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Mechanics of Materials 40 (2008) 565–574

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Effect of vibratory weld conditioning on welded valve properties

Lu Qinghua *, Chen Ligong, Ni Chunzhen
Institute of Welding, School of Materials Science and Engineering, Shanghai Jiaotong University, Shanghai 200030, China

Received 29 October 2006

Abstract

The approach to improve the quality of full welded valve by the application of vibratory weld conditioning (VWC) was
investigated in this paper. The effect of VWC on the welded joint properties was studied. Cylinders with different thick-
nesses were welded by submerged arc welding (SAW). The experiment results show that the vibration applied during weld-
ing generally reduces the residual deformation and stress. The yield strength, as well as the tensile strength, does not change
distinctively in vibratory SAW (V-SAW) when compared with that in normal SAW (N-SAW). The bend property has been
improved in V-SAW. Fracture test was carried out using single edge notch bend (SENB) specimens. The fracture surfaces
of failed weld metal (WM) specimens are characterized by dimple-like structures. The depth and the density of these dim-
ples are increased after the vibration applied in welding. River marking, the characteristic of cleavage fracture, is observed
in the heat-affected zone (HAZ) specimens. The possible solidification behaviour in VWC is discussed in this paper.
Ó 2007 Elsevier Ltd. All rights reserved.

Keywords: Vibratory weld conditioning; Residual stress; Dimple density

1. Introduction ture exceeding 240 °C in the seal area of valves

Due to the intense concentration of heat source of
welding, regions near weld line undergo severe ther-
mal cycles. The thermal cycles cause non-uniform
heating and cooling in the material, thus generating
inhomogeneous plastic deformation, residual stress
and a wide coarse grained region in the weldment
(Murugan et al., 1998; Teng and Chang, 1997; Lee
et al., 1992; Eigenmann et al., 1994). In valve weld-
ing, the welding deformation should be seriously
controlled not to affect the rotation and leak tight-
ness of the valve body. At the same time, tempera-
*
Corresponding author. Tel.: +86 21 26370517; fax: +86 21
34202540.
E-mail address: aurora-luqh@sjtu.edu.cn (L. Qinghua).
during welding will lead to the failure of rubber seal
rings. Special care should be taken not to overheat
valve bodies. All these have presented a difficult
problem in the process of production.
Vibratory weld conditioning (VWC) technology is
the process of vibrating workpiece with periodical
force during welding to improve the properties of
welded joint (Goncharevich et al., 1990). Many stud-
ies have been carried out on VWC (Munsi et al., 1999;
Munsi, 1999; Aoki et al., 1995). Compared to heat
stress relief, VWC has the advantages of less invest-
ment, more convenient operation, less pollution
and shorter manufacturing period. Relative to vibra-
tory stress relief (VSR), VWC vibrates workpiece in
the whole welding process and it mainly effects the
welding solidification to improve the quality.

0167-6636/$ - see front matter Ó 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mechmat.2007.11.001
566 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574

Although various vibratory welding techniques Table 3

have been employed in different applications with Welding parameters
varying degrees of success, the effect of vibration Welding layer Arc voltage, Welding Welding speed,
on the mechanical properties and fracture toughness U/V current, I/A V (m min1)
in valve welding are not yet fully understood. This Root runs 220–240 30–32 0.20
investigation was, therefore, undertaken to study Fill runs 190–220 29–31 0.20
Final weld run 210–230 32–35 0.20
the influence of vibration on the properties and frac-
ture toughness of valve welds in submerged arc
welding (SAW). 25

2. VWC welding test

0
2.1. Testing materials 5

A105, a forged steel, was selected for the research

44
R7

52
project. The fluxed core wire was H08MnA in
2.0 mm diameter. The flux was OP122 provided by
the Oerlikon Company. The chemical compositions
of the base metal and the filler metal are provided in

Table 1. Table 2 gives the mechanical properties of
A105.
2.2. Welding procedure
Two different welding procedures, normal SAW
(N-SAW) and vibratory SAW (V-SAW), were car-
ried out in two groups. One group of welds was made
through N-SAW in its entirety to serve as a basis for
comparison, and the other was made through V-
SAW. In each group, two cylinders, 840 mm in out-
side diameter, 450 mm in length, and 44 mm and
52 mm in thickness, respectively, were multi-pass
butt welded. These cylinders were thoroughly
cleaned of dirt, dust oil and grease before welding.
The corresponding welding parameter details are
given in Table 3. Fig. 1 shows a schematic represen-
tation of the weld joint preparation. The two cylin-
ders and the welding equipment are shown in Fig. 2.
The vibratory accelerator was fastened tightly to the
2
10
8
All dimensions are in mm.
Fig. 1. Schematic representation of the weld joint preparation.
working platform. After the electric engine was
powered, the welded cylinders were vibrated with
the working platform under a cyclic loading gener-
ated by the eccentric rotor in the engine. The desired
vibratory frequency and acceleration were 54–59 rps
and 6 ms2, obtained by switching frequency and
acceleration knobs of power amplifier unit.
3. Residual deformation and stress test
3.1. Residual deformation and stress measurement
Residual deformation and stress are results of
temperature gradient, restraint intensity and depen-

Table 1
Chemical compositions of A105 and its deposit metal (wt%)
C Si Mn P S Ni Cr Cu Mo
A105 0.224 0.26 0.73 0.016 0.031 0.05 0.028 0.14 0.014
H08MnA 0.078 0.32 1.13 0.019 0.013 0.03 0.035 0.12 0.017

Table 2
Mechanical properties of A105
Yield strength, Tensile strength, Elongation rate, Impact toughness, Reduction of cross-sectional
rs (MPa) rb (MPa) d5 (%) Akv (J) area, w (%)
311 491 55 38.44 35
 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574 567

Left- 44 mm in thickness Right- 52 mm in thickness

A1 d1 c1 b1 a1 A2

B1 B2

C1 C2
c2 d2 a2 b2

Stress testing points

Axial deformation testing points: A1A2, B1B2, and C1C2

Fig. 2. Photograph of SAW process. Radial deformation testing points: a1a2, b1b2, c1c2, and d1d2

Fig. 3. Schematic representation of testing points distribution.

dency of material properties on temperature, such
as yield strength, elasticity modulus, and thermal
expansion coefficient. Welding heat input causes
temperature gradient in steel structure. Along with
temperature cooling down after welding, residual
stress appears around welding zone and causes
welding deformation.
Welding deformations were measured by three-
dimensional high-accuracy apparatus. The axial
deformation testing points were set 400 mm away
from the weld centre and the radial deformation
testing points were 200 mm away from the weld
centre.
Residual stress measurements were carried out
on weld centre-line, fusion line, heat-affected zone
(HAZ), and base metal (BM), respectively (schemat-
ically shown in Fig. 3). The blind hole drilling
method, a semi-destructive residual stress measuring Fig. 4. Residual stresses measurement by blind hole method.
method, was used in this test. The measuring proce-
dure was performed in compliance with ASTM
Standard Test Method E837-85. Fig. 4 shows the N-SAW
2.5
measurement of the welding residual stress. V-SAW

2.0
3.2. Test results
Deformation d/mm

1.5
Fig. 5 shows the comparison of welding deforma-
tion under different welding conditions. It indicates 1.0
that either axial deformation or radial deformation
is significantly decreased by utilizing vibratory weld- 0.5
ing. Note that the axial deformation is significantly
less sensitive than the radial deformation. The data 0.0
1 2 3
indicate only an 8% decrease in axial deformation
1-Axial deformation 2-Radial deformation-Left 3-Radial deformation-Right
but in radial deformation, a 64% decrease in the
thinner cylinder to a total deformation of 1.1 mm Fig. 5. Results of welding deformation.
568 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574

a 350 b 160
The maximum residual stress The minimum residual stress
140
N-SAW N-SAW
300
V-SA W V- SAW

min/MPa
max/MPa

120

250 100

Residual stress
Residual stress

80
200
60

150 40

20
100
-20 0 20 40 60 80 100 120 140 160 -20 0 20 40 60 80 100 120 140 160

Distance to weld centre line d/mm Distance to weld centre line d/mm

c 200
d 300
180 The axial residual stress The circumferential residual stress
N-SAW 270 N-SAW
160
V-SAW V- SAW

cir/MPa
240
axi/MPa

140

120 210

100 180
Residual stress
Residual stress

80 150
60
120
40
90
20
60
0
-20 0 20 40 60 80 100 120 140 160 -20 0 20 40 60 80 100 120 140 160

Distance to weld centre line d/mm Distance to weld centre line d/mm

Fig. 6. Residual stress comparison between N-SAW and V-SAW in: (a) maximum residual stress; (b) minimum residual stress; (c) axial
residual stress; and (d) circumferential residual stress.

and a 43% decrease in the thicker one to a total of in N-SAW. It can be explained that the residual
2.1 mm. stress in axial direction with no constrains can be
The results of residual stress obtained are released more easily than that in the radial direction
presented in Figs. 6 and 7. Significant reductions with constrains. It may be felt that the axial residual
of welding residual stress have been achieved in stress is fully relieved. So, the vibration applied dur-
V-SAW. But in Fig. 6c, the axial residual stress ing welding has less influence on the axial residual
in V-SAW is found to be slightly lower than that stress than the radial one.
During the welding (heating) cycle, temperature
Normal SAW rises rapidly in the welding zone, while the expan-
/MPa

200 V-SAW sion of hot metal is restricted by the surrounding

cold metal, resulting in compressive stress in the
welding zone. In the cooling cycle, the surfaces of
Average residual stress

150
welding zone have a higher cooling rate than other
parts of the weld. With decreasing temperature,
100
the shrinkage of the surface metal with a higher
cooling rate is restricted by the surrounding hot
50 weld metal, which leads to a tensile stress at the out-
side of welding zone while the inside hot weld metal
0 is still under compressive stress. The testing results
1 2 3 4
were the tensile stress due to 2 mm depth, blind hole
1- max 2- min 3- x 4- y
drilled in the workpiece surface by the blind hole
Fig. 7. Results of average welding residual stress. drilling method.
 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574 569

4. Mechanical test given in Table 4, which illustrate that the yield

and tensile strength of the welded joint derived are
4.1. Tensile test not quite different between N-SAW and V-SAW.

Plate-like tensile test specimens were prepared

4.2. Bend test
from N-SAW and V-SAW workpieces, respectively.
The tensile specimens were 250 mm in length,
The purpose of bend test was to ensure the duc-
20 mm in width and 10 mm in thickness. The speci-
tility of valve welds. The specimens were taken with
mens were taken with their length perpendicular to
their length perpendicular to the weld line and the
the weld line and the loading direction perpendicu-
loading direction parallel to the welding direction.
lar to the welding direction. These specimens were
Fig. 9 shows the schematic representation of the
checked for surface finish, as poor surface finish
specimens. The loading position is in the middle of
may give rise to stress concentrating notches, which
the weld as shown in Fig. 10. Cambered axle diam-
would affect the results. The test was carried out at
eter was equal to 30 mm, and bending angle equal to
room temperature (20 °C) with the loading speed of
180°.
0.1 mm/s. During each test, the chart of load versus
Fig. 11 gives the tested specimens in different
load-line displacement was obtained.
welding conditions. It can be seen that all specimens
Fig. 8 shows the tensile specimens after test. The
have excellent bend properties. Moreover, speci-
results of yield strength and tensile strength are
mens of V-SAW have no visible crack. One speci-
men in N-SAW, shown in Fig. 12, with a crack
less than 3 mm, still can be considered qualified.

Fig. 8. Tensile test specimen after test.

Weld
30
Table 4

10
Mechanical properties for different welding conditions (MPa)
No. Yield strength Tensile strength
N-SAW V-SAW N-SAW V-SAW 55
1 422 419 567 556
2 437 418 565 567 150
3 394 423 569 564
4 421 416 555 558 All dimensions are in mm.
Average value 418.5 419 564 561.3
Fig. 10. Schematic representation of the set-up for a bend test.

R=2
20

150 10

All dimensions are in mm.

Fig. 9. Bend test specimen dimension.
570 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574

Table 5
Geometrical dimension of CTOD specimens
Condition Specimen Thickness, Width,
no. B (mm) W (mm)
Welded seam (N-SAW) W1 18.24 36.26
W2 18.12 36.00
W3 18.26 36.14
HAZ (N-SAW) HAZ1 18.18 36.14
HAZ2 18.12 36.08
HAZ3 18.20 36.14
Fig. 11. Specimens in V-SAW after bend testing. Welded seam (V-SAW) V-W1 18.14 36.16
V-W2 18.16 36.20
V-W3 18.16 36.20
HAZ (V-SAW) V-HAZ1 18.22 36.10
V-HAZ2 18.14 36.08
V-HAZ3 18.12 36.12

kness
B

ic
valve th
W

Fig. 13. Sampling of CTOD test specimens.

Fig. 12. A less than 3 mm crack in N-SAW specimen.

So the adoption of vibration during welding can

improve the bend property.

5. Fracture toughness test

Fracture toughness was determined in terms of

crack-tip opening displacement (CTOD) in this
paper. The single edge notch bend (SENB) specimen
was used. The dimensions of specimens are given in
Table 5. These specimens were fatigue pre-cracked
at room temperature to an initial crack length (a0)
given by a0/W = 0.5. Parameter W is the specimen
width. Sampling of the CTOD test specimens is pre-
sented in Fig. 13. The length of CTOD specimen is Fig. 14. CTOD test apparatus.
parallel to the valve axial and width along the annu-
lar direction. The fracture test, performed in compli- d was calculated according to the following equa-
ance with BS7448: Part 2, was carried out on the tion (ASTM):
MTS 809 Axial/Torsional Test System at a constant
ram displacement rate of 0.1 mm/s at 20 °C. Fig. 14 K 2I ð1  l2 Þ rp ðW  a0 ÞV p
d¼ þ ð1Þ
shows the CTOD test apparatus. The CTOD value 2ry E rp ðW  a0 Þ þ a0 þ Z
 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574 571

where KI is the Mode I stress intensity factor, l the
Poisson’s ratio, ry the yield stress at the correspond-
ing temperature, E the Young Modulus, rp the plas-
tic rotational factor (for SENB specimen, rp is equal
to 0.44), Vp the plastic component of clipper open-
ing and Z the knife edge thickness. Z is equal to 0
in this paper.
Initiation and propagation development of a fati-
gue crack relies on the configuration of the sample,
crack length and loading conditions. This relation-
ship determines the stress intensity factor (KI) at
the fatigue crack tip, which can be determined for
a three-point bend by the following equations:
vibration imposed in welding uniforms the welded
joint.
The range of toughness values in HAZ is larger
than that in other groups. It is well-known that
when the base metal is welded, the zone close to
the fusion line is subjected to a severe thermal cycle,
which brings out a significant modification of the
original microstructure. The toughness of HAZ is
conditioned by the type of microstructures at the
crack front as well as the crack position, orientation
and propagation, which indicates that the presence
of small brittle zones in HAZ is enough to deterio-
rate the HAZ toughness.

FS a 
0
KI ¼  f ð2Þ
BW 1:5 W
 0:5 h       2 i
 a  3 aW0 1:99  aW0 1  aW0 2:15  3:93 aW0 þ 2:7 aW0
0
f ¼   1:5 ð3Þ
W 2 1 þ 2a0 1  a0
W W

where F is the load, S the span. 6. Fractography analysis

The test results are illustrated in Table 6. The
average CTOD values of WM and HAZ under V-
SAW condition are greater than the corresponding
values under N-SAW condition. Regardless of
whether vibration is applied in welding or not, the
fracture toughness of WM is higher than that of
HAZ. In N-SAW, the average CTOD value of
WM is approximately 4.3 times that of HAZ. How-
ever, this difference is reduced to 2.1 times when the
vibration is applied in SAW. It indicates that the
Fig. 15 indicates the SEM observation of typical
fracture surface for WM and HAZ in N-SAW and
V-SAW, respectively.
Ductile fracture, coupled with dimple-like char-
acteristics, is prevalent in WM. The observation
shows that both the depth and the density of dim-
ples are dependent on the welding conditions. Com-
paring the fracture features of Fig. 15a and b, it is
clear that the WM under V-SAW condition has a

Table 6
CTOD test results
Condition No. Initial crack length, Load, F (kN) CGOD, Vp (mm) CTOD, d (mm)
a0 (mm)
Welded seam (N-SAW) W1 19.49 2.90E+02 3.507 1.017
W2 18.97 2.99E+02 2.635 0.778
W3 19.8 2.74E+02 2.2534 0.663
HAZ (N-SAW) HAZ1 19.11 2.50E+02 0.590 0.200
HAZ2 18.52 2.35E+02 0.400 0.142
HAZ3 19.00 2.33E+02 0.718 0.231
Welded seam (V-SAW) V-W1 19.09 3.16E+02 3.138 0.926
V-W2 18.66 3.29E+02 3.134 0.935
V-W3 19.36 3.04E+02 2.442 0.730
HAZ (V-SAW) V-HAZ1 19.36 2.20E+02 0.362 0.130
V-HAZ2 19.03 2.84E+02 1.400 0.434
V-HAZ3 18.63 2.69E+02 2.1713 0.645
572 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574
Fig. 15. Fractographs showing typical of fracture surfaces of (a) WM in N-SAW, (b) WM in V-SAW, (c) HAZ in N-SAW and (d) HAZ in
V-SAW.
ductile fracture with significantly higher dimple den-
sity than that under N-SAW condition. This finding
seems reasonable when considering the larger values
of fracture resistance present in V-SAW specimens
compared to that identified in N-SAW cases.
Whereas the cleavage facets are observed in HAZ
specimens under N-SAW and V-SAW conditions
(Fig. 15c and d), river markings are predominantly
on the cleavage facets. This feature is indicative of
brittle fracture (Dieter, 1986). And it has been noted
that some second-phase particles, containing ele-
ments of Mn and Si, are evident within HAZ spec-
imens, as shown in Fig. 15d. It is likely that these
particles are formed from the H08MnA fluxed core
wire during welding.
7. Discussion
In general, the fracture toughness is propor-
tional to the size of subgrains (Tseng and Savage,
1971). Thus, conditions leading to coarse subgrains
result in a greater susceptibility to brittle cracking
than do conditions causing a fine solidification
substructure. The subgrains formation by VWC
can be explained thus, in the presence of forced
vibration in the melt, the overheated melt can be
driven from the centre to the periphery of welding
pool during solidification. The vibration of liquid
metal can contribute to increasing the rate of heat
transfer and the removal of liquid superheat, which
decreases the likelihood of remelting of initial
solid grains. The temperature gradient from the
centre to the edge of the pool is decreased and
the undercooled zone is dispersed in the entire bulk
liquid. Accordingly, recrystallization can proceed
simultaneously throughout the undercooled melt
around a number of floating nuclei. Fragmenta-
tion, nucleation and growth can happen within
the entire melt, which give rise to the refinement
of grains.
 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574
Fig. 16. Microstructures of (a) N-SAW WM and (b) V-SAW WM specimens under TEM.
In addition, the velocity in V-SAW with the help
of vibration is greater than that of non-vibratory
weld pool (Kou and Le, 1985). This significant
higher weld pool velocity apparently produces a
higher cooling rate during solidification. According
to the principles of solidification (Flemings, 1974),
higher cooling rate allows less time for the coarsen-
ing of subgrain to occur during solidification, result-
ing in a finer subgrain structure.
Moreover, the mechanical energies provided by
external vibration increase the boundary plastic
deformation and dislocation density. Then the dis-
locations with high density will tangle and pile up
to combine to make small-angle sub-boundaries.
Fig. 16 shows the microstructures of weld specimens
in N-SAW and V-SAW by transmission electron
microscopy (TEM) examinations, respectively. The
finer subgrain structure and higher dislocation den-
sity are observed in V-SAW specimen. Because of
the existance of fine subgrain, there are more sub-
grain boundaries where the dislocations are hin-
dered and piled up. These sub-boundaries act as
barriers for the crack to propagate. Therefore,
vibration induced in welding favours this dynamic
recrystallization and improves weld properties.
The vibratory welding method has produced
some of the other useful changes effects besides
grain refining. One effect is gas removal. Vibration
facilitates the release of dissolved gases and the
resulting weld beads greatly exhibit reduced poros-
ity. Another beneficial effect is to facilitate drifting
inclusions to the slag with the imposed vibration
from the molten welding pool. As a result, the quan-
tity as well as the size of the inclusion is decreased,
573
the internal welding defect is reduced and a uniform
weld joint is obtained.
8. Conclusions
1. Vibration applied to valve welding produces a
significant decrease in the welding deformation.
An 8% decrease in axial deformation, a 64%
decrease in the thinner cylinder and a 43%
decrease in the thicker one are achieved.
2. The welding maximum and minimum residual
stresses have been achieved reduced through the
application of vibratory welding. And the vibra-
tion applied during welding has less influence on
the axial residual stress than the radial one due to
no constraint in axial direction.
3. The yield and tensile strength of the welded joint
are almost independent of vibration in this pro-
cess. The 180° bend property under V-SAW con-
dition indicates excellence without any crack.
4. The average CTOD values of WM and HAZ
under V-SAW condition are greater than that
under N-SAW condition. Regardless of whether
vibration applied in welding or not, the fracture
toughness of WM is higher than that of HAZ.
The microstructural changes and coarsening have
a substantial effect on HAZ fracture toughness
decrease.
5. The presence of dimple-like structures on the
WM fracture surface indicates that the WM fails
in a ductile mode. Vibration is applied during
welding tends to reduce dimple size and increase
dimple density. Cleavage facets and some second-
phase particles are observed in HAZ specimens.
574 L. Qinghua et al. / Mechanics of Materials 40 (2008) 565–574
The variations in fractograph under different
welding conditions are closely related to the
substructure.
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