses to structural integrity?
o
Static
load capacity
o
Fatigue
o
Fracture assessment per AS 4100 / BS 7910
·
Treatment
of residual stress in current Codes and Standards and limitations
·
Principles
of distortion control (“5S” principles):
o
Design
(joint design, modularity definition, …)
o
In-process
(sequencing, support, …)
o
Post-process
(thermal and/or mechanical,…)
·
Real-word
case studies:
o
shipbuilding
o
pressure
equipment
o
steel
construction, …
· Closure and Q/A
·
Unique
fatigue behaviors in welded structures
·
Traditional
fatigue design and life evaluation methods in Codes and Standards
o
Nominal
stress methods
o
Hot
spot stress methods
o
Notch
stress methods
o Applications in AS 4100 and calculation examples: * Weld sizing for static load capacity; * Weld category based fatigue design
· Structural stress based master S-N curve method adopted ASME B&PV Div 2 Code and API 579-RP/ASME
FFS-1
o Basis and calculation procedure
o Master S-N (E-N) curve definition and usage
o How to use the master S-N curve method to support weld category based method. e.g. AS 4100, when dealing with complex joint types or loading conditions
o Applications examples
o Joint positioning
o Joint type selection
o Joint type detailing
The Course will be especially relevant to all professionals in automotive, aerospace, steel construction, steel bridge design, power generation, naval and shipbuilding, defence, offshore construction, pipelines and other industries that apply welding. Designers, structural engineers, consultant engineers, mechanical engineers, welding and production engineers, maintenance and quality control engineers, as well as researchers. Attendees are encouraged to bring along their design problems to contribute to discussions and local case studies.
Dr. Pingsha Dong is Robert F. Beck Professor of Engineering, Professor of Navel Architecture and Marine at the University of Michigan. His novel modeling methods for residual stress/distortion and fatigue have been adopted by ASME Div 2 and API 579 RP Codes and Standards since 2007. Over the last two decades, Prof. Dong has taught short courses in fatigue design, fracture control, residual stress and distortion control in over a dozen countries around the globe.
Professor Dong has published more than 300 peer-reviewed papers in archive journals and major conference proceedings, including over 20 plenary and keynote lectures at major international conferences. He has received numerous prestigious national and international awards, including AWS Comfort Adams Lecture Award (2019), SNAME Helmer L. Hann Awards (both in 2012 and 2007), IIW Evgeny Paton Prize (2008), R&D Magazine's R&D 100 Award (2006), TIME Magazine's Math Innovator (2005), Aviation Week and Space Technology's Aerospace Laurels Award (2004), SAE Henry Ford Award (2003), AWS R.D. Thomas Award, and ASME G.E.O. Widera Literature Award (2002), among many others. He is a Fellow of ASME, AWS and IIW.
Payment is required at the time of booking. Cancelation four weeks prior to the start date will not be refunded.
A certificate of attainment will be issued to all attendees by Weld Australia.
For further information, simply contact: Danielle Pennington (Corporate Engagement Manager) on 0493 024 505 or d.pennington@weldaustralia.com.au, or otherwise contact events@weldaustralia.com.au.