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Sample records for aluminum weld strength

  1. U-Groove aluminum weld strength improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1996-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe peaking, which induces bending under uniaxial loading. The filler strain-hardening decreased with increasing filler pass sequence, producing the weakest welds on the last pass side. Current welding schedules unknowingly compound these effects which reduce the weld strength. A depeaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve depeaking in the welding process. The intent is to combine the strongest weld pass side with the peaking induced bending tension to provide a more uniform stress and stronger weld under axial tensile loading.

  2. U-groove aluminum weld strength improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1995-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe peaking which induces bending under uniaxial loading. The filler strain-hardening deceased with increasing filler pass sequence, producing the weakest welds on the last pass side. Current welding schedules unknowingly compound these effects which reduce the weld strength. A de-peaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve de-peaking in the welding process. Intent is to combine the strongest weld pass side with the peaking induced bending tension to provide a more uniform stress and stronger weld under axial tensile loading.

  3. U-Groove Aluminum Weld Strength Improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1997-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. One is the source of peaking in which the extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe angular distortion that induces bending under uniaxial loading. The other is the filler strain hardening decreasing with increasing filler pass sequences, producing the weakest welds on the last weld pass side. Both phenomena are governed by weld pass sequences. Many industrial welding schedules unknowingly compound these effects, which reduce the weld strength. A depeaking index model was developed to select filler pass thickness, pass numbers, and sequences to improve depeaking in the welding process. The result was to select the number and sequence of weld passes to reverse the peaking angle such as to combine the strongest weld pass side with the peaking induced bending tension component side to provide a more uniform stress and stronger weld under axial tensile loading.

  4. Weld geometry strength effect in 2219-T87 aluminum

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.; Novak, H. L.; Mcilwain, M. C.

    1981-01-01

    A theory of the effect of geometry on the mechanical properties of a butt weld joint is worked out based upon the soft interlayer weld model. Tensile tests of 45 TIG butt welds and 6 EB beads-on-plate in 1/4-in. 2219-T87 aluminum plate made under a wide range of heat sink and power input conditions are analyzed using this theory. The analysis indicates that purely geometrical effects dominate in determining variations in weld joint strength with heat sink and power input. Variations in weld dimensions with cooling rate are significant as well as with power input. Weld size is suggested as a better indicator of the condition of a weld joint than energy input.

  5. Influence of Aluminum Content on Grain Refinement and Strength of AZ31 Magnesium GTA Weld Metal

    SciTech Connect

    Babu, N. Kishore; Cross, Carl E.

    2012-06-28

    The goal is to characterize the effect of Al content on AZ31 weld metal, the grain size and strength, and examine role of Al on grain refinement. The approach is to systematically vary the aluminum content of AZ31 weld metal, Measure average grain size in weld metal, and Measure cross-weld tensile properties and hardness. Conclusions are that: (1) increased Al content in AZ31 weld metal results in grain refinement Reason: higher undercooling during solidification; (2) weld metal grain refinement resulted in increased strength & hardness Reason: grain boundary strengthening; and (3) weld metal strength can be raised to wrought base metal levels.

  6. A hot-cracking mitigation technique for welding high-strength aluminum alloy

    SciTech Connect

    Yang, Y.P.; Dong, P.; Zhang, J.; Tian, X.

    2000-01-01

    A hot-cracking mitigation technique for gas tungsten arc welding (GTAW) of high-strength aluminum alloy 2024 is presented. The proposed welding technique incorporates a trailing heat sink (an intense cooling source) with respect to the welding torch. The development of the mitigation technique was based on both detailed welding process simulation using advanced finite element techniques and systematic laboratory experiments. The finite element methods were used to investigate the detailed thermomechanical behavior of the weld metal that undergoes the brittle temperature range (BTR) during welding. As expected, a tensile deformation zone within the material BTR region was identified behind the weld pool under conventional GTA welding process conventional GTA welding process conditions for the aluminum alloy studied. To mitigate hot cracking, the tensile zone behind the weld pool must be eliminated or reduce to a satisfactory level if the weld metal hot ductility cannot be further improved. With detailed computational modeling, it was found that by the introduction of a trailing heat sink at some distance behind the welding arc, the tensile strain rate with respect to temperature in the zone encompassing the BTR region can be significantly reduced. A series of parametric studies were also conducted to derive optimal process parameters for the trailing heat sink. The experimental results confirmed the effectiveness of the trailing heat sink technique. With a proper implementation of the trailing heat sink method, hot cracking can be completely eliminated in welding aluminum alloy 2024 (AA 2024).

  7. Effects of Failure Modes on Strength of Aluminum Resistance Spot Welds

    SciTech Connect

    Sun, Xin; Stephens, Elizabeth V.; Davies, Richard W.; Khaleel, Mohammad A.; Spinella, Donald J.

    2005-04-01

    This paper examines the effects of failure modes on the static strength and total energy absorption of aluminum spot-welded samples using experimental, statistical, and analytical approaches. The main failure modes for aluminum spot welds are nugget pullout and interfacial fracture. Two populations of aluminum spot welds were studied. Within each population, coupon configurations of lap shear, cross tension and coach peel were considered. Thirty replicate static strength tests were performed for each coupon configuration. The resulted peak load and energy absorption level associated with each failure mode was studied using statistical models. Next, an analytical model was developed to determine the failure mode of an aluminum resistance spot weld based on stress analysis. It is found that weld size, sheet thickness, and level of weld porosity and defects are the main factors determining the cross tension failure mode for an aluminum spot weld. The peak load and energy absorption levels for the cross tension and coach peel samples tested are found not to be very sensitive to the failure modes under static loading.

  8. The Strength and Characteristics of VPPA Welded 2219-T87 Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Jemian, W. A.

    1985-01-01

    A study of the variable polarity plasma arc (VPPA) welding process and those factors that control the structure and properties of VPPA welded aluminum alloy 2219-T87 was conducted. The importance of joint preparation, alignment of parts and welding process variables are already established. Internal weld defects have been eliminated. However, a variation of properties was found to be due to the size variation of interdendritic particles in the fusion zone. These particles contribute to the void formation process, which controls the ultimate tensile strength of the welded alloy. A variation of 150 microns in particle size correlated with a 10 ksi variation of ultimate tensile strength. It was found that all fracture surfaces were of the dimple rupture type, with fracture initiating within the fusion zone.

  9. Improved TIG weld joint strength in aluminum alloy 2219-T87 by filler metal substitution

    NASA Technical Reports Server (NTRS)

    Poorman, R. M.; Lovoy, C. V.

    1972-01-01

    The results of an investigation on weld joint characteristics of aluminum alloy 2219-T87 are given. Five different alloys were utilized as filler material. The mechanical properties of the joints were determined at ambient and cryogenic temperatures for weldments in the as-welded condition and also, for weldments after elevated temperature exposures. Other evaluations included hardness surveys, stress corrosion susceptibility, and to a limited extent, the internal metallurgical weld structures. The overall results indicate that M-943 filler weldments are superior in strength to weldments containing either the standard 2319 filler or fillers 2014, 2020, and a dual wire feed consisting of three parts 2319 and one part 5652. In addition, no deficiencies were evident in M-934 filler weldments with regard to ductility, joint strength after elevated temperature exposure, weld hardness, metallographic structures, or stress corrosion susceptibility.

  10. Neural Network Prediction of Aluminum-Lithium Weld Strengths from Acoustic Emission Amplitude Data

    NASA Technical Reports Server (NTRS)

    Hill, Eric v. K.; Israel, Peggy L.; Knotts, Gregory L.

    1993-01-01

    Acoustic Emission (AE) flaw growth activity was monitored in aluminum-lithium weld specimens from the onset tensile loading to failure. Data on actual ultimate strengths together with AE data from the beginning of loading up to 25 percent of the expected ultimate strength were used to train a backpropagation neural network to predict ultimate strengths. Architecturally, the fully interconnected network consisted of an input layer for the AE amplitude data, a hidden layer to accommodate failure mechanism mapping, and an output layer for ultimate strength prediction. The trained network was the applied to the prediction of ultimate strengths in the remaining six specimens. The worst case prediction error was found to be +2.6 percent.

  11. Weld bead reinforcement removal: A method of improving the strength and ductility of peaked welds in 2219-T87 aluminum alloy plate

    NASA Technical Reports Server (NTRS)

    Lovoy, C. V.

    1979-01-01

    The results of a study to determine the degree to which the ductility and tensile properties of peaked welds could be enhanced by removing the reinforcing bead and fairing the weld nugget into the adjacent parent metal are presented. The study employed 2219-T87 aluminum alloy plate, tungsten inert gas (TIG) welding, and 2319 filler wire. The study concluded that significant improvements in peak weld, ultimate strength, and ductility can be obtained through removal and fairing of the weld reinforcing bead. The specimens so treated and tested in this program exhibited ultimate strength improvements of 2 to 3 percent for peak angles of 5.8 to 10 degrees and 10 to 22 percent for welds with peak angles of 11.7 to 16.9 degrees. It was also determined that removal of the weld bead enhanced the ability of peaked welds to straighten when exposed to cyclic loading at stress levels above the yield strength.

  12. Development of a technology for laser welding of the 1424 aluminum alloy with a high strength of the welded joint

    NASA Astrophysics Data System (ADS)

    Annin, B. D.; Fomin, V. M.; Karpov, E. V.; Malikov, A. G.; Orishich, A. M.; Cherepanov, A. N.

    2015-11-01

    Results of an experimental study of properties of joints obtained by using different regimes of laser welding of the 1424 alloy (Al-Mg-Li) are reported. The strength and structure of the welded joints are determined. The influence of various types of welded joint straining on its strength is studied. It is demonstrated that the joint strength increases in the case of plastic straining.

  13. Effects of stress concentration on the fatigue strength of 7003-T5 aluminum alloy butt joints with weld reinforcement

    NASA Astrophysics Data System (ADS)

    Zhu, Zongtao; Li, Yuanxing; Zhang, Mingyue; Hui, Chen

    2015-03-01

    7003-T5 Aluminum (Al) alloy plates with a thickness of 5 mm are welded by gas metal arc welding (GMAW) method in this work. In order to investigate the influence of stress concentration introduced by weld reinforcement on fatigue strength, the stress concentration factor of the butt joint is calculated. Microscopic and X-ray techniques were utilized to make sure there are no weld defects with large size in butt weld, which can induce extra stress concentration. The cyclic stress - number of cycles to failure (S-N) curves of the joints with and without the welder were obtained by fatigue testing, and the results show that the fatigue strength of 7003-T5 Al alloy butt joints with the weld reinforcement is 50 MPa, which is only 45% of the joints without the weld reinforcement. Fracture surface observation indicated that the fatigue source and propagation are dissimilar for the specimens with and without the welder due to the stress concentration at the weld root. The stress concentration with a factor of 1.7 has great effect on the fatigue strength, but little influence on the tensile strength.

  14. Effects of porosity on weld-joint tensile strength of aluminum alloys

    NASA Technical Reports Server (NTRS)

    Lovoy, C. V.

    1974-01-01

    Tensile properties in defect-free weldments of aluminum alloys 2014-T6 and 2219-T87 (sheet and plate) are shown to be related to the level or concentration of induced simulated porosity. The scatter diagram shows that the ultimate tensile strength of the weldments displays the most pronounced linear relationship with the level of porosity. The relationships between yield strength or elongation and porosity are either trivial or inconsequential in the lower and intermediate levels of porosity content. In highly concentrated levels of porosity, both yield strength and elongation values decrease markedly. Correlation coefficients were obtained by simple straight line regression analysis between the variables of ultimate tensile strength and pore level. The coefficients were greater, indicating a better correlation, using a pore area accumulation concept or pore volume accumulation than the accumulation of the pore diameters. These relationships provide a useful tool for assessing the existing aerospace radiographic acceptance standards with respect to permissible porosity. In addition, these relationships, in combination with known design load requirements, will serve as an engineering guideline in determining when a weld repair is necessary based on accumulative pore level as detected by radiographic techniques.

  15. Study of mechanical joint strength of aluminum alloy 7075-T6 and dual phase steel 980 welded by friction bit joining and weld-bonding under corrosion medium

    SciTech Connect

    Lim, Yong Chae; Squires, Lile; Pan, Tsung-Yu; Miles, Michael; Song, Guang-Ling; Wang, Yanli; Feng, Zhili

    2014-12-30

    We have employed a unique solid-sate joining process, called friction bit joining (FBJ), to spot weld aluminum alloy (AA) 7075-T6 and dual phase (DP) 980 steel. Static joint strength was studied in the lap shear tension configuration. In addition, weld-bonding (adhesive + FBJ) joints were studied in order to evaluate the ability of adhesive to mitigate the impact of corrosion on joint properties. Accelerated laboratory cyclic corrosion tests were carried out for both FBJ only and weld-bonding joints. Furthermore, the FBJ only joints that emerged from corrosion testing had lap shear failure loads that were significantly lower than freshly prepared joints. However, weld-bonding specimens retained more than 80% of the lap shear failure load of the freshly prepared weld-bonding specimens. Moreover, examination of joint cross sections confirmed that the presence of adhesive in the weld-bonding joints mitigated the effect of the corrosion environment, compared to FBJ only joints.

  16. Study of mechanical joint strength of aluminum alloy 7075-T6 and dual phase steel 980 welded by friction bit joining and weld-bonding under corrosion medium

    DOE PAGESBeta

    Lim, Yong Chae; Squires, Lile; Pan, Tsung-Yu; Miles, Michael; Song, Guang-Ling; Wang, Yanli; Feng, Zhili

    2014-12-30

    We have employed a unique solid-sate joining process, called friction bit joining (FBJ), to spot weld aluminum alloy (AA) 7075-T6 and dual phase (DP) 980 steel. Static joint strength was studied in the lap shear tension configuration. In addition, weld-bonding (adhesive + FBJ) joints were studied in order to evaluate the ability of adhesive to mitigate the impact of corrosion on joint properties. Accelerated laboratory cyclic corrosion tests were carried out for both FBJ only and weld-bonding joints. Furthermore, the FBJ only joints that emerged from corrosion testing had lap shear failure loads that were significantly lower than freshly preparedmore » joints. However, weld-bonding specimens retained more than 80% of the lap shear failure load of the freshly prepared weld-bonding specimens. Moreover, examination of joint cross sections confirmed that the presence of adhesive in the weld-bonding joints mitigated the effect of the corrosion environment, compared to FBJ only joints.« less

  17. Ultrasonic Spot Welding of Aluminum to High-Strength Low-Alloy Steel: Microstructure, Tensile and Fatigue Properties

    NASA Astrophysics Data System (ADS)

    Patel, V. K.; Bhole, S. D.; Chen, D. L.

    2014-04-01

    The structural applications of lightweight aluminum alloys inevitably involve dissimilar welding with steels and the related durability issues. This study was aimed at evaluating the microstructural change, lap shear tensile load, and fatigue resistance of dissimilar ultrasonic spot-welded joints of aluminum-to-galvanized high-strength low-alloy (HSLA) steel. Two non-uniform layers were identified in between Al and HSLA steel via SEM/EDS and XRD. One was an Al-Zn eutectic layer and the other was a thin (<2 μm) layer of intermetallic compound (IMC) of Al and Fe in the nugget zone. The lap shear tensile testing gave a maximum load of 3.7 kN and the sample failed initially in between the Al-Zn eutectic film and Al-Fe IMC, and afterward from the region containing Al on both matching fracture surfaces. The fatigue test results showed a fatigue limit of about 0.5 kN (at 1 × 107 cycles). The maximum cyclic stress at which transition of the fatigue fracture from transverse through-thickness crack growth mode to the interfacial failure mode occurs increases with increasing energy input.

  18. Automated and aluminum welding technology

    NASA Astrophysics Data System (ADS)

    Jones, Clyde S.

    1994-10-01

    Automated welding technology and techniques for welding advanced aluminum alloys with potential for industrial and commercial applications have been developed by the National Aeronautics and Space Administration at the Marshall Space Flight Center. These technologies are being offered to private companies for commercial development, and include: Variable polarity plasma arc welding, a welding process that produces high-quality aluminum welds for fabrication of the space shuttle external tank and space station common module structures. This process uses reverse polarity pulses to produce welds virtually free of internal defects. Advanced weld sensor technology, comprised of machine vision-based weld seam tracking that uses both structured and global laser illumination for finding weld joints, even those difficult to discern by the human eye. Weld pool feedback is accomplished with a vision system to measure arc symmetry and molten weld pool geometry. A weld bead profiler trails the welding torch. It provides feedback to the process control system, which records quality control data.

  19. Forming Limits of Weld Metal in Aluminum Alloys and Advanced High-Strength Steels

    SciTech Connect

    Stephens, Elizabeth V.; Smith, Mark T.; Grant, Glenn J.; Davies, Richard W.

    2010-10-25

    This work characterizes the mechanical properties of DP600 laser welded TWBs (1 mm-1.5 mm) near and in the weld, as well as their limits of formability. The approach uses simple uniaxial experiments to measure the variability in the forming limits of the weld region, and uses a theoretical forming limit diagram calculation to establish a probabilistic distribution of weld region imperfection using an M-K method approach

  20. Aluminum laser welding optimization

    NASA Astrophysics Data System (ADS)

    Chmelíčková, Hana; Halenka, Viktor; Lapšanská, Hana; Havelková, Martina

    2007-04-01

    Pulsed Nd:YAG laser with maximal power 150 W is used in our laboratory to cut, drill and weld metal and non-metal thin materials to thickness 2 mm. Welding is realized by fixed processing head or movable fiber one with beam diameter 0,6 mm in focus plane. Welding of stainless and low-carbon steel was tested before and results are publicized and used in practice. Now the goal of our experiment was optimization of process parameters for aluminum that has other physical properties than steels, lower density, higher heat conductivity and surface reflexivity. Pure alumina specimen 0,8 mm and Al-Mg-Si alloy 0,5 mm prepared for butt welds. Problem with surface layer of Al IIO 3 was overcome by sanding and chemical cleaning with grinding paste. Critical parameters for good weld shape are specimen position from beam focus plane, pulse length and energy, pulse frequency and the motion velocity that determines percentage of pulse overlap. Argon as protective gas was used with speed 6 liters per second. Thermal distribution in material can be modeled by numerical simulation. Software tool SYSWELD makes possible to fit laser as surface heat source, define weld geometry, and make meshing of specimen to finite elements and compute heat conduction during process. Color isotherms, vectors, mechanical deformations and others results can be study in post-processing.

  1. Laser welding of aluminum alloys

    SciTech Connect

    Leong, K.H.; Sabo, K.R.; Sanders, P.G.; Spawr, W.J.

    1997-03-01

    Recent interest in reducing the weight of automobiles to increase fuel mileage has focused attention on the use of aluminum and associated joining technologies. Laser beam welding is one of the more promising methods for high speed welding of aluminum. Consequently, substantial effort has been expended in attempting to develop a robust laser beam welding process. Early results have not been very consistent in the process requirements but more definitive data has been produced recently. This paper reviews the process parameters needed to obtain consistent laser welds on 5,000 series aluminum alloys and discusses the research necessary to make laser processing of aluminum a reality for automotive applications.

  2. Shear strength of fillet welds in aluminum alloy 2219. [for use on the solid rocket motor and external tank

    NASA Technical Reports Server (NTRS)

    Lovoy, C. V.

    1978-01-01

    Fillet size is discussed in terms of theoretical or design dimensions versus as-welded dimensions, drawing attention to the inherent conservatism in the design load sustaining capabilities of fillet welds. Emphasis is placed on components for the solid rocket motor, external tank, and other aerospace applications. Problems associated with inspection of fillet welds are addresses and a comparison is drawn between defect counts obtained by radiographic inspection and by visual examination of the fracture plane. Fillet weld quality is related linearly to ultimate shear strength. Correlation coefficients are obtained by simple straight line regression analysis between the variables of ultimate shear strength and accumulative discontinuity summation. Shear strength allowables are found to be equivalent to 57 percent of butt weld A allowables (F sub tu.)

  3. Ultrasonic Additive Manufacturing: Weld Optimization for Aluminum 6061, Development of Scarf Joints for Aluminum Sheet Metal, and Joining of High Strength Metals

    NASA Astrophysics Data System (ADS)

    Wolcott, Paul J.

    Ultrasonic additive manufacturing (UAM) is a low temperature, solid-state manufacturing process that enables the creation of layered, solid metal structures with designed anisotropies and embedded materials. As a low temperature process, UAM enables the creation of active composites containing smart materials, components with embedded sensors, thermal management devices, and many others. The focus of this work is on the improvement and characterization of UAM aluminum structures, advancing the capabilities of ultrasonic joining into sheet geometries, and examination of dissimilar material joints using the technology. Optimized process parameters for Al 6061 were identified via a design of experiments study indicating a weld amplitude of 32.8 synum and a weld speed of 200 in/min as optimal. Weld force and temperature were not significant within the levels studied. A methodology of creating large scale builds is proposed, including a prescribed random stacking sequence and overlap of 0.0035 in. (0.0889 mm) for foils to minimize voids and maximize mechanical strength. Utilization of heat treatments is shown to significantly increase mechanical properties of UAM builds, within 90% of bulk material. The applied loads during the UAM process were investigated to determine the stress fields and plastic deformation induced during the process. Modeling of the contact mechanics via Hertzian contact equations shows that significant stress is applied via sonotrode contact in the process. Contact modeling using finite element analysis (FEA), including plasticity, indicates that 5000 N normal loads result in plastic deformation in bulk aluminum foil, while at 3000 N no plastic deformation occurs. FEA studies on the applied loads during the process, specifically a 3000 N normal force and 2000 N shear force, show that high stresses and plastic deformation occur at the edges of a welded foil, and base of the UAM build. Microstructural investigations of heat treated foils confirms

  4. Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

    NASA Technical Reports Server (NTRS)

    Bjorkman, Gerry; Cantrell, Mark; Carter, Robert

    2003-01-01

    Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading

  5. FRICTION-STIR-LAP-WELDS OF AA6111 ALUMINUM ALLOY

    SciTech Connect

    Yadava, Manasij; Mishra, Rajiv S.; Chen, Y. L.; Gayden, X.; Grant, Glenn J.

    2007-01-09

    Lap joints of 1 mm thick AA6111 aluminum sheets were made by friction stir welding, using robotic and conventional machines. Welds were made for advancing as well as retreating side loading. Thinning in welds was quantified. Lap shear test of welds was conducted in as-welded and paint-baked conditions. Conventional machine welds showed less thinning and better strength than robotic machine welds. Process forces in conventional machine welding were higher. Paint bake treatment improved the weld strength; but the improvement varied with process parameters. Advancing side loaded welds achieved higher strength than the retreating side loaded welds. Fracture location was found to occur on the loaded side of the weld and along the thinning defect.

  6. Partially melted zone in aluminum welds

    NASA Astrophysics Data System (ADS)

    Huang, Chen-Che

    The partially melted zone (PMZ) is a region immediately outside the weld metal where grain boundary (GB) liquation can occur and cause intergranular cracking. Aluminum alloys are known to be susceptible to liquation and liquation cracking. The PMZ of alloy 2219 (essentially Al-6.3Cu) was studied. Liquation is initiated eutectically. Solidification of the GB liquid was directional---upward and toward the weld as a result of the temperature gradients across the PMZ. The liquated material solidifies with severe segregation into a low-strength, low-ductility structure consisting of a solute-depleted ductile phase and a solute-rich brittle eutectic. In tensile testing the maximum load and displacement before failure were both far below those of the base metal. The GB eutectic fractured while the adjacent Cu-depleted a deformed readily under tension. The solidification mode of the grain boundary liquid was mostly planar. However, cellular solidification was also observed near the bottom of partial-penetration welds, where temperature gradients were lowest. The liquation mechanisms in wrought multicomponent aluminum alloys during welding were also studied. Three mechanisms were identified. They cover most, if not all, wrought aluminum alloys. Liquation cracking in the PMZ was investigated in full-penetration aluminum welds. Liquation cracking occurs because the solidifying PMZ is pulled by a solidifying and thus contracting weld metal that is stronger than the PMZ. Liquation cracking can occur if there is significant liquation in the PMZ, if there is no solidification cracking in the adjacent weld metal, and if the PMZ becomes lower in solid fraction (and hence strength) during its terminal solidification than the solidifying weld metal. Liquation cracking in the PMZ was also investigated in partial-penetration aluminum welds. The papillary (nipple) type penetration common in welding with spray transfer of the filler wire actually oscillates along the weld and promotes

  7. Microhardness, strength and strain field characterization of self-reacting friction stir and plug welds of dissimilar aluminum alloys

    NASA Astrophysics Data System (ADS)

    Horton, Karla Renee

    Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA2014-T6 plate on the advancing side and an AA2219-T87 plate on the retreating side and a SR-FSW (AA2014-T6 to AA2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures. The initial weld microstructure analysis showed a nugget region with fine grains and a displaced weld seam from the advancing side past the thermo-mechanical affected zone (TMAZ) into the nugget region. The displaced material shared the same hardness as the parent material. Dynamic recrystallization was observed in the SR-FSW zone and the displaced weld seam region. The welds revealed a fine grain structure in the SR-FSW zone with a sharp demarcation seen on the advancing side and fairly diffuse flow observed on the retreating side. The parent material hardness is 145 HV700g with a drop in hardness starting at the HAZ to 130 HV700g. The hardness further drops in the TMAZ to118 HV700g with an increase representing a dispersed interface of AA2014-T6 material to 135 HV700g. The hardness then drops significantly within the nugget region to 85 HV700g followed by an increase through the retreating side TMAZ into the HAZ to 135 HV 700g. There was a sharp increase in the hardness value within

  8. Influences of post weld heat treatment on tensile strength and microstructure characteristics of friction stir welded butt joints of AA2014-T6 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Rajendran, C.; Srinivasan, K.; Balasubramanian, V.; Balaji, H.; Selvaraj, P.

    2016-08-01

    Friction stir welded (FSWed) joints of aluminum alloys exhibited a hardness drop in both the advancing side (AS) and retreating side (RS) of the thermo-mechanically affected zone (TMAZ) due to the thermal cycle involved in the FSW process. In this investigation, an attempt has been made to overcome this problem by post weld heat treatment (PWHT) methods. FSW butt (FSWB) joints of Al-Cu (AA2014-T6) alloy were PWHT by two methods such as simple artificial aging (AA) and solution treatment followed by artificial aging (STA). Of these two treatments, STA was found to be more beneficial than the simple aging treatment to improve the tensile properties of the FSW joints of AA2014 aluminum alloy.

  9. REAL TIME ULTRASONIC ALUMINUM SPOT WELD MONITORING SYSTEM

    SciTech Connect

    Regalado, W. Perez; Chertov, A. M.; Maev, R. Gr.

    2010-02-22

    Aluminum alloys pose several properties that make them one of the most popular engineering materials: they have excellent corrosion resistance, and high weight-to-strength ratio. Resistance spot welding of aluminum alloys is widely used today but oxide film and aluminum thermal and electrical properties make spot welding a difficult task. Electrode degradation due to pitting, alloying and mushrooming decreases the weld quality and adjustment of parameters like current and force is required. To realize these adjustments and ensure weld quality, a tool to measure weld quality in real time is required. In this paper, a real time ultrasonic non-destructive evaluation system for aluminum spot welds is presented. The system is able to monitor nugget growth while the spot weld is being made. This is achieved by interpreting the echoes of an ultrasound transducer located in one of the welding electrodes. The transducer receives and transmits an ultrasound signal at different times during the welding cycle. Valuable information of the weld quality is embedded in this signal. The system is able to determine the weld nugget diameter by measuring the delays of the ultrasound signals received during the complete welding cycle. The article presents the system performance on aluminum alloy AA6022.

  10. Particulate and gaseous emissions when welding aluminum alloys.

    PubMed

    Cole, Homer; Epstein, Seymour; Peace, Jon

    2007-09-01

    Fabrication and repair of aluminum components and structures commonly involves the use of electric arc welding. The interaction of the arc and the metal being welded generates ultraviolet radiation, metallic oxides, fumes, and gases. Aluminum is seldom used as the pure metal but is often alloyed with other metals to improve strength and other physical properties. Therefore, the exact composition of any emissions will depend on the welding process and the particular aluminum alloy being welded. To quantify such emissions, The Aluminum Association sponsored several studies to characterize arc welding emissions by the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes for various combinations of base and filler alloys. In all cases, the tests were conducted under conditions that could be found in a production weld shop without forced ventilation. The concentrations of each analyte that a welder could be exposed to were greatly affected by the welding process, the composition of the base and filler alloys, the position of the welder, and the welding helmet. The results obtained can be used by employers to identify and control potential hazards associated with the welding of aluminum alloys and can provide the basis for hazard communication to employees involved in the welding of these alloys. PMID:17620189

  11. Torsion strength of continuous drive friction weld joint of round bar aluminum A6061 affected by single cone geometry of friction area

    NASA Astrophysics Data System (ADS)

    Irawan, Yudy Surya; Amirullah, Muhammad; Gumilang, Galih Bramantya Dian; Oerbandono, Tjuk; Suprapto, Wahyono

    2016-03-01

    This paper describes the effect of single cone geometry of friction area on torsion strength of continuous drive friction weld (CDFW) joint of round bar aluminum alloys A6061. Single cone geometry on friction area was determined with ratio of upper diameter (D1) and lower diameter (D2), D1/D2 of cone. Ratios of D1/D2 used were 0.02, 0.25, 0.65, 0.8 and 1. Friction time was 120 seconds. Torsion strength test, macro and microstructure, micro-hardness test were conducted. The results show that D1/D2 of 0.25 gives maximum torsion strength of CDFW joint. It is thought that it occurs due to the wider area of Zpl zone, smaller grain size and more Mg2Si precipitate in the Zpl and Zpd zone and nil or minimum porosity in the CDFW joint.

  12. Fracturing behavior of aluminum alloys with welded joints

    NASA Astrophysics Data System (ADS)

    Polyakov, V. V.; Kolubaev, E. A.; Salita, D. S.; Dmitriev, A. A.; Lependin, A. A.

    2015-10-01

    In this paper, properties of aluminum-magnesium alloys with welded joints are investigated. The joints are produced by the friction stir welding under various conditions. This fact is used for studying the principles and patterns of defect structure development. Mechanical properties are evaluated by static tension tests. The impact of welding process conditions on loading curves and strength properties is analysed. Fracture surface structures for samples with and without welded joints are studied, and results are compared. It is revealed, that differences in deformation behavior and mechanical properties of aluminum-magnesium alloys produced under different welding process conditions are caused by developing of structure defects in a welded joints, mostly, nonuniformities/discontinuities of various types. The obtained results can be used for improvement and development of new welding process conditions for aluminum-magnesium alloys.

  13. Theoretical Model of the Effect of Crack Tip Blunting on the Ultimate Tensile Strength of Welds in 2219-T87 Aluminum

    NASA Technical Reports Server (NTRS)

    Beil, R. J.

    1982-01-01

    A theoretical model representing blunting of a crack tip radius through diffusion of vacancies is presented. The model serves as the basis for a computer program which calculates changes, due to successive weld heat passes, in the ultimate tensile strength of 2219-T81 aluminum. In order for the model to yield changes of the same order in the ultimate tensile strength as that observed experimentally, a crack tip radius of the order of .001 microns is required. Such sharp cracks could arise in the fusion zone of a weld from shrinkage cavities or decohered phase boundaries between dendrites and the eutectic phase, or, possibly, from plastic deformation due to thermal stresses encountered during the welding process. Microstructural observations up to X2000 (resolution of about .1 micron) did not, in the fusion zone, show structural details which changed significantly under the influence of a heat pass, with the exception of possible small changes in the configuration of the interdendritic eutectic and in porosity build-up in the remelt zone.

  14. Weld Repair of Thin Aluminum Sheet

    NASA Technical Reports Server (NTRS)

    Beuyukian, C. S.; Mitchell, M. J.

    1986-01-01

    Weld repairing of thin aluminum sheets now possible, using niobium shield and copper heat sinks. Refractory niobium shield protects aluminum adjacent to hole, while copper heat sinks help conduct heat away from repair site. Technique limits tungsten/inert-gas (TIG) welding bombardment zone to melt area, leaving surrounding areas around weld unaffected. Used successfully to repair aluminum cold plates on Space Shuttle, Commercial applications, especially in sealing fractures, dents, and holes in thin aluminum face sheets or clad brazing sheet in cold plates, heat exchangers, coolers, and Solar panels. While particularly suited to thin aluminum sheet, this process also used in thicker aluminum material to prevent surface damage near weld area.

  15. Ultrasonic Butt Welding of Aluminum, Copper and Steel Plate Specimens

    NASA Astrophysics Data System (ADS)

    Tsujino, Jiromaru; Ueoka, Tetsugi; Fujita, Yuki; Watanabe, Ichiro

    1994-05-01

    Characteristics of ultrasonic butt welding of the same and of different metal plates are studied. The ultrasonic vibration source used has eight 15-kHz bolt-clamped Langevin-type lead-zircon-titanate (PZT) transducers of 60 mm diameter and is driven by a 50-kW static induction thyristor power amplifier. Welding specimens of aluminum, copper and steel plates of 6 mm thickness are successfully joined end-to-end with weld strength almost equal to that of an aluminum specimen. The input power required for aluminum, aluminum and copper, and aluminum and steel plates are about 5 kW/cm2, 5.5 kW/cm2 and 3.5 kW/cm2, respectively. The measured temperature rise at the specimen side surface and elongation of the welded specimen during a tensile test correspond to weld strength. The hardness distributions along the weldment of welded specimens are measured and the maximum temperature rise in an aluminum welding specimen is estimated to be over 480°C from the reduction of hardness at a welding specimen surface.

  16. Aluminum alloy welding and stress-corrosion testing. Final report

    SciTech Connect

    Gates, W.G.; Jimenez, E.

    1981-04-01

    The weldability, strength, and corrosion resistance of four 5XXX aluminum alloys electron beam welded to 6061-T6 aluminum alloy without a filler metal were evaluated. Adding filler metal raises weld energy requirements and makes the process more difficult to control. In this study, instead of using a filler metal, a high-magnesium 5XXX alloy was welded to the 6061 alloy. The four 5XXX alloys used (5456-H321, 5052-H34, 5086-H323, and 5083-H32) were selected for their high magnesium content which reduces weld crack sensitivity.

  17. Comparing Laser Welding Technologies with Friction Stir Welding for Production of Aluminum Tailor-Welded Blanks

    SciTech Connect

    Hovanski, Yuri; Carsley, John; Carlson, Blair; Hartfield-Wunsch, Susan; Pilli, Siva Prasad

    2014-01-15

    A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

  18. Interpretation of aluminum-alloy weld radiography

    NASA Technical Reports Server (NTRS)

    Duren, P. C.; Risch, E. R.

    1971-01-01

    Report proposes radiographic terminology standardization which allows scientific interpretation of radiographic films to replace dependence on individual judgement and experience. Report includes over 50 photographic pages where radiographs of aluminum welds with defects are compared with prepared weld sections photomacrographs.

  19. Microstructure analysis in friction welding of copper and aluminum

    NASA Astrophysics Data System (ADS)

    Wibowo, A. G. Wahyu; Ismail, Rifky; Jamari, J.

    2016-04-01

    The Friction welding is a welding method with utilizing heat generated due to friction. Surfaces of two materials to be joined, one rotates the other being idle, is contacted by a pressure force. Friction on the second contact surface is done continuously so that the heat generated by the continuous friction will continue to rise. With the heat and the pressure force on the second surface to the second meeting of the material reaches its melting temperature then there is the process of welding. This paper examines the influence of the pressure force, rotational speed and contact time on friction welding of Aluminum (Al) and Copper (Cu) to the quality of welded joints. Friction welding process is performed on a friction welding machine that is equipped with the loading mechanism. The parameters used are the pressure force, rotational speed and friction time. Determination of the quality of welding is done by testing the tensile strength, hardness, and micro structure on the weld joint areas. The results showed that the friction welding quality is very good, this is evidenced by the results of a tensile strength test where the fault occurs outside the weld joint and increased violence in the weld joint. On the results visually cuts the welding area did not reveal any porosity so that it can be concluded that each metal contacts have melted perfectly and produce a connection with good quality.

  20. Properties of VPPA-Welded 2219-T87 Aluminum

    NASA Technical Reports Server (NTRS)

    Wilson, W.; Jemian, W. A.

    1986-01-01

    Metallurgical properties and effects of welding described. Report describes investigation of welding of 2219-T87 aluminum alloy by variable-polarity plasma-arc (VPPA) process. Research was to determine highest strength attainable with this alloy and process and to estimate changes in weld properties caused by variations of process controls. Alloy 2219 strong and heat treatable and retains structural integrity up to 600 degrees F (316 degress C). Is principal structural alloy of Space Shuttle external tank. VPPA process offers many advantages and replaces tungsten/inert-gas process used. In over 24,000 in. (610 m) of welds on tank, there has been no internal defect requiring manual repair.

  1. Monitoring of solidification crack propagation mechanism in pulsed laser welding of 6082 aluminum

    NASA Astrophysics Data System (ADS)

    von Witzendorff, P.; Kaierle, S.; Suttmann, O.; Overmeyer, L.

    2016-03-01

    Pulsed laser sources with pulse durations in the millisecond regime can be used for spot welding and seam welding of aluminum. Seam welds are generally produced with several overlapping spot welds. Hot cracking has its origin in the solidification process of individual spot welds which determines the cracking morphology along the seam welding. This study used a monitoring unit to capture the crack geometry within individual spot welds during seam welding to investigate the conditions for initiation, propagation and healing (re-melting) of solidification cracking within overlapping pulsed laser welds. The results suggest that small crack radii and high crack angles with respect to welding direction are favorable conditions for crack healing which leads to crack-free seam welds. Optimized pulse shapes were used to produce butt welds of 0.5 mm thick 6082 aluminum alloys. Tensile tests were performed to investigate the mechanical strength in the as-welded condition.

  2. Friction-Stir Welding of Aluminum For the Space Program

    NASA Technical Reports Server (NTRS)

    Jones, Clyde S.; Smelser, Jerry W. (Technical Monitor)

    2002-01-01

    The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

  3. Filler wire for aluminum alloys and method of welding

    NASA Technical Reports Server (NTRS)

    Bjorkman, Jr., Gerald W. O. (Inventor); Cho, Alex (Inventor); Russell, Carolyn K. (Inventor)

    2003-01-01

    A weld filler wire chemistry has been developed for fusion welding 2195 aluminum-lithium. The weld filler wire chemistry is an aluminum-copper based alloy containing high additions of titanium and zirconium. The additions of titanium and zirconium reduce the crack susceptibility of aluminum alloy welds while producing good weld mechanical properties. The addition of silver further improves the weld properties of the weld filler wire. The reduced weld crack susceptibility enhances the repair weldability, including when planishing is required.

  4. Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

    NASA Astrophysics Data System (ADS)

    Perez Regalado, Waldo Josue

    The real-time ultrasonic spot weld monitoring system, introduced by our research group, has been designed for the unsupervised quality characterization of the spot welding process. It comprises the ultrasonic transducer (probe) built into one of the welding electrodes and an electronics hardware unit which gathers information from the transducer, performs real-time weld quality characterization and communicates with the robot programmable logic controller (PLC). The system has been fully developed for the inspection of spot welds manufactured in steel alloys, and has been mainly applied in the automotive industry. In recent years, a variety of materials have been introduced to the automotive industry. These include high strength steels, magnesium alloys, and aluminum alloys. Aluminum alloys have been of particular interest due to their high strength-to-weight ratio. Resistance spot welding requirements for aluminum vary greatly from those of steel. Additionally, the oxide film formed on the aluminum surface increases the heat generation between the copper electrodes and the aluminum plates leading to accelerated electrode deterioration. Preliminary studies showed that the real-time quality inspection system was not able to monitor spot welds manufactured with aluminum. The extensive experimental research, finite element modelling of the aluminum welding process and finite difference modeling of the acoustic wave propagation through the aluminum spot welds presented in this dissertation, revealed that the thermodynamics and hence the acoustic wave propagation through an aluminum and a steel spot weld differ significantly. For this reason, the hardware requirements and the algorithms developed to determine the welds quality from the ultrasonic data used on steel, no longer apply on aluminum spot welds. After updating the system and designing the required algorithms, parameters such as liquid nugget penetration and nugget diameter were available in the ultrasonic data

  5. Ultrasonic butt welding of aluminum, aluminum alloy and stainless steel plate specimens.

    PubMed

    Tsujino, Jiromaru; Hidai, Kazuaki; Hasegawa, Atsushi; Kanai, Ryoichi; Matsuura, Hisanori; Matsushima, Kaoru; Ueoka, Tetsugi

    2002-05-01

    Welding characteristics of aluminum, aluminum alloy and stainless steel plate specimens of 6.0 mm thickness by a 15 kHz ultrasonic butt welding system were studied. There are no detailed welding condition data of these specimens although the joining of these materials are required due to anticorrosive and high strength characteristics for not only large specimens but small electronic parts especially. These specimens of 6.0 mm thickness were welded end to end using a 15 kHz ultrasonic butt welding equipment with a vibration source using eight bolt-clamped Langevin type PZT transducers and a 50 kW static induction thyristor power amplifier. The stainless steel plate specimens electrolytically polished were joined with welding strength almost equal to the material strength under rather large vibration amplitude of 25 microm (peak-to-zero value), static pressure 70 MPa and welding time of 1.0-3.0 s. The hardness of stainless steel specimen adjacent to a welding surface increased about 20% by ultrasonic vibration. PMID:12159968

  6. Bond formation in ultrasonically welded aluminum sheet metal

    NASA Astrophysics Data System (ADS)

    Wilkosz, Daniel Edward

    Ultrasonic welding (USW), a solid state joining technology, has been used to bond aluminum alloys commonly used in the automotive industry. Bonding occurs due to USW's high frequency (˜20 kHz) in-plane vibration of sample interfaces while being held under moderate clamp pressure normal to the plane of vibration. Vibration and clamp pressure are transmitted into bond formation via contact with a weld-tip. To better understand how weld-tip geometry affected bond formation, experiments were conducted to quantify how tip geometry influenced plastic deformation characteristics between fully welded coupons of 0.9mm thick AA6111-T4 aluminum alloy. Weld-interface microstructure features were documented by optical microscopy and features quantified in a 19 point matrix. Correlation between microstructure features, such as rolling-wakes, and resulting weld bond strengths of more than 3.0kN is made. Weld zone microstructure features appear to result from deformation at and severe migration of the original weld interface during USW. To confirm this hypothesis, intrinsic and extrinsic markers were employed to monitor weld interface deformation characteristics. Various physical and analytical techniques were used in conjunction with these markers to show that joining of "like" and "dislike" aluminum samples is achieved through mechanical mixing of mating interfaces and not by elemental diffusion. It is also hypothesized that severe deformation of the original interface would result in areas of high residual strain within a formed weld zone. To investigate this and the influence that tip geometry may have on residual strain, fully welded samples were annealed at 500°C for a controlled period of time and recovery, recrystallization and grain growth characteristics were monitored. In all welds, initial recrystallization and grain growth occurred at the outer ends of weld zones and along weld interfaces where the most turbulent mixing and grain size reduction was observed

  7. Explosive Welding of Aluminum to Aluminum: Analysis, Computations and Experiments

    NASA Astrophysics Data System (ADS)

    Grignon, F.; Benson, D.; Vecchio, K. S.; Meyers, M. A.

    2004-07-01

    6061 T0 aluminum alloy was joined to 6061 T0 aluminum alloy by explosive welding. This is a process in which the controlled energy of a detonating explosive is used to create a metallic bond between two similar or dissimilar materials. The welding conditions were tailored to produce both wavy and straight interfaces. A three-pronged study was used to establish the conditions for straight weld formation: (a) analytical calculation of the domain of weldability; (b) characterization of the explosive welding experiments carried out under different conditions, and (c) 2D finite differences simulation of these tests using the explicit Eulerian hydrocode Raven with a Johnson-Cook constitutive equation for the Al alloy. The numerical simulation and the analytical calculations confirm the experimental results and explain the difficulties met for obtaining a continuous straight interface along the entire weld.

  8. Butt Welding Joint of Aluminum Alloy by Space GHTA Welding Process in Vacuum

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Shinike, Shuhei; Ekuni, Tomohide; Terajima, Noboru; Tsukuda, Yoshiyuki; Imagawa, Kichiro

    Aluminum alloys have been used widely in constructing various space structures including the International Space Station (ISS) and launch vehicles. For space applications, welding experiments on aluminum alloy were performed using the GHTA (Gas Hollow Tungsten Arc) welding process using a filler wire feeder in a vacuum. We investigated the melting phenomenon of the base metal and filler wire, bead formation, and the effects of wire feed speed on melting characteristics. The melting mechanism in the base metal during the bead on a plate with wire feed was similar to that for the melt run without wire feed. We clarified the effects of wire feed speed on bead sizes and configurations. Furthermore, the butt welded joint welded using the optimum wire feed speed, and the joint tensile strengths were evaluated. The tensile strength of the square butt joint welded by the pulsed DC GHTA welding with wire feed in a vacuum is nearly equal to that of the same joint welded by conventional GTA (Gas Tungsten Arc) welding in air.

  9. Weld repair method for aluminum lithium seam

    NASA Technical Reports Server (NTRS)

    McGee, William Floyd (Inventor); Rybicki, Daniel John (Inventor)

    1998-01-01

    Aluminum-lithium plates are butt-welded by juxtaposing the plates and making a preliminary weld from the rear or root side of the seam. An initial weld is then made from the face side of the seam, which may cause a defect in the root portion. A full-size X-ray is made and overlain over the seam to identify the defects. The defect is removed from the root side, and rewelded. Material is then removed from the face side, and the cavity is rewelded. The procedure repeats, alternating from the root side to the face side, until the weld is sound.

  10. Heat Treatment of Friction-Stir-Welded 7050 Aluminum Plates

    NASA Technical Reports Server (NTRS)

    Petter, George E.; Figert, John D.; Rybicki, Daniel J.; Burns, Timothy

    2006-01-01

    A method of heat treatment has been developed to reverse some of the deleterious effects of friction stir welding of plates of aluminum alloy 7050. This alloy is considered unweldable by arc and high-energy-density beam fusion welding processes. The alloy can be friction stir welded, but as-welded workpieces exhibit low ductility, low tensile and yield strengths, and low resistance to stress corrosion cracking. Heat treatment according to the present method increases tensile and yield strengths, and minimizes or eliminates stress corrosion cracking. It also increases ductility. This method of heat treatment is a superior alternative to a specification-required heat treatment that caused the formation of large columnar grains, which are undesired. Workpieces subjected to the prior heat treatment exhibited elongations <2 percent, and standard three-point bend specimens shattered. The development of the present heat treatment method was guided partly by the principles that (1) by minimizing grain sizes and relieving deformation stresses, one can minimize or eliminate stress corrosion cracking and (2) the key to maximizing strength and eliminating residual stresses is to perform post-weld solution heating for as long a time as possible while incurring little or no development of large columnar grains in friction stir weld nuggets. It is necessary to perform some of the solution heat treatment (to soften the alloy and improve machine welding parameters) before welding. The following is an example of thickness- dependent pre- and post-weld heat treatments according to the present method: For plates 0.270 in. (approx.6.86 mm) thick milled from plates 4.5 in. (114.3 mm) thick, perform pre-weld solution heating at 890 F (477 C) for 1 hour, then cool in air. After friction stir welding, perform solution heating for 10 minutes, quench, hold at room temperature for 96 hours, then age at 250 F (121 C) for 5 hours followed by 325 F (163 C) for 27 hours.

  11. Influences of post-weld heat treatment on tensile properties of friction stir-welded AA6061 aluminum alloy joints

    SciTech Connect

    Elangovan, K.; Balasubramanian, V.

    2008-09-15

    This paper reports on studies of the influences of various post-weld heat treatment procedures on tensile properties of friction stir-welded AA6061 aluminum alloy joints. Rolled plates of 6-mm thick AA6061 aluminum alloy were used to fabricate the joints. Solution treatment, an artificial aging treatment and a combination of both were given to the welded joints. Tensile properties such as yield strength, tensile strength, elongation and joint efficiency were evaluated. Microstructures of the welded joints were analyzed using optical microscopy and transmission electron microscopy. A simple artificial aging treatment was found to be more beneficial than other treatment methods to enhance the tensile properties of the friction stir-welded AA6061 aluminum alloy joints.

  12. Laser-welded Dissimilar Steel-aluminum Seams for Automotive Lightweight Construction

    NASA Astrophysics Data System (ADS)

    Schimek, M.; Springer, A.; Kaierle, S.; Kracht, D.; Wesling, V.

    By reducing vehicle weight, a significant increase in fuel efficiency and consequently a reduction in CO 2 emissions can be achieved. Currently a high interest in the production of hybrid weld seams between steel and aluminum exists. Previous methods as laser brazing are possible only by using fluxes and additional materials. Laser welding can be used to join steel and aluminum without the use of additives. With a low penetration depth increases in tensile strength can be achieved. Recent results from laser welded overlap seams show that there is no compromise in strength by decreasing penetration depth in the aluminum.

  13. Microhardness Testing of Aluminum Alloy Welds

    NASA Technical Reports Server (NTRS)

    Bohanon, Catherine

    2009-01-01

    A weld is made when two pieces of metal are united or fused together using heat or pressure, and sometimes both. There are several different types of welds, each having their own unique properties and microstructure. Strength is a property normally used in deciding which kind of weld is suitable for a certain metal or joint. Depending on the weld process used and the heat required for that process, the weld and the heat-affected zone undergo microstructural changes resulting in stronger or weaker areas. The heat-affected zone (HAZ) is the region that has experienced enough heat to cause solid-state microstructural changes, but not enough to melt the material. This area is located between the parent material and the weld, with the grain structure growing as it progresses respectively. The optimal weld would have a short HAZ and a small fluctuation in strength from parent metal to weld. To determine the strength of the weld and decide whether it is suitable for the specific joint certain properties are looked at, among these are ultimate tensile strength, 0.2% offset yield strength and hardness. Ultimate tensile strength gives the maximum load the metal can stand while the offset yield strength gives the amount of stress the metal can take before it is 0.2% longer than it was originally. Both of these are good tests, but they both require breaking or deforming the sample in some way. Hardness testing, however, provides an objective evaluation of weld strengths, and also the difference or variation in strength across the weld and HAZ which is difficult to do with tensile testing. Hardness is the resistance to permanent or plastic deformation and can be taken at any desired point on the specimen. With hardness testing, it is possible to test from parent metal to weld and see the difference in strength as you progress from parent material to weld. Hardness around grain boundaries and flaws in the material will show how these affect the strength of the metal while still

  14. Modeling aluminum-lithium alloy welding characteristics

    NASA Technical Reports Server (NTRS)

    Bernstein, Edward L.

    1996-01-01

    The purpose of this project was to develop a finite element model of the heat-affected zone in the vicinity of a weld line on a plate in order to determine an accurate plastic strain history. The resulting plastic strain increments calculated by the finite element program were then to be used to calculate the measure of damage D. It was hoped to determine the effects of varying welding parameters, such as beam power, efficiency, and weld speed, and the effect of different material properties on the occurrence of microfissuring. The results were to be compared first to the previous analysis of Inconel 718, and then extended to aluminum 2195.

  15. Friction Pull Plug Welding in Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    Brooke, Shane A.; Bradford, Vann

    2012-01-01

    NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

  16. A study on friction stir welding of 12mm thick aluminum alloy plates

    NASA Astrophysics Data System (ADS)

    Kumar, Deepati Anil; Biswas, Pankaj; Tikader, Sujoy; Mahapatra, M. M.; Mandal, N. R.

    2013-12-01

    Most of the investigations regarding friction stir welding (FSW) of aluminum alloy plates have been limited to about 5 to 6 mm thick plates. In prior work conducted the various aspects concerning the process parameters and the FSW tool geometry were studied utilizing friction stir welding of 12 mm thick commercial grade aluminum alloy. Two different simple-to-manufacture tool geometries were used. The effect of varying welding parameters and dwell time of FSW tool on mechanical properties and weld quality was examined. It was observed that in order to achieve a defect free welding on such thick aluminum alloy plates, tool having trapezoidal pin geometry was suitable. Adequate tensile strength and ductility can be achieved utilizing a combination of high tool rotational speed of about 2000 r/min and low speed of welding around 28 mm/min. At very low and high dwell time the ductility of welded joints are reduced significantly.

  17. FRICTION STIR SPOT WELDING OF 6016 ALUMINUM ALLOY

    SciTech Connect

    Mishra, Rajiv S.; Webb, S.; Freeney, T. A.; Chen, Y. L.; Gayden, X.; Grant, Glenn J.; Herling, Darrell R.

    2007-01-08

    Friction stir spot welding (FSSW) of 6016 aluminum alloy was evaluated with conventional pin tool and new off-center feature tools. The off-center feature tool provides significant control over the joint area. The tool rotation rate was varied between 1000 and 2500 rpm. Maximum failure strength was observed in the tool rotation range of 1200-1500 rpm. The results are interpreted in the context of material flow in the joint and influence of thermal input on microstructural changes. The off-center feature tool concept opens up new possibilities for plunge-type friction stir spot welding.

  18. FRICTION STIR LAP WELDING OF ALUMINUM - POLYMER USING SCRIBE TECHNOLOGY

    SciTech Connect

    Upadhyay, Piyush; Hovanski, Yuri; Fifield, Leonard S.; Simmons, Kevin L.

    2015-02-16

    Friction Stir Scribe (FSS) technology is a relatively new variant of Friction Stir Welding (FSW) which enables lap joining of dissimilar material with very different melting points and different high temperature flow behaviors. The cutter scribe attached at the tip of FSW tool pin effectively cuts the high melting point material such that a mechanically interlocking feature is created between the dissimilar materials. The geometric shape of this interlocking feature determines the shear strength attained by the lap joint. This work presents first use of scribe technology in joining polymers to aluminum alloy. Details of the several runs of scribe welding performed in lap joining of ~3.175mm thick polymers including HDPE, filled and unfilled Nylon 66 to 2mm thick AA5182 are presented. The effect of scribe geometry and length on weld interlocking features is presented along with lap shear strength evaluations.

  19. Friction Pull Plug Welding in Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    Brooke, Shane A.; Bradford, Vann; Burkholder, Jonathon

    2011-01-01

    NASA fs Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for External Tank. FPPW was easily selected as the primary process used to close out the termination hole on the Constellation Program fs ARES I Upper Stage circumferential Self ] Reacting Friction Stir Welds (SR ]FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR ]FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process fs limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

  20. Laser assisted arc welding for aluminum alloys

    SciTech Connect

    Fuerschbach, P.W.

    2000-01-01

    Experiments have been performed using a coaxial end-effector to combine a focused laser beam and a plasma arc. The device employs a hollow tungsten electrode, a focusing lens, and conventional plasma arc torch nozzles to co-locate the focused beam and arc on the workpiece. Plasma arc nozzles were selected to protect the electrode from laser generated metal vapor. The project goal is to develop an improved fusion welding process that exhibits both absorption robustness and deep penetration for small scale (<1.5 mm thickness) applications. On aluminum alloys 6061 and 6111, the hybrid process has been shown to eliminate hot cracking in the fusion zone. Fusion zone dimensions for both stainless steel and aluminum were found to be wider than characteristic laser welds, and deeper than characteristic plasma arc welds.

  1. Mechanical Properties of Friction Stir Welded Aluminum Alloys 5083 and 5383

    NASA Astrophysics Data System (ADS)

    Paik, Jeoom Kee

    2009-09-01

    The use of high-strength aluminum alloys is increasing in shipbuilding industry, particularly for the design and construction of war ships, littoral surface craft and combat ships, and fast passenger ships. While various welding methods are used today to fabricate aluminum ship structures, namely gas metallic arc welding (GMAW), laser welding and friction stir welding (FSW), FSW technology has been recognized to have many advantages for the construction of aluminum structures, as it is a low-cost welding process. In the present study, mechanical properties of friction stir welded aluminum alloys are examined experimentally. Tensile testing is undertaken on dog-bone type test specimen for aluminum alloys 5083 and 5383. The test specimen includes friction stir welded material between identical alloys and also dissimilar alloys, as well as unwelded (base) alloys. Mechanical properties of fusion welded aluminum alloys are also tested and compared with those of friction stir welded alloys. The insights developed from the present study are documented together with details of the test database. Part of the present study was obtained from the Ship Structure Committee project SR-1454 (Paik, 2009), jointly funded by its member agencies

  2. An investigation into geometry and microstructural effects upon the ultimate tensile strengths of butt welds

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S.

    1992-01-01

    A mathematical theory was evaluated empirically. This theory predicts weld ultimate tensile strength based on material properties and fusion line angles, mismatch, peaking, and weld widths. Welds were made on 1/4 and 1/2 in. aluminum 2219-T87, their geometries were measured, they were tensile tested, and these results were compared to theoretical predictions. Statistical analysis of results was performed to evaluate correlation of theory to results for many different categories of weld geometries.

  3. Strength of Welded Aircraft Joints

    NASA Technical Reports Server (NTRS)

    Brueggeman, W C

    1937-01-01

    This investigation is a continuation of work started in 1928 and described in NACA-TR-348 which shows that the insertion of gusset plates was the most satisfactory way of strengthening a joint. Additional tests of the present series show that joints of this type could be improved by cutting out the portion of the plate between the intersecting tubes. T and lattice joints in thin-walled tubing 1 1/2 by 0.020 inch have somewhat lower strengths than joints in tubing of greater wall thickness because of failure by local buckling. In welding the thin-walled tubing, the recently developed "carburizing flux" process was found to be the only method capable of producing joints free from cracks. The "magnetic powder" inspection was used to detect cracks in the joints and flaws in the tubing.

  4. Linear Anomaly in Welded 2219-T87 Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Jemian, Wartan A.

    1987-01-01

    Study of causes and significance of two types of linear anomalies sometimes appearing in radiographs of welds described in preliminary report. Manifested as light or dark linear features parallel to weld line in radiograph of weld. Contains diagrams and descriptions of phenomena occurring during welding process. Includes microdensitometer traces from x-radiographs of actual welds and from computer simulations based calculation of x-ray transmission through assumed weld structures. Concludes anomalies not unique to 2219-T87 aluminum alloy.

  5. Effect of Interfacial Reaction on the Mechanical Performance of Steel to Aluminum Dissimilar Ultrasonic Spot Welds

    NASA Astrophysics Data System (ADS)

    Xu, Lei; Wang, Li; Chen, Ying-Chun; Robson, Joe D.; Prangnell, Philip B.

    2016-01-01

    The early stages of formation of intermetallic compounds (IMC) have been investigated in dissimilar aluminum to steel welds, manufactured by high power (2.5 kW) ultrasonic spot welding (USW). To better understand the influence of alloy composition, welds were produced between a low-carbon steel (DC04) and two different aluminum alloys (6111 and 7055). The joint strengths were measured in lap shear tests and the formation and growth behavior of IMCs at the weld interface were characterized by electron microscopy, for welding times from 0.2 to 2.4 seconds. With the material combinations studied, the η (Fe2Al5) intermetallic phase was found to form first, very rapidly in the initial stage of welding, with a discontinuous island morphology. Continuous layers of η and then θ (FeAl3) phase were subsequently seen to develop on extending the welding time to greater than 0.7 second. The IMC layer formed in the DC04-AA7055 combination grew thicker than for the DC04-AA6111 welds, despite both weld sets having near identical thermal histories. Zinc was also found to be dissolved in the IMC phases when welding with the AA7055 alloy. After post-weld aging of the aluminum alloy, fracture in the lap shear tests always occurred along the joint interface; however, the DC04-AA6111 welds had higher fracture energy than the DC04-AA7055 combination.

  6. Shear Strength of Aluminum Oxynitride

    NASA Astrophysics Data System (ADS)

    Dandekar, Dattatraya P.; Vaughan, Brian A. M.; Proud, William G.

    2007-06-01

    Aluminum oxynitride (AlON) is a transparent, polycrystalline cubic spinel. The results of investigations^1-4 on shock response of AlON permit determination of the equation of state, and shear strength retained under shock compression. Whereas the values of the HEL of AlON holds no surprises, the inelastic response of AlON reported in Ref. 1-4 differ significantly and is stress dependent. The results of Ref. 1-2 show that AlON retains a shear strength of 3 to 4 GPa when shocked up to around 20 GPa, but the results of Ref, 3-4 seem to suggest a possible loss of shear strength when shocked to 16 GPa and beyond. Our analysis examines the observed differences in the inelastic response of AlON reported in these four studies . 1. J. U. Cazamias, et. al., in Fundamental Issues and Applications of Shock-Wave and High Strain Rate Phenomena, Eds. Staudhammer, Murr, and Meyers, Elsevier, NY, 173 (2001). 2. B. A. M. Vaughn, et.al., Shock Physics, Cavendish Laboratory, Report SP/1092 (2001) 3. T. Sekine, et.al., J. Appl. Phys. 94, 4803 (2003). 4. T. F. Thornhill, et.al., Shock Compression of Matter-2005, Eds. Furnish, Elert, Russell, White, AIP, NY, 143 (2006).

  7. FSW of Aluminum Tailor Welded Blanks across Machine Platforms

    SciTech Connect

    Hovanski, Yuri; Upadhyay, Piyush; Carlson, Blair; Szymanski, Robert; Luzanski, Tom; Marshall, Dustin

    2015-02-16

    Development and characterization of friction stir welded aluminum tailor welded blanks was successfully carried out on three separate machine platforms. Each was a commercially available, gantry style, multi-axis machine designed specifically for friction stir welding. Weld parameters were developed to support high volume production of dissimilar thickness aluminum tailor welded blanks at speeds of 3 m/min and greater. Parameters originally developed on an ultra-high stiffness servo driven machine where first transferred to a high stiffness servo-hydraulic friction stir welding machine, and subsequently transferred to a purpose built machine designed to accommodate thin sheet aluminum welding. The inherent beam stiffness, bearing compliance, and control system for each machine were distinctly unique, which posed specific challenges in transferring welding parameters across machine platforms. This work documents the challenges imposed by successfully transferring weld parameters from machine to machine, produced from different manufacturers and with unique control systems and interfaces.

  8. Aluminum U-groove weld enhancement based on experimental stress analyses

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1995-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures because of their sealing and assembly integrity and general elastic performance; their inelastic mechanics are generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the tab thickness between the grooves produce severe peaking, which induces bending moment under uniaxial loading. The filler strain hardening decreased with increasing filler pass sequence. These combined effects reduce the weld strength, and a depeaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve the welding process results over the current normal weld schedule.

  9. Inertia-friction welding of a particulate-reinforced aluminum-matrix composite

    NASA Astrophysics Data System (ADS)

    Cola, M. J.; Baeslack, W. A., III; Altshuller, B.; Sjostrom, T.

    Inertia-friction welds were produced between an aluminum-matrix composite tube and a monolithic aluminum alloy bar. The effects of flywheel speed and axial pressure, and the effect of the flywheel speed/axial pressure interaction for a tube-to-bar joint geometry were statistically evaluated. Welds were evaluated with light and scanning-electron microscopy, tensile tested, and measured for hardness. Light microscopy of the interface region of selected inertia-friction welds were sound and free of discontinuities. The tensile strength of the inertia-friction welds was 82 percent of the aluminum-composite base material. Failures were at, or near the weld interface. Fractography of failed tensile specimen fracture surfaces revealed a varying topography and mixed-mode fracture morphology.

  10. Weld Growth Mechanisms and Failure Behavior of Three-Sheet Resistance Spot Welds Made of 5052 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Li, Yang; Yan, Fuyu; Luo, Zhen; Chao, Y. J.; Ao, Sansan; Cui, Xuetuan

    2015-06-01

    This paper investigates the weld nugget formation in three-sheet aluminum alloy resistance spot welding. The nugget formation process in three equal thickness sheets and three unequal thickness sheets of 5052 aluminum alloy were studied. The results showed that the nugget was initially formed at the workpiece/workpiece interfaces (i.e., both upper interface and lower interface). The two small nuggets then grew along the radial direction and axial direction (welding direction) as the welding time increased. Eventually, the two nuggets fused into one large nugget. During the welding process, the Peltier effect between the Cu-Al caused the shift of the nugget in the welding direction. In addition, the mechanical strength and fracture mode of the weld nuggets at the upper and lower interfaces were also studied using tensile shear specimen configuration. Three failure modes were identified, namely interfacial, mixed, and pullout. The critical welding time and critical nugget diameter corresponding to the transitions of these modes were investigated. Finally, an empirical failure load formula for three-sheet weld similar to two-sheet spot weld was developed.

  11. Microstructures and Mechanical Properties of Friction Stir Spot Welded Aluminum Alloy AA2014

    NASA Astrophysics Data System (ADS)

    Babu, S.; Sankar, V. S.; Janaki Ram, G. D.; Venkitakrishnan, P. V.; Madhusudhan Reddy, G.; Prasad Rao, K.

    2013-01-01

    Friction stir spot welding (FSSW) is a relatively recent development, which can provide a superior alternative to resistance spot welding and riveting for fabrication of aluminum sheet metal structures. In the current work, FSSW experiments were conducted in 3-mm thick sheets of aluminum alloy 2014 in T4 and T6 conditions, with and without Alclad layers. The effects of tool geometry and welding process parameters on joint formation were investigated. A good correlation between process parameters, bond width, hook height, joint strength, and fracture mode was observed. The presence of Alclad layers and the base metal temper condition were found to have no major effect on joint formation and joint strength. Friction stir spot welds produced under optimum conditions were found to be superior to riveted joints in lap-shear and cross-tension tests. The prospects of FSSW in aluminum sheet metal fabrication are discussed.

  12. Study of inertia welding: the sensitivity of weld configuration and strength to variations in welding parameters

    SciTech Connect

    Mote, M.W.

    1981-12-01

    An experiment is described which is designed to demonstrate the forgiveness of inertia welding, that is, the relative insensitivity of weld strength to variations in energy (rotational speed of parts) and axial force. Although easily observed variations in the welding parameters produced easily observed changes in weldment configuration and changes in dimension (upset), only extremes in parameters produced changes in weld strength. Consequently, process monitoring and product inspection would be sufficient for quality assurance in a production environment.

  13. A new technique for the strengthening of aluminum tungsten inert gas weld metals: using carbon nanotube/aluminum composite as a filler metal.

    PubMed

    Fattahi, M; Nabhani, N; Rashidkhani, E; Fattahi, Y; Akhavan, S; Arabian, N

    2013-01-01

    The effect of multi-walled carbon nanotube (MWCNT) on the mechanical properties of aluminum multipass weld metal prepared by the tungsten inert gas (TIG) welding process was investigated. High energy ball milling was used to disperse MWCNT in the aluminum powder. Carbon nanotube/aluminum composite filler metal was fabricated for the first time by hot extrusion of ball-milled powders. After welding, the tensile strength, microhardness and MWCNT distribution in the weld metal were investigated. The test results showed that the tensile strength and microhardness of weld metal was greatly increased when using the filler metal containing 1.5 wt.% MWCNT. Therefore, according to the results presented in this paper, it can be concluded that the filler metal containing MWCNT can serve as a super filler metal to improve the mechanical properties of TIG welds of Al and its alloys. PMID:23948441

  14. Improving fatigue strength of welded joints

    NASA Astrophysics Data System (ADS)

    Takamori, Hiroyuki

    One series of fatigue tests was carried out on coverplated bridge girders with small fatigue cracks that had been treated in 1976. The treatment and preconditions were reported in NCHRP Report 206. The Category E' coverplated. beams that were removed from the Yellow Mill Pond Bridge in 1997 had been retrofitted in 1976 by either air hammer peening or GTA remelting the weld toe. Most of the details had small fatigue cracks at the time the retrofit was carried out. No detectable fatigue cracking was observed at the treated coverplate ends after 20 years of service on I-95 and an estimated 56 million truck passages. All beams were tested at a stress range of 69 MPa (10 ksi). Cracks eventually developed from the root of the transverse end welds and propagated through the weld throat and from there into the beam flange via the longitudinal welds. The fatigue resistance of the treated weld toe details was improved to Category C. The one GTA remelted detail that recracked at the weld toe exceeded Category D. The second series of tests was carried out on large scale HPS-485W steel plate girders with as-welded and ultrasonic impact treated (UIT) details. The UIT treatment was applied to the weld toe of transverse stiffeners welded to the web and flanges (Category C details) and to coverplated ends (Category E' details). The as-welded details cracked as expected at their corresponding fatigue resistance. All UIT treated details were improved. The treated transverse stiffeners achieved Category B fatigue resistance. The treated coverplated details achieved Category C. The third series of tests was conducted on large scale HPS-485W steel plate girders with undermatched groove welded details at flange transition. The objectives of using undermatched weld materials compared to the base material is to reduce the potentiality of hydrogen cracking at flange groove welds and to improve the fatigue strength of the welded joints. Fatigue strength of undermatched welded joints was

  15. Fatigue performance of welded aluminum deck structures

    SciTech Connect

    Haagensen, P.J.; Ranes, M.; Kluken, A.O.; Kvale, I.

    1996-12-01

    Aluminum alloys are used increasingly in load carrying structures where low weight and low maintenance costs are at a premium. Helicopter decks, structures for living quarters and personnel transfer bridges between platforms are examples of offshore applications. While these structures are not usually subjected to high fatigue loads, the increasing use of aluminum in high speed ships, and more recently in highway bridge structures, makes the question of fatigue performance more important. In this paper the fatigue properties of small scale weldments in an AA6005 alloy are compared with the results of fatigue tests on full scale sections of welded extrusions in the same material, which were used in an aluminum bridge deck structure. The fatigue performance is also compared with the fatigue clauses in the new British design code BS8118 for aluminium structures and the proposed Eurocode 9. The prospects of using a new joining technique, friction stir welding (FSW), in the production of large scale panels for deck and ship hull structures is discussed. The FSW process is described briefly, and some fatigue test data are presented.

  16. Effect of Welding Speeds on Mechanical Properties of Level Compensation Friction Stir Welded 6061-T6 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Wen, Quan; Yue, Yumei; Ji, Shude; Li, Zhengwei; Gao, Shuangsheng

    2016-04-01

    In order to eliminate the flash, arc corrugation and concave in weld zone, level compensation friction stir welding (LCFSW) was put forward and successfully applied to weld 6061-T6 aluminum alloy with varied welding speed at a constant tool rotational speed of 1,800 rpm in the present study. The glossy joint with equal thickness of base material can be attained, and the shoulder affected zone (SAZ) was obviously reduced. The results of transverse tensile test indicate that the tensile strength and elongation reach the maximum values of 248 MPa and 7.1% when the welding speed is 600 mm/min. The microhardness of weld nugget (WN) is lower than that of base material. The tensile fracture position locates at the heat affected zone (HAZ) of the advancing side (AS), where the microhardness is the minimum. The fracture surface morphology represents the typical ductile fracture.

  17. CO2 laser beam welding of 6061-T6 aluminum alloy thin plate

    NASA Astrophysics Data System (ADS)

    Hirose, Akio; Kobayashi, Kojiro F.; Todaka, Hirotaka

    1997-12-01

    Laser beam welding is an attractive welding process for age-hardened aluminum alloys, because its low heat input minimizes the width of weld fusion and heat-affected zones (HAZs). In the present work, 1-mm-thick age-hardened Al-Mg-Si alloy, 6061-T6, plates were welded with full penetration using a 2.5-kW CO2 laser. Fractions of porosity in the fusion zones were less than 0.05 pct in bead-on-plate welding and less than 0.2 pct in butt welding with polishing the groove surface before welding. The width of a softened region in the-laser beam welds was less than 1/4 times that of a tungsten inert gas (TIG) weld. The softened region is caused by reversion of strengthening β″ (Mg2Si) precipitates due to weld heat input. The hardness values of the softened region in the laser beam welds were almost fully recovered to that of the base metal after an artificial aging treatment at 448 K for 28.8 ks without solution annealing, whereas those in the TIG weld were not recovered in a partly reverted region. Both the bead-on-plate weld and the butt weld after the postweld artificial aging treatment had almost equivalent tensile strengths to that of the base plate.

  18. Damage Tolerance Assessment of Friction Pull Plug Welds in an Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    McGill, Preston; Burkholder, Jonathan

    2012-01-01

    Friction stir welding is a solid state welding process used in the fabrication of cryogenic propellant tanks. Self-reacting friction stir welding is one variation of the friction stir weld process being developed for manufacturing tanks. Friction pull plug welding is used to seal the exit hole that remains in a circumferential self-reacting friction stir weld. A friction plug weld placed in a self-reacting friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data relating residual strength capability to flaw size in an aluminum alloy friction plug weld will be presented.

  19. Integration of NASA-sponsored studies on aluminum welding

    NASA Technical Reports Server (NTRS)

    Masubuchi, K.

    1972-01-01

    The results are presented of numerous studies relating to aluminum alloy welding. The subjects covered include: (1) effects of porosity on weld joint performance, (2) sources of porosity, (3) weld thermal effects, (4) residual stresses and distortion, and (5) manufacturing process system control.

  20. Aluminum oxide filler prevents obstructions in tubing during welding

    NASA Technical Reports Server (NTRS)

    Okelly, K. P.

    1966-01-01

    Granular aluminum oxide is used as filler in serpentine tubing while welding the tubing to a flat surface. The filler eliminates obstructions in the tubes formed by molten weld nuggets and is porous enough to allow gases to escape from the welding area.

  1. Metallurgical and mechanical properties of laser welded high strength low alloy steel

    PubMed Central

    Oyyaravelu, Ramachandran; Kuppan, Palaniyandi; Arivazhagan, Natarajan

    2016-01-01

    The study aimed at investigating the microstructure and mechanical properties of Neodymium-Doped Yttrium Aluminum Garnet (Nd:YAG) laser welded high strength low alloy (HSLA) SA516 grade 70 boiler steel. The weld joint for a 4 mm thick plate was successfully produced using minimum laser power of 2 kW by employing a single pass without any weld preheat treatment. The micrographs revealed the presence of martensite phase in the weld fusion zone which could be due to faster cooling rate of the laser weldment. A good correlation was found between the microstructural features of the weld joints and their mechanical properties. The highest hardness was found to be in the fusion zone of cap region due to formation of martensite and also enrichment of carbon. The hardness results also showed a narrow soft zone at the heat affected zone (HAZ) adjacent to the weld interface, which has no effect on the weld tensile strength. The yield strength and ultimate tensile strength of the welded joints were 338 MPa and 549 MPa, respectively, which were higher than the candidate metal. These tensile results suggested that the laser welding process had improved the weld strength even without any weld preheat treatment and also the fractography of the tensile fractured samples showed the ductile mode of failure. PMID:27222751

  2. Metallurgical and mechanical properties of laser welded high strength low alloy steel.

    PubMed

    Oyyaravelu, Ramachandran; Kuppan, Palaniyandi; Arivazhagan, Natarajan

    2016-05-01

    The study aimed at investigating the microstructure and mechanical properties of Neodymium-Doped Yttrium Aluminum Garnet (Nd:YAG) laser welded high strength low alloy (HSLA) SA516 grade 70 boiler steel. The weld joint for a 4 mm thick plate was successfully produced using minimum laser power of 2 kW by employing a single pass without any weld preheat treatment. The micrographs revealed the presence of martensite phase in the weld fusion zone which could be due to faster cooling rate of the laser weldment. A good correlation was found between the microstructural features of the weld joints and their mechanical properties. The highest hardness was found to be in the fusion zone of cap region due to formation of martensite and also enrichment of carbon. The hardness results also showed a narrow soft zone at the heat affected zone (HAZ) adjacent to the weld interface, which has no effect on the weld tensile strength. The yield strength and ultimate tensile strength of the welded joints were 338 MPa and 549 MPa, respectively, which were higher than the candidate metal. These tensile results suggested that the laser welding process had improved the weld strength even without any weld preheat treatment and also the fractography of the tensile fractured samples showed the ductile mode of failure. PMID:27222751

  3. Reinforcing aluminum alloys with high strength fibers

    NASA Technical Reports Server (NTRS)

    Kolpashnikov, A. I.; Manuylov, V. F.; Chukhin, B. D.; Shiryayev, Y. V.; Shurygin, A. S.

    1982-01-01

    A study is made of the possibility of reinforcing aluminum and aluminum based alloys with fibers made of high strength steel wire. The method of introducing the fibers is described in detail. Additional strengthening by reinforcement of the high alloy system Al - An - Mg was investigated.

  4. Welding High Strength Modern Line Pipe Steel

    NASA Astrophysics Data System (ADS)

    Goodall, Graeme Robertson

    The effect of modern mechanized girth welding on high strength line pipe has been investigated. The single cycle grain coarsened heat affected zone in three grade 690 line pipe steels and a grade 550 steel has been simulated using a Gleeble thermo-mechanical simulator. The continuous cooling transformation diagrams applicable to the grain coarsened heat affected zone resulting from a range of heat inputs applicable to modern mechanized welding have been established by dilatometry and metallography. The coarse grained heat affected zone was found to transform to lath martensite, bainite, and granular bainite depending on the cooling rate. The impact toughness of the steels was measured using Charpy impact toughness and compared to the toughness of the grain coarsened heat affected zone corresponding to a welding thermal cycle. The ductile to brittle transition temperature was found to be lowest for the steel with the highest hardenability. The toughness resulting from three different thermal cycles including a novel interrupted intercritically reheated grain coarsened (NTR ICR GC HAZ) that can result from dual torch welding at fast travel speed and close torch spacing have been investigated. All of the thermally HAZ regions showed reduced toughness that was attributed to bainitic microstructure and large effective grain sizes. Continuous cooling transformation diagrams for five weld metal chemistries applicable to mechanized pulsed gas metal arc welding of modern high strength pipe steel (SMYS>550 MPa) have been constructed. Welds at heat inputs of 1.5 kJmm-1 and 0.5 kJmm-1 have been created for simulation and analysis. Dilatometric analysis was performed on weld metal specimens cut from single pass 1.5 kJmm-1 as deposited beads. The resulting microstructures were found to range from martensite to polygonal ferrite. There is excellent agreement between the simulated and as deposited weld metal regions. Toughness testing indicates improved energy absorption at -20

  5. Friction stir welding process to repair voids in aluminum alloys

    NASA Technical Reports Server (NTRS)

    Rosen, Charles D. (Inventor); Litwinski, Edward (Inventor); Valdez, Juan M. (Inventor)

    1999-01-01

    The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

  6. Ultrasonic Impact Treatment to Improve Stress Corrosion Cracking Resistance of Welded Joints of Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Yu, J.; Gou, G.; Zhang, L.; Zhang, W.; Chen, H.; Yang, Y. P.

    2016-06-01

    Stress corrosion cracking is one of the major issues for welded joints of 6005A-T6 aluminum alloy in high-speed trains. High residual stress in the welded joints under corrosion results in stress corrosion cracking. Ultrasonic impact treatment was used to control the residual stress of the welded joints of 6005A-T6 aluminum alloy. Experimental tests show that ultrasonic impact treatment can induce compressive longitudinal and transverse residual stress in the welded joint, harden the surface, and increase the tensile strength of welded joints. Salt-fog corrosion tests were conducted for both an as-welded sample and an ultrasonic impact-treated sample. The surface of the treated sample had far fewer corrosion pits than that of the untreated sample. The treated sample has higher strength and lower tensile residual stress than the untreated sample during corrosion. Therefore, ultrasonic impact treatment is an effective technique to improve the stress corrosion cracking resistance of the welded joints of 6005A-T6 aluminum alloy.

  7. Ultrasonic Impact Treatment to Improve Stress Corrosion Cracking Resistance of Welded Joints of Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Yu, J.; Gou, G.; Zhang, L.; Zhang, W.; Chen, H.; Yang, Y. P.

    2016-07-01

    Stress corrosion cracking is one of the major issues for welded joints of 6005A-T6 aluminum alloy in high-speed trains. High residual stress in the welded joints under corrosion results in stress corrosion cracking. Ultrasonic impact treatment was used to control the residual stress of the welded joints of 6005A-T6 aluminum alloy. Experimental tests show that ultrasonic impact treatment can induce compressive longitudinal and transverse residual stress in the welded joint, harden the surface, and increase the tensile strength of welded joints. Salt-fog corrosion tests were conducted for both an as-welded sample and an ultrasonic impact-treated sample. The surface of the treated sample had far fewer corrosion pits than that of the untreated sample. The treated sample has higher strength and lower tensile residual stress than the untreated sample during corrosion. Therefore, ultrasonic impact treatment is an effective technique to improve the stress corrosion cracking resistance of the welded joints of 6005A-T6 aluminum alloy.

  8. Microstructures in laser welded high strength steels

    NASA Astrophysics Data System (ADS)

    Rizzi, P.; Bellingeri, S.; Massimino, F.; Baldissin, D.; Battezzati, L.

    2009-01-01

    In this work, the effect of laser welding on the microstructure was studied for three Advanced High Strength Steels: transformation induced plasticity steel (TRIP), dual phase steel (DP) and martensitic steel. Two sheets of the same steel were laser welded and a microstructural study was performed by optical microscopy, scanning electron microscopy and X-ray diffraction. For all samples the welded zone was constituted by martensite and the heat affected zone shows a continuous change in microstructure depending on temperatures reached and on the different cooling rates. The change in mechanical properties in the welded area was followed by Vickers micro-hardness measurements. Quasi binary phase diagrams were calculated and, according to position of T0 lines, it was deduced that austenite is the primary phase forming during rapid solidification for all steels.

  9. Improved microstructure and mechanical properties in gas tungsten arc welded aluminum joints by using graphene nanosheets/aluminum composite filler wires.

    PubMed

    Fattahi, M; Gholami, A R; Eynalvandpour, A; Ahmadi, E; Fattahi, Y; Akhavan, S

    2014-09-01

    In the present study, different amounts of graphene nanosheets (GNSs) were added to the 4043 aluminum alloy powders by using the mechanical alloying method to produce the composite filler wires. With each of the produced composite filler wires, one all-weld metal coupon was welded using the gas tungsten arc (GTA) welding process. The microstructure, mechanical properties and fracture surface morphology of the weld metals have been evaluated and the results are compared. As the amount of GNSs in the composition of filler wire is increased, the microstructure of weld metal was changed from the dendritic structure to fine equiaxed grains. Furthermore, the tensile strength and microhardness of weld metal was improved, and is attributed to the augmented nucleation and retarded growth. From the results, it was seen that the GNSs/Al composite filler wire can be used to improve the microstructure and mechanical properties of GTA weld metals of aluminum and its alloys. PMID:24981209

  10. Joining Uranium to Aluminum using Electron Beam Welding and an Explosively Clad Niobium Interlayer

    SciTech Connect

    Elmer, J W; Terrill, P; Brasher, D; Butler, D

    2001-06-12

    A uranium alloy was joined to a high strength aluminum alloy using a commercially pure niobium interlayer. Joining of the Nb interlayer to the aluminum alloy was performed using an explosive welding process, while joining the Nb interlayer to the uranium alloy was performed using an electron beam welding process. Explosive welding was selected to bond the Nb to the aluminum alloy in order to minimize the formation of brittle intermetallic phases. Electron beam welding was selected to join the Nb to the uranium alloy in order to precisely control melting so as to minimize mixing of the two metals. A Modified Faraday Cup (MFC) technique using computer-assisted tomography was employed to determine the power distribution of the electron beam so that the welding parameters could be directly transferred to other welding machines. Optical microscopy, scanning electron microscopy, microhardness, and tensile testing of the welds were used to characterize the resulting joints. This paper presents the welding techniques and processing parameters that were developed to produce high integrity ductile joints between these materials.

  11. Investigation of aluminum-steel joint formed by explosion welding

    NASA Astrophysics Data System (ADS)

    Kovacs-Coskun, T.; Volgyi, B.; Sikari-Nagl, I.

    2015-04-01

    Explosion welding is a solid state welding process that is used for the metallurgical joining of metals. Explosion cladding can be used to join a wide variety of dissimilar or similar metals [1]. This process uses the controlled detonation of explosives to accelerate one or both of the constituent metals into each other in such a manner as to cause the collision to fuse them together [2]. In this study, bonding ability of aluminum and steel with explosion welding was investigated. Experimental studies, microscopy, microhardness, tensile and bend test showed out that, aluminum and steel could be bonded with a good quality of bonding properties with explosion welding.

  12. Enabling high speed friction stir welding of aluminum tailor welded blanks

    NASA Astrophysics Data System (ADS)

    Hovanski, Yuri

    Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding (FSW) has traditionally been applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translate to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum FSW components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability using a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.

  13. Tool For Friction Stir Tack Welding of Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    Bjorkman, Gerald W.; Dingler, Johnny W.; Loftus, Zachary

    2003-01-01

    A small friction-stir-welding tool has been developed for use in tack welding of aluminum-alloy workpieces. It is necessary to tack-weld the workpieces in order to hold them together during friction stir welding because (1) in operation, a full-size friction-stir-welding tool exerts a large force that tends to separate the workpieces and (2) clamping the workpieces is not sufficient to resist this force. It is possible to tack the pieces together by gas tungsten arc welding, but the process can be awkward and time-consuming and can cause sufficient damage to necessitate rework. Friction stir tack welding does not entail these disadvantages. In addition, friction stir tack welding can be accomplished by use of the same automated equipment (except for the welding tool) used in subsequent full friction stir welding. The tool for friction stir tack welding resembles the tool for full friction stir welding, but has a narrower shoulder and a shorter pin. The shorter pin generates a smaller workpiece-separating force so that clamping suffices to keep the workpieces together. This tool produces a continuous or intermittent partial-penetration tack weld. The tack weld is subsequently consumed by action of the larger tool used in full friction stir welding tool.

  14. Diode laser welding of aluminum to steel

    SciTech Connect

    Santo, Loredana; Quadrini, Fabrizio; Trovalusci, Federica

    2011-05-04

    Laser welding of dissimilar materials was carried out by using a high power diode laser to join aluminum to steel in a butt-joint configuration. During testing, the laser scan rate was changed as well as the laser power: at low values of fluence (i.e. the ratio between laser power and scan rate), poor joining was observed; instead at high values of fluence, an excess in the material melting affected the joint integrity. Between these limiting values, a good aesthetics was obtained; further investigations were carried out by means of tensile tests and SEM analyses. Unfortunately, a brittle behavior was observed for all the joints and a maximum rupture stress about 40 MPa was measured. Apart from the formation of intermeltallic phases, poor mechanical performances also depended on the chosen joining configuration, particularly because of the thickness reduction of the seam in comparison with the base material.

  15. The feasibility of producing aluminum-lithium structures for cryogenic tankage applications by laser beam welding

    NASA Technical Reports Server (NTRS)

    Martukanitz, R. P.; Lysher, K. G.

    1993-01-01

    Aluminum-lithium alloys exhibit high strength, high elastic modulus, and low density as well as excellent cryogenic mechanical properties making them ideal material candidates for cryogenic tanks. NASA has proposed the use of 'built-up' structure for panels fabricated into cryogenic tanks replacing current conventional machining. Superplastically formed stiffeners would be joined to sheet (tank skin) that had been roll formed to the radius of the tank in order to produce panels. Aluminum-lithium alloys of interest for producing the built-up structure include alloy 2095-T6 stiffeners to 2095-T8 sheet and alloy 8090-T6 stiffeners to 2090-T83 sheet. Laser welding, with comparable joint properties, offers the following advantages over conventional welding: higher production rates, minimal degradation within the heat affected zones, and full process automation. This study established process parameters for laser beam welding, mechanical property determinations, metallographic characterization, and fabrication of prototype panels. Tensile tests representing partial penetration of the skin alloys provided joint efficiencies between 65 and 77 percent, depending upon alloy and degree of penetration. Results of tension shear tests of lap welds indicated that the combination of 2095-T6 to 2090-T8 exhibited significantly higher weld shear strength at the interface in comparison to welds of 8090-T6 to 2090-T83. The increased shear strength associated with 2095 is believed to be due to the alloy's ability to precipitation strengthening (naturally age) after welding.

  16. Friction Stir Spot Welding of Advanced High Strength Steels

    SciTech Connect

    Hovanski, Yuri; Grant, Glenn J.; Santella, M. L.

    2009-11-13

    Friction stir spot welding techniques were developed to successfully join several advanced high strength steels. Two distinct tool materials were evaluated to determine the effect of tool materials on the process parameters and joint properties. Welds were characterized primarily via lap shear, microhardness, and optical microscopy. Friction stir spot welds were compared to the resistance spot welds in similar strength alloys by using the AWS standard for resistance spot welding high strength steels. As further comparison, a primitive cost comparison between the two joining processes was developed, which included an evaluation of the future cost prospects of friction stir spot welding in advanced high strength steels.

  17. High-Speed Friction-Stir Welding To Enable Aluminum Tailor-Welded Blanks

    SciTech Connect

    Hovanski, Yuri; Upadhyay, Piyush; Carsley, John; Luzanski, Tom; Carlson, Blair; Eisenmenger, Mark; Soulami, Ayoub; Marshall, Dustin; Landino, Brandon; Hartfield-Wunsch, Susan

    2015-05-01

    Current joining technologies for automotive aluminum alloys are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding has been traditionally applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translate to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum welded components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability utilizing a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.

  18. Heat treatment stabilizes welded aluminum jigs and tool structures

    NASA Technical Reports Server (NTRS)

    Mehnert, R. S.

    1966-01-01

    Heat treatment processes, applied after welding but before machining, imparts above normal stability to welded aluminum jigs and tool structures. Weight saving will not be realized in these tools if rigidity equal to that of a comparable steel tool is required.

  19. Renewal of corrosion protection of coated aluminum after welding

    NASA Technical Reports Server (NTRS)

    Higgins, R. H.

    1969-01-01

    Effectiveness of conversion coatings designed to protect aluminum alloys against atmospheric corrosion is reduced after exposure to high temperature or welding. Damaged coating should be manually stripped six inches from the weld and then recoated by sponge or spray with the original solution.

  20. Gas Contamination In Plasma-Arc-Welded Aluminum

    NASA Technical Reports Server (NTRS)

    Mcclure, John C.; Torres, Martin R.; Gurevitch, Alan C.; Newman, Robert A.

    1992-01-01

    Document describes experimental investigation on visible and tactile effects of gaseous contaminants in variable-polarity plasma arc (VPPA) welding of 2219 T-87 aluminum alloy. Contaminant gases (nitrogen, methane, oxygen, and hydrogen) introduced in argon arc and in helium shield gas in various controlled concentrations. Report represents results of experiments in form of photographs of fronts, backs, polished cross sections, and etched cross sections of welds made with various contaminants at various concentrations. Provides detailed discussion of conditions under which welds made.

  1. An inelastic analysis of a welded aluminum joint

    NASA Technical Reports Server (NTRS)

    Vaughan, R. E.

    1994-01-01

    Butt-weld joints are most commonly designed into pressure vessels which then become as reliable as the weakest increment in the weld chain. In practice, weld material properties are determined from tensile test specimen and provided to the stress analyst in the form of a stress versus strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of welds. The weld specimens are analyzed using classical elastic and plastic theory to provide a basis for modeling the inelastic properties in a finite-element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of prediction methods. The weld considered in this study is a multiple-pass aluminum 2219-T87 butt weld with thickness of 1.40 in. The weld specimen is modeled using the finite-element code ABAQUS. The finite-element model is used to produce the stress-strain behavior in the elastic and plastic regimes and to determine Poisson's ratio in the plastic region. The value of Poisson's ratio in the plastic regime is then compared to experimental data. The results of the comparisons are used to explain multipass weld behavior and to make recommendations concerning the analysis and testing of welds.

  2. An inelastic analysis of a welded aluminum joint

    NASA Astrophysics Data System (ADS)

    Vaughan, R. E.

    1994-09-01

    Butt-weld joints are most commonly designed into pressure vessels which then become as reliable as the weakest increment in the weld chain. In practice, weld material properties are determined from tensile test specimen and provided to the stress analyst in the form of a stress versus strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of welds. The weld specimens are analyzed using classical elastic and plastic theory to provide a basis for modeling the inelastic properties in a finite-element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of prediction methods. The weld considered in this study is a multiple-pass aluminum 2219-T87 butt weld with thickness of 1.40 in. The weld specimen is modeled using the finite-element code ABAQUS. The finite-element model is used to produce the stress-strain behavior in the elastic and plastic regimes and to determine Poisson's ratio in the plastic region. The value of Poisson's ratio in the plastic regime is then compared to experimental data. The results of the comparisons are used to explain multipass weld behavior and to make recommendations concerning the analysis and testing of welds.

  3. Aluminum Tailor-Welded Blanks for High Volume Automotive Applications

    SciTech Connect

    Hovanski, Yuri; Upadhyay, Piyush; Pilli, Siva Prasad; Carlson, Blair; Carsley, John; Hartfield-Wunsch, Susan; Eisenmenger, Mark

    2014-02-04

    A Design of Experiment based approach is used to systematically investigate relationships between 8 different welding factors (4 related to tool geometry, 4 related to weld process control) and resulting weld properties including strength, elongation and formability in 1.2mm-2mm thick friction stir welding of AA5182-O for TWB application. The factors that result in most significant effects are elucidated. The interactions between several key factors like plunge depth, tool tilt, pin feature and pin length on the overall weld quality is discussed. Appropriate levels of factors that lead to excellent weld properties are also identified.

  4. Material Interactions in a Novel Pinless Tool Approach to Friction Stir Spot Welding Thin Aluminum Sheet

    NASA Astrophysics Data System (ADS)

    Bakavos, Dimitrios; Chen, Yingchun; Babout, Laurent; Prangnell, Phil

    2011-05-01

    The requirement for a probe, or pin, in friction stir spot welding (FSSW) leads to an undesirable keyhole and "hooking," which can influence the fracture path and weld strength. Furthermore, the full weld cycle for FSSW is typically longer than ideal for the automotive industry, being 2 to 5 seconds. Here, it is shown that using a novel pinless tool design it is possible to achieve high lap shear strength (~3.4 kN) in thin aluminum sheet (~1 mm thick), with short weld cycle times (<1 second). Several techniques have been exploited to study the material flow and mechanisms of weld formation in pinless FSSW, including high-resolution X-ray tomography, to understand the role of the tool design and weld parameters. Despite the "simple" nature of a pinless tool, material flow in the weld zone was found to be surprisingly complex and strongly influenced by surface features on the tool, which greatly increased the penetration of the plastic zone into the bottom sheet. Because of the rapid thermal cycle and high level of grain refinement, the weld zone was found to develop a higher strength than the parent material with little evidence of a heat affected zone (HAZ) after postweld natural aging.

  5. Interfacial characterization of joint between mild steel and aluminum alloy welded by resistance spot welding

    SciTech Connect

    Qiu Ranfeng; Shi Hongxin; Zhang Keke; Tu Yimin; Iwamoto, Chihiro; Satonaka, Shinobu

    2010-07-15

    The interfacial characteristics of resistance spot welded steel-aluminum alloy joint have been investigated using electron microscopy. The results reveal that reaction product FeAl{sub 3} is generated in the peripheral region of the weld while a reaction layer consisting of Fe{sub 2}Al{sub 5} adjacent to steel and FeAl{sub 3} adjacent to aluminum alloy forms in the central region of the weld, and that the morphology and thickness of the reaction layer vary with the position at the welding interface.

  6. Welded repairs of punctured thin-walled aluminum pressure vessels

    NASA Technical Reports Server (NTRS)

    Jones, D. J.

    1969-01-01

    Punctures in thin-walled aluminum pressure vessels are repaired by plugging the hole with an interference-fit disc and welding the unit. The repaired vessels withstood test pressures in excess of vessel ultimate design values for 2-, 4-, and 6-inch holes in 0.202-inch-thick aluminum alloy parent material.

  7. Effects of friction stir welding on microstructure of 7075 aluminum

    SciTech Connect

    Rhodes, C.G.; Mahoney, M.W.; Bingel, W.H.; Spurling, R.A.; Bampton, C.C.

    1997-01-01

    Friction stir welding is a relatively new technique developed by The Welding Institute (TWI) for the joining of aluminum alloys. The technique, based on friction heating at the faying surfaces of two pieces to be joined, results in a joint created by interface deformation, heat, and solid-state diffusion. In evaluating friction stir welding, critical issues (beyond a sound joint) include microstructure control and localized mechanical property variations. A serious problem with fusion welding, even when a sound weld can be made, is the complete alteration of microstructure and the attendant loss of mechanical properties. Being a solid-state process, friction stir welding has the potential to avoid significant changes in microstructure and mechanical properties. The objective of this study was to evaluate the microstructural changes effected by friction stir welding of 7075 Al.

  8. An inelastic analysis of a welded aluminum joint

    NASA Astrophysics Data System (ADS)

    Vaughan, Robert E.; Schonberg, William P.

    1995-02-01

    Butt weld joints are most commonly designed into pressure vessels by using weld material properties that are determined from a tensile test. These properties are provided to the stress analyst in the form of a stress vs strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of multiple pass aluminum 2219-T87 butt welds. The weld specimens are analyzed using classical plasticity theory to provide a basis for modeling the inelastic properties in a finite element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of currently available numerical prediction methods.

  9. Friction Stir Welding of Age-Hardenable Aluminum Alloys: A Parametric Approach Using RSM Based GRA Coupled With PCA

    NASA Astrophysics Data System (ADS)

    Vijayan, D.; Rao, V. S.

    2014-04-01

    Age-hardenable aluminum alloys, primarily used in the aerospace, automobile and marine industries (2×××, 6××× and 7×××), can be welded using solid-state welding techniques. Friction stir welding is an emerging solid-state welding technique used to join both similar and dissimilar materials. The strength of a friction stir welded joint depends on the joining process parameters. Therefore, a combination of the statistical techniques of a response surface methodology based on a grey relational analysis coupled to a principal component analysis was proposed to select the process parameters suitable for joining AA 2024 and AA 6061 aluminum alloys via friction stir welding. The significant process parameters, such as rotational speed, welding speed, axial load and pin shapes (PS) were considered during the statistical experiment. The results indicate that the square PS plays a vital role and yields an ultimate tensile strength of 141 MPa for an elongation of 12 % versus cylinder and taper pin profiles. The root cause for joint strength loss and fracture mode was analyzed using scanning electron microscopy. Severe material flow during macro defects, such as pin holes and porosity, degrades the joint strength by approximately 44 % for AA 2024 and 51 % for AA 6061 fabricated FS-welded aluminum alloys relative to the base material. The results of this approach are useful for accurately controlling the response and optimize the process parameters.

  10. Drawn arc stud welding: Crossing over from steel to aluminum

    SciTech Connect

    Ramasamy, S.

    2000-01-01

    In their quest to reduce vehicle weights, car manufacturers are exploring further use of aluminum, including more aluminum components in body construction. To acquire a better understanding of aluminum stud welding, auto manufacturers worldwide have formed a task force to conduct research on aluminum joining methods. Currently, Emhart Fastening Teknologies is working with this group in development programs such as Earthing studs, WELDFAST and Self-Pierce Rivet (SPR). The global automotive industry is clearly committed to the increased use of aluminum in cars and trucks. This presents enormous challenges and responsibilities for assembly systems suppliers, particularly those specializing in welding processes. Continuing strides in the technological sophistication of DASW is bringing this process to the forefront in advancing the use of aluminum in vehicles throughout the world.

  11. Corrosion Behavior of Aluminum-Steel Weld-Brazing Joint

    NASA Astrophysics Data System (ADS)

    Shi, Yu; Li, Jie; Zhang, Gang; Huang, Jiankang; Gu, Yufen

    2016-05-01

    Dissimilar metals of 1060 aluminum and galvanized steel were joined with a lap joint by pulsed double-electrode gas metal arc weld brazing with aluminum-magnesium and aluminum-silicon filler metals. The corrosion behavior of the weld joints was investigated with immersion corrosion and electrochemical corrosion tests, and the corrosion morphology of the joints was analyzed with scanning electron microscopy (SEM). Galvanic corrosion was found to occur when the samples were immersed in corrosive media, and the corrosion rate of joints was increased with increased heat input of the workpiece. Comparison of the corrosion properties of weld joints with different filler wires indicated that the corrosion rate of weld joints with aluminum-silicon filler wire was larger than that of weld joints with aluminum-magnesium filler wire. Results also showed that the zinc-rich zone of weld joints was prone to corrosion. The corrosion behavior of zinc-rich zone was analyzed with SEM equipped with an energy-dispersive x-ray spectroscopy analysis system based on the test results.

  12. 2XXX Aluminum Self Reacting Friction Stir Weld Development

    NASA Technical Reports Server (NTRS)

    Brown, Randy J.; Schneider, Jules; Hartley, Paula J.; Russell, Carolyn; Lawless, Kirby; Jones, Chip

    2003-01-01

    Weld process development are: (1) Execute a two-phased design of experiment (DOE) approach: process DOE to establish rotation and travel speeds and forge load;set-up DOE to establish allowable gap and centerline offset. (2) Determine the effect of process parameters on strength and weld quality: room and -320 deg F tensile testing; metalllurgical and NDE evaluation. (3) Weld quality goals: visual and radiographic acceptable; room temperature ultimate strength.

  13. Weld peaking on heavy aluminum structures

    NASA Technical Reports Server (NTRS)

    Bayless, E.; Poorman, R.; Sexton, J.

    1978-01-01

    Weld peaking is usually undesirable in any welded structure. In heavy structures, the forces involved in the welding process become very large and difficult to handle. With the shuttle's solid rocket booster, the weld peaking resulted in two major problems: (1) reduced mechanical properties across the weld joint, and (2) fit-up difficulties in subsequent assembly operation. Peaking from the weld shrinkage forces can be fairly well predicted in simple structures; however, in welding complicated assemblies, the amount of peaking is unpredictable because of unknown stresses from machining and forming, stresses induced by the fixturing, and stresses from welds in other parts of the assembly. When excessive peaking is encountered, it can be corrected using the shrinkage forces resulting from the welding process. Application of these forces is discussed in this report.

  14. High-Speed Friction-Stir Welding to Enable Aluminum Tailor-Welded Blanks

    NASA Astrophysics Data System (ADS)

    Hovanski, Yuri; Upadhyay, Piyush; Carsley, John; Luzanski, Tom; Carlson, Blair; Eisenmenger, Mark; Soulami, Ayoub; Marshall, Dustin; Landino, Brandon; Hartfield-Wunsch, Susan

    2015-05-01

    Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and they have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high volumes. While friction-stir welding (FSW) has been traditionally applied at linear velocities less than 1 m/min, high-volume production applications demand the process be extended to higher velocities more amenable to cost-sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low-to-moderate welding velocities do not directly translate to high-speed linear FSW. Therefore, to facilitate production of high-volume aluminum FSW components, parameters were developed with a minimum welding velocity of 3 m/min. With an emphasis on weld quality, welded blanks were evaluated for postweld formability using a combination of numerical and experimental methods. An evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum TWBs, which provided validation of the numerical and experimental analysis of laboratory-scale tests.

  15. Laser welding of aeronautical and automobile aluminum alloys

    NASA Astrophysics Data System (ADS)

    Boukha, Z.; Sánchez-Amaya, J. M.; Amaya-Vázquez, M. R.; González-Rovira, L.; Botana, F. J.

    2012-04-01

    Laser beam welding (LBW) show clear advantages compared with other techniques, as the low heat input, the high localization ability, the high welding speed, the high flexibility, the high weld quality and the high production rate. However, its applicability to aluminum alloys is limited, as they generally have high reflectivity, high thermal conductivity and low viscosity. In the present study, it is analyzed the laser weldability of four aluminum alloys (2024, 5083, 6082 and 7075). High penetration butt welds could be obtained with a high power diode laser under conduction regime. The properties of the weld beads such as the microstructure and microhardness were analyzed. A linear function between the input laser fluence and the volume of melted material was obtained for the four alloys.

  16. Gas-tungsten arc welding of aluminum alloys

    DOEpatents

    Frye, Lowell D.

    1984-01-01

    A gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to provide a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surfaces are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy contiguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

  17. Gas-tungsten arc welding of aluminum alloys

    DOEpatents

    Frye, L.D.

    1982-03-25

    The present invention is directed to a gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to profice a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surface are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy continguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

  18. Yield detection in aluminum welded joints using photostress

    NASA Technical Reports Server (NTRS)

    Gambrell, S. C., Jr.; Kavikondala, K.

    1994-01-01

    Previous work using photostress to analyze behavior of aluminum welded joints was useful to determine mechanical properties of the weld and parent materials along the centerline of the joint. It was shown that significant differences exist in the stress-strain characteristics at points beginning at the centerline of the weld and extending for a distance of one inch to either side of the weld. Because of the highly variable behavior detected in the previous work, it was decided to extend the work to investigate behavior of joints 1/8, 1/2, and 1.40 inches thick.

  19. Effect of Preheating in Hybrid Friction Stir Welding of Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Yaduwanshi, D. K.; Bag, S.; Pal, S.

    2014-10-01

    The controlled energy input into the system by introducing an extra heat source to enhance the material flow along with reduction of the plunging force remains a potential area of considerate for the development of hybrid friction stir welding (FSW) process. Hence, the effect of preheating on the weld joint properties is evaluated using plasma-assisted friction stir welding (P-FSW) process for joining aluminum alloy. A comparative study of mechanical and macro-microstructural characterizations of weld joint by FSW and P-FSW has been performed. Transverse tensile strength of weld joint is approximately 95% of base metal produced by P-FSW and is 8% more than conventional FSW welds. The effect of preheating enhances material flow and dissolution of fine oxide particles by plasma arc results in increase of strength and marginal modification of deformation behavior. The preheating brings uniformly distributed hardness in weld zone and the magnitude is higher in the advancing side with overall increase in average hardness value. Grain sizes are much finer due to the pinning effect of Al2O3 particles that retarded grain growth following recrystallization during P-FSW and thus led to more pronounced reduction in grain size and relatively brittle fracture during tensile loading of welded joint. Overall, the influence of preheating acts quite homogeneously throughout the structure as compared to conventional FSW. However, the results reveal that the development of P-FSW is still in initial stage and needs to improve in various aspects.

  20. Microstructural Investigation of Friction-Stir-Welded 7005 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Xu, Xuesong; Lu, Yan; Zheng, Feiyan; Chen, Bin

    2015-11-01

    This paper is aimed to investigate the microstructure of 7005 aluminum sheets joined by friction-stir welding as well as their mechanical properties. Specimens with ten different sets of welding parameters were studied. Tensile test and fracture analysis determined that the joint of the best quality was obtained at the rotation speed of 1000 rpm matching with the travel speed of 200 mm/min, and the travel speed has more impact on the ultimate tensile strength. Optical microscope observation was applied to this high-quality specimen and gave evidence to explaining the formation of the onion ring structure. Electron back-scattered diffraction (EBSD) technique was employed to characterize the textures and revealed the evolution of microstructures during friction stir processing. The EBSD results showed that the grains maintain their original orientations at relatively low deformation while the orientations rotate under increasing strain. Accumulated rotation will turn the textures into mixed shear components, which finally results in grain refinement and contributes to the high quality of the joint.

  1. Experimental Study of Stationary Shoulder Friction Stir Welded 7N01-T4 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Ji, S. D.; Meng, X. C.; Li, Z. W.; Ma, L.; Gao, S. S.

    2016-03-01

    Stationary shoulder friction stir welding (SSFSW) was successfully used to weld 7N01-T4 aluminum alloy with the thickness of 4 mm. Effects of welding speed on formations, microstructures, and mechanical properties of SSFSW joint were investigated in detail. Under a constant rotational velocity of 2000 rpm, defect-free joints with smooth surface and small flashes are attained using welding speeds of 20 and 30 mm/min. Macrostructure of nugget zone in cross section presents kettle shape. For 7N01-T4 aluminum alloy with low thermal conductivity, decreasing welding speed is beneficial to surface formation of joint. With the increase of welding speed, mechanical properties of joints firstly increase and then decrease. When the welding speed is 30 mm/min, the tensile strength and elongation of joint reach the maximum values of 379 MPa and 7.9%, equivalent to 84.2 and 52% of base material, respectively. Fracture surface morphology exhibits typical ductile fracture. In addition, the minimum hardness value of joint appears in the heat affected zone.

  2. Analysis and Comparison of Aluminum Alloy Welded Joints Between Metal Inert Gas Welding and Tungsten Inert Gas Welding

    NASA Astrophysics Data System (ADS)

    Zhao, Lei; Guan, Yingchun; Wang, Qiang; Cong, Baoqiang; Qi, Bojin

    2015-09-01

    Surface contamination usually occurs during welding processing and it affects the welds quality largely. However, the formation of such contaminants has seldom been studied. Effort was made to study the contaminants caused by metal inert gas (MIG) welding and tungsten inert gas (TIG) welding processes of aluminum alloy, respectively. SEM, FTIR and XPS analysis was carried out to investigate the microstructure as well as surface chemistry. These contaminants were found to be mainly consisting of Al2O3, MgO, carbide and chromium complexes. The difference of contaminants between MIG and TIG welds was further examined. In addition, method to minimize these contaminants was proposed.

  3. Friction Stir Spot Welding of 6061 Aluminum-to-Copper

    NASA Astrophysics Data System (ADS)

    Heideman, Robert J.

    Friction stir spot welding (FSSW) between 1.5mm thick 6061 Al on top and 1.5mm thick Cu at bottom was conducted. First, weld parameters and the weld macrostructure that were necessary to form good quality welds, as determined using lap shear weld strength, were identified. Tool rotation speed and tool pin length are key variables that control weld strength. To obtain high quality strong welds, a Cu ring extruded upward from the lower Cu sheet into the upper 6061 Al-sheet, which promoted bonding and interlocking between the sheets, and an Al-rich stir zone between Cu ring and weld keyhole were both necessary. Second, a technique where the tool remained in the sample after FSSW helped determine the material flow that takes place during high quality weld formation and the functions of the welding tool features. The tool threads cause 6061 Al from the upper sheet to move downward into the region near the threads. The tool shoulder causes a counter flow movement of 6061 Al that results in the formation of the Al-rich stir zone and also causes the upward extrusion of the lower Cu sheet. This technique also identified that a Cu-rich material forms on the tool tip, that this material sheds and rebuilds during subsequent welds, and that this material can form large Cu-rich particles that can completely fill the tool threads, impede proper material flow and lead to a low strength, poor quality weld. Third, to further understand welding parameters, weld temperatures, torque, and vertical forces were measured. Temperature data was collected using a tool holder that permitted wireless thermocouple data collection. Through these measurements, rotational plunge weld energy was recognized as important in determining if a quality weld formed, and weld plunge rate was identified as the welding parameter that significantly impacted rotational weld plunge energy. The final phase of research was to improve weld quality consistency. Through repetitive trials with a single tool

  4. The effects of aluminum oxide on inertial welding of aluminum in space applications

    NASA Astrophysics Data System (ADS)

    Smith, Michael H.

    1992-05-01

    Inertial friction welding of 2219 aluminum alloy studs to 2219 aluminum alloy plates is investigated in air and in an argon atmosphere to determine the effects of an intact oxide layer on weld quality. Scratch-brushing of plates and studs was performed in an argon atmosphere to break up the oxide layer and prevent reformation prior to testing. Argon was used to simulate the near-oxygen free space environment. Weld quality was determined by a bend test and by measurement of the fraction of the weld surface area that was dimpled in appearance following fracture of the weld. The fundamental theories of friction and wear that are applicable to friction welding are reviewed. A brief survey of current welding methods that may have application in space is presented, as well as a discussion of their feasibility and limitations. Characteristics of the space station are discussed as well as their consequences on welding in space. A qualitative model of the process of inertial friction welding based on the theories of friction and observations of welds and weld fractures is developed and presented.

  5. Effect of the Number of Welding Repairs with GTAW on the Mechanical Behavior of AA7020 Aluminum Alloy Welded Joints

    NASA Astrophysics Data System (ADS)

    Maya-Johnson, Santiago; Santa, Juan Felipe; Mejía, Oscar L.; Aristizábal, Santiago; Ospina, Sebastian; Cortés, Paula Andrea; Giraldo, Jorge Enrique

    2015-10-01

    In this work, two different tests were done to establish the effect of heating cycles by welding in an AA7020-T6 aluminum alloy welded with ER5087 and ER5356 electrodes. During 10 months, welds were done to simulate in the laboratory several welding repairs (up to six repairs). Tensile and hardness measurements were done to evaluate the evolution of the properties against time. It was found that a single pass is enough to generate a heat-affected zone (HAZ) of 30 mm, and after four repairs the width of the HAZ exceeds 210 mm. In the HAZ, two regions were observed: the dissolution zone, which recovers a percentage of hardness by natural aging, and the over-aging zone, showing no increase in hardness. The results indicate that there is a maximum number of welding repairs that can be performed in a heat-treatable aluminum superstructure before it fails on the HAZ of the base material, since the tensile strength is reduced around 40 pct compared to the base metal.

  6. Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    McGill, Preston; Burkholder, Jonathan

    2012-01-01

    Friction stir welding is a solid state welding process used in the fabrication of various aerospace structures. Self-reacting and conventional friction stir welding are variations of the friction stir weld process employed in the fabrication of cryogenic propellant tanks which are classified as pressurized structure in many spaceflight vehicle architectures. In order to address damage tolerance behavior associated with friction stir welds in these safety critical structures, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data describing fracture behavior, residual strength capability, and cyclic mission life capability of friction stir welds at ambient and cryogenic temperatures have been generated and will be presented in this paper. Fracture behavior will include fracture toughness and tearing (R-curve) response of the friction stir welds. Residual strength behavior will include an evaluation of the effects of lack of penetration on conventional friction stir welds, the effects of internal defects (wormholes) on self-reacting friction stir welds, and an evaluation of the effects of fatigue cycled surface cracks on both conventional and selfreacting welds. Cyclic mission life capability will demonstrate the effects of surface crack defects on service load cycle capability. The fracture data will be used to evaluate nondestructive inspection and proof test requirements for the welds.

  7. Microstructural Characterization of Friction Stir Welded Aluminum-Steel Joints

    NASA Astrophysics Data System (ADS)

    Patterson, Erin E.; Hovanski, Yuri; Field, David P.

    2016-03-01

    This work focuses on the microstructural characterization of aluminum to steel friction stir welded joints. Lap weld configuration coupled with scribe technology used for the weld tool have produced joints of adequate quality, despite the significant differences in hardness and melting temperatures of the alloys. Common to friction stir processes, especially those of dissimilar alloys, are microstructural gradients including grain size, crystallographic texture, and precipitation of intermetallic compounds. Because of the significant influence that intermetallic compound formation has on mechanical and ballistic behavior, the characterization of the specific intermetallic phases and the degree to which they are formed in the weld microstructure is critical to predicting weld performance. This study used electron backscatter diffraction, energy dispersive spectroscopy, scanning electron microscopy, and Vickers micro-hardness indentation to explore and characterize the microstructures of lap friction stir welds between an applique 6061-T6 aluminum armor plate alloy and a RHA homogeneous armor plate steel alloy. Macroscopic defects such as micro-cracks were observed in the cross-sectional samples, and binary intermetallic compound layers were found to exist at the aluminum-steel interfaces of the steel particles stirred into the aluminum weld matrix and across the interfaces of the weld joints. Energy dispersive spectroscopy chemical analysis identified the intermetallic layer as monoclinic Al3Fe. Dramatic decreases in grain size in the thermo-mechanically affected zones and weld zones that evidenced grain refinement through plastic deformation and recrystallization. Crystallographic grain orientation and texture were examined using electron backscatter diffraction. Striated regions in the orientations of the aluminum alloy were determined to be the result of the severe deformation induced by the complex weld tool geometry. Many of the textures observed in the weld

  8. Microstructural Characterization of Friction Stir Welded Aluminum-Steel Joints

    NASA Astrophysics Data System (ADS)

    Patterson, Erin E.; Hovanski, Yuri; Field, David P.

    2016-06-01

    This work focuses on the microstructural characterization of aluminum to steel friction stir welded joints. Lap weld configuration coupled with scribe technology used for the weld tool have produced joints of adequate quality, despite the significant differences in hardness and melting temperatures of the alloys. Common to friction stir processes, especially those of dissimilar alloys, are microstructural gradients including grain size, crystallographic texture, and precipitation of intermetallic compounds. Because of the significant influence that intermetallic compound formation has on mechanical and ballistic behavior, the characterization of the specific intermetallic phases and the degree to which they are formed in the weld microstructure is critical to predicting weld performance. This study used electron backscatter diffraction, energy dispersive spectroscopy, scanning electron microscopy, and Vickers micro-hardness indentation to explore and characterize the microstructures of lap friction stir welds between an applique 6061-T6 aluminum armor plate alloy and a RHA homogeneous armor plate steel alloy. Macroscopic defects such as micro-cracks were observed in the cross-sectional samples, and binary intermetallic compound layers were found to exist at the aluminum-steel interfaces of the steel particles stirred into the aluminum weld matrix and across the interfaces of the weld joints. Energy dispersive spectroscopy chemical analysis identified the intermetallic layer as monoclinic Al3Fe. Dramatic decreases in grain size in the thermo-mechanically affected zones and weld zones that evidenced grain refinement through plastic deformation and recrystallization. Crystallographic grain orientation and texture were examined using electron backscatter diffraction. Striated regions in the orientations of the aluminum alloy were determined to be the result of the severe deformation induced by the complex weld tool geometry. Many of the textures observed in the weld

  9. Effect of Postweld Aging Treatment on Fatigue Behavior of Pulsed Current Welded AA7075 Aluminum Alloy Joints

    NASA Astrophysics Data System (ADS)

    Balasubramanian, V.; Ravisankar, V.; Madhusudhan Reddy, G.

    2008-04-01

    This article reports the effect of postweld aging treatment on fatigue behavior of pulsed current welded AA 7075 aluminum alloy joints. AA7075 aluminum alloy (Al-Zn-Mg-Cu alloy) has gathered wide acceptance in the fabrication of light weight structures requiring high strength-to weight ratio, such as transportable bridge girders, military vehicles, road tankers, and railway transport systems. The preferred welding processes of AA7075 aluminum alloy are frequently gas tungsten arc welding (GTAW) process and gas metal arc welding (GMAW) process due to their comparatively easier applicability and better economy. Weld fusion zones typically exhibit coarse columnar grains because of the prevailing thermal conditions during weld metal solidification. This often results inferior weld mechanical properties and poor resistance to hot cracking. In this investigation, an attempt has been made to refine the fusion zone grains by applying pulsed current welding technique. Rolled plates of 10 mm thickness have been used as the base material for preparing multipass welded joints. Single V butt joint configuration has been prepared for joining the plates. The filler metal used for joining the plates is AA 5356 (Al-5Mg (wt.%)) grade aluminum alloy. Four different welding techniques have been used to fabricate the joints and they are: (i) continuous current GTAW (CCGTAW), (ii) pulsed current GTAW (PCGTAW), (iii) continuous current GMAW (CCGMAW), and (iv) pulsed current GMAW (PCGMAW) processes. Argon (99.99% pure) has been used as the shielding gas. Rotary bending fatigue testing machine has been used to evaluate fatigue behavior of the welded joints. Current pulsing leads to relatively finer and more equi-axed grain structure in GTA and GMA welds. Grain refinement is accompanied by an increase in fatigue life and endurance limit. Simple postweld aging treatment applied to the joints is found to be beneficial to enhance the fatigue performance of the welded joints.

  10. Transition material improves spot welding of aluminum to steel

    SciTech Connect

    Not Available

    1994-06-01

    Weight is one of the primary enemies of improved fuel economy in automobiles. To help address this problem, a simple yet highly effective clad metal transition material has been developed. It allows automotive engineers to spot weld aluminum to steel using existing conventional production equipment and practices, thereby enabling them to use aluminum in place of heavier steel without expensive changes in production methods. The idea of the new materials technology is to permit the joining of aluminum to steel using conventional spot welding techniques. Numerous welding and corrosion studies have been conducted on the clad transition material approach by auto manufacturers, industry suppliers and various independent organizations. The success of these tests has prompted manufacturers in the US, Europe and Japan to accelerate production and field testing of clad transition materials on cars with an eye toward volume application.

  11. Homogeneity of Mechanical Properties of Underwater Friction Stir Welded 2219-T6 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Liu, H. J.; Zhang, H. J.; Yu, L.

    2011-11-01

    Underwater friction stir welding (FSW) has been demonstrated to be available for the improvement in tensile strength of normal FSW joints. In order to illuminate the intrinsic reason for strength improvement through underwater FSW, a 2219 aluminum alloy was underwater friction stir welded and the homogeneity of mechanical properties of the joint was investigated by dividing the joint into three layers. The results indicate that the tensile strength of the three layers of the joint is all improved by underwater FSW, furthermore, the middle and lower layers have larger extent of strength improvement than the upper layer, leading to an increase in the homogeneity of mechanical properties of the joint. The minimum hardness value of each layer, especially the middle and lower layers, is improved under the integral water cooling effect, which is the intrinsic reason for the strength improvement of underwater joint.

  12. 49 CFR 178.68 - Specification 4E welded aluminum cylinders.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Specification 4E welded aluminum cylinders. 178.68... PACKAGINGS Specifications for Cylinders § 178.68 Specification 4E welded aluminum cylinders. (a) Type, size and service pressure. A DOT 4E cylinder is a welded aluminum cylinder with a water capacity...

  13. 49 CFR 178.68 - Specification 4E welded aluminum cylinders.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Specification 4E welded aluminum cylinders. 178.68... FOR PACKAGINGS Specifications for Cylinders § 178.68 Specification 4E welded aluminum cylinders. (a) Type, size and service pressure. A DOT 4E cylinder is a welded aluminum cylinder with a water...

  14. 49 CFR 178.68 - Specification 4E welded aluminum cylinders.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Specification 4E welded aluminum cylinders. 178.68... PACKAGINGS Specifications for Cylinders § 178.68 Specification 4E welded aluminum cylinders. (a) Type, size and service pressure. A DOT 4E cylinder is a welded aluminum cylinder with a water capacity...

  15. 49 CFR 178.68 - Specification 4E welded aluminum cylinders.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Specification 4E welded aluminum cylinders. 178.68... PACKAGINGS Specifications for Cylinders § 178.68 Specification 4E welded aluminum cylinders. (a) Type, size and service pressure. A DOT 4E cylinder is a welded aluminum cylinder with a water capacity...

  16. 49 CFR 178.68 - Specification 4E welded aluminum cylinders.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Specification 4E welded aluminum cylinders. 178.68... PACKAGINGS Specifications for Cylinders § 178.68 Specification 4E welded aluminum cylinders. (a) Type, size and service pressure. A DOT 4E cylinder is a welded aluminum cylinder with a water capacity...

  17. Flaw growth behavior in thick welded plates of 2219-T87 aluminum at room and cryogenic temperatures

    NASA Technical Reports Server (NTRS)

    Forman, R. G.; Glorioso, S. V.; Medlock, J. D.

    1973-01-01

    Axial load fatigue and fracture tests were conducted on thick welded plates of 2219-T87 aluminum alloy to determine the tensile strength properties and the flaw growth behavior in electron beam, gas metal arc, and pulse current gas tungsten arc welds for plates 6.35 centimeters (2.5 in.) thick. The tests were conducted in room temperature air and in liquid nitrogen environments. Specimens were tested in both the as-welded and the aged after welding conditions. The experimental crack growth rate were correlated with theoretical crack growth rate predictions for semielliptical surface flaws.

  18. Microstructure and Mechanical Performance of Friction Stir Spot-Welded Aluminum-5754 Sheets

    NASA Astrophysics Data System (ADS)

    Pathak, N.; Bandyopadhyay, K.; Sarangi, M.; Panda, Sushanta Kumar

    2013-01-01

    Friction stir spot welding (FSSW) is a recent trend of joining light-weight sheet metals while fabricating automotive and aerospace body components. For the successful application of this solid-state welding process, it is imperative to have a thorough understanding of the weld microstructure, mechanical performance, and failure mechanism. In the present study, FSSW of aluminum-5754 sheet metal was tried using tools with circular and tapered pin considering different tool rotational speeds, plunge depths, and dwell times. The effects of tool design and process parameters on temperature distribution near the sheet-tool interface, weld microstructure, weld strength, and failure modes were studied. It was found that the peak temperature was higher while welding with a tool having circular pin compared to tapered pin, leading to a bigger dynamic recrystallized stir zone (SZ) with a hook tip bending towards the upper sheet and away from the keyhole. Hence, higher lap shear separation load was observed in the welds made from circular pin compared to those made from tapered pin. Due to influence of size and hardness of SZ on crack propagation, three different failure modes of weld nugget were observed through optical cross-sectional micrograph and SEM fractographs.

  19. Experiments and simulation for 6061-T6 aluminum alloy resistance spot welded lap joints

    NASA Astrophysics Data System (ADS)

    Florea, Radu Stefanel

    and base metal of the joints. Neutron diffraction results showed residual stresses in the weld are approximately 40% lower than the yield strength of the parent material, with maximum variation occurring in the vertical position of the specimen because of the orientation of electrode clamping forces that produce a non-uniform solidification pattern. In the final section a theoretical continuum modeling framework for 6061-T6 aluminum resistance spot welded joints is presented.

  20. Investigation of Torsional Strength of the VT6 Weld Joint Produced by Linear Friction Welding

    NASA Astrophysics Data System (ADS)

    Suleimanova, G. R.; Kabirov, R. R.; Karavaeva, M. V.; Ershova, Yu. A.; Zhilyaev, A. P.

    2015-10-01

    Results of measurement of torsional strength of the weld joint of the VT6 titanium alloy produced by linear friction welding are presented. For a comparison, the same method was used to test monolithic specimens of the VT6 alloy. Torsional strength values of the weld joint (τUS = 861 MPa and φ = 110°) correspond to the strength of the monolithic material. In this case, the specimens fail along the base metal.

  1. 2195 Aluminum-Copper-Lithium Friction Plug Welding Development

    NASA Technical Reports Server (NTRS)

    Takeshita, Rike P.; Hartley, Paula J.; Baker, Kent S.

    1997-01-01

    Technology developments and applications of friction plug welding is presented. This friction repair welding technology is being studied for implementation on the Space Transportation System's Super Light Weight External Tank. Single plug repairs will be used on a vast majority of weld defects, however, linear defects of up to several inches can be repaired by overlapping plug welds. Methods and results of tensile, bend, simulated service, surface crack tension and other tests at room and cryogenic temperatures is discussed. Attempts to implement Friction Plug Welding has led to both tool and process changes in an attempt to minimize expansive tooling and lengthy implementation times. Process control equipment and data storage methods intended for large scale production will also be addressed. Benefits include increased strength and toughness, decreased weld repair time, automated and highly reliable process, and a lower probability of having to re-repair defect locations.

  2. Electromagnetic hammer removes weld distortions from aluminum tanks

    NASA Technical Reports Server (NTRS)

    Schwinghamer, R. J.

    1965-01-01

    Distortions around weld areas on sheet-aluminum tanks and other structures are removed with a portable electromagnetic hammer. The hammer incorporates a coil that generates a controlled high-energy pulsed magnetic field over localized areas on the metal surface.

  3. Computer simulation of resistance spot welding in aluminum: Part 1

    SciTech Connect

    Browne, D.J.; Chandler, H.W.; Evans, J.T.; Wen, J.

    1995-10-01

    A computer-based model of resistance spot welding with hemispherical electrode tips has been developed to include simulation of elastic-plastic mechanical deformation as well as ohmic heating and thermal conduction. The primary effect of the mechanical deformation is in its influence on the contact read and current density developed at the faying surface. The model was used to simulate spot welding in aluminum alloys. Preliminary results show the effects of variations in input current, contact resistance, applied force and position of the cooling water with respect to the electrode tip. It is shown that the value of the contact resistance has a large effect on nugget formation in the spot welding of aluminum alloys and that the applied force has a significant effect arising from its effect on the area of contact at the faying surface. The formation of a resistance spot weld in aluminum is also sensitive to the position of the cooling water-electrode interface because of the high thermal conductivity of aluminum alloys.

  4. Effects of high frequency current in welding aluminum alloy 6061

    NASA Technical Reports Server (NTRS)

    Fish, R. E.

    1968-01-01

    Uncontrolled high frequency current causes cracking in the heat-affected zone of aluminum alloy 6061 weldments during tungsten inert gas ac welding. Cracking developed when an improperly adjusted superimposed high frequency current was agitating the semimolten metal in the areas of grain boundary.

  5. Mechanical and microstructural characterization of single and double pass Aluminum AA6061 friction stir weld joints

    NASA Astrophysics Data System (ADS)

    Othman, N. H.; Shah, L. H.; Ishak, M.

    2015-12-01

    This study focuses on the effect of single pass (SP), double sided pass (DSP) and normal double pass (NDP) method on friction stir welding of aluminum AA6061. Two pieces of AA6061 alloy with thickness of 6 mm were friction stir welded by using conventional milling machine. The rotational speeds that were used in this study were 800 rpm, 1000 rpm and 1200 rpm, respectively. The welding speed is fixed to 100 mm/min. Microstructure observation of welded area was studied by using optical microscope. Tensile test and Vickers hardness test were used to evaluate the mechanical properties of this specimen. Mechanical property analysis results indicate that at low rotational speeds, defects such as surface lack of fill and tunneling in the welded area can be observed. Vickers hardness of specimens however did not vary much when rotational speed is varied. Welded specimens using single pass method shows higher tensile strength and hardness value compared to both double pass methods up to 180.61 MPa. Moreover, DSP showed better tensile test and hardness test compared to NDP method. The optimum parameters were found to be single pass method with 1200 rpm of rotational speed. Therefore economically sound to only perform SP method to obtain maximum tensile strength for AA6061 FSW with thickness of 6 mm.

  6. Microstructural issues in a friction-stir-welded aluminum alloy

    SciTech Connect

    Flores, O.V.; Kennedy, C.; Murr, L.E.; Brown, D.; Pappu, S.; Nowak, B.M.; McClure, J.C.

    1998-02-03

    Recent observations of microstructures associated with friction-stir welding (FSW) in a number of aluminum alloys have consistently demonstrated the actual weld zone to consist of a (dynamically) recrystallized grain structure resulting from the extreme, solid-state, plastic deformation characterizing the process. Because of solubilities associated with the various precipitates in 7075 and 6061 aluminum alloys, and the fact that the precipitates were either homogeneously distributed throughout both the original (unwelded) work-piece plates and the well zones (or formed varying densities of Widmanstaetten patterns within the original and recrystallized grains), it has been difficult to follow the stirring of stable, second-phase particles from the base metal (work-piece) into the weld zone. In the present investigation, a compositionally modified 1100 aluminum alloy (nominally 99.2% Al, 0.5% Fe, 0.15% Cu, 0.12% Si, 0.05 Mn, 0.04 Ti, balance in weight percent of Be and Mg), forming a stable microdendritic (second-phase), equiaxed, cell structure was friction-stir welded. These thermally stable, geometrically specific, precipitates in the base metal were compared with their disposition within the friction-stir-weld zone. In addition, as-cast plates of this alloy were cold-rolled 50% and friction-stir-welded in order to compare these two schedules (as-cast and 50% cold-rolled) in terms of residual hardness variations and related microstructural issues as well as the effect of prior deformation on the friction-stir welding process.

  7. Influence of Solute Content and Solidification Parameters on Grain Refinement of Aluminum Weld Metal

    NASA Astrophysics Data System (ADS)

    Schempp, Philipp; Cross, Carl Edward; Pittner, Andreas; Rethmeier, Michael

    2013-07-01

    Grain refinement provides an important possibility to enhance the mechanical properties ( e.g., strength and ductility) and the weldability (susceptibility to solidification cracking) of aluminum weld metal. In the current study, a filler metal consisting of aluminum base metal and different amounts of commercial grain refiner Al Ti5B1 was produced. The filler metal was then deposited in the base metal and fused in a GTA welding process. Additions of titanium and boron reduced the weld metal mean grain size considerably and resulted in a transition from columnar to equiaxed grain shape ( CET). In commercial pure aluminum (Alloy 1050A), the grain-refining efficiency was higher than that in the Al alloys 6082 and 5083. Different welding and solidification parameters influenced the grain size response only slightly. Furthermore, the observed grain-size reduction was analyzed by means of the undercooling parameter P and the growth restriction parameter Q, which revealed the influence of solute elements and nucleant particles on grain size.

  8. Microstructural evolution of 6063 aluminum during friction-stir welding

    SciTech Connect

    Sato, Y.S.; Kokawa, Hiroyuki; Enomoto, Masatoshi; Jogan, Shigetoshi

    1999-09-01

    The microstructural distribution associated with a hardness profile in a friction-stir-welded, age-hardenable 6063 aluminum alloy has been characterized by transmission electron microscopy (TEM) and orientation imaging microscopy (OIM). The friction-stir process produces a softened region in the 6063 Al weld. Frictional heating and plastic flow during friction-stir welding create fine recrystallized grains in the weld zone and recovered grains in the thermomechanically affected zone. The hardness profile depends greatly on the precipitate distribution and only slightly on the grain size. The softened region is characterized by dissolution and growth of the precipitates during the welding. Simulated weld thermal cycles with different peak temperatures have shown that the precipitates are dissolved at temperatures higher than 675 K and that the density of the strengthening precipitate was reduced by thermal cycles lower than 675 K. A comparison between the thermal cycles and isothermal aging has suggested precipitation sequences in the softened region during friction-stir welding.

  9. Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

    NASA Technical Reports Server (NTRS)

    Russell, Carolyn; Bjorkman, Gerry; McCool, Carolyn (Technical Monitor)

    2000-01-01

    A viewgraph presentation outlines NASA Marshall Space Flight Center, Lockheed Martin Michoud Space Systems, and McCook Metals' development an aluminum-copper weld filler wire for fusion welding 2195 aluminum lithium. The aluminum-copper based weld filler wire has been identified as B218, which is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The Super Lightweight External Tank for the NASA Space Shuttle Program consists of 2195 welded with 4043 aluminum-silicon weld filler wire. The B218 filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties. An initial characterization of the B218 weld filler wire was performed consisting of initial weld and repair weld evaluation comparing B218 and 4043. The testing involved room temperature and cryogenic tensile testing along with fracture toughness testing. B218 weld filler wire proved to produce enhanced initial and repair weld tensile and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding 2195 and other aluminum lithium alloys over 4043.

  10. Neural Network Modeling of Weld Pool Shape in Pulsed-Laser Aluminum Welds

    SciTech Connect

    Iskander, Y.S.; Oblow, E.M.; Vitek, J.M.

    1998-11-16

    A neural network model was developed to predict the weld pool shape for pulsed-laser aluminum welds. Several different network architectures were examined and the optimum architecture was identified. The neural network was then trained and, in spite of the small size of the training data set, the network accurately predicted the weld pool shape profiles. The neural network output was in the form of four weld pool shape parameters (depth, width, half-width, and area) and these were converted into predicted weld pool profiles with the use of the actual experimental poo1 profiles as templates. It was also shown that the neural network model could reliably predict the change from conduction-mode type shapes to keyhole-mode shapes.

  11. Heat Treatment of Friction Stir Welded 7X50 Aluminum

    NASA Technical Reports Server (NTRS)

    Petter, George E. (Inventor); Figert, John D. (Inventor); Rybicki, Daniel J. (Inventor); Burnes, Timothy H. (Inventor)

    2004-01-01

    A method for treating alloy before and after friction stir welding, the method comprising the following steps. First solution heat treating a multiplicity of aluminum-zinc alloy engineered components for a first time period at a first temperature. First air cooling the components in ambient air at room temperatwe until the components are cooled to room temperature. Friction stir welding the components to form an assembly. Second solution heat treating the assembly for a second time period at a second temperature. Additional steps and embodiments are considered.

  12. Microstructural and Mechanical Characteristics of Aluminum Alloy AA5754 Friction Stir Spot Welds

    NASA Astrophysics Data System (ADS)

    Mahmoud, T. S.; Khalifa, T. A.

    2014-03-01

    In the present investigation, friction stir spot welding on annealed aluminum alloy AA5754 sheets was performed. The influences of the tool rotational speed and tool stirring (dwell) time on the weld structure and static strength of welds were evaluated. The results revealed that the width of the completely metallurgical-bonded region increases with the increasing tool rotational speed and/or the dwell time up to certain levels. Increasing such parameters beyond these levels slightly reduces the width of the bonding region. The stirred zone exhibited higher microhardness than that of the base material. The tensile-shear force was found to increase with the increasing tool rotational speed and/or dwell time up to a certain level (9s). Higher tool rotational speeds and/or prolonged dwell times slightly reduce(s) the tensile-shear force.

  13. Aluminum Rayleigh Taylor Strength Measurements and Calculations

    SciTech Connect

    Lindquist, M J; Cavallo, R M; Lorenz, K T; Pollaine, S M; Remington, B A; Raevsky, V A

    2007-01-10

    A traditional approach to the study of material strength has been revitalized at the Russian Federal Nuclear Center (VNIIEF). Rayleigh Taylor strength experiments have long been utilized to measure the material response of metals at high pressure and strain rates. A modulated (sinusoidal or sawtooth perturbation) surface is shocklessly (quasi-isentropically) accelerated by a high explosive (HE) driver, and radiography is used to measure the perturbation amplitude as a function of time. The Aluminum T-6061 targets are designed with several sets of two-dimensional sawtooth perturbations machined on the loading surface. The HE driver was designed to reach peak pressures in the range of 200 to 300 kbar and strain rates in the range of 10{sup 4} - 10{sup 6} s{sup -1}. The standard constitutive strength models, Steinberg-Guinan (SG) [1], Steinberg-Lund (SL) [2], Preston-Tonks-Wallace (PTW) [3], Johnson-Cooke (JC) [4], and Mechanical Threshold Stress (MTS) [5], have been calibrated by traditional techniques: (Hopkinson-Bar, Taylor impact, flyer plate/shock-driven experiments). The VNIIEF experimental series accesses a strain rate regime not attainable using traditional methods. We have performed a detailed numerical study with a two-dimensional Arbitrary Lagrangian Eulerian hydrodynamics computer code containing several constitutive strength models to predict the perturbation growth. Results show that the capabilities of the computational methodology predict the amplitude growth to within 5 percent of the measured data, thus validating both the code and the strength models under the given conditions and setting the stage for credible future design work using different materials.

  14. The effect of welding on the strength of aluminium stiffened plates subject to combined uniaxial compression and lateral pressure

    NASA Astrophysics Data System (ADS)

    Pedram, Masoud; Khedmati, Mohammad Reza

    2014-03-01

    Nowadays aluminum stiffened plates are one of the major constituents of the marine structures, espe¬cially high-speed vessels. On one hand, these structures are subject to various forms of loading in the harsh sea envi¬ronment, like hydrostatic lateral pressures and in-plane compression. On the other hand, fusion welding is often used to assemble those panels. The common marine aluminum alloys in the both 5,000 and 6,000 series, however, lose a re¬markable portion of their load carrying capacity due to welding. This paper presents the results of sophisticated finite-element investigations considering both geometrical and mechanical imperfections. The tested models were those pro¬posed by the ultimate strength committee of 15th ISSC. The presented data illuminates the effects of welding on the strength of aluminum plates under above-mentioned load conditions.

  15. Investigation on the Explosive Welding of 1100 Aluminum Alloy and AZ31 Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Chen, Pengwan; Feng, Jianrui; Zhou, Qiang; An, Erfeng; Li, Jingbo; Yuan, Yuan; Ou, Sanli

    2016-07-01

    The undesirable properties of magnesium alloys include easy embrittlement, low oxidation resistance, and difficulty in welding with other materials. Their application in industry is, therefore, restricted. In this paper, plates of 1100 aluminum alloy and AZ31 magnesium alloy were successfully welded together using the explosive welding technique. The influences of the welding parameters on the weld quality were investigated. The surface morphology and microstructure near the weld interface were examined by optical microscopy, scanning electron microscopy (equipped with energy-dispersive x-ray spectroscopy), and transmission electron microscopy. The experimental results demonstrated the typical wavy bonding interface. In addition, elemental diffusion with a thickness of approximately 3 μm occurred near the bonding interface. The two plates were joined together well at the atomic scale. Nanograins with a size of approximately 5 nm were observed in the diffusion layer. The microhardness and shear strength were measured to evaluate the mechanical properties, which confirmed that a high quality of bonding was acquired.

  16. Investigation on the Explosive Welding of 1100 Aluminum Alloy and AZ31 Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Chen, Pengwan; Feng, Jianrui; Zhou, Qiang; An, Erfeng; Li, Jingbo; Yuan, Yuan; Ou, Sanli

    2016-06-01

    The undesirable properties of magnesium alloys include easy embrittlement, low oxidation resistance, and difficulty in welding with other materials. Their application in industry is, therefore, restricted. In this paper, plates of 1100 aluminum alloy and AZ31 magnesium alloy were successfully welded together using the explosive welding technique. The influences of the welding parameters on the weld quality were investigated. The surface morphology and microstructure near the weld interface were examined by optical microscopy, scanning electron microscopy (equipped with energy-dispersive x-ray spectroscopy), and transmission electron microscopy. The experimental results demonstrated the typical wavy bonding interface. In addition, elemental diffusion with a thickness of approximately 3 μm occurred near the bonding interface. The two plates were joined together well at the atomic scale. Nanograins with a size of approximately 5 nm were observed in the diffusion layer. The microhardness and shear strength were measured to evaluate the mechanical properties, which confirmed that a high quality of bonding was acquired.

  17. Welding Phenomenon and Removal Mechanism of Aluminum-Oxide Films by Space GHTA Welding Process in Vacuum

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Ekuni, Tomohide; Kamei, Misa; Tsukuda, Yoshiyuki; Terajima, Noboru; Yamashita, Masahiro; Imagawa, Kichiro; Masubuchi, Koichi

    Aluminum alloys have been widely used in constructing various space structures including the ISS (International Space Station) and launch vehicles. In order to apply the welding technology in space, welding experiments on aluminum alloy were performed using by the GHTA (Gas Hollow Tungsten Arc) welding processes using an inverter controlled DC/AC GTA welding machine in vacuum. We observed the removal mechanism of aluminum-oxide films on molten metal in detail during the welding using a high-speed video camera. As a result, it is clarified that the impact arc pressure produced by pulsed current mechanically crushes and removes aluminum-oxide films on the molten pool. This removal mechanism of aluminum-oxide films is completely different from a removal mechanism by cleaning action.

  18. Simulating weld-fusion boundary microstructures in aluminum alloys

    NASA Astrophysics Data System (ADS)

    Kostrivas, Anastasios D.; Lippold, John C.

    2004-02-01

    A fundamental study of weld-fusion boundary microstructure evolution in aluminum alloys was conducted in an effort to understand equiaxed grain zone formation and fusion boundary nucleation and growth phenomena. In addition to commercial aluminum alloys, experimental Mg-bearing alloys with Zr and Sc additions were studied along with the widely used Cu- and Licontaining alloy 2195-T8. This article describes work conducted to clarify the interrelation among composition, base metal substrate, and temperature as they relate to nucleation and growth phenomena at the fusion boundary.

  19. Microstructural characterization and mechanical properties of high power ultrasonic spot welded aluminum alloy AA6111–TiAl6V4 dissimilar joints

    SciTech Connect

    Zhang, C.Q. Robson, J.D.; Ciuca, O.; Prangnell, P.B.

    2014-11-15

    Aluminum alloy AA6111 and TiAl6V4 dissimilar alloys were successfully welded by high power ultrasonic spot welding. No visible intermetallic reaction layer was detected in as-welded AA6111/TiAl6V4 welds, even when transmission electron microscopy was used. The effects of welding time and natural aging on peak load and fracture energy were investigated. The peak load and fracture energy of welds increased with an increase in welding time and then reached a plateau. The lap shear strength (peak load) can reach the same level as that of similar Al–Al joints. After natural aging, the fracture mode of welds transferred from ductile fracture of the softened aluminum to interfacial failure due to the strength recovery of AA6111. - Highlights: • Dissimilar Al/Ti welds were produced by high power ultrasonic spot welding. • No visible intermetallic reaction layer was detected on weld interface. • The lap shear strength can reach the same level as that of similar Al–Al joints. • The fracture mode becomes interfacial failure after natural aging.

  20. Strength analysis of laser welded lap joint for ultra high strength steel

    NASA Astrophysics Data System (ADS)

    Jeong, Young Cheol; Kim, Cheol Hee; Cho, Young Tae; Jung, Yoon Gyo

    2013-12-01

    Several industries including the automotive industry have recently applied the process of welding high strength steel. High strength steel is steel that is harder than normal high strength steel, making it much stronger and stiffer. HSS can be formed in pieces that can be up to 10 to 15 percent thinner than normal steel without sacrificing strength, which enables weight reduction and improved fuel economy. Furthermore, HSS can be formed into complex shapes that can be welded into structural areas. This study is based on previous experiments and is aimed at establishing the stress distribution for laser welded high strength steel. Research on the stress distribution for laser welded high strength steel is conducted by using Solid Works, a program that analyzes the stress of a virtual model. In conclusion, we found that the stress distribution is changed depending on the shape of welded lap joint. In addition, the Influence of the stress distribution on welded high strength steel can be used to standard for high energy welding of high strength steel, and we can also predict the region in welded high strength steel that may cracked.

  1. Mechanical shielding reduces weld surface cracking in 6061 T6 aluminum

    NASA Technical Reports Server (NTRS)

    Hill, J. E.

    1968-01-01

    Mechanical shield of high melting point material protects 6061-T6 aluminum welded with high frequency ac tungsten arc equipment. It is held in place around the weld bead area and eliminates heat check cracks.

  2. Aluminum/steel wire composite plates exhibit high tensile strength

    NASA Technical Reports Server (NTRS)

    1966-01-01

    Composite plate of fine steel wires imbedded in an aluminum alloy matrix results in a lightweight material with high tensile strength. Plates have been prepared having the strength of titanium with only 85 percent of its density.

  3. Parametric studies on tensile strength in joining AA6061- T6 and AA7075-T6 by gas metal arc welding process

    NASA Astrophysics Data System (ADS)

    Ishak, M.; Noordin, N. F. M.; Shah, L. H.

    2015-12-01

    Proper selection of the welding parameters can result in better joining. In this study, the effects of various welding parameters on tensile strength in joining dissimilar aluminum alloys AA6061-T6 and AA7075-T6 were investigated. 2 mm thick samples of both base metals were welded by semi-automatic gas metal arc welding (GMAW) using filler wire ER5356. The welding current, arc voltage and welding speed were chosen as variables parameters. The strength of each specimen after the welding operations were tested and the effects of these parameters on tensile strength were identified by using Taguchi method. The range of parameter for welding current were chosen from 100 to 115 A, arc voltage from 17 to 20 V and welding speed from 2 to 5 mm/s. L16 orthogonal array was used to obtained 16 runs of experiments. It was found that the highest tensile strength (194.34 MPa) was obtained with the combination of a welding current of 115 A, welding voltage of 18 V and welding speed of 4 mm/s. Through analysis of variance (ANOVA), the welding voltage was the most effected parameter on tensile strength with percentage of contribution at 41.30%.

  4. Impact Welding of Aluminum to Copper and Stainless Steel by Vaporizing Foil Actuator: Effect of Heat Treatment Cycles on Mechanical Properties and Microstructure

    NASA Astrophysics Data System (ADS)

    Vivek, Anupam; Hansen, Steven; Benzing, Jake; He, Mei; Daehn, Glenn

    2015-10-01

    This work studies the mechanical property effect of microstructure on impact welds of aluminum alloy AA6061 with both copper alloy Cu 110 and stainless steel AISI 304. AA6061-T6 and T4 temper aluminum sheets of 1 mm thickness were launched toward copper and stainless steel targets using the vaporizing foil actuator technique. Flyer plate velocities, measured via photonic Doppler velocimetry, were observed to be approximately 800 m/s. The welded aluminum-copper samples were subjected to instrumented peel testing, microhardness testing, energy-dispersive X-ray spectroscopy, and scanning electron microscopy. The welded joints exhibited cracks through their continuous intermetallic layers. The cracks were impeded upon encountering a ductile metallic wave. The welds created with T6 temper flyer sheets were found to have smaller intermetallic-free and wavy interface regions as compared to those created with T4 temper flyer sheets. Peel strength tests of the two weld combinations resulted in failure along the interface in the case of the T6 flyer welds, while the failure generally occurred in the parent aluminum for the T4 temper flyer welds. Half of the T4 flyer welds were subjected to aging for 18 h at 433 K (160 °C) to convert the aluminum sheet to the T6 condition. Although the aged flyer material did not attain the hardness of the as-received T6 material, it was found to be significantly stronger than the T4 material. These welds retained their strength after the aging process, and diffusion across the interface was minimal. The welded aluminum-stainless steel samples were analyzed on a more basic level than aluminum-copper samples, but were found to exhibit similar results.

  5. High Temperature Analysis of Aluminum-Lithium 2195 Alloy to Aid in the Design of Improved Welding Techniques

    NASA Technical Reports Server (NTRS)

    Talia, George E.; Widener, Christian

    1996-01-01

    Aluminum-lithium alloys have extraordinary properties. The addition of lithium to an aluminum alloy decreases its density, while making large increases in its strength and hardness. The down side is that they are unstable at higher temperatures, and are subsequently difficult to weld or even manufacture. Martin Marietta, though, developed an aluminum-lithium alloy 2195 that was reported to have exceptional properties and good weldability. Thus, it was chosen as the alloy for the space shuttles super light external tank. Unfortunately, welding 2195 has turned out to be much more of a challenge than anticipated. Thus, research has been undergone in order to understand the mechanisms that are causing the welding problems. Gas reactions have been observed to be detrimental to weld strength. Water vapor has often been identified as having a significant role in these reactions. Nitrogen, however, has also been shown to have a direct correlation to porosity. These reactions were suspected as being complex and responsible for the two main problems of welding 2195. One, the initial welds of 2195 are much weaker than the parent metal. Second, each subsequent welding pass increases the size and number of cracks and porosity, yielding significant reductions in strength. Consequently, the objective of this research was to characterize the high-temperature reactions of 2195 in order to understand the mechanisms for crack growth and the formation of porosity in welds. In order to accomplish that goal, an optical hot-stage microscope, HSM, was used to observe those reactions as they occurred. Surface reactions of 2195 were observed in a variety of environments, such as air, vacuum, nitrogen and helium. For comparison, some samples of Al-2219 were also observed. Some of the reacted surfaces were then analyzed on a scanning electron microscope, SEM. Additionally, a gas chromatograph was used to analyze the gaseous products of the high temperature reactions.

  6. Neutron diffraction studies of welds of aerospace aluminum alloys

    SciTech Connect

    Martukanitz, R.P.; Howell, P.R.; Payzant, E.A.; Spooner, S.; Hubbard, C.R.

    1996-10-01

    Neutron diffraction and electron microscopy were done on residual stress in various regions comprising variable polarity plasma arc welds of alloys 2219 (Al-6.3Cu) and 2195 (Al-4.0Cu-1.0Li-0.5Mg-0.5Ag). Results indicate that lattice parameter changes in the various weld regions may be attributed to residual stresses generated during welding, as well as local changes in microstructure. Distribution of longitudinal and transverse stress of welded panels shows peaks of tension and compression, respectively, within the HAZ and corroborate earlier theoretical results. Position of these peaks are related to position of minimum strength within the HAZ, and the magnitude of these peaks are a fraction of the local yield strength in this region. Weldments of alloy 2195-T8 exhibited higher peak residual stress than alloy 2219-T87. Comparison of neutron diffraction and microstructural analysis indicate decreased lattice parameters associated with the solid solution of the near HAZ; this results in decreased apparent tensile residual stress within this region and may significantly alter interpretation of residual stress measurements of these alloys. Considerable relaxation of residual stress occurs during removal of specimens from welded panels and was used to aid in differentiating changes in lattice parameters attributed to residual stress from welding and modifications in microstructure.

  7. Investigation of the Microstructure of Joints of Aluminum Alloys Produced by Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Kolubaev, E. A.

    2015-02-01

    Special features of the microstructure of joints of aluminum-magnesium and aluminum-copper alloys produced by friction stir welding are analyzed. It is demonstrated that a layered structure with ultradisperse grains is produced by friction stir welding at the center of the weld joint. An analogy is drawn between the microstructures of joints produced by friction stir welding and surface layer produced by sliding friction.

  8. Application of slip-band visualization technique to tensile analysis of laser-welded aluminum alloy

    NASA Astrophysics Data System (ADS)

    Muchiar, -; Yoshida, Sanichiro J.; Widiastuti, Rini; Kusnowo, A.; Takahashi, Kunimitsu; Sato, Shunichi

    1997-03-01

    Recently we have developed a new optical interferometric technique capable of visualizing slip band occurring in a deforming solid-state object. In this work we applied this technique to a tensile analysis of laser-welded aluminum plate samples, and successfully revealed stress concentration that shows strong relationships with the tensile strength and the fracture mechanism. We believe that this method is a new, convenient way to analyze the deformation characteristics of welded objects and evaluate the quality of welding. The analysis has been made for several types of aluminum alloys under various welding conditions, and has shown the following general results. When the penetration is deep, a slip band starts appearing at the fusion zone in an early stage of the elastic region of the strain-stress curve and stays there till the sample fractures at that point. When the penetration is shallow, a slip band appears only after the yield point and moves vigorously over the whole surface of the sample till a late stage of plastic deformation when the slip band stays at the fusion zone where the sample eventually fractures. When the penetration depth is medium, some intermediate situation of the above two extreme cases is observed.

  9. Effect of zirconium addition on welding of aluminum grain refined by titanium plus boron

    NASA Astrophysics Data System (ADS)

    Zaid, A. I. O.

    2014-06-01

    Aluminum oxidizes freely in ordinary atmosphere which makes its welding difficult and weak, particularly it solidifies in columnar structure with large grains. Therefore, it is anticipated that the effect of addition of some grain refiners to its melt before solidification is worth while investigating as it may enhance its weldabilty and improve its mechanical strength. In this paper, the effect of addition of zirconium at a weight of 0.1% (which corresponds to the peretictic limit on the aluminum-zirconium base phase diagram) to commercially pure aluminum, grain refined by Ti+B on its weldability, using gas tungsten arc welding, GTAW, method which was formerly known as TIG. A constant current level of 30 AC Ampere was used because it removes the oxides during the welding process. Metallographic examination of the weldments of the different combinations of Al with Al and Al with its microalloys: in the heat affected zone, HAZ, and away from it was carried out and examined for HAZ width, porosity, cracks and microhardness. It was found that grain refining by Ti+B or Zr resulted in enhancement of the weldment.

  10. Ultrasonic assessment of tension shear strength in resistance spot welding

    NASA Astrophysics Data System (ADS)

    Moghanizadeh, Abbas

    2015-05-01

    Resistance spot welding is extensively used to join sheet steel in the automotive industry. Ultrasonic non-destructive techniques for evaluation of the mechanical properties of resistance spot welding are presented. The aim of this study is to develop the capability of the ultrasonic techniques as an efficient tool in the assessment of the welding characterization. Previous researches have indicated that the measurements of ultrasonic attenuation are sensitive to grain- size variations in an extensive range of metallic alloys. Other researchers have frequently described grain sizes which are able to have significant effects on the physical characteristics of the material. This research provides a novel method to estimate the tension-shear strengths of the resistance spot welding directly from the ultrasonic attenuation measurements. The effects of spot welding parameters on the ultrasonic waves are further investigated. The results confirm that it is possible to determine the spot welding parameters for individual quality by using ultrasonic test.

  11. Effects of conventional welding and laser welding on the tensile strength, ultimate tensile strength and surface characteristics of two cobalt-chromium alloys: a comparative study.

    PubMed

    Madhan Kumar, Seenivasan; Sethumadhava, Jayesh Raghavendra; Anand Kumar, Vaidyanathan; Manita, Grover

    2012-06-01

    The purpose of this study was to evaluate the efficacy of laser welding and conventional welding on the tensile strength and ultimate tensile strength of the cobalt-chromium alloy. Samples were prepared with two commercially available cobalt-chromium alloys (Wironium plus and Diadur alloy). The samples were sectioned and the broken fragments were joined using Conventional and Laser welding techniques. The welded joints were subjected to tensile and ultimate tensile strength testing; and scanning electron microscope to evaluate the surface characteristics at the welded site. Both on laser welding as well as on conventional welding technique, Diadur alloy samples showed lesser values when tested for tensile and ultimate tensile strength when compared to Wironium alloy samples. Under the scanning electron microscope, the laser welded joints show uniform welding and continuous molt pool all over the surface with less porosity than the conventionally welded joints. Laser welding is an advantageous method of connecting or repairing cast metal prosthetic frameworks. PMID:23858281

  12. Friction Stir Spot Welding of Advanced High Strength Steels

    SciTech Connect

    Santella, Michael L; Hovanski, Yuri; Grant, Glenn J; Frederick, D Alan; Dahl, Michael E

    2009-02-01

    Friction stir spot welding was used to join two advanced high-strength steels using polycrystalline cubic boron nitride tooling. Numerous tool designs were employed to study the influence of tool geometry on weld joints produced in both DP780 and a hot-stamp boron steel. Tool designs included conventional, concave shouldered pin tools with several pin configurations; a number of shoulderless designs; and a convex, scrolled shoulder tool. Weld quality was assessed based on lap shear strength, microstructure, microhardness, and bonded area. Mechanical properties were functionally related to bonded area and joint microstructure, demonstrating the necessity to characterize processing windows based on tool geometry.

  13. Friction Stir Spot Welding of Advanced High Strength Steels

    SciTech Connect

    Hovanski, Yuri; Santella, M. L.; Grant, Glenn J.

    2009-12-28

    Friction stir spot welding was used to join two advanced high-strength steels using polycrystalline cubic boron nitride tooling. Numerous tool designs were employed to study the influence of tool geometry on weld joints produced in both DP780 and a hot-stamp boron steel. Tool designs included conventional, concave shouldered pin tools with several pin configurations; a number of shoulderless designs; and a convex, scrolled shoulder tool. Weld quality was assessed based on lap shear strength, microstructure, microhardness, and bonded area. Mechanical properties were functionally related to bonded area and joint microstructure, demonstrating the necessity to characterize processing windows based on tool geometry.

  14. Structure-property relationships of dissimilar friction stir welded aluminum alloys

    NASA Astrophysics Data System (ADS)

    Quinones, Rogie Irwin Rodriguez

    In this work, the relationship between microstructure and mechanical properties of dissimilar friction stir welded AA6061-to-AA7050 aluminum alloys were evaluated. Experimental results from this study revealed that static strength increased with the tool rotational speed and was correlated with the material intermixing. Fully-reversed low cycle fatigue experimental results showed an increase in the strain hardening properties as well as the number of cycles-to-failure as the tool rotational speed was increased. Furthermore, under both static and cyclic loading, fracture of the joint was dominated by the AA6061 alloy side of the weld. In addition, inspection of the fatigue surfaces revealed that cracks initiated from intermetallic particles located near the surface. In order to determine the corrosion resistance of the dissimilar joint, corrosion defects were produced on the crown surface of the weld by static immersion in 3.5% NaCl for various exposure times. Results revealed localized corrosion damage in the thermo-mechanically affected and heat affected zones. Results demonstrated a decrease in the fatigue life, with evidence of crack initiation at the corrosion defects; however, the fatigue life was nearly independent of the exposure time. This can be attributed to total fatigue life dominated by incubation time. Furthermore, two types of failure were observed: fatigue crack initiation in the AA6061 side at high strain amplitudes (>0.3%); and fatigue crack initiation in the AA7050 side at low strain amplitudes (<0.2%). Lastly, a microstructure-sensitive model based on a multi-stage fatigue damage concept was extended to the dissimilar friction stir welded joints in order to capture the crack initiation and propagation in as-welded and pre-corroded conditions. Good correlation between experimental fatigue results and the model was achieved based on the variation in the initial defect size, microstructure, and mechanical properties of the dissimilar friction stir

  15. The effect of postprocessing on tensile property and microstructure evolution of friction stir welding aluminum alloy joint

    SciTech Connect

    Hu, Z.L.; Wang, X.S.; Pang, Q.; Huang, F.; Qin, X.P.; Hua, L.

    2015-01-15

    Friction stir welding is an efficient manufacturing method for joining aluminum alloy and can dramatically reduce grain size conferring excellent plastic deformation properties. Consequently, friction stir welding is used to manufacture tailor welded blanks to optimize weight or performance in the final component. In the study, the microstructural evolution and mechanical properties of friction stir welding joint during plastic forming and subsequent heat treatment were investigated. The microstructural characteristics of the friction stir welding joints were studied by Electron Backscattered Diffraction and Transmission Electron Microscopy. The mechanical properties were evaluated by tensile and microhardness tests. It is found that the tensile and yield strengths of friction stir welding joints are significantly improved after severe plastic deformation due to the grain refinement. Following heat treatment, the strength of the friction stir welding joints significantly decrease due to the obvious abnormal grain growth. Careful attention must be given to the processing route of any friction stir welding joint intended for plastic forming, especially the annealing between forming passes. Severe plastic deforming of the friction stir welding joint leads to a high level of stored energy/dislocation density, which causes the abnormal grain growth during subsequent heat treatment, and consequently reduce the mechanical properties of the friction stir welding joint. - Highlights: • Great changes are observed in the microstructure of FSW joint after postprocessing. • Postprocessing shows great effect on the microstructure stability of FSW joint. • The weld shows more significant decrease in strength than the BM due to the AGG. • Attention must be given to the processing route of FSW joint for plastic forming.

  16. Role of the micro/macro structure of welds in crack nucleation and propagation in aerospace aluminum-lithium alloy

    SciTech Connect

    Talia, G.E.

    1996-02-01

    Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. (1) In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.

  17. Role of the micro/macro structure of welds in crack nucleation and propagation in aerospace aluminum-lithium alloy

    NASA Technical Reports Server (NTRS)

    Talia, George E.

    1996-01-01

    Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds [1]. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. [1] In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.

  18. TIG welding of aluminum alloys for the APS storage ring - a UHV application

    SciTech Connect

    Goeppner, G.A.

    1996-05-29

    The Advanced Photon Source (APS) incorporates a 7-GeV positron storage ring 1104 meters in circumference. The storage ring vacuum system is designed to maintain a pressure of 1 nTorr or less with a circulating current of 300 mA to enable beam lifetimes of greater than 10 hours. The vacuum chamber is an aluminum extrusion of 6063T5 alloy. There are 235 separate aluminum vacuum chambers in the storage ring connected by stainless steel bellows assemblies. Aluminum was chosen for the vacuum chamber because it can be economically extruded and machined, has good thermal conductivity, low thermal emissivity, a low outgassing rate, low residual radioactivity, and is non-magnetic. The 6063 aluminum-silicon-magnesium alloy provides high strength combined with good machining and weldability characteristics. The extrusion process provides the interior surface finish needed for the ultrahigh vacuum (UHV) environments There are six different vacuum chambers with the same extrusion cross section. The average vacuum chamber length is 171.6 inches. The extruded vacuum chambers are welded to flange assemblies made up of machined 2219 aluminum alloy pieces and 2219 aluminum vacuum flanges from a commercial source.

  19. Mechanical strength of laser-welded cobalt-chromium alloy.

    PubMed

    Baba, N; Watanabe, I; Liu, J; Atsuta, M

    2004-05-15

    The purpose of this study was to investigate the effect of the output energy of laser welding and welding methods on the joint strength of cobalt-chromium (Co-Cr) alloy. Two types of cast Co-Cr plates were prepared, and transverse sections were made at the center of the plate. The cut surfaces were butted against one another, and the joints welded with a laser-welding machine at several levels of output energy with the use of two methods. The fracture force required to break specimens was determined by means of tensile testing. For the 0.5-mm-thick specimens, the force required to break the 0.5-mm laser-welded specimens at currents of 270 and 300 A was not statistically different (p > 0.05) from the results for the nonwelded control specimens. The force required to break the 1.0-mm specimens double-welded at a current of 270 A was the highest value among the 1.0-mm laser-welded specimens. The results suggested that laser welding under the appropriate conditions improved the joint strength of cobalt- chromium alloy. PMID:15116400

  20. High Strength and Compatible Aluminum Alloy for Hydrogen-Peroxide Fuel Tanks

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2004-01-01

    This paper describes the development of a new high strength and Hydrogen Peroxide (HP) propellant compatible aluminum alloy for NASA Hyper-X vehicle's fuel tanks and structures. The tensile strength of the new alloy is more than 3 times stronger than the conventional 5254 alloy while it still maintains HP compatibility similar to 5254 (Class 1 category). The alloy development strategy consists of selecting certain rare earth and transition metals, with unique electrochemical properties, that will not act as catalysts to decompose liquid HP at the atomic level. Such elements will added to the aluminum alloy and the mixture will be cast and rolled into thin sheet metals. Test coupons are machined from sheet metals for HP long-term exposure testing and mechanical properties testing. In addition, the ability to weld the new alloy using Friction Stir Welding has also been explored. Currently, aluminum alloy 5254 is the state-of-the-art material for HP storage, but its yield strength is very low (420 ksi) and may not be suitable for the development of light-weight fuel tanks for Hyper-X vehicles. The new high strength and HP compatible alloy could represent an enabling material technology for NASA's Hyper-X vehicles, where flight weight reduction is a critical requirement. These X-planes are currently under studied as air-breathing hypersonic research vehicles featuring a lifting body configuration with a Rocket Based Combined Cycle (RBCC) engine system.

  1. High strength cast aluminum alloy development

    NASA Astrophysics Data System (ADS)

    Druschitz, Edward A.

    The goal of this research was to understand how chemistry and processing affect the resulting microstructure and mechanical properties of high strength cast aluminum alloys. Two alloy systems were investigated including the Al-Cu-Ag and the Al-Zn-Mg-Cu systems. Processing variables included solidification under pressure (SUP) and heat treatment. This research determined the range in properties that can be achieved in BAC 100(TM) (Al-Cu micro-alloyed with Ag, Mn, Zr, and V) and generated sufficient property data for design purposes. Tensile, stress corrosion cracking, and fatigue testing were performed. CuAl2 and Al-Cu-Fe-Mn intermetallics were identified as the ductility limiting flaws. A solution treatment of 75 hours or longer was needed to dissolve most of the intermetallic CuAl 2. The Al-Cu-Fe-Mn intermetallic was unaffected by heat treatment. These results indicate that faster cooling rates, a reduction in copper concentration and a reduction in iron concentration might increase the ductility of the alloy by decreasing the size and amount of the intermetallics that form during solidification. Six experimental Al-Zn-Mg-Cu series alloys were produced. Zinc concentrations of 8 and 12wt% and Zn/Mg ratios of 1.5 to 5.5 were tested. Copper was held constant at 0.9%. Heat treating of the alloys was optimized for maximum hardness. Al-Zn-Mg-Cu samples were solution treated at 441°C (826°F) for 4 hours before ramping to 460°C (860°F) for 75 hours and then aged at 120°C (248°F) for 75 hours. X-ray diffraction showed that the age hardening precipitates in most of these alloys was the T phase (Mg32Zn 31.9Al17.1). Tensile testing of the alloys showed that the best mechanical properties were obtained in the lowest alloy condition. Chilled Al-8.2Zn-1.4Mg-0.9Cu solidified under pressure resulted in an alloy with a yield strength of 468MPa (68ksi), tensile strength of 525MPa (76ksi) and an elongation of 9%.

  2. Laser welding aluminum without filler metal using continuous wave and pulsed Nd:YAG lasers

    SciTech Connect

    Bransch, H.N.

    1994-12-31

    A problem with automotive aluminum tubing applications, particularly for air conditioning heat exchanger assemblies, is terminating the tube reliably and inexpensively. An alternative to upsetting and mchining threads to the tube end is welding a nut (made from a stronger, easily machinable alloy such as Al 5456 or Al 6061) to lengths of tubing (made from a softer alloy such as Al 3003). Laser welding was investigated in order to reduce heat input and increase process speeds copared to brazing or gas metal arc welding (GMAW). Nd:YAG lasers were selected as beam source because of better absorptivity of the wavelength compared to CO{sub 2} lasers and simplified tooling with fiber optic beam delivery. It wa determined that a pulsed Nd:YAG laser produced 1.0 mm penetration at 0.3 m/min with 400 W average power, and 1.0 mm penetration at 0.75 m/min with 1000 W average power, however, an Al 4047 filler metal was required to eliminate solidification cracking. A 1900 W CW laser could weld the Al 3003 tube to the Al 5456 nut without filler metal, however, there was insufficient penetration (0.25 mm) to meet the mechanical and hermeticity requirements. To enhance penetration, but still reduce the tendency for hot cracking, the 1900 W average power beam was sine wave modulated from 400 W to 3600 W at 250 Hz and usd to weld the Al 3003 directly to the Al 5456. These parameters produced 1.2 mm penetration at 1.2 m/min without significant cracking and without using a filler metal. In addition, the welds passed all hermeticity and tensile strength tests. This combination of materials, joint design, and laser parameters produced tube assemblies that passed a leak check (300 psi nitrogen in 60{degrees}C water for 1 min) and tensile (tube breakage 100 mm from the joint, 5.2 kN tensile strength).

  3. Strength of Welded Joints in Tubular Members for Aircraft

    NASA Technical Reports Server (NTRS)

    Whittemore, H L; Brueggeman, W C

    1931-01-01

    The object of this investigation is to make available to the aircraft industry authoritative information on the strength, weight, and cost of a number of types of welded joints. This information will, also, assist the aeronautics branch in its work of licensing planes by providing data from which the strength of a given joint may be estimated. As very little material on the strength of aircraft welds has been published, it is believed that such tests made by a disinterested governmental laboratory should be of considerable value to the aircraft industry. Forty joints were welded under procedure specifications and tested to determine their strengths. The weight and time required to fabricate were also measured for each joint.

  4. Joining aluminum to titanium alloy by friction stir lap welding with cutting pin

    SciTech Connect

    Wei, Yanni; Li, Jinglong; Xiong, Jiangtao; Huang, Fu; Zhang, Fusheng; Raza, Syed Hamid

    2012-09-15

    Aluminum 1060 and titanium alloy Ti-6Al-4V plates were lap joined by friction stir welding. A cutting pin of rotary burr made of tungsten carbide was employed. The microstructures of the joining interface were observed by scanning electron microscopy. Joint strength was evaluated by a tensile shear test. During the welding process, the surface layer of the titanium plate was cut off by the pin, and intensively mixed with aluminum situated on the titanium plate. The microstructures analysis showed that a visible swirl-like mixed region existed at the interface. In this region, the Al metal, Ti metal and the mixed layer of them were all presented. The ultimate tensile shear strength of joint reached 100% of 1060Al that underwent thermal cycle provided by the shoulder. - Highlights: Black-Right-Pointing-Pointer FSW with cutting pin was successfully employed to form Al/Ti lap joint. Black-Right-Pointing-Pointer Swirl-like structures formed due to mechanical mixing were found at the interface. Black-Right-Pointing-Pointer High-strength joints fractured at Al suffered thermal cycle were produced.

  5. Friction stir welding of thin-sheet, age-hardenable aluminum alloys: A study of process/structure/property relationships

    NASA Astrophysics Data System (ADS)

    Shukla, Alpesh Khushalchand

    Friction Stir Welding (FSW) is a relatively new joining process that, as a solid-state process, offers several advantages over conventional fusion welding. Although FSW has been used extensively for the joining of age-hardenable aluminum alloys, the detailed effects of process parameters on the microstructures and mechanical properties of these welds have not been studied, especially for thin-sheet alloys. The present study investigated the FSW of thin-sheet, age-hardenable aluminum alloys, including: the development and optimization of welding process parameters that produce high-integrity, defect-free welds; the systematic evaluation of the effect of the base metal microstructure, FSW process parameters, and corresponding weld zone thermal conditions on microstructure evolution across the weld zone; the analysis of FSW mechanical properties and fracture behavior; and the development of relationships between the process parameters, microstructure, properties, and fracture that allow the optimization of weld performance. Two alloy systems, viz., Al-Cu-Mg (2024) and Al-Cu-Li (2195) in naturally-aged and artificially-aged conditions, respectively, were studied. Process optimization in 1 mm thick 2024-T3 sheet resulted in superior properties versus those of FS welds in thick sheet and plate, and nearly 100% joint efficiency. Microstructures, hardness and tensile properties of FS welds in 2024-T3 exhibited a strong dependency on process parameters. The heat of welding promoted various weld zone microstructures that were produced via the dissolution of base metal GPB zones, the nucleation of GBP and GPB II, and the nucleation and coarsening of S phase. SZ hardness for 2024-T3 welds exhibited a strong, but unusual dependency on the FSW process parameters, which was related to different mechanisms related to GPB zone formation. The microstructures of FS welds in 1 mm thick 2195-T8 were generally insensitive to the FSW process parameters. For all weld heat inputs, FSW

  6. Precipitate evolution in friction stir welding of 2219-T6 aluminum alloys

    SciTech Connect

    Chen, Y.C.; Feng, J.C.; Liu, H.J.

    2009-06-15

    Precipitate evolution in friction stir welding of 2219-T6 aluminum alloys was characterized by transmission electron microscopy. In the weld nugget zone and the thermo-mechanically affected zone some metastable precipitates overaged to equilibrium phase while others solutionized into the aluminum solid solution. In the heat-affected zone the precipitates coarsened.

  7. Investigation of Strength Recovery in Welds of NUCu-140 Steel Through Multipass Welding and Isothermal Post-Weld Heat Treatments

    NASA Astrophysics Data System (ADS)

    Bono, Jason T.; DuPont, John N.; Jain, Divya; Baik, Sung-Il; Seidman, David N.

    2015-11-01

    NUCu-140 is a ferritic copper precipitation-strengthened steel that is a candidate material for use in many naval and structural applications. Previous work has shown that the heat-affected zone (HAZ) and fusion zone (FZ) of NUCu-140 exhibit softening that is due to dissolution of the copper-rich precipitates. This study aims to recover the FZ and HAZ strength by re-precipitation of the copper-rich precipitates through either multiple weld passes or an isothermal post-weld heat treatment (PWHT). The potential use of multiple thermal cycles was investigated with HAZ simulations using a Gleeble thermo-mechanical simulator. The HAZ simulations represented two weld thermal cycles with different combinations of peak temperatures during the initial and secondary weld passes. To investigate the potential for a PWHT for strength recovery, gas tungsten arc weld samples were isothermally heated for various times and temperatures. Microhardness measurements revealed no strength recovery in the multipass HAZ samples. The time-dependent precipitate characteristics were modeled under the HAZ thermal cycle conditions, and the results showed that the lack of strength recovery could be attributed to insufficient time for re-precipitation during the secondary weld pass. Conversely, full strength recovery in the HAZ was observed in the isothermally heat treated samples. Atom probe tomography analysis correlated this strength recovery to re-precipitation of the copper-rich precipitates during the isothermal PWHT.

  8. Laser Overlap Welding of Zinc-coated Steel on Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Kashani, Hamed Tasalloti; Kah, Paul; Martikainen, Jukka

    Local reinforcement of aluminum with laser welded patches of zinc-coated steel can effectively contribute to crashworthiness, durability and weight reduction of car body. However, the weld between Zn-coated steel and aluminum is commonly susceptible to defects such as spatter, cavity and crack. The vaporization of Zn is commonly known as the main source of instability in the weld pool and cavity formation, especially in a lap joint configuration. Cracks are mainly due to the brittle intermetallic compounds growing at the weld interface of aluminum and steel. This study provides a review on the main metallurgical and mechanical concerns regarding laser overlap welding of Zn-coated steel on Al-alloy and the methods used by researchers to avoid the weld defects related to the vaporization of Zn and the poor metallurgical compatibility between steel and aluminum.

  9. Microprobe investigation of brittle segregates in aluminum MIG and TIG welds

    NASA Technical Reports Server (NTRS)

    Larssen, P. A.; Miller, E. L.

    1968-01-01

    Quantitative microprobe analysis of segregated particles in aluminum MIG /Metal Inert Gas/ and TIG /Tungsten Inert Gas/ welds indicated that there were about ten different kinds of particles, corresponding to ten different intermetallic compounds. Differences between MIG and TIG welds related to the individual cooling rates of these welds.

  10. Does bipolar electrocoagulation time affect vessel weld strength?

    PubMed Central

    Harrison, J D; Morris, D L

    1991-01-01

    The value of the bipolar electrocoagulator in the haemostasis of bleeding ulcers is controversial. We have therefore investigated the effect of different coagulation times on vessel weld strength achieved by the bipolar device. Welds were then made in vessels of known diameter using a standard 10F endoscopic haemostatic probe at coagulation times of two and 20 seconds. The intravascular temperature achieved at each time was measured. Vessel weld strength achieved by bipolar electrocoagulation was much greater at 20 seconds (approximately twice that at two seconds) and was highly significantly greater at all vessel diameters. There was a gradual reduction in weld strength with increasing vessel diameter, an effect that was seen for both two and 20 seconds of electrocoagulation. Intravascular temperature was significantly higher at 20 seconds than at two seconds. We conclude that vessel weld strength is related to coagulation time and that any future studies comparing the bipolar electrocoagulator with other haemostatic devices should use longer periods of bipolar electrocoagulation and record the coagulation time in order to optimise the clinical value of the device. PMID:1864540

  11. Optimizing the parameters for laser beam welding of aluminum-lithium alloy 2195

    SciTech Connect

    Jan, R.; Howell, P.R.; Martukanitz, R.P.

    1996-12-31

    Aluminum-lithium alloy 2195 is of considerable interest in the aerospace industry because of its high strength, high stiffness, and low density. Laser processing of this material offers potential advantages in processing speed and material cost savings. An investigation was conducted to determine the effect of laser beam process and material parameters on weld characteristics. The issues addressed were coupling efficiency, process stability, solidification cracking, and strengthening mechanisms. The results indicated that coupling of a laser beam with aluminum alloys is enhanced by lithium additions; and process stability and crack sensitivity is improved when using a defocused laser beam and silicon-rich filler alloys. In addition, the fusion zone exhibits a high degree of solute partitioning but not strengthening precipitates.

  12. The Strength of the Metal. Aluminum Oxide Interface

    NASA Technical Reports Server (NTRS)

    Pepper, S. V.

    1984-01-01

    The strength of the interface between metals and aluminum oxide is an important factor in the successful operation of devices found throughout modern technology. One finds the interface in machine tools, jet engines, and microelectronic integrated circuits. The strength of the interface, however, should be strong or weak depending on the application. The diverse technological demands have led to some general ideas concerning the origin of the interfacial strength, and have stimulated fundamental research on the problem. Present status of our understanding of the source of the strength of the metal - aluminum oxide interface in terms of interatomic bonds are reviewed. Some future directions for research are suggested.

  13. Textures in Single-Crystal Aluminum Friction Stir Spot Welds

    NASA Astrophysics Data System (ADS)

    Shibayanagi, Toshiya; Gerlich, Adrian P.; Kashihara, Keizo; North, Thomas H.

    2009-04-01

    The present article examines the textural features produced during friction stir spot welding of single-crystal aluminum sheet. The crystal has the {111} plane perpendicular to the normal direction (ND) of the sheet, and the left< { 1 10} rightrangle direction parallel to the growth direction (GD). Friction stir spot welding was carried out using a rotation speed of 1500 rpm and a dwell time of 2 seconds, and completed spot welds were characterized using a combination of optical microscopy and electron backscatter diffraction (EBSD). The EBSD measurements indicate there are no significant changes in orientation in locations more than 840 μm from the stir-zone extremity. The orientation distribution in the thermomechanically-affected zone (TMAZ) region conformed with the {110}⊥ND orientation within 580 μm of the stir-zone extremity. In the location immediately adjacent to the stir-zone extremity, there was a deviation from the {110}//ND orientation due to a combination of compressive loading perpendicular to the stir-zone boundary and shear loading in the direction of tool rotation. It is suggested a {111}⊥ND texture in the stir zone is associated with material flow imposed by the thread on the rotating pin.

  14. Radiographic detection of defects in friction stir welding on aluminum alloy AMg5M

    SciTech Connect

    Tarasov, Sergei Yu. Kolubaev, Evgeny A.; Rubtsov, Valery E.

    2014-11-14

    In order to reveal weld defects specific to friction stir welding we undertook radiographic inspection of AMg5M aluminum alloy welded joints. Weld defects in the form of voids have been revealed in the weld obtained under the non-optimal rotation and feed rate. Both shape and size of these defects have been confirmed by examining metallographically successive sections prepared in the weld plane as well as in the plane transversal to the tool feed direction. Linear defects have been also found in the sections that are not seen in the radiographic images. Both the preferable localization and origination of the defects have been analyzed.

  15. The effects of microstructure on MIC susceptibility in high strength aluminum alloys

    SciTech Connect

    Walsh, D.W.

    1999-11-01

    Aluminum alloys, and in particular Al-Li-Cu alloys are attractive to the aerospace industry. The high specific strength and stiffness of these alloys will improve lift efficiency, fuel economy, performance and increase payload capabilities of air and spacecraft. The objectives of this work were to examine the corrosion behavior of Al 2195 (UNS A92195) (Al-4Cu-1Li) and to assess the effect of welding on corrosion behavior in biologically active and in sterile waters. Al 2219 (UNS A922 19) samples were used in parallel tests to provide a baseline for the data generated. In this study samples were exposed to mild corrosive water solutions in both the as received and as welded conditions. The results of the study indicate exposure to biologically active solutions increases the corrosion rate. In addition, welding increases the corrosion rate in both Al 2195 and Al 2219, and causes severe localization in Al 2195. Furthermore, autogenously welded Al 2195 samples were more susceptible to attack than heterogeneously welded Al 2195 samples. Heterogeneously welded samples in both materials also had high corrosion rates, but only the Al 2195 material was subject to localization of attack. The partially melted zones of Al 2195 samples were subject to severe, focused attack. In Al 2219, interdendritic constituents in welded areas and intergranular constituents in base material were cathodic to the Al rich matrix materials. In Al 2195, some interdendritic constituents in welded areas and intergranular constituents in base material were anodic to the Al rich matrix materials. Corrosion resistance was correlated to material microstructure using optical microscopy, scanning electron microscopy, electron probe microanalysis and polarization resistance.

  16. Characteristics of laser beam welds of age-hardenable 6061-T6 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Hirose, Akio; Kobayashi, Kojiro F.

    2003-03-01

    Laser beam welding is attractive for joining age-hardenable aluminum alloys, because its low over-all heat input results in a narrow weld heat affected zone (HAZ), where softening caused by dissolution of age precipitates occurs. In the present work, 1mm-thick 6061-T6 aluminum alloy plates were welded using a 2.5 kW CO2 laser and it was experimentally proved that the width of the softened region in the laser beam weld was less than 1/7 that of a TIG weld. Moreover the hardness in the softened region of the laser beam weld was found to be almost fully recovered to the base metal hardness by applying a post-weld aging treatment at 443 K for 28.8 ks without solution annealing unlike the TIG weld. These results characterize the advantage of laser beam welding in joining of the age-hardenable aluminum alloy as compared with the conventional arc welding. The hardness distributions in the HAZ were theoretically evaluated based on kinetic equations describing the dissolution of hardening β' (Mg2Si) precipitates and the precipitation of non-hardening β' (Mg2Si) precipitates during the weld thermal cycles to quantitatively prove above mentioned advantageous characteristics of laser beam welding.

  17. High Strength Stainless Steel Properties that Affect Resistance Welding

    SciTech Connect

    Kanne, W.R.

    2001-08-01

    This report discusses results of a study on selected high strength stainless steel alloy properties that affect resistance welding. The austenitic alloys A-286, JBK-75 (Modified A-286), 21-6-9, 22-13-5, 316 and 304L were investigated and compared. The former two are age hardenable, and the latter four obtain their strength through work hardening. Properties investigated include corrosion and its relationship to chemical cleaning, the effects of heat treatment on strength and surface condition, and the effect of mechanical properties on strength and weldability.

  18. Tensile Strength of Welded Steel Tubes : First Series of Experiments

    NASA Technical Reports Server (NTRS)

    Rechtlich, A

    1928-01-01

    The purpose of the experiments was to determine the difference in the strength of steel tubes welded by different methods, as compared with one another and also with unwelded, unannealed tubes, including; moreover, a comparison of the results obtained by experienced and inexperienced welders.

  19. The Mechanical Behavior of Friction-Stir Spot Welded Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Güler, Hande

    2014-09-01

    Aluminum and alloys are widely used in the automotive industry due to the light weight, good formability, and malleability. Spot welding is the most commonly used joining method of these materials, but the high current requirements and the inconsistent quality of the final welds make this process unsuitable. An alternative welding technique, the friction-stir spot welding process, can also be successfully used in joining of aluminum and alloys. In this study, 1-mm-thick AA5754 Al-alloy plates in the H-111 temper conditions were joined by friction-stir spot welding using two different weld parameters such as tool rotational speed and dwell time. Mechanical properties of the joints were obtained with extensive hardness measurements and tensile shear tests. The effect of these parameters on the failure modes of welded joints was also determined.

  20. The Mechanical Behavior of Friction-Stir Spot Welded Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Güler, Hande

    2014-10-01

    Aluminum and alloys are widely used in the automotive industry due to the light weight, good formability, and malleability. Spot welding is the most commonly used joining method of these materials, but the high current requirements and the inconsistent quality of the final welds make this process unsuitable. An alternative welding technique, the friction-stir spot welding process, can also be successfully used in joining of aluminum and alloys. In this study, 1-mm-thick AA5754 Al-alloy plates in the H-111 temper conditions were joined by friction-stir spot welding using two different weld parameters such as tool rotational speed and dwell time. Mechanical properties of the joints were obtained with extensive hardness measurements and tensile shear tests. The effect of these parameters on the failure modes of welded joints was also determined.

  1. Recovery of Mechanical Properties of a 6061-T6 Aluminum Weld by Heat Treatment After Welding

    NASA Astrophysics Data System (ADS)

    Pérez, Javier Serrano; Ambriz, Ricardo Rafael; López, Francisco Fernando Curiel; Vigueras, David Jaramillo

    2016-07-01

    The dilution effects in welds of a 6061-T6 (Al-Si-Mg) alloy obtained by the modified indirect electric arc (MIEA), using an ER4043 filler metal (Al-Si), and postweld heat treatment (PWHT) were analyzed. The soft zone (55 to 70 HV0.1) formed by the microstructural transformation in the heat-affected zone (HAZ) was eliminated. The hardness measurements were presented on a traditional microhardness profile and mapping representation. A hardening effect of the fusion zone was observed; the hardness values were above 120 HV0.1 and tended to be uniform. This behavior could be attributed to the chemical composition of the filler metal, the Mg migration from the base to the weld metal, and the reversible process of the PWHT, which promotes precipitation hardening. Improvement for yield (260 MPa) and tensile strength (310 MPa) of the MIEA joints was observed; these values were similar to those obtained for the base metal. However, the presence of porosity in the fusion zone limits the ductility of the joints (4.3 pct). Even though the yield and tensile strengths of the base metal and welded joints were similar, the stress concentration due to porosity in the weld metal generated data dispersion in fatigue life. As a consequence, the high-cycle fatigue life decreases with respect to the base metal. In contrast, when the crack propagates under elastic conditions, the crack-tip singularity is affected by the porosity in the weld metal (stress liberator). This aspect, in conjunction with the hardening effect in joints subjected to PWHT, improves the fatigue crack growth rate when compared to the as-welded condition.

  2. Recovery of Mechanical Properties of a 6061-T6 Aluminum Weld by Heat Treatment After Welding

    NASA Astrophysics Data System (ADS)

    Pérez, Javier Serrano; Ambriz, Ricardo Rafael; López, Francisco Fernando Curiel; Vigueras, David Jaramillo

    2016-05-01

    The dilution effects in welds of a 6061-T6 (Al-Si-Mg) alloy obtained by the modified indirect electric arc (MIEA), using an ER4043 filler metal (Al-Si), and postweld heat treatment (PWHT) were analyzed. The soft zone (55 to 70 HV0.1) formed by the microstructural transformation in the heat-affected zone (HAZ) was eliminated. The hardness measurements were presented on a traditional microhardness profile and mapping representation. A hardening effect of the fusion zone was observed; the hardness values were above 120 HV0.1 and tended to be uniform. This behavior could be attributed to the chemical composition of the filler metal, the Mg migration from the base to the weld metal, and the reversible process of the PWHT, which promotes precipitation hardening. Improvement for yield (260 MPa) and tensile strength (310 MPa) of the MIEA joints was observed; these values were similar to those obtained for the base metal. However, the presence of porosity in the fusion zone limits the ductility of the joints (4.3 pct). Even though the yield and tensile strengths of the base metal and welded joints were similar, the stress concentration due to porosity in the weld metal generated data dispersion in fatigue life. As a consequence, the high-cycle fatigue life decreases with respect to the base metal. In contrast, when the crack propagates under elastic conditions, the crack-tip singularity is affected by the porosity in the weld metal (stress liberator). This aspect, in conjunction with the hardening effect in joints subjected to PWHT, improves the fatigue crack growth rate when compared to the as-welded condition.

  3. Defect detection in aluminum laser welds using an anisotropic magnetoresistive sensor array

    SciTech Connect

    Allweins, K.; Kreutzbruck, M. von; Gierelt, G.

    2005-05-15

    For the detection of defects in aluminum laser welds an anisotropic magnetoresistive (AMR) sensor array was implemented in an eddy current testing system. The reliability of weld testing is strongly influenced by the texture of the laser weld whose field response significantly superimposes the defect's magnetic signature. A finite-element model was used to determine the influence of the weld's topology on the detection of defects such as porosities and inclusions hosted in the aluminum matrix. When using an AMR sensor array with field sensitivity of better than 1 nT/{radical}Hz defects with a radius smaller than 100 {mu}m could be detected and classified.

  4. The effect of iron dilution on strength of nickel/steel and Monel/steel welds

    SciTech Connect

    Fout, S.L.; Wamsley, S.D.

    1983-03-28

    The weld strength, as a function of iron content, for nickel/steel and Monel/steel welds was determined. Samples were prepared using a Gas Metal Arc (GMAW) automatic process to weld steel plate together with nickel or Monel to produce a range of iron contents typical of weld compositions. Tensile specimens of each iron content were tested to obtain strength and ductility measurements for that weld composition. Data indicate that at iron contents of less than 20% iron in a nickel/steel weld, the weld fails at the weld interface, due to a lack of fusion. Between 20% and 35% iron, the highest iron dilution that could be achieved in a nickel weld, the welds were stronger than the steel base metal. This indicates that a minimum amount of iron dilution (20%) is necessary for good fusion and optimum strength. On the other hand for Monel/steel welds, test results showed that the welds had good strength and integrity between 10% and 27% iron in the weld. Above 35% iron, the welds have less strength and are more brittle. The 35% iron content also corresponds to the iron dilution in Monel welds that has been shown to produce an increase in corrosion rate. This indicates that the iron dilution in Monel welds should be kept below 35% iron to maximize both the strength and corrosion resistance. 2 refs., 6 figs., 3 tabs.

  5. Creep rupture strength of activated-TIG welded 316L(N) stainless steel

    NASA Astrophysics Data System (ADS)

    Sakthivel, T.; Vasudevan, M.; Laha, K.; Parameswaran, P.; Chandravathi, K. S.; Mathew, M. D.; Bhaduri, A. K.

    2011-06-01

    316L(N) stainless steel plates were joined using activated-tungsten inert gas (A-TIG) welding and conventional TIG welding process. Creep rupture behavior of 316L(N) base metal, and weld joints made by A-TIG and conventional TIG welding process were investigated at 923 K over a stress range of 160-280 MPa. Creep test results showed that the enhancement in creep rupture strength of weld joint fabricated by A-TIG welding process over conventional TIG welding process. Both the weld joints fractured in the weld metal. Microstructural observation showed lower δ-ferrite content, alignment of columnar grain with δ-ferrite along applied stress direction and less strength disparity between columnar and equiaxed grains of weld metal in A-TIG joint than in MP-TIG joint. These had been attributed to initiate less creep cavitation in weld metal of A-TIG joint leading to improvement in creep rupture strength.

  6. Superplastic Forming of Aluminum Multisheet Structures Fabricated Using Friction Stir Welding and Refill Friction Stir Spot Welding

    SciTech Connect

    Grant, Glenn J.; Herling, Darrell R.; Arbegast, William J.; Allen, Casey D.; Degen, Cassandra M.

    2006-12-20

    5083 aluminum multisheet packs that can be SPF formed into 3-D structural or integrally stiffened panels. Several configurations of 3-sheet egg crate and truss structures were friction stir welded and hot gas SPF formed in a parallel-platen SPF press. Data on weld conditions for optimum SPF forming as well as pre- and post- forming microstructures will be presented. It is found that FSW process conditions are a key feature of a successful SPF forming operation and the nugget microstructures and other features of the weld zone can be optimized to produce a wide range of weld region elongations. Friction Stir Welding may prove to be the enabler that allows aluminum to be considered in multisheet and integrally stiffened SPF Aluminum structures.

  7. The study on microstructural and mechanical properties of weld heat affected zone of 7075-T651 aluminum alloy

    SciTech Connect

    Hwang, R.Y.; Chou, C.P.

    1997-12-22

    Aluminum alloys play an important role in aerospace industry due to their high strength and low density. The general accepted precipitation behavior of 7075 alloy was represented as: supersaturated solid solution {alpha}{sub ss} {yields} Gp zones {yields} {eta}{prime}(MgZn{sub 2}) {yields} {eta}(MgZn{sub 2}). The Addition of Cu in Al-Zn-Mg alloy would promote the transformation of GP zones into {eta}{prime}(MgZn{sub 2}) phase and stabilize the {eta}(MgZn{sub 2}) phase. The T6 temper has the maximum strength but lower ductility. The T73 temper may lose some strength, but can gain higher corrosion resistance and lower susceptibility to stress corrosion cracking as compared to the T6 temper. The welding fabrication can produce thermal cycling on the weldment. In the heat affected zone (HAZ) beside the fusion zone, different temperatures can be obtained. This would cause change of microstructure in the HAZ of aluminum alloy weldment. Many workers studied the behavior of weld HAZ by cutting the HAZ into many small pieces or using short time isothermal heat treatment to simulate the HAZ. This may lose some information, especially near the fusion zone, because high temperature gradient occurred in this region. In this study, the Gleeble system was used to simulate the weld HAZ. It can accurately simulate every point of weld HAZ by heating and cooling the specimen to the thermal history of weld HAZ as the same as measured. The microstructural and mechanical properties of weld HAZ of 7075-T651 alloy were investigated.

  8. Mathematical modeling and experimental validation of gas metal arc welding of aluminum alloys

    NASA Astrophysics Data System (ADS)

    Guo, Hao

    2004-11-01

    Both mathematical modeling and experiments have been conducted on the GMAW of aluminum alloys. Transient weld shapes and distributions of temperature and velocity were calculated by a three-dimensional numerical model. The final weld bead shape and dimensions and peak temperature in the heat-affected zone (HAZ) were obtained. Metallurgical characterizations including microscopy and Knoop micro-hardness measurements were performed on experimental samples. The experimental weld bead shape and dimensions were in agreement with modeling predictions. It was found that a crater-shaped weld pool was formed as a result of weld pool dynamics. The combined effect of a series of droplet impingements and hydrostatic force caused the fluid level at the rear end of weld pool to vary periodically to form ripples on the weld bead. Also, the high peak temperature near the fusion line caused the HAZ softening. The lack of penetration in the cold weld is due to the lack of pre-heating by the welding arc. Three techniques were then proposed to increase the energy input at the initial stage of welding and improve cold weld penetration. The crater formation at the end of the welding process is due to the rapid solidification of the weld pool. The crater was filled and crater cracking was reduced by reducing welding current and reversing the welding direction at the same time before terminating the arc.

  9. Characterization of disk-laser dissimilar welding of titanium alloy Ti-6Al-4V to aluminum alloy 2024

    NASA Astrophysics Data System (ADS)

    Caiazzo, Fabrizia; Alfieri, Vittorio; Cardaropoli, Francesco; Corrado, Gaetano; Sergi, Vincenzo

    2013-02-01

    Both technical and economic reasons suggest to join dissimilar metals, benefiting from the specific properties of each material in order to perform flexible design. Adhesive bonding and mechanical joining have been traditionally used although adhesives fail to be effective in high-temperature environments and mechanical joining are not adequate for leak-tight joints. Friction stir welding is a valid alternative, even being difficult to perform for specific joint geometries and thin plates. The attention has therefore been shifted to laser welding. Interest has been shown in welding titanium to aluminum, especially in the aviation industry, in order to benefit from both corrosive resistance and strength properties of the former, and low weight and cost of the latter. Titanium alloy Ti-6Al-4V and aluminum alloy 2024 are considered in this work, being them among the most common ones in aerospace and automotive industries. Laser welding is thought to be particularly useful in reducing the heat affected zones and providing deep penetrative beads. Nevertheless, many challenges arise in welding dissimilar metals and the aim is further complicated considering the specific features of the alloys in exam, being them susceptible to oxidation on the upper surface and porosity formation in the fused zone. As many variables are involved, a systematic approach is used to perform the process and to characterize the beads referring to their shape and mechanical features, since a mixture of phases and structures is formed in the fused zone after recrystallization.

  10. Laser Welded versus Resistance Spot Welded Bone Implants: Analysis of the Thermal Increase and Strength

    PubMed Central

    Fornaini, Carlo; Meleti, Marco; Bonanini, Mauro; Lagori, Giuseppe; Vescovi, Paolo; Merigo, Elisabetta; Nammour, Samir

    2014-01-01

    Introduction. The first aim of this “ex vivo split mouth” study was to compare the thermal elevation during the welding process of titanium bars to titanium implants inserted in pig jaws by a thermal camera and two thermocouples. The second aim was to compare the strength of the joints by a traction test with a dynamometer. Materials and Methods. Six pigs' jaws were used and three implants were placed on each side of them for a total of 36 fixtures. Twelve bars were connected to the abutments (each bar on three implants) by using, on one side, laser welding and, on the other, resistance spot welding. Temperature variations were recorded by thermocouples and by thermal camera while the strength of the welded joint was analyzed by a traction test. Results. For increasing temperature, means were 36.83 and 37.06, standard deviations 1.234 and 1.187, and P value 0.5763 (not significant). For traction test, means were 195.5 and 159.4, standard deviations 2.00 and 2.254, and P value 0.0001 (very significant). Conclusion. Laser welding was demonstrated to be able to connect titanium implant abutments without the risk of thermal increase into the bone and with good results in terms of mechanical strength. PMID:25110731

  11. Dissimilar friction stir welding of aluminum alloys reinforced with carbon nanotubes

    NASA Astrophysics Data System (ADS)

    Pantelis, D. I.; Karakizis, P. N.; Dragatogiannis, D. A.; Charitidis, C. A.

    2016-01-01

    This chapter is devoted to studying the possibility of incorporating carbon nanotubes (CNTs) as reinforcing fillers in dissimilar metal matrices joints produced by friction stir welding (FSW), as well as the impact of this incorporation on the microstructural and mechanical properties of these joints. Carbon nanotubes are extensively used as a reinforcing material in nanocomposites, due to their high stiffness and strength. FSW is a solid-state welding process of joining aluminum and other metallic alloys and has been employed in the aerospace, rail, automotive, and marine industries. Recently, friction stir processing (FSP), a derivative method of FSW, has been employed as an alternative for the production of metal matrix composites (MMCs). In this work, the process parameters were optimized in order to achieve nondefective welds, with and without the addition of CNTs. Two main cases were studied: (1) FSP was optimized by changing the tool rotational and travel speed as well as the number and direction of FSW passes, and (2) a Taguchi design scheme was adopted to further investigate the FSP in relevance to three factors (number, direction of passes, and tool rotational speed). Mechanical behavior was studied, and the local mechanical properties of the produced MMCs were compared with their bulk counterparts and parent materials. More specifically, the measured mechanical properties in the micro- and nanoscale (namely hardness and elastic modulus) are correlated with the microstructure and the presence of fillers.

  12. Relationship between apposition pressure during welding and tensile strength of the acute weld

    NASA Astrophysics Data System (ADS)

    Wu, Paul J.; Walsh, Joseph T., Jr.

    2001-05-01

    Dye-assisted photothermal welding is a technique used to close wounds by thermally cross-linking collagen across apposed tissue edges. For a successful weld, not only do laser parameters have to be optimized, but also apposition of the incision has to be consistent and controlled. The objective of this study was to quantify the relationship between the applied apposition pressure (i.e., the compressive force holding the wound closed during the welding procedure divided by the area of the skin-to-skin interface) and the tensile strength of the wound following the welding procedure. By using a clamping device made of two complementary pieces, each 3 cm wide with a row of 10 equally spaced blunt wire mesh tips, the apposition pressure along a 2-cm-long incision in each albino guinea pig was quantified using a 127-micrometers -thick load cell and varied from 0-1.8 kgf/cm2. A continuous wave, Nd:YAG laser emitting 10.0 W of 1.06-micrometers radiation from a 600-micrometers -diameter fiber irradiating a 5-mm-diameter spot size was scanned across the incision in order to deliver 300 J of total energy. As the apposition pressure of the incisions was increased, the resulting tensile strength of welded skin increased in a sigmoidal manner. For this welding technique, an apposition pressure of at least 1.2 kgf/cm2 is necessary to obtain maximum weld strength of the skin (2.56+/- 0.36 kg/cm2).

  13. The effect of impurity gasses on variable polarity plasma arc welded 2219 aluminum

    NASA Technical Reports Server (NTRS)

    Mcclure, John C.; Torres, Martin R.; Gurevitch, Alan C.; Newman, Robert A.

    1989-01-01

    Variable polarity plasma arc (VPPA) welding has been used with considerable success by NASA for the welds on the Space Shuttle External Tank as well as by others concerned with high quality welded structures. The effects of gaseous contaminants on the appearance of VPPA welds on 2219 aluminum are examined so that a welder can recognize that such contamination is present and take corrective measures. There are many possible sources of such contamination including, contaminated gas bottles, leaks in the gas plumbing, inadequate shield gas flow, condensed moisture in the gas lines or torch body, or excessive contaminants on the workpiece. The gasses chosen for study in the program were nitrogen, oxygen, methane, and hydrogen. Welds were made in a carefully controlled environment and comparisons were made between welds with various levels of these contaminants and welds made with research purity (99.9999 percent) gasses. Photographs of the weld front and backside as well as polished and etched cross sections are presented.

  14. Residual Stresses in Friction-Stir-Welded 2195 and 7075 Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Hatamleh, Omar; Rivero, Iris V.; Maredia, Arif

    2008-12-01

    Surface residual stresses (RSs) were characterized along friction-stir-welded 2195 and 7075 aluminum alloy (AA) plates. The surface measurements were obtained through X-ray diffraction (XRD) at five different locations along the weld. Each location consisted of several regions across the welded plate including the weld nugget, thermomechanically affected zone (TMAZ), heat-affected zone (HAZ), and base material. Measurements revealed that RSs were not uniform along the welded plate, with the highest RSs obtained on the middle of the plate. The RSs across the weld were also asymmetric relative to the weld centerline, with RSs as high as 231 MPa in the TMAZ for the retreating side of the weld.

  15. Laser beam interactions with vapor plumes during Nd:YAG laser welding on aluminum

    NASA Astrophysics Data System (ADS)

    Peebles, H. C.; Russo, A. J.; Hadley, G. R.; Akau, R. L.

    Welds produced on pure aluminum targets using pulsed Nd:YAG lasers can be accurately described using a relatively simple conduction mode heat transfer model provided that the fraction of laser energy absorbed is known and the amount of metal vaporized is smalled however at laser fluences commonly used in many production welding schedules significant aluminum vaporization does occur. The possible mechanisms have been identified which could result in laser beam attenuation by the vapor plume.

  16. Microstructure and Strength Characteristics of Alloy 617 Welds

    SciTech Connect

    T.C. Totemeier; H. Tian; D.E. Clark; J.A. Simpson

    2005-06-01

    Three types of high-temperature joints were created from alloy 617 base metal: fusion welds, braze joints, and diffusion bonds. The microstructures of all joint types and tensile properties of fusion welds and braze joints were characterized. Sound fusion welds were created by the GTAW process with alloy 617 filler wire. Cross-weld tensile strengths were equal to the parent metal at temperatures of 25, 800, and 1000°C; ductilities of the joints were only slightly lower than that of the parent metal. Failure occurred in the weld fusion zone at room temperature and in the parent metal at elevated temperatures. Incomplete wetting occurred in joints produced by vacuum brazing using AWS BNi-1 braze alloy, believed to be due to tenacious Al and Ti oxide formation. Incompletely bonded butt joints showed relatively poor tensile properties. A second set of braze joints has been created with faying surfaces electroplated with pure Ni prior to brazing; characterization of these joints is in progress. Conditions resulting in good diffusion bonds characterized by grain growth across the bondline and no porosity were determined: vacuum bonding at 1150°C for 3 hours with an initial uniaxial stress of 20 MPa (constant ram displacement). A 15 µm thick pure Ni interlayer was needed to achieve grain growth across the bondline. Tensile testing of diffusion bonds is in progress

  17. Fatigue strength reduction factors for welds based on nondestructive examination

    SciTech Connect

    Hechmer, J.L.; Kuhn, E.J. III

    1999-02-01

    Based on the author`s hypothesis that nondestructive examination (NDE) has a major role in predicting the fatigue life of pressure vessels, a project was initiated to develop a defined relationship between NDE and fatigue strength reduction factors (FSRF). Even though a relationship should apply to both base metal and weld metal, the project was limited to weld metal because NDE for base metal is reasonably well established, whereas NDE for weld metal is more variable, depending on application. A matrix of FSRF was developed based on weld type (full penetration, partial penetration, and fillet weld) versus the NDE that is applied. The NDE methods that are included are radiographic testing (RT), ultrasonic testing (UT), magnetic particle testing (MT), dye penetrant testing (PT), and visual testing (VT). The first two methods (RT and UT) are volumetric examinations, and the remaining three are surface examinations. Seven combinations of volumetric and surface examinations were defined; thus, seven levels of FSRF are defined. Following the initial development of the project, a PVRC (Pressure Vessel Research Council) grant was obtained for the purpose of having a broad review. The report (Hechmer, 1998) has been accepted by PVRC. This paper presents the final matrix, the basis for the FSRF, and key definitions for accurate application of the FSRF matrix. A substantial amount of additional information is presented in the PVRC report (Hechmer, 1998).

  18. Technique for in-place welding of aluminum backed up by a combustible material

    NASA Technical Reports Server (NTRS)

    Spagnuolo, A. C.

    1971-01-01

    Welding external aluminum jacket, tightly wrapped around inner layer of wood composition fiberboard, in oxygen free environment prevents combustion and subsequent damage to underlying fiberboard. Technique also applies to metal cutting in similar assemblies without disassembly to remove combustible materials from welding heat proximity.

  19. The microstructure of aluminum A5083 butt joint by friction stir welding

    NASA Astrophysics Data System (ADS)

    Jasri, M. A. H. M.; Afendi, M.; Ismail, A.; Ishak, M.

    2015-05-01

    This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the plate form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected.

  20. The microstructure of aluminum A5083 butt joint by friction stir welding

    SciTech Connect

    Jasri, M. A. H. M.; Afendi, M.; Ismail, A.; Ishak, M.

    2015-05-15

    This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the plate form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected.

  1. Optimal welding parameters for very high power ultrasonic additive manufacturing of smart structures with aluminum 6061 matrix

    NASA Astrophysics Data System (ADS)

    Wolcott, Paul J.; Hehr, Adam; Dapino, Marcelo J.

    2014-03-01

    Ultrasonic additive manufacturing (UAM) is a recent solid state manufacturing process that combines ad- ditive joining of thin metal tapes with subtractive milling operations to generate near net shape metallic parts. Due to the minimal heating during the process, UAM is a proven method of embedding Ni-Ti, Fe-Ga, and PVDF to create active metal matrix composites. Recently, advances in the UAM process utilizing 9 kW very high power (VHP) welding has improved bonding properties, enabling joining of high strength materials previously unweldable with 1 kW low power UAM. Consequently, a design of experiments study was conducted to optimize welding conditions for aluminum 6061 components. This understanding is critical in the design of UAM parts containing smart materials. Build parameters, including weld force, weld speed, amplitude, and temperature were varied based on a Taguchi experimental design matrix and tested for me- chanical strength. Optimal weld parameters were identi ed with statistical methods including a generalized linear model for analysis of variance (ANOVA), mean e ects plots, and interaction e ects plots.

  2. Effect of thermal exposure, forming, and welding on high-temperature, dispersion-strengthened aluminum alloy: Al-8Fe-1V-2Si

    NASA Technical Reports Server (NTRS)

    Kennedy, J. R.; Gilman, P. S.; Zedalis, M. S.; Skinner, D. J.; Peltier, J. M.

    1991-01-01

    The feasibility of applying conventional hot forming and welding methods to high temperature aluminum alloy, Al-8Fe-1V-2Si (FVS812), for structural applications and the effect of thermal exposure on mechanical properties were determined. FVS812 (AA8009) sheet exhibited good hot forming and resistance welding characteristics. It was brake formed to 90 deg bends (0.5T bend radius) at temperatures greater than or equal to 390 C (730 F), indicating the feasibility of fabricating basic shapes, such as angles and zees. Hot forming of simple contoured-flanged parts was demonstrated. Resistance spot welds with good static and fatigue strength at room and elevated temperatures were readily produced. Extended vacuum degassing during billet fabrication reduced porosity in fusion and resistance welds. However, electron beam welding was not possible because of extreme degassing during welding, and gas-tungsten-arc welds were not acceptable because of severely degraded mechanical properties. The FVS812 alloy exhibited excellent high temperature strength stability after thermal exposures up to 315 C (600 F) for 1000 h. Extended billet degassing appeared to generally improve tensile ductility, fatigue strength, and notch toughness. But the effects of billet degassing and thermal exposure on properties need to be further clarified. The manufacture of zee-stiffened, riveted, and resistance-spot-welded compression panels was demonstrated.

  3. Tensile and flexural strength of commercially pure titanium submitted to laser and tungsten inert gas welds.

    PubMed

    Atoui, Juliana Abdallah; Felipucci, Daniela Nair Borges; Pagnano, Valéria Oliveira; Orsi, Iara Augusta; Nóbilo, Mauro Antônio de Arruda; Bezzon, Osvaldo Luiz

    2013-01-01

    This study evaluated the tensile and flexural strength of tungsten inert gas (TIG) welds in specimens made of commercially pure titanium (CP Ti) compared with laser welds. Sixty cylindrical specimens (2 mm diameter x 55 mm thick) were randomly assigned to 3 groups for each test (n=10): no welding (control), TIG welding (10 V, 36 A, 8 s) and Nd:YAG laser welding (380 V, 8 ms). The specimens were radiographed and subjected to tensile and flexural strength tests at a crosshead speed of 1.0 mm/min using a load cell of 500 kgf applied on the welded interface or at the middle point of the non-welded specimens. Tensile strength data were analyzed by ANOVA and Tukey's test, and flexural strength data by the Kruskal-Wallis test (α=0.05). Non-welded specimens presented significantly higher tensile strength (control=605.84 ± 19.83) (p=0.015) and flexural strength (control=1908.75) (p=0.000) than TIG- and laser-welded ones. There were no significant differences (p>0.05) between the welding types for neither the tensile strength test (TIG=514.90 ± 37.76; laser=515.85 ± 62.07) nor the flexural strength test (TIG=1559.66; laser=1621.64). As far as tensile and flexural strengths are concerned, TIG was similar to laser and could be suitable to replace laser welding in implant-supported rehabilitations. PMID:24474361

  4. A Micro-Electrochemical Study of Friction Stir Welded Aluminum 6061-T6

    NASA Technical Reports Server (NTRS)

    Hintze, Paul E.; Calle, Luz M.

    2005-01-01

    The corrosion behavior of friction stir welded Aluminum alloy 606 1-T6 was studied using a micro-electrochemical cell. The micro-electrochemical cell has a measurement area of about 0.25 square mm which allows for measurement of corrosion properties at a very small scale. The corrosion and breakdown potentials were measured at many points inside and outside the weld along lines perpendicular to the weld. The breakdown potential is approximately equal inside and outside the weld; however, it is lower in the narrow border between the weld and base material. The results of electrochemical measurements were correlated to micro-structural analysis. The corrosion behavior of the friction stir welded samples was compared to tungsten inert gas (TIG) welded samples of the same material.

  5. Improvements of welding characteristics of aluminum alloys with YAG laser and TIG arc hybrid system

    NASA Astrophysics Data System (ADS)

    Fujinaga, Shigeki; Ohashi, Ryoji; Katayama, Seiji; Matsunawa, Akira

    2003-03-01

    In high power YAG laser welding of steels, a rectangularly modulated beam with high peak power is usually used to get deep penetration. On the other hand, many spatters and solidification cracks are generated when some aluminum alloys are welded with a rectangularly modulated beam because of its high heat conductivity, high reflectivity, low surface tension, large contraction, wide solidification temperature range, etc. Therefore, a properly modulated beam or a continuous beam is usually used in aluminum alloy welding, although the penetration depth is shallow. In this research, sinusoidal wave or rectangularly modulated wave of YAG laser combined with TIG arc was tried to improve the weldability of A6061 aluminum alloy. As a result, when TIG arc was superimposed behind the YAG laser beam, deeply penetrated weld beads with good surface appearances were produced without spatter losses and cracks.

  6. Fatigue Strength and Related Characteristics of Aircraft Joints I : Comparison of Spot-Weld and Rivet Patterns in 24s-t Alclad and 75s-t Alclad

    NASA Technical Reports Server (NTRS)

    Russell, H W; Jackson, L R; Grover, H J; Beaver, W W

    1944-01-01

    Report contains detailed results of a number of fatigue tests on spot-welded joints in aluminum alloys. The tests described include: (1) fatigue tests on spot-welded lap joints in sheets of unequal thickness of alclad 24s-t. These tests indicate that the fatigue strength of a spot-welded joint in sheets of two different gages is slightly higher than that of a similar joint in two sheets of the thinner gage but definitely lower than that of a similar joint in two sheets of the thicker gage. (2) Fatigue tests on spot-welded alclad 75s-t spot-welded lap-joint specimens of alclad 75s-t were not any stronger in fatigue than similar specimens of alclad 24s-t. (3) Fatigue tests on lap-joint specimens spot -welded after various surface preparations--these included ac welding wire-brushed surfaces, dc welding wire-brushed surfaces, and dc welding chemically cleaned surfaces. While the ac welds were strongest statically, the dc welds on wire-brushed surfaces were strongest in fatigue. Specimens prepared in this way were very nearly as strong as the best riveted specimens tested for comparison. (4) Fatigue tests on specimens spot-welded with varying voltage so as to include a wide range of static spot-weld strengths. The fatigue strengths were in the same order as the static strengths but showed less range. (author)

  7. Stress corrosion in high-strength aluminum alloys

    NASA Technical Reports Server (NTRS)

    Dorward, R. C.; Hasse, K. R.

    1980-01-01

    Report describes results of stress-corrosion tests on aluminum alloys 7075, 7475, 7050, and 7049. Tests compare performance of original stress-corrosion-resistant (SCR) aluminum, 7075, with newer, higher-strength SCR alloys. Alloys 7050 and 7049 are found superior in short-transverse cross-corrosion resistance to older 7075 alloy; all alloys are subject to self-loading effect caused by wedging of corrosion products in cracks. Effect causes cracks to continue to grow, even at very-low externally applied loads.

  8. Taguchi Optimization of Pulsed Current GTA Welding Parameters for Improved Corrosion Resistance of 5083 Aluminum Welds

    NASA Astrophysics Data System (ADS)

    Rastkerdar, E.; Shamanian, M.; Saatchi, A.

    2013-04-01

    In this study, the Taguchi method was used as a design of experiment (DOE) technique to optimize the pulsed current gas tungsten arc welding (GTAW) parameters for improved pitting corrosion resistance of AA5083-H18 aluminum alloy welds. A L9 (34) orthogonal array of the Taguchi design was used, which involves nine experiments for four parameters: peak current ( P), base current ( B), percent pulse-on time ( T), and pulse frequency ( F) with three levels was used. Pitting corrosion resistance in 3.5 wt.% NaCl solution was evaluated by anodic polarization tests at room temperature and calculating the width of the passive region (∆ E pit). Analysis of variance (ANOVA) was performed on the measured data and S/ N (signal to noise) ratios. The "bigger is better" was selected as the quality characteristic (QC). The optimum conditions were found as 170 A, 85 A, 40%, and 6 Hz for P, B, T, and F factors, respectively. The study showed that the percent pulse-on time has the highest influence on the pitting corrosion resistance (50.48%) followed by pulse frequency (28.62%), peak current (11.05%) and base current (9.86%). The range of optimum ∆ E pit at optimum conditions with a confidence level of 90% was predicted to be between 174.81 and 177.74 mVSCE. Under optimum conditions, the confirmation test was carried out, and the experimental value of ∆ E pit of 176 mVSCE was in agreement with the predicted value from the Taguchi model. In this regard, the model can be effectively used to predict the ∆ E pit of pulsed current gas tungsten arc welded joints.

  9. Self-Reacting Friction Stir Welding for Aluminum Complex Curvature Applications

    NASA Technical Reports Server (NTRS)

    Brown, Randy J.; Martin, W.; Schneider, J.; Hartley, P. J.; Russell, Carolyn; Lawless, Kirby; Jones, Chip

    2003-01-01

    This viewgraph representation provides an overview of sucessful research conducted by Lockheed Martin and NASA to develop an advanced self-reacting friction stir technology for complex curvature aluminum alloys. The research included weld process development for 0.320 inch Al 2219, sucessful transfer from the 'lab' scale to the production scale tool and weld quality exceeding strenght goals. This process will enable development and implementation of large scale complex geometry hardware fabrication. Topics covered include: weld process development, weld process transfer, and intermediate hardware fabrication.

  10. Ultrasonic-assisted friction stir welding on V95AT1 (7075) aluminum alloy

    NASA Astrophysics Data System (ADS)

    Tarasov, S. Yu.; Rubtsov, V. Ye.; Kolubaev, E. A.; Ivanov, A. N.; Fortuna, S. V.; Eliseev, A. A.

    2015-10-01

    Ultrasonic-assisted friction stir butt welding on aluminum alloy V95AT1 (7075) has been carried out. Samples have been characterized using metallography, microhardness and XRD. As shown, ultrasonic treatment during welding provides extra plasticizing of metal and better stirring efficiency. The latter serves for elimination of defects, such as root flaw and grain refining in the stir zone. The stress state in the welded joint is characterized by tensile stress in the direction of the weld seam centerline and compression in the transversal direction. The ultrasonic treatment was shown to increase the compression stress and relieve the tensile one.

  11. Forge Welding of Magnesium Alloy to Aluminum Alloy Using a Cu, Ni, or Ti Interlayer

    NASA Astrophysics Data System (ADS)

    Yamagishi, Hideki; Sumioka, Junji; Kakiuchi, Shigeki; Tomida, Shogo; Takeda, Kouichi; Shimazaki, Kouichi

    2015-08-01

    The forge-welding process was examined to develop a high-strength bonding application of magnesium (Mg) alloy to aluminum (Al) alloy under high-productivity conditions. The effect of the insert material on the tensile strength of the joints, under various preheat temperatures and pressures, was investigated by analyzing the reaction layers of the bonded interface. The tensile strengths resulting from direct bonding, using pure copper (Cu), pure nickel (Ni), and pure titanium (Ti) inserts were 56, 100, 119, and 151 MPa, respectively. The maximum joint strength reached 93 pct with respect to the Mg cast billet. During high-pressure bonding, a microscopic plastic flow occurred that contributed to an anchor effect and the generation of a newly formed surface at the interface, particularly prominent with the Ti insert in the form of an oxide layer. The bonded interfaces of the maximum-strength inserts were investigated using scanning electron microscopy-energy-dispersive spectroscopy and electron probe microanalysis. The diffusion reaction layer at the bonded interface consisted of brittle Al-Mg intermetallics having a thickness of approximately 30 μm. In contrast, for the three inserts, the thicknesses of the diffusion reaction layer were infinitely thin. For the pure Ti insert, exhibiting the maximum tensile strength value among the inserts tested, focused ion beam-transmission electron microscopy-EDS analysis revealed a 60-nm-thick Al-Ti reaction layer, which had formed at the bonded interface on the Mg alloy side. Thus, a high-strength Al-Mg bonding method in air was demonstrated, suitable for mass production.

  12. Microstructure and Fatigue Properties of Ultrasonic Spot Welded Joints of Aluminum 5754 Alloy

    NASA Astrophysics Data System (ADS)

    Mirza, F. A.; Macwan, A.; Bhole, S. D.; Chen, D. L.

    2016-05-01

    The purpose of this investigation was to evaluate the microstructural change, lap shear tensile load, and fatigue resistance of ultrasonic spot welded joints of aluminum 5754 alloy for automotive applications. A unique "necklace"-type structure with very fine equiaxed grains was observed to form along the weld line due to the mechanical interlocking coupled with the occurrence of dynamic recrystallization. The maximum lap shear tensile strength of 85 MPa and the fatigue limit of about 0.5 kN (at 1 × 107 cycles) were achieved. The tensile fracture occurred at the Al/Al interface in the case of lower energy inputs, and at the edge of nugget zone in the case of higher energy inputs. The maximum cyclic stress for the transition of fatigue fracture mode from the transverse through-thickness crack growth to the interfacial failure increased with increasing energy input. Fatigue crack propagation was mainly characterized by the formation of fatigue striations, which usually appeared perpendicular to the fatigue crack propagation.

  13. Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - Part II: Finite Element Analyses of Nugget Growth

    SciTech Connect

    Sun, Xin; Khaleel, Mohammad A.

    2004-07-01

    This paper summarizes work on finite element modeling of nugget growth for resistance spot welding of aluminum alloy to steel. It is a sequel to a previous paper on experimental studies of resistance spot welding of aluminum to steel using a transition material. Since aluminum alloys and steel cannot be readily fusion welded together due to their drastically different thermal physical properties, a cold-rolled clad material was introduced as a transition to aid the resistance welding process. Coupled electrical-thermal-mechanical finite element analyses were performed to simulate the nugget growth and heat generation patterns during the welding process. The predicted nugget growth results were compared to the experimental weld cross sections. Reasonable comparisons of nugget size were achieved. The finite element simulation procedures were also used in the electrode selection state to help reduce weld expulsion and improve weld quality.

  14. Comparison of the Effects of Tool Geometry for Friction Stir Welding Thin Sheet Aluminum Alloys for Aerospace Applications

    NASA Technical Reports Server (NTRS)

    Merry, Josh; Takeshita, Jennifer; Tweedy, Bryan; Burford, Dwight

    2006-01-01

    In this presentation, the results of a recent study on the effect of pin tool design for friction stir welding thin sheets (0.040") of aluminum alloys 2024 and 7075 are provided. The objective of this study was to investigate and document the effect of tool shoulder and pin diameter, as well as the presence of pin flutes, on the resultant microstructure and mechanical properties at both room temperature and cryogenic temperature. Specifically, the comparison between three tools will include: FSW process load analysis (tool forces required to fabricate the welds), Static Mechanical Properties (ultimate tensile strength, yield strength, and elongation), and Process window documenting the range of parameters that can be used with the three pin tools investigated. All samples were naturally aged for a period greater than 10 days. Prior research has shown 7075 may require post weld heat treatment. Therefore, an additional pair of room temperature and cryogenic temperature samples was post-weld aged to the 7075-T7 condition prior to mechanical testing.

  15. Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding.

    PubMed

    Ampaiboon, Anusit; Lasunon, On-Uma; Bubphachot, Bopit

    2015-01-01

    We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10-20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%. PMID:26491719

  16. Effects of Fusion Tack Welds on Self-Reacting Friction Stir Welds

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.; Pendleton, M. L.; Brooke, S. A.; Russell, C. K.

    2012-01-01

    In order to know whether fusion tack welds would affect the strength of self-reacting friction stir seam welds in 2195-T87 aluminum alloy, the fracture stresses of 144 tensile test coupons cut from 24 welded panels containing segments of friction stir welds were measured. Each of the panels was welded under unique processing conditions. A measure of the effect of the tack welds for each panel was devised. An analysis of the measures of the tack weld effect supported the hypothesis that fusion tack welds do not affect the strength of self-reacting friction stir welds to a 5% level of confidence.

  17. High Strength Discontinuously Reinforced Aluminum For Rocket Applications

    NASA Technical Reports Server (NTRS)

    Pandey, A. B.; Shah, S. R.; Shadoan, M.

    2003-01-01

    This study presents results on the development of a new aluminum alloy with very high strength and ductility. Five compositions of Al-Mg-Sc-Gd-Zr alloy were selected for this purpose. These alloys were also reinforced with 15 volume percent silicon-carbide and boron-carbide particles to produce Discontinuously Reinforced Aluminum (DRA) materials. Matrix alloys and DRA were processed using a powder metallurgy process. The helium gas atomization produced very fine powder with cellular-dentritic microstructure. The microstructure of matrix alloys showed fine Al3Sc based precipitate which provides significant strengthening in these alloys. DRA showed uniform distribution of reinforcement in aluminum matrix. DRA materials were tested at -320 F, 75 F in air and 7S F in gaseous hydrogen environments and matrix alloys were tested at 75 F in air. DRA showed high strengths in the range of 89-111 ksi (614-697 MPa) depending on alloy compositions and test environments. Matrix alloys had a good combination of strength, 84-89 ksi (579-621 MPa) and ductility, 4.5-6.5%. The properties of these materials can further be improved by proper control of processing parameters.

  18. Bobbin-Tool Friction-Stir Welding of Thick-Walled Aluminum Alloy Pressure Vessels

    SciTech Connect

    Dalder, E C; Pastrnak, J W; Engel, J; Forrest, R S; Kokko, E; Ternan, K M; Waldron, D

    2007-06-06

    It was desired to assemble thick-walled Al alloy 2219 pressure vessels by bobbin-tool friction-stir welding. To develop the welding-process, mechanical-property, and fitness-for-service information to support this effort, extensive friction-stir welding-parameter studies were conducted on 2.5 cm. and 3.8 cm. thick 2219 Al alloy plate. Starting conditions of the plate were the fully-heat-treated (-T62) and in the annealed (-O) conditions. The former condition was chosen with the intent of using the welds in either the 'as welded' condition or after a simple low-temperature aging treatment. Since preliminary stress-analyses showed that stresses in and near the welds would probably exceed the yield-strength of both 'as welded' and welded and aged weld-joints, a post-weld solution-treatment, quenching, and aging treatment was also examined. Once a suitable set of welding and post-weld heat-treatment parameters was established, the project divided into two parts. The first part concentrated on developing the necessary process information to be able to make defect-free friction-stir welds in 3.8 cm. thick Al alloy 2219 in the form of circumferential welds that would join two hemispherical forgings with a 102 cm. inside diameter. This necessitated going to a bobbin-tool welding-technique to simplify the tooling needed to react the large forces generated in friction-stir welding. The bobbin-tool technique was demonstrated on both flat-plates and plates that were bent to the curvature of the actual vessel. An additional issue was termination of the weld, i.e. closing out the hole left at the end of the weld by withdrawal of the friction-stir welding tool. This was accomplished by friction-plug welding a slightly-oversized Al alloy 2219 plug into the termination-hole, followed by machining the plug flush with both the inside and outside surfaces of the vessel. The second part of the project involved demonstrating that the welds were fit for the intended service. This

  19. Formation of Brittle Phases During Pulsed Current Gas Tungsten Arc Welding of Titanium to Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Wei, Shouzheng; Li, Yajiang; Wang, Juan; Liu, Kun

    2014-04-01

    Welding of titanium alloy TA15 to aluminum alloy Al 2024 was conducted by pulsed current gas tungsten arc welding using AlSi12 filler metal. Formation process of phases near the Ti/Al interface was discussed. Titanium and aluminum were partially fusion welded in the upper part while brazed together in the middle and bottom parts of the joint. In the upper part of the joint, intermetallics Ti3Al + Ti5Si3, TiAl + Ti5Si3, and TiAl3 were formed as three layers orderly from the titanium side to the weld metal. In the middle and bottom parts of the joint, intermetallics Ti5Si3 and TiAl3 were formed as two layers near the Ti/Al interface.

  20. Bond strength of cementitious borehole plugs in welded tuff

    SciTech Connect

    Akgun, H.; Daemen, J.J.K.

    1991-02-01

    Axial loads on plugs or seals in an underground repository due to gas, water pressures and temperature changes induced subsequent to waste and plug emplacement lead to shear stresses at the plug/rock contact. Therefore, the bond between the plug and rock is a critical element for the design and effectiveness of plugs in boreholes, shafts or tunnels. This study includes a systematic investigation of the bond strength of cementitious borehole plugs in welded tuff. Analytical and numerical analysis of borehole plug-rock stress transfer mechanics is performed. The interface strength and deformation are studied as a function of Young`s modulus ratio of plug and rock, plug length and rock cylinder outside-to-inside radius ratio. The tensile stresses in and near an axially loaded plug are analyzed. The frictional interface strength of an axially loaded borehole plug, the effect of axial stress and lateral external stress, and thermal effects are also analyzed. Implications for plug design are discussed. The main conclusion is a strong recommendation to design friction plugs in shafts, drifts, tunnels or boreholes with a minimum length to diameter ratio of four. Such a geometrical design will reduce tensile stresses in the plug and in the host rock to a level which should minimize the risk of long-term deterioration caused by excessive tensile stresses. Push-out tests have been used to determine the bond strength by applying an axial load to cement plugs emplaced in boreholes in welded tuff cylinders. A total of 130 push-out tests have been performed as a function of borehole size, plug length, temperature, and degree of saturation of the host tuff. The use of four different borehole radii enables evaluation of size effects. 119 refs., 42 figs., 20 tabs.

  1. Low-temperature friction-stir welding of 2024 aluminum

    SciTech Connect

    Benavides, S.; Li, Y.; Murr, L.E.; Brown, D.; McClure, J.C.

    1999-09-10

    Solid-state, friction-stir welding (FSW) has been demonstrated to involve dynamic recrystallization producing ultra-fine, equiaxed grain structures to facilitate superplastic deformation as the welding or joining mechanism. Since the recrystallization temperature also decreases with increasing strain rate, the FSW process is somewhat complicated because the ambient temperature, the frictional heating fraction, and the adiabatic heating fraction (proportional to the product of strain and strain-rate) will all influence both the recrystallization and grain growth within the FSW zone. Significantly reducing the ambient temperature of the base metal or work pieces to be welded would be expected to reduce the residual weld-zone grain size. The practical consequences of this temperature reduction would be the achievement of low-temperature welding. This study compares the residual grain sizes and microstructures in 2024 Al friction-stir welded at room temperature ({approximately} 30 C) and low temperature ({minus} 30 C).

  2. Friction Stir Weld Failure Mechanisms in Aluminum-Armor Structures Under Ballistic Impact Loading Conditions

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Pandurangan, B.; Arakere, A.; Yen, C.-F.; Cheeseman, B. A.

    2013-01-01

    A critical assessment is carried out of the microstructural changes in respect of the associated reductions in material mechanical properties and of the attendant ballistic-impact failure mechanisms in prototypical friction stir welding (FSW) joints found in armor structures made of high-performance aluminum alloys (including solution-strengthened and age-hardenable aluminum alloy grades). It is argued that due to the large width of FSW joints found in thick aluminum-armor weldments, the overall ballistic performance of the armor is controlled by the ballistic limits of its weld zones (e.g., heat-affected zone, the thermomechanically affected zone, the nugget, etc.). Thus, in order to assess the overall ballistic survivability of an armor weldment, one must predict/identify welding-induced changes in the material microstructure and properties, and the operative failure mechanisms in different regions of the weld. Toward this end, a procedure is proposed in the present study which combines the results of the FSW process modeling, basic physical-metallurgy principles concerning microstructure/property relations, and the fracture mechanics concepts related to the key blast/ballistic-impact failure modes. The utility of this procedure is demonstrated using the case of a solid-solution strengthened and cold-worked aluminum alloy armor FSW-weld test structure.

  3. Friction Stir Welding for Aluminum Metal Matrix Composites (MMC's) (Center Director's Discretionary Fund, Project No. 98-09)

    NASA Technical Reports Server (NTRS)

    Lee, J. A.; Carter, R. W.; Ding, J.

    1999-01-01

    This technical memorandum describes an investigation of using friction stir welding (FSW) process for joining a variety of aluminum metal matrix composites (MMC's) reinforced with discontinuous silicon-carbide (SiC) particulate and functional gradient materials. Preliminary results show that FSW is feasible to weld aluminum MMC to MMC or to aluminum-lithium 2195 if the SiC reinforcement is <25 percent by volume fraction. However, a softening in the heat-affected zone was observed and is known to be one of the major limiting factors for joint strength. The pin tool's material is made from a low-cost steel tool H-13 material, and the pin tool's wear was excessive such that the pin tool length has to be manually adjusted for every 5 ft of weldment. Initially, boron-carbide coating was developed for pin tools, but it did not show a significant improvement in wear resistance. Basically, FSW is applicable mainly for butt joining of flat plates. Therefore, FSW of cylindrical articles such as a flange to a duct with practical diameters ranging from 2-5 in. must be fully demonstrated and compared with other proven MMC joining techniques for cylindrical articles.

  4. Effect of cooling rate on microstructure of friction-stir welded AA1100 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Yi, D.; Mironov, S.; Sato, Y. S.; Kokawa, H.

    2016-06-01

    In this work, the microstructural changes occurring during cooling of friction-stir welded aluminum alloy AA1100 were evaluated. To this end, friction-stir welding (FSW) was performed in a wide range of cooling rates of 20-62 K/s and the evolved microstructures were studied by using electron backscatter diffraction. Below 0.6 Tm (Tm being the melting point), the stir zone material was found to experience no significant changes during cooling. At higher FSW temperatures, however, notable changes occurred in the welded material, including grain growth, sharpening of texture, reduction of the fraction of high-angle boundaries and material softening.

  5. Effects of weld metal strength and defects on the ductility of HSLA-100 plates

    SciTech Connect

    Dexter, R.J.; Ferrell, M.

    1995-12-31

    Wide-plate tension tests were performed on high-strength low-alloy steel, minimum yield strength of 690 MPa, with various controlled intentional defects in both undermatched and overmatched welds. Lack-of-fusion areas on the sidewall comprising about 10 percent of the cross-section resulted in full net-section strength. Weld undercut to a depth of 12 percent of the thickness resulted in gross-section yielding and good elongation. Misalignment (offset) of 3 mm slightly reduced the elongation relative to plates within tolerances. There was no consistent difference between the results of the undermatched welds and the overmatched welds.

  6. Transverse texture and microstructure gradients in friction-stir welded 2519 aluminum.

    SciTech Connect

    Bingert, J. F.; Fonda, R. W.

    2003-01-01

    Friction-stir welding produces severe thermomechanical transients that generate crystallographic texture evolution throughout the weld-affected microstructure . In this study, a friction stir weld in a coarse-grained 2519 aluminum plate was investigated in order to resolve the influence of these thermal and deformation effects on texture and microstructure development . Automated electron backscatter diffraction (EBSD) was applied to spatially resolve orientations in the base metal, weld nugget, and thermomechanical and heat-affected zones. Results show a gradient demarcated by an alteration in boundary character, texture, and precipitate distribution between the thermomechanical affected zone and the recrystallized weld nugget . EBSD scans and microstructural characterizations reveal substructure evolution from the base plate to the nugget indicative of dynamic recovery and recrystallization processes . Experimental results of texture evolution, however, did not directly follow from considerations of simplified deformation gradients and resultant simple shear textures resulting from restricted glide .

  7. Stability of the grain structure in 2219-O aluminum alloy friction stir welds during solution treatment

    SciTech Connect

    Chen, Y.C. . E-mail: armstrong@hit.edu.cn; Feng, J.C.; Liu, H.J.

    2007-02-15

    The stability of the grain structure in 2219-O aluminum alloy friction stir welds during solution treatment has been investigated. Experimental results show that the solution treatment causes drastic grain growth, Grain growth initiates at the surface and the bottom of the weld and then extends to the weld centre within several minutes. The solution treatment temperature and the welding heat input have a significant effect on grain growth. The higher the solution temperature, or the higher the welding heat input, the greater the grain growth. The instability of the grains is attributed to an imbalance between thermodynamic driving forces for grain growth and the pinning forces impeding grain boundary migration during solution treatment.

  8. Influence of Alloy and Solidification Parameters on Grain Refinement in Aluminum Weld Metal due to Inoculation

    SciTech Connect

    Schempp, Philipp; Tang, Z.; Cross, Carl E.; Seefeld, T.; Pittner, A.; Rethmeier, M.

    2012-06-28

    The goals are: (1) Establish how much Ti/B grain refiner is need to completely refine aluminum weld metal for different alloys and different welding conditions; (2) Characterize how alloy composition and solidification parameters affect weld metal grain refinement; and (3) Apply relevant theory to understand observed behavior. Conclusions are: (1) additions of Ti/B grain refiner to weld metal in Alloys 1050, 5083, and 6082 resulted in significant grain refinement; (2) grain refinement was more effective in GTAW than LBW, resulting in finer grains at lower Ti content - reason is limited time available for equiaxed grain growth in LBW (inability to occlude columnar grain growth); (3) welding travel speed did not markedly affect grain size within GTAW and LBW clusters; and (4) application of Hunt CET analysis showed experimental G to be on the order of the critical G{sub CET}; G{sub CET} was consistently higher for GTAW than for LBW.

  9. Hazard of ultraviolet radiation emitted in gas tungsten arc welding of aluminum alloys

    PubMed Central

    NAKASHIMA, Hitoshi; UTSUNOMIYA, Akihiro; FUJII, Nobuyuki; OKUNO, Tsutomu

    2015-01-01

    Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema. The extent of the hazard of UVR varies depending on the welding method and conditions. Therefore, it is important to identify the levels of UVR that are present under various conditions. In this study, we experimentally evaluated the hazard of UVR emitted in gas tungsten arc welding (GTAW) of aluminum alloys. The degree of hazard of UVR is measured by the effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines. The effective irradiances measured in this study are in the range 0.10–0.91 mW/cm2 at a distance of 500 mm from the welding arc. The maximum allowable exposure times corresponding to these levels are only 3.3–33 s/day. This demonstrates that unprotected exposure to UVR emitted by GTAW of aluminum alloys is quite hazardous in practice. In addition, we found the following properties of the hazard of UVR. (1) It is more hazardous at higher welding currents than at lower welding currents. (2) It is more hazardous when magnesium is included in the welding materials than when it is not. (3) The hazard depends on the direction of emission from the arc. PMID:26632121

  10. Hazard of ultraviolet radiation emitted in gas tungsten arc welding of aluminum alloys.

    PubMed

    Nakashima, Hitoshi; Utsunomiya, Akihiro; Fujii, Nobuyuki; Okuno, Tsutomu

    2016-01-01

    Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema. The extent of the hazard of UVR varies depending on the welding method and conditions. Therefore, it is important to identify the levels of UVR that are present under various conditions. In this study, we experimentally evaluated the hazard of UVR emitted in gas tungsten arc welding (GTAW) of aluminum alloys. The degree of hazard of UVR is measured by the effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines. The effective irradiances measured in this study are in the range 0.10-0.91 mW/cm(2) at a distance of 500 mm from the welding arc. The maximum allowable exposure times corresponding to these levels are only 3.3-33 s/day. This demonstrates that unprotected exposure to UVR emitted by GTAW of aluminum alloys is quite hazardous in practice. In addition, we found the following properties of the hazard of UVR. (1) It is more hazardous at higher welding currents than at lower welding currents. (2) It is more hazardous when magnesium is included in the welding materials than when it is not. (3) The hazard depends on the direction of emission from the arc. PMID:26632121