Akanksha Verma et al.

/ International Journal of Engineering Science and Technology (IJEST)

VIBRATORY STRESS,
SOLIDIFICATION AND
MICROSTRUCTURE OF WELDMENTS
UNDER VIBRATORY WELDING
CONDITION-A REVIEW
1.AKANKSHA VERMA
Project Fellow, Mechanical Engineering Department
Institute Of Technology, Banaras Hindu University,Varanasi,India
Phone- +91-8948071579,
Email: akanksha.best15@gmail.com

2. S.P. TEWARI
Professor, Mechanical Engineering Department
Institute Of Technology, Banaras Hindu University,Varanasi,India
Phone- +91-9721683806,
Email: sptewari_itbhu@yahoo.com

3. JYOTI PRAKASH
Senior Research Fellow, Mechanical Engineering Department
Institute Of Technology, Banaras Hindu University,Varanasi,India
Phone.+91-9415285037,
Email: jpjpitbhu@gmail.com

Abstract
Welding processes induce a state of residual stress into materials and jobs. This poses a series of problems, in
terms of dimensional stability, corrosion cracking, reduced fatigue life and structural integrity . Thermal cycle
produced near weld line generates residual stress and inhomogeneous plastic deformation in weldments.
Understanding of grain nucleation and grain growth becomes necessary that are influenced under welding
conditions. After completion of nucleation, the solidification process will continue with nucleus growth .With
vibratory weld conditioning, the enhancement of weld metal microstructure can be achieved. The mechanical
properties, level of residual stresses, and deformation can also be affected . Structural changes of the welds
prepared under vibratory conditions affects the mechanical properties of the welds. The vibration during
welding benefits energy absorbed in impact toughness test of weld metal and improves fracture behavior. This
paper presents the microstructure, solidification behaviour and residual stress relaxation under vibratory welding
condition.
Keywords: vibratory stress relief ,microstructure,VSR,TSR
1.Introduction
Vibratory Stress Relief, often abbreviated VSR, is a non-thermal stress relief method used by the metal working
industry to enhance the dimensional stability and mechanical integrity of castings, forgings, and welded
components, chiefly for two categories of these metal workpieces. Precision components which are machined
or aligned to tight dimensional or geometric tolerances. Examples include machine tool bases or columns,
components of paper mill, mining equipment, or other large-scale processing machinery, and centrifuge
rotors.Heavily loaded metal workpieces which are components designed and built with the ability to withstand

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heavy loads. Examples include lifting yokes, clamshell buckets, crane bases, vibratory screening system frames,
ingot processing, and rolling mill equipment.These stresses, called residual stresses[1], because they reside
within the metal workpiece, rather than as a result of external loading, are caused by rapid, unequal cooling.
This unequal cooling occurs during welding, casting, forging, rough machining or hot rolling. These stresses
often lead to distortion or warping of the structure during machining, assembly, testing, transport, field-use or
over time. In extreme cases, residual stress can cause structural failure. Almost all vibratory stress relief
equipment manufacturers and procedures use the workpieces own resonant frequency to boost the loading
experienced by induced vibration, so to maximize the degree of stress relief achieved. Some equipment and
procedures are designed to operate near, but not at, workpiece resonances, but independent research[2] has
consistently shown resonant frequency vibration to be more effective. Vibratory relief setup is shown in fig. 1.

Fig. 1 Vibratory Stress Relief Setup

2. Mechanism of Solidification of Weldments Under Vibratory Condition

Dvornak et al. [6] while studying the solidification under vibratory conditions concluded that the grain
refinement so observed was due to the lower energy required for the nucleation of the solid phase. However, the
rapid removal of latent heat of solidification from the solid-liquid interface played a minor part in the grain
refinement under vibration.
Watanabe and Nakamura [7] investigated the effect of electromagnetic stirring on microstructure of SVS 310S.
They examined the parameters to achieve grain refinement like magnetic field intensity, the frequency of
alternating stirring and the relative distance from electrode to magnetic field centre. Bead on plate TIG weld
were made under the condition that welding current was 60A and travel speed was 3 cm/minute. A significant
decrease in the grain size of weld metal could be achieved when the electrode was located 1-2 cm apart from the
magnetic field centre in the welding direction and the stirring frequency was 0.5-1 Hz. This might be due to
fragmentation and the increase in constitutional supercooling ahead of solidification interface due to the molten
metal stirring assisted by the weld metal in grain refining.
Sobolev [8] studied the effect of liquid metal solidification during welding process in the ultrasonic field and
analyzed that critical undercooling provoked volumetric nucleation and critical pressure which was near the
cavitation bubbles caused breakage of the formed crystals.
Wei [9] introduced longitudinal steady state sinusoidal vibrations into the unidirectional dendrite solidification
process of Al-3 Mg alloy in first (470 Hz), second (1050 Hz) and third (1736 Hz) order resonant frequencies of
solidification system to produce strong vibrational response out of less exciting energy. He observed that alloy
mechanical properties are appreciably improved if the second and third order resonant frequencies are applied
Ch. Vives [10] studied the influence of electromagnetic vibrations (50 Hz) imposed during solidification on
grain refinement in the 1085 and 2214 Al alloys. He observed extensive grain refinement in both the alloys due
to imposed vibration.
Yamamoto et al. [11] vibrated molten puddle with low frequency pulsed MIG welding process. The degree of
this vibration depended on switching frequency of unit pulsed conditions and there was an optimum frequency
range of 10-30 Hz. Large difference between two pulsed current values promoted the molten puddle vibration.

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This gave rise to molten puddle stirring which resulted in remarkable grain refinement of weld structure of
commercially available Al-Mg alloy base metal (A 5052) and wire within the optimum frequency range,
especially 30 Hz.
Lu Qinghua , Chen Ligong, Ni Chunzhen[12] studied that The microscopic structure has dramatically changed
after V-SAW. Vibratory energy breaks up the growing dendritic grains in the weld and the HAZ. A significantly
higher weld pool velocity which leads to a faster the heat removal during solidification is produced in VWC.
Thus, the higher the cooling rate, the more the nuclei coming into play, and the smaller the grain size. And a
finer grain size benefits the mechanical properties.
B.Pucko,V.Gliha[13] explained that there is a positive effect of vibration during welding on impact
toughness.Vibration stabilizes microstructures to become more resistant to heat affects that could minimize
impact toughness. Type of fracture turns more ductile with vibrating during welding. Vibration after welding
intensifies effects of heat affect like microstructural changes in some temperature ranges. Vibration during
welding holds back such changes.
3.Effect of vibration during welding on mechanical properties and microstructure of weldments
Many researchers [14,15 ] analyzed the effect of vibration on residual stresses of welded joints and concluded
that vibration reduced residual stresses in welds. Few of the researchers used vibration processing before and
after welding, the latter at low frequency (80 Hz) and measured residual stresses at several points in the middle
section of the weld face. Their finding was that reduction in residual stresses in welds depended not on
processing but on conditions of ensuing operations in use. They recommended that heat treatment is not always
necessary.
Izdinska [17,18] studied the effect of ultrasonic treatment upon fatigue properties of welded joints. His finding
was that due to ultrasonic reduction macroscopic residual stresses had a favourable effect on the fatigue
properties. This finding was rather favorable when compared with annealing.
Yoneda, Kondo and Ishino [19] investigated the primary crystal morphology and the mechanical properties in
hypoeutectic Al-Cu alloys (e.g. Al-6Cu, Al-11Cu, Al-15Cu) vibrated mechanically during primary
solidification. The relationships between primary crystal morphology and the strength were also considered.
Due to vibration primary Al morphology is refined and distributed uniformly. They also observed that with
increasing frequency the tensile strength of specimen increases. However, it was more frequent that the fracture
propagated through the primary crystal and the eutectic, consequently the tensile strength of vibrated specimen
increased.
Galyash, Kolomeets, Kozin, Lopatin and Tsema [20] applied low frequency vibration treatment for stabilizing
welded and cast products. They developed and automated measuring system for vibrotreatment efficiency
control. Control method was based on variation of amplitude-frequency characteristics of the structure
(displacement of resonance peaks, changes of their width and loss coefficients) prior to and after vibrotreatment.
They concluded that vibrotreatment does not reduce cyclic durability of welded joints and resulted in a
considerable reduction of deformations. The complex (technique) developed is recommended for size
stabilization of structures.
Miclosi et al. [21] found good effect of electromagnetic oscillation upon the characteristics of weld. They found
that the present of the electromagnetic axial pulsation of the electric arc led to smaller penetration and enlarged
the width of the weld. This is favourable effect from the point of view of heat cracking because deep and narrow
weld run a higher risk of heat cracking.
Lu Qinghua et al.[22]states that Vibration facilitates the release of dissolved gases and the resulting weld beads
greatly exhibit reduced porosity. Another beneficial effect is to facilitate drifting inclusions to the slag with the
imposed vibration from the molten welding pool. Moreover, the mechanical energies provided by external
vibration increase the boundary plastic deformation and dislocation density. Then the dislocations with high
density will tangle and pile up to combine to make small-angle sub-boundaries .The welding maximum and
minimum residual stresses have been achieved reduced through the application of vibratory welding and the
vibration applied during welding has less influence on the axial residual stress than the radial one due to no
constraint in axial direction.
Jijin Xu, Ligong Chen, Chunzhen N [23] found VWC can reduce the residual hoop stresses at the outer surface
and the maximum residual stresses; but VWC has only a slight effect on the residual axial stresses at the outer
surface. The residual stresses are lower than the yield strength when using VWC, which improves the safety of
welded structures VWC makes the residual stresses decrease and their peak values are lower than the yield
strength. Therefore, VWC can decrease the susceptibility of a weld to fatigue damage, stress corrosion cracking
and fracture, and improve the safety of welded structures.
S. Spooner et al[24] analyzed 300-type stainless steel plates and found that the residual stresses within the HAZ
and base metal in the conventionally welded plate and in the vibratory-treated plate exhibit small differences
which are comparable to the estimate of experimental error. This comparison is limited to results in the HAZ

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and base metal. On the basis of these residual stress measurements no degradation of mechanical properties
from vibratory treatment during welding is expected.
J.S Hornsey[25] found that The Vibratory stress relieving can be employed for stabilization of the size of
suitable weldments prior to their machining and servicing as a replacement of stress relief annealing. The VSR
process is used for lowering of residual stresses and stabilization of the size of different weldments such as
frames of forming machines, machine frames, grey cast iron castings, etc. which were up to now subjected to
stress relief annealing. VSR does not negatively affect the static dynamic strength of welded joints and
weldments, fracture and notch toughness and homogeneity of welded joints. Based on the attained data the
implementation of VSR procedures as a replacement of stress relief annealing for the stabilization of weldments,
castings and forging leads to high savings of production costs to our national economy.
I. A. Shulyak et al.[26] Compared with the existing SM-402 vibratory sieves, the SNV sieving machine is
characterized by a larger specific throughput, a noise and external vibration level reduced by between one-half
and two-thirds, and effective self-cleaning of the screening surface. The anticipated saving resulting from the
adoption of this machine is 14,800 rubles per annum.
William F. Hahn [27]studied that both resonant and sub-resonant vibrations can relieve residual stresses in parts.
Resonant VSR produces the greatest residual stress relief. Subresonant VSR can get stress relief, whose effect
depends on the driven frequency employed. The larger tip deflection the driven frequency produces, the greater
reduction of residual stresses. Larger excitation amplitude produces greater residual stress relief. Stress
reduction is greater for parts with lower level of initial residual stresses.
4. VSR and TSR consideration
Historically, the first type of stress relief was performed on castings by storing them outside for months or even
years. This was referred to as curing, a term used for long-term storage of freshly hewn wood. Fresh castings
were referred to as being green, meaning, they were prone to distortion during precision machining, just as
green wood bows during cutting. Later, thermal stress relief (TSR) was developed to alleviate the lengthy time
requirements of curing. It has been known for many years, however, that TSR has limitations or shortcomings,
specifically:
i)Furnace size: workpieces can be too large to fit.
ii)Not effective on all alloys, among them austenitic stainless steels.
iii)Should not be used on welded structures made of low-carbon, high-strength steels, which can suffer loss of
physical properties and/or crack initiation if thermally stress relieved.
iv)Cannot be used on workpieces that have been quenched and tempered (Q&T) without risking loss of physical
properties. Vibratory stress relief can be successfully applied, if some level of ductility is present after Q&T,
together with acceptable workpiece geometry (which determines resonant vibration frequency required).
v)Often not suitable for rough-machined components, due to difficulty in removing scale (rust-colored skin that
develops on ferrous components while in-furnace), without damaging machined surfaces.
vi)Asymmetrical-shaped workpieces, which are difficult to cool while maintaining uniform temperature, can
develop new, unacceptably high-level, residual stress patterns during the last stage of TSR. Cooling rates can be
slowed, but with increased costs.
Metal components, whose function would be enhanced by stress relief, and fall into one or more of the above
categories, are strong candidates for VSR for quality-related reasons.
Wuich [16] while discussing the vibration method (VSR) explained that welding, forging and other processes
induced internal stresses in Fe based structural parts which led to deformations and dimensional tolerance
reductions. The vibration method is an alternative to heat treatment and offers a number of technical and
economical advantages. The iron and steel parts weighing from 50 Kg upto 200 tons were vibrated-100 Hz for
30 minutes to relieve the internal stresses for the material structure.
J.S Hornsey[25] found that The Vibratory stress relieving can be employed for stabilization of the size of
suitable weldments prior to their machining and servicing as a replacement of stress relief annealing. The VSR
process is used for lowering of residual stresses and stabilization of the size of different weldments such as
frames of forming machines, machine frames, grey cast iron castings, etc. which were up to now subjected to
stress relief annealing. VSR does not negatively affect the static dynamic strength of welded joints and
weldments, fracture and notch toughness and homogeneity of welded joints. Based on the attained data the
implementation of VSR procedures as a replacement of stress relief annealing for the stabilization of weldments,
castings and forging leads to high savings of production costs to our national economy.
Further, there is a strong economic incentive to use vibratory stress relief on large workpieces, since stress relief
using a furnace (thermal stress relief or TSR) is highly energy-intensive; consuming much natural gas, and
hence, producing much CO2. The cost of TSR is approximately proportional to a metal components weight or
overall size, estimated to be $ 2500 USD for the structure pictured, plus transportation costs, which might
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involve special transport permits, to and from a furnace. VSR Treatment would cost a company owning
appropriate equipment less than 15% as much ( $ 400 ) as TSR Treatment, chiefly amortization of equipment
investment plus labor, and a modest amount of electrical consumption, and treatment would take less than two
hours, with no transport required.
5. Conclusion
The study of the previous work reviews that a vibration reduces residual stresses in welds .Some researchers
recommended that heat treatment is not always necessary, whereas some researchers applied low frequency
vibration treatment for stablizing welded and cast product and also found that vibration facilitates the release of
dissolved gases and the resulting weld beads greatly exhibit reduced porosity. Few of the researchers observed
that mechanical properties of the welds prepared under vibratory conditions are dependent on the structural
changes of the welds and the oscillatory conditions modify grain nucleation and grain growth during liquid to
solid transformation, therefore, it becomes necessary to provide an understanding of grain nucleation and grain
growth that are influenced under welding conditions. Vibration stabilizes microstructures to become more
resistant to heat affects that could minimize impact toughness . Some researchers described different theory to
initiate nucleation in the weld deposit and concurrently promote epitaxial grain refinement, it is essential to
either increase the driving force, or reduce the free energy barrier. The vibration method is an alternative to heat
treatment and offers a number of technical and economical advantages.
6. References
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