University of Malta
 

Mechanics of Welding
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Description

The mechanics of welding and joining technologies research group focuses on the assessment 

and numerical simulation of:

  • Conventional fusion MIG, TIG and SAW welding
  • Friction stir welding
  • Laser welding
  • Polymer joining techniques
  • Soldering

The aim of this research is to provide support tools and general design rules for the prediction and mitigation of thermal gradients, residual stresses and distortion developed in the design and manufacturing of welded and joined structures. A number of numerical finite element thermo-elasto-plastic models, visco-plastic fluid mechanics models and analytical algorithms have been developed. These models have been verified by means of full-scale experimental tests. The numerical models provide a computationally economic, simple to apply, adaptable and robust predictive tools that can be used to assess aerospace, automotive, fluid storage structures, marine and semi-conductor welded components structural performance during the early design stages.

Welding 

Funded Projects

Selected Publications

  • Gray T G F, Camilleri D and McPherson N,Control of Welding Distortion in Thin Plate Fabrication: Design Support Exploiting Computational Simulation,Woodhead Publishing Limited, ISBN-10: 085709047X, ISBN-13: 978-0857090478
  • Mollicone P., Gray T.G.F. and Camilleri D,Experimental Investigation and Finite Element Analysis of Welding Induced Residual Stresses,J.Strain Anal.Eng.Des., 47, 3, 140-152, Professional Engineering Publishing Ltd.
  • Camilleri D,,Thermo-mechanical Behaviour of DBC Substrate Assemblies Subject to Soldering Fabrication Processes,Soldering and Surface Mount Technology, 24, 2. Emerald Group Publishing Ltd.
  • Gray T G F and Camilleri D,Using Computationally Efficient Reduced-Solution Methods to Understand Welding Distortion,' Chpt 5, 124-165 in 'Minimization of Welding Distortion and Buckling - Modelling and Implementation,' edited by Michaleris P,Woodhead Publishing Limited, ISBN-10: 184569662X, ISBN-13: 978-1845696627.
  • Camilleri D, Mollicone P and Gray T G F,Computational Methods and Experimental Validation of Welding Distortion Models,Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 2007, 221, 4, 235-249, Professional Engineering Publishing Ltd.
  • Camilleri D, Comlekci T and Gray T G F,Computational Prediction of Out-of-Plane Welding Distortion and Experimental Investigation,J.Strain Anal.Eng.Des., 40, 2, 161-176, Professional Engineering Publishing Ltd (Awarded Central Electricity Generating Board Prize) .

Publications

  • Camilleri D, Micallef D and Mollicone P,Thermal Stresses and Distortion Developed in Mild Steel DH36 Friction Stir Welded Plates: An Experimental and Numerical Assessment,Journal of Thermal Stresses, 2015, 38, 5, 485-508
  • Micallef D, Camilleri d, Toumpis A, Galloway A and Arbaoui,Local Heat Generation and Material Flow in Friction Stir Welding of Mild Steel Assemblies,Journal of Materials: Design and Application (in print – published online)
  • Athanasios T, Galloway A, Cater S, Micallef D, Camilleri D, Poletz N and Arbaoui L,Advances in Friction Stir Welding of Steel – Project HILDA,Transport Research Arena 2014 TRA 2014, Paris, France
  • Camilleri D, McPherson N. and Gray T.G.F,The Applicability of using Low Transformation Temperature Welding Wire to Minimize Unwanted Residual Stresses and Distortions,Int. J. Pressure Vessels and Piping, 110, 2-8, Elsevier Ltd.
  • P. Mollicone, M. Muscat, R. Debono,Process and Structural Models for Resistance Spot Welding,Proceedings of the International CAE Conference 2013
  • M.Muscat, D.Sciberras,Finite element models for spot welds,NAFEMS World Congress NWC 2013, Salzburg, Austria, 9th – 11th June 2013
  • Micallef D, Camilleri D and Mollicone,Simplified Thermo-elastoplastic Numerical Modelling Techniques Applied to Friction Stir Welding of Mild Steel,Proceedings of the ASME 2013 Int. Mech. Eng. Congress & Exposition, SanDiego USA.
  • Camilleri D and Gray T G F,Minimisation of Distortion in Welding Thin-Walled Pressure Vessels and Tanks,MechE Seminar – Advances in Fabrication of Pressure Vessels and Pipping Systems, Manufacturing the Future, London, UK
  • Mollicone, P.; Muscat, M.; Said, M.,Computational Models for Resistance Spot Welding,Proceedings of the ASME 2012 11th Biennial Conference on Engineering Systems Design and Analysis ESDA2012
  • M. Muscat, C. Agius, P. Mollicone,Finite Element models for assessing the structural integrity of spot welds,Proceedings of the EnginSoft International Conference 2011, CAE technologies for industry
  • Mollicone P.,Experimental Validation of Finite Element Simulations to predict Welding Induced Residual Stresses,Proceedings of the EnginSoft International Conference 2011, CAE technologies for industry
  • Camilleri D, Gray T.G.F and McPherson N,Optimizing Tack Welding Fabrication Procedures Using Numerical Finite Element Models,,J.Ship Prod., 26, 2, 117-134, Society of Naval Architects and Marine Engineers.
  • Camilleri D, Gray T G F and McPherson, N,Tacking Fabrication Procedural Influences on Out-of-plane Welding Distortion,5th UK Distortion Forum, Rotherham, U.K.
  • Camilleri D, Gray T G F, McPherson N,,Procedural Tacking Fabrication Influences on Welding Distortion,Welding in the World 53, 403-408, Singapore.
  • M.Muscat, K.Degiorgio, J.Wood,Comparison between different approaches for the evaluation of the hot spot structural stress in welded pressure vessel components,ASME PVP Pressure Vessels and Piping Division Conference July 26-30, 2009, Prague, Czech Republic
  • Camilleri D,Integrating Finite Element Analysis in Design and Manufacture of Welded Structures,17th Annual Engineering Conference – Marine Engineering: Beyond Our Shores, Malta.
  • Camilleri D, Gray T G F, McPherson N,Numerical Modelling of MIG Welded Multiply-Stiffened Plate Structures to Optimize Fabrication Procedure,17th International Conference and Tutorial Workshop – Computer Technology in Welding and Manufacturing Cranfield, UK.
  • Camilleri D, Gray T G F, Nash D,Mitigation of Welding Distortion and Residual Stresses via Cryogenic CO2 Cooling – Numerical Investigation,17th International Conference and Tutorial Workshop – Computer Technology in Welding and Manufacturing, Cranfield, UK.
  • Mollicone P, Camilleri D and Gray T G F,Procedural Influences on Non-linear Distortions in Welded Thin-Plate Fabrication,Thin-Walled Structures, 46, 7-9, 1021-1034 Elsevier Ltd.
  • Mollicone P, Camilleri D, Gray T G F,Procedural Influences on Non-linear Distortions in Welded Thin-Plate Fabrication,Professor Jim Rhodes Retiral Conference Thin Walled Structures Glasgow, UK.
  • Camilleri D and Gray T G F,Optimization of Welded Lightweight Multiple-Stiffener Plate Structures to Minimise Unwanted Shape Distortion,Welding and Cutting, 5, 6, 320-327, Deutscher Verlag fur Schweisstechnik GmbH.
  • Camilleri D, Comlekci T, Gray T G F,Thermal Distortion of Stiffened Plate due to Fillet Welds - Computational and Experimental Investigation,Journal of Thermal Stresses, 29, 2, 111-137, Taylor and Francis Inc.
  • Mollicone P, Camilleri D, and Gray T G,Effects of Tack Welds and Restraints on Thin Plate Welding Distortion,4th UK Distortion Forum, Newcastle University, U.K.
  • Camilleri D, Gray T G F and Mollicone P,Computational Methods and Experimental Validation of Welding Distortion Simulation,IMechE Seminar – Modelling of Manufacturing Processes, London, UK.
  • Camilleri D, Mollicone P, Comlekci T, Gray T G F,Computational Methods for the Prediction of Out-of-Plane Deformation in Thin Plate Welded Structures,Proc. 14th Annual Conf. of Association for Computational Mechanics in Engineering, Belfast, UK. 7-11
  • Gray T G F, Camilleri D, Mollicone P,Experimental Validation of Computational Methods for Welding Distortion Prediction,22nd Symposium on Experimental Mechanics of Solids, Jachranka, Poland. 65-84,
  • Mollicone P, Camilleri D, Gray T G F and Comlekci T,Simple Thermo-Elastic-Plastic Models for Welding Distortion Simulation,,J.Mater.Process.Technol., 176, 1-3, 77-86, Elsevier Ltd.
  • Camilleri D, Mollicone P and Gray T G F,Alternative Simulation Techniques for Distortion of Thin Plate due to Fillet-Welded Stiffeners,Modell Simul Mater Sci Eng, 14, 8, 1307-1327, Institute of Physics Publishing.
  • Camilleri D, Comlekci T and Gray T G F,,Design Support Tool for Prediction of Welding Distortion in Multiply Stiffened Plate Structures: Experimental and Computational Investigation,J.Ship Prod., 21, 4, 219-234, Society of Naval Architects and Marine Engineers.
  • Mollicone P, Camilleri D, Comlekci T, Gray T G F,Thermo-Elastic-Plastic Finite Element Models for Gas-Shielded Metal-Arc Welding Fabrication,Proc. TCN CAE 2005, Lecce, Italy.
  • Camilleri D, Comlekci T, Gray T G F,Finite Element Analysis of Out-of-plane Distortion in Plates due to Double-Sided Fillet-Welded Attachments,Proc. NAFEMS World Congress 2005 St.Julians, Malta.
  • Camilleri D, Comlekci T, Gray T G F,Computationally Efficient Welding Simulation Technique for the Prediction of Out-of-Plane Distortion in Double-Sided Fillet Welding,Proc. TCN CAE 2005, Lecce, Italy.
  • Camilleri D and Gray T G F,Computationally Efficient Welding Distortion Simulation Techniques,Modell Simul Mater Sci Eng, 13, 8, 1365-1382, Institute of Physics Publishing.
  • Camilleri D, Comlekci T and Gray T.G.F,Support Tools for Design and Manufacture of Thin-Plate Welded Structures,1st UK Distortion Forum, Rotherham, U.K.
  • Camilleri D, Comlekci T and Gray T G F,Use of Thermography to Calibrate Fusion Welding Procedures in Virtual Fabrication Applications,Proc. of Inframation 2004 Conference Las Vegas, USA. 5, 121 -131
  • Camilleri D, Comlekci T, Lee C K, Tan H, Gray T G F,,Investigation of Temperature Transients during Flux-Cored CO2/Ar Butt Welding of CMn steel plates,,Proc. Int. Conf. on Metal Fabrication and Welding Technology Nottingham, UK.
  • Camilleri D, Comlekci T, Gray T G F,Out-of-Plane Distortion of CMn Steel Plates during Flux-Cored CO2/Ar Automatic Butt Welding,Proc. Int. Conf. on Metal Fabrication and Welding Technology Nottingham, UK. 117-127
  • Comlekci T, Camilleri D and Gray T G F,Finite Element Representation of Experimental Surface Deformation Data from Fusion Welded Plates,Proc. 11th Annual Conf. of Association for Computational Mechanics in Engineering, Glasgow, UK. 33-36
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Last Updated: 6 May 2015

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