Heri Wibowo, Slamet Karyono, Tri Adi Prasetya, Ahmad Fikrie, Agus Widyianto
The mechanical strength and distortion management of GMAW-welded low-carbon steel (A36) joints are investigated in this work. GMAW is a combination of heat sinking and clamping procedures. Dimensional precision and structural reliability are compromised due to the substantial distortion caused during welding. To solve this problem, this research looks at a thermal-mechanical strategy that uses heat sinks and mechanical clamps in tandem when welding. Untreated joints (As-welded) and three different treatment variants (HS5-4C, HS27-4C, and HS27-6C) were tested in different experimental configurations. Using a 27°C water-cooled heat sink and six steel clamps, the HS27-6C treatment significantly decreased longitudinal distortion, going from 6.7 mm (As-welded) to 0.85 mm, an astonishing 87% reduction. Mechanical testing showed that in all configurations, the tensile strength was approximately 500 MPa and that weld integrity was preserved since failures were in the base metal rather than the weld metal. Microstructural examination revealed an increase in Acicular Ferrite (AF) content in the weld metal for treated samples, particularly HS27-6C, which enhanced toughness, and microhardness tests verified consistent hardness values (e.g., weld metal (WM): ~200 HV, heat-affected zone (HAZ): ~170 HV, base metal (BM): ~150 HV). Mechanical restriction, in the form of clamps, reduces unequal expansion and contraction during solidification, and thermal management, accomplished by dispersing excess heat, is responsible for the method’s efficacy. This integrated approach offers a realistic and cost-effective means of reducing distortion without sacrificing mechanical performance. This is particularly noteworthy in the structural, automotive, and manufacturing sectors, where precise control over dimensions is important Copyright © 2025, Authors.
Department of Mechanical and Automotive Engineering, Universitas Negeri, Yogyakarta Colombo str., 1, Depok District, Sleman Regency, Yogyakarta Special Region, 55281, Indonesia; Department of Mechanical Engineering Education, Universitas Negeri, Yogyakarta Colombo str., 1, Depok District, Sleman Regency, Yogyakarta Special Region, 55281, Indonesia
