Evaluation of a combined heat sink and clamping method to mitigate weld distortion in low carbon steel using GMAW

Authors

DOI:

https://doi.org/10.15587/1729-4061.2025.328730

Keywords:

thermal conductors, acicular ferrite, deformation, material characteristics, metal inert gas welding

Abstract

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

Author Biographies

Heri Wibowo, Universitas Negeri Yogyakarta

Doctorate

Department of Mechanical and Automotive Engineering

Slamet Karyono, Universitas Negeri Yogyakarta

Doctorate Student

Department of Mechanical Engineering Education

Tri Adi Prasetya, Universitas Negeri Yogyakarta

Doctorate Student

Department of Mechanical Engineering Education

Ahmad Fikrie, Universitas Negeri Yogyakarta

Doctorate Student

Department of Mechanical and Automotive Engineering

Agus Widyianto, Universitas Negeri Yogyakarta

Doctorate

Department of Mechanical and Automotive Engineering

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Evaluation of a combined heat sink and clamping method to mitigate weld distortion in low carbon steel using GMAW

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Published

2025-06-25

How to Cite

Wibowo, H., Karyono, S., Prasetya, T. A., Fikrie, A., & Widyianto, A. (2025). Evaluation of a combined heat sink and clamping method to mitigate weld distortion in low carbon steel using GMAW. Eastern-European Journal of Enterprise Technologies, 3(12 (135), 15–27. https://doi.org/10.15587/1729-4061.2025.328730

Issue

Vol. 3 No. 12 (135) (2025): Materials Science

Section

Materials Science

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Copyright (c) 2025 Heri Wibowo, Slamet Karyono, Tri Adi Prasetya, Ahmad Fikrie, Agus Widyianto

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