Welding Induced Distortion in Fabrication Processes: A Review of the Various Mitigation and Control Techniques

Welding is a widely used and effective method of joining metals. However, serious challenges are often encountered in the process due to welding distortion. Distortions result from the thermal expansion and shrinkage of metals during the welding process. This review paper focuses on the mechanisms associated with welding distortion and various mitigation techniques adaptable by fabrication industries. Whereas full prevention of distortion is unattainable with a finite geometric accuracy, it can essentially be controlled to minimize the undesired impact of distortion on the geometric integrity, hence increasing the manufacturing efficiency and decreasing the production cost. This paper categorizes distortions into out-of-plane and in-plane deformation modes and describes the factors which influence distortions - welding parameters, sequences, and material properties. Furthermore, a review of traditional and novel mitigation strategies, such as the optimization of welding parameters and improved determination and prediction of the welding sequence schedule. In this review, based on the synthesis of current publications, efforts have been made to guide fabrication industries in determining appropriate procedures and parameters to be selected according to job requirements, with the sole aim of offering better weld quality and lowering of manufacturing cost.