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Sample records for automated weld characterization

  1. Automated Weld Characterization Using the Thermoelectric Method

    NASA Technical Reports Server (NTRS)

    Fulton, J. P.; Wincheski, B.; Namkung, M.

    1992-01-01

    The effective assessment of the integrity of welds is a complicated NDE problem that continues to be a challenge. To be able to completely characterize a weld, detailed knowledge of its tensile strength, ductility, hardness, microstructure, macrostructure, and chemical composition is needed. NDE techniques which can provide information on any of these features are extremely important. In this paper, we examine a seldom used approach based on the thermoelectric (TE) effect for characterizing welds and their associated heat affected zone (HAZ). The thermoelectric method monitors the thermoelectric power which is sensitive to small changes in the kinetics of the conduction electrons near the Fermi surface that can be caused by changes in the local microstructure. The technique has been applied to metal sorting, quality testing, flaw detection, thickness gauging of layers, and microscopic structural analysis. To demonstrate the effectiveness of the technique for characterizing welds, a series of tungsten-inert-gas welded Inconel-718 samples were scanned with a computer controlled TE probe. The samples were then analyzed using a scanning electron microscope and Rockwell hardness tests to characterize the weld and the associated HAZ. We then correlated the results with the TE measurements to provide quantitative information on the size of the HAZ and the degree of hardness of the material in the weld region. This provides potentially valuable information on the strength and fatigue life of the weld. We begin the paper by providing a brief review of the TE technique and then highlight some of the factors that can effect the measurements. Next, we provide an overview of the experimental procedure and discuss the results. Finally, we summarize our findings and consider areas for future research.

  2. 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.

  3. Programmable Automated Welding System (PAWS)

    NASA Technical Reports Server (NTRS)

    Kline, Martin D.

    1994-01-01

    An ambitious project to develop an advanced, automated welding system is being funded as part of the Navy Joining Center with Babcock & Wilcox as the prime integrator. This program, the Programmable Automated Welding System (PAWS), involves the integration of both planning and real-time control activities. Planning functions include the development of a graphical decision support system within a standard, portable environment. Real-time control functions include the development of a modular, intelligent, real-time control system and the integration of a number of welding process sensors. This paper presents each of these components of the PAWS and discusses how they can be utilized to automate the welding operation.

  4. Automated generation of weld path trajectories.

    SciTech Connect

    Sizemore, John M.; Hinman-Sweeney, Elaine Marie; Ames, Arlo Leroy

    2003-06-01

    AUTOmated GENeration of Control Programs for Robotic Welding of Ship Structure (AUTOGEN) is software that automates the planning and compiling of control programs for robotic welding of ship structure. The software works by evaluating computer representations of the ship design and the manufacturing plan. Based on this evaluation, AUTOGEN internally identifies and appropriately characterizes each weld. Then it constructs the robot motions necessary to accomplish the welds and determines for each the correct assignment of process control values. AUTOGEN generates these robot control programs completely without manual intervention or edits except to correct wrong or missing input data. Most ship structure assemblies are unique or at best manufactured only a few times. Accordingly, the high cost inherent in all previous methods of preparing complex control programs has made robot welding of ship structures economically unattractive to the U.S. shipbuilding industry. AUTOGEN eliminates the cost of creating robot control programs. With programming costs eliminated, capitalization of robots to weld ship structures becomes economically viable. Robot welding of ship structures will result in reduced ship costs, uniform product quality, and enhanced worker safety. Sandia National Laboratories and Northrop Grumman Ship Systems worked with the National Shipbuilding Research Program to develop a means of automated path and process generation for robotic welding. This effort resulted in the AUTOGEN program, which has successfully demonstrated automated path generation and robot control. Although the current implementation of AUTOGEN is optimized for welding applications, the path and process planning capability has applicability to a number of industrial applications, including painting, riveting, and adhesive delivery.

  5. Wire-Guide Manipulator For Automated Welding

    NASA Technical Reports Server (NTRS)

    Morris, Tim; White, Kevin; Gordon, Steve; Emerich, Dave; Richardson, Dave; Faulkner, Mike; Stafford, Dave; Mccutcheon, Kim; Neal, Ken; Milly, Pete

    1994-01-01

    Compact motor drive positions guide for welding filler wire. Drive part of automated wire feeder in partly or fully automated welding system. Drive unit contains three parallel subunits. Rotations of lead screws in three subunits coordinated to obtain desired motions in three degrees of freedom. Suitable for both variable-polarity plasma arc welding and gas/tungsten arc welding.

  6. The Marshall Automated Weld System (MAWS)

    NASA Astrophysics Data System (ADS)

    Russell, Carolyn K.; Lawless, Kirby G.; Nunes, A. C.

    A fully automated welding system, which can operate totally independent of human intervention, is currently unavailable in the welding industry. Development of the Marshall Automated Weld System (MAWS) has been undertaken to fill this void. The system will enable application of statistical process control practices to assure weld quality prior to post weld nondestructive testing. The Variable Polarity Plasma Arc (VPPA) welding process has been baselined for MAWS because it has eliminated process related defects in the welding of the Space Shuttle External Tank. The few remaining weld defects occurring on the tank can be associated with human error. The system integrates multiple sensors (providing real time information on weld bead geometry, weld joint location, wirefeed entry, and inert gas quality) with a weld model (describing weld geometry in relation to critical parameters) and computer controlled VPPA weld equipment. This system is designed to provide real-time, closed-loop control of the weld as it is being made.

  7. The Marshall Automated Weld System (MAWS)

    NASA Astrophysics Data System (ADS)

    Russell, Carolyn K.; Lawless, Kirby G.; Nunes, A. C.

    A fully automated welding system, which can operate totally independent of human intervention, is currently unavailable in the welding industry. Development of the Marshall Automated Weld System (MAWS) has been undertaken to fill this void. The system will enable application of statistical process control practices to assure weld quality prior to post weld nondestructive testing. The Variable Polarity Plasma Arc (VPPA) welding process has been baselined for MAWS because it has eliminated process related defects in the welding of the Space Shuttle External Tank. The few remaining weld defects occurring on the tank can be associated with human error. The system integrates multiple sensors (providing real time information on weld bead geometry, weld joint location, wirefeed entry, and inert gas quality) with a weld model (describing weld geometry in relation to critical parameters) and computer-controlled VPPA weld equipment. This system is designed to provide real-time, closed-loop control of the weld as it is being made.

  8. Analysis And Control System For Automated Welding

    NASA Technical Reports Server (NTRS)

    Powell, Bradley W.; Burroughs, Ivan A.; Kennedy, Larry Z.; Rodgers, Michael H.; Goode, K. Wayne

    1994-01-01

    Automated variable-polarity plasma arc (VPPA) welding apparatus operates under electronic supervision by welding analysis and control system. System performs all major monitoring and controlling functions. It acquires, analyzes, and displays weld-quality data in real time and adjusts process parameters accordingly. Also records pertinent data for use in post-weld analysis and documentation of quality. System includes optoelectronic sensors and data processors that provide feedback control of welding process.

  9. Robotic Tool Changer For Automated Welding

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Spencer, Carl N.

    1994-01-01

    Prototype robotic tool changer for automated welding system eliminates need for most manual tool setups and attendant problems: operates rapidly, always chooses designated tool, maneuvers tip of welding torch or other tool in correct position, and reliably connects water, gas, welding wire, high-voltage electrical signals, and ground. Also loads tools other than those for welding. Intended for use in robotic work cell producing all good parts, no rejects. In production, robot welds part, tests for flaws, and reworks as necessary before releasing it.

  10. Weld line detection and process control for welding automation

    NASA Astrophysics Data System (ADS)

    Yang, Sang-Min; Cho, Man-Ho; Lee, Ho-Young; Cho, Taik-Dong

    2007-03-01

    Welding has been widely used as a process to join metallic parts. But because of hazardous working conditions, workers tend to avoid this task. Techniques to achieve the automation are the recognition of joint line and process control. A CCD (charge coupled device) camera with a laser stripe was applied to enhance the automatic weld seam tracking in GMAW (gas metal arc welding). The adaptive Hough transformation having an on-line processing ability was used to extract laser stripes and to obtain specific weld points. The three-dimensional information obtained from the vision system made it possible to generate the weld torch path and to obtain information such as the width and depth of the weld line. In this study, a neural network based on the generalized delta rule algorithm was adapted to control the process of GMAW, such as welding speed, arc voltage and wire feeding speed. The width and depth of the weld joint have been selected as neurons in the input layer of the neural-network algorithm. The input variables, the width and depth of the weld joint, are determined by image information. The voltage, weld speed and wire feed rate are represented as the neurons in the output layer. The results of the neural-network learning applied to the welding are as follows: learning ratio 0.5, momentum ratio 0.7, the number of hidden layers 2 and the number of hidden units 8. They have significant influence on the weld quality.

  11. Computer Programs For Automated Welding System

    NASA Technical Reports Server (NTRS)

    Agapakis, John E.

    1993-01-01

    Computer programs developed for use in controlling automated welding system described in MFS-28578. Together with control computer, computer input and output devices and control sensors and actuators, provide flexible capability for planning and implementation of schemes for automated welding of specific workpieces. Developed according to macro- and task-level programming schemes, which increases productivity and consistency by reducing amount of "teaching" of system by technician. System provides for three-dimensional mathematical modeling of workpieces, work cells, robots, and positioners.

  12. Residual stress characterization of welds and post-weld processes using x-ray diffraction techniques

    NASA Astrophysics Data System (ADS)

    Brauss, Michael E.; Pineault, James A.; Eckersley, John S.

    1998-03-01

    This paper illustrates the importance of residual stress characterization in welds and post weld processes. The failure to characterize residual stresses created during welding and/or post weld processes can lead to unexpected occurrences of stress corrosion cracking, distortion, fatigue cracking as well as instances of over design or over processing. The development of automated residual stress mapping and the availability of portable and fast equipment have now made the characterization of residual stresses using x-ray diffraction practical for process control and optimization. The paper presents examples where x-ray diffraction residual stress characterization techniques were applied on various kinds of welds including arc welds, TIG welds, resistance welds, laser welds and electron beam welds. The nondestructive nature of the x-ray diffraction technique has made the residual stress characterization of welds a useful tool for process optimization and failure analysis, particularly since components can be measured before and after welding and post welding processes. Some examples presented show the residual stresses before and after the application of post weld processes such as shot peening, grinding and heat treatment.

  13. Welding rework data acquisition and automation

    NASA Technical Reports Server (NTRS)

    Romine, Peter L.

    1996-01-01

    Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these.

  14. Automated GMA welding of austenitic stainless steel pipe

    SciTech Connect

    Tahash, G.J.

    1996-12-31

    The study focused on reducing weld cycle times of rotatable subassemblies (spools) using automated welding equipment. A unique automatic Gas Metal Arc Welding (GMAW) system was used to produce a series of pipe to pipe welds on 141 mm (5 in.) schedule 80 seamless stainless steel pipe. After manual tack welding, the adaptive control system welded the root pass of the argon gas backed open vee groove circumferential butt joints in the IG rotated position with short circuiting transfer GMAW. The fill and cover passes were welded automatically with spray transfer GMAW. Automatic welding cycle times were found to be 50--80 percent shorter than the current techniques of roll welding with Shielded Metal Arc Welding and manual Gas Tungsten Arc Welding. Weld costs ({Brit_pounds}/m), including amortization, for the various systems were compared. The cost of automated GMA welds was virtually equivalent to the most competitive methods while depositing 75% more filler metal per year. Also investigated were metallurgical effects generated by weld thermal cycling, and the associated effects on mechanical properties of the weld joint. Mechanical properties of the welds met or exceeded those of the base metal. Sensitization of the pipe did not occur in the heat affected zone (HAZ), based on the absence of evidence of intergranular attack in modified Strauss corrosion tests and despite the fact of interpass temperatures well above recommended maximums. Cooling rates of 3--5 C/s in the heat affected zone of the four pass welds were measured by thermocouple technique and found to be within the non-sensitizing range for this alloy.

  15. Automated weld torch guidance control system

    NASA Technical Reports Server (NTRS)

    Smith, H. E.; Wall, W. A.; Burns, M. R., Jr. (Inventor)

    1986-01-01

    A device for automatically controlling the movement of a welding torch while welding an elongated joint is described. A charge injection television camera is carried on a movable support. The camera includes a matrix of individual light sensing video elements which generate voltages responsive to light reflected off of the joint and surrounding areas of the work piece. The voltages produced by the pixels are converted to digital words which are fed to a microprocessor for generating an error signal. This error signal is fed to a digital motor which is used to drive a movable support upon which the television camera is carried.

  16. Advanced computer architecture specification for automated weld systems

    NASA Technical Reports Server (NTRS)

    Katsinis, Constantine

    1994-01-01

    This report describes the requirements for an advanced automated weld system and the associated computer architecture, and defines the overall system specification from a broad perspective. According to the requirements of welding procedures as they relate to an integrated multiaxis motion control and sensor architecture, the computer system requirements are developed based on a proven multiple-processor architecture with an expandable, distributed-memory, single global bus architecture, containing individual processors which are assigned to specific tasks that support sensor or control processes. The specified architecture is sufficiently flexible to integrate previously developed equipment, be upgradable and allow on-site modifications.

  17. Exoscope Update: Automated Laser Welding Of Circumferential Tissue Anastomoses

    NASA Astrophysics Data System (ADS)

    Sauer, Jude S.; McGuire, Kevin P.; Hinshaw, J. Raymond

    1989-09-01

    The speed, accuracy and efficiency of using laser energy to fuse together or weld living tissue makes laser tissue welding one of the most exciting areas of medical research today. Numerous investigators using animal models and several surgeons conducting clinical studies have demonstrated many promising potential applications of laser tissue welding. Accurate tissue positioning and well controlled delivery of laser energy during laser welding are essential for consistently successful laser tissue repairs. Many surgical procedures involve the creation of functional anastomoses, which are patent connections between hollow, tubular tissue structures, like bowel, blood vessels or fallopian tubes. We are developing the Exoscope SystemTM to automate and simplify the production of laser welded end-to-end and end-to-side anastomoses. Any laser light that can be passed through an optical fiber can be used in this system. The Exoscope SystemTM employs a fiber optic Exoscope Device,TM which provides for the precise placement of laser energy onto the abutted tissue seam, and a biocompatible, dissolvable intraluminal PolySurgeTM stent, which holds the tissue in circumferential apposition during lasing. The feasibility of employing the Exoscope SystemTM technique for the construction of rabbit small bowel anastomoses was successfully demonstrated in a Phase I study comparing 30 Exoscope SystemTM laser welded anastomoses to 30 conventional sutured anastomoses.

  18. Automation of the electron-beam welding process

    NASA Astrophysics Data System (ADS)

    Koleva, E.; Dzharov, V.; Kardjiev, M.; Mladenov, G.

    2016-03-01

    In this work, the automatic control is considered of the vacuum and cooling systems of the located in the IE-BAS equipment for electron-beam welding, evaporation and surface modification. A project was elaborated for the control and management based on the development of an engineering support system using existing and additional technical means of automation. Optimization of the indicators, which are critical for the duration of reaching the working regime and stopping the operation of the installation, can be made using experimentally obtained transient characteristics. The automation of the available equipment aimed at improving its efficiency and the repeatability of the obtained results, as well as at stabilizing the process parameters, should be integrated in an Engineering Support System which, besides the operator supervision, consists of several subsystems for equipment control, data acquisition, information analysis, system management and decision-making support.

  19. Laser based spot weld characterization

    NASA Astrophysics Data System (ADS)

    Jonietz, Florian; Myrach, Philipp; Rethmeier, Michael; Suwala, Hubert; Ziegler, Mathias

    2016-02-01

    Spot welding is one of the most important joining technologies, especially in the automotive industry. Hitherto, the quality of spot welded joints is tested mainly by random destructive tests. A nondestructive testing technique offers the benefit of cost reduction of the testing procedure and optimization of the fabrication process, because every joint could be examined. This would lead to a reduced number of spot welded joints, as redundancies could be avoided. In the procedure described here, the spot welded joint between two zinc-coated steel sheets (HX340LAD+Z100MB or HC340LA+ZE 50/50) is heated optically on one side. Laser radiation and flash light are used as heat sources. The melted zone, the so called "weld nugget" provides the mechanical stability of the connection, but also constitutes a thermal bridge between the sheets. Due to the better thermal contact, the spot welded joint reveals a thermal behavior different from the surrounding material, where the heat transfer between the two sheets is much lower. The difference in the transient thermal behavior is measured with time resolved thermography. Hence, the size of the thermal contact between the two sheets is determined, which is directly correlated to the size of the weld nugget, indicating the quality of the spot weld. The method performs well in transmission with laser radiation and flash light. With laser radiation, it works even in reflection geometry, thus offering the possibility of testing with just one-sided accessibility. By using heating with collimated laser radiation, not only contact-free, but also remote testing is feasible. A further convenience compared to similar thermographic approaches is the applicability on bare steel sheets without any optical coating for emissivity correction. For this purpose, a proper way of emissivity correction was established.

  20. Automated Variable-Polarity Plasma-Arc Welding

    NASA Technical Reports Server (NTRS)

    Numes, A. C., Jr.; Bayless, E. O., Jr.; Jones, S. C., III; Munafo, P.; Munafo, A.; Biddle, A.; Wilson, W.

    1984-01-01

    Variable-polarity plasma-arc methods produces better welds at lower cost than gas-shielded tungsten-arc welding in assemblies. Weld porosity very low and costs of joint preparation, depeaking, inspection, and weld repair minimized.

  1. Development of automated welding process for field fabrication of thick walled pressure vessels. Fourth quarter, FY 1980

    SciTech Connect

    Not Available

    1980-12-19

    Progress is reported in research on the automated welding of heavy steel plate for the fabrication of pressure vessels. Information is included on: torch and shield adaptation; mechanical control of the welding process; welding parameters; joint design; filler wire optimizaton; nondestructive testing of welds; and weld repair. (LCL)

  2. Design, construction, and characterization of a novel robotic welding fume generator and inhalation exposure system for laboratory animals.

    PubMed

    Antonini, James M; Afshari, Aliakbar A; Stone, Sam; Chen, Bean; Schwegler-Berry, Diane; Fletcher, W Gary; Goldsmith, W Travis; Vandestouwe, Kurt H; McKinney, Walter; Castranova, Vincent; Frazer, David G

    2006-04-01

    Respiratory effects observed in welders have included lung function changes, metal fume fever, bronchitis, and a possible increase in the incidence of lung cancer. Many questions remain unanswered regarding the causality and possible underlying mechanisms associated with the potential toxic effects of welding fume inhalation. The objective of the present study was to construct a completely automated, computer-controlled welding fume generation and inhalation exposure system to simulate real workplace exposures. The system comprised a programmable six-axis robotic welding arm, a water-cooled arc welding torch, and a wire feeder that supplied the wire to the torch at a programmed rate. For the initial studies, gas metal arc welding was performed using a stainless steel electrode. A flexible trunk was attached to the robotic arm of the welder and was used to collect and transport fume from the vicinity of the arc to the animal exposure chamber. Undiluted fume concentrations consistently ranged from 90-150 mg/m(3) in the animal chamber during welding. Temperature and humidity remained constant in the chamber during the welding operation. The welding particles were composed of (from highest to lowest concentration) iron, chromium, manganese, and nickel as measured by inductively coupled plasma atomic emission spectroscopy. Size distribution analysis indicated the mass median aerodynamic diameter of the generated particles to be approximately 0.24 microm with a geometric standard deviation (sigma(g)) of 1.39. As determined by transmission and scanning electron microscopy, the generated aerosols were mostly arranged as chain-like agglomerates of primary particles. Characterization of the laboratory-generated welding aerosol has indicated that particle morphology, size, and chemical composition are comparable to stainless steel welding fume generated in other studies. With the development of this novel system, it will be possible to establish an animal model using

  3. 3D Polymer Weld Seam Characterization Based on Optical Coherence Tomography for Laser Transmission Welding Applications

    NASA Astrophysics Data System (ADS)

    Schmitt, Robert; Mallmann, Guilherme; Devrient, Martin; Schmidt, Michael

    Laser transmission welding is an established single-stage plastic joining process, which enables hermetically sealed joints under the workpiece surface. The process requires joining partners with proper degrees of transmission and absorption to the processing wavelength. For reaching a stable process an in-process quality assurance is very valuable. Current monitoring systems have a limited usage, as no quantitative information of the weld itself is obtained without its destruction. In medical and pharmaceutical applications a weld with leakage is e.g. unacceptable. The main objective of this paper is the presentation of the optical coherence tomography as a tool for the quality assurance in laser transmission welding. This approach enables the measurement of any residual gap, weld geometry, internal pores and leaks. The presented results show that this technique allows even the characterization of welds using joining partners with thicknesses of 2 mm or with glass fiber reinforcement levels of 30% per weight.

  4. Programmable Automated Welding System (PAWS): Control of welding through software and hardware

    NASA Technical Reports Server (NTRS)

    Kline, Martin D.; Doyle, Thomas E.

    1994-01-01

    The ATD phase of the PAWS program ended in November 1992 and the follow-on ManTech program was started in September 1993. The system will be industrially hardened during the first year of this program. Follow-on years will focus upon the transition into specific end-user sites. These implementations will also expand the system into other welding processes (e.g. FCAW, GTAW, PAW). In addition, the architecture is being developed for application to other non-welding robotic processes (e.g. inspection, surface finishing). Future development is anticipated to encompass hardening for extreme environments, expanded exception handling techniques, and application to a range of manipulators.

  5. Automated Characterization Of Vibrations Of A Structure

    NASA Technical Reports Server (NTRS)

    Bayard, David S.; Yam, Yeung; Mettler, Edward; Hadaegh, Fred Y.; Milman, Mark H.; Scheid, Robert E.

    1992-01-01

    Automated method of characterizing dynamical properties of large flexible structure yields estimates of modal parameters used by robust control system to stabilize structure and minimize undesired motions. Based on extraction of desired modal and control-design data from responses of structure to known vibrational excitations. Applicable to terrestrial structures where vibrations are important - aircraft, buildings, bridges, cranes, and drill strings.

  6. 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

  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. Computer automation of ultrasonic testing. [inspection of ultrasonic welding

    NASA Technical Reports Server (NTRS)

    Yee, B. G. W.; Kerlin, E. E.; Gardner, A. H.; Dunmyer, D.; Wells, T. G.; Robinson, A. R.; Kunselman, J. S.; Walker, T. C.

    1974-01-01

    Report describes a prototype computer-automated ultrasonic system developed for the inspection of weldments. This system can be operated in three modes: manual, automatic, and computer-controlled. In the computer-controlled mode, the system will automatically acquire, process, analyze, store, and display ultrasonic inspection data in real-time. Flaw size (in cross-section), location (depth), and type (porosity-like or crack-like) can be automatically discerned and displayed. The results and pertinent parameters are recorded.

  9. Welding.

    ERIC Educational Resources Information Center

    South Carolina State Dept. of Education, Columbia. Office of Vocational Education.

    This curriculum guide is designed for use by South Carolina vocational education teachers as a continuing set of lesson plans for a two-year course on welding. Covered in the individual sections of the guide are the following topics: an orientation to welding, oxyacetylene welding, advanced oxyacetylene welding, shielded metal arc welding, TIG…

  10. Detailed characterization of welding fumes in personal exposure samples

    NASA Astrophysics Data System (ADS)

    Quémerais, B.; Mino, James; Amin, M. R.; Golshahi, H.; Izadi, H.

    2015-05-01

    The objective of the project was to develop a method allowing for detailed characterization of welding particles including particle number concentration, size distribution, surface chemistry and chemical composition of individual particles, as well as metal concentration of various welding fumes in personal exposure samples using regular sampling equipment. A sample strategy was developed to evaluate the variation of the collection methods on mass concentration. Samples were collected with various samplers and filters at two different locations using our collection system. The first location was using a robotic welding system while the second was manual welding. Collected samples were analysed for mass concentration using gravimetryand metal concentration using ICP/OES. More advanced analysis was performed on selected filters using X-Ray Photoelectron Spectroscopy to determine surface composition of the particles, and X-Ray Diffraction to determine chemical composition of the fumes. Results showed that the robotic system had a lot of variation in space when the collection system was located close to the weld. Collection efficiency was found to be quite variable depending upon the type of filter. As well, metal concentrations in blank filters were dependent upon the type of filter with MCE presenting with the highest blank values. Results obtained with the XRD and XPS systems showed that it was possible to analyse a small of powdered welding fume sample but results on filters were not conclusive.

  11. Characterization of Cassini GPHS Fueled-Clad Production Girth Welds

    SciTech Connect

    Franco-Ferreira, E.A.

    2000-03-23

    Fueled clads for radioisotope power systems are produced by encapsulating {sup 238}PuO{sub 2} in iridium alloy cups, which are joined at their equators by gas tungsten arc welding. Cracking problems at the girth weld tie-in area during production of the Galileo/Ulysses GPHS capsules led to the development of a first-generation ultrasonic test for girth weld inspection at the Savannah River Plant. A second-generation test and equipment with significantly improved sensitivity and accuracy were jointly developed by the Oak Ridge Y-12 Plant and Westinghouse Savannah River Company for use during the production of Cassini GPHS capsules by the Los Alamos National Laboratory. The test consisted of Lamb wave ultrasonic scanning of the entire girth weld from each end of the capsule combined with a time-of-flight evaluation to aid in characterizing nonrelevant indications. Tangential radiography was also used as a supplementary test for further evaluation of reflector geometry. Each of the 317 fueled GPHS capsules, which were girth welded for the Cassini Program, was subjected to a series of nondestructive tests that included visual, dimensional, helium leak rate, and ultrasonic testing. Thirty-three capsules were rejected prior to ultrasonic testing. Of the 44 capsules rejected by the standard ultrasonic test, 22 were upgraded to flight quality through supplementary testing for an overall process acceptance rate of 82.6%. No confirmed instances of weld cracking were found.

  12. Longitudinal seam weld characterization by focused ultrasonics

    NASA Astrophysics Data System (ADS)

    Bisbee, Laney H.; Nottingham, Lawrence

    1996-11-01

    Increasingly, the detectability limits placed on inspection methodologies applied to the assessment of critical high energy components in fossil fuelled power plants are being forced to lower values. Most notably, recent events involving longitudinal seam welded piping have raised the question of lowering the detectibility limit for ultrasonics to a level necessary for resolving incipient creep damage. Historically, several testing methods were required for the detection of defects over the range of anticipated flaw sizes in an economically and technically acceptable manner. However, unyielding limitations exist for several of these currently used methods. While accepting that the detection of isolated creep cavities is not technically feasible with current conventional ultrasonic methods, the detection of high density cavitation sheets or zones prior to microcrack initiation has been demonstrated and successfully applied to field inspection of critical welds using focused ultrasonics. This paper describes the equipment and verification process used to extend the detectability limit of a field ultrasonic systems for longitudinal seam weld evaluations to approaching that of an acoustic microscope for the identification of incipient creep cavitation.

  13. Characterization of Nitinol Laser-Weld Joints by Nondestructive Testing

    NASA Astrophysics Data System (ADS)

    Wohlschlögel, Markus; Gläßel, Gunter; Sanchez, Daniela; Schüßler, Andreas; Dillenz, Alexander; Saal, David; Mayr, Peter

    2015-12-01

    Joining technology is an integral part of today's Nitinol medical device manufacturing. Besides crimping and riveting, laser welding is often applied to join components made from Nitinol to Nitinol, as well as Nitinol components to dissimilar materials. Other Nitinol joining techniques include adhesive bonding, soldering, and brazing. Typically, the performance of joints is assessed by destructive mechanical testing, on a process validation base. In this study, a nondestructive testing method—photothermal radiometry—is applied to characterize small Nitinol laser-weld joints used to connect two wire ends via a sleeve. Two different wire diameters are investigated. Effective joint connection cross sections are visualized using metallography techniques. Results of the nondestructive testing are correlated to data from destructive torsion testing, where the maximum torque at fracture is evaluated for the same joints and criteria for the differentiation of good and poor laser-welding quality by nondestructive testing are established.

  14. Metabolomic characterization of laborers exposed to welding fumes.

    PubMed

    Wang, Kuo-Ching; Kuo, Ching-Hua; Tian, Tze-Feng; Tsai, Mong-Hsun; Chiung, Yin-Mei; Hsiech, Chun-Ming; Tsai, Sung-Jeng; Wang, San-Yuan; Tsai, Dong-Ming; Huang, Chiang-Ching; Tseng, Y Jane

    2012-03-19

    The complex composition of welding fumes, multiplicity of molecular targets, diverse cellular effects, and lifestyles associated with laborers vastly complicate the assessment of welding fume exposure. The urinary metabolomic profiles of 35 male welders and 16 male office workers at a Taiwanese shipyard were characterized via (1)H NMR spectroscopy and pattern recognition methods. Blood samples for the same 51 individuals were also collected, and the expression levels of the cytokines and other inflammatory markers were examined. This study dichotomized the welding exposure variable into high (welders) versus low (office workers) exposures to examine the differences of continuous outcome markers-metabolites and inflammatory markers-between the two groups. Fume particle assessments showed that welders were exposed to different concentrations of chromium, nickel, and manganese particles. Multivariate statistical analysis of urinary metabolomic patterns showed higher levels of glycine, taurine, betaine/TMAO, serine, S-sulfocysteine, hippurate, gluconate, creatinine, and acetone and lower levels of creatine among welders, while only TNF-α was significantly associated with welding fume exposure among all cytokines and other inflammatory markers measured. Of the identified metabolites, the higher levels of glycine, taurine, and betaine among welders were suspected to play some roles in modulating inflammatory and oxidative tissue injury processes. In this metabolomics experiment, we also discovered that the association of the identified metabolites with welding exposure was confounded by smoking, but not with drinking, which is a finding consistent with known modified response of inflammatory markers among smokers. Our results correspond with prior studies that utilized nonmetabolomic analytical techniques and suggest that the metabolomic profiling is an efficient method to characterize the overall effect of welding fume exposure and other confounders. PMID:22292500

  15. B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

    NASA Technical Reports Server (NTRS)

    Bjorkman, Gerry; Russell, Carolyn

    2000-01-01

    NASA Marshall Space Flight Center, Lockheed Martin Space Systems- Michoud Operations, and McCook Metals have developed an aluminum-copper weld filler wire for fusion welding aluminum lithium alloy 2195. The aluminum-copper based weld filler wire has been identified as B218, a McCook Metals designation. B218 is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties over the 4043 aluminum-silicon weld filler wire, which is currently used to weld 2195 on the Super Lightweight External Tank for the NASA Space Shuttle Program. An initial characterization was performed consisting of a repair weld evaluation using B218 and 4043 weld filler wires. The testing involved room temperature and cryogenic repair weld tensile testing along with fracture toughness testing. From the testing, B218 weld filler wire produce enhanced repair weld tensile strength, ductility, and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding aluminum lithium alloy 2195 over 4043.

  16. Welding.

    ERIC Educational Resources Information Center

    Lehigh County Area Vocational-Technical School, Schnecksville, PA.

    This curriculum guide provides materials for a 12-unit secondary course in welding. Purpose stated for the flexible entry and exit course is to help students master manipulative skills to develop successful welding techniques and to gain an understanding of the specialized tools and equipment used in the welding field. Units cover oxyacetylene…

  17. Automated tissue characterization in MR imaging

    NASA Astrophysics Data System (ADS)

    Braun, Juergen; Bernarding, Johannes; Koennecke, Hans-Christian; Wolf, Karl J.; Tolxdorff, Thomas

    2000-04-01

    A histogram-based segmentation technique was extended to exploit information acquired by manifold MRI techniques. An automated method was used to combine T2-weighted imaging, diffusion-weighted imaging (DWI), and derived maps of the quantitative apparent diffusion coefficient (ADC). DWI allows the early detection of cerebral ischemia, and the calculated ADC value may provide information on pathophysiologic changes. Different optionally shaped clusters were characterized as separate local density maxima in the resultant 3D histogram. Cluster borders were determined by detecting density minima. Distinct but related clusters could be merged in the histogram using the Euclidian distance and a score describing the spatial neighborhood of pixels in the image. In healthy volunteers, gray matter, white matter, muscle, skin, adipose tissue, and cerebrospinal fluid were clearly identified by the automated analysis. In stroke patients, ischemic regions were reliably segmented irrespective of shape, size, and location. The time course of relative ADC changes in ischemic lesions was determined. Results were confirmed by a radiologist. The proposed automatic segmentation algorithm can be used without restrictions for the fast analysis of any multidimensional dataset. The method has proved to be reliable for determining quantities containing information on the physiologic state of tissue, such as the ADC.

  18. Welding Research

    NASA Technical Reports Server (NTRS)

    1982-01-01

    Welding fabrication and welding processes were studied. The following research projects are reported: (1) welding fabrication; (2) residual stresses and distortion in structural weldments in high strength steels; (3) improvement of reliability of welding by in process sensing and control (development of smart welding machines for girth welding of pipes); (4) development of fully automated and integrated welding systems for marine applications; (5) advancement of welding technology; (6) research on metal working by high power laser (7) flux development; (8) heat and fluid flow; (9) mechanical properties developments.

  19. Automated clustering-based workload characterization

    NASA Technical Reports Server (NTRS)

    Pentakalos, Odysseas I.; Menasce, Daniel A.; Yesha, Yelena

    1996-01-01

    The demands placed on the mass storage systems at various federal agencies and national laboratories are continuously increasing in intensity. This forces system managers to constantly monitor the system, evaluate the demand placed on it, and tune it appropriately using either heuristics based on experience or analytic models. Performance models require an accurate workload characterization. This can be a laborious and time consuming process. It became evident from our experience that a tool is necessary to automate the workload characterization process. This paper presents the design and discusses the implementation of a tool for workload characterization of mass storage systems. The main features of the tool discussed here are: (1)Automatic support for peak-period determination. Histograms of system activity are generated and presented to the user for peak-period determination; (2) Automatic clustering analysis. The data collected from the mass storage system logs is clustered using clustering algorithms and tightness measures to limit the number of generated clusters; (3) Reporting of varied file statistics. The tool computes several statistics on file sizes such as average, standard deviation, minimum, maximum, frequency, as well as average transfer time. These statistics are given on a per cluster basis; (4) Portability. The tool can easily be used to characterize the workload in mass storage systems of different vendors. The user needs to specify through a simple log description language how the a specific log should be interpreted. The rest of this paper is organized as follows. Section two presents basic concepts in workload characterization as they apply to mass storage systems. Section three describes clustering algorithms and tightness measures. The following section presents the architecture of the tool. Section five presents some results of workload characterization using the tool.Finally, section six presents some concluding remarks.

  20. Study of Mechanical Properties and Characterization of Pipe Steel welded by Hybrid (Friction Stir Weld + Root Arc Weld) Approach

    SciTech Connect

    Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray; Wasson, Andrew J; Fairchild, Doug P; Wang, Yanli; Feng, Zhili

    2015-01-01

    Friction stir welding (FSW) has recently attracted attention as an alternative construction process for gas/oil transportation applications due to advantages compared to fusion welding techniques. A significant advantage is the ability of FSW to weld the entire or nearly the entire wall thickness in a single pass, while fusion welding requires multiple passes. However, when FSW is applied to a pipe or tube geometry, an internal back support anvil is required to resist the plunging forces exerted during FSW. Unfortunately, it may not be convenient or economical to use internal backing support due to limited access for some applications. To overcome this issue, ExxonMobil recently developed a new concept, combining root arc welding and FSW. That is, a root arc weld is made prior to FSW that supports the normal loads associated with FSW. In the present work, mechanical properties of a FSW + root arc welded pipe steel are reported including microstructure and microhardness.

  1. Automated gunshot residue particle search and characterization.

    PubMed

    Tillman, W L

    1987-01-01

    The main disadvantage to gunshot residue (GSR) particle analysis utilizing scanning electron microscope/energy dispersive X-ray (SEM/EDX) instrumentation has been the excessive operator time required for search and identification. This study uses an automated particle search and characterization program for unattended GSR search and identification. This system allows for automatic matrix search, particle sizing, chemical typing, and spectral aquisition with subsequent storage of data to disk for later operator review and verification. This work describes various aspects of the program, determines appropriate parameters adequate for both unique and characteristic GSR particle identification, and evaluates the reliability of data obtained. Samples are collected via the tape lift method from test-firings of .38, .32, .25, and .22 caliber handguns at time after firing intervals of 0 to 6 h. Unique GSR particles are consistently and correctly identified by this method on tape lift samples taken up to 4 h after firing. False positive results of unique GSR particles are not encountered on control handblank samples. This technique appears to provide the forensic science community with an operator-free method of reliable GSR particle search and an improved analyst-time-per-case ratio. PMID:3819690

  2. Automated Flaw Detection Scheme For Cast Austenitic Stainless Steel Weld Specimens Using Hilbert Huang Transform Of Ultrasonic Phased Array Data

    SciTech Connect

    Khan, T.; Majumdar, Shantanu; Udpa, L.; Ramuhalli, Pradeep; Crawford, Susan L.; Diaz, Aaron A.; Anderson, Michael T.

    2012-01-01

    The objective of this work is to develop processing algorithms to detect and localize the flaws using NDE ultrasonic data. Data was collected using cast austenitic stainless steel (CASS) weld specimens on-loan from the U.S. nuclear power industry’s Pressurized Water Reactor Owners Group (PWROG) specimen set. Each specimen consists of a centrifugally cast stainless steel (CCSS) pipe section welded to a statically cast (SCSS) or wrought (WRSS) section. The paper presents a novel automated flaw detection and localization scheme using low frequency ultrasonic phased array inspection signals in the weld and heat affected zone of the base materials. The major steps of the overall scheme are preprocessing and region of interest (ROI) detection followed by the Hilbert Huang transform (HHT) of A-scans in the detected ROIs. HHT offers time-frequency-energy distribution for each ROI. The accumulation of energy in a particular frequency band is used as a classification feature for the particular ROI.

  3. Fracture mechanics characterization of welds: Fatigue life analysis of notches at welds: J(sub Ic) fracture toughness tests for weld metal

    NASA Astrophysics Data System (ADS)

    Underwood, John H.

    1995-03-01

    In this report two methods of fracture analysis of welds will be emphasized, one addressing fatigue life testing and analysis of notches at welds, and the other addressing the final fracture of the welded component and the fracture toughness tests used to characterize final fracture. These fatigue and fracture methods will be described by referring to recent work from the technical literature and from the U.S. Army Armament Research, Development, and Engineering Center, primarily fracture case study and fracture test method development investigations. A brief general summary will be given of fatigue and fracture methods and concepts that have application to welded structures. Specific fatigue crack initiation tests and analysis methods will be presented, using example results from a welded stainless steel box beam of a cannon carriage. Recent improvements and simplifications in J.integral fracture toughness tests will be described, particularly those related to welds. Fracture toughness measurements for various stainless steel weld metals and heat treatments will also be described.

  4. Zone wise local characterization of welds using digital image correlation technique

    NASA Astrophysics Data System (ADS)

    Saranath, K. M.; Sharma, Abhay; Ramji, M.

    2014-12-01

    The process of welding is associated with high and varying thermal gradients across the weld, resulting in inhomogeneous material properties surrounding the weldment. A proper understanding of the varying mechanical properties of the weld and surrounding materials is important in designing and modelling of components with weld. In the present study the characterization of different zones such as fusion zone, heat affected zones and unaffected base material of a deposited weld is carried out using digital image correlation (DIC) technique. A methodology using the micrographic observation and image processing is proposed for accurate identification of various weld zones. The response of welded samples in the elastic and plastic region is compared with the virgin sample. Full range stress-strain curves are obtained for each zone using the whole field strain measurement involving DIC. The parameters investigated are Young's modulus, Poisson's ratio, yield stress, strain hardening exponent and strength coefficient. A study regarding the variation of properties with respect to varying weld currents of 100 A, 130 A and 150 A is carried out. The Vickers microhardness measurement is also conducted to obtain the variation in hardness across weldment. Fusion zone of all the welded samples have reported lower Young's modulus and higher yield strength compared to virgin samples. The Vickers hardness values obtained for fusion and heat affected zones are in line with the yield stress variation obtained zone wise. Proposed zone wise local characterization of welds using digital image correlation. Weld zones are identified using a strain based method coupled with micrographs. Full range stress-strain curves are extracted for each local weld zones. Local elastic, plastic properties and microhardness across the weld are extracted. Local properties of welds produced using different current ratings are compared.

  5. A Mobile Automated Characterization System (MACS) for indoor floor characterization

    SciTech Connect

    Richardson, B.S.; Haley, D.C.; Dudar, A.M.; Ward, C.R.

    1995-03-01

    The Savannah River Technology Center (SRTC) and Oak Ridge National Laboratory are developing an advanced Mobile Automated Characterization System (MACS) to characterize indoor contaminated floors. MACS is based upon Semi-Intelligent Mobile Observing Navigator (SIMON), an earlier floor characterization system developed at SRTC. MACS will feature enhanced navigation systems, operator interface, and an interface to simplify integration of additional sensors. The enhanced navigation system will provide the capability to survey large open areas much more accurately than is now possible with SIMON, which is better suited for hallways and corridors that provide the means for recalibrating position and heading. MACS operator interface is designed to facilitate MACS`s use as a tool for health physicists, thus eliminating the need for additional training in the robot`s control language. Initial implementation of MACS will use radiation detectors. Additional sensors, such as PCB sensors currently being developed, will be integrated on MACS in the future. Initial use of MACS will be focused toward obtaining comparative results with manual methods. Surveys will be conducted both manually and with MACS to compare relative costs and data quality. While clear cost benefits anticipated, data quality benefits should be even more significant.

  6. CHARACTERIZATION OF DEFECTS IN ALLOY 152, 52 AND 52M WELDS

    SciTech Connect

    Bruemmer, Stephen M.; Toloczko, Mychailo B.; Olszta, Matthew J.; Seffens, Rob J.; Efsing, Pal G.

    2009-08-27

    Defect distributions have been documented by optical metallography, scanning electron microscopy and electron backscatter diffraction in alloy 152 and 52 mockups welds, alloy 52 and 52M overlay mockups and an alloy 52M inlay. Primary defects were small cracks at grain boundaries except for more extensive cracking in the dilution zone of an alloy 52 overlay on 304SS. Detailed characterizations of the dilution zone cracks were performed by analytical transmission electron microscopy identifying grain boundary titanium-nitride precipitation associated with the intergranular separations. I. INTRODUCTION Weldments continue to be a primary location of stress-corrosion cracking (SCC) in light-water reactor systems. While problems related to heat-affected-zone (HAZ) sensitization and intergranular (IG) SCC of austenitic stainless alloys in boiling-water reactors (BWRs) have been significantly reduced, SCC has now been observed in HAZs of non-sensitized materials and in dissimilar metal welds where Ni-base alloy weld metals are used. IGSCC in weld metals has been observed in both BWRs and pressurized water reactors (PWRs) with recent examples for PWR pressure vessel penetrations producing the most concern. This has led to the replacement of alloy 600/182/82 welds with higher Cr, more corrosion-resistant replacement materials (alloy 690/152/52/52M). Complicating this issue has been a known susceptibility to cracking during welding [1-7] of these weld metals. There is a critical need for an improved understanding of the weld metal metallurgy and defect formation in Ni-base alloy welds to effectively assess long-term performance. A series of macroscopic to microscopic examinations were performed on available mockup welds made with alloy 52 or alloy 152 plus selected overlay and inlay mockups. The intent was to expand our understanding of weld metal structures in simulated LWR service components with a focus on as-welded defects. Microstructural features, defect distributions

  7. Characterization of Defocused Electron Beams and Welds in Stainless Steel and Refractory Metals using the Enhanced Modified Faraday Cup Diagnostic

    SciTech Connect

    Elmer, J W

    2009-01-23

    As the first part of a project to compare new generation, continuous wave, laser welding technology to traditional electron beam welding technology, electron beam welds were made on commercially pure vanadium refractory metal and 21-6-9 austenitic stainless steel. The electron beam welds were made while employing EB diagnostics to fully characterize the beams so that direct comparisons could be made between electron beam and laser beams and the welds that each process produces.

  8. Mechanical Characterization of Copper-Copper Wires Joined by Friction Welding Using Instrumented Indentation Technique

    NASA Astrophysics Data System (ADS)

    Morales, M.; Xuriguera, E.; Martínez, M.; Padilla, J. A.; Molera, J.; Ferrer, N.; Segarra, M.; Espiell, F.

    2014-11-01

    Friction welding samples of both the fire-refined high-conductivity (FRHC) and electrolytically tough pitch (ETP) copper alloy wires have been mechanically characterized by instrumented indentation technique and tensile test. Hardness profiles in the perpendicular direction to the weld interface, in both the central and peripheral zones, of the as-welded FRHC-FRHC and ETP-ETP samples have been investigated at nano-/micrometric scale. The microstructures of welds have been observed using both the optical microscopy and scanning electronic microscopy. The results show the typical friction welding zones: the interface zone, the thermo-mechanically affected zone (TMAZ), and the transition zone between the TMAZ and the base metal zone (BMZ) that present a microstructure and hardness close to the base metal. No presence of a heat-affected zone is observed. Although both welds show the same tendency in hardness distribution, FHRC-FHRC weld presents a TMAZ narrower than ETP-ETP one, which produces a stronger drop in hardness with increasing of the distance from welding central line, and a higher difference in hardness between the central and peripheral zones. The tensile tests of ETP-ETP welds showed that all samples broke by the BMZ that is far away from the interface of the welded joint, while the most of the FRHC-FRHC welds are broken at the TMAZ region at low strengths. These appreciable differences in mechanical properties for the FHRC-FHRC welds are probably generated by a stronger variation in their microstructural properties. Therefore, it may justify the welding failures in the FHRC-FHRC weld at the typical tensile stress for an industrial cold-drawn process of wires.

  9. 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.

  10. Characterization of Tungsten Inert Gas (TIG) Welding Fume Generated by Apprentice Welders.

    PubMed

    Graczyk, Halshka; Lewinski, Nastassja; Zhao, Jiayuan; Concha-Lozano, Nicolas; Riediker, Michael

    2016-03-01

    Tungsten inert gas welding (TIG) represents one of the most widely used metal joining processes in industry. Its propensity to generate a greater portion of welding fume particles at the nanoscale poses a potential occupational health hazard for workers. However, current literature lacks comprehensive characterization of TIG welding fume particles. Even less is known about welding fumes generated by welding apprentices with little experience in welding. We characterized TIG welding fume generated by apprentice welders (N = 20) in a ventilated exposure cabin. Exposure assessment was conducted for each apprentice welder at the breathing zone (BZ) inside of the welding helmet and at a near-field (NF) location, 60cm away from the welding task. We characterized particulate matter (PM4), particle number concentration and particle size, particle morphology, chemical composition, reactive oxygen species (ROS) production potential, and gaseous components. The mean particle number concentration at the BZ was 1.69E+06 particles cm(-3), with a mean geometric mean diameter of 45nm. On average across all subjects, 92% of the particle counts at the BZ were below 100nm. We observed elevated concentrations of tungsten, which was most likely due to electrode consumption. Mean ROS production potential of TIG welding fumes at the BZ exceeded average concentrations previously found in traffic-polluted air. Furthermore, ROS production potential was significantly higher for apprentices that burned their metal during their welding task. We recommend that future exposure assessments take into consideration welding performance as a potential exposure modifier for apprentice welders or welders with minimal training. PMID:26464505

  11. Characterization of Tungsten Inert Gas (TIG) Welding Fume Generated by Apprentice Welders

    PubMed Central

    Graczyk, Halshka; Lewinski, Nastassja; Zhao, Jiayuan; Concha-Lozano, Nicolas; Riediker, Michael

    2016-01-01

    Tungsten inert gas welding (TIG) represents one of the most widely used metal joining processes in industry. Its propensity to generate a greater portion of welding fume particles at the nanoscale poses a potential occupational health hazard for workers. However, current literature lacks comprehensive characterization of TIG welding fume particles. Even less is known about welding fumes generated by welding apprentices with little experience in welding. We characterized TIG welding fume generated by apprentice welders (N = 20) in a ventilated exposure cabin. Exposure assessment was conducted for each apprentice welder at the breathing zone (BZ) inside of the welding helmet and at a near-field (NF) location, 60cm away from the welding task. We characterized particulate matter (PM4), particle number concentration and particle size, particle morphology, chemical composition, reactive oxygen species (ROS) production potential, and gaseous components. The mean particle number concentration at the BZ was 1.69E+06 particles cm−3, with a mean geometric mean diameter of 45nm. On average across all subjects, 92% of the particle counts at the BZ were below 100nm. We observed elevated concentrations of tungsten, which was most likely due to electrode consumption. Mean ROS production potential of TIG welding fumes at the BZ exceeded average concentrations previously found in traffic-polluted air. Furthermore, ROS production potential was significantly higher for apprentices that burned their metal during their welding task. We recommend that future exposure assessments take into consideration welding performance as a potential exposure modifier for apprentice welders or welders with minimal training. PMID:26464505

  12. Microstructure characterization of laser welded Ti-6Al-4V fusion zones

    SciTech Connect

    Xu, Pei-quan; Li, Leijun Zhang, Chunbo

    2014-01-15

    The as-welded microstructure of laser-welded Ti-6Al-4V is characterized as a function of CO2 key-hole mode laser welding speed. Martensitic α′ is the predominant phase, with some α and retained β. Phase transformation is affected by the cooling rate through laser welding speed. A higher welding speed of 1.6 to 2.0 m/min produced more martensite α′ and less retained β in the welds. 1.4 m/min welding speed produced small amounts of α, besides the martensite α′. A trace of δ titanium hydride phase seems to have formed in the weld fusion zone. Moiré fringes are a common feature in the TEM microstructure, due to abundance of multi-phase interfaces. Tensile twins and clusters of dislocations indicate that plastic deformation has happened in the as-welded microstructure, indicating the local stress levels to be approaching the yield stress on-cooling during laser welding.

  13. Welding.

    ERIC Educational Resources Information Center

    Baldwin, Harold; Whitney, Gregory

    This curriculum guide is intended to assist vocational instructors in preparing students for entry-level employment as welders and preparing them for advanced training in the workplace. The package contains an overview of new and emerging welding technologies, a competency/skill and task list, an instructor's guide, and an annotated bibliography.…

  14. Welding.

    ERIC Educational Resources Information Center

    Cowan, Earl; And Others

    The curriculum guide for welding instruction contains 16 units presented in six sections. Each unit is divided into the following areas, each of which is color coded: terminal objectives, specific objectives, suggested activities, and instructional materials; information sheet; transparency masters; assignment sheet; test; and test answers. The…

  15. Physical and chemical characterization of airborne particles from welding operations in automotive plants.

    PubMed

    Dasch, Jean; D'Arcy, James

    2008-07-01

    Airborne particles were characterized from six welding operations in three automotive plants, including resistance spot welding, metal inert gas (MIG) welding and tungsten inert gas (TIG) welding of aluminum and resistance spot welding, MIG welding and weld-through sealer of galvanized steel. Particle levels were measured throughout the process area to select a sampling location, followed by intensive particle sampling over one working shift. Temporal trends were measured, and particles were collected on filters to characterize their size and chemistry. In all cases, the particles fell into a bimodal size distribution with very large particles >20 mum in diameter, possibly emitted as spatter or metal expulsions, and very small particles about 1 mum in diameter, possibly formed from condensation of vaporized metal. The mass median aerodynamic diameter was about 1 mum, with only about 7% of the particle mass present as ultrafine particles <100 nm. About half the mass of aluminum welding particles could be accounted for by chemical analysis, with the remainder possibly present as oxygen. Predominant species were organic carbon, elemental carbon, iron, and aluminum. More than 80% of the particle mass could be accounted for from steel welding, primarily present as iron, organic carbon, zinc, and copper. Particle concentrations and elemental concentrations were compared with allowable concentrations as recommended by the Occupational Safety and Health Administration and the American Conference of Governmental Industrial Hygienists. In all cases, workplace levels were at least 11 times lower than recommended levels. PMID:18464098

  16. Ultrasonic spot welding of dissimilar materials: characterization of welded joints and parametric optimization

    NASA Astrophysics Data System (ADS)

    Satpathy, M. P.; Sahoo, S. K.

    2016-02-01

    Material joining is one of the key manufacturing processes used to assemble metallic and non-metallic parts for several applications. But the industries are facing many difficulties in joining of thin sheets of dissimilar metals by the conventional welding process because of their differences in chemical composition, physical and mechanical properties. Thus, ultrasonic welding is a solid state joining process used for joining of small elements in microelectronics industries. In this process, acoustic horn and booster are the important assets. The accuracy and strength of the welding depend mainly on their geometry. This proposed work deals with the design and modelling of an acoustic stepped sonotrode with booster using finite element analysis (FEA). From this analysis, the actual length of the horn is obtained by gradually decreasing its theoretical length. The quality of the weld is reckoned by its weld strength and the combinations of different process parameters. These are examined using the principal components coupled with grey relational analysis approach which is showing good agreement between the predicted values with experimental results. Fractographic examination of weld zone and hardness are also used to explore the weld quality.

  17. Automated Tow Placement Processing and Characterization of Composites

    NASA Technical Reports Server (NTRS)

    Prabhakaran, R.

    2004-01-01

    The project had one of the initial objectives as automated tow placement (ATP), in which a robot was used to place a collimated band of pre-impregnated ribbons or a wide preconsolidated tape onto a tool surface. It was proposed to utilize the Automated Tow Placement machine that was already available and to fabricate carbon fiber reinforced PEEK (polyether-ether-ketone) matrix composites. After initial experiments with the fabrication of flat plates, composite cylinders were to be fabricated. Specimens from the fabricated parts were to be tested for mechanical characterization. A second objective was to conduct various types of tests for characterizing composite specimens cured by different fabrication processes.

  18. Characterization of AZ31B wrought magnesium alloy joints welded by high power fiber laser

    SciTech Connect

    Wang Zemin; Gao Ming Tang Haiguo; Zeng Xiaoyan

    2011-10-15

    A 6 kW fiber laser is used to weld AZ31B wrought magnesium alloy and the characterization of welded joints are studied by the observations of bead size, microstructure and mechanical properties. The accepted joints without macro-defects can be obtained when the laser power is in the range of 2.5 to 4.0 kW. Typical hexagonal dendrites are observed in the fusion zone, whose average semi-axis length increases with increasing heat input or decreasing welding speed. The minimum ultimate tensile strength of welded joints reaches 227 MPa, 94.6% of the base metal. And when the heat input reduces to 48 J/mm or lower, the joints are fractured in the base metal, showing stronger failure strength compared to the base metal. For the joints ruptured in the weld metal, the fracture surface is characterized by a ductile-brittle mixed pattern consisting of both dimples and cleavages. Finally, the formation mechanism of pore in the welds is discussed and summarized by the pore morphologies on the fracture surface. - Highlights: {yields} Accepted joints of AZ31B Mg alloy are produced by high power fiber laser. {yields} Optimal welding parameters are summarized by experimental observations. {yields} Obvious hexagonal dendrites are observed in the fusion zone. {yields} The joints are stronger than base metal as the heat input is lower than 48 J/mm. {yields} Pore formation mechanism of welded joints is discussed and summarized.

  19. Highly automated optical characterization with FTIR spectrometry

    NASA Technical Reports Server (NTRS)

    Perry, G. L. E.; Szofran, F. R.

    1989-01-01

    The procedure for evaluating the characteristics of II-VI semiconducting infrared sensor materials with a Fourier Transform Infrared (FTIR) spectrometer system will be discussed. While the method of mapping optical characteristics with a spectrometer has been employed previously, this system is highly automated compared to other systems where the optical transmission data are obtained using a FTIR system with a small stationary aperture in the optical path and moving the specimen behind the aperture. The hardware and software, including an algorithm developed for extracting cut-on wavelengths of spectra, as well as several example results, are described to illustrate the advanced level of the system. Additionally, data from transverse slices and longitudinal wafers of the aforementioned semiconductors will be used to show the accuracy of the system in predicting trends in materials such as shapes of growth interfaces and compositional uniformity.

  20. Measurement system for systematic hydrological characterization of unsaturated fractured welded tuff in a mined underground tunnel.

    PubMed

    Cook, P J; Salve, R; Freifeld, B M; Tsang, Y T

    2003-01-01

    A field investigation of unsaturated flow through a lithophysal unit of fractured welded tuff containing lithophysal cavities has been initiated. To characterize flow in this spatially heterogeneous medium, a systematic approach has been developed to perform tests in boreholes drilled at regular intervals in an underground tunnel (drift). The purpose of the testing is to quantify the amounts of water seeping into the drift versus the amount of water moving around the drift when released into boreholes at many equidistant locations along the drift. In this paper, we describe the test equipment system that has been built for this purpose. Because the field-scale measurements--of liquid flow in the unsaturated, fractured rocks--require continuous testing for periods of days to weeks, the control of test equipment has been fully automated, allowing operation with no human presence at the field site. Preliminary results from the first set of tests indicate that, while the effects of evaporation on characterization of hydrological properties of the rock can be significant, these effects can be controlled and quantified. These tests give insight into the role of the cavities as potential storage during the initial transient flow prior to the breakthrough of water at the drift crown, as well as the role of connected fractures that provide the subsequent quasi-steady flow. In addition to the stated purpose of realizing the flow partitioning, the results yield values for the effective porosity in the pathways for liquid flow in the regions tested thus far. PMID:12873008

  1. Laser beam welding of Waspaloy: Characterization and corrosion behavior evaluation

    NASA Astrophysics Data System (ADS)

    Shoja Razavi, Reza

    2016-08-01

    In this work, a study on Nd:YAG laser welding of Waspaloy sheets has been made. Microstructures, phase changes and hardness of the laser joint were investigated using optical microscopy, scanning electron microscopy (SEM), field emission scanning electron microscopy (FESEM), energy dispersive spectroscopy (EDS), X-ray diffraction analysis (XRD) and vickers microhardness (HV0.3). Corrosion behavior of the weldment at low temperature in 3.5%wt NaCl solution at room temperature was also investigated using open circuit potential and cyclic potentiodynamic polarization tests. Hot corrosion studies were conducted on samples in the molten salt environment (Na2SO4-60%V2O5) at 900 °C for 50 h. Results indicated that the microstructure of weld zone was mainly dendritic grown epitaxially in the direction perpendicular to the weld boundary and heat transfer. Moreover, the Ti-Mo carbide particles were observed in the structure of the weld zone and base metal. The average size of carbides formed in the base metal (2.97±0.5 μm) was larger than that of the weld zone (0.95±0.2 μm). XRD patterns of the weld zone and base metal showed that the laser welding did not alter the phase structure of the weld zone, being in γ-Ni(Cr) single phase. Microhardness profile showed that the hardness values of the weld zone (210-261 HV) were lower than that of the base metal (323-330 HV). Electrochemical and hot corrosion tests indicated that the corrosion resistance of the weld metal was greater than the base metal in both room and high temperatures.

  2. A computational method for automated characterization of genetic components.

    PubMed

    Yordanov, Boyan; Dalchau, Neil; Grant, Paul K; Pedersen, Michael; Emmott, Stephen; Haseloff, Jim; Phillips, Andrew

    2014-08-15

    The ability to design and construct synthetic biological systems with predictable behavior could enable significant advances in medical treatment, agricultural sustainability, and bioenergy production. However, to reach a stage where such systems can be reliably designed from biological components, integrated experimental and computational techniques that enable robust component characterization are needed. In this paper we present a computational method for the automated characterization of genetic components. Our method exploits a recently developed multichannel experimental protocol and integrates bacterial growth modeling, Bayesian parameter estimation, and model selection, together with data processing steps that are amenable to automation. We implement the method within the Genetic Engineering of Cells modeling and design environment, which enables both characterization and design to be integrated within a common software framework. To demonstrate the application of the method, we quantitatively characterize a synthetic receiver device that responds to the 3-oxohexanoyl-homoserine lactone signal, across a range of experimental conditions. PMID:24628037

  3. Metallurgical and Corrosion Characterization of POST Weld Heat Treated Duplex Stainless Steel (uns S31803) Joints by Friction Welding Process

    NASA Astrophysics Data System (ADS)

    Asif M., Mohammed; Shrikrishna, Kulkarni Anup; Sathiya, P.

    2016-02-01

    The present study focuses on the metallurgical and corrosion characterization of post weld heat treated duplex stainless steel joints. After friction welding, it was confirmed that there is an increase in ferrite content at weld interface due to dynamic recrystallization. This caused the weldments prone to pitting corrosion attack. Hence the post weld heat treatments were performed at three temperatures 1080∘C, 1150∘C and 1200∘C with 15min of aging time. This was followed by water and oil quenching. The volume fraction of ferrite to austenite ratio was balanced and highest pit nucleation resistance were achieved after PWHT at 1080∘C followed by water quench and at 1150∘C followed by oil quench. This had happened exactly at parameter set containing heating pressure (HP):40 heating time (HT):4 upsetting pressure (UP):80 upsetting time (UP):2 (experiment no. 5). Dual phase presence and absence of precipitates were conformed through TEM which follow Kurdjumov-Sachs relationship. PREN of ferrite was decreasing with increase in temperature and that of austenite increased. The equilibrium temperature for water quenching was around 1100∘C and that for oil quenching was around 1140∘C. The pit depths were found to be in the range of 100nm and width of 1.5-2μm.

  4. Evaluation and characterization of General Purpose Heat Source girth welds for the Cassini mission

    SciTech Connect

    Lynch, C.M.; Moniz, P.F.; Reimus, M.A.H.

    1998-12-31

    General Purpose Heat Sources (GPHSs) are components of Radioisotopic thermoelectric Generators (RTGs) which provide electric power for deep space missions. Each GPHS consists of a {sup 238}Pu oxide ceramic pellet encapsulated in a welded iridium alloy shell which forms a protective barrier against the release of plutonia in the unlikely event of a launch-pad failure or reentry incident. GPHS fueled clad girth weld flaw detection was paramount to ensuring this safety function, and was accomplished using both destructive and non-destructive evaluation techniques. The first girth weld produced from each welding campaign was metallographically examined for flaws such as incomplete weld penetration, cracks, or porosity which would render a GPHS unacceptable for flight applications. After an acceptable example weld was produced, the subsequently welded heat sources were evaluated non-destructively for flaws using ultrasonic immersion testing. Selected heat sources which failed ultrasonic testing would be radiographed, and/or, destructively evaluated to further characterize and document anomalous indications. Metallography was also performed on impacted heat sources to determine the condition of the welds.

  5. MECHANICAL PROPERTIES AND MICROSTRUCTURAL CHARACTERIZATION OF A MULTILAYERED MULTIPASS FRICTION STIR WELD IN STEEL

    SciTech Connect

    Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray; Qiao, Dongxiao; Wang, Yanli; Zhang, Wei; Feng, Zhili

    2013-01-01

    Multilayered multipass friction stir welding (MM-FSW) makes it possible to use FSW to fabricate thick-section structures. In this work, MM-FSW was demonstrated on a high strength low alloy steel; ASTM A572 Grade 50. Three steel plates with thicknesses of 0.18", 0.18", 0.24" respectively were stacked and friction stir welded together to form a 0.6" thick welded structure. The welded plate was sectioned into rectangular bars transverse to the weld direction for tensile testing to evaluate mechanical properties. Digital image correlation (DIC) was employed to map the local strain fields during tensile testing. The initial failure was found to occur simultaneously at the bottom and middle layers away from the weld zone. The top layer failed last in the base metal. The failure locations were consistent among different samples tested. Also, Charpy V-notch impact tests were conducted for weld metal, heat affected zone, and the base metal at each layer as a function of temperature. The weld microstructures were characterized using optical and electron microscopy and micro-hardness mapping.

  6. APFIM characterization of a high phosphorus Russian RPV weld

    NASA Astrophysics Data System (ADS)

    Miller, M. K.; Russell, K. F.

    1996-03-01

    A microstructural characterization of a high phosphorus (0.035 wt% P) weld from the pressure vessel of a Russian VVER nuclear reactor has been performed. The microstructure of these steels consists of intragranular and intergranular vanadium carbonitride precipitates of average composition 51.3 ± 0.9 at% V, 18.8 ± 0.7 at% C, 22.1 ± 0.7 at% N, 4.9 ± 0.4 at% Cr, 2.4 ± 0.3 at% Mo, 0.36 ± 0.05 at% Fe, 0.07 ± 0.05 at% B and 0.03 ± 0.03 at% P. The lath and grain boundaries were also coated with a thin film of molybdenum carbonitride precipitates. The phosphorus coverage at the boundaries in the unirradiated material was ˜ 13% of a monolayer in agreement with predictions from the McLean model of equilibrium segregation. After neutron irradiation to a fluence of 1.15 × 10 20 n cm -2, the phosphorus coverage had increased significantly to up to ˜ 60% of a monolayer. This result indicates that neutron irradiation significantly enhanced the phosphorus segregation process. Phosphorus and copper clusters were also observed in the matrix of the neutron-irradiated material.

  7. An automated test system for terahertz receiver characterization

    NASA Astrophysics Data System (ADS)

    Kuenzi, Linda C.; Groppi, Christopher E.; Wheeler, Caleb H.; Mani, Hamdi

    2014-07-01

    An automated test system was developed to characterize detectors for the Kilopixel Array Pathfinder Project (KAPPa), a 16-pixel 2D integrated heterodyne focal plane array. Although primarily designed for KAPPa, the system can be used with other instruments to automate tests that might be tedious and time-consuming by hand. Mechanical components include an adjustable structure of aluminum t-slot framing that supports a rotating chopper. Driven by a stepper motor, the wheel alternates between blackbodies at room temperature and 77 K. The cold load consists of absorbing material submerged in liquid nitrogen in an open Styrofoam cooler. Python scripts control the mechanical system, interface with receiver components, and process data. Test system operation was verified by sweeping the local oscillator frequency with a Virginia Diodes room temperature receiver. The system was then integrated with the KAPPa receiver to allow complete and automated testing of all array pixels with minimal user intervention.

  8. Porosity in millimeter-scale welds of stainless steel : three-dimensional characterization.

    SciTech Connect

    Aagesen, Larry K.; Madison, Jonathan D.

    2012-05-01

    A variety of edge joints utilizing a continuous wave Nd:YAG laser have been produced and examined in a 304-L stainless steel to advance fundamental understanding of the linkage between processing and resultant microstructure in high-rate solidification events. Acquisition of three-dimensional reconstructions via micro-computed tomography combined with traditional metallography has allowed for qualitative and quantitative characterization of weld joints in a material system of wide use and broad applicability. The presence, variability and distribution of porosity, has been examined for average values, spatial distributions and morphology and then related back to fundamental processing parameters such as weld speed, weld power and laser focal length.

  9. Dual wire weld feed proportioner

    NASA Technical Reports Server (NTRS)

    Nugent, R. E.

    1968-01-01

    Dual feed mechanism enables proportioning of two different weld feed wires during automated TIG welding to produce a weld alloy deposit of the desired composition. The wires are fed into the weld simultaneously. The relative feed rates of the wires and the wire diameters determine the weld deposit composition.

  10. Microstructural characterization in dissimilar friction stir welding between 304 stainless steel and st37 steel

    SciTech Connect

    Jafarzadegan, M.; Feng, A.H.; Abdollah-zadeh, A.; Saeid, T.; Shen, J.; Assadi, H.

    2012-12-15

    In the present study, 3 mm-thick plates of 304 stainless steel and st37 steel were welded together by friction stir welding at a welding speed of 50 mm/min and tool rotational speed of 400 and 800 rpm. X-ray diffraction test was carried out to study the phases which might be formed in the welds. Metallographic examinations, and tensile and microhardness tests were used to analyze the microstructure and mechanical properties of the joint. Four different zones were found in the weld area except the base metals. In the stir zone of the 304 stainless steel, a refined grain structure with some features of dynamic recrystallization was evidenced. A thermomechanically-affected zone was characterized on the 304 steel side with features of dynamic recovery. In the other side of the stir zone, the hot deformation of the st37 steel in the austenite region produced small austenite grains and these grains transformed to fine ferrite and pearlite and some products of displacive transformations such as Widmanstatten ferrite and martensite by cooling the material after friction stir welding. The heat-affected zone in the st37 steel side showed partially and fully refined microstructures like fusion welding processes. The recrystallization in the 304 steel and the transformations in the st37 steel enhanced the hardness of the weld area and therefore, improved the tensile properties of the joint. - Highlights: Black-Right-Pointing-Pointer FSW produced sound welds between st37 low carbon steel and 304 stainless steel. Black-Right-Pointing-Pointer The SZ of the st37 steel contained some products of allotropic transformation. Black-Right-Pointing-Pointer The material in the SZ of the 304 steel showed features of dynamic recrystallization. Black-Right-Pointing-Pointer The finer microstructure in the SZ increased the hardness and tensile strength.

  11. Microstructural characterization of dissimilar welds between alloy 800 and HP heat-resistant steel

    SciTech Connect

    Dehmolaei, R.; Shamanian, M. Kermanpur, A.

    2008-10-15

    In this study, dissimilar welds between HP heat-resistant steel and Incoloy 800 were made with four different filler materials including: 309 stainless steel and nickel-based Inconel 82, 182 and 617. The microstructure of the base metals, weld metals and their interfaces were characterized by utilizing optical and scanning electron microscopy. Grain boundaries migration in the weld metals was studied. It was found that the migration of grain boundaries in the Inconel 82 weld metal was very extensive. Precipitates of TiC and M{sub 23}C{sub 6} (M = Cr and Mo) in the Inconel 617 weld metal are identified. The necessary conditions for the formation of cracks close to the fusion line of the 309-HP joints are described. Furthermore unmixed zone near the fusion line between HP steel base metal and Inconel 82 weld metal is discussed. An epitaxial growth is characterized at the fusion line of the 309-Alloy 800 and Inconel 617-Alloy 800 joints.

  12. Characterization of the Micro Textures in a Friction Stir Weld

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Nunes, Arthur C.

    2004-01-01

    In friction stir welding (FSW), a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. The Dynamically-Recrystallized-Zone (DXZ) of a polished and etched FSW cross-section exhibits contrasting bands (the "onion-ring" structure), the origins of which are unclear. An orientation image mapping (OIM) study suggests that the corresponding bands may correspond respectively to a "straight-through" current of metal bypassing the pin tool in a single rotation or less and a "maelstrom" current rotating a number of times around the pin tool.

  13. Semiconductor defect data reduction for process automation and characterization

    SciTech Connect

    Tobin, K.W.; Gleason, S.S.; Karnowski, T.P.; Bennett, M.H.

    1996-05-01

    Automation tools for semiconductor defect data analysis are becoming necessary as device density and wafer sizes continue to increase. These tools are needed to efficiently and robustly process the increasing amounts of data to quickly characterize manufacturing processes and accelerate yield learning. An image-based method is presented for analyzing process signatures from defect data distributions. Applications are presented of enhanced statistical process control, automatic process characterization, and intelligent sub-sampling of event distributions for off-line high-resolution defect review.

  14. Characterization of weld imperfections in 2195 Al-Li alloy: Experimental approaches towards mechanisms

    NASA Astrophysics Data System (ADS)

    Zaidi, Anwer Arif

    1997-10-01

    2195 Al-Li alloy apparently offers significantly higher strength to weight ratio than the 2219 aluminum alloy. It was discovered that 2195 Al-Li has a greater tendency to crack, generates peculiar kind of porosity, and is vulnerable to deleterious microparticulate emission during welding than its 2219 predecessor. An experimental investigation has been carried to characterize these weld imperfections in 2195 Al-Li alloy. This work presents a scientific account of an analytical study and of the clues it has provided towards an understanding of the weld imperfections in 2195 Al-Li welds. The study begins with the observation of peculiar pore formation in 2195 welds, which occurs not as in the case of 2219 welds upon solidification, but in a thermal ageing process subsequent to solidification. An apparent reaction (DTA) between the fusion zone dendritic surface and nitrogen gas implies a porous fusion zone. Tiny surface melting sites, designated as Blisters, due to its resemblance to skin blisters, testify to the conjunction of outgassing and melting effects and suggest that porosity formation in the solid phase depends upon local melting as well as outgassing. The absence of a dark magnesium rich substance, designated as smut in the immediate vicinity of a crack opening next to a weld repair bead implies either an umbrella of gas emission keeping off a condensate evaporated under the welding arc or, possibly an expulsion of atomized, liquified metal from the crack itself in the form of microparticulate emission. These microparticulate emission from VPPA welds takes various forms herein labeled as smut, snow, and Lava. It is attributed to a gas generating reaction taking place at molten grain boundaries or crack surfaces. The reaction could only be release of hydrogen displaced from lithium hydrides by a coming influx of dissolved nitrogen. There appears to be a close link between porosity, cracking and microparticulate emission. Observations of melting on the surface

  15. Innovative technology summary report: mobile automated characterization system

    SciTech Connect

    1999-04-01

    The Mobile Automated Characterization System (MACS) has been developed by Oak Ridge National Laboratory (ORNL) and the Savannah River Technology Center (SRTC) for the U.S. Department of Energy's (DOE) Robotics Technology Development Program as an automated floor surface contamination characterization system. MACS was designed for use by Health Physics (HP) personnel in the performance of floor surveys of known or suspected contaminated areas, to be used during any floor characterization task which has significant open areas requiring radiological surveys. MACS was designed to automate the collection, storage and analysis of large, open floor areas, relieving the HP personnel of this portion of the floor characterization task. MACS does not require a dedicated full time operator and can be setup by the normal HP staff to survey the open areas while other techniques are used on the more constrained areas. The HP personnel performing the other characterization activities can monitor the MACS progress and address any problems encountered by MACS during survey operations. MACS is designed for unattended operation and has safety and operational monitoring functions which will safely shut the system down if any difficulties are encountered. During survey operations, MACS generates a map of surveyed areas with color-coding indicating radiation levels. This map is displayed on the control console monitor during operation and can be printed for survey result documentation. MACS produces data files containing data for all sensors used during a survey, providing a complete record of samples taken and contamination levels found for all areas traversed during a survey. This data can be processed to produce tabular output of the survey results.

  16. Characterization of the structural details of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor

    NASA Astrophysics Data System (ADS)

    Liu, Xia; Ji, Hui-jun; Liu, Peng; Wang, Peng; Lu, Feng-gui; Gao, Yu-lai

    2014-06-01

    The existence of residual austenite in weld metal plays an important role in determining the properties and dimensional accuracy of welded rotors. An effective corrosive agent and the metallographic etching process were developed to clearly reveal the characteristics of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor. Moreover, the details of the distribution, shape, length, length-to-width ratio, and the content of residual austenite were systematically characterized using the Image-Pro Plus image analysis software. The results revealed that the area fraction of residual austenite was approximately 6.3% in the observed weld seam; the average area, length, and length-to-width ratio of dispersed residual austenite were quantitatively evaluated to be (5.5 ± 0.1) μm2, (5.0 ± 0.1) μm, and (2.2 ± 0.1), respectively. The newly developed corrosive agent and etching method offer an appropriate approach to characterize residual austenite in the weld metal of welded rotors in detail.

  17. Evaluation of High Temperature Properties and Microstructural Characterization of Resistance Spot Welded Steel Lap Shear Joints

    NASA Astrophysics Data System (ADS)

    Gupta, R. K.; Anil Kumar, V.; Panicker, Paul G.

    2016-02-01

    Joining of thin sheets (0.5 mm) of stainless steel 304 and 17-4PH through resistance spot welding is highly challenging especially when joint is used for high temperature applications. Various combinations of stainless steel sheets of thickness 0.5 mm are spot welded and tested at room temperature as well as at high temperatures (800 K, 1,000 K, 1,200 K). Parent metal as well as spot welded joints are tested and characterized. It is observed that joint strength of 17-4PH steel is highest and then dissimilar steel joint of 17-4PH with SS-304 is moderate and of SS-304 is lowest at all the temperatures. Joint strength of 17-4PH steel is found to be >80% of parent metal properties up to 1,000 K then drastic reduction in strength is noted at 1,200 K. Gradual reduction in strength of SS-304 joint with increase in temperature from 800 to 1,200 K is noted. At 1,200 K, joint strength of all combinations of joints is found to be nearly same. Microstructural evaluation of weld nugget after testing at different temperatures shows presence of tempered martensite in 17-4PH containing welds and homogenized structure in stainless steel 304 weld.

  18. Characterization of ferritic G. M. A. weld deposits in 9% Ni steel for cryogenic applications

    SciTech Connect

    Mahin, K.W.

    1980-04-01

    Low temperature containment vessels of 9% Ni are normally fabricated using the shielded metal arc (S.M.A.W.) or the gas metal arc (G.M.A.W.) welding processes. Available filler metals compatible with these processes are highly alloyed austenitics, whose strength levels undermatch those of the base plate. A more efficient weld joint would be a low alloy ferritic deposit. Although acceptable matching ferritic gas tungsten arc weld (G.T.A.W.) wires have been developed, similar progress has not been made in the area of ferritic G.M.A. weld wires. Most of the prior work in this area has focused on correlating composition with mechanical properties, without a corresponding evaluation of resultant microstructure. The study presented focused on establishing correlations between chemistry, microstructure and mechanical properties for four different ferritic G.M.A. weld deposits in 9% Ni steel, with the purpose of developing a better understanding of the factors controlling the 77K (-196/sup 0/C) toughness behavior of these weld metals. Microstructural characterization was carried out using standard optical and scanning electron microscopes, as well as a variety of advanced analytical techniques, including transmission electron microscopy (T.E.M.), scanning T.E.M., Moessbauer spectroscopy and Auger electron spectroscopy.

  19. Automated EEG analysis: characterizing the posterior dominant rhythm.

    PubMed

    Lodder, Shaun S; van Putten, Michel J A M

    2011-08-30

    Automated interpretation of clinical EEG recordings will reduce subjectivity and visual bias from analysis and can reduce the time required for interpretation. As a first step in the design of a fully automated system, a method is presented to characterize the main properties of the posterior dominant rhythm (PDR), in particular its frequency, symmetry and reactivity. The presented method searches for dominant peaks in the EEG spectra during eyes-closed states with a three-component curve-fitting technique. From the fitted curve, the frequency and amplitude are estimated. The symmetry and the reactivity are found using the spectral power at the PDR frequencies. In addition, a certainty value is introduced as a measure of confidence for each estimate. The method was evaluated on a test set of 1215 clinical EEG recordings and compared to the PDR frequencies obtained from the visual analysis, as reported in the diagnostic reports. The calculated PDR frequencies were within 1.2Hz of the visual estimates in 92.5% of the cases. Even higher accuracies were reached when estimates with low certainty values were discarded. The presented method quantifies essential features of the PDR with a matched accuracy to visual inspection, making it a feasible contribution to the design of a fully automated interpretation system. PMID:21722667

  20. Advanced characterization of twins using automated electron backscatter diffraction

    SciTech Connect

    Wright, S. I.; Bingert, J. F.; Mason, T. A.; Larson, R. J.

    2002-01-01

    This paper describes results obtained using an automated, crystallographically-based technique for twin identification. The technique is based on the automated collection of spatially specific orientation measurements by electron backscatter diffraction (EBSD) in the scanning electron microscope (SEM). The key features of the analysis are identification of potential twin boundaries by their misorientation character, identification of the distinct boundary planes among the symmetrically equivalent candidates, and validation of these boundaries through comparison with the boundary and twin plane traces in the sample cross section. Results on the application of this technique to deformation twins in zirconium are analyzed for the effect of twin type and amount and sense of uniaxial deformation. The accumulation of strain tends to increase the misorientation deviation at least to the degree of the trace deviation compared with recrystallization twins in nickel. In addition to the results on characterizing the twin character, results on extending the twin analysis to automated identification of parent and daughter material for structures exhibiting twin deformation are reported as well.

  1. Automated characterization of Z-technology sensor modules

    NASA Astrophysics Data System (ADS)

    Gilcrest, Andrew S.

    1991-11-01

    Detailed radiometric characterization data must be reviewed at the module level (2048 IR detectors) prior to integrating the hardware into higher level assemblies. Software has been developed that highly automates the process of reducing test data for noise, responsivity, uniformity, output offset, saturation, linearity, filter pole location, and crosstalk. Output consists of both text and graphics at different levels of detail in order to accommodate the needs of engineering, test, manufacturing, quality assurance, and program management. All the results are placed on a LAN so that the necessary reviews can occur in essentially a paperless environment.

  2. Challenges of an automated spectral responsivity characterization system

    NASA Astrophysics Data System (ADS)

    McKee, Greg

    2013-01-01

    An essential part of characterizing and improving imaging system performance and modeling is the determination of spectral responsivity; namely the spectral band-shape and out-of-band response. These complicated measurements have heretofore been difficult to make with consistency with do-it-yourself solutions. To address this industry-wide problem, Labsphere has developed an automated spectral response measurement stations, incorporating several techniques to enhance accuracy and ease of use. This presentation will cover the physics and considerations behind the scaling of these types of systems and the experimental methodology required to assure absolute traceability, as well as some of the lessons learned along the way.

  3. Microstructure Characterization of Laser-Welded Nb-Microalloyed Silicon-Aluminum TRIP Steel

    NASA Astrophysics Data System (ADS)

    Grajcar, A.; Różański, M.; Stano, S.; Kowalski, A.

    2014-09-01

    This work presents the results of a microstructural characterization of welds in Nb-microalloyed TRIP steel with silicon partially replaced by aluminum. Tests of laser welding of thermomechanically processed sheet samples were carried out using keyhole welding and a solid-state laser. Welding penetration tests were conducted for heat input values between 0.037 and 0.048 kJ/mm. Identification of different microstructural constituents was carried out using light microscopy and scanning electron microscopy in the fusion zone (FZ), heat-affected zone (HAZ), and base metal. Special focus was put on the effect of cooling conditions on the stabilization of retained austenite in different zones. The intercritical, fine-grained, and coarse-grained regions of the HAZ were identified. It was determined that enriching austenite with carbon in the intercritical HAZ stabilizes this phase at a level close to the base metal, i.e., a 15% volume fraction. Despite a high cooling rate in the FZ and HAZ, interlath retained austenite is also present in these zones. The research involved microhardness measurements and characterizing non-metallic inclusions formed in the fusion zone. A good correlation between microstructures formed in different weld regions and microhardness results was obtained.

  4. Automated flaw detection scheme for cast austenitic stainless steel weld specimens using Hilbert-Huang transform of ultrasonic phased array data

    SciTech Connect

    Khan, Tariq; Majumdar, Shantanu; Udpa, Lalita; Ramuhalli, Pradeep; Crawford, Susan; Diaz, Aaron; Anderson, Michael T.

    2012-05-17

    The objective of this work is to develop processing algorithms to detect and localize flaws using ultrasonic phased-array data. Data was collected on cast austenitic stainless stell (CASS) weld specimens onloan from the U.S. nuclear power industry' Pressurized Walter Reactor Owners Group (PWROG) traveling specimen set. Each specimen consists of a centrifugally cast stainless stell (CCSS) pipe section welded to a statically cst(SCSS) or wrought (WRSS) section. The paper presents a novel automated flaw detection and localization scheme using low frequency ultrasonic phased array inspection singals from the weld and heat affected zone of the based materials. The major steps of the overall scheme are preprocessing and region of interest (ROI) detection followed by the Hilbert-Huang transform (HHT) of A-scans in the detected ROIs. HHT offers time-frequency-energy distribution for each ROI. The Accumulation of energy in a particular frequency band is used as a classification feature for the particular ROI.

  5. Automated flaw detection scheme for cast austenitic stainless stell weld specimens using Hilbert-Huang transform of ultrasonic phased array data

    NASA Astrophysics Data System (ADS)

    Khan, Tariq; Majumdar, Shantanu; Udpa, Lalita; Ramuhalli, Pradeep; Crawford, Susan; Diaz, Aaron; Anderson, Michael T.

    2012-05-01

    The objective of this work is to develop processing algorithms to detect and localize flaws using ultrasonic phased-array data. Data was collected on cast austenitic stainless stell (CASS) weld specimens onloan from the U.S. nuclear power industry' Pressurized Walter Reactor Owners Group (PWROG) traveling specimen set. Each specimen consists of a centrifugally cast stainless stell (CCSS) pipe section welded to a statically cst(SCSS) or wrought (WRSS) section. The paper presents a novel automated flaw detection and localization scheme using low frequency ultrasonic phased array inspection singals from the weld and heat affected zone of the based materials. The major steps of the overall scheme are preprocessing and region of interest (ROI) detection followed by the Hilbert-Huang transform (HHT) of A-scans in the detected ROIs. HHT offers time-frequency-energy distribution for each ROI. The Accumulation of energy in a particular frequency band is used as a classification feature for the particular ROI.

  6. Process Development and Microstructural Characterization on Friction Plug Welded 2195 and 2219 Alloys

    NASA Technical Reports Server (NTRS)

    Li, Z. X.; Cantrell, M. A.; Brown, R. J.; McCool, A. (Technical Monitor)

    2000-01-01

    This document is a viewgraph presentation about Friction Plug Welding (FPW). It reviews the process of FPW, showing pictures which review the process. It also reviews the microstructural characterization using Transmission Electron Microscopy. There are several charts which are included for further information.

  7. Mechanical characterization of densely welded Apache Leap tuff

    SciTech Connect

    Fuenkajorn, K.; Daemen, J.J.K.

    1991-06-01

    An empirical criterion is formulated to describe the compressive strength of the densely welded Apache Leap tuff. The criterion incorporates the effects of size, L/D ratio, loading rate and density variations. The criterion improves the correlation between the test results and the failure envelope. Uniaxial and triaxial compressive strengths, Brazilian tensile strength and elastic properties of the densely welded brown unit of the Apache Leap tuff have been determined using the ASTM standard test methods. All tuff samples are tested dry at room temperature (22 {plus_minus} 2{degrees}C), and have the core axis normal to the flow layers. The uniaxial compressive strength is 73.2 {plus_minus} 16.5 MPa. The Brazilian tensile strength is 5.12 {plus_minus} 1.2 MPa. The Young`s modulus and Poisson`s ratio are 22.6 {plus_minus} 5.7 GPa and 0.20 {plus_minus} 0.03. Smoothness and perpendicularity do not fully meet the ASTM requirements for all samples, due to the presence of voids and inclusions on the sample surfaces and the sample preparation methods. The investigations of loading rate, L/D radio and cyclic loading effects on the compressive strength and of the size effect on the tensile strength are not conclusive. The Coulomb strength criterion adequately represents the failure envelope of the tuff under confining pressures from 0 to 62 MPa. Cohesion and internal friction angle are 16 MPa and 43 degrees. The brown unit of the Apache Leap tuff is highly heterogeneous as suggested by large variations of the test results. The high intrinsic variability of the tuff is probably caused by the presence of flow layers and by nonuniform distributions of inclusions, voids and degree of welding. Similar variability of the properties has been found in publications on the Topopah Spring tuff at Yucca Mountain. 57 refs., 32 figs., 29 tabs.

  8. Microstructural characterization of dissimilar welds between Incoloy 800H and 321 Austenitic Stainless Steel

    SciTech Connect

    Sayiram, G. Arivazhagan, N.

    2015-04-15

    In this work, the microstructural character of dissimilar welds between Incoloy 800H and 321 Stainless Steel has been discussed. The microscopic examination of the base metals, fusion zones and interfaces was characterized using an optical microscope and scanning electron microscopy. The results revealed precipitates of Ti (C, N) in the austenitic matrix along the grain boundaries of the base metals. Migration of grain boundaries in the Inconel 82 weld metal was very extensive when compared to Inconel 617 weldment. Epitaxial growth was observed in the 617 weldment which increases the strength and ductility of the weld metal. Unmixed zone near the fusion line between 321 Stainless Steel and Inconel 82 weld metal was identified. From the results, it has been concluded that Inconel 617 filler metal is a preferable choice for the joint between Incoloy 800H and 321 Stainless Steel. - Highlights: • Failure mechanisms produced by dissimilar welding of Incoloy 800H to AISI 321SS • Influence of filler wire on microstructure properties • Contemplative comparisons of metallurgical aspects of these weldments • Microstructure and chemical studies including metallography, SEM–EDS • EDS-line scan study at interface.

  9. Study of ultrasonic characterization and propagation in austenitic welds: The MOSAICS project

    SciTech Connect

    Chassignole, Bertrand; Recolin, Patrick; Leymarie, Nicolas; Gueudré, Cécile; Guy, Philippe; Elbaz, Deborah

    2015-03-31

    Regulatory requirements enforce a volumetric inspection of welded components of nuclear equipments. However, the multi-pass austenitic welds are characterized by anisotropic and heterogeneous structures which lead to numerous disturbances of the ultrasonic beam. The MOSAICS project supported by the ANR (French National Research Agency) aims at matching various approaches to improve the prediction of the ultrasonic testing in those welds. The first stage consists in characterizing the weld structure (determination of the columnar grain orientation and measurements of elastic constants and attenuation coefficients). The techniques of characterization provide input data for the modeling codes developed in another task of the project. For example, a 3D version of the finite elements code ATHENA is developed by EDF R and D to take into account anisotropic texture in any direction. Semi-analytical models included in CIVA software are also improved to better predict the ultrasonic propagation in highly anisotropic and heterogeneous structures. The last stage deals with modeling codes validation based on experimental inspections on representative mock-ups containing calibrated defects. The objective of this paper is to give an overview of the MOSAICS project and to present specific results illustrating the various tasks.

  10. Study of ultrasonic characterization and propagation in austenitic welds: The MOSAICS project

    NASA Astrophysics Data System (ADS)

    Chassignole, Bertrand; Recolin, Patrick; Leymarie, Nicolas; Gueudré, Cécile; Guy, Philippe; Elbaz, Deborah

    2015-03-01

    Regulatory requirements enforce a volumetric inspection of welded components of nuclear equipments. However, the multi-pass austenitic welds are characterized by anisotropic and heterogeneous structures which lead to numerous disturbances of the ultrasonic beam. The MOSAICS project supported by the ANR (French National Research Agency) aims at matching various approaches to improve the prediction of the ultrasonic testing in those welds. The first stage consists in characterizing the weld structure (determination of the columnar grain orientation and measurements of elastic constants and attenuation coefficients). The techniques of characterization provide input data for the modeling codes developed in another task of the project. For example, a 3D version of the finite elements code ATHENA is developed by EDF R&D to take into account anisotropic texture in any direction. Semi-analytical models included in CIVA software are also improved to better predict the ultrasonic propagation in highly anisotropic and heterogeneous structures. The last stage deals with modeling codes validation based on experimental inspections on representative mock-ups containing calibrated defects. The objective of this paper is to give an overview of the MOSAICS project and to present specific results illustrating the various tasks.

  11. Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing.

    PubMed

    Villegas, Irene F; Palardy, Genevieve

    2016-01-01

    This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints. PMID:26890931

  12. Variable polarity arc welding

    NASA Technical Reports Server (NTRS)

    Bayless, E. O., Jr.

    1991-01-01

    Technological advances generate within themselves dissatisfactions that lead to further advances in a process. A series of advances in welding technology which culminated in the Variable Polarity Plasma Arc (VPPA) Welding Process and an advance instituted to overcome the latest dissatisfactions with the process: automated VPPA welding are described briefly.

  13. Characterization of Solid State Phase Transformation in Continuously Heated and Cooled Ferritic Weld Metal

    SciTech Connect

    Narayana, B; Mills, Michael J.; Specht, Eliot D; Santella, Michael L; Babu, Sudarsanam Suresh

    2010-12-01

    Arc welding processes involve cooling rates that vary over a wide range (1-100 K/s). The final microstructire is thus a product of the heating and cooling cycles experienced by the weld in addition to the weld composition. It has been shown that the first phase to form under weld cooling conditions may not be that predicted by equilibrium calculations. The partitioning of different interstitial/substitutional alloying elements at high temperatures can dramatically affect the subsequent phase transformations. In order to understand the effect of alloying on phase transformation temperatures and final microstructures time-resolved X-ray diffraction technique has been successfully used for characterization. The work by Jacot and Rappaz on pearlitic steels provided insight into austenitization of hypoeutectic steels using a finite volume model. However there is very little work done on the effect of heating and cooling rates on the phase transformation paths in bainitic/martensitic steels and weld metals. Previous work on a weld with higher aluminum content, deposited with a FCAW-S process indicated that even at aluminum levels where the primary phase to solidify from liquid should be delta ferrite, non-equilibrium austenite was observed. The presence of inhomogeneity in composition of the parent microstructure has been attributed to differences in transformation modes, temperatures and microstructures in dual-phase, TRIP steels and ferritic welds. The objectives of the work included the identification of the stability regions of different phases during heating and cooling, differences in the effect of weld heating and cooling rates on the phase transformation temperatures, and the variation in phase fractions of austenite and ferrite in the two phase regions as a function of temperature. The base composition used for the present work is a Fe-1%Al-2%Mn-1%Ni-0.04%C weld metal. A pseudo-binary phase diagram shows the expected solidification path under equilibrium

  14. Automated detection, characterization, and tracking of filaments from SDO data

    NASA Astrophysics Data System (ADS)

    Buchlin, Eric; Vial, Jean-Claude; Mercier, Claude

    2016-07-01

    Thanks to the cadence and continuity of AIA and HMI observations, SDO offers unique data for detecting, characterizing, and tracking solar filaments, until their eruptions, which are often associated with coronal mass ejections. Because of the requirement of short latency when aiming at space weather applications, and because of the important data volume, only an automated detection can be worked out. We present the code "FILaments, Eruptions, and Activations detected from Space" (FILEAS) that we have developed for the automated detection and tracking of filaments. Detections are based on the analysis of AIA 30.4 nm He II images and on the magnetic polarity inversion lines derived from HMI. Following the tracking of filaments as they rotate with the Sun, filament characteristics are computed and a database of filaments parameters is built. We present the algorithms and performances of the code, and we compare its results with the filaments detected in Hα and already present in the Heliophysics Events Knowledgebase. We finally discuss the possibility of using such a code to detect eruptions in real time.

  15. Gas mixing apparatus for automated gas sensor characterization

    NASA Astrophysics Data System (ADS)

    Helwig, Nikolai; Schüler, Marco; Bur, Christian; Schütze, Andreas; Sauerwald, Tilman

    2014-05-01

    We developed a computer-controlled gas mixing system that provides automated test procedures for the characterization of gas sensors. The focus is the generation of trace gases (e.g. VOCs like benzene or naphthalene) using permeation furnaces and pre-dilution of test gases. With these methods, the sensor reaction can be analyzed at very low gas concentrations in the ppb range (parts per billion) and even lower. The pre-dilution setup enables to cover a high concentration range (1:62 500) within one test procedure. Up to six test gases, humidity, oxygen content, total flow and their variation over time can be controlled via a LabVIEW-based user-interface.

  16. Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Newman, John A.; Smith, Stephen W.; Seshadri, Banavara R.; James, Mark A.; Brazill, Richard L.; Schultz, Robert W.; Donald, J. Keith; Blair, Amy

    2015-01-01

    An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

  17. Deformation Characterization of Friction-Stir-Welded Tubes by Hydraulic Bulge Testing

    NASA Astrophysics Data System (ADS)

    Pang, Q.; Hu, Z. L.; Pan, X.; Zuo, X. Q.

    2014-10-01

    In this article, the large-diameter thin-walled aluminum alloy tubes were produced using a hybrid process combining friction-stir welding (FSW) and spinning. For this novel process, rolled aluminum alloy sheets with a thickness about 2-3 times the wall thickness of target tube, were FSW to form cylinders, and then the cylinders were subjected to spinning to get thin-walled aluminum alloy tubes. Both experimental and simulation study were conducted to investigate the deformation characterization of the FSW tube during hydraulic bulge testing, and the stress and strain states and thickness distribution of the FSW tube were investigated. It was found that the common defects of FSW tube can be significantly improved by specific welding devices. The ductility of the tube is considerably improved with nearly two times higher bulge ratio than as-spun tube after annealing treatment at 300°C. But the annealed tube still shows a high nonuniform wall thickness distribution due to the inhomogeneous deformation characteristics. With increasing deformation of the tube, the gap between the hoop and axial stress for the weld and base metal (BM) decreases. However, the hoop and axial stress of the weld are always greater than those of the BM at the same pressure.

  18. Deformation Characterization of Friction-Stir-Welded Tubes by Hydraulic Bulge Testing

    NASA Astrophysics Data System (ADS)

    Pang, Q.; Hu, Z. L.; Pan, X.; Zuo, X. Q.

    2014-09-01

    In this article, the large-diameter thin-walled aluminum alloy tubes were produced using a hybrid process combining friction-stir welding (FSW) and spinning. For this novel process, rolled aluminum alloy sheets with a thickness about 2-3 times the wall thickness of target tube, were FSW to form cylinders, and then the cylinders were subjected to spinning to get thin-walled aluminum alloy tubes. Both experimental and simulation study were conducted to investigate the deformation characterization of the FSW tube during hydraulic bulge testing, and the stress and strain states and thickness distribution of the FSW tube were investigated. It was found that the common defects of FSW tube can be significantly improved by specific welding devices. The ductility of the tube is considerably improved with nearly two times higher bulge ratio than as-spun tube after annealing treatment at 300°C. But the annealed tube still shows a high nonuniform wall thickness distribution due to the inhomogeneous deformation characteristics. With increasing deformation of the tube, the gap between the hoop and axial stress for the weld and base metal (BM) decreases. However, the hoop and axial stress of the weld are always greater than those of the BM at the same pressure.

  19. Synchrotron X-ray CT characterization of friction-welded joints in tial turbocharger components

    NASA Astrophysics Data System (ADS)

    Sun, J. G.; Kropf, A. J.; Vissers, D. R.; Sun, W. M.; Katsoudas, J.; Yang, N.; Fei, D.

    2012-05-01

    Titanium aluminide (TiAl) is an advanced intermetallic material and is being investigated for application in turbocharger components for diesel engines. A TiAl turbocharger rotor consists of a cast TiAl turbine wheel and a Ti-alloy shaft that are joined by friction welding. Although friction welding is an established industrial process, it is still challenging to join dissimilar materials especially for brittle intermetallics. These joints are therefore required to be inspected using a nondestructive evaluation (NDE) method. In this study, synchrotron X-ray computed tomography (CT) developed at the Advanced Photon Source at Argonne National Laboratory was used for NDE characterization of friction-welded joint in three TiAl turbocharger rotors. The filtered synchrotron X-ray source has high peak energies to penetrate thick metallic materials, and the detector (imager) has high spatial resolutions to resolve small flaws. The CT inspections revealed detailed 3D crack distributions within poorly welded joints. The crack detection sensitivity and resolution was calibrated and found to be correlated well with destructive examination.

  20. Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel

    DOE PAGESBeta

    Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray; Yu, Xinghua; Qiao, Dongxiao; Wang, Yanli; Zhang, Wei; Feng, Zhili

    2014-01-01

    A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductilemore » fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.« less

  1. Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel

    SciTech Connect

    Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray; Yu, Xinghua; Qiao, Dongxiao; Wang, Yanli; Zhang, Wei; Feng, Zhili

    2014-01-01

    A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductile fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.

  2. Characterization of airborne particles generated from metal active gas welding process.

    PubMed

    Guerreiro, C; Gomes, J F; Carvalho, P; Santos, T J G; Miranda, R M; Albuquerque, P

    2014-05-01

    This study is focused on the characterization of particles emitted in the metal active gas welding of carbon steel using mixture of Ar + CO2, and intends to analyze which are the main process parameters that influence the emission itself. It was found that the amount of emitted particles (measured by particle number and alveolar deposited surface area) are clearly dependent on the distance to the welding front and also on the main welding parameters, namely the current intensity and heat input in the welding process. The emission of airborne fine particles seems to increase with the current intensity as fume-formation rate does. When comparing the tested gas mixtures, higher emissions are observed for more oxidant mixtures, that is, mixtures with higher CO2 content, which result in higher arc stability. These mixtures originate higher concentrations of fine particles (as measured by number of particles by cm(3) of air) and higher values of alveolar deposited surface area of particles, thus resulting in a more severe worker's exposure. PMID:24730680

  3. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

    SciTech Connect

    Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; Payzant, E. Andrew; Kolbus, Lindsay M.

    2015-09-08

    This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stir zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.

  4. Mechanical and interfacial characterization of laser welded Co-Cr alloy with different joint configurations

    PubMed Central

    Kokolis, John; Chakmakchi, Makdad; Theocharopoulos, Antonios; Prombonas, Anthony

    2015-01-01

    PURPOSE The mechanical and interfacial characterization of laser welded Co-Cr alloy with two different joint designs. MATERIALS AND METHODS Dumbbell cast specimens (n=30) were divided into 3 groups (R, I, K, n=10). Group R consisted of intact specimens, group I of specimens sectioned with a straight cut, and group K of specimens with a 45° bevel made at the one welding edge. The microstructure and the elemental distributions of alloy and welding regions were examined by an SEM/EDX analysis and then specimens were loaded in tension up to fracture. The tensile strength (TS) and elongation (ε) were determined and statistically compared among groups employing 1-way ANOVA, SNK multiple comparison test (α=.05) and Weibull analysis where Weibull modulus m and characteristic strength σο were identified. Fractured surfaces were imaged by a SEM. RESULTS SEM/EDX analysis showed that cast alloy consists of two phases with differences in mean atomic number contrast, while no mean atomic number was identified for welded regions. EDX analysis revealed an increased Cr and Mo content at the alloy-joint interface. All mechanical properties of group I (TS, ε, m and σο) were found inferior to R while group K showed intermediated values without significant differences to R and I, apart from elongation with group R. The fractured surfaces of all groups showed extensive dendritic pattern although with a finer structure in the case of welded groups. CONCLUSION The K shape joint configuration should be preferred over the I, as it demonstrates improved mechanical strength and survival probability. PMID:25722836

  5. Concurrent ultrasonic weld evaluation system

    DOEpatents

    Hood, Donald W.; Johnson, John A.; Smartt, Herschel B.

    1987-01-01

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

  6. Concurrent ultrasonic weld evaluation system

    DOEpatents

    Hood, D.W.; Johnson, J.A.; Smartt, H.B.

    1985-09-04

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

  7. Concurrent ultrasonic weld evaluation system

    DOEpatents

    Hood, D.W.; Johnson, J.A.; Smartt, H.B.

    1987-12-15

    A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder is disclosed. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws. 5 figs.

  8. Improvements of a spatial frequency analyzer for automated characterization of holographic recording materials.

    PubMed

    Couture, J J; Tanguay, D

    1992-05-10

    A spatial frequency analyzer was designed to simplify characterization studies for new holographic recording materials. Mechanical movements were automated and a complete informational system gave rapid characterization results. A good fringe stabilization unit was improved by adding simple holographic optical beam combiners. Experimental characterization of two different recording materials shows the versatility of this automated apparatus. Also we present modulation-transfer-function curves of dichromated gelatin between 500 and 3500 cycles/mm obtained with polarization volume transmission holograms. PMID:20725176

  9. Energy Characterization of Short-Circuiting Transfer of Metal Droplet in Gas Metal Arc Welding

    NASA Astrophysics Data System (ADS)

    Yi, Luo; Yang, Zhu; Xiaojian, Xie; Rui, Wan

    2015-08-01

    The structure-borne acoustic emission (AE) signals were detected in real time in gas metal arc (GMA) welding and pulse GMA (P-GMA) welding. According to the AE signals, the mode of short-circuiting transfer was analyzed, and the energy gradient and total energy were calculated. The calculation to the AE signals of one metal droplet transfer (MDT) showed that the energy gradient increased with increasing welding heat input not only in GMA welding but also in P-GMA welding. The energy gradient of one MDT in P-GMA welding was higher than that in GMA welding, which indicated that a high energy gradient was the basic reason for the additional vibration energy provided by pulse effect in P-GMA welding. The total energy of AE signals increased with increasing welding heat input not only in GMA welding but also in P-GMA welding. The total energy of AE signals in P-GMA welding was higher than that in GMA welding, which indicated that the additional vibration energy provided by welding pulses was the main cause of the grain structure refining in P-GMA welding. So, the results provided another means to predict the weld grain size and optimize the welding process by AE signals detected in welding.

  10. An automated Langmuir probe controller for plasma characterization

    NASA Astrophysics Data System (ADS)

    Bustos, A.; Juarez, A. M.; de Urquijo, J.; Muñoz, M.

    2016-08-01

    We present the design, construction and test of an automated electronic controller for a Langmuir plasma probe. The novel aspect of this system lies in the isolation of the high voltage present in the discharge from the grounded reference of the controller. This controller detects currents over the range from  ±1 μA to  ±50 mA, using dynamic and automated switching of a transresistance amplifier. This automated Langmuir probe (LP) system has been successfully tested in a glow discharge in argon at 0.8 and 10 Torr.

  11. Atom probe tomography characterization of radiation-sensitive KS-01 weld

    NASA Astrophysics Data System (ADS)

    Miller, M. K.; Russell, K. F.; Sokolov, M. A.; Nanstad, R. K.

    2003-08-01

    The microstructure of a radiation-sensitive KS-01 test weld has been characterized by atom probe tomography. The levels of copper, manganese, nickel and chromium in this weld were amongst the highest of all the steels used in Western reactor pressure vessels. After neutron irradiation to a fluence of 0.8 × 10 23 n m -2 ( E>1 MeV) at a temperature of 288 °C, this weld exhibited a large Charpy T41J shift of 169 K, a large shift of the fracture toughness transition temperature of 160 K, a decrease in upper shelf energy from 118 to ˜78 J, and an increase in the yield strength from 600 to 826 MPa. However, the mechanical properties data conformed to the master curve. Atom probe tomography revealed a high number density (˜3 × 10 24 m -3) of Cu-, Mn-, Ni-, Si- and P-enriched precipitates and a lower number density (˜1 × 10 23 m -3) of P clusters.

  12. Physicochemical Characterization of Simulated Welding Fume from a Spark Discharge System

    PubMed Central

    Park, Jae Hong; Mudunkotuwa, Imali A.; Kim, Jong Sung; Stanam, Aditya; Thorne, Peter S.; Grassian, Vicki H.; Peters, Thomas M.

    2014-01-01

    This study introduces spark discharge system (SDS) as a way to simulate welding fumes. The SDS was developed using welding rods as electrodes with an optional coagulation chamber. The size, morphology, composition, and concentration of the fume produced and the concentration of ozone (O3) and nitrogen oxides (NOX) were characterized. The number median diameter (NMD) and total number concentration (TNC) of fresh fume particles were ranged 10–23 nm and 3.1×107–6×107 particles/cm3, respectively. For fresh fume particles, the total mass concentration (TMC) measured gravimetrically ranged 85–760 μg/m3. The size distribution was stable over a period of 12 h. The NMD and TNC of aged fume particles were ranged 81–154 nm and 1.5×106–2.7×106 particles/cm3, respectively. The composition of the aged fume particles was dominated by Fe and O with an estimated stoichiometry between that of Fe2O3 and Fe3O4. Concentrations of O3 and NOX were ranged 0.07–2.2 ppm and 1–20 ppm, respectively. These results indicate that the SDS is capable of producing stable fumes over a long-period that are similar to actual welding fumes. This system may be useful in toxicological studies and evaluation of instrumentation. PMID:25097299

  13. Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    Horton, Karla Renee

    2011-01-01

    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 AA 2014-T6 plate on the advancing side and an AA 2219-T87 plate on the retreating side and a SR-FSW (AA 2014-T6 to AA 2219-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.

  14. Characterization of the corrosion resistance of biologically active solutions: The effects of anodizing and welding

    NASA Technical Reports Server (NTRS)

    Walsh, Daniel W.

    1991-01-01

    An understanding of fabrication processes, metallurgy, electrochemistry, and microbiology is crucial to the resolution of microbiologically influenced corrosion (MIC) problems. The object of this effort was to use AC impedance spectroscopy to characterize the corrosion resistance of Type II anodized aluminum alloy 2219-T87 in sterile and biologically active media and to examine the corrosion resistance of 316L, alloy 2219-T87, and titanium alloy 6-4 in the welded and unwelded conditions. The latter materials were immersed in sterile and biologically active media and corrosion currents were measured using the polarization resistance (DC) technique.

  15. Analysis and Characterization of the Role of Ni Interlayer in the Friction Welding of Titanium and 304 Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Muralimohan, C. H.; Ashfaq, M.; Ashiri, Rouholah; Muthupandi, V.; Sivaprasad, K.

    2016-01-01

    Joining of commercially pure Ti to 304 stainless steel by fusion welding processes possesses problems due to the formation of brittle intermetallic compounds in the weld metal, which degrade the mechanical properties of the joints. Solid-state welding processes are contemplated to overcome these problems. However, intermetallic compounds are likely to form even in Ti-SS joints produced with solid-state welding processes such as friction welding process. Therefore, interlayers are employed to prevent the direct contact between two base metals and thereby mainly to suppress the formation of brittle Ti-Fe intermetallic compounds. In the present study, friction-welded joints between commercially pure titanium and 304 stainless steel were obtained using a thin nickel interlayer. Then, the joints were characterized by optical microscopy, scanning electron microscopy, energy dispersive spectrometry, and X-ray diffractometry. The mechanical properties of the joints were evaluated by microhardness survey and tensile tests. Although the results showed that the tensile strength of the joints is even lower than titanium base metal, it is higher than that of the joints which were produced without nickel interlayer. The highest hardness value was observed at the interface between titanium and nickel interlayers indicating the formation of Ni-Ti intermetallic compounds. Formation these compounds was validated by XRD patterns. Moreover, in tensile tests, fracture of the joints occurred along this interface which is related to its brittle nature.

  16. Characterization of a Friction Stir Weld in Aluminum Alloy 7055 Using Microhardness, Electrical Conductivity, and Differential Scanning Calorimetry (DSC)

    NASA Astrophysics Data System (ADS)

    Bush, Ralph; Kiyota, Michelle; Kiyota, Catherine

    2016-04-01

    Optical microscopy, microhardness, electrical conductivity, and differential scanning calorimetry (DSC) were used to characterize the microstructure, hardness, and precipitate structure as a function of position in a friction stir weld, naturally aged for 10 years, in aluminum alloy 7055. Results are shown for the as-welded/naturally aged condition and for a weld that was post-aged using a -T76 regimen. The grain structure and microhardness results reveal the expected central recrystallized region, a thermo-mechanical affected zone (TMAZ), and heat-affected zone (HAZ) with typical changes in microhardness. DSC scans for the as-welded/naturally aged condition indicate a precipitate structure similar to that of a naturally aged condition in the central recrystallized region. Maximum precipitate coarsening and overaging occurs near the TMAZ/HAZ boundary with reduced precipitate dissolution and coarsening as the distance from the weld increases. The post-weld aging resulted in the transformation of GP zones to more stable precipitates plus coarsening of the more stable η' and η precipitates. A combination of DSC testing and CALPHAD calculations allowed calculation of precipitate volume fraction in the HAZ. The precipitate volume fraction decreased monotonically from 0.052 in the baseline material to 0.044 at the TMAZ/HAZ interface.

  17. Characterization of a Friction Stir Weld in Aluminum Alloy 7055 Using Microhardness, Electrical Conductivity, and Differential Scanning Calorimetry (DSC)

    NASA Astrophysics Data System (ADS)

    Bush, Ralph; Kiyota, Michelle; Kiyota, Catherine

    2016-07-01

    Optical microscopy, microhardness, electrical conductivity, and differential scanning calorimetry (DSC) were used to characterize the microstructure, hardness, and precipitate structure as a function of position in a friction stir weld, naturally aged for 10 years, in aluminum alloy 7055. Results are shown for the as-welded/naturally aged condition and for a weld that was post-aged using a -T76 regimen. The grain structure and microhardness results reveal the expected central recrystallized region, a thermo-mechanical affected zone (TMAZ), and heat-affected zone (HAZ) with typical changes in microhardness. DSC scans for the as-welded/naturally aged condition indicate a precipitate structure similar to that of a naturally aged condition in the central recrystallized region. Maximum precipitate coarsening and overaging occurs near the TMAZ/HAZ boundary with reduced precipitate dissolution and coarsening as the distance from the weld increases. The post-weld aging resulted in the transformation of GP zones to more stable precipitates plus coarsening of the more stable η' and η precipitates. A combination of DSC testing and CALPHAD calculations allowed calculation of precipitate volume fraction in the HAZ. The precipitate volume fraction decreased monotonically from 0.052 in the baseline material to 0.044 at the TMAZ/HAZ interface.

  18. Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

    NASA Technical Reports Server (NTRS)

    Seshadri, Banavara R.; Smith, Stephen W.; Newman, John A.

    2013-01-01

    Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

  19. Single crystals for welding research

    SciTech Connect

    David, S.A.; Boatner, L.A.

    1991-01-01

    Most welds last for many years, but a few fail after a relatively short time. Knowing the reasons why welds fail is important because cracks in welds can threaten the safety of people in buildings, airplanes, ships, automobiles, and power plants. Bad welds can lead to costly, extended shutdowns of industrial facilities such as petroleum refineries. Thus, research on this very important fabrication technology is critical to the multibillion-dollar welding industry. Research at ORNL and elsewhere strives to determine the structural features that make some welds strong and others weak. The goals are to find cost-effective ways to characterize the structure and strength of a new weld, correctly predict whether it will last a long time, and determine the welding conditions most likely to produce high-quality welds. There is more to welding than meets the eye. The cracks that make welds fail result from the complexities of microstructures formed during welding. Thus weld microstructure is linked to weld properties such as mechanical strength. As the hot weld material cools from a liquid into a solid, the crystalline grains grow at different speeds and in different directions, forming a new microstructure. By using single crystals rather than polycrystalline alloys to study different weld microstructures, scientists at ORNL have developed a way to predict more accurately the microstructures of various welds. The results could guide welders in providing the right conditions (correct welding speed, heat input, and weld thickness) for producing safer, higher-quality, and longer-lasting welds.

  20. Effect of Welding Current and Time on the Microstructure, Mechanical Characterizations, and Fracture Studies of Resistance Spot Welding Joints of AISI 316L Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Kianersi, Danial; Mostafaei, Amir; Mohammadi, Javad

    2014-09-01

    This article aims at investigating the effect of welding parameters, namely, welding current and welding time, on resistance spot welding (RSW) of the AISI 316L austenitic stainless steel sheets. The influence of welding current and welding time on the weld properties including the weld nugget diameter or fusion zone, tensile-shear load-bearing capacity of welded materials, failure modes, energy absorption, and microstructure of welded nuggets was precisely considered. Microstructural studies and mechanical properties showed that the region between interfacial to pullout mode transition and expulsion limit is defined as the optimum welding condition. Electron microscopic studies indicated different types of delta ferrite in welded nuggets including skeletal, acicular, and lathy delta ferrite morphologies as a result of nonequilibrium phases, which can be attributed to a fast cooling rate in the RSW process. These morphologies were explained based on Shaeffler, WRC-1992, and pseudo-binary phase diagrams. The optimum microstructure and mechanical properties were achieved with 8-kA welding current and 4-cycle welding time in which maximum tensile-shear load-bearing capacity or peak load of the welded materials was obtained at 8070 N, and the failure mode took place as button pullout with tearing from the base metal. Finally, fracture surface studies indicated that elongated dimples appeared on the surface as a result of ductile fracture in the sample welded in the optimum welding condition.

  1. Microstructural Characterization and Mechanical Properties Analysis of Weld Metals with Two Ni Contents During Post-Weld Heat Treatments

    NASA Astrophysics Data System (ADS)

    Wu, Da-yong; Han, Xiu-lin; Tian, Hong-tao; Liao, Bo; Xiao, Fu-ren

    2015-05-01

    This study designed post-weld heat treatments, including reheating and tempering, associated with hot bending to investigate the microstructures, toughness, and hardness of two weld metals with different Ni contents (<1 wt pct level). The results indicated that a high Ni content decreased the ferrite transformation temperature and increased the proportion of acicular ferrite (AF). Furthermore, a high Ni content promoted the martensite/austenite (M/A) constituent formation after reheating. The promotion of the M/A formation increased the number of cementite particles, and accelerated cementite coarsening during tempering. The large-angle grain boundary density from the AF improved the toughness despite the negative effect of cementite. The strengthening contributions were calculated, and the grain refinement was the greatest. The high Ni content decreased the effective grain size with a 2 deg tolerance angle, thus enhancing the grain refinement contribution.

  2. Characterization of coarse bainite transformation in low carbon steel during simulated welding thermal cycles

    SciTech Connect

    Lan, Liangyun; Kong, Xiangwei; Qiu, Chunlin

    2015-07-15

    Coarse austenite to bainite transformation in low carbon steel under simulated welding thermal cycles was morphologically and crystallographically characterized by means of optical microscope, transmission electron microscope and electron backscattered diffraction technology. The results showed that the main microstructure changes from a mixture of lath martensite and bainitic ferrite to granular bainite with the increase in cooling time. The width of bainitic laths also increases gradually with the cooling time. For a welding thermal cycle with relatively short cooling time (e.g. t{sub 8/5} is 30 s), the main mode of variant grouping at the scale of individual prior austenite grains changes from Bain grouping to close-packed plane grouping with the progress of phase transformation, which results in inhomogeneous distribution of high angle boundaries. As the cooling time is increased, the Bain grouping of variants becomes predominant mode, which enlarges the effective grain size of product phase. - Highlights: • Main microstructure changes and the width of lath structure increases with cooling time. • Variant grouping changes from Bain zone to close-packed plane grouping with the transformation. • The change of variant grouping results in uneven distribution of high angle grain boundary. • Bain grouping is main mode for large heat input, which lowers the density of high angle boundary.

  3. Multiscale Characterization of Deformation Mechanisms in the Weld Joint of a Nickel-based Superalloy

    SciTech Connect

    Barabash, Oleg M.; Horton, Joe; Babu, Suresh; Vitek, John; David, Stan; Ice, Gene; Barabash, Rozaliya

    2007-12-19

    Multiscale plastic deformation in the heat affected zone (HAZ) of a Ni-based single crystal superalloy has been characterized using white microbeam synchrotron diffraction measurements together with OIM imaging, electron and optical microscopy. Characteristic length scales on the macro, meso and nano scale are determined. Dissolution of the {gamma} - phase particles during heating and secondary precipitation of {gamma} - phase during cooling is found, as well as formation and multiplication of dislocations. This process is more intense as one approaches the fusion line (FL). In the regions immediately neighboring the FL, {gamma} - phase particles dissolve completely and re-precipitate from the solid solution in the form of very small (50-70nm) particles. In the immediate vicinity of the FL, the temperature gradient and the rate of it's change reaches maximal values and causes the formation of large amounts of dislocations. Dislocations are concentrated in the ? matrix of the single crystal superalloy. X-ray Laue diffraction (both conventional and microbeam) and electron microscopy show that alternating dislocations slip systems dominate in the HAZ with typical Burgers vector b=[110]. Local lattice rotations in different zones of the weld joint are linking with the microslip events in different zones of the weld.

  4. Multiscale Characterization of Deformation Mechanisms in the Weld Joint of a Nickel-based Superalloy

    SciTech Connect

    Barabash, Oleg M

    2005-01-01

    Multiscale plastic deformation in the heat affected zone (HAZ) of a Ni-based single crystal superalloy has been characterized using white microbeam synchrotron diffraction measurements together with OIM imaging, electron and optical microscopy. Characteristic length scales on the macro, meso and nano scale are determined. Dissolution of the {gamma}{prime} - phase particles during heating and secondary precipitation of {gamma}{prime} - phase during cooling is found, as well as formation and multiplication of dislocations. This process is more intense as one approaches the fusion line (FL). In the regions immediately neighboring the FL, {gamma}{prime} - phase particles dissolve completely and re-precipitate from the solid solution in the form of very small (50-70nm) particles. In the immediate vicinity of the FL, the temperature gradient and the rate of it's change reaches maximal values and causes the formation of large amounts of dislocations. Dislocations are concentrated in the {gamma} matrix of the single crystal superalloy. X-ray Laue diffraction (both conventional and microbeam) and electron microscopy show that alternating dislocations slip systems dominate in the HAZ with typical Burgers vector b=[110]. Local lattice rotations in different zones of the weld joint are linking with the microslip events in different zones of the weld.

  5. Multiscale characterization of deformation mechanisms in the weld joint of a nickel-based superalloy

    SciTech Connect

    Barabash, Oleg M; Horton Jr, Joe A; Babu, Sudarsanam S; Vitek, John Michael; David, Stan A; Ice, Gene E; Barabash, Rozaliya

    2005-01-01

    Multiscale plastic deformation in the heat affected zone (HAZ) of a Ni-based single crystal superalloy has been characterized using white microbeam synchrotron diffraction measurements together with OIM imaging, electron and optical microscopy. Characteristic length scales on the macro, meso and nano scale are determined. Dissolution of the gamma' - phase particles during heating and secondary precipitation of gamma' during cooling is found, as well as formation and multiplication of dislocations. This process is more intense as one approaches the fusion line (FL). In the regions immediately neighboring the FL, gamma' - phase particles dissolve completely and re-precipitate from the solid solution in the form of very small (10-20nm) particles. In the immediate vicinity of the FL, the temperature gradient and the rate of it's change reaches maximal values and causes the formation of large amounts of dislocations. Dislocations are concentrated in the gamma matrix of the single crystal superalloy. X-ray Laue diffraction (both conventional and microbeam) and electron microscopy show that alternating dislocations slip systems dominate in the HAZ with Burgers vector b=[110] and dislocation lines [1-12] and [1-1-2] ; or b=[-110], dislocation lines [112] and [11-2] . Each of these two dislocation groups forms two Z-shaped dislocation lines fluctuating around two cubic directions [100] and [010]. Local lattice rotations in different zones of the weld joint are linking with the microslip events in different zones of the weld.

  6. Robotics for welding research

    SciTech Connect

    Braun, G.; Jones, J.

    1984-09-01

    The welding metallurgy research and education program at Colorado School of Mines (CSM) is helping industries make the transition toward automation by training students in robotics. Industry's interest is primarily in pick and place operations, although robotics can increase efficiency in areas other than production. Training students to develop fully automated robotic welding systems will usher in new curriculum requirements in the area of computers and microprocessors. The Puma 560 robot is CSM's newest acquisition for welding research 5 references, 2 figures, 1 table.

  7. Status report. Characterization of Weld Residual Stresses on a Full-Diameter SNF Interim Storage Canister Mockup.

    SciTech Connect

    Enos, David; Bryan, Charles R.

    2015-08-01

    This report documents the mockup specifications and manufacturing processes; the initial cutting of the mockup into three cylindrical pieces for testing and the measured strain changes that occurred during the cutting process; and the planned weld residual stress characterization activities and the status of those activities.

  8. High Temperature Corrosion and Characterization Studies in Flux Cored Arc Welded 2.25Cr-1Mo Power Plant Steel

    NASA Astrophysics Data System (ADS)

    Kumaresh Babu, S. P.; Natarajan, S.

    2010-07-01

    Higher productivity is registered with Flux cored arc welding (FCAW) process in many applications. Further, it combines the characteristics of shielded metal arc welding (SMAW), gas metal arc welding (GMAW), and submerged arc welding (SAW) processes. This article describes the experimental work carried out to evaluate and compare corrosion and its inhibition in SA 387 Gr.22 (2.25Cr-1Mo) steel weldments prepared by FCAW process with four different heat inputs exposed to hydrochloric acid medium at 0.1, 0.5, and 1.0 M concentrations. The parent metal, weld metal, and heat-affected zone are chosen as regions of exposure for the study carried out at 100 °C. Electrochemical polarization techniques such as Tafel line extrapolation (Tafel) and linear polarization resistance (LPR) have been used to measure the corrosion current. The role of hexamine and mixed inhibitor (thiourea + hexamine in 0.5 M HCl), each at 100 ppm concentration is studied in these experiments. Microstructural observation, hardness survey, surface characterization, and morphology using scanning electron microscope (SEM) and x-ray diffraction (XRD) have been made on samples to highlight the nature and extent of film formation. The film is found to contain Fe2Si, FeSi2, FeMn3, Fe7Mo3, Fe3O4, FeO, FeCr, AlO7Fe3SiO3, and KFe4Mn77Si19.

  9. Microstructure Characterization and Stress Corrosion Evaluation of Autogenous and Hybrid Friction Stir Welded Al-Cu-Li 2195 Alloy

    NASA Technical Reports Server (NTRS)

    Li, Zhixian; Arbegast, William J.; Meletis, Efstathios I.

    1997-01-01

    Friction stir welding process is being evaluated for application on the Al-Cu-Li 2195 Super-Light Weight External Tank of the Space Transportation System. In the present investigation Al-Cu-Li 2195 plates were joined by autogenous friction stir welding (FSW) and hybrid FSW (friction stir welding over existing variable polarity plasma arc weld). Optical microscopy and transmission electron microscopy (TEM) were utilized to characterize microstructures of the weldments processed by both welding methods. TEM observations of autogenous FSW coupons in the center section of the dynamically-recrystallized zone showed an equiaxed recrystallized microstructure with an average grain size of approx. 3.8 microns. No T(sub 1), precipitates were present in the above-mentioned zone. Instead, T(sub B) and alpha precipitates were found in this zone with a lower population. Alternate immersion, anodic polarization, constant load, and slow strain tests were carried out to evaluate the general corrosion and stress-corrosion properties of autogenous and hybrid FSW prepared coupons. The experimental results will be discussed.

  10. 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.

  11. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

    DOE PAGESBeta

    Brewer, Luke N.; Bennett, Martin S.; Baker, B. W.; Payzant, E. Andrew; Kolbus, Lindsay M.

    2015-09-08

    This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stirmore » zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.« less

  12. Characterization of the Microstructures and the Cryogenic Mechanical Properties of Electron Beam Welded Inconel 718

    NASA Astrophysics Data System (ADS)

    Kwon, Soon Il; Bae, Sang Hyun; Do, Jeong Hyeon; Jo, Chang Yong; Hong, Hyun Uk

    2016-02-01

    The microstructures and the cryogenic mechanical properties of electron beam (EB) welds between cast and forged Inconel 718 superalloys with a thickness of 10 mm were investigated in comparison with gas tungsten arc (GTA) welds. EB welding with a heat input lower than 250 J/mm caused the formation of liquation microfissuring in the cast-side heat-affected-zone (HAZ) of the EB welds. HAZ liquation microfissuring appeared to be associated with the constitutional liquation of primary NbC carbides at the grain boundaries. Compared with the GTA welding process, the EB welding produced welds with superior microstructure, exhibiting fine dendritic structure associated with the reduction in size and fraction of the Laves phase due to the rapid cooling rate. This result was responsible for the superior mechanical properties of the EB welds at 77 K (-196 °C). Laves particles in both welds were found to provide the preferential site for the crack initiation and propagation, leading to a significant decrease in the Charpy impact toughness at 77 K (-196 °C). Crack initiation and propagation induced by Charpy impact testing were discussed in terms of the dendrite arm spacing, the Laves size and the dislocation structure ahead of the crack arisen from the fractured Laves phase in the two welds.

  13. Weld analysis and control system

    NASA Technical Reports Server (NTRS)

    Kennedy, Larry Z. (Inventor); Rodgers, Michael H. (Inventor); Powell, Bradley W. (Inventor); Burroughs, Ivan A. (Inventor); Goode, K. Wayne (Inventor)

    1994-01-01

    The invention is a Weld Analysis and Control System developed for active weld system control through real time weld data acquisition. Closed-loop control is based on analysis of weld system parameters and weld geometry. The system is adapted for use with automated welding apparatus having a weld controller which is capable of active electronic control of all aspects of a welding operation. Enhanced graphics and data displays are provided for post-weld analysis. The system provides parameter acquisition, including seam location which is acquired for active torch cross-seam positioning. Torch stand-off is also monitored for control. Weld bead and parent surface geometrical parameters are acquired as an indication of weld quality. These parameters include mismatch, peaking, undercut, underfill, crown height, weld width, puddle diameter, and other measurable information about the weld puddle regions, such as puddle symmetry, etc. These parameters provide a basis for active control as well as post-weld quality analysis and verification. Weld system parameters, such as voltage, current and wire feed rate, are also monitored and archived for correlation with quality parameters.

  14. Automated circuit fabrication and direct characterization of carbon nanotube vibrations.

    PubMed

    Zeevi, G; Shlafman, M; Tabachnik, T; Rogachevsky, Z; Rechnitz, S; Goldshtein, I; Shlafman, S; Gordon, N; Alchanati, G; Itzhak, M; Moshe, Y; Hajaj, E M; Nir, H; Milyutin, Y; Izraeli, T Y; Razin, A; Shtempluck, O; Kotchtakov, V; Yaish, Y E

    2016-01-01

    Since their discovery, carbon nanotubes have fascinated many researchers due to their unprecedented properties. However, a major drawback in utilizing carbon nanotubes for practical applications is the difficulty in positioning or growing them at specific locations. Here we present a simple, rapid, non-invasive and scalable technique that enables optical imaging of carbon nanotubes. The carbon nanotube scaffold serves as a seed for nucleation and growth of small size, optically visible nanocrystals. After imaging the molecules can be removed completely, leaving the surface intact, and thus the carbon nanotube electrical and mechanical properties are preserved. The successful and robust optical imaging allowed us to develop a dedicated image processing algorithm through which we are able to demonstrate a fully automated circuit design resulting in field effect transistors and inverters. Moreover, we demonstrate that this imaging method allows not only to locate carbon nanotubes but also, as in the case of suspended ones, to study their dynamic mechanical motion. PMID:27396506

  15. Automated circuit fabrication and direct characterization of carbon nanotube vibrations

    NASA Astrophysics Data System (ADS)

    Zeevi, G.; Shlafman, M.; Tabachnik, T.; Rogachevsky, Z.; Rechnitz, S.; Goldshtein, I.; Shlafman, S.; Gordon, N.; Alchanati, G.; Itzhak, M.; Moshe, Y.; Hajaj, E. M.; Nir, H.; Milyutin, Y.; Izraeli, T. Y.; Razin, A.; Shtempluck, O.; Kotchtakov, V.; Yaish, Y. E.

    2016-07-01

    Since their discovery, carbon nanotubes have fascinated many researchers due to their unprecedented properties. However, a major drawback in utilizing carbon nanotubes for practical applications is the difficulty in positioning or growing them at specific locations. Here we present a simple, rapid, non-invasive and scalable technique that enables optical imaging of carbon nanotubes. The carbon nanotube scaffold serves as a seed for nucleation and growth of small size, optically visible nanocrystals. After imaging the molecules can be removed completely, leaving the surface intact, and thus the carbon nanotube electrical and mechanical properties are preserved. The successful and robust optical imaging allowed us to develop a dedicated image processing algorithm through which we are able to demonstrate a fully automated circuit design resulting in field effect transistors and inverters. Moreover, we demonstrate that this imaging method allows not only to locate carbon nanotubes but also, as in the case of suspended ones, to study their dynamic mechanical motion.

  16. Automated objective characterization of visual field defects in 3D

    NASA Technical Reports Server (NTRS)

    Fink, Wolfgang (Inventor)

    2006-01-01

    A method and apparatus for electronically performing a visual field test for a patient. A visual field test pattern is displayed to the patient on an electronic display device and the patient's responses to the visual field test pattern are recorded. A visual field representation is generated from the patient's responses. The visual field representation is then used as an input into a variety of automated diagnostic processes. In one process, the visual field representation is used to generate a statistical description of the rapidity of change of a patient's visual field at the boundary of a visual field defect. In another process, the area of a visual field defect is calculated using the visual field representation. In another process, the visual field representation is used to generate a statistical description of the volume of a patient's visual field defect.

  17. 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

  18. Microstructural characterization and hardness properties of electric resistance welding titanium joints for dental applications.

    PubMed

    Ceschini, Lorella; Boromei, Iuri; Morri, Alessandro; Nardi, Diego; Sighinolfi, Gianluca; Degidi, Marco

    2015-06-01

    The electric resistance welding procedure is used to join a titanium bar with specific implant abutments in order to produce a framework directly in the oral cavity of the patient. This investigation studied the effects of the welding process on microstructure and hardness properties of commercially pure (CP2 and CP4) Ti components. Different welding powers and cooling procedures were applied to bars and abutments, normally used to produce the framework, in order to simulate the clinical intraoral welding procedure. The analyses highlighted that the joining process did not induce appreciable changes in the geometry of the abutments. However, because of unavoidable microstructural modifications in the welded zones, the hardness decreased to values lower than those of the unwelded CP2 and CP4 Ti grades, irrespective of the welding environments and parameters. PMID:26045042

  19. An approach for a comprehensive automation of electro-optical (EO) sensor characterization setups

    NASA Astrophysics Data System (ADS)

    Dave, Amit; Sharma, Jitendra; Sukheja, Anil; Kumar, Sumit; Mishra, Ashish; Goswami, D. R.

    2016-05-01

    Space Applications Centre develops various electro-optical (EO) sensors for space borne platforms and inter-planetary missions. Sensor complexities vary for different applications and therefore performance evaluation and characterization pose different challenges. Performance optimization tasks demand repeated measurements and characterization needs to be done under different phases of testing. It is difficult to meet such requirements in case of short sensor development lifecycles or tight schedules. Activities which are amenable to automation are identified and targeted to reduce the manual intervention and to avoid delays due to errors and to speed up the overall activity. Laboratory instruments, either in-house developed or COTS, play an important role in automating the test setup as they have different types of interfaces and have their own complications. In order to make an automated test setup, software intelligence need to be built based on the instrument feedback and the other check points based on the test sequence. A complete automation needs machine intelligence and sufficient amount of traceability, so that the process can be easily verified for confidence. Overall software architecture should be such that it allows connecting various types of instruments, decision making based on output of the device under test, complete traceability and fault tolerance. In this paper authors have identified the activities that can be automated for various EO sensor categories and approaches are discussed for automation with radiometric calibration, spectral response measurement and focusing as test cases. Also, software architecture is presented which allows uniform access to instruments, back-end database and macro level automation process.

  20. Stainless Steel 18-10 CO2 Laser Welding And Plasma Diagnostics

    SciTech Connect

    Amar, Taibi; Michel, Laurent

    2008-09-23

    The welding of materials by CO2 laser took significant considerations in industry, for the reason of the quality of the carried out weldings, and for other many advantages, but the automation of the welding operation requires a control system in real time. The operation of welding is an operation of interaction between the radiation (laser), and the matter (welded part), which is characterized by the vaporization of the matter, formation of the keyhole in material, and appearance of plasma over the material. This study relates to the relation between the welding (molten material) and the plasma which is formed on material. The light emitted by plasma during laser welding was recorded by an OMA detector (Optical Multichannel Analyzer) over a wavelength width of 450 A ring . The analysis of this light allows to determine the composition of this plasma, its dimensions, and the state of its energy according to the laser parameters. The welded material is the stainless steel 18-10, it was found that the intensity of the light emitted by plasma depends on laser power, the welding speed, the flow rate of assist gas. The relation between the plasma and the state of the bead were analyzed for on-line monitoring welding.

  1. Development and characterization for the automated surface mount assembly

    SciTech Connect

    Yerganian, S.S.; Grice, J.V.

    1996-11-01

    Development of the ability to automatically assemble surface mount devices on circuits is described, including the characterization of the assembly process and improvements made to the system to increase the accuracy and repeatability of this process. The accuracy and repeatability of the system were characterized by measurements of the individual system components as well as the actual placement of components on a specially designed gauge. The forces and stresses experienced by the components when handled by the system were analyzed. The ability to deliver surface mount components to the system was developed by the design and development of stick magazines, vibratory feeders, a feeder control system, and an automatic stick magazine loader.

  2. Semi-automated potentiometric titration method for uranium characterization.

    PubMed

    Cristiano, B F G; Delgado, J U; da Silva, J W S; de Barros, P D; de Araújo, R M S; Lopes, R T

    2012-07-01

    The manual version of the potentiometric titration method has been used for certification and characterization of uranium compounds. In order to reduce the analysis time and the influence of the analyst, a semi-automatic version of the method was developed in the Brazilian Nuclear Energy Commission. The method was applied with traceability assured by using a potassium dichromate primary standard. The combined standard uncertainty in determining the total concentration of uranium was around 0.01%, which is suitable for uranium characterization. PMID:22154105

  3. Submerged-arc welding slags: characterization and leaching strategies for the removal of aluminum and titanium.

    PubMed

    Annoni, Raquel; Souza, Poliana Santos; Petrániková, Martina; Miskufova, Andrea; Havlík, Tomáš; Mansur, Marcelo Borges

    2013-01-15

    In the present study, submerged-arc welding slags were characterized by applying a variety of methods, including X-ray fluorescence, X-ray diffraction, particle size, Raman spectroscopy, and scanning electron microscope with energy dispersive X-ray analysis. The content of Al proved to be quite similar within neutral and acid slags (10-14%), while that of Ti proved to be much higher in acid slags (approximately 10%) than in neutral slags (<1%). The presence of spinel structures associated with Al species could also be identified in the analyzed samples. This characterization study was accompanied by leaching tests performed under changing operating conditions in an attempt to evaluate to what extent the Al and Ti bearing components could be removed from the slags. The leaching work involved three distinct strategies: (i) NaOH leaching followed by H(2)SO(4) leaching, (ii) acid leaching (HCl and H(2)SO(4)) using oxidizing/reducing agents, and (iii) slag calcination followed by H(2)SO(4) leaching. In the best result, 80% of Al was extracted in one single leaching stage after calcination of the acid slag with NaCl+C at 900 °C. By contrast, the removal of Ti proved to be unsatisfactory. PMID:23274794

  4. Relationship Between Microstructure, Strength, and Fracture in an Al-Zn-Mg Electron Beam Weld: Part I: Microstructure Characterization

    NASA Astrophysics Data System (ADS)

    Puydt, Quentin; Flouriot, Sylvain; Ringeval, Sylvain; De Geuser, Frédéric; Parry, Guillaume; Deschamps, Alexis

    2014-09-01

    This work presents a detailed, multiscale, spatially resolved study of the microstructure of an electron beam butt weld of the EN-AW 7020 (Al-Zn-Mg) alloy. Using a combination of optical, scanning and transmission electron microscopy, differential scanning calorimetry, and small-angle X-ray scattering, the distribution of phases in the different areas of the heat-affected zone and of the fusion zone is quantitatively characterized, for two different aging states: naturally aged after welding and artificially aged at 423 K (150 °C). The heat-affected zone consists of regions experiencing different levels of precipitate dissolution and coarsening during welding as well as new precipitation during post-welding heat treatment (PWHT). The microstructure of the fusion zone is typical from a fast solidification process, with a strong solute segregation in the interdendritic zones. The precipitate distribution after PWHT follows this solute distribution, and the resulting hardness is much lower than the relatively homogeneous value in the base metal and the heat-affected zone.

  5. Relationship Between Microstructure, Strength, and Fracture in an Al-Zn-Mg Electron Beam Weld: Part I: Microstructure Characterization

    NASA Astrophysics Data System (ADS)

    Puydt, Quentin; Flouriot, Sylvain; Ringeval, Sylvain; De Geuser, Frédéric; Parry, Guillaume; Deschamps, Alexis

    2014-12-01

    This work presents a detailed, multiscale, spatially resolved study of the microstructure of an electron beam butt weld of the EN-AW 7020 (Al-Zn-Mg) alloy. Using a combination of optical, scanning and transmission electron microscopy, differential scanning calorimetry, and small-angle X-ray scattering, the distribution of phases in the different areas of the heat-affected zone and of the fusion zone is quantitatively characterized, for two different aging states: naturally aged after welding and artificially aged at 423 K (150 °C). The heat-affected zone consists of regions experiencing different levels of precipitate dissolution and coarsening during welding as well as new precipitation during post-welding heat treatment (PWHT). The microstructure of the fusion zone is typical from a fast solidification process, with a strong solute segregation in the interdendritic zones. The precipitate distribution after PWHT follows this solute distribution, and the resulting hardness is much lower than the relatively homogeneous value in the base metal and the heat-affected zone.

  6. Automated segmentation and shape characterization of volumetric data.

    PubMed

    Galinsky, Vitaly L; Frank, Lawrence R

    2014-05-15

    Characterization of complex shapes embedded within volumetric data is an important step in a wide range of applications. Standard approaches to this problem employ surface-based methods that require inefficient, time consuming, and error prone steps of surface segmentation and inflation to satisfy the uniqueness or stability of subsequent surface fitting algorithms. Here we present a novel method based on a spherical wave decomposition (SWD) of the data that overcomes several of these limitations by directly analyzing the entire data volume, obviating the segmentation, inflation, and surface fitting steps, significantly reducing the computational time and eliminating topological errors while providing a more detailed quantitative description based upon a more complete theoretical framework of volumetric data. The method is demonstrated and compared to the current state-of-the-art neuroimaging methods for segmentation and characterization of volumetric magnetic resonance imaging data of the human brain. PMID:24521852

  7. Automated site characterization for robotic sample acquisition systems

    NASA Technical Reports Server (NTRS)

    Scholl, Marija S.; Eberlein, Susan; Yates, Gigi; Schumate, Michael S.; Majani, Eric; Anderson, Charles H.; Sloan, Jeffrey A.

    1991-01-01

    A mobile, semi-autonomous vehicle with multiple sensors and on-board intelligence is proposed for performing preliminary scientific investigations on extraterrestrial bodies prior to human exploration. Two technologies, a hybrid optical-digital computer system based on optical correlator technology and an image and instrument data analysis system, provide complementary capabilities which might be part of an instrument package for an intelligent robotic vehicle. The hybrid digital-optical vision system could perform real-time image classification tasks using an optical correlator with programmable matched filters under control of a digital microcomputer. The data analysis system would analyze visible and multiband imagery to extract mineral composition and textural information for geologic characterization. Together these technologies would support the site characterization needs of a robotic vehicle for both navigational and scientific purposes.

  8. Neutron Diffraction Characterization of Residual Strain in Welded Inconel 718 for NASA Space Shuttle Flow Liners

    SciTech Connect

    Rathod, C.R.; Vaidyanathan, R.; Livescu, V.; Clausen, B.; Bourke, M. A. M.; Notardonato, W.U.; Femminineo, M.

    2004-06-28

    This work quantitatively assesses residual strains and stresses associated with the weld repair process used to repair cracks on NASA's space shuttle flow liners. The coupons used in this investigation were made of the same INCONEL 718 alloy used for the flow liners. They were subjected to identical welding and certification procedures that were carried out on the space shuttle. Neutron diffraction measurements at Los Alamos National Laboratory determined residual strains at selected locations in a welded coupon at 293 K and 135 K. The weld repair process introduced Mises effective residual stresses of up to 555 MPa. On comparing the measurements at 293 K and 135 K, no significant change to the residual strain profile was noted at the low temperature. This indicated minimal mismatch in the coefficients of thermal expansion between the base metal and the weld.

  9. Defect characterization in pipe-to-pipe welds in large diameter stainless steel piping

    SciTech Connect

    Rawl, D.E. Jr.; West, S.L.; Wheeler, D.A.; Louthan, M.R. Jr.

    1990-01-01

    Metallurgical evaluation of pipe-to-pipe welds in large-diameter, Type 304 stainless steel piping used to construct the moderator/coolant water systems for Savannah River Site reactors has demonstrated that small weld defects found in this 1950-vintage system do not compromise the integrity of the system. The weld defects were too small for detection by the pre-service standard radiographic inspection, but were found through systematic ultrasonic testing (UT) and penetrant testing (PT) evaluations of piping that had been removed during upgrades to the piping system. The defects include lack of weld penetration, slag inclusions, and other weld metal discontinuities. These discontinuities typically did not propagate during more than 35 years of service. The defects examined were too small and isolated to degrade the mechanical properties of the pipe-to-pipe weldments and therefore did not compromise the integrity of the piping system. 14 refs., 7 figs.

  10. Welding technology transfer task/laser based weld joint tracking system for compressor girth welds

    NASA Technical Reports Server (NTRS)

    Looney, Alan

    1991-01-01

    Sensors to control and monitor welding operations are currently being developed at Marshall Space Flight Center. The laser based weld bead profiler/torch rotation sensor was modified to provide a weld joint tracking system for compressor girth welds. The tracking system features a precision laser based vision sensor, automated two-axis machine motion, and an industrial PC controller. The system benefits are elimination of weld repairs caused by joint tracking errors which reduces manufacturing costs and increases production output, simplification of tooling, and free costly manufacturing floor space.

  11. Customized orbital welding meets the challenge of titanium welding

    SciTech Connect

    1996-12-01

    Titanium has emerged as the material of choice for tubing used in surface condensers around the world in both new and retrofit configurations. A major worldwide supplier of steam surface condensers to the electric utility industry, Senior Engineering is finding an increased use of titanium tubes and tube sheets in condenser specifications. When compared to other alloys, titanium`s light weight is efficient in design, handling, transportation and installation activities. Additionally, it maintains a stable price structure. Senior Engineering implements an orbital welding process using fusion gas tungsten arc welding (GTAW) for its titanium tube-to-tube sheet welding. Orbital welding involves the use of a welding apparatus placed inside a tube or pipe to automatically and precisely weld a 360-deg joint. When welding manually, a welder stops several times during the weld due to the large amount of time and fatigue involved in achieving 360-deg welds, which results in lack of fusion. An automated orbital welding system, however, can accomplish the task as one continuous weld. This reduces process time and decreases lack of fusion. The orbital welding systems, featuring a microprocessor-based controller, an inverter-based power supply, an expandable mandrel and a customized torch shroud, reduced welding labor by 35%. The improved labor efficiency justified the addition of two more of the systems in January 1996.

  12. Characterization of tool wear and weld optimization in the friction-stir welding of cast aluminum 359+20% SiC metal-matrix composite

    SciTech Connect

    Fernandez, G.J.; Murr, L.E

    2004-03-15

    Tool wear for threaded steel pin tools declines with decreasing rotation speed and increasing traverse or weld speeds for the friction-stir welding (FSW) of Al 359+20% SiC metal-matrix composite (MMC). Less than 10% tool wear occurs when the threaded tool erodes to a self-optimized shape resembling a pseudo-hour glass at weld traverse distances in excess of 3 m. There is only a 7% reduction in the SiC mean particle size in the weld zone for self-optimized pin tools with no threads as compared with a 25% variation for threaded tools wearing significantly at the start of welding. The weld zone becomes more homogeneous for efficient welding with self-optimized tools, and there is a reduction in the weld zone grain size due to dynamic recrystallization, which facilitates the solid-state flow. Transmission electron microscopy shows little difference in the dislocation density from the base material to the weld zone, but there is a propensity of dislocation loops in the weld zone. The weld zone is observed to harden by as much as 30%, in contrast to the base material, as a consequence of the recrystallized grain size reduction and the SiC particles distributed therein.

  13. Development of automated welding process for field fabrication of thick walled pressure vessels. Technical progress report, second quarter, FY 1980, ending March 28, 1980

    SciTech Connect

    Schneider, U.A.

    1980-01-01

    Progress on a metallurgical contract is reported: (1) specifications of 2 1/4 chromium-1 molybdenum low alloy steel plate for a coal gasification project; (2) methods of welding and analyses of helium-argon mixtures for welding; and (3) tensile properties of welded joints. (LTN)

  14. Impact Modeling of Spot Welds

    NASA Astrophysics Data System (ADS)

    Yancey, Robert N.

    2004-06-01

    Resistance spot welds in most current finite element crash models are characterized as a rigid link at the location of the weld which transfers the load but is not designed to fail. Newer weld elements in the popular finite element analysis codes include the option of incorporating a failure criteria for the weld element. As many automotive companies move towards the use of high-strength steels, the dynamic behavior of the spot welds will become increasingly important and the failure of any welds should be incorporated during the simulation. The failure criteria will be influenced by mesh size, weld element properties, weld element type, surrounding material properties, strain rate, and weld placement. The influence of some of these parameters using current spot weld modeling techniques will be discussed along with recommendations for future work in this area.

  15. Unique applications of personal computers in the welding environment

    SciTech Connect

    Glickstein, S.S.

    1990-12-31

    The personal computer was found to be useful in supporting a variety of welding applications: 3-D representation of crack propagation using CADD software, storage and retrieval of photographic data using an image capture board, automated positioning of the welding electrode for GTA welding, interactive computer based voice communication for welding operations, surface temperature measurements of welded structures, and inventory control of weld material through use of bar codes.

  16. Characterization of the Micro-Welding Process for Repair of Nickel Base Superalloys

    NASA Astrophysics Data System (ADS)

    Durocher, J.; Richards, N. L.

    2007-12-01

    Micro-welding is a low-heat input process whereby a metal or cermet, is deposited by the generation of a low-power arc between a consumable electrode and a substrate. The low-heat input of this process offers unique advantages over more common welding processes such as gas tungsten arc, plasma arc, laser, and electron beam welding. At present, the repair of turbine blades and vanes commonly involves gas tungsten arc welding and these components are susceptible to heat affected zone cracking during the weld repair process; vacuum brazing is also used but mainly on low-stress components such as stators. In this study, the low-heat input characteristic of micro-welding has been utilized to simulate repair of Inconel (Trade Mark of Special Metals) 625, Inconel 718, and Inconel 722 filler alloys to a cast Inconel 738 substrate. The effect of micro-welding process parameters on the deposition rate, coating quality, and substrate has been investigated.

  17. Development and characterization of a resistance spot welding aerosol generator and inhalation exposure system.

    PubMed

    Afshari, Aliakbar; Zeidler-Erdely, Patti C; McKinney, Walter; Chen, Bean T; Jackson, Mark; Schwegler-Berry, Diane; Friend, Sherri; Cumpston, Amy; Cumpston, Jared L; Leonard, H Donny; Meighan, Terence G; Frazer, David G; Antonini, James M

    2014-10-01

    Limited information exists regarding the health risks associated with inhaling aerosols that are generated during resistance spot welding of metals treated with adhesives. Toxicology studies evaluating spot welding aerosols are non-existent. A resistance spot welding aerosol generator and inhalation exposure system was developed. The system was designed by directing strips of sheet metal that were treated with an adhesive to two electrodes of a spot welder. Spot welds were made at a specified distance from each other by a computer-controlled welding gun in a fume collection chamber. Different target aerosol concentrations were maintained within the exposure chamber during a 4-h exposure period. In addition, the exposure system was run in two modes, spark and no spark, which resulted in different chemical profiles and particle size distributions. Complex aerosols were produced that contained both metal particulates and volatile organic compounds (VOCs). Size distribution of the particles was multi-modal. The majority of particles were chain-like agglomerates of ultrafine primary particles. The submicron mode of agglomerated particles accounted for the largest portion of particles in terms of particle number. Metal expulsion during spot welding caused the formation of larger, more spherical particles (spatter). These spatter particles appeared in the micron size mode and accounted for the greatest amount of particles in terms of mass. With this system, it is possible to examine potential mechanisms by which spot welding aerosols can affect health, as well as assess which component of the aerosol may be responsible for adverse health outcomes. PMID:25140455

  18. Characterization of complex carbide–silicide precipitates in a Ni–Cr–Mo–Fe–Si alloy modified by welding

    SciTech Connect

    Bhattacharyya, D. Davis, J.; Drew, M.; Harrison, R.P.; Edwards, L.

    2015-07-15

    Nickel based alloys of the type Hastelloy-N™ are ideal candidate materials for molten salt reactors, as well as for applications such as pressure vessels, due to their excellent resistance to creep, oxidation and corrosion. In this work, the authors have attempted to understand the effects of welding on the morphology, chemistry and crystal structure of the precipitates in the heat affected zone (HAZ) and the weld zone of a Ni–Cr–Mo–Fe–Si alloy similar to Hastelloy-N™ in composition, by using characterization techniques such as scanning and transmission electron microscopy. Two plates of a Ni–Cr–Mo–Fe–Si alloy GH-3535 were welded together using a TiG welding process without filler material to achieve a joint with a curved molten zone with dendritic structure. It is evident that the primary precipitates have melted in the HAZ and re-solidified in a eutectic-like morphology, with a chemistry and crystal structure only slightly different from the pre-existing precipitates, while the surrounding matrix grains remained unmelted, except for the zones immediately adjacent to the precipitates. In the molten zone, the primary precipitates were fully melted and dissolved in the matrix, and there was enrichment of Mo and Si in the dendrite boundaries after solidification, and re-precipitation of the complex carbides/silicides at some grain boundaries and triple points. The nature of the precipitates in the molten zone varied according to the local chemical composition. - Graphical abstract: Display Omitted - Highlights: • Ni-based alloy with Cr, Mo, Si, Fe and C was welded, examined with SEM, EBSD, and TEM. • Original Ni{sub 2}(Mo,Cr){sub 4}(Si,C) carbides changed from equiaxed to lamellar shape in HAZ. • Composition and crystal structure remained almost unchanged in HAZ. • Original carbides changed to lamellar Ni{sub 3}(Mo,Cr){sub 3}(Si,C) in some cases in weld metal. • Precipitates were mostly incoherent, but semi-coherent in some cases in weld

  19. Microstructural and mechanical characterization of postweld heat-treated thermite weld in rails

    SciTech Connect

    Ilic, N.; Jovanovic, M.T.; Todorovic, M.; Trtanj, M.; Saponjic, P.

    1999-10-01

    This paper describes a comparative study of the hardness characteristics, mechanical properties, microstructures, and fracture mechanisms of the thermite welded rail steel joints before and after heat treatment. It has been found that heat treatment of the welded joint improves the mechanical properties (UTS and elongation), and changes the fracture mechanism from brittle to ductile. Improved strength and elongation are attributed to the finer ferrite-pearlite microstructure and the different fracture mechanism. Microporosity and numerous inclusions were seen on the fracture surface of the welded joint. The chemical composition of the inclusions indicated that the molten thermite mixture had reacted with the magnesite lining of the ladle and the feeder.

  20. 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 .

  1. Welding Sensor System

    NASA Technical Reports Server (NTRS)

    1993-01-01

    A system originally designed for welding components of the huge Space Shuttle external tank led to a laser-based automated welder for industrial use. A laser sensor tracks the seam where two pieces of metal are to be joined, measures gaps, misfits and automatically corrects welding of torch distance and height. A small industrial computer translates the sensor's information to the weld head and records and displays weld data for control purposes and analysis. The system was modified for commercial use by Marshall Space Flight Center (MSFC), Martin Marietta and Applied Research, Inc., which produces the commercial system. Applications are in industrial welding processes that require repetitive operations and a high degree of reliability.

  2. Welding--Trade or Profession?

    ERIC Educational Resources Information Center

    Albright, C. E.; Smith, Kenneth

    2006-01-01

    This article discusses a collaborative program between schools with the purpose of training and providing advanced education in welding. Modern manufacturing is turning to automation to increase productivity, but it can be a great challenge to program robots and other computer-controlled welding and joining systems. Computer programming and…

  3. Characterization of exposures to airborne nanoscale particles during friction stir welding of aluminum.

    PubMed

    Pfefferkorn, Frank E; Bello, Dhimiter; Haddad, Gilbert; Park, Ji-Young; Powell, Maria; McCarthy, Jon; Bunker, Kristin Lee; Fehrenbacher, Axel; Jeon, Yongho; Virji, M Abbas; Gruetzmacher, George; Hoover, Mark D

    2010-07-01

    Friction stir welding (FSW) is considered one of the most significant developments in joining technology over the last half century. Its industrial applications are growing steadily and so are the number of workers using this technology. To date, there are no reports on airborne exposures during FSW. The objective of this study was to investigate possible emissions of nanoscale (<100 nm) and fine (<1 microm) aerosols during FSW of two aluminum alloys in a laboratory setting and characterize their physicochemical composition. Several instruments measured size distributions (5 nm to 20 microm) with 1-s resolution, lung deposited surface areas, and PM(2.5) concentrations at the source and at the breathing zone (BZ). A wide range aerosol sampling system positioned at the BZ collected integrated samples in 12 stages (2 nm to 20 microm) that were analyzed for several metals using inductively coupled plasma mass spectrometry. Airborne aerosol was directly collected onto several transmission electron microscope grids and the morphology and chemical composition of collected particles were characterized extensively. FSW generates high concentrations of ultrafine and submicrometer particles. The size distribution was bimodal, with maxima at approximately 30 and approximately 550 nm. The mean total particle number concentration at the 30 nm peak was relatively stable at approximately 4.0 x 10(5) particles cm(-3), whereas the arithmetic mean counts at the 550 nm peak varied between 1500 and 7200 particles cm(-3), depending on the test conditions. The BZ concentrations were lower than the source concentrations by 10-100 times at their respective peak maxima and showed higher variability. The daylong average metal-specific concentrations were 2.0 (Zn), 1.4 (Al), and 0.24 (Fe) microg m(-3); the estimated average peak concentrations were an order of magnitude higher. Potential for significant exposures to fine and ultrafine aerosols, particularly of Al, Fe, and Zn, during FSW may

  4. Characterization of Exposures to Airborne Nanoscale Particles During Friction Stir Welding of Aluminum

    PubMed Central

    Pfefferkorn, Frank E.; Bello, Dhimiter; Haddad, Gilbert; Park, Ji-Young; Powell, Maria; Mccarthy, Jon; Bunker, Kristin Lee; Fehrenbacher, Axel; Jeon, Yongho; Virji, M. Abbas; Gruetzmacher, George; Hoover, Mark D.

    2010-01-01

    Friction stir welding (FSW) is considered one of the most significant developments in joining technology over the last half century. Its industrial applications are growing steadily and so are the number of workers using this technology. To date, there are no reports on airborne exposures during FSW. The objective of this study was to investigate possible emissions of nanoscale (<100 nm) and fine (<1 μm) aerosols during FSW of two aluminum alloys in a laboratory setting and characterize their physicochemical composition. Several instruments measured size distributions (5 nm to 20 μm) with 1-s resolution, lung deposited surface areas, and PM2.5 concentrations at the source and at the breathing zone (BZ). A wide range aerosol sampling system positioned at the BZ collected integrated samples in 12 stages (2 nm to 20 μm) that were analyzed for several metals using inductively coupled plasma mass spectrometry. Airborne aerosol was directly collected onto several transmission electron microscope grids and the morphology and chemical composition of collected particles were characterized extensively. FSW generates high concentrations of ultrafine and submicrometer particles. The size distribution was bimodal, with maxima at ∼30 and ∼550 nm. The mean total particle number concentration at the 30 nm peak was relatively stable at ∼4.0 × 105 particles cm−3, whereas the arithmetic mean counts at the 550 nm peak varied between 1500 and 7200 particles cm−3, depending on the test conditions. The BZ concentrations were lower than the source concentrations by 10–100 times at their respective peak maxima and showed higher variability. The daylong average metal-specific concentrations were 2.0 (Zn), 1.4 (Al), and 0.24 (Fe) μg m−3; the estimated average peak concentrations were an order of magnitude higher. Potential for significant exposures to fine and ultrafine aerosols, particularly of Al, Fe, and Zn, during FSW may exist, especially in larger scale industrial

  5. Automated fabrication, characterization and transport of ICF pellets. Final report, March 1, 1979-October 31, 1980

    SciTech Connect

    Clifford, D W; Boyd, B A; Lilienkamp, R H

    1980-12-01

    The near-term objectives of the contract were threefold: (1) evaluate techniques for the production of frozen hydrogen microspheres and demonstrate concepts for coating them; (2) develop and demonstrate an optical characterization system which could lead to automated pellet inspection; and (3) develop and demonstrate a preliminary electrostatic pellet transport control system. This report describes the equipment assembled for these experiments and the results obtained.

  6. Experimental characterization of creep damage in a welded steel pipe section using a nonlinear ultrasonic technique

    NASA Astrophysics Data System (ADS)

    Ehrlich, C.; Kim, J.-Y.; Jacobs, L. J.; Qu, J.; Wall, J.

    2012-05-01

    To ensure the long and safe operation of power plants, structural parts must be monitored for damage. In the case of welded steel pipes that maintain high pressures in high temperature environments, a common cause of failure is creep damage. Severe creep damage often occurs in the heat affected zone (HAZ). Previous research has shown that nonlinear acoustic techniques are sensitive to creep damage. This research develops a procedure using longitudinal waves to obtain the nonlinearity parameter on a welded steel pipe in order to detect creep damage. These experiments show higher levels of nonlinearity in the HAZ. Additional measurements on an undamaged, welded sample suggest that the high nonlinearity is due to creep (stresses at a high temperature for extended time) damage and not welding (high temperature only for a short time).

  7. Experimental characterization of the weld pool flow in a TIG configuration

    NASA Astrophysics Data System (ADS)

    Stadler, M.; Masquère, M.; Freton, P.; Franceries, X.; Gonzalez, J. J.

    2014-11-01

    Tungsten Inert Gas (TIG) welding process relies on heat transfer between plasma and work piece leading to a metallic weld pool. Combination of different forces produces movements on the molten pool surface. One of our aims is to determine the velocity on the weld pool surface. This provides a set of data that leads to a deeper comprehension of the flow behavior and allows us to validate numerical models used to study TIG parameters. In this paper, two diagnostic methods developed with high speed imaging for the determination of velocity of an AISI 304L stainless steel molten pool are presented. Application of the two methods to a metallic weld pool under helium with a current intensity of 100 A provides velocity values around 0.70 m/s which are in good agreement with literature works.

  8. Microstructural characterization of the HAZ in AISI 444 ferritic stainless steel welds

    SciTech Connect

    Silva, Cleiton C. Farias, Jesualdo P.; Miranda, Helio C.; Guimaraes, Rodrigo F.; Menezes, John W.A.; Neto, Moises A.M.

    2008-05-15

    Ferritic stainless steel is used as a coating for equipment in the petroleum refining industry. Welding is the main manufacturing and maintenance process used. However, little information on the metallurgical alterations caused by welding of these steels is found in the literature, prompting this study. In this study the authors evaluated the HAZ microstructure of AISI 444 ferritic stainless steel welded plates, by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results indicated that a weld thermal cycle caused microphase precipitation in the HAZ of the ferritic stainless steel. Also needle-like Laves phase precipitation occurred in the HAZ, near the partially-melted zone. Other secondary phases such as chi and sigma were observed, as well as nitride, carbide and carbonitride precipitates.

  9. 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.

  10. Laser-assisted friction stir welding of aluminum alloy lap joints: microstructural and microhardness characterizations

    NASA Astrophysics Data System (ADS)

    Casalino, Giuseppe; Campanelli, Sabina L.; Contuzzi, Nicola; Angelastro, Andrea; Ludovico, Antonio D.

    2014-02-01

    Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. The laser Assisted Friction Stir Welding (LAFSW) combines a Friction Stir Welding machine and a laser system. Laser power is used to preheat and to plasticize the volume of the workpiece ahead of the rotating tool; the workpiece is then joined in the same way as in the conventional FSW process. In this work an Ytterbium fiber laser with maximum power of 4 kW and a commercial FSW machine were coupled. Both FSW and LAFSW tests were conducted on 3 mm thick 5754H111 aluminum alloy plates in lap joint configuration with a constant tool rotation rate and with different feed rates. The two processes were compared and evaluated in terms of differences in the microstructure and in the micro-hardness profile.

  11. Improved techniques of parallel gap welding and monitoring

    NASA Technical Reports Server (NTRS)

    Mardesich, N.; Gillanders, M. S.

    1984-01-01

    Welding programs which show that parallel gas welding is a reliable process are discussed. When monitoring controls and nondestructive tests are incorporated into the process, parallel gap welding becomes more reliable and cost effective. The panel fabrication techniques and the HAC thermal cycling test indicate reliable product integrity. The design and building of automated tooling and fixturing for welding are discussed.

  12. Automated video quality measurement based on manmade object characterization and motion detection

    NASA Astrophysics Data System (ADS)

    Kalukin, Andrew; Harguess, Josh; Maltenfort, A. J.; Irvine, John; Algire, C.

    2016-05-01

    Automated video quality assessment methods have generally been based on measurements of engineering parameters such as ground sampling distance, level of blur, and noise. However, humans rate video quality using specific criteria that measure the interpretability of the video by determining the kinds of objects and activities that might be detected in the video. Given the improvements in tracking, automatic target detection, and activity characterization that have occurred in video science, it is worth considering whether new automated video assessment methods might be developed by imitating the logical steps taken by humans in evaluating scene content. This article will outline a new procedure for automatically evaluating video quality based on automated object and activity recognition, and demonstrate the method for several ground-based and maritime examples. The detection and measurement of in-scene targets makes it possible to assess video quality without relying on source metadata. A methodology is given for comparing automated assessment with human assessment. For the human assessment, objective video quality ratings can be obtained through a menu-driven, crowd-sourced scheme of video tagging, in which human participants tag objects such as vehicles and people on film clips. The size, clarity, and level of detail of features present on the tagged targets are compared directly with the Video National Image Interpretability Rating Scale (VNIIRS).

  13. Weld penetration and defect control

    SciTech Connect

    Chin, B.A.

    1992-05-15

    Highly engineered designs increasingly require the use of improved materials and sophisticated manufacturing techniques. To obtain optimal performance from these engineered products, improved weld properties and joint reliability are a necessarily. This requirement for improved weld performance and reliability has led to the development of high-performance welding systems in which pre-programmed parameters are specified before any welding takes place. These automated systems however lack the ability to compensate for perturbations which arise during the welding process. Hence the need for systems which monitor and control the in-process status of the welding process. This report discusses work carried out on weld penetration indicators and the feasibility of using these indicators for on-line penetration control.

  14. RapTOR: Automated sequencing library preparation and suppression for rapid pathogen characterization ( 7th Annual SFAF Meeting, 2012)

    ScienceCinema

    Lane, Todd [SNL

    2013-02-11

    Todd Lane on "RapTOR: Automated sequencing library preparation and suppression for rapid pathogen characterization" at the 2012 Sequencing, Finishing, Analysis in the Future Meeting held June 5-7, 2012 in Santa Fe, New Mexico.

  15. RapTOR: Automated sequencing library preparation and suppression for rapid pathogen characterization ( 7th Annual SFAF Meeting, 2012)

    SciTech Connect

    Lane, Todd

    2012-06-01

    Todd Lane on "RapTOR: Automated sequencing library preparation and suppression for rapid pathogen characterization" at the 2012 Sequencing, Finishing, Analysis in the Future Meeting held June 5-7, 2012 in Santa Fe, New Mexico.

  16. Atom probe tomography characterizations of high nickel, low copper surveillance RPV welds irradiated to high fluences

    NASA Astrophysics Data System (ADS)

    Miller, M. K.; Powers, K. A.; Nanstad, R. K.; Efsing, P.

    2013-06-01

    The Ringhals Units 3 and 4 reactors in Sweden are pressurized water reactors (PWRs) designed and supplied by Westinghouse Electric Company, with commercial operation in 1981 and 1983, respectively. The reactor pressure vessels (RPVs) for both reactors were fabricated with ring forgings of SA 508 class 2 steel. Surveillance blocks for both units were fabricated using the same weld wire heat, welding procedures, and base metals used for the RPVs. The primary interest in these weld metals is because they have very high nickel contents, with 1.58 and 1.66 wt.% for Unit 3 and Unit 4, respectively. The nickel content in Unit 4 is the highest reported nickel content for any Westinghouse PWR. Although both welds contain less than 0.10 wt.% copper, the weld metals have exhibited high irradiation-induced Charpy 41-J transition temperature shifts in surveillance testing. The Charpy impact 41-J shifts and corresponding fluences are 192 °C at 5.0 × 1023 n/m2 (>1 MeV) for Unit 3 and 162 °C at 6.0 × 1023 n/m2 (>1 MeV) for Unit 4. These relatively low-copper, high-nickel, radiation-sensitive welds relate to the issue of so-called late-blooming nickel-manganese-silicon phases. Atom probe tomography measurements have revealed ˜2 nm-diameter irradiation-induced precipitates containing manganese, nickel, and silicon, with phosphorus evident in some of the precipitates. However, only a relatively few number of copper atoms are contained within the precipitates. The larger increase in the transition temperature shift in the higher copper weld metal from the Ringhals R3 Unit is associated with copper-enriched regions within the manganese-nickel-silicon-enriched precipitates rather than changes in their size or number density.

  17. Characterization of Microstructures across the Heat-Affected Zone of the Modified 9Cr-1Mo Weld Joint to Understand Its Role in Promoting Type IV Cracking

    NASA Astrophysics Data System (ADS)

    Laha, K.; Chandravathi, K. S.; Parameswaran, P.; Rao, K. Bhanu Sankara; Mannan, S. L.

    2007-01-01

    In the postweld heat-treated (PWHT) fusion welded modified 9Cr-1Mo steel joint, a soft zone was identified at the outer edge of the heat-affected zone (HAZ) of the base metal adjacent to the deposited weld metal. Hardness and tensile tests were performed on the base metal subjected to soaking for 5 minutes at temperatures below Ac1 to above Ac3 and tempering at the PWHT condition. These tests indicated that the soft zone in the weld joint corresponds to the intercritical region of HAZ. Creep tests were conducted on the base metal and cross weld joint. At relatively lower stresses and higher test temperatures, the weld joint possessed lower creep rupture life than the base metal, and the difference in creep rupture life increased with the decrease in stress and increase in temperature. Preferential accumulation of creep deformation coupled with extensive creep cavitation in the intercritical region of HAZ led to the premature failure of the weld joint in the intercritical region of the HAZ, commonly known as type IV cracking. The microstructures across the HAZ of the weld joint have been characterized to understand the role of microstructure in promoting type IV cracking. Strength reduction in the intercritical HAZ of the joint resulted from the combined effects of coarsening of dislocation substructures and precipitates. Constrained deformation of the soft intercritical HAZ sandwich between relatively stronger constitutes of the joint induced creep cavitation in the soft zone resulting in premature failure.

  18. Experimental characterization and macro-modeling of mechanical strength of multi-sheets and multi-materials spot welds under pure and mixed modes I and II

    NASA Astrophysics Data System (ADS)

    Chtourou, Rim; Haugou, Gregory; Leconte, Nicolas; Zouari, Bassem; Chaari, Fahmi; Markiewicz, Eric

    2015-09-01

    Resistance Spot Welding (RSW) of multiple sheets with multiple materials are increasingly realized in the automotive industry. The mechanical strength of such new generation of spot welded assemblies is not that much dealt with. This is true in particular for experiments dedicated to investigate the mechanical strength of spot weld made by multi sheets of different grades, and their macro modeling in structural computations. Indeed, the most published studies are limited to two sheet assemblies. Therefore, in the first part of this work an advanced experimental set-up with a reduced mass is proposed to characterize the quasi-static and dynamic mechanical behavior and rupture of spot weld made by several sheets of different grades. The proposed device is based on Arcan test, the plates contribution in the global response is, thus, reduced. Loading modes I/II are, therefore, combined and well controlled. In the second part a simplified spot weld connector element (macroscopic modeling) is proposed to describe the nonlinear response and rupture of this new generation of spot welded assemblies. The weld connector model involves several parameters to be set. The remaining parameters are finally identified through a reverse engineering approach using mechanical responses of experimental tests presented in the first part of this work.

  19. Automated tissue characterization of in vivo atherosclerotic plaques by intravascular optical coherence tomography images

    PubMed Central

    Ughi, Giovanni Jacopo; Adriaenssens, Tom; Sinnaeve, Peter; Desmet, Walter; D’hooge, Jan

    2013-01-01

    Intravascular optical coherence tomography (IVOCT) is rapidly becoming the method of choice for the in vivo investigation of coronary artery disease. While IVOCT visualizes atherosclerotic plaques with a resolution <20µm, image analysis in terms of tissue composition is currently performed by a time-consuming manual procedure based on the qualitative interpretation of image features. We illustrate an algorithm for the automated and systematic characterization of IVOCT atherosclerotic tissue. The proposed method consists in a supervised classification of image pixels according to textural features combined with the estimated value of the optical attenuation coefficient. IVOCT images of 64 plaques, from 49 in vivo IVOCT data sets, constituted the algorithm’s training and testing data sets. Validation was obtained by comparing automated analysis results to the manual assessment of atherosclerotic plaques. An overall pixel-wise accuracy of 81.5% with a classification feasibility of 76.5% and per-class accuracy of 89.5%, 72.1% and 79.5% for fibrotic, calcified and lipid-rich tissue respectively, was found. Moreover, measured optical properties were in agreement with previous results reported in literature. As such, an algorithm for automated tissue characterization was developed and validated using in vivo human data, suggesting that it can be applied to clinical IVOCT data. This might be an important step towards the integration of IVOCT in cardiovascular research and routine clinical practice. PMID:23847728

  20. Characterization of Friction Stir Welded Tubes by Means of Tube Bulge Test

    SciTech Connect

    D'Urso, G.; Longo, M.; Giardini, C.

    2011-05-04

    Mechanical properties of friction stir welded joints are generally evaluated by means of conventional tensile test. This testing method might provide insufficient information because maximum strain obtained in tensile test before necking is small; moreover, the application of tensile test is limited when the joint path is not linear or even when the welds are executed on curved surfaces. Therefore, in some cases, it would be preferable to obtain the joints properties from other testing methods. Tube bulge test can be a valid solution for testing circumferential or longitudinal welds executed on tubular workpieces. The present work investigates the mechanical properties and the formability of friction stir welded tubes by means of tube bulge tests. The experimental campaign was performed on tubular specimens having a thickness of 3 mm and an external diameter of 40 mm, obtained starting from two semi-tubes longitudinally friction stir welded. The first step, regarding the fabrication of tubes, was performed combining a conventional forming process and friction stir welding. Sheets in Al-Mg-Si-Cu alloy AA6060 T6 were adopted for this purpose. Plates having a dimension of 225x60 mm were bent (with a bending axis parallel to the main dimension) in order to obtain semi-tubes. A particular care was devoted to the fabrication of forming devices (punch and die) in order to minimize the springback effects. Semi-tubes were then friction stir welded by means of a CNC machine tool. Some preliminary tests were carried out by varying the welding parameters, namely feed rate and rotational speed. A very simple tool having flat shoulder and cylindrical pin was used. The second step of the research was based on testing the welded tubes by means of tube bulge test. A specific equipment having axial actuators with a conical shape was adopted for this study. Some analyses were carried out on the tubes bulged up to a certain pressure level. In particular, the burst pressure and the

  1. Characterization of Friction Stir Welded Tubes by Means of Tube Bulge Test

    NASA Astrophysics Data System (ADS)

    D'Urso, G.; Longo, M.; Giardini, C.

    2011-05-01

    Mechanical properties of friction stir welded joints are generally evaluated by means of conventional tensile test. This testing method might provide insufficient information because maximum strain obtained in tensile test before necking is small; moreover, the application of tensile test is limited when the joint path is not linear or even when the welds are executed on curved surfaces. Therefore, in some cases, it would be preferable to obtain the joints properties from other testing methods. Tube bulge test can be a valid solution for testing circumferential or longitudinal welds executed on tubular workpieces. The present work investigates the mechanical properties and the formability of friction stir welded tubes by means of tube bulge tests. The experimental campaign was performed on tubular specimens having a thickness of 3 mm and an external diameter of 40 mm, obtained starting from two semi-tubes longitudinally friction stir welded. The first step, regarding the fabrication of tubes, was performed combining a conventional forming process and friction stir welding. Sheets in Al-Mg-Si-Cu alloy AA6060 T6 were adopted for this purpose. Plates having a dimension of 225×60 mm were bent (with a bending axis parallel to the main dimension) in order to obtain semi-tubes. A particular care was devoted to the fabrication of forming devices (punch and die) in order to minimize the springback effects. Semi-tubes were then friction stir welded by means of a CNC machine tool. Some preliminary tests were carried out by varying the welding parameters, namely feed rate and rotational speed. A very simple tool having flat shoulder and cylindrical pin was used. The second step of the research was based on testing the welded tubes by means of tube bulge test. A specific equipment having axial actuators with a conical shape was adopted for this study. Some analyses were carried out on the tubes bulged up to a certain pressure level. In particular, the burst pressure and the

  2. Characterization of microstructures and mechanical properties of Inconel 617/310 stainless steel dissimilar welds

    SciTech Connect

    Shah Hosseini, H. Shamanian, M.; Kermanpur, A.

    2011-04-15

    The microstructure and mechanical properties of Inconel 617/310 austenitic stainless steel dissimilar welds were investigated in this work. Three types of filler materials, Inconel 617, Inconel 82 and 310 austenitic stainless steels were used to obtain dissimilar joint using the gas tungsten arc welding process. Microstructural observations showed that there was no evidence of any possible cracking in the weldments achieved by the nickel-base filler materials. The welds produced by 617 and 310 filler materials displayed the highest and the lowest ultimate tensile strength and total elongation, respectively. The impact test results indicated that all specimens exhibited ductile fracture. Among the fillers, Inconel 617 exhibited superlative fracture toughness (205 J). The mechanical properties of the Inconel 617 filler material were much better than those of other fillers. - Research Highlights: {yields} A fine dendritic structure was seen for the Inconel 617 weld metal. {yields} A number of cracks were initiated when the 310 SS filler metal was used. {yields} All welded samples showed ductile fracture. {yields} The Inconel 617 filler material presents the optimum mechanical properties.

  3. Characterization of welded HP 9-4-30 steel for the advanced solid rocket motor

    NASA Technical Reports Server (NTRS)

    Watt, George William

    1990-01-01

    Solid rocket motor case materials must be high-strength, high-toughness, weldable alloys. The Advanced Solid Rocket Motor (ASRM) cases currently being developed will be made from a 9Ni-4Co quench and temper steel called HP 9-4-30. These ultra high-strength steels must be carefully processed to give a very clean material and a fine grained microstructure, which insures excellent ductility and toughness. The HP 9-4-30 steels are vacuum arc remelted and carbon deoxidized to give the cleanliness required. The ASRM case material will be formed into rings and then welded together to form the case segments. Welding is the desired joining technique because it results in a lower weight than other joining techniques. The mechanical and corrosion properties of the weld region material were fully studied.

  4. Characterization of Plastic flow and Resulting Micro-Textures in a Friction Stir Weld

    NASA Technical Reports Server (NTRS)

    Schneider, J. A.; Nunes, A. C., Jr.

    2003-01-01

    The mechanically affected zone of a friction stir weld (FSW) cross section exhibits two distinct microstructural regions, possibly the residues of two distinct currents of metal in the FSW flow process. In this study the respective textures of these microstructural regions are investigated using orientation image mapping (OIM).

  5. PROCESSING AND CHARACTERIZATION OF WELDED BONDS BETWEEN THERMOSET AND THERMOPLASTIC COMPOSITES

    EPA Science Inventory

    To assemble complex structures with short cycle times, the feasibility of welding thermoplastic (TP) to thermoset (TS) composites is demonstrated using a phenomenological approach. The effect of the thermal degradation of the TS composite (AS4/3501-6) on its shear strength is ass...

  6. Automated recognition and characterization of solar active regions based on the SOHO/MDI images

    NASA Technical Reports Server (NTRS)

    Pap, J. M.; Turmon, M.; Mukhtar, S.; Bogart, R.; Ulrich, R.; Froehlich, C.; Wehrli, C.

    1997-01-01

    The first results of a new method to identify and characterize the various surface structures on the sun, which may contribute to the changes in solar total and spectral irradiance, are shown. The full disk magnetograms (1024 x 1024 pixels) of the Michelson Doppler Imager (MDI) experiment onboard SOHO are analyzed. Use of a Bayesian inference scheme allows objective, uniform, automated processing of a long sequence of images. The main goal is to identify the solar magnetic features causing irradiance changes. The results presented are based on a pilot time interval of August 1996.

  7. Fully automated segmentation and characterization of the dendritic trees of retinal horizontal neurons

    SciTech Connect

    Kerekes, Ryan A; Gleason, Shaun Scott; Martins, Rodrigo; Dyer, Michael

    2010-01-01

    We introduce a new fully automated method for segmenting and characterizing the dendritic tree of neurons in confocal image stacks. Our method is aimed at wide-field-of-view, low-resolution imagery of retinal neurons in which dendrites can be intertwined and difficult to follow. The approach is based on 3-D skeletonization and includes a method for automatically determining an appropriate global threshold as well as a soma detection algorithm. We provide the details of the algorithm and a qualitative performance comparison against a commercially available neurite tracing software package, showing that a segmentation produced by our method more closely matches the ground-truth segmentation.

  8. Development of an animal model to study the potential neurotoxic effects associated with welding fume inhalation.

    PubMed

    Antonini, James M; O'Callaghan, James P; Miller, Diane B

    2006-09-01

    Serious questions have been raised regarding a possible causal association between neurological effects in welders and the presence of manganese in welding fume. An experimental model is needed that could examine the potential neurotoxic effect of manganese after pulmonary exposure to welding fume. The National Institute for Occupational Safety and Health (NIOSH) has recently finished construction of a completely automated, computer controlled welding fume generation and inhalation exposure system for laboratory animals. The system is comprised of a programmable six-axis robotic welding arm and a water-cooled arc welding torch. A flexible trunk has been attached to the robotic arm of the welder and is used to collect and transport fume from the vicinity of the arc to the animal exposure chamber. Preliminary fume characterization studies have indicated that particle morphology, size, and chemical composition were comparable to welding fume generated in the workplace. Animal inhalation studies are currently underway. With the development of this novel system, an animal model has been established using controlled welding exposures to investigate the possible mechanisms by which welding fume may affect the central nervous system. PMID:16546258

  9. Automated detection and characterization of microstructural features: application to eutectic particles in single crystal Ni-based superalloys

    NASA Astrophysics Data System (ADS)

    Tschopp, M. A.; Groeber, M. A.; Fahringer, R.; Simmons, J. P.; Rosenberger, A. H.; Woodward, C.

    2010-03-01

    Serial sectioning methods continue to produce an abundant amount of image data for quantifying the three-dimensional nature of material microstructures. Here, we discuss a methodology to automate detecting and characterizing eutectic particles taken from serial images of a production turbine blade made of a heat-treated single crystal Ni-based superalloy (PWA 1484). This method includes two important steps for unassisted eutectic particle characterization: automatically identifying a seed point within each particle and segmenting the particle using a region growing algorithm with an automated stop point. Once detected, the segmented eutectic particles are used to calculate microstructural statistics for characterizing and reconstructing statistically representative synthetic microstructures for single crystal Ni-based superalloys. The significance of this work is its ability to automate characterization for analysing the 3D nature of eutectic particles.

  10. Welding wire pressure sensor assembly

    NASA Technical Reports Server (NTRS)

    Morris, Timothy B. (Inventor); Milly, Peter F., Sr. (Inventor); White, J. Kevin (Inventor)

    1994-01-01

    The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

  11. Welding wire pressure sensor assembly

    NASA Astrophysics Data System (ADS)

    Morris, Timothy B.; Milly, Peter F.; White, J. Kevin

    1993-05-01

    The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

  12. Welding wire pressure sensor assembly

    NASA Astrophysics Data System (ADS)

    Morris, Timothy B.; Milly, Peter F., Sr.; White, J. Kevin

    1994-04-01

    The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

  13. Characterization of the Lactobacillus casei group and the Lactobacillus acidophilus group by automated ribotyping.

    PubMed

    Ryu, C S; Czajka, J W; Sakamoto, M; Benno, Y

    2001-01-01

    A total of 91 type and reference strains of the Lactobacillus casei group and the L acidophilus group were characterized by the automated ribotyping device Riboprinter microbial characterization system. The L. casei group was divided into five (C1-C5) genotypes by ribotyping. Among them, the strain of L. casei ATCC 334 was clustered to the same genotype group as most of L. paracasei strains and L casei JCM 1134T generated a riboprint pattern that was different from the type strain of L. zeae. These results supported the designation of L. casei ATCC 334 as the neotype strain, but were not consistent with the reclassification of L. casei JCM 1134T as L. zeae. The L. acidophilus group was also divided into 14 (A1-A11, B1-B3) genotypes by ribotyping. L. acidophilus, L. amylovorus, L. crispatus and L. gallinarum generated ribotype patterns that were distinct from the patterns produced by L. gasseri and L. johnsonii. This result confirmed previous data that the L. acidophilus group divided to two major clusters. Five strains of L. acidophilus and two strains of L. gasseri were correctly reidentified by ribotyping. Most strains belonging to the L. casei group and the L. acidophilus group were discriminated at the species level by automated ribotyping. Thus this RiboPrinter system yields rapid, accurate and reproducible genetic information for the identification of many strains. PMID:11386416

  14. Implementation and automation of a Faraday experiment for the magneto-optical characterization of ferrofluids

    NASA Astrophysics Data System (ADS)

    Velásquez, A. A.; Urquijo, J. P.

    2016-01-01

    This work presents the design, assembly and automation of a Faraday experiment for use in characterization of the magneto-optical response of fluids and ferrofluids. The magneto-optical Faraday experiment was automated using programmable equipment, controlled through the IEEE-488 port via Standard Commands for Programmable Instruments executed from a graphical interface developed in LabVIEW software. To calibrate the system the Verdet constants of distilled water and isopropyl alcohol were measured, obtaining an error percentage less than 2% for both fluids. Subsequently we used the system for measuring the Verdet constant of a ferrofluid of iron oxide nanoparticles diluted in distilled water, which was synthesized and, before its dilution, characterized by scanning electron microscopy, room temperature Mössbauer spectroscopy and vibrating sample magnetometry. We found that the Verdet constant of the diluted ferrofluid was smaller than that of distilled water, indicating opposite contributions of the effects of the diamagnetic and paramagnetic phases present in the ferrofluid to the magneto-optical effect. Details of the assembly, control of the experiment and development of the measurements are presented in this paper.

  15. Automated microwave double resonance spectroscopy: A tool to identify and characterize chemical compounds

    NASA Astrophysics Data System (ADS)

    Martin-Drumel, Marie-Aline; McCarthy, Michael C.; Patterson, David; McGuire, Brett A.; Crabtree, Kyle N.

    2016-03-01

    Owing to its unparalleled structural specificity, rotational spectroscopy is a powerful technique to unambiguously identify and characterize volatile, polar molecules. We present here a new experimental approach, automated microwave double resonance (AMDOR) spectroscopy, to rapidly determine the rotational constants of these compounds without a priori knowledge of elemental composition or molecular structure. This task is achieved by rapidly acquiring the classical (frequency vs. intensity) broadband spectrum of a molecule using chirped-pulse Fourier transform microwave (FTMW) spectroscopy and subsequently analyzing it in near real-time using complementary cavity FTMW detection and double resonance. AMDOR measurements provide a unique "barcode" for each compound from which rotational constants can be extracted. To illustrate the power of this approach, AMDOR spectra of three aroma compounds — trans-cinnamaldehyde, α-, and β-ionone — have been recorded and analyzed. The prospects to extend this approach to mixture characterization and purity assessment are described.

  16. AUTOMATED BATCH CHARACTERIZATION OF ICF SHELLS WITH VISION-ENABLED OPTICAL MICROSCOPE SYSTEM

    SciTech Connect

    HUANG,H; STEPHENS,R.B; HILL,D.W; LYON,C; NIKROO,A; STEINMAN,D.A

    2003-06-01

    OAK-B135 Inertial Confinement Fusion (ICF) shells are mesoscale objects with nano-scale dimensional and nano-surface finish requirements. Currently, the shell dimensions are measured by white-light interferometry and an image analysis method. These two methods complement each other and give a rather complete data set on a single shell. The process is, however, labor intensive. They have developed an automation routine to fully characterize a shell in one shot and perform unattended batch measurements. The method is useful to the ICF program both for production screening and for full characterization. It also has potential for Inertial Fusion Energy (IFE) power plant where half a million shells need to be processed daily.

  17. Automated microwave double resonance spectroscopy: A tool to identify and characterize chemical compounds.

    PubMed

    Martin-Drumel, Marie-Aline; McCarthy, Michael C; Patterson, David; McGuire, Brett A; Crabtree, Kyle N

    2016-03-28

    Owing to its unparalleled structural specificity, rotational spectroscopy is a powerful technique to unambiguously identify and characterize volatile, polar molecules. We present here a new experimental approach, automated microwave double resonance (AMDOR) spectroscopy, to rapidly determine the rotational constants of these compounds without a priori knowledge of elemental composition or molecular structure. This task is achieved by rapidly acquiring the classical (frequency vs. intensity) broadband spectrum of a molecule using chirped-pulse Fourier transform microwave (FTMW) spectroscopy and subsequently analyzing it in near real-time using complementary cavity FTMW detection and double resonance. AMDOR measurements provide a unique "barcode" for each compound from which rotational constants can be extracted. To illustrate the power of this approach, AMDOR spectra of three aroma compounds - trans-cinnamaldehyde, α-, and β-ionone - have been recorded and analyzed. The prospects to extend this approach to mixture characterization and purity assessment are described. PMID:27036441

  18. Toolkit for the Automated Characterization of Optical Trapping Forces on Microscopic Particles

    NASA Astrophysics Data System (ADS)

    Glaser, Joseph; Hoeprich, David; Resnick, Andrew

    2014-03-01

    Optical traps have been in use in microbiological studies for the past 40 years to obtain noninvasive control of microscopic particles. However, the magnitude of the applied forces is often unknown. Therefore, we have developed an automated data acquisition and processing system which characterizes trap properties for known particle geometries. Extensive experiments and measurements utilizing well-characterized objects were performed and compared to literature to confirm the system's performance. This system will enable the future analysis of a trapped primary cilium, a slender rod-shaped organelle with aspect ratio L/R >30, where `L' is the cilium length and `R' the cilium diameter. The trapping of cilia is of primary importance, as it will lead to the precise measurements of mechanical properties of the organelle and its significance to the epithelial cell. Support from the National Institutes of Health, 1R15DK092716 is gratefully acknowledged.

  19. An automated measurement system for characterization of RF and gradient coil parameters.

    PubMed

    Boyer, J S; Wright, S M; Porter, J R

    1998-01-01

    A fully automated laboratory-based measurement system for characterization of coil system parameters is presented. This method uses an inexpensive personal computer (PC)-controlled stepper motor positioning system in conjunction with a network/spectrum analyzer and an analog-to-digital converter (A/D) board that allows high resolution data acquisition in an unattended manner. A graphical interface was created for complete control of stepper motor movement, measurement, and data acquisition. The system is capable of performing a wide range of measurements that can, either individually or combined, characterize radiofrequency (RF) and gradient coils used in MRI. Measurement methods, theory, and results for conductor and shield current distributions, mutual impedance, and magnetic fields are given. Comparisons with theoretical calculations are included to validate the accuracy and utility of the system. PMID:9626895

  20. Automated High-Throughput Characterization of Single Neurons by Means of Simplified Spiking Models

    PubMed Central

    Hagens, Olivier; Naud, Richard; Koch, Christof; Gerstner, Wulfram

    2015-01-01

    Single-neuron models are useful not only for studying the emergent properties of neural circuits in large-scale simulations, but also for extracting and summarizing in a principled way the information contained in electrophysiological recordings. Here we demonstrate that, using a convex optimization procedure we previously introduced, a Generalized Integrate-and-Fire model can be accurately fitted with a limited amount of data. The model is capable of predicting both the spiking activity and the subthreshold dynamics of different cell types, and can be used for online characterization of neuronal properties. A protocol is proposed that, combined with emergent technologies for automatic patch-clamp recordings, permits automated, in vitro high-throughput characterization of single neurons. PMID:26083597

  1. EMAT weld inspection and weld machine diagnostic system for continuous coil processing lines

    NASA Astrophysics Data System (ADS)

    Latham, Wayne M.; MacLauchlan, Daniel T.; Geier, Dan P.; Lang, Dennis D.

    1996-11-01

    Weld breaks of steel coil during cold rolling and continuous pickling operations are a significant source of lost productivity and product yield. Babcock and Wilcox Innerspec Technologies has developed a weld process control system which monitors the key variables of the welding process and determines the quality of the welds generated by flash butt welding equipment. This system is known as the Temate 2000 Automated Flash Butt Weld Inspection and Weld Machine Diagnostic System. The Temate 2000 system utilizes electro- magnetic acoustic transducer (EMAT) technology as the basis for performing on-line, real-time, nondestructive weld quality evaluation. This technique accurately detects voids, laps, misalignment and over/under trim conditions in the weld. Results of the EMAT weld inspection are immediately presented to the weld machine operator for disposition. Welding process variables such as voltage, current, platen movements and upset pressures are monitored and collected with the high speed data acquisition system. This data is processed and presented in real-time display to indicate useful welding process information such as platen crabbing, upset force, peak upset current, and many others. Alarming for each variable is provided and allows detailed maintenance reports and summary information to be generated. All weld quality and process parameter data are stored, traceable to each unique weld, and available for post process evaluation. Installation of the Temate 2000 system in a major flat rolled steel mill has contributed to near elimination of weld breakage and increased productivity at this facility.

  2. Experimental and theoretical characterization of deep penetration welding threshold induced by 1-μm laser

    NASA Astrophysics Data System (ADS)

    Zou, J. L.; He, Y.; Wu, S. K.; Huang, T.; Xiao, R. S.

    2015-12-01

    The deep penetration-welding threshold (DPWT) is the critical value that describes the welding mode transition from the thermal conduction to the deep penetration. The objective of this research is to clarify the DPWT induced by the lasers with wavelength of 1 μm (1-μm laser), based on experimental observation and theoretical analysis. The experimental results indicated that the DPWT was the ratio between laser power and laser spot diameter (P/d) rather than laser power density (P/S). The evaporation threshold was smaller than the DPWT, while the jump threshold of the evaporated mass flux in the molten pool surface was consistent with the DPWT. Based on the force balance between the evaporation recoil pressure and the surface tension pressure at the gas-liquid interface of the molten pool as well as the temperature field, we developed a self-focusing model, which further confirmed the experimental results.

  3. G-Tunnel Welded Tuff Mining Experiment instrumentation evaluations; Yucca Mountain Site Characterization Project

    SciTech Connect

    Zimmerman, R.M.; Bellman, R.A. Jr.; Mann, K.L.; Thompson, T.W.

    1992-04-01

    Designers and analysts of radioactive waste repositories must be able to predict the mechanical behavior of the host rock. Sandia National Laboratory has conducted a mine-by experiment in welded tuff so that information could be obtained regarding the response of the rock to a drill and blast excavation process, where smooth-blasting techniques were used. This report describes the results of the evaluations of nine different instrument or measurement systems used in conjunction with these mining activities.

  4. Welding, Bonding and Fastening, 1984

    NASA Technical Reports Server (NTRS)

    Buckley, J. D. (Editor); Stein, B. A. (Editor)

    1985-01-01

    A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Soceity, and Society of Manufacturing Engineers conference on Welding, Bonding, and Fastening at Langley Research Center, Hampton, VA, on October 23 to 25, 1984 is given. Papers were presented on technology developed in current research programs relevant to welding, bonding, and fastening of structural materials required in fabricating structures and mechanical systems used in the aerospace, hydrospace, and automotive industries. Topics covered in the conference included equipment, hardware and materials used when welding, brazing, and soldering, mechanical fastening, explosive welding, use of unique selected joining techniques, adhesives bonding, and nondestructive evaluation. A concept of the factory of the future was presented, followed by advanced welding techniques, automated equipment for welding, welding in a cryogenic atmosphere, blind fastening, stress corrosion resistant fasteners, fastening equipment, explosive welding of different configurations and materials, solid-state bonding, electron beam welding, new adhesives, effects of cryogenics on adhesives, and new techniques and equipment for adhesive bonding.

  5. Microstructural Characterization of Thermomechanical and Heat-Affected Zones of an Inertia Friction Welded Astroloy

    NASA Astrophysics Data System (ADS)

    Oluwasegun, K. M.; Olawale, J. O.; Ige, O. O.; Shittu, M. D.; Adeleke, A. A.; Malomo, B. O.

    2014-08-01

    The behaviour of γ' phase to thermal and mechanical effects during rapid heating of Astroloy, a powder metallurgy nickel-based superalloy has been investigated. The thermo-mechanical-affected zone (TMAZ) and heat-affected zone (HAZ) microstructures of an inertia friction welded (IFW) Astroloy were simulated using a Gleeble thermo-mechanical simulation system. Detailed microstructural examination of the simulated TMAZ and HAZ and those present in actual IFW specimens showed that γ' particles persisted during rapid heating up to a temperature where the formation of liquid is thermodynamically favored and subsequently re-solidified eutectically. The result obtained showed that forging during the thermo-mechanical simulation significantly enhanced resistance to weld liquation cracking of the alloy. This is attributable to strain-induced rapid isothermal dissolution of the constitutional liquation products within 150 μm from the center of the forged sample. This was not observed in purely thermally simulated samples. The microstructure within the TMAZ of the as-welded alloy is similar to the microstructure in the forged Gleeble specimens.

  6. Advances in welding science - a perspective

    SciTech Connect

    David, S.A.; Vitek, J.M.; Babu, S.S.; DebRoy, T.

    1995-02-01

    The ultimate goal of welding technology is to improve the joint integrity and increase productivity. Over the years, welding has been more of an art than a science, but in the last few decades major advances have taken place in welding science and technology. With the development of new methodologies at the crossroads of basic and applied sciences, enormous opportunities and potential exist to develop a science-based tailoring of composition, structure, and properties of welds with intelligent control and automation of the welding processes.

  7. Welding Curriculum.

    ERIC Educational Resources Information Center

    Alaska State Dept. of Education, Juneau. Div. of Adult and Vocational Education.

    This competency-based curriculum guide is a handbook for the development of welding trade programs. Based on a survey of Alaskan welding employers, it includes all competencies a student should acquire in such a welding program. The handbook stresses the importance of understanding the principles associated with the various elements of welding.…

  8. Welding IV.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

    Instructional objectives and performance requirements are outlined in this course guide for Welding IV, a competency-based course in advanced arc welding offered at the Community College of Allegheny County to provide students with proficiency in: (1) single vee groove welding using code specifications established by the American Welding Society…

  9. Weld pool oscillation during GTA welding of mild steel

    SciTech Connect

    Xiao, Y.H.; Ouden, G. den . Dept. of Materials Science and Engineering)

    1993-08-01

    In this paper the results are reported of a study dealing with the oscillation behavior of weld pools in the case of GTA bead-on-plate welding of mild steel, Fe 360. During welding, the weld pool was brought into oscillation by applying short current pulses, and the oscillation frequency and amplitude were measured by monitoring the arc voltage. It was found that the oscillation of the partially penetrated weld pool is dominated by one of two different oscillation modes (Mode 1 and Mode 2) depending on the welding conditions, whereas the oscillation of the fully penetrated weld pool is characterized by a third oscillation mode (Mode 3). It is possible to maintain partially penetrated weld pool oscillation in Mode 1 by choosing appropriate welding conditions. Under these conditions, an abrupt decrease in oscillation frequency occurs when the weld pool transfers from partial penetration to full penetration. Thus, weld penetration can be in-process controlled by monitoring the oscillation frequency during welding.

  10. An automated instrument for human STR identification: design, characterization, and experimental validation.

    PubMed

    Hurth, Cedric; Smith, Stanley D; Nordquist, Alan R; Lenigk, Ralf; Duane, Brett; Nguyen, David; Surve, Amol; Hopwood, Andrew J; Estes, Matthew D; Yang, Jianing; Cai, Zhi; Chen, Xiaojia; Lee-Edghill, John G; Moran, Nina; Elliott, Keith; Tully, Gillian; Zenhausern, Frederic

    2010-10-01

    The microfluidic integration of an entire DNA analysis workflow on a fully integrated miniaturized instrument is reported using lab-on-a-chip automation to perform DNA fingerprinting compatible with CODIS standard relevant to the forensic community. The instrument aims to improve the cost, duration, and ease of use to perform a "sample-to-profile" analysis with no need for human intervention. The present publication describes the operation of the three major components of the system: the electronic control components, the microfluidic cartridge and CE microchip, and the optical excitation/detection module. Experimental details are given to characterize the level of performance, stability, reliability, accuracy, and sensitivity of the prototype system. A typical temperature profile from a PCR amplification process and an electropherogram of a commercial size standard (GeneScan 500™, Applied Biosystems) separation are shown to assess the relevance of the instrument to forensic applications. Finally, we present a profile from an automated integrated run where lysed cells from a buccal swab were introduced in the system and no further human intervention was required to complete the analysis. PMID:20931618

  11. Study on visual image information detection of external angle weld based on arc welding robot

    NASA Astrophysics Data System (ADS)

    Liu, Xiaorui; Liu, Nansheng; Sheng, Wei; Hu, Xian; Ai, Xiaopu; Wei, Yiqing

    2009-11-01

    Nowadays, the chief development trend in modern welding technology is welding automation and welding intelligence. External angle weld has a certain proportion in mechanical manufacture industries. In the real-time welding process, due to hot deformation and the fixture of workpieces used frequently, torch will detach welding orbit causes deviation, which will affect welding quality. Therefore, elimination weld deviation is the key to the weld automatic tracking system. In this paper, the authors use the self-developed structured light vision sensor system which has significant advantage compared with arc sensors to capture real-time weld images. In the project of VC++6.0 real-time weld image processing, after binaryzation with threshold value seventy, 3*1 median filter, thinning, obtain weld main stripe. Then, using the extraction algorithm this paper proposed to obtain weld feature points, and compute position of weld. Experiment result verified that the extraction algorithm can locate feature points rapidly and compute the weld deviation accurately.

  12. Automatic Welding System

    NASA Technical Reports Server (NTRS)

    1982-01-01

    Robotic welding has been of interest to industrial firms because it offers higher productivity at lower cost than manual welding. There are some systems with automated arc guidance available, but they have disadvantages, such as limitations on types of materials or types of seams that can be welded; susceptibility to stray electrical signals; restricted field of view; or tendency to contaminate the weld seam. Wanting to overcome these disadvantages, Marshall Space Flight Center, aided by Hayes International Corporation, developed system that uses closed-circuit TV signals for automatic guidance of the welding torch. NASA granted license to Combined Technologies, Inc. for commercial application of the technology. They developed a refined and improved arc guidance system. CTI in turn, licensed the Merrick Corporation, also of Nashville, for marketing and manufacturing of the new system, called the CT2 Optical Trucker. CT2 is a non-contracting system that offers adaptability to broader range of welding jobs and provides greater reliability in high speed operation. It is extremely accurate and can travel at high speed of up to 150 inches per minute.

  13. Imaging and characterization of a subhorizontal non-welded interface from point source elastic scattering response

    NASA Astrophysics Data System (ADS)

    Minato, Shohei; Ghose, Ranajit

    2014-05-01

    The inverse scattering of seismic waves can reveal the spatial distribution of the elastic compliances along a non-welded interface, such as a fracture surface. The spatial heterogeneity along the surface of a fracture is a key determinant for fracture-associated hydraulic properties. In this paper, we demonstrate that the inverse scattering solution can be successfully applied to the point source response of a subhorizontal fracture. In the scale of seismic exploration, it is more appropriate to consider spherical waves from a point source than plane waves. Further, from only the P-wave point source response it is possible to estimate both normal and tangential fracture compliances. The synthetic seismic wavefield due to a P-wave point source in a 2-D elastic medium was computed using a time-domain finite difference approach. On this spherical wave data set, the correct estimation of the position and dip of the non-welded interface was possible through reverse-time migration followed by least-square fitting of the maximum amplitude of the P-P reflection. In order to estimate the heterogeneity along the non-welded interface, we first extract the elastic wavefield at the interface position. The extrapolated wavefield is then rotated such that the horizontal axis aligns along the fracture plane. Next, using this extrapolated and rotated wavefield, we solve the linear-slip boundary condition to obtain the distribution of normal and tangential compliances. Our result shows that the estimates of normal compliance are very accurate around the dominant frequency of the incident seismic wavefield. At lower frequencies, the estimated compliance distribution is less accurate and rather smooth due to the presence of evanescent waves. Extracting the distribution of the tangential compliance requires a larger stabilization factor. For a correct estimation of the tangential compliance, one needs S-wave sources or multiple sources providing more grazing angles to avoid the shadow

  14. Resistance spot welding of ultra-fine grained steel sheets produced by constrained groove pressing: Optimization and characterization

    SciTech Connect

    Khodabakhshi, F.; Kazeminezhad, M. Kokabi, A.H.

    2012-07-15

    Constrained groove pressing as a severe plastic deformation method is utilized to produce ultra-fine grained low carbon steel sheets. The ultra-fine grained sheets are joined via resistance spot welding process and the characteristics of spot welds are investigated. Resistance spot welding process is optimized for welding of the sheets with different severe deformations and their results are compared with those of as-received samples. The effects of failure mode and expulsion on the performance of ultra-fine grained sheet spot welds have been investigated in the present paper and the welding current and time of resistance spot welding process according to these subjects are optimized. Failure mode and failure load obtained in tensile-shear test, microhardness, X-ray diffraction, transmission electron microscope and scanning electron microscope images have been used to describe the performance of spot welds. The region between interfacial to pullout mode transition and expulsion limit is defined as the optimum welding condition. The results show that optimum welding parameters (welding current and welding time) for ultra-fine grained sheets are shifted to lower values with respect to those for as-received specimens. In ultra-fine grained sheets, one new region is formed named recrystallized zone in addition to fusion zone, heat affected zone and base metal. It is shown that microstructures of different zones in ultra-fine grained sheets are finer than those of as-received sheets. - Highlights: Black-Right-Pointing-Pointer Resistance spot welding process is optimized for joining of UFG steel sheets. Black-Right-Pointing-Pointer Optimum welding current and time are decreased with increasing the CGP pass number. Black-Right-Pointing-Pointer Microhardness at BM, HAZ, FZ and recrystallized zone is enhanced due to CGP.

  15. Automated segmentation and characterization of esophageal wall in vivo by tethered capsule optical coherence tomography endomicroscopy

    PubMed Central

    Ughi, Giovanni J.; Gora, Michalina J.; Swager, Anne-Fré; Soomro, Amna; Grant, Catriona; Tiernan, Aubrey; Rosenberg, Mireille; Sauk, Jenny S.; Nishioka, Norman S.; Tearney, Guillermo J.

    2016-01-01

    Optical coherence tomography (OCT) is an optical diagnostic modality that can acquire cross-sectional images of the microscopic structure of the esophagus, including Barrett’s esophagus (BE) and associated dysplasia. We developed a swallowable tethered capsule OCT endomicroscopy (TCE) device that acquires high-resolution images of entire gastrointestinal (GI) tract luminal organs. This device has a potential to become a screening method that identifies patients with an abnormal esophagus that should be further referred for upper endoscopy. Currently, the characterization of the OCT-TCE esophageal wall data set is performed manually, which is time-consuming and inefficient. Additionally, since the capsule optics optimally focus light approximately 500 µm outside the capsule wall and the best quality images are obtained when the tissue is in full contact with the capsule, it is crucial to provide feedback for the operator about tissue contact during the imaging procedure. In this study, we developed a fully automated algorithm for the segmentation of in vivo OCT-TCE data sets and characterization of the esophageal wall. The algorithm provides a two-dimensional representation of both the contact map from the data collected in human clinical studies as well as a tissue map depicting areas of BE with or without dysplasia. Results suggest that these techniques can potentially improve the current TCE data acquisition procedure and provide an efficient characterization of the diseased esophageal wall. PMID:26977350

  16. Automated segmentation and characterization of esophageal wall in vivo by tethered capsule optical coherence tomography endomicroscopy.

    PubMed

    Ughi, Giovanni J; Gora, Michalina J; Swager, Anne-Fré; Soomro, Amna; Grant, Catriona; Tiernan, Aubrey; Rosenberg, Mireille; Sauk, Jenny S; Nishioka, Norman S; Tearney, Guillermo J

    2016-02-01

    Optical coherence tomography (OCT) is an optical diagnostic modality that can acquire cross-sectional images of the microscopic structure of the esophagus, including Barrett's esophagus (BE) and associated dysplasia. We developed a swallowable tethered capsule OCT endomicroscopy (TCE) device that acquires high-resolution images of entire gastrointestinal (GI) tract luminal organs. This device has a potential to become a screening method that identifies patients with an abnormal esophagus that should be further referred for upper endoscopy. Currently, the characterization of the OCT-TCE esophageal wall data set is performed manually, which is time-consuming and inefficient. Additionally, since the capsule optics optimally focus light approximately 500 µm outside the capsule wall and the best quality images are obtained when the tissue is in full contact with the capsule, it is crucial to provide feedback for the operator about tissue contact during the imaging procedure. In this study, we developed a fully automated algorithm for the segmentation of in vivo OCT-TCE data sets and characterization of the esophageal wall. The algorithm provides a two-dimensional representation of both the contact map from the data collected in human clinical studies as well as a tissue map depicting areas of BE with or without dysplasia. Results suggest that these techniques can potentially improve the current TCE data acquisition procedure and provide an efficient characterization of the diseased esophageal wall. PMID:26977350

  17. An automated system for the acoustical and aerodynamic characterization of small air moving devices

    NASA Astrophysics Data System (ADS)

    Schmitt, Jeff G.; Nelson, David A.; Phillips, John

    2005-09-01

    A plenum fixture for use in the measurement of acoustic emissions of air moving devices used to cool electronic equipment under the actual aerodynamic conditions of operation has been standardized in ISO 10302 and ANSI S12.11. This fixture has proven to be a valuable tool for use in the characterization of these devices. However, as many in industry have discovered, the construction of the plenum to the standardized specifications can quite complex, and the use of the plenum to fully characterize air moving devices can be quite laborious and tedious. Under contract to the NASA Glenn Research Center, which has a significant interest in the acoustic emissions of the air moving devices it uses to cool racks and payloads that are installed on the International Space Station, the authors have developed a fully automated fan test plenum that operates under software control. This plenum has been developed to facilitate rapid acoustic characterization of fans and other air moving devices, both independently and when operating into real world inlet conditions, obstructions and aerodynamic loads. The plenum slider has been calibrated to allow full development of fan curve data in parallel with acoustic emission data.

  18. Creep in Topopah Spring Member welded tuff. Yucca Mountain Site Characterization Project

    SciTech Connect

    Martin, R.J. III; Boyd, P.J.; Noel, J.S.; Price, R.H.

    1995-06-01

    A laboratory investigation has been carried out to determine the effects of elevated temperature and stress on the creep deformation of welded tuffs recovered from Busted Butte in the vicinity of Yucca Mountain, Nevada. Water saturated specimens of tuff from thermal/mechanical unit TSw2 were tested in creep at a confining pressure of 5.0 MPa, a pore pressure of 4.5 MPa, and temperatures of 25 and 250 C. At each stress level the load was held constant for a minimum of 2.5 {times} 10{sup 5} seconds and for as long as 1.8 {times} 10{sup 6} seconds. One specimen was tested at a single stress of 80 MPa and a temperature of 250 C. The sample failed after a short time. Subsequent experiments were initiated with an initial differential stress of 50 or 60 MPa; the stress was then increased in 10 MPa increments until failure. The data showed that creep deformation occurred in the form of time-dependent axial and radial strains, particularly beyond 90% of the unconfined, quasi-static fracture strength. There was little dilatancy associated with the deformation of the welded tuff at stresses below 90% of the fracture strength. Insufficient data have been collected in this preliminary study to determine the relationship between temperature, stress, creep deformation to failure, and total failure time at a fixed creep stress.

  19. 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.

  20. Arc-Light Reflector For Television Weld Monitoring

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S.

    1989-01-01

    Conical, stainless-steel mirror attached to end of welding torch improves distribution of light on work-piece as welding monitored through torch by television. Television monitoring protects operators from intense arc light and facilitates automated welding. Simple, small, and easy to install and remove, mirror relatively nonintrusive.

  1. Novel Process Revolutionizes Welding Industry

    NASA Technical Reports Server (NTRS)

    2008-01-01

    Glenn Research Center, Delphi Corporation, and the Michigan Research Institute entered into a research project to study the use of Deformation Resistance Welding (DRW) in the construction and repair of stationary structures with multiple geometries and dissimilar materials, such as those NASA might use on the Moon or Mars. Traditional welding technologies are burdened by significant business and engineering challenges, including high costs of equipment and labor, heat-affected zones, limited automation, and inconsistent quality. DRW addresses each of those issues, while drastically reducing welding, manufacturing, and maintenance costs.

  2. Advanced Welding Torch

    NASA Technical Reports Server (NTRS)

    1996-01-01

    In order to more easily join the huge sections of the Space Shuttle external tank, Marshall Space Flight Center initiated development of the existing concept of Variable Polarity Plasma Arc (VPPA) welding. VPPA welding employs a variable current waveform that allows the system to operate for preset time increments in either of two polarity modes for effective joining of light alloys. Marshall awarded the torch contract to B & B Precision Machine, which produced a torch for the Shuttle, then automated the system, and eventually delivered a small torch used by companies such as Whirlpool for sheet metal welding of appliance parts and other applications. The dependability of the torch offers cost and time advantages.

  3. Ultrasonic Welding of Graphite/Thermoplastic Composite

    NASA Technical Reports Server (NTRS)

    Hardy, S. S.; Page, D. B.

    1982-01-01

    Ultrasonic welding of graphite/thermoplastic composite materials eliminates need for fasteners (which require drilling or punching, add weight, and degrade stiffness) and can be totally automated in beam fabrication and assembly jigs. Feasibility of technique has been demonstrated in laboratory tests which show that neither angular orientation nor vacuum affect weld quality.

  4. Advanced Welding Concepts

    NASA Technical Reports Server (NTRS)

    Ding, Robert J.

    2010-01-01

    Four advanced welding techniques and their use in NASA are briefly reviewed in this poster presentation. The welding techniques reviewed are: Solid State Welding, Friction Stir Welding (FSW), Thermal Stir Welding (TSW) and Ultrasonic Stir Welding.

  5. Microstructure characterization of heat affected zone after welding in Mod.9Cr–1Mo steel

    SciTech Connect

    Sawada, K.; Hara, T.; Tabuchi, M.; Kimura, K.; Kubushiro, K.

    2015-03-15

    The microstructure of the heat affected zone after welding was investigated in Mod.9Cr–1Mo steel, using TEM and STEM-EDX. The microstructure of thin foil was observed at the fusion line, and at the positions of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm and 3.5 mm to the base metal side of the fusion line. Martensite structure with very fine lath and high dislocation density was confirmed at all positions. Twins with a twin plane of (112) were locally observed at all positions. Elemental mapping was obtained for all positions by means of STEM-EDX. Inclusions of mainly Si were formed at the fusion line but not at the other positions. No precipitates could be detected at the fusion line or at the position of 0.5 mm. On the other hand, MX particles were observed at the positions of 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm and 3.5 mm even after welding. M{sub 23}C{sub 6} particles were also confirmed at the positions of 2.0 mm, 2.5 mm, 3.0 mm and 3.5 mm. Very fine equiaxed grains were locally observed at the positions of 2.0 mm and 2.5 mm. The Cr content of the equiaxed grains was about 12 mass%, although the martensite area included about 8 mass% Cr. - Graphical abstract: Display Omitted - Highlights: • Nonequilibrium microstructure of heat affected zone was observed after welding in Mod.9Cr–1Mo steel. • Inclusions containing Si were detected at the fusion line. • Undissolved M{sub 23}C{sub 6} and MX particles were confirmed in heat affected zone. • Twins with a twin plane of (112) were locally observed at all positions. • Very fine ferrite grains with high Cr content were observed in fine grained heat affected zone.

  6. On the Microstructural and Mechanical Characterization of Hybrid Laser-Welded Al-Zn-Mg-Cu Alloys

    NASA Astrophysics Data System (ADS)

    Wu, S. C.; Hu, Y. N.; Song, X. P.; Xue, Y. L.; Peng, J. F.

    2015-04-01

    Butt-welded 2-mm-thick high-strength aluminum alloys have been welded using a hybrid fiber laser and pulsed arc heat source system with the ER5356 filler. The microstructure, size of precipitates, texture, grain size and shape, change of strengthening elements, mechanical properties, and surface-based fatigue fracture characteristics of hybrid-welded joints were investigated in detail. The results indicate that the hybrid welds and the unaffected base materials have the lowest and largest hardness values, respectively, compared with the heat-affected zone. It is resonably believed that the elemental loss, coarse grains, and changed precipitates synthetically produce the low hardness and tensile strengths of hybrid welds. Meanwhile, the weaker grain boundary inside welds appears to initiate a microcrack. Besides, there exists an interaction of fatigue cracks and gas pores and microstructures.

  7. Characterization of Porosity Development in Oxidized Graphite using Automated Image Analysis Techniques

    SciTech Connect

    Contescu, Cristian I; Burchell, Timothy D

    2009-09-01

    This document reports on initial activities at ORNL aimed at quantitative characterization of porosity development in oxidized graphite specimens using automated image analysis (AIA) techniques. A series of cylindrical shape specimens were machined from nuclear-grade graphite (type PCEA, from GrafTech International). The specimens were oxidized in air to various levels of weight loss (between 5 and 20 %) and at three oxidation temperatures (between 600 and 750 oC). The procedure used for specimen preparation and oxidation was based on ASTM D-7542-09. Oxidized specimens were sectioned, resin-mounted and polished for optical microscopy examination. Mosaic pictures of rectangular stripes (25 mm x 0.4 mm) along a diameter of sectioned specimens were recorded. A commercial software (ImagePro) was evaluated for automated analysis of images. Because oxidized zones in graphite are less reflective in visible light than the pristine, unoxidized material, the microstructural changes induced by oxidation can easily be identified and analyzed. Oxidation at low temperatures contributes to development of numerous fine pores (< 100 m2) distributed more or less uniformly over a certain depth (5-6 mm) from the surface of graphite specimens, while causing no apparent external damage to the specimens. In contrast, oxidation at high temperatures causes dimensional changes and substantial surface damage within a narrow band (< 1 mm) near the exposed graphite surface, but leaves the interior of specimens with little or no changes in the pore structure. Based on these results it appears that weakening and degradation of mechanical properties of graphite materials produced by uniform oxidation at low temperatures is related to the massive development of fine pores in the oxidized zone. It was demonstrated that optical microscopy enhanced by AIA techniques allows accurate determination of oxidant penetration depth and of distribution of porosity in oxidized graphite materials.

  8. SME@XSEDE: An automated spectral synthesis tool for stellar characterization

    NASA Astrophysics Data System (ADS)

    Hebb, Leslie; Cargile, Phillip

    2015-01-01

    Over the last decade, large scale discovery surveys like Kepler have produced vast catalogs of newly discovered extrasolar planetary systems. Most of these systems require stellar characterization of the host stars in order to derive the host star masses and completely solve for the planetary properties. Currently, there is no widely accepted and standardized method to determine fundamental parameters from stellar spectra. Here, we present a new approach to automating stellar characterization of large datasets of high resolution spectra. Our software, called SME@XSEDE, is based on one of the most widely used spectral synthesis algorithms, Spectroscopy Made Easy (SME), originally described in Valenti and Piskanov (1996). Like SME, SME@XSEDE compares an observed spectrum to synthetic model spectra derived through radiative transfer calculations for a range of stellar parameters in order to find the global stellar properties (temperature, gravity, metallicity, vsini, and individual abundances) that result in a synthetic spectrum that best matches an observed spectrum. We use the XSEDE super computer cluster to run many sets of initial guesses of stellar parameters to determine robust SME-based solutions without extensive, hands-on work. In this paper, we describe our software in detail and compare results derived from the application of SME@XSEDE to several well-studied datasets of stellar parameters including Valenti and Fischer 2005, Torres et al. 2012, and Huber et al 2013.

  9. Effect of Pulse Parameters on Weld Quality in Pulsed Gas Metal Arc Welding: A Review

    NASA Astrophysics Data System (ADS)

    Pal, Kamal; Pal, Surjya K.

    2011-08-01

    The weld quality comprises bead geometry and its microstructure, which influence the mechanical properties of the weld. The coarse-grained weld microstructure, higher heat-affected zone, and lower penetration together with higher reinforcement reduce the weld service life in continuous mode gas metal arc welding (GMAW). Pulsed GMAW (P-GMAW) is an alternative method providing a better way for overcoming these afore mentioned problems. It uses a higher peak current to allow one molten droplet per pulse, and a lower background current to maintain the arc stability. Current pulsing refines the grains in weld fusion zone with increasing depth of penetration due to arc oscillations. Optimum weld joint characteristics can be achieved by controlling the pulse parameters. The process is versatile and easily automated. This brief review illustrates the effect of pulse parameters on weld quality.

  10. Sensor Control of Robot Arc Welding

    NASA Technical Reports Server (NTRS)

    Sias, F. R., Jr.

    1983-01-01

    The potential for using computer vision as sensory feedback for robot gas-tungsten arc welding is investigated. The basic parameters that must be controlled while directing the movement of an arc welding torch are defined. The actions of a human welder are examined to aid in determining the sensory information that would permit a robot to make reproducible high strength welds. Special constraints imposed by both robot hardware and software are considered. Several sensory modalities that would potentially improve weld quality are examined. Special emphasis is directed to the use of computer vision for controlling gas-tungsten arc welding. Vendors of available automated seam tracking arc welding systems and of computer vision systems are surveyed. An assessment is made of the state of the art and the problems that must be solved in order to apply computer vision to robot controlled arc welding on the Space Shuttle Main Engine.

  11. Weld penetration and defect control. Final report

    SciTech Connect

    Chin, B.A.

    1992-05-15

    Highly engineered designs increasingly require the use of improved materials and sophisticated manufacturing techniques. To obtain optimal performance from these engineered products, improved weld properties and joint reliability are a necessarily. This requirement for improved weld performance and reliability has led to the development of high-performance welding systems in which pre-programmed parameters are specified before any welding takes place. These automated systems however lack the ability to compensate for perturbations which arise during the welding process. Hence the need for systems which monitor and control the in-process status of the welding process. This report discusses work carried out on weld penetration indicators and the feasibility of using these indicators for on-line penetration control.

  12. Advanced characterization techniques in understanding the roles of nickel in enhancing strength and toughness of submerged arc welding high strength low alloy steel multiple pass welds in the as-welded condition

    NASA Astrophysics Data System (ADS)

    Sham, Kin-Ling

    Striving for higher strength along with higher toughness is a constant goal in material properties. Even though nickel is known as an effective alloying element in improving the resistance of a steel to impact fracture, it is not fully understood how nickel enhances toughness. It was the goal of this work to assist and further the understanding of how nickel enhanced toughness and maintained strength in particular for high strength low alloy (HSLA) steel submerged arc welding multiple pass welds in the as-welded condition. Using advanced analytical techniques such as electron backscatter diffraction, x-ray diffraction, electron microprobe, differential scanning calorimetry, and thermodynamic modeling software, the effect of nickel was studied with nickel varying from one to five wt. pct. in increments of one wt. pct. in a specific HSLA steel submerged arc welding multiple pass weldment. The test matrix of five different nickel compositions in the as-welded and stress-relieved condition was to meet the targeted mechanical properties with a yield strength greater than or equal to 85 ksi, a ultimate tensile strength greater than or equal to 105 ksi, and a nil ductility temperature less than or equal to -140 degrees F. Mechanical testing demonstrated that nickel content of three wt. pct and greater in the as-welded condition fulfilled the targeted mechanical properties. Therefore, one, three, and five wt. pct. nickel in the as-welded condition was further studied to determine the effect of nickel on primary solidification mode, nickel solute segregation, dendrite thickness, phase transformation temperatures, effective ferrite grain size, dislocation density and strain, grain misorientation distribution, and precipitates. From one to five wt. pct nickel content in the as-welded condition, the primary solidification was shown to change from primary delta-ferrite to primary austenite. The nickel partitioning coefficient increased and dendrite/cellular thickness was

  13. Welding Technician

    ERIC Educational Resources Information Center

    Smith, Ken

    2009-01-01

    About 95% of all manufactured goods in this country are welded or joined in some way. These welded products range in nature from bicycle handlebars and skyscrapers to bridges and race cars. The author discusses what students need to know about careers for welding technicians--wages, responsibilities, skills needed, career advancement…

  14. Pulsed-Current Welding Of Nickel-Based Alloy

    NASA Technical Reports Server (NTRS)

    Gamwell, W. R.; Kurgan, C.; Malone, T. W.

    1993-01-01

    Joints as strong (or stronger than) joints made with constant current. Report based on study of pulsed-current versus constant-current gas/tungsten arc welding of butt joints between panels of nickel-based alloy 718. In pulsed-current welding, arc current alternated between high and low value. Enables greater control of freezing and depth of penetration of weld puddle at given heat input. Thicker sections joined. Readily incorporated into automated welding system, with resultant greater uniformity and reproducibility of welds than attained in manual welding.

  15. Micro-hardness measurement and micro-structure characterization of T91 weld metal irradiated in SINQ Target-3

    NASA Astrophysics Data System (ADS)

    Jia, X.; Dai, Y.

    2005-08-01

    This work is concerned with the micro-structure and mechanical behavior of T91 weld metal before and after an irradiation in SINQ Target-3. Optical and TEM observations and micro-hardness tests were performed to identify the irradiation effects. Before irradiation, the micro-structure of the T91 weld metals consisted of mainly tempered martensite and retained ferrite area. Precipitates in the weld metal are predominately M 7C 3 carbides, and few M 23C 6 particles are observed along the martensitic lath and primary austenite grain boundaries. The dislocation density in the weld metal is much higher than that in the base metal. The main feature of the irradiated micro-structure of the weld metal are small defects (black dots) and faulted Frank interstitial loops at lower irradiation temperature and a high density of helium bubbles appear at higher irradiation dose and temperature. The results are comparable with those of the T91 base metal irradiated under the same condition in the previous work. The weld metal and heat affected zone (HAZ) show much higher hardness than the base metal before irradiation, showing that no post-weld heat treatment (PWHT) has been applied to the weld metal. Irradiation hardening increases with irradiation dose below 10 dpa, but decreases at higher dose, which might be related to the transformation of M 7C 3 precipitates to M 23C 6 at higher irradiation temperatures.

  16. Automated characterization of normal and pathologic lung tissue by topological texture analysis of multidetector CT

    NASA Astrophysics Data System (ADS)

    Boehm, H. F.; Fink, C.; Becker, C.; Reiser, M.

    2007-03-01

    Reliable and accurate methods for objective quantitative assessment of parenchymal alterations in the lung are necessary for diagnosis, treatment and follow-up of pulmonary diseases. Two major types of alterations are pulmonary emphysema and fibrosis, emphysema being characterized by abnormal enlargement of the air spaces distal to the terminal, nonrespiratory bronchiole, accompanied by destructive changes of the alveolar walls. The main characteristic of fibrosis is coursening of the interstitial fibers and compaction of the pulmonary tissue. With the ability to display anatomy free from superimposing structures and greater visual clarity, Multi-Detector-CT has shown to be more sensitive than the chest radiograph in identifying alterations of lung parenchyma. In automated evaluation of pulmonary CT-scans, quantitative image processing techniques are applied for objective evaluation of the data. A number of methods have been proposed in the past, most of which utilize simple densitometric tissue features based on the mean X-ray attenuation coefficients expressed in terms of Hounsfield Units [HU]. Due to partial volume effects, most of the density-based methodologies tend to fail, namely in cases, where emphysema and fibrosis occur within narrow spatial limits. In this study, we propose a methodology based upon the topological assessment of graylevel distribution in the 3D image data of lung tissue which provides a way of improving quantitative CT evaluation. Results are compared to the more established density-based methods.

  17. Automation&Characterization of US Air Force Bench Top Wind Tunnels - Summary Report

    SciTech Connect

    Hardy, J.E.

    2006-03-23

    The United States Air Force Precision Measurement Equipment Laboratories (PMEL) calibrate over 1,000 anemometer probes per year. To facilitate a more efficient calibration process for probe-style anemometers, the Air Force Metrology and Calibration Program underwent an effort to modernize the existing PMEL bench top wind tunnels. Through a joint effort with the Department of Energy's Oak Ridge National Laboratory, the performance of PMEL wind tunnels was improved. The improvement consisted of new high accuracy sensors, automatic data acquisition, and a software-driven calibration process. As part of the wind tunnel upgrades, an uncertainty analysis was completed, laser Doppler velocimeter profiling was conducted to characterize the velocities at probe locations in the wind tunnel, and pitot tube calibrations of the wind tunnel were verified. The bench top wind tunnel accuracy and repeatability has been measured for nine prototype wind tunnel systems and valuable field experience has been gained with these wind tunnels at the PMELs. This report describes the requirements for the wind tunnel improvements along with actual implementation strategies and details. Lessons-learned from the automation, the velocity profiling, and the software-driven calibration process will also be discussed.

  18. Pulse shaping effects on weld porosity in laser beam spot welds : contrast of long- & short- pulse welds.

    SciTech Connect

    Ellison, Chad M.; Perricone, Matthew J.; Faraone, Kevin M.; Norris, Jerome T.

    2007-10-01

    Weld porosity is being investigated for long-pulse spot welds produced by high power continuous output lasers. Short-pulse spot welds (made with a pulsed laser system) are also being studied but to a much small extent. Given that weld area of a spot weld is commensurate with weld strength, the loss of weld area due to an undefined or unexpected pore results in undefined or unexpected loss in strength. For this reason, a better understanding of spot weld porosity is sought. Long-pulse spot welds are defined and limited by the slow shutter speed of most high output power continuous lasers. Continuous lasers typically ramp up to a simmer power before reaching the high power needed to produce the desired weld. A post-pulse ramp down time is usually present as well. The result is a pulse length tenths of a second long as oppose to the typical millisecond regime of the short-pulse pulsed laser. This study will employ a Lumonics JK802 Nd:YAG laser with Super Modulation pulse shaping capability and a Lasag SLS C16 40 W pulsed Nd:YAG laser. Pulse shaping will include square wave modulation of various peak powers for long-pulse welds and square (or top hat) and constant ramp down pulses for short-pulse welds. Characterization of weld porosity will be performed for both pulse welding methods.

  19. In Situ Robotic Inspection Of Welds

    NASA Technical Reports Server (NTRS)

    Van Wyk, Lisa M.; Garcia, Raul C., Jr.; Gilbert, Jeffrey L.

    1992-01-01

    Automated system reduces delays in inspection and rework. System reduces inspection-and-rework delay from days to hours. Path of inspection sensors taken directly from welding path saving time in programming for inspection. Inspection data stored so not lost as inspection equipment turned off. Same robot welding workpiece used to inspect it. In preparation, welding tool mounted on end effector of robot replaced with eddy-current or ultrasonic sensor. Robot recalls welding path from memory and retraces it, recording sensor output as it proceeds.

  20. Friction welding.

    NASA Technical Reports Server (NTRS)

    Moore, T. J.

    1972-01-01

    Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

  1. Microstructural characterization of weld joints of 9Cr reduced activation ferritic martensitic steel fabricated by different joining methods

    SciTech Connect

    Thomas Paul, V.; Saroja, S.; Albert, S.K.; Jayakumar, T.; Rajendra Kumar, E.

    2014-10-15

    This paper presents a detailed electron microscopy study on the microstructure of various regions of weldment fabricated by three welding methods namely tungsten inert gas welding, electron beam welding and laser beam welding in an indigenously developed 9Cr reduced activation ferritic/martensitic steel. Electron back scatter diffraction studies showed a random micro-texture in all the three welds. Microstructural changes during thermal exposures were studied and corroborated with hardness and optimized conditions for the post weld heat treatment have been identified for this steel. Hollomon–Jaffe parameter has been used to estimate the extent of tempering. The activation energy for the tempering process has been evaluated and found to be corresponding to interstitial diffusion of carbon in ferrite matrix. The type and microchemistry of secondary phases in different regions of the weldment have been identified by analytical transmission electron microscopy. - Highlights: • Comparison of microstructural parameters in TIG, electron beam and laser welds of RAFM steel • EBSD studies to illustrate the absence of preferred orientation and identification of prior austenite grain size using phase identification map • Optimization of PWHT conditions for indigenous RAFM steel • Study of kinetics of tempering and estimation of apparent activation energy of the process.

  2. Laser Welding Characterization of Kovar and Stainless Steel Alloys as Suitable Materials for Components of Photonic Devices Packaging

    SciTech Connect

    Fadhali, M. M. A.; Zainal, Saktioto J.; Munajat, Y.; Jalil, A.; Rahman, R.

    2010-03-11

    The weldability of Kovar and stainless steel alloys by Nd:YAG laser beam is studied through changing of some laser beam parameters. It has been found that there is a suitable interaction of the pulsed laser beam of low power laser pulse with both the two alloys. The change of thermophysical properties with absorbed energy from the laser pulse is discussed in this paper which reports the suitability of both Kovar and stainless steel 304 as the base materials for photonic devices packaging. We used laser weld system (LW4000S from Newport) which employs Nd:YAG laser system with two simultaneous beams output for packaging 980 nm high power laser module. Results of changing both laser spot weld width and penetration depth with changing both the pulse peak power density, pulse energy and pulse duration show that there are good linear relationships between laser pulse energy or peak power density and pulse duration with laser spot weld dimensions( both laser spot weld width and penetration depth). Therefore we concluded that there should be an optimization for both the pulse peak power and pulse duration to give a suitable aspect ratio (laser spot width to penetration depth) for achieving the desired welds with suitable penetration depth and small spot width. This is to reduce the heat affected zone (HAZ) which affects the sensitive optical components. An optimum value of the power density in the order of 10{sup 5} w/cm{sup 2} found to be suitable to induce melting in the welded joints without vaporization. The desired ratio can also be optimized by changing the focus position on the target material as illustrated from our measurements. A theoretical model is developed to simulate the temperature distribution during the laser pulse heating and predict the penetration depth inside the material. Samples have been investigated using SEM with EDS. The metallographic measurements on the weld spot show a suitable weld yield with reasonable weld width to depth ratio.

  3. Welded tuff porosity characterization using mercury intrusion, nitrogen and ethylene glycol monoethyl ether sorption and epifluorescence microscopy

    USGS Publications Warehouse

    Reddy, M.M.; Claassen, H.C.; Rutherford, D.W.; Chiou, C.T.

    1994-01-01

    Porosity of welded tuff from Snowshoe Mountain, Colorado, was characterized by mercury intrusion porosimetry (MIP), nitrogen sorption porosimetry, ethylene glycol monoethyl ether (EGME) gas phase sorption and epifluorescence optical microscopy. Crushed tuff of two particle-size fractions (1-0.3 mm and less than 0.212 mm), sawed sections of whole rock and crushed tuff that had been reacted with 0.1 N hydrochloric acid were examined. Average MIP pore diameter values were in the range of 0.01-0.02??m. Intrusion volume was greatest for tuff reacted with 0.1 N hydrochloric acid and least for sawed tuff. Cut rock had the smallest porosity (4.72%) and crushed tuff reacted in hydrochloric acid had the largest porosity (6.56%). Mean pore diameters from nitrogen sorption measurements were 0.0075-0.0187 ??m. Nitrogen adsorption pore volumes (from 0.005 to 0.013 cm3/g) and porosity values (from 1.34 to 3.21%) were less than the corresponding values obtained by MIP. More than half of the total tuff pore volume was associated with pore diameters < 0.05??m. Vapor sorption of EGME demonstrated that tuff pores contain a clay-like material. Epifluorescence microscopy indicated that connected porosity is heterogeneously distributed within the tuff matix; mineral grains had little porosity. Tuff porosity may have important consequences for contaminant disposal in this host rock. ?? 1994.

  4. Towards a characterization of information automation systems on the flight deck

    NASA Astrophysics Data System (ADS)

    Dudley, Rachel Feddersen

    This thesis summarizes research to investigate the characteristics that define information automation systems used on aircraft flight decks and the significant impacts that these characteristics have on pilot performance. Major accomplishments of the work include the development of a set of characteristics that describe information automation systems on the flight deck and an experiment designed to study a subset of these characteristics. Information automation systems on the flight deck are responsible for the collection, processing, analysis, and presentation of data to the flightcrew. These systems pose human factors issues and challenges that must be considered by designers of these systems. Based on a previously developed formal definition of information automation for aircraft flight deck systems, an analysis process was developed and conducted to reach a refined set of information automation characteristics. In this work, characteristics are defined as a set of properties or attributes that describe an information automation system's operation or behavior, which can be used to identify and assess potential human factors issues. Hypotheses were formed for a subset of the characteristics: Automation Visibility, Information Quality, and Display Complexity. An experimental investigation was developed to measure performance impacts related to these characteristics, which showed mixed results of expected and surprising findings, with many interactions. A set of recommendations were then developed based on the experimental observations. Ensuring that the right information is presented to pilots at the right time and in the appropriate manner is the job of flight deck system designers. This work provides a foundation for developing recommendations and guidelines specific to information automation on the flight deck with the goal of improving the design and evaluation of information automation systems before they are implemented.

  5. 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.

  6. Real-time, automated characterization of surfaces for alpha and beta radiation

    SciTech Connect

    Egidi, P.V.; Flynn, C.R.; Blair, M.S.; Selfridge, R.J.

    1997-12-31

    A new data collection system, called ABACUS{trademark}, has been developed that automates and expedites the collection, conversion, and reporting of radiological survey data of surfaces. Field testing of the system by Oak Ridge National Laboratory/Environmental Technology Section is currently underway. Preliminary results are presented. The system detects, discriminates, and separately displays the results for alpha and beta contamination scans on floors and walls with a single pass. Fixed-position static counting is also possible for quantitative measuring. The system is currently configured with five 100 cm{sup 2} dual-phosphor plastic scintillation detectors mounted in a lightweight aluminum fixture that holds the detectors in a fixed array. ABACUS{trademark} can be configured with other detectors if desired. Ratemeter/scalars traditionally coupled to individual detectors have been replaced by a single unit that houses the power supply and discriminator circuit boards to support up to five detectors. The system is designed to be used by a single operator. Each detector`s position and data are transmitted once per second and recorded on a nearby laptop computer. The data are converted to appropriate units, color-coded, and mapped to display graphically the findings for each detector in real-time. Reports can be generated immediately following the survey. Survey data can be exported in a variety of formats. Benefits of ABACUS{trademark} are: (1) immediate feedback to decision makers using the observational approach to characterization or remediation, (2) thorough documentation of survey results, (3) increased statistical confidence in scans by recording counts every second, (4) reduced paperwork and elimination of transcription errors, and (5) time and cost savings for collection, conversion, mapping, evaluating, and reporting data over traditional methods.

  7. Performance assessment of automated tissue characterization for prostate H and E stained histopathology

    NASA Astrophysics Data System (ADS)

    DiFranco, Matthew D.; Reynolds, Hayley M.; Mitchell, Catherine; Williams, Scott; Allan, Prue; Haworth, Annette

    2015-03-01

    Reliable automated prostate tumor detection and characterization in whole-mount histology images is sought in many applications, including post-resection tumor staging and as ground-truth data for multi-parametric MRI interpretation. In this study, an ensemble-based supervised classification algorithm for high-resolution histology images was trained on tile-based image features including histogram and gray-level co-occurrence statistics. The algorithm was assessed using different combinations of H and E prostate slides from two separate medical centers and at two different magnifications (400x and 200x), with the aim of applying tumor classification models to new data. Slides from both datasets were annotated by expert pathologists in order to identify homogeneous cancerous and non-cancerous tissue regions of interest, which were then categorized as (1) low-grade tumor (LG-PCa), including Gleason 3 and high-grade prostatic intraepithelial neoplasia (HG-PIN), (2) high-grade tumor (HG-PCa), including various Gleason 4 and 5 patterns, or (3) non-cancerous, including benign stroma and benign prostatic hyperplasia (BPH). Classification models for both LG-PCa and HG-PCa were separately trained using a support vector machine (SVM) approach, and per-tile tumor prediction maps were generated from the resulting ensembles. Results showed high sensitivity for predicting HG-PCa with an AUC up to 0.822 using training data from both medical centres, while LG-PCa showed a lower sensitivity of 0.763 with the same training data. Visual inspection of cancer probability heatmaps from 9 patients showed that 17/19 tumors were detected, and HG-PCa generally reported less false positives than LG-PCa.

  8. Automated metric characterization of urban structure using building decomposition from very high resolution imagery

    NASA Astrophysics Data System (ADS)

    Heinzel, Johannes; Kemper, Thomas

    2015-03-01

    Classification approaches for urban areas are mostly of qualitative and semantic nature. They produce interpreted classes similar to those from land cover and land use classifications. As a complement to those classes, quantitative measures directly derived from the image could lead to a metric characterization of the urban area. While these metrics lack of qualitative interpretation they are able to provide objective measure of the urban structures. Such quantitative measures are especially important in rapidly growing cities since, beside of the growth in area, they can provide structural information for specific areas and detect changes. Rustenburg, which serves as test area for the present study, is amongst the fastest growing cities in South Africa. It reveals a heterogeneous face of housing and building structures reflecting social and/or economic differences often linked to the spatial distribution of industrial and local mining sites. Up to date coverage with aerial photographs is provided by aerial surveys in regular intervals. Also recent satellite systems provide imagery with suitable resolution. Using such set of very high resolution images a fully automated algorithm has been developed which outputs metric classes by systematically combining important measures of building structure. The measurements are gained by decomposition of buildings directly from the imagery and by using methods from mathematical morphology. The decomposed building objects serve as basis for the computation of grid statistics. Finally a systematic combination of the single features leads to combined metrical classes. For the dominant urban structures verification results indicate an overall accuracy of at least 80% on the single feature level and 70% for the combined classes.

  9. Infrared sensing techniques for adaptive robotic welding

    SciTech Connect

    Lin, T.T.; Groom, K.; Madsen, N.H.; Chin, B.A.

    1986-01-01

    The objective of this research is to investigate the feasibility of using infrared sensors to monitor the welding process. Data were gathered using an infrared camera which was trained on the molten metal pool during the welding operation. Several types of process perturbations which result in weld defects were then intentionally induced and the resulting thermal images monitored. Gas tungsten arc using ac and dc currents and gas metal arc welding processes were investigated using steel, aluminum and stainless steel plate materials. The thermal images obtained in the three materials and different welding processes revealed nearly identical patterns for the same induced process perturbation. Based upon these results, infrared thermography is a method which may be very applicable to automation of the welding process.

  10. Relationship Between Microstructure, Strength, and Fracture in an Al-Zn-Mg Electron Beam Weld: Part II: Mechanical Characterization and Modeling

    NASA Astrophysics Data System (ADS)

    Puydt, Quentin; Flouriot, Sylvain; Ringeval, Sylvain; De Geuser, Frédéric; Estevez, Rafael; Parry, Guillaume; Deschamps, Alexis

    2014-12-01

    This paper presents an experimental and modeling study of the mechanical behavior of an electron beam welded EN-AW 7020 aluminum alloy. The heterogeneous distribution of mechanical properties is characterized by micro-tensile tests and by strain field measurements using digital image correlation technic. These results are related to the microstructural observation presented in the companion paper. The mechanical behavior of the weld is simulated by a finite element model including a Gurson-type damage evolution model for void evolution. The model is shown to be capable of describing accurately experimental situations where the sample geometry is varied, resulting in stress triaxiality ratios ranging from 0.45 to 1.3.

  11. Relationship Between Microstructure, Strength, and Fracture in an Al-Zn-Mg Electron Beam Weld: Part II: Mechanical Characterization and Modeling

    NASA Astrophysics Data System (ADS)

    Puydt, Quentin; Flouriot, Sylvain; Ringeval, Sylvain; De Geuser, Frédéric; Estevez, Rafael; Parry, Guillaume; Deschamps, Alexis

    2014-09-01

    This paper presents an experimental and modeling study of the mechanical behavior of an electron beam welded EN-AW 7020 aluminum alloy. The heterogeneous distribution of mechanical properties is characterized by micro-tensile tests and by strain field measurements using digital image correlation technic. These results are related to the microstructural observation presented in the companion paper. The mechanical behavior of the weld is simulated by a finite element model including a Gurson-type damage evolution model for void evolution. The model is shown to be capable of describing accurately experimental situations where the sample geometry is varied, resulting in stress triaxiality ratios ranging from 0.45 to 1.3.

  12. Soldadura (Welding). Spanish Translations for Welding.

    ERIC Educational Resources Information Center

    Hohhertz, Durwin

    Thirty transparency masters with Spanish subtitles for key words are provided for a welding/general mechanical repair course. The transparency masters are on such topics as oxyacetylene welding; oxyacetylene welding equipment; welding safety; different types of welds; braze welding; cutting torches; cutting with a torch; protective equipment; arc…

  13. WELDING TORCH

    DOEpatents

    Correy, T.B.

    1961-10-01

    A welding torch into which water and inert gas are piped separately for cooling and for providing a suitable gaseous atmosphere is described. A welding electrode is clamped in the torch by a removable collet sleeve and a removable collet head. Replacement of the sleeve and head with larger or smaller sleeve and head permits a larger or smaller welding electrode to be substituted on the torch. (AEC)

  14. Advances in inspection automation

    NASA Astrophysics Data System (ADS)

    Weber, Walter H.; Mair, H. Douglas; Jansen, Dion; Lombardi, Luciano

    2013-01-01

    This new session at QNDE reflects the growing interest in inspection automation. Our paper describes a newly developed platform that makes the complex NDE automation possible without the need for software programmers. Inspection tasks that are tedious, error-prone or impossible for humans to perform can now be automated using a form of drag and drop visual scripting. Our work attempts to rectify the problem that NDE is not keeping pace with the rest of factory automation. Outside of NDE, robots routinely and autonomously machine parts, assemble components, weld structures and report progress to corporate databases. By contrast, components arriving in the NDT department typically require manual part handling, calibrations and analysis. The automation examples in this paper cover the development of robotic thickness gauging and the use of adaptive contour following on the NRU reactor inspection at Chalk River.

  15. Versatile Friction Stir Welding/Friction Plug Welding System

    NASA Technical Reports Server (NTRS)

    Carter, Robert

    2006-01-01

    A proposed system of tooling, machinery, and control equipment would be capable of performing any of several friction stir welding (FSW) and friction plug welding (FPW) operations. These operations would include the following: Basic FSW; FSW with automated manipulation of the length of the pin tool in real time [the so-called auto-adjustable pin-tool (APT) capability]; Self-reacting FSW (SRFSW); SR-FSW with APT capability and/or real-time adjustment of the distance between the front and back shoulders; and Friction plug welding (FPW) [more specifically, friction push plug welding] or friction pull plug welding (FPPW) to close out the keyhole of, or to repair, an FSW or SR-FSW weld. Prior FSW and FPW systems have been capable of performing one or two of these operations, but none has thus far been capable of performing all of them. The proposed system would include a common tool that would have APT capability for both basic FSW and SR-FSW. Such a tool was described in Tool for Two Types of Friction Stir Welding (MFS- 31647-1), NASA Tech Briefs, Vol. 30, No. 10 (October 2006), page 70. Going beyond what was reported in the cited previous article, the common tool could be used in conjunction with a plug welding head to perform FPW or FPPW. Alternatively, the plug welding head could be integrated, along with the common tool, into a FSW head that would be capable of all of the aforementioned FSW and FPW operations. Any FSW or FPW operation could be performed under any combination of position and/or force control.

  16. Robotic and automatic welding development at the Marshall Space Flight Center

    NASA Technical Reports Server (NTRS)

    Jones, C. S.; Jackson, M. E.; Flanigan, L. A.

    1988-01-01

    Welding automation is the key to two major development programs to improve quality and reduce the cost of manufacturing space hardware currently undertaken by the Materials and Processes Laboratory of the NASA Marshall Space Flight Center. Variable polarity plasma arc welding has demonstrated its effectiveness on class 1 aluminum welding in external tank production. More than three miles of welds were completed without an internal defect. Much of this success can be credited to automation developments which stabilize the process. Robotic manipulation technology is under development for automation of welds on the Space Shuttle's main engines utilizing pathfinder systems in development of tooling and sensors for the production applications. The overall approach to welding automation development undertaken is outlined. Advanced sensors and control systems methodologies are described that combine to make aerospace quality welds with a minimum of dependence on operator skill.

  17. Plasma arc welding weld imaging

    NASA Technical Reports Server (NTRS)

    Rybicki, Daniel J. (Inventor); Mcgee, William F. (Inventor)

    1994-01-01

    A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.

  18. Automated classification of Permanent Scatterers time-series based on statistical characterization tests

    NASA Astrophysics Data System (ADS)

    Berti, Matteo; Corsini, Alessandro; Franceschini, Silvia; Iannacone, Jean Pascal

    2013-04-01

    The application of space borne synthetic aperture radar interferometry has progressed, over the last two decades, from the pioneer use of single interferograms for analyzing changes on the earth's surface to the development of advanced multi-interferogram techniques to analyze any sort of natural phenomena which involves movements of the ground. The success of multi-interferograms techniques in the analysis of natural hazards such as landslides and subsidence is widely documented in the scientific literature and demonstrated by the consensus among the end-users. Despite the great potential of this technique, radar interpretation of slope movements is generally based on the sole analysis of average displacement velocities, while the information embraced in multi interferogram time series is often overlooked if not completely neglected. The underuse of PS time series is probably due to the detrimental effect of residual atmospheric errors, which make the PS time series characterized by erratic, irregular fluctuations often difficult to interpret, and also to the difficulty of performing a visual, supervised analysis of the time series for a large dataset. In this work is we present a procedure for automatic classification of PS time series based on a series of statistical characterization tests. The procedure allows to classify the time series into six distinctive target trends (0=uncorrelated; 1=linear; 2=quadratic; 3=bilinear; 4=discontinuous without constant velocity; 5=discontinuous with change in velocity) and retrieve for each trend a series of descriptive parameters which can be efficiently used to characterize the temporal changes of ground motion. The classification algorithms were developed and tested using an ENVISAT datasets available in the frame of EPRS-E project (Extraordinary Plan of Environmental Remote Sensing) of the Italian Ministry of Environment (track "Modena", Northern Apennines). This dataset was generated using standard processing, then the

  19. Robotic Variable Polarity Plasma Arc (VPPA) Welding

    NASA Technical Reports Server (NTRS)

    Jaffery, Waris S.

    1993-01-01

    The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.

  20. Onorbit electron beam welding experiment definition

    NASA Technical Reports Server (NTRS)

    1989-01-01

    The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.

  1. Robotic Variable Polarity Plasma Arc (VPPA) welding

    NASA Astrophysics Data System (ADS)

    Jaffery, Waris S.

    1993-02-01

    The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.

  2. Automated Guided-Wave Scanning Developed to Characterize Materials and Detect Defects

    NASA Technical Reports Server (NTRS)

    Martin, Richard E.; Gyekenyeski, Andrew L.; Roth, Don J.

    2004-01-01

    The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center has developed a scanning system that uses guided waves to characterize materials and detect defects. The technique uses two ultrasonic transducers to interrogate the condition of a material. The sending transducer introduces an ultrasonic pulse at a point on the surface of the specimen, and the receiving transducer detects the signal after it has passed through the material. The aim of the method is to correlate certain parameters in both the time and frequency domains of the detected waveform to characteristics of the material between the two transducers. The scanning system is shown. The waveform parameters of interest include the attenuation due to internal damping, waveform shape parameters, and frequency shifts due to material changes. For the most part, guided waves are used to gauge the damage state and defect growth of materials subjected to various mechanical or environmental loads. The technique has been applied to polymer matrix composites, ceramic matrix composites, and metal matrix composites as well as metallic alloys. Historically, guided wave analysis has been a point-by-point, manual technique with waveforms collected at discrete locations and postprocessed. Data collection and analysis of this type limits the amount of detail that can be obtained. Also, the manual movement of the sensors is prone to user error and is time consuming. The development of an automated guided-wave scanning system has allowed the method to be applied to a wide variety of materials in a consistent, repeatable manner. Experimental studies have been conducted to determine the repeatability of the system as well as compare the results obtained using more traditional NDE methods. The following screen capture shows guided-wave scan results for a ceramic matrix composite plate, including images for each of nine calculated parameters. The system can

  3. Welding Curriculum.

    ERIC Educational Resources Information Center

    EASTCONN Regional Educational Services Center, North Windham, CT.

    The purpose of this welding program is to provide students with skills and techniques to become employed as advanced apprentice welders. The welding program manual includes the following sections: (1) course description; (2) general objectives; (3) competencies; (4) curriculum outline for 13 areas; (5) 13 references; and (6) student progress…

  4. Welding III.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

    Instructional objectives and performance requirements are outlined in this course guide for Welding III, an advanced course in arc welding offered at the Community College of Allegheny County to provide students with the proficiency necessary for industrial certification. The course objectives, which are outlined first, specify that students will…

  5. Welding II.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

    Instructional objectives and performance requirements are outlined in this course guide for Welding II, a performance-based course offered at the Community College of Allegheny County to introduce students to out-of-position shielded arc welding with emphasis on proper heats, electrode selection, and alternating/direct currents. After introductory…

  6. Robotic Vision for Welding

    NASA Technical Reports Server (NTRS)

    Richardson, R. W.

    1986-01-01

    Vision system for robotic welder looks at weld along axis of welding electrode. Gives robot view of most of weld area, including yet-unwelded joint, weld pool, and completed weld bead. Protected within welding-torch body, lens and fiber bundle give robot closeup view of weld in progress. Relayed to video camera on robot manipulator frame, weld image provides data for automatic control of robot motion and welding parameters.

  7. WELDING METHOD

    DOEpatents

    Cornell, A.A.; Dunbar, J.V.; Ruffner, J.H.

    1959-09-29

    A semi-automatic method is described for the weld joining of pipes and fittings which utilizes the inert gasshielded consumable electrode electric arc welding technique, comprising laying down the root pass at a first peripheral velocity and thereafter laying down the filler passes over the root pass necessary to complete the weld by revolving the pipes and fittings at a second peripheral velocity different from the first peripheral velocity, maintaining the welding head in a fixed position as to the specific direction of revolution, while the longitudinal axis of the welding head is disposed angularly in the direction of revolution at amounts between twenty minutas and about four degrees from the first position.

  8. Tailoring defect free fusion welds based on phenomenological modeling

    NASA Astrophysics Data System (ADS)

    Kumar, Amit

    In the last few decades, phenomenological models of fusion welding have provided important understanding and information about the welding processes and welded materials. For example, numerical calculations of heat transfer and fluid flow in welding have enabled accurate quantitative calculations of thermal cycles and fusion zone geometry in fusion welding. In many simple systems such as gas tungsten arc (GTA) butt welding, the computed thermal cycles have been used to quantitatively understand weld metal phase compositions, grain sizes and inclusion structure. However, fabrication of defect free welds with prescribed attributes based on scientific principles still remains to be achieved. In addition, higher fabrication speeds are often limited by the occurrence of humping defects which are characterized by periodic bead-like appearance. Furthermore, phenomenological models have not been applied to tailor welds with given attributes. The goal of the present work is to apply the principles of heat transfer and fluid flow to attain defects free welds with prescribed attributes. Since there are a large number of process variables in welding, the desired weld attributes such as the weld geometry and structure are commonly produced by empirically adjusting the welding variables. However, this approach does not always produce optimum welds and inappropriate choice of variables can lead to poor welds. The existing transport phenomena based models of welding can only predict weld characteristics for a given set of input welding variables. What is needed, and not currently available, is a capability to systematically determine multiple paths to tailor weld geometry and assess robustness of each individual solution to achieve safe, defect free welds. Therefore, these heat transfer and fluid flow based models are restructured to predict the welding conditions to achieve the defect free welds with desired attributes. Systematic tailoring of weld attributes based on scientific

  9. Automated system for characterizing laser pulses. Final report Jan-Jun 83

    SciTech Connect

    Atkinson, L.A.; Fox, J.A.

    1983-08-01

    An automated data acquisition system consisting of a Photon drag monitor, pyroelectric detector, digitizer, and computer is used to accurately and reproducibly calculate laser pulse peak intensity as well as many other important parameters including energy and pulse lengths. This system, along with a working computer program, is explained in detail.

  10. Development and evaluation of an automated reflectance microscope system for the petrographic characterization of bituminous coals

    SciTech Connect

    Hoover, D. S.; Davis, A.

    1980-10-01

    The development of automated coal petrographic techniques will lessen the demands on skilled personnel to do routine work. This project is concerned with the development and successful testing of an instrument which will meet these needs. The fundamental differences in reflectance of the three primary maceral groups should enable their differentiation in an automated-reflectance frequency histogram (reflectogram). Consequently, reflected light photometry was chosen as the method for automating coal petrographic analysis. Three generations of an automated system (called Rapid Scan Versions I, II and III) were developed and evaluated for petrographic analysis. Their basic design was that of a reflected-light microscope photometer with an automatic stage, interfaced with a minicomputer. The hardware elements used in the Rapid Scan Version I limited the system's flexibility and presented problems with signal digitization and measurement precision. Rapid Scan Version II was designed to incorporate a new microscope photometer and computer system. A digital stepping stage was incorporated into the Rapid Scan Version III system. The precision of reflectance determination of this system was found to be +- 0.02 percent reflectance. The limiting factor in quantitative interpretation of Rapid Scan reflectograms is the resolution of reflectance populations of the individual maceral groups. Statistical testing indicated that reflectograms were highly reproducible, and a new computer program, PETAN, was written to interpret the curves for vitrinite reflectance parameters ad petrographic.

  11. Solution-Based Electro-Orientation Spectroscopy for the Automated, Quantitative Characterization and Sorting of 1D Nanomaterials

    NASA Astrophysics Data System (ADS)

    Akin, Cevat; Shan, Jerry; Yi, Jingang; Feldman, Leonard; Durand, Corentin; Li, An-Ping

    2014-11-01

    The electrical-transport properties of 1D nanomaterials are often poorly known and vary with size and surface effects. Traditional quantitative characterization methods require specialized facilities and are usually slow, invasive and not suitable for the large number of measurements needed to statistically characterize samples with a heterogeneous distribution of properties. Here, we introduce a contactless, solution-based method to rapidly and quantitatively measure the electrical properties of 1D nanomaterials based on their transient alignment behavior in AC electric fields of different frequencies. The electro-orientation method can be automated and is compatible with further solution-based techniques for nanowire alignment and assembly, including electrophoresis, dielectrophoresis and flow control. We demonstrate the accuracy of the solution-based method using a variety of insulating, semiconducting and metallic nanowires, and show that electro-orientation spectroscopy can detect true nanoscale surface effects on the electrical conductivity of 1D nanomaterials. We further discuss our progress toward implementing the method in a microfluidic device capable of automated electrical characterization and sorting of nanowires and nanotubes.

  12. Apparatus for the concurrent ultrasonic inspection of partially completed welds

    DOEpatents

    Johnson, John A.

    2000-01-01

    An apparatus for the concurrent nondestructive evaluation of partially completed welds is described and which is used in combination with an automated welder and which includes an ultrasonic signal generator mounted on the welder and which generates an ultrasonic signal which is directed toward one side of the partially completed welds; an ultrasonic signal receiver mounted on the automated welder for detecting ultrasonic signals which are transmitted by the ultrasonic signal generator and which are reflected or diffracted from one side of the partially completed weld or which passes through a given region of the partially completed weld; and an analysis assembly coupled with the ultrasonic signal receiver and which processes the ultrasonic signals received by the ultrasonic signal receiver to identify welding flaws in the partially completed weld.

  13. Effect of friction stir welding parameters on defect formation

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

    Friction stir welding is a perspective method for manufacturing automotive parts, aviation and space technology. One of the major problems is the formation of welding defects and weld around the welding zone. The formation of defect is the main reason failure of the joint. A possible way to obtain defect-free welded joints is the selection of the correct welding parameters. Experimental results describing the effect of friction stir welding process parameters on the defects of welded joints on aluminum alloy AMg5M have been shown. The weld joint defects have been characterized using the non-destructive radioscopic and ultrasound phase array methods. It was shown how the type and size of defects determine the welded joint strength.

  14. Inspection of thick welded joints using laser-ultrasonic SAFT.

    PubMed

    Lévesque, D; Asaumi, Y; Lord, M; Bescond, C; Hatanaka, H; Tagami, M; Monchalin, J-P

    2016-07-01

    The detection of defects in thick butt joints in the early phase of multi-pass arc welding would be very valuable to reduce cost and time in the necessity of reworking. As a non-contact method, the laser-ultrasonic technique (LUT) has the potential for the automated inspection of welds, ultimately online during manufacturing. In this study, testing has been carried out using LUT combined with the synthetic aperture focusing technique (SAFT) on 25 and 50mm thick butt welded joints of steel both completed and partially welded. EDM slits of 2 or 3mm height were inserted at different depths in the multi-pass welding process to simulate a lack of fusion. Line scans transverse to the weld are performed with the generation and detection laser spots superimposed directly on the surface of the weld bead. A CCD line camera is used to simultaneously acquire the surface profile for correction in the SAFT processing. All artificial defects but also real defects are visualized in the investigated thick butt weld specimens, either completed or partially welded after a given number of passes. The results obtained clearly show the potential of using the LUT with SAFT for the automated inspection of arc welds or hybrid laser-arc welds during manufacturing. PMID:27062646

  15. An integrated model for optimizing weld quality

    SciTech Connect

    Zacharia, T.; Radhakrishnan, B.; Paul, A.J.; Cheng, C.

    1995-06-01

    Welding has evolved in the last few decades from almost an empirical art to an activity embodying the most advanced tools of, various basic and applied sciences. Significant progress has been made in understanding the welding process and welded materials. The improved knowledge base has been useful in automation and process control. In view of the large number of variables involved, creating an adequately large database to understand and control the welding process is expensive and time consuming, if not impractical. A recourse is to simulate welding processes through a set of mathematical equations representing the essential physical processes of welding. Results obtained from the phenomenological models depend crucially on the quality of the physical relations in the models and the trustworthiness of input data. In this paper, recent advances in the mathematical modeling of fundamental phenomena in welds are summarized. State of the art mathematical models, advances in computational techniques, emerging high performance computers, and experimental validation techniques have provided significant insight into the fundamental factors that control the development of the weldment. Current status and scientific issues in heat and fluid flow in welds, heat source metal interaction, and solidification microstructure are assessed. Future research areas of major importance for understanding the fundamental phenomena in weld behavior are identified.

  16. Effect of Welding Heat Input on the Corrosion Resistance of Carbon Steel Weld Metal

    NASA Astrophysics Data System (ADS)

    Lu, Yongxin; Jing, Hongyang; Han, Yongdian; Xu, Lianyong

    2016-02-01

    The corrosion resistance of carbon steel weld metal with three different microstructures has been systematically evaluated using electrochemical techniques with the simulated produced water containing CO2 at 90 °C. Microstructures include acicular ferrite, polygonal ferrite, and a small amount of pearlite. With welding heat input increasing, weld metal microstructure becomes more uniform. Electrochemical techniques including potentiodynamic polarization curve, linear polarization resistance, and electrochemical impedance spectroscopy were utilized to characterize the corrosion properties on weld joint, indicating that the best corrosion resistance corresponded to the weld metal with a polygonal ferrite microstructure, whereas the weld metal with the acicular ferrite + polygonal ferrite microstructure showed the worst corrosion resistance. The samples with high welding heat input possessed better corrosion resistance. Results were discussed in terms of crystal plane orientation, grain size, and grain boundary type found in each weld metal by electron backscatter diffraction test.

  17. Performance prediction of mechanical excavators from linear cutter tests on Yucca Mountain welded tuffs; Yucca Mountain Site Characterization Project

    SciTech Connect

    Gertsch, R.; Ozdemir, L.

    1992-09-01

    The performances of mechanical excavators are predicted for excavations in welded tuff. Emphasis is given to tunnel boring machine evaluations based on linear cutting machine test data obtained on samples of Topopah Spring welded tuff. The tests involve measurement of forces as cutters are applied to the rock surface at certain spacing and penetrations. Two disc and two point-attack cutters representing currently available technology are thus evaluated. The performance predictions based on these direct experimental measurements are believed to be more accurate than any previous values for mechanical excavation of welded tuff. The calculations of performance are predicated on minimizing the amount of energy required to excavate the welded tuff. Specific energy decreases with increasing spacing and penetration, and reaches its lowest at the widest spacing and deepest penetration used in this test program. Using the force, spacing, and penetration data from this experimental program, the thrust, torque, power, and rate of penetration are calculated for several types of mechanical excavators. The results of this study show that the candidate excavators will require higher torque and power than heretofore estimated.

  18. Auxiliary Illumination For Viewing Along A Welding Torch

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Gutow, David A.

    1993-01-01

    Auxiliary optical subsystem provides additional illumination for through-torch vision system of type used in automated or semiautomated arc welding. Also useful during operation of torch to view parts in shadows cast by arc light.

  19. Automated, high-throughput derivation, characterization and differentiation of induced pluripotent stem cells.

    PubMed

    Paull, Daniel; Sevilla, Ana; Zhou, Hongyan; Hahn, Aana Kim; Kim, Hesed; Napolitano, Christopher; Tsankov, Alexander; Shang, Linshan; Krumholz, Katie; Jagadeesan, Premlatha; Woodard, Chris M; Sun, Bruce; Vilboux, Thierry; Zimmer, Matthew; Forero, Eliana; Moroziewicz, Dorota N; Martinez, Hector; Malicdan, May Christine V; Weiss, Keren A; Vensand, Lauren B; Dusenberry, Carmen R; Polus, Hannah; Sy, Karla Therese L; Kahler, David J; Gahl, William A; Solomon, Susan L; Chang, Stephen; Meissner, Alexander; Eggan, Kevin; Noggle, Scott A

    2015-09-01

    Induced pluripotent stem cells (iPSCs) are an essential tool for modeling how causal genetic variants impact cellular function in disease, as well as an emerging source of tissue for regenerative medicine. The preparation of somatic cells, their reprogramming and the subsequent verification of iPSC pluripotency are laborious, manual processes limiting the scale and reproducibility of this technology. Here we describe a modular, robotic platform for iPSC reprogramming enabling automated, high-throughput conversion of skin biopsies into iPSCs and differentiated cells with minimal manual intervention. We demonstrate that automated reprogramming and the pooled selection of polyclonal pluripotent cells results in high-quality, stable iPSCs. These lines display less line-to-line variation than either manually produced lines or lines produced through automation followed by single-colony subcloning. The robotic platform we describe will enable the application of iPSCs to population-scale biomedical problems including the study of complex genetic diseases and the development of personalized medicines. PMID:26237226

  20. Characterizing interplanetary shocks for development and optimization of an automated solar wind shock detection algorithm

    NASA Astrophysics Data System (ADS)

    Cash, M. D.; Wrobel, J. S.; Cosentino, K. C.; Reinard, A. A.

    2014-06-01

    Human evaluation of solar wind data for interplanetary (IP) shock identification relies on both heuristics and pattern recognition, with the former lending itself to algorithmic representation and automation. Such detection algorithms can potentially alert forecasters of approaching shocks, providing increased warning of subsequent geomagnetic storms. However, capturing shocks with an algorithmic treatment alone is challenging, as past and present work demonstrates. We present a statistical analysis of 209 IP shocks observed at L1, and we use this information to optimize a set of shock identification criteria for use with an automated solar wind shock detection algorithm. In order to specify ranges for the threshold values used in our algorithm, we quantify discontinuities in the solar wind density, velocity, temperature, and magnetic field magnitude by analyzing 8 years of IP shocks detected by the SWEPAM and MAG instruments aboard the ACE spacecraft. Although automatic shock detection algorithms have previously been developed, in this paper we conduct a methodical optimization to refine shock identification criteria and present the optimal performance of this and similar approaches. We compute forecast skill scores for over 10,000 permutations of our shock detection criteria in order to identify the set of threshold values that yield optimal forecast skill scores. We then compare our results to previous automatic shock detection algorithms using a standard data set, and our optimized algorithm shows improvements in the reliability of automated shock detection.

  1. Object-based Dune Analysis: Automated dune mapping and pattern characterization for Ganges Chasma and Gale crater, Mars

    NASA Astrophysics Data System (ADS)

    Vaz, David A.; Sarmento, Pedro T. K.; Barata, Maria T.; Fenton, Lori K.; Michaels, Timothy I.

    2015-12-01

    A method that enables the automated mapping and characterization of dune fields on Mars is described. Using CTX image mosaics, the introduced Object-based Dune Analysis (OBDA) technique produces an objective and reproducible mapping of dune morphologies over extensive areas. The data set thus obtained integrates a large variety of data, allowing a simple cross-analysis of dune patterns, spectral and morphometric information, and mesoscale wind models. Two dune fields, located in Gale crater and Ganges Chasma, were used to test and validate the methodology. The segmentation of dune-related morphologies is highly efficient, reaching overall accuracies of 95%. In addition, we show that the automated segmentation of slipface traces is also possible with expected accuracies of 85-90%. A qualitative and quantitative comparison of the final outputs with photointerpretations is performed, and the precision of the directional characterization of the dune patterns is evaluated. We demonstrate a good agreement between the OBDA outputs and the photointerpreted dune morphologies, with local trend deviations below 45° for 80-95% of the mapped areas. Because the developed algorithm is tuned for the recognition of linear features from the imagery, the slipfaces of small barchans can be preferentially overlooked owing to their small extent at the spatial resolution of the CTX mosaics. Dune types composed of longer linear morphologies are much better represented, including correct mapping of secondary structures. Having proved the effectiveness and accuracy of the mapping procedure, we discuss its future applications for the improvement of dune catalogs on Mars.

  2. Laser Welding Systems For Hermetic Sealing

    NASA Astrophysics Data System (ADS)

    Bosnos, Charles M.

    1986-11-01

    High-speed laser welding systems have been developed to hermetically seal electronic packages, diaphragms, etc., for commercial, medical, and military applications. An inert atmosphere chamber is incorporated when welding must be done in a moisture-free and oxygen-free gas environment. Interface of a multi-axis positioner and computer numerical control with the laser allows programmability of all weld schedule parameters. This degree of automation minimizes process deviation, decreases the risk of human error, and accommodates dimensional tolerances and dissimilarities in part configuration.

  3. Effect of Seam Welding on Forming Limits of IF-Steel Sheet

    NASA Astrophysics Data System (ADS)

    Sutariya, D.; Raval, H.; Kalaivani, K.; Hariharan, K.; Prabhu, A.; Narasimhan, K.

    2011-08-01

    Laser welding is the most commonly used process for producing Tailor Welded Blanks (TWB). Although laser welding is best suited for TWB applications, it is an expensive process. In this work an alternate cheap process, seam welding, is used to produce welded sheets of IF-steel of same grade and thickness. The effect of this welding on forming limit strains is explored in this work. Forming behavior is characterized by Forming Limit Diagram (FLD). The FLDs of welded blanks are compared with that of un-welded blanks. The effect of longitudinal, transverse and 450 weld orientation on formability is studied. Weld location includes both centered and offset weld location in the transverse weld orientation. Numerical simulations are carried out by considering weld as a zone. Experimental results are compared with the predictions carried out by FE method.

  4. Syllabus in Trade Welding.

    ERIC Educational Resources Information Center

    New York State Education Dept., Albany. Bureau of Secondary Curriculum Development.

    The syllabus outlines material for a course two academic years in length (minimum two and one-half hours daily experience) leading to entry-level occupational ability in several welding trade areas. Fourteen units covering are welding, gas welding, oxyacetylene welding, cutting, nonfusion processes, inert gas shielded-arc welding, welding cast…

  5. Automated data acquisition technology development:Automated modeling and control development

    NASA Technical Reports Server (NTRS)

    Romine, Peter L.

    1995-01-01

    This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing.

  6. Automated Performance Characterization of DSN System Frequency Stability Using Spacecraft Tracking Data

    NASA Technical Reports Server (NTRS)

    Pham, Timothy T.; Machuzak, Richard J.; Bedrossian, Alina; Kelly, Richard M.; Liao, Jason C.

    2012-01-01

    This software provides an automated capability to measure and qualify the frequency stability performance of the Deep Space Network (DSN) ground system, using daily spacecraft tracking data. The results help to verify if the DSN performance is meeting its specification, therefore ensuring commitments to flight missions; in particular, the radio science investigations. The rich set of data also helps the DSN Operations and Maintenance team to identify the trends and patterns, allowing them to identify the antennas of lower performance and implement corrective action in a timely manner. Unlike the traditional approach where the performance can only be obtained from special calibration sessions that are both time-consuming and require manual setup, the new method taps into the daily spacecraft tracking data. This new approach significantly increases the amount of data available for analysis, roughly by two orders of magnitude, making it possible to conduct trend analysis with good confidence. The software is built with automation in mind for end-to-end processing. From the inputs gathering to computation analysis and later data visualization of the results, all steps are done automatically, making the data production at near zero cost. This allows the limited engineering resource to focus on high-level assessment and to follow up with the exceptions/deviations. To make it possible to process the continual stream of daily incoming data without much effort, and to understand the results quickly, the processing needs to be automated and the data summarized at a high level. Special attention needs to be given to data gathering, input validation, handling anomalous conditions, computation, and presenting the results in a visual form that makes it easy to spot items of exception/deviation so that further analysis can be directed and corrective actions followed.

  7. Automated Performance Characterization of DSN System Frequency Stability Using Spacecraft Tracking Data

    NASA Technical Reports Server (NTRS)

    Pham, Timothy T.; Machuzak, Richard J.; Bedrossian, Alina; Kelly, Richard M.; Liao, Jason C.

    2012-01-01

    This software provides an automated capability to measure and qualify the frequency stability performance of the Deep Space Network (DSN) ground system, using daily spacecraft tracking data. The results help to verify if the DSN performance is meeting its specification, therefore ensuring commitments to flight missions; in particular, the radio science investigations. The rich set of data also helps the DSN Operations and Maintenance team to identify the trends and patterns, allowing them to identify the antennas of lower performance and implement corrective action in a timely manner. Unlike the traditional approach where the performance can only be obtained from special calibration sessions that are both time-consuming and require manual setup, the new method taps into the daily spacecraft tracking data. This new approach significantly increases the amount of data available for analysis, roughly by two orders of magnitude, making it possible to conduct trend analysis with good confidence. The software is built with automation in mind for end-to-end processing. From the inputs gathering to computation analysis and later data visualization of the results, all steps are done automatically, making the data production at near zero cost. This allows the limited engineering resource to focus on high-level assessment and to follow up with the exceptions/deviations. To make it possible to process the continual stream of daily incoming data without much effort, and to understand the results quickly, the processing needs to be automated and the data summarized at a high level. Special attention needs to be given to data gathering, input validation, handling anomalous conditions, computation, and presenting the results in a visual form that makes it easy to spot items of exception/ deviation so that further analysis can be directed and corrective actions followed.

  8. Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

    NASA Technical Reports Server (NTRS)

    Jones, C. S.; Gangl, K. J.

    1986-01-01

    In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

  9. Microstructure characterization and weldability evaluation of the weld heat affected zone (HAZ) in 310HCbN tubing

    SciTech Connect

    Lundin, C.D.; Qiao, C.Y.P.

    1995-08-01

    Metallographic evaluation on the Gleeble simulated HAZ samples of 310HCbN tubing material was performed in order to reveal potential degradation in mechanical properties and corrosion resistance. The carbide evolutionary process in the HAZ samples was studied. It is indicated that 310HCbN material showed a weld HAZ sensitization tendency that is associated with the formation of Cr{sub 23}C{sub 6}.

  10. Automated and Online Characterization of Adherent Cell Culture Growth in a Microfabricated Bioreactor

    PubMed Central

    Jaccard, Nicolas; Macown, Rhys J.; Super, Alexandre; Griffin, Lewis D.; Veraitch, Farlan S.

    2014-01-01

    Adherent cell lines are widely used across all fields of biology, including drug discovery, toxicity studies, and regenerative medicine. However, adherent cell processes are often limited by a lack of advances in cell culture systems. While suspension culture processes benefit from decades of development of instrumented bioreactors, adherent cultures are typically performed in static, noninstrumented flasks and well-plates. We previously described a microfabricated bioreactor that enables a high degree of control on the microenvironment of the cells while remaining compatible with standard cell culture protocols. In this report, we describe its integration with automated image-processing capabilities, allowing the continuous monitoring of key cell culture characteristics. A machine learning–based algorithm enabled the specific detection of one cell type within a co-culture setting, such as human embryonic stem cells against the background of fibroblast cells. In addition, the algorithm did not confuse image artifacts resulting from microfabrication, such as scratches on surfaces, or dust particles, with cellular features. We demonstrate how the automation of flow control, environmental control, and image acquisition can be employed to image the whole culture area and obtain time-course data of mouse embryonic stem cell cultures, for example, for confluency. PMID:24692228

  11. Automated multilayer segmentation and characterization in 3D spectral-domain optical coherence tomography images

    NASA Astrophysics Data System (ADS)

    Hu, Zhihong; Wu, Xiaodong; Hariri, Amirhossein; Sadda, SriniVas R.

    2013-03-01

    Spectral-domain optical coherence tomography (SD-OCT) is a 3-D imaging technique, allowing direct visualization of retinal morphology and architecture. The various layers of the retina may be affected differentially by various diseases. In this study, an automated graph-based multilayer approach was developed to sequentially segment eleven retinal surfaces including the inner retinal bands to the outer retinal bands in normal SD-OCT volume scans at three different stages. For stage 1, the four most detectable and/or distinct surfaces were identified in the four-times-downsampled images and were used as a priori positional information to limit the graph search for other surfaces at stage 2. Eleven surfaces were then detected in the two-times-downsampled images at stage 2, and refined in the original image space at stage 3 using the graph search integrating the estimated morphological shape models. Twenty macular SD-OCT (Heidelberg Spectralis) volume scans from 20 normal subjects (one eye per subject) were used in this study. The overall mean and absolute mean differences in border positions between the automated and manual segmentation for all 11 segmented surfaces were -0.20 +/- 0.53 voxels (-0.76 +/- 2.06 μm) and 0.82 +/- 0.64 voxels (3.19 +/- 2.46 μm). Intensity and thickness properties in the resultant retinal layers were investigated. This investigation in normal subjects may provide a comparative reference for subsequent investigations in eyes with disease.

  12. Characterization of the morphological properties of welding fume particles by transmission electron microscopy and digital image analysis.

    PubMed

    Farrants, G; Schüler, B; Karlsen, J; Reith, A; Langård, S

    1989-09-01

    The morphological characteristics of welding fume particles have been determined using transmission electron microscopy (TEM) and automatic image analysis (AIA). Two personal samples and one background sample were collected using a new, easy to handle sampling method, during tungsten inert gas (TIG) and manual metal arc (MMA) welding on Inconel in the same shop. The collection method gave samples which were suitable for TEM and AIA. Electron micrographs were taken in a transmission electron microscope and further analyzed using an image analysis unit. Aggregates composed of many individual particles were analyzed both for the parameters of the aggregate and for the parameters of the individual particles by using an algorithm based on a grain boundary reconstruction technique. The morphological parameters allowed the welding fume's particulate matter to be divided into three types - here called small, medium, and large - with a somewhat unclear distinction between medium and large. Medium and large particles occur either as individual particles or as clusters of approximately spherical particles with average diameters of 0.07 and 0.15 microm, respectively. Small particles occur almost exclusively as long chains or lace-like structures of aggregates of particles, often in the range of 5-10 microm. The aggregates have an average projected area of 2.6 x 10-3 microm2 and are composed of several hundred individual particles. PMID:2801515

  13. Development of an Automated and Sensitive Microfluidic Device for Capturing and Characterizing Circulating Tumor Cells (CTCs) from Clinical Blood Samples

    PubMed Central

    Gogoi, Priya; Sepehri, Saedeh; Zhou, Yi; Gorin, Michael A.; Paolillo, Carmela; Capoluongo, Ettore; Gleason, Kyle; Payne, Austin; Boniface, Brian; Cristofanilli, Massimo; Morgan, Todd M.; Fortina, Paolo; Pienta, Kenneth J.; Handique, Kalyan; Wang, Yixin

    2016-01-01

    Current analysis of circulating tumor cells (CTCs) is hindered by sub-optimal sensitivity and specificity of devices or assays as well as lack of capability of characterization of CTCs with clinical biomarkers. Here, we validate a novel technology to enrich and characterize CTCs from blood samples of patients with metastatic breast, prostate and colorectal cancers using a microfluidic chip which is processed by using an automated staining and scanning system from sample preparation to image processing. The Celsee system allowed for the detection of CTCs with apparent high sensitivity and specificity (94% sensitivity and 100% specificity). Moreover, the system facilitated rapid capture of CTCs from blood samples and also allowed for downstream characterization of the captured cells by immunohistochemistry, DNA and mRNA fluorescence in-situ hybridization (FISH). In a subset of patients with prostate cancer we compared the technology with a FDA-approved CTC device, CellSearch and found a higher degree of sensitivity with the Celsee instrument. In conclusion, the integrated Celsee system represents a promising CTC technology for enumeration and molecular characterization. PMID:26808060

  14. Development of an Automated and Sensitive Microfluidic Device for Capturing and Characterizing Circulating Tumor Cells (CTCs) from Clinical Blood Samples.

    PubMed

    Gogoi, Priya; Sepehri, Saedeh; Zhou, Yi; Gorin, Michael A; Paolillo, Carmela; Capoluongo, Ettore; Gleason, Kyle; Payne, Austin; Boniface, Brian; Cristofanilli, Massimo; Morgan, Todd M; Fortina, Paolo; Pienta, Kenneth J; Handique, Kalyan; Wang, Yixin

    2016-01-01

    Current analysis of circulating tumor cells (CTCs) is hindered by sub-optimal sensitivity and specificity of devices or assays as well as lack of capability of characterization of CTCs with clinical biomarkers. Here, we validate a novel technology to enrich and characterize CTCs from blood samples of patients with metastatic breast, prostate and colorectal cancers using a microfluidic chip which is processed by using an automated staining and scanning system from sample preparation to image processing. The Celsee system allowed for the detection of CTCs with apparent high sensitivity and specificity (94% sensitivity and 100% specificity). Moreover, the system facilitated rapid capture of CTCs from blood samples and also allowed for downstream characterization of the captured cells by immunohistochemistry, DNA and mRNA fluorescence in-situ hybridization (FISH). In a subset of patients with prostate cancer we compared the technology with a FDA-approved CTC device, CellSearch and found a higher degree of sensitivity with the Celsee instrument. In conclusion, the integrated Celsee system represents a promising CTC technology for enumeration and molecular characterization. PMID:26808060

  15. 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.

  16. Role of welding parameters in determining the geometrical appearance of weld pool

    SciTech Connect

    Kovacevic, R.; Cao, Z.N.; Zhang, Y.M.

    1996-10-01

    A three-dimensional numerical model is developed to describe the fluid flow and heat transfer in weld pools. Both full penetration and free deformation of the top and bottom weld pool surfaces are considered. Temperature distribution and fluid flow field are obtained. In order to analyze the influence of welding parameters on the geometrical appearance of weld pools, a normalized model is developed to characterize the geometrical appearance of weld pools. It is found that welding current can significantly affect the geometrical shape. When welding current increases, the curvature of the pool boundary at the trailing end increases. The effect of the welding speed on the geometrical appearance is slight, although its influence on the pool size is great. In the interest range of arc length (from 1 mm to 4 mm), the arc length can affect both the size and the shape of the weld pool. However, compared with the welding current and speed, its influences are much weaker, GTA welding experiments are performed to verify the validity of the numerical models. The appearance of weld pools was obtained by using machine vision and a high-shutter speed camera. It is found that the calculated results have a good agreement with the experimental ones.

  17. 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.

  18. Welding development for V-Cr-Ti alloys

    SciTech Connect

    Goodwin, G.M.; King, J.F.

    1994-09-01

    Welds have been produced and characterized using the gas-tungsten arc (GTA) and electron beam (EB) welding processes. Thin sheet (0.75 mm) welds were made with three levels of interstitial contamination, and hardness and tensile properties were found to be strongly affected by oxygen pickup. Thick-section (6 mm) welds have been produced using both processes, and no embrittlement is experienced when high purity atmosphere is maintained. Metallographic examination shows a narrow, but coarse grained, heat affected zone for the GTA welds. Transition joint welding development between vanadium alloy and stainless steel has shown encouraging results.

  19. Microstructural characterization of an SA508–309L/308L–316L domestic dissimilar metal welded safe-end joint

    SciTech Connect

    Ming, Hongliang; Zhang, Zhiming; Wang, Jianqiu Han, En-Hou; Ke, Wei

    2014-11-15

    The microstructure of an SA508–309L/308L–316L domestic dissimilar metal welded safe-end joint was characterized in this work by optical microscopy, scanning electron microscopy (with electron back scattering diffraction) and micro-hardness testing. Epitaxial growth and competitive growth are evident in the 308L–316L fusion boundary regions. A martensite layer, carbon-depleted zones, and type-II and type-I boundaries are found in the SA508–309L fusion boundary regions, while only martensite and austenite mixed zones are observed in the SA508–308L fusion boundary regions. The microstructure near the fusion boundary and the microstructure transition in the SA508 heat affected zone are quite complex. Both for SA508–309L/308L and 308L–316L, the highest residual strain is located on the outside of the weldment. The residual strain and the grain boundary character distribution change with increasing distance from the fusion boundary in the heat affected zone of 316L. Micro-hardness measurements also reveal non-uniform mechanical properties across the weldment. - Highlights: • The microstructure of SA508 HAZ, especially near the FB, is very complex. • The outside of the dissimilar metal welded joint has the highest residual. • The micro-hardness distributions along the DMWJ are non-uniform.

  20. 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.

  1. Y-12 Plant remedial action Technology Logic Diagram: Volume 3, Technology evaluation data sheets: Part B, Characterization; robotics/automation

    SciTech Connect

    1994-09-01

    The Y-12 Plant Remedial Action Technology Logic Diagram (TLD) was developed to provide a decision-support tool that relates environmental restoration (ER) problems at the Y-12 Plant to potential technologies that can remediate theses problems. The TLD identifies the research, development, demonstration, testing, and evaluation needed for sufficient development of these technologies to allow for technology transfer and application to remedial action (RA) activities. The TLD consists of three volumes. Volume 1 contains an overview of the TLD, an explanation of the program-specific responsibilities, a review of identified technologies, and the rankings of remedial technologies. Volume 2 contains the logic linkages among environmental management goals, environmental problems, and the various technologies that have the potential to solve these problems. Volume 3 contains the TLD data sheets. This report is Part B of Volume 3 and contains the Characterization and Robotics/Automation sections.

  2. Mechanical characterization of two thermoplastic composites fabricated by automated tow placement

    NASA Technical Reports Server (NTRS)

    Dickinson, Larry C.; Deaton, Jerry W.

    1993-01-01

    AS4/PEEK towpreg and IM7/Radel 8320 slit tape were used to make flat panels by automated tow placement. The panels were tested in notched and un-notched tension, notched and un-notched compression and compression after impact (CAI) at room temperature and under hot/wet conditions (notched and un-notched compression and CAI only). The properties were compared with AS4/PEEK tape laminate properties found in the literature. The tow placed AS4/PEEK material was stronger in tension but weaker in compression than the AS4/PEEK tape laminates. The tow placed AS4/PEEK was stronger but less stiff than the tow placed IM7/Radel 8320 in all compression tests. The IM7/Radel performed better in all other mechanical tests. The IM7/Radel outperformed the AS4/PEEK in all CAI tests.

  3. Dynamic Characterization of Growth and Gene Expression Using High-throughput Automated Flow cytometry

    PubMed Central

    Zuleta, Ignacio A.; Aranda-Díaz, Andrés; Li, Hao; El-Samad, Hana

    2014-01-01

    Cells adjust to changes in environmental conditions using complex regulatory programs. These cellular programs are the result of an intricate interplay between gene expression, cellular growth rate, and protein degradation fluxes. New technologies that enable simultaneous and time-resolved measurements of these variables are necessary to dissect cellular homeostatic strategies. Here, we report the development of a novel automated flow-cytometry robotic setup that enables real-time measurement of precise and simultaneous relative growth and protein synthesis rates of multiplexed microbial populations across many conditions. These measurements generate quantitative profiles of dynamically-evolving protein synthesis and degradation rates. We demonstrate this setup in the context of gene regulation of the unfolded protein response (UPR) and uncover a dynamic and complex landscape of gene expression, growth dynamics, and proteolysis following perturbations. PMID:24608180

  4. A review on ultrasound-based thyroid cancer tissue characterization and automated classification.

    PubMed

    Acharya, U R; Swapna, G; Sree, S V; Molinari, F; Gupta, S; Bardales, R H; Witkowska, A; Suri, J S

    2014-08-01

    In this paper, we review the different studies that developed Computer Aided Diagnostic (CAD) for automated classification of thyroid cancer into benign and malignant types. Specifically, we discuss the different types of features that are used to study and analyze the differences between benign and malignant thyroid nodules. These features can be broadly categorized into (a) the sonographic features from the ultrasound images, and (b) the non-clinical features extracted from the ultrasound images using statistical and data mining techniques. We also present a brief description of the commonly used classifiers in ultrasound based CAD systems. We then review the studies that used features based on the ultrasound images for thyroid nodule classification and highlight the limitations of such studies. We also discuss and review the techniques used in studies that used the non-clinical features for thyroid nodule classification and report the classification accuracies obtained in these studies. PMID:24206204

  5. Extraction, identification, and functional characterization of a bioactive substance from automated compound-handling plastic tips.

    PubMed

    Watson, John; Greenough, Emily B; Leet, John E; Ford, Michael J; Drexler, Dieter M; Belcastro, James V; Herbst, John J; Chatterjee, Moneesh; Banks, Martyn

    2009-06-01

    Disposable plastic labware is ubiquitous in contemporary pharmaceutical research laboratories. Plastic labware is routinely used for chemical compound storage and during automated liquid-handling processes that support assay development, high-throughput screening, structure-activity determinations, and liability profiling. However, there is little information available in the literature on the contaminants released from plastic labware upon DMSO exposure and their resultant effects on specific biological assays. The authors report here the extraction, by simple DMSO washing, of a biologically active substance from one particular size of disposable plastic tips used in automated compound handling. The active contaminant was identified as erucamide ((Z)-docos-13-enamide), a long-chain mono-unsaturated fatty acid amide commonly used in plastics manufacturing, by gas chromatography/mass spectroscopy analysis of the DMSO-extracted material. Tip extracts prepared in DMSO, as well as a commercially obtained sample of erucamide, were active in a functional bioassay of a known G-protein-coupled fatty acid receptor. A sample of a different disposable tip product from the same vendor did not release detectable erucamide following solvent extraction, and DMSO extracts prepared from this product were inactive in the receptor functional assay. These results demonstrate that solvent-extractable contaminants from some plastic labware used in the contemporary pharmaceutical research and development (R&D) environment can be introduced into physical and biological assays during routine compound management liquid-handling processes. These contaminants may further possess biological activity and are therefore a potential source of assay-specific confounding artifacts. PMID:19470712

  6. Innovative Tools Advance Revolutionary Weld Technique

    NASA Technical Reports Server (NTRS)

    2009-01-01

    (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

  7. Design considerations for remotely operated welding in space: Task definition and visual weld monitoring experiment

    NASA Astrophysics Data System (ADS)

    Reynerson, Charles M.

    1993-05-01

    This thesis explores the concept of welding in a space environment with the use of automation. Since the amount of time astronauts can work outside a spacecraft is limited, future construction and repair tasks will likely be assisted by automation. It is also likely that remote space welding will be needed for the construction of large-scale space structures in earth orbit as well as for lunar and Martian ground-based structures. Due to the complex nature of the tasks to be accomplished, the equipment will probably not be fully autonomous but instead supervised by a human operator. The welding fabrication problem in space is examined in a broad sense including some of the considerations for designing a human supervisory remote welding system. The history of space welding processes is examined, as well as current research in the field. A task definition and functional analysis is provided to assist future designers in outlining typical operational sequences for such a remote welding system. Such analysis is important when deciding whether the human operator should perform certain tasks or if the operator should supervise the automated system while it performs the tasks.

  8. Gray-Scale Processing For Tracking Of Welds

    NASA Technical Reports Server (NTRS)

    Gutow, David A.

    1989-01-01

    Digital analysis of video-image-processing system contributes to automation of weld-seam tracking. Makes no contact with seam. Small television camera views seam just ahead of point currently being welded. Arc provides illumination. Periodically frame grabber digitizes video image and stores in computer memory as gray-scale values. Seam located by analyzing Hough-transform arrays of derivatives of digitally-filtered image data. Information on location and orientation of seam used as feedback by welding robot to correct deviations of electrode from seam as welding continues.

  9. Variable-Polarity Plasma Arc Welding Of Alloy 2219

    NASA Technical Reports Server (NTRS)

    Walsh, Daniel W.; Nunes, Arthur C., Jr.

    1989-01-01

    Report presents results of study of variable-polarity plasma arc (VPPA) welding of aluminum alloy 2219. Consists of two parts: Examination of effects of microsegregation and transient weld stress on macrosegregation in weld pool and, electrical characterization of straight- and reverse-polarity portions of arc cycle.

  10. An information model based weld schedule database

    SciTech Connect

    Kleban, S.D.; Knorovsky, G.A.; Hicken, G.K.; Gershanok, G.A.

    1997-08-01

    As part of a computerized system (SmartWeld) developed at Sandia National Laboratories to facilitate agile manufacturing of welded assemblies, a weld schedule database (WSDB) was also developed. SmartWeld`s overall goals are to shorten the design-to-product time frame and to promote right-the-first-time weldment design and manufacture by providing welding process selection guidance to component designers. The associated WSDB evolved into a substantial subproject by itself. At first, it was thought that the database would store perhaps 50 parameters about a weld schedule. This was a woeful underestimate: the current WSDB has over 500 parameters defined in 73 tables. This includes data bout the weld, the piece parts involved, the piece part geometry, and great detail about the schedule and intervals involved in performing the weld. This complex database was built using information modeling techniques. Information modeling is a process that creates a model of objects and their roles for a given domain (i.e. welding). The Natural-Language Information Analysis methodology (NIAM) technique was used, which is characterized by: (1) elementary facts being stated in natural language by the welding expert, (2) determinism (the resulting model is provably repeatable, i.e. it gives the same answer every time), and (3) extensibility (the model can be added to without changing existing structure). The information model produced a highly normalized relational schema that was translated to Oracle{trademark} Relational Database Management Systems for implementation.

  11. Investigation of underwater welding of steel

    SciTech Connect

    Shannon, G.J.; Watson, J.; Deans, W.F. . Dept. of Engineering)

    1994-12-01

    The preliminary underwater welding study described forms part of a European funded research program (EUREKA EU194) which involves a feasibility study into laser welding applications in the offshore oil industry. An investigation was undertaken using a 1.2 KW carbon dioxide laser for underwater butt welding of BS 4360 43A and 50D steel, in order to assess the quality of the welds and to achieve an understanding of the laser/water/material interaction. Using a high-speed camera, the temporal behavior of the melt pool and ''plasma'' dynamics surrounded by an aqueous environment were monitored. Experiments were undertaken to characterize the attenuation of the laser beam in the water as a function of various focal length optics and depth of water. The effect of energy input conditions on the weld bead appearance and mechanical properties were also examined. The interaction of the laser beam with water produced a wave-guiding mechanism in which the focused beam instantaneously vaporizes the water and directs the beam on to the workpiece. The underwater weld beads exhibited sound microstructures over a range of weld energy inputs, mainly due to the formation of a ''dry region'' during welding. Metallurgical analysis of the welds showed a slight increase in hardness, though other post-weld mechanical strengths were similar to in-air results.

  12. Nondestructive Ultrasonic Inspection of Friction Stir Welds

    NASA Astrophysics Data System (ADS)

    Tabatabaeipour, M.; Hettler, J.; Delrue, S.; Van Den Abeele, K.

    Friction Stir Welding (FSW) is a relatively new solid-state welding procedure developed at The Welding Institute (TWI-UK) and the technique is widely employed for welding aluminum alloys in various applications. In order to examine the quality of the welds and to detect a variety of welding flaws such as wormholes and root-flaws, it is required to develop a methodical inspection technique that can be used for the identification and localization of such defects. The most prevalent and risky defect in this type of welding is the barely visible root flaw with a length varying from 100-700 μm. Due to the extreme characteristics of the flaw, off-the-shelf ultrasonic weld inspection methods are not always able to readily detect this type of minute defect feature. Here, we propose a novel approach to characterize root flaws using an oblique incident ultrasonic C-scan backscattering analysis. The implementation consists of an immersion ultrasonic testing method in pulse echo (i.e. backscatter) mode with a 3.5 MHz transducer, and makes use of an empirical procedure to engender of a shear wave dominated excitation at the root surface, and to properly gate the received signal for root flaw examination. By scanning the surface above the welded component, a C-scan image displaying the backscatter response from the root surface of the nugget zone can be obtained which allows a simple interpretation of the root flaw status of the weld.

  13. 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.

  14. Pearson's Functions to Describe FSW Weld Geometry

    SciTech Connect

    Lacombe, D.; Coupard, D.; Tcherniaeff, S.; Girot, F.; Gutierrez-Orrantia, M. E.

    2011-01-17

    Friction stir welding (FSW) is a relatively new joining technique particularly for aluminium alloys that are difficult to fusion weld. In this study, the geometry of the weld has been investigated and modelled using Pearson's functions. It has been demonstrated that the Pearson's parameters (mean, standard deviation, skewness, kurtosis and geometric constant) can be used to characterize the weld geometry and the tensile strength of the weld assembly. Pearson's parameters and process parameters are strongly correlated allowing to define a control process procedure for FSW assemblies which make radiographic or ultrasonic controls unnecessary. Finally, an optimisation using a Generalized Gradient Method allows to determine the geometry of the weld which maximises the assembly tensile strength.

  15. Narrow gap laser welding

    DOEpatents

    Milewski, J.O.; Sklar, E.

    1998-06-02

    A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables. 34 figs.

  16. Narrow gap laser welding

    DOEpatents

    Milewski, John O.; Sklar, Edward

    1998-01-01

    A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables.

  17. Effect of Post-Weld Heat Treatment on Creep Rupture Properties of Grade 91 Steel Heavy Section Welds

    SciTech Connect

    Li, Leijun

    2012-11-02

    This project will conduct a systematic metallurgical study on the effect of post-weld heat treatment (PWHT) on the creep rupture properties of P91 heavy section welds. The objective is to develop a technical guide for selecting PWHT parameters, and to predict expected creep-rupture life based on the selection of heat treatment parameters. The project consists of four interdependent tasks: Experimentally and numerically characterize the temperature fields of typical post-weld heat treatment procedures for various weld and joint configurations to be used in Gen IV systems. Characterize the microstructure of various regions, including the weld fusion zone, coarse-grain heat-affected zone, and fine-grain heat affected zone, in the welds that underwent the various welding and PWHT thermal histories. Conduct creep and creep-rupture testing of coupons extracted from actual and physically simulated welds. Establish the relationship among PWHT parameters, thermal histories, microstructure, creep, and creep-rupture properties.

  18. Weld pool oscillation during pulsed GTA welding

    SciTech Connect

    Aendenroomer, A.J.R.; Ouden, G. den

    1996-12-31

    This paper deals with weld pool oscillation during pulsed GTA welding and with the possibility to use this oscillation for in-process control of weld penetration. Welding experiments were carried out under different welding conditions. During welding the weld pool was triggered into oscillation by the normal welding pulses or by extra current pulses. The oscillation frequency was measured both during the pulse time and during the base time by analyzing the arc voltage variation using a Fast Fourier Transformation program. Optimal results are obtained when full penetration occurs during the pulse time and partial penetration during the base time. Under these conditions elliptical overlapping spot welds are formed. In the case of full penetration the weld pool oscillates in a low frequency mode (membrane oscillation), whereas in the case of partial penetration the weld pool oscillates in a high frequency mode (surface oscillation). Deviation from the optimal welding conditions occurs when high frequency oscillation is observed during both pulse time and base time (underpenetration) or when low frequency oscillation is observed during both pulse time and base time (overpenetration). In line with these results a penetration sensing system with feedback control was designed, based on the criterion that optimal weld penetration is achieved when two peaks are observed in the frequency distribution. The feasibility of this sensing system for orbital tube welding was confirmed by the results of experiments carried out under various welding conditions.

  19. Characterization of available automated external defibrillators in the market based on the product manuals in 2014

    PubMed Central

    Ho, Chik Leung; Cheng, Ka Wai; Ma, Tze Hang; Wong, Yau Hang; Cheng, Ka Lok; Kam, Chak Wah

    2016-01-01

    BACKGROUND: To popularize the wide-spread use of automated external defibrillator (AED) to save life in sudden cardiac arrest, we compared the strength and weakness of different types of AEDs to enable a sound selection based on regional requirement. METHODS: This was a retrospective descriptive study. Different types of AEDs were compared according to the information of AEDs from manuals and brochures provided by the manufacturers. Fifteen types of AEDs were divided into 3 groups, basic, intermediate and advanced. RESULTS: Lifeline™ AUTO AED had the best performance in price, portability and user-friendly among AEDs of basic level. It required less time for shock charging. Samaritan PAD defibrillator was superior in price, portability, durability and characteristic among AEDs of intermediate level. It had the longest warranty and highest protection against water and dust. Lifeline™ PRO AED had the best performance in most of the criteria among AEDs of advanced level and offered CPR video and manual mode for laypersons and clinicians respectively. CONCLUSION: Lifeline™ AUTO AED, Samaritan PAD defibrillator, Lifeline™ PRO AED are superior in AEDs of basic, intermediate and advanced levels, respectively. A feasible AED may be chosen by users according to the regional requirement and the current information about the best available products. PMID:27313810

  20. Evaluation of an Automated Reflectance Microscope system for coal characterization. Technical report 18

    SciTech Connect

    Liscinsky, D. S.; Vastola, F.

    1980-01-01

    The potential of an Automated Reflectance Microscope (ARM) system to determine the petrographic composition of a coal has been examined. The analysis involves the automatic scanning of a polished coal surface with a reflectance microscope. The reflectivity of consecutive 4-square-micrometer spots on the surface is measured by a photomultiplier tube and recorded by a microcomputer. This study was aimed at making the interpretation of a reflectogram more straightforward, that is, increasing the ability to discriminate among species. Although hardware improvements to decrease the spot size and the error associated with each reading would allow some increase in the ability to discriminate among species, the heterogeneous nature of the surface still limits the qualitative and quantitative information that can be derived from a reflectogram. Therefore a real-time data processing algorithm was implemented during data acquisition to study the effects that processing can have on a reflectogram. By measuring connectivity, it was found that edge readings could be indirectly eliminated. This greatly improved the ability to discriminate among species. Further investigation led to the conclusion that physical particle size has a major effect on a reflectogram. The concentration of coal in a pellet also has an effect on the ability to discriminate among species. A bonus of using processing to enhance the data was the ability to simultaneously gather information on particle size distributions. Based on the results the potential of an ARM system is improved by algorithm enhancement. The processing of the data allows some of the inherent limitations to be reduced.

  1. Automated benign & malignant thyroid lesion characterization and classification in 3D contrast-enhanced ultrasound.

    PubMed

    Acharya, U Rajendra; S, Vinitha Sree; Molinari, Filippo; Garberoglio, Roberto; Witkowska, Agnieszka; Suri, Jasjit S

    2012-01-01

    In this work, we present a Computer Aided Diagnosis (CAD) based technique for automatic classification of benign and malignant thyroid lesions in 3D contrast-enhanced ultrasound images. The images were obtained from 20 patients. Fine needle aspiration biopsy and histology confirmed malignancy. Discrete Wavelet Transform (DWT) and texture based features were extracted from the thyroid images. The resulting feature vectors were used to train and test three different classifiers: K-Nearest Neighbor (K-NN), Probabilistic Neural Network (PNN), and Decision Tree (DeTr) using ten-fold cross validation technique. Our results show that combination of DWT and texture features in the K-NN classifier resulted in a classification accuracy of 98.9%, a sensitivity of 98%, and a specificity of 99.8%. Thus, the preliminary results of the proposed technique show that it could be adapted as an adjunct tool that can give valuable second opinions to the doctors regarding the nature of the thyroid nodule. The technique is cost-effective, non-invasive, fast, completely automated and gives more objective and reproducible results compared to manual analysis of the ultrasound images. We however intend to establish the clinical applicability of this technique by evaluating it with more data in the future. PMID:23365926

  2. Spectroscopic characterization of laser-induced plasma created during welding with a pulsed Nd:YAG laser

    SciTech Connect

    Lacroix, D.; Jeandel, G.; Boudot, C.

    1997-05-01

    A spectroscopic study of a laser-induced plume created during the welding of stainless steel and other materials (iron and chromium) has been carried out. A pulsed Nd:YAG laser of 1000 W average power is used. The evolutions of the electron temperature and electron density have been studied for several welding parameters. We use working powers from 300 to 900 W and pulse durations between 1.5 and 5 ms. The influence of shielding gases like nitrogen and argon has been taken into account. Temperature and density calculations are based on the observation of the relative intensities and shapes of the emission peaks. We assume that the plasma is in local thermal equilibrium. The temperature is calculated with the Boltzmann plot method and the density with the Stark broadening of an iron line. The electron temperatures vary in the range of 4500{endash}7100 K, electron density between 3{times}10{sup 22} and 6.5{times}10{sup 22} m{sup {minus}3}. The absorption of the laser beam in the plasma is calculated using the Inverse Bremsstrahlung theory. {copyright} {ital 1997 American Institute of Physics.}

  3. Fabrication and characterization of metal-packaged fiber Bragg grating sensor by one-step ultrasonic welding

    NASA Astrophysics Data System (ADS)

    Zhang, Yumin; Zhu, Lianqing; Luo, Fei; Dong, Mingli; Ding, Xiangdong; He, Wei

    2016-06-01

    A metallic packaging technique of fiber Bragg grating (FBG) sensors is developed for measurement of strain and temperature, and it can be simply achieved via one-step ultrasonic welding. The average strain transfer rate of the metal-packaged sensor is theoretically evaluated by a proposed model aiming at surface-bonded metallic packaging FBG. According to analytical results, the metallic packaging shows higher average strain transfer rate compared with traditional adhesive packaging under the same packaging conditions. Strain tests are performed on an elaborate uniform strength beam for both tensile and compressive strains; strain sensitivities of approximately 1.16 and 1.30 pm/μɛ are obtained for the tensile and compressive situations, respectively. Temperature rising and cooling tests are also executed from 50°C to 200°C, and the sensitivity of temperature is 36.59 pm/°C. All the measurements of strain and temperature exhibit good linearity and stability. These results demonstrate that the metal-packaged sensors can be successfully fabricated by one-step welding technique and provide great promise for long-term and high-precision structural health monitoring.

  4. Preliminary numerical modeling for the G-Tunnel welded tuff mining experiment; Yucca Mountain site characterization project

    SciTech Connect

    Johnson, R.L.; Bauer, S.J.

    1991-09-01

    Yucca Mountain, located in Southern Nevada, is to be considered as a potential site for a nuclear waste repository. Located in Rainier Mesa on the Nevada Test Site, G-Tunnel has been the site of a series of experiments, part of whose purpose is to evaluate measurement techniques for rock mechanics before testing in the Exploratory Shaft. Rainier Mesa is composed of welded and nonwelded tuffs that have thermal and mechanical properties and stress states similar to those of tuffs expected to be encountered at Yucca Mountain. A series of finite element calculations were performed to aid in designing instrumentation for the experiments in G-Tunnel and later to correlate with measured data. In this report are presented the results of the preliminary finite element calculations performed in conjunction with experimental measurements of drift convergence, or closure, and rock mass relaxation zones made before, during, and after completing the welded tuff mining experiment in G-Tunnel. Tape extensometer measurements of drift convergences and measurements determined by multiple point borehole extensometers are compared with corresponding calculated values using linear elastic and jointed rock material models. 9 refs., 25 figs., 7 tabs.

  5. 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.

  6. Optimal Weld Parameters, Weld Microstructure, Mechanical Properties, and Hydrogen Absorption: An Effective Analysis

    NASA Astrophysics Data System (ADS)

    Bhattacharya, J.; Pal, T. K.

    2011-10-01

    Weld bead-in-grooves were deposited on low alloy, high strength steel plates (ASTM A 517 Grade "F") with a commercial flux-cored filler wire, Auto-MIG 420, at different welding conditions. Microstructure and mechanical properties of welds were characterized by means of optical microscopy, SEM, TEM, EPMA, microhardness measurements, tensile tests, and Charpy impact tests. Hydrogen content of weld metals in as-weld condition and after exposing in simulated service condition was measured by LECO Gas Analyzer. Microstructure of weld metals consisted primarily of lath martensite with small amount of M-A constituents (Martensite-Austenite alternating layers). For some particular welding conditions, such as higher heat input and lower preheat temperatures etc., acicular ferrite is observed with lath martensite. Welds consisting of acicular ferrite in the microstructure showed improved mechanical properties as well as lower hydrogen absorption. The study provides guidelines for selecting proper welding conditions, which results in lower propensity to absorb hydrogen during service, as well as better mechanical properties. Necessity of post-weld heat treatment processes, which is mainly performed to achieve toughness, may be reduced; consequently saving cost and time of the welding process.

  7. Action potential characterization of human induced pluripotent stem cell-derived cardiomyocytes using automated patch-clamp technology.

    PubMed

    Scheel, Olaf; Frech, Stefanie; Amuzescu, Bogdan; Eisfeld, Jörg; Lin, Kun-Han; Knott, Thomas

    2014-10-01

    Recent progress in embryonic stem cell (ESC) and induced pluripotent stem cell (iPSC) research led to high-purity preparations of human cardiomyocytes (CMs) differentiated from these two sources-suitable for tissue regeneration, in vitro models of disease, and cardiac safety pharmacology screening. We performed a detailed characterization of the effects of nifedipine, cisapride, and tetrodotoxin (TTX) on Cor.4U(®) human iPSC-CM, using automated whole-cell patch-clamp recordings with the CytoPatch™ 2 equipment, within a complex assay combining multiple voltage-clamp and current-clamp protocols in a well-defined sequence, and quantitative analysis of several action potential (AP) parameters. We retrieved three electrical phenotypes based on AP shape: ventricular, atrial/nodal, and S-type (with ventricular-like depolarization and lack of plateau). To suppress spontaneous firing, present in many cells, we injected continuously faint hyperpolarizing currents of -10 or -20 pA. We defined quality criteria (both seal and membrane resistance over 1 GΩ), and focused our study on cells with ventricular-like AP. Nifedipine induced marked decreases in AP duration (APD): APD90 (49.8% and 40.8% of control values at 1 and 10 μM, respectively), APD50 (16.1% and 12%); cisapride 0.1 μM increased APD90 to 176.2%; and tetrodotoxin 10 μM decreased maximum slope of phase to 33.3% of control, peak depolarization potential to 76.3% of control, and shortened APD90 on average to 80.4%. These results prove feasibility of automated voltage- and current-clamp recordings on human iPSC-CM and their potential use for in-depth drug evaluation and proarrhythmic liability assessment, as well as for diagnosis and pharmacology tests for cardiac channelopathy patients. PMID:25353059

  8. RootAnalyzer: A Cross-Section Image Analysis Tool for Automated Characterization of Root Cells and Tissues

    PubMed Central

    Chopin, Joshua; Laga, Hamid; Huang, Chun Yuan; Heuer, Sigrid; Miklavcic, Stanley J.

    2015-01-01

    The morphology of plant root anatomical features is a key factor in effective water and nutrient uptake. Existing techniques for phenotyping root anatomical traits are often based on manual or semi-automatic segmentation and annotation of microscopic images of root cross sections. In this article, we propose a fully automated tool, hereinafter referred to as RootAnalyzer, for efficiently extracting and analyzing anatomical traits from root-cross section images. Using a range of image processing techniques such as local thresholding and nearest neighbor identification, RootAnalyzer segments the plant root from the image’s background, classifies and characterizes the cortex, stele, endodermis and epidermis, and subsequently produces statistics about the morphological properties of the root cells and tissues. We use RootAnalyzer to analyze 15 images of wheat plants and one maize plant image and evaluate its performance against manually-obtained ground truth data. The comparison shows that RootAnalyzer can fully characterize most root tissue regions with over 90% accuracy. PMID:26398501

  9. Advanced Automated Solar Filament Detection and Characterization Code: Description, Performance, and Results

    NASA Astrophysics Data System (ADS)

    Bernasconi, P. N.; Rust, D. M.

    2004-12-01

    We have developed a code for automated detection and classification of solar filaments in full-disk H-alpha images that can contribute to Living With a Star science investigations and space weather forecasting. The program can reliably identify filaments, determine their chirality and other relevant parameters like the filaments area and their average orientation with respect to the equator, and is capable of tracking the day-by-day evolution of filaments while they travel across the visible disk. Detecting the filaments when they appear and tracking their evolution can provide not only early warnings of potentially hazardous conditions but also improve our understanding of solar filaments and their implications for space weather at 1 AU. The code was recently tested by analyzing daily H-alpha images taken at the Big Bear Solar Observatory during a period of four years (from mid 2000 until mid 2004). It identified and established the chirality of more than 5000 filaments without human intervention. We compared the results with the filament list manually compiled by Pevtsov et al. (2003) over the same period of time. The computer list matches the Pevtsov et al. list fairly well. The code results confirm the hemispherical chirality rule: dextral filaments predominate in the north and sinistral ones predominate in the south. The main difference between the two lists is that the code finds significantly more filaments without an identifiable chirality. This may be due to a tendency of human operators to be biased, thereby assigning a chirality in less clear cases, while the code is totally unbiased. We also have found evidence that filaments with definite chirality tend to be larger and last longer than the ones without a clear chirality signature. We will describe the major code characteristics and present and discuss the tests results.

  10. Advanced Automated Solar Filament Detection And Characterization Code: Description, Performance, And Results

    NASA Astrophysics Data System (ADS)

    Bernasconi, Pietro N.; Rust, David M.; Hakim, Daniel

    2005-05-01

    We present a code for automated detection, classification, and tracking of solar filaments in full-disk Hα images that can contribute to Living With a Star science investigations and space weather forecasting. The program can reliably identify filaments; determine their chirality and other relevant parameters like filament area, length, and average orientation with respect to the equator. It is also capable of tracking the day-by-day evolution of filaments while they travel across the visible disk. The code was tested by analyzing daily Hα images taken at the Big Bear Solar Observatory from mid-2000 until beginning of 2005. It identified and established the chirality of thousands of filaments without human intervention. We compared the results with a list of filament proprieties manually compiled by Pevtsov, Balasubramaniam and Rogers (2003) over the same period of time. The computer list matches Pevtsov's list with a 72% accuracy. The code results confirm the hemispheric chirality rule stating that dextral filaments predominate in the north and sinistral ones predominate in the south. The main difference between the two lists is that the code finds significantly more filaments without an identifiable chirality. This may be due to a tendency of human operators to be biased, thereby assigning a chirality in less clear cases, while the code is totally unbiased. We also have found evidence that filaments obeying the chirality rule tend to be larger and last longer than the ones that do not follow the hemispherical rule. Filaments adhering to the hemispheric rule also tend to be more tilted toward the equator between latitudes 10∘ and 30∘, than the ones that do not.

  11. An automated image-based tool for pupil plane characterization of EUVL tools

    NASA Astrophysics Data System (ADS)

    Levinson, Zac; Smith, Jack S.; Fenger, Germain; Smith, Bruce W.

    2016-03-01

    Pupil plane characterization will play a critical role in image process optimization for EUV lithography (EUVL), as it has for several lithography generations. In EUVL systems there is additional importance placed on understanding the ways that thermally-induced system drift affect pupil variation during operation. In-situ full pupil characterization is therefore essential for these tools. To this end we have developed Quick Inverse Pupil (QUIP)—a software suite developed for rapid characterization of pupil plane behavior based on images formed by that system. The software consists of three main components: 1) an image viewer, 2) the model builder, and 3) the wavefront analyzer. The image viewer analyzes CDSEM micrographs or actinic mask micrographs to measure either CDs or through-focus intensity volumes. The software is capable of rotation correction and image registration with subpixel accuracy. The second component pre-builds a model for a particular imaging system to enable rapid pupil characterization. Finally, the third component analyzes the results from the image viewer and uses the optional pre-built model for inverse solutions of pupil plane behavior. Both pupil amplitude and phase variation can be extracted using this software. Inverse solutions are obtained through a model based algorithm which is built on top of commercial rigorous full-vector simulation software.

  12. TOWARDS AN AUTOMATED TOOL FOR CHANNEL-NETWORK CHARACTERIZATIONS, MODELING, AND ASSESSMENT

    EPA Science Inventory

    Detailed characterization of channel networks for hydrologic and geomorphic models has traditionally been a difficult and expensive proposition, and lack of information has thus been a common limitation of modeling efforts. With the advent of datasets derived from high-resolutio...

  13. 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.

  14. Electroslag and electrogas welding

    NASA Technical Reports Server (NTRS)

    Campbell, H. C.

    1972-01-01

    These two new joining methods perform welding in the vertical position, and therein lies the secret of their impressive advantages in material handling, in weld preparation, in welding speed, in freedom from distortion, and in weld soundness. Once the work has been set in the proper vertical position for welding, no further plate handling is required. The molten filler metal is held in place by copper shoes or dams, and the weld is completed in one pass.

  15. Effect of Pre- and Post-weld Heat Treatments on Linear Friction Welded Ti-5553

    NASA Astrophysics Data System (ADS)

    Wanjara, Priti; Dalgaard, Elvi; Gholipour, Javad; Cao, Xinjin; Cuddy, Jonathan; Jonas, John J.

    2014-10-01

    Linear friction welding allows solid-state joining of near-beta ( β) titanium alloy Ti-5553 (Ti-5Al-5V-5Mo-3Cr). In the as-welded condition, the weld zone (WZ) exhibits β grain refinement and marked softening as compared with Ti-5553 in the solution heat treated and aged condition. The softening of the weldment is attributed to the depletion of the strengthening alpha ( α) phase in the WZ and the adjacent thermo-mechanically affected zone (TMAZ). Specifically, in near- β titanium alloys, the strength of the material mainly depends on the shape, size, distribution, and fraction of the primary α and other decomposition products of the β phase. Hence, a combination of pre- and post-weld heat treatments were applied to determine the conditions that allow mitigating the α phase depletion in the WZ and TMAZ of the welds. The mechanical response of the welded samples to the heat treatments was determined by performing microhardness measurements and tensile testing at room temperature with an automated 3D deformation measurement system. It was found that though the joint efficiency in the as-welded condition was high (96 pct), strain localization and failure occurred in the TMAZ. The application of post-weld solution heat treatment with aging was effective in restoring α, increasing the joint efficiency (97 to 99 pct) and inducing strain localization and failure in the parent material region.

  16. Automated Characterization of Spent Fuel through the Multi-Isotope Process (MIP) Monitor

    SciTech Connect

    Coble, Jamie B.; Orton, Christopher R.; Schwantes, Jon M.

    2012-07-31

    This research developed an algorithm for characterizing spent nuclear fuel (SNF) samples based on simulated gamma spectra. The gamma spectra for a variety of light water reactor fuels typical of those found in the United States were simulated. Fuel nuclide concentrations were simulated in ORIGEN-ARP for 1296 fuel samples with a variety of reactor designs, initial enrichments, burn ups, and cooling times. The results of the ORIGEN-ARP simulation were then input to SYNTH to simulate the gamma spectrum for each sample. These spectra were evaluated with partial least squares (PLS)-based multivariate analysis methods to characterize the fuel according to reactor type (pressurized or boiling water reactor), enrichment, burn up, and cooling time. Characterizing some of the features in series by using previously estimated features in the prediction greatly improves the performance. By first classifying the spent fuel reactor type and then using type-specific models, the prediction error for enrichment, burn up, and cooling time improved by a factor of two to four. For some features, the prediction was further improved by including additional information, such as including the predicted burn up in the estimation of cooling time. The optimal prediction flow was determined based on the simulated data. A PLS discriminate analysis model was developed which perfectly classified SNF reactor type. Burn up was predicted within 0.1% root mean squared percent error (RMSPE) and both cooling time and initial enrichment within approximately 2% RMSPE.

  17. Automated fuel pin loading system

    DOEpatents

    Christiansen, D.W.; Brown, W.F.; Steffen, J.M.

    An automated loading system for nuclear reactor fuel elements utilizes a gravity feed conveyor which permits individual fuel pins to roll along a constrained path perpendicular to their respective lengths. The individual lengths of fuel cladding are directed onto movable transports, where they are aligned coaxially with the axes of associated handling equipment at appropriate production stations. Each fuel pin can be be reciprocated axially and/or rotated about its axis as required during handling steps. The fuel pins are inerted as a batch prior to welding of end caps by one of two disclosed welding systems.

  18. Automated fuel pin loading system

    DOEpatents

    Christiansen, David W.; Brown, William F.; Steffen, Jim M.

    1985-01-01

    An automated loading system for nuclear reactor fuel elements utilizes a gravity feed conveyor which permits individual fuel pins to roll along a constrained path perpendicular to their respective lengths. The individual lengths of fuel cladding are directed onto movable transports, where they are aligned coaxially with the axes of associated handling equipment at appropriate production stations. Each fuel pin can be reciprocated axially and/or rotated about its axis as required during handling steps. The fuel pins are inserted as a batch prior to welding of end caps by one of two disclosed welding systems.

  19. Characterization of low alloy ferritic steel–Ni base alloy dissimilar metal weld interface by SPM techniques, SEM/EDS, TEM/EDS and SVET

    SciTech Connect

    Wang, Siyan; Ding, Jie; Ming, Hongliang; Zhang, Zhiming; Wang, Jianqiu

    2015-02-15

    The interface region of welded A508–Alloy 52 M is characterized by scanning probe microscope (SPM) techniques, scanning electron microscopy (SEM)/energy dispersive spectroscopy (EDS), transmission electron microscopy (TEM)/Energy Dispersive Spectroscopy (EDS) and scanning vibrate electrode technique (SVET). The regions along the welded A508–Alloy 52 M interface can be categorized into two types according to their different microstructures. In the type-I interface region, A508 and Alloy 52 M are separated by the fusion boundary, while in the type-II interface region, A508 and Alloy 52 M are separated by a martensite zone. A508, martensite zone and grain boundaries in Alloy 52 M are ferromagnetic while the Alloy 52 M matrix is paramagnetic. The Volta potentials measured by scanning Kelvin probe force microscopy (SKPFM) of A508, martensite zone and Alloy 52 M follow the order: V{sub 52} {sub M} > V{sub A508} > V{sub martensite}. The corrosion behavior of A508–Alloy 52 M interface region is galvanic corrosion, in which Alloy 52 M is cathode while A508 is anode. The martensite dissolves faster than Alloy 52 M, but slower than A508 in the test solution. - Highlights: • The A508–Alloy 52 M interface regions can be categorized into two types. • The chromium depleted region is observed along the Alloy 52 M grain boundary. • The Alloy 52 M grain boundaries which are close to the interface are ferromagnetic. • Martensite zone has lower Volta potential but higher corrosion resistance than A508.

  20. WELDING APPARATUS

    DOEpatents

    Correy, T.B.; DeWitt, D.E.; Nelson, I.V.

    1963-04-23

    This patent covers an arrangement for replacing air in a welding chamber with an inert gas. This operation usually is time-consuming because of the tendency of the inert gas to mix with the air being removed from the welding chamber. The chamber is open at the bottom and has at its top a cover and a porous plate a little below the cover. The inert gas is admitted to the chamber through two screened openings in the cover. On passing through the porous plate, the gas acts as a piston extending across the chamber and moving downwardly to expel the air through the lower open end of the chamber, with a minimum of mixing with the air being expelled. (AEC)

  1. WELDING PROCESS

    DOEpatents

    Zambrow, J.; Hausner, H.

    1957-09-24

    A method of joining metal parts for the preparation of relatively long, thin fuel element cores of uranium or alloys thereof for nuclear reactors is described. The process includes the steps of cleaning the surfaces to be jointed, placing the sunfaces together, and providing between and in contact with them, a layer of a compound in finely divided form that is decomposable to metal by heat. The fuel element members are then heated at the contact zone and maintained under pressure during the heating to decompose the compound to metal and sinter the members and reduced metal together producing a weld. The preferred class of decomposable compounds are the metal hydrides such as uranium hydride, which release hydrogen thus providing a reducing atmosphere in the vicinity of the welding operation.

  2. Vaccum Gas Tungsten Arc Welding, phase 1

    NASA Technical Reports Server (NTRS)

    Weeks, J. L.; Krotz, P. D.; Todd, D. T.; Liaw, Y. K.

    1995-01-01

    This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

  3. 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.

  4. Characterization of the genus Bifidobacterium by automated ribotyping and 16S rRNA gene sequences.

    PubMed

    Sakata, Shinji; Ryu, Chun Sun; Kitahara, Maki; Sakamoto, Mitsuo; Hayashi, Hidenori; Fukuyama, Masafumi; Benno, Yoshimi

    2006-01-01

    In order to characterize the genus Bifidobacterium, ribopatterns and approximately 500 bp (Escherichia coli positions 27 to 520) of 16S rRNA gene sequences of 28 type strains and 64 reference strains of the genus Bifidobacterium were determined. Ribopatterns obtained from Bifidobacterium strains were divided into nine clusters (clusters I-IX) with a similarity of 60%. Cluster V, containing 17 species, was further subdivided into 22 subclusters with a similarity of 90%. In the genus Bifidobacterium, four groups were shown according to Miyake et al.: (i) the Bifidobacterium longum infantis-longum-suis type group, (ii) the B. catenulatum-pseudocatenulatum group, (iii) the B. gallinarum-saeculare-pullorum group, and (iv) the B. coryneforme-indicum group, which showed higher than 97% similarity of the 16S rRNA gene sequences in each group. Using ribotyping analysis, unique ribopatterns were obtained from these species, and they could be separated by cluster analysis. Ribopatterns of six B. adolescentis strains were separated into different clusters, and also showed diversity in 16S rRNA gene sequences. B. adolescentis consisted of heterogeneous strains. The nine strains of B. pseudolongum subsp. pseudolongum were divided into five subclusters. Each type strain of B. pseudolongum subsp. pseudolongum and B. pseudolongum subsp. globosum and two intermediate groups, which were suggested by Yaeshima et al., consisted of individual clusters. B. animalis subsp. animalis and B. animalis subsp. lactis could not be separated by ribotyping using Eco RI. We conclude that ribotyping is able to provide another characteristic of Bifidobacterium strains in addition to 16S rRNA gene sequence phylogenetic analysis, and this information suggests that ribotyping analysis is a useful tool for the characterization of Bifidobacterium species in combination with other techniques for taxonomic characterization. PMID:16428867

  5. Automation of aggregate characterization using laser profiling and digital image analysis

    NASA Astrophysics Data System (ADS)

    Kim, Hyoungkwan

    2002-08-01

    Particle morphological properties such as size, shape, angularity, and texture are key properties that are frequently used to characterize aggregates. The characteristics of aggregates are crucial to the strength, durability, and serviceability of the structure in which they are used. Thus, it is important to select aggregates that have proper characteristics for each specific application. Use of improper aggregate can cause rapid deterioration or even failure of the structure. The current standard aggregate test methods are generally labor-intensive, time-consuming, and subject to human errors. Moreover, important properties of aggregates may not be captured by the standard methods due to a lack of an objective way of quantifying critical aggregate properties. Increased quality expectations of products along with recent technological advances in information technology are motivating new developments to provide fast and accurate aggregate characterization. The resulting information can enable a real time quality control of aggregate production as well as lead to better design and construction methods of portland cement concrete and hot mix asphalt. This dissertation presents a system to measure various morphological characteristics of construction aggregates effectively. Automatic measurement of various particle properties is of great interest because it has the potential to solve such problems in manual measurements as subjectivity, labor intensity, and slow speed. The main efforts of this research are placed on three-dimensional (3D) laser profiling, particle segmentation algorithms, particle measurement algorithms, and generalized particle descriptors. First, true 3D data of aggregate particles obtained by laser profiling are transformed into digital images. Second, a segmentation algorithm and a particle measurement algorithm are developed to separate particles and process each particle data individually with the aid of various kinds of digital image

  6. Automated characterization of cell shape changes during amoeboid motility by skeletonization

    PubMed Central

    2010-01-01

    Background The ability of a cell to change shape is crucial for the proper function of many cellular processes, including cell migration. One type of cell migration, referred to as amoeboid motility, involves alternating cycles of morphological expansion and retraction. Traditionally, this process has been characterized by a number of parameters providing global information about shape changes, which are insufficient to distinguish phenotypes based on local pseudopodial activities that typify amoeboid motility. Results We developed a method that automatically detects and characterizes pseudopodial behavior of cells. The method uses skeletonization, a technique from morphological image processing to reduce a shape into a series of connected lines. It involves a series of automatic algorithms including image segmentation, boundary smoothing, skeletonization and branch pruning, and takes into account the cell shape changes between successive frames to detect protrusion and retraction activities. In addition, the activities are clustered into different groups, each representing the protruding and retracting history of an individual pseudopod. Conclusions We illustrate the algorithms on movies of chemotaxing Dictyostelium cells and show that our method makes it possible to capture the spatial and temporal dynamics as well as the stochastic features of the pseudopodial behavior. Thus, the method provides a powerful tool for investigating amoeboid motility. PMID:20334652

  7. Colorization and Automated Segmentation of Human T2 MR Brain Images for Characterization of Soft Tissues

    PubMed Central

    Attique, Muhammad; Gilanie, Ghulam; Hafeez-Ullah; Mehmood, Malik S.; Naweed, Muhammad S.; Ikram, Masroor; Kamran, Javed A.; Vitkin, Alex

    2012-01-01

    Characterization of tissues like brain by using magnetic resonance (MR) images and colorization of the gray scale image has been reported in the literature, along with the advantages and drawbacks. Here, we present two independent methods; (i) a novel colorization method to underscore the variability in brain MR images, indicative of the underlying physical density of bio tissue, (ii) a segmentation method (both hard and soft segmentation) to characterize gray brain MR images. The segmented images are then transformed into color using the above-mentioned colorization method, yielding promising results for manual tracing. Our color transformation incorporates the voxel classification by matching the luminance of voxels of the source MR image and provided color image by measuring the distance between them. The segmentation method is based on single-phase clustering for 2D and 3D image segmentation with a new auto centroid selection method, which divides the image into three distinct regions (gray matter (GM), white matter (WM), and cerebrospinal fluid (CSF) using prior anatomical knowledge). Results have been successfully validated on human T2-weighted (T2) brain MR images. The proposed method can be potentially applied to gray-scale images from other imaging modalities, in bringing out additional diagnostic tissue information contained in the colorized image processing approach as described. PMID:22479421

  8. Weld pool phenomena

    SciTech Connect

    David, S.A.; Vitek, J.M.; Zacharia, T.; DebRoy, T.

    1994-09-01

    During welding, the composition, structure and properties of the welded structure are affected by the interaction of the heat source with the metal. The interaction affects the fluid flow, heat transfer and mass transfer in the weld pool, and the solidification behavior of the weld metal. In recent years, there has been a growing recognition of the importance of the weld pool transport processes and the solid state transformation reactions in determining the composition, structure and properties of the welded structure. The relation between the weld pool transport processes and the composition and structure is reviewed. Recent applications of various solidification theories to welding are examined to understand the special problems of weld metal solidification. The discussion is focussed on the important problems and issues related to weld pool transport phenomena and solidification. Resolution of these problems would be an important step towards a science based control of composition, structure and properties of the weld metal.

  9. Friction plug welding

    NASA Technical Reports Server (NTRS)

    Takeshita, Riki (Inventor); Hibbard, Terry L. (Inventor)

    2001-01-01

    Friction plug welding (FPW) usage is advantageous for friction stir welding (FSW) hole close-outs and weld repairs in 2195 Al--Cu--Li fusion or friction stir welds. Current fusion welding methods of Al--Cu--Li have produced welds containing varied defects. These areas are found by non-destructive examination both after welding and after proof testing. Current techniques for repairing typically small (<0.25) defects weaken the weldment, rely heavily on welders' skill, and are costly. Friction plug welding repairs increase strength, ductility and resistance to cracking over initial weld quality, without requiring much time or operator skill. Friction plug welding while pulling the plug is advantageous because all hardware for performing the weld can be placed on one side of the workpiece.

  10. Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur C., Jr.

    2008-01-01

    Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and promises to be an important welding process for any industries where welds of optimal quality are demanded. This article provides an introduction to the FSW process. The chief concern is the physical effect of the tool on the weld metal: how weld seam bonding takes place, what kind of weld structure is generated, potential problems, possible defects for example, and implications for process parameters and tool design. Weld properties are determined by structure, and the structure of friction stir welds is determined by the weld metal flow field in the vicinity of the weld tool. Metal flow in the vicinity of the weld tool is explained through a simple kinematic flow model that decomposes the flow field into three basic component flows: a uniform translation, a rotating solid cylinder, and a ring vortex encircling the tool. The flow components, superposed to construct the flow model, can be related to particular aspects of weld process parameters and tool design; they provide a bridge to an understanding of a complex-at-first-glance weld structure. Torques and forces are also discussed. Some simple mathematical models of structural aspects, torques, and forces are included.

  11. Total esterase activity in human saliva: Validation of an automated assay, characterization and behaviour after physical stress.

    PubMed

    Tecles, Fernando; Tvarijonaviciute, Asta; De Torre, Carlos; Carrillo, José M; Rubio, Mónica; García, Montserrat; Cugat, Ramón; Cerón, José J

    2016-07-01

    Although saliva has esterase activity, this activity has not been characterized or studied in individuals subjected to physical stress. The aim of this report was to develop and validate an automated spectrophotometric assay for total esterase activity measurement in human saliva, as well as to study the contribution of different enzymes on this activity and its behaviour under physical stress in healthy subjects. The assay used 4-nitrophenyl acetate as substrate and was precise, accurate and provided low limits of detection and quantification. Inhibition with diisopropylfluorophosphate showed that cholinesterase, carboxylesterase and cholesterol esterase contributions not represented more than 20% of total esterase. Addition of standards of lipase and albumin to saliva samples showed that both proteins significantly contributed to esterase activity only when equal or higher than 11.6 IU/L and 250 μg/mL, respectively. Western blot analyses showed absence of paraoxonase-1 and high amount of carbonic anhydrase-VI. The high affinity of purified carbonic anhydrase-VI for the substrate supported a major contribution of this enzyme. Total esterase activity and alpha-amylase was measured in saliva samples from 12 healthy male students before and after participation in an indoor football match. The activity significantly increased after match and positively correlated with salivary alpha-amylase. This method could be used as a biomarker of physical stress in humans, with carbonic anhydrase-VI being the esterase that contributed more to the activity of the assay. PMID:27045801

  12. The Bubble Box: Towards an Automated Visual Sensor for 3D Analysis and Characterization of Marine Gas Release Sites.

    PubMed

    Jordt, Anne; Zelenka, Claudius; von Deimling, Jens Schneider; Koch, Reinhard; Köser, Kevin

    2015-01-01

    Several acoustic and optical techniques have been used for characterizing natural and anthropogenic gas leaks (carbon dioxide, methane) from the ocean floor. Here, single-camera based methods for bubble stream observation have become an important tool, as they help estimating flux and bubble sizes under certain assumptions. However, they record only a projection of a bubble into the camera and therefore cannot capture the full 3D shape, which is particularly important for larger, non-spherical bubbles. The unknown distance of the bubble to the camera (making it appear larger or smaller than expected) as well as refraction at the camera interface introduce extra uncertainties. In this article, we introduce our wide baseline stereo-camera deep-sea sensor bubble box that overcomes these limitations, as it observes bubbles from two orthogonal directions using calibrated cameras. Besides the setup and the hardware of the system, we discuss appropriate calibration and the different automated processing steps deblurring, detection, tracking, and 3D fitting that are crucial to arrive at a 3D ellipsoidal shape and rise speed of each bubble. The obtained values for single bubbles can be aggregated into statistical bubble size distributions or fluxes for extrapolation based on diffusion and dissolution models and large scale acoustic surveys. We demonstrate and evaluate the wide baseline stereo measurement model using a controlled test setup with ground truth information. PMID:26690168

  13. The Bubble Box: Towards an Automated Visual Sensor for 3D Analysis and Characterization of Marine Gas Release Sites

    PubMed Central

    Jordt, Anne; Zelenka, Claudius; Schneider von Deimling, Jens; Koch, Reinhard; Köser, Kevin

    2015-01-01

    Several acoustic and optical techniques have been used for characterizing natural and anthropogenic gas leaks (carbon dioxide, methane) from the ocean floor. Here, single-camera based methods for bubble stream observation have become an important tool, as they help estimating flux and bubble sizes under certain assumptions. However, they record only a projection of a bubble into the camera and therefore cannot capture the full 3D shape, which is particularly important for larger, non-spherical bubbles. The unknown distance of the bubble to the camera (making it appear larger or smaller than expected) as well as refraction at the camera interface introduce extra uncertainties. In this article, we introduce our wide baseline stereo-camera deep-sea sensor bubble box that overcomes these limitations, as it observes bubbles from two orthogonal directions using calibrated cameras. Besides the setup and the hardware of the system, we discuss appropriate calibration and the different automated processing steps deblurring, detection, tracking, and 3D fitting that are crucial to arrive at a 3D ellipsoidal shape and rise speed of each bubble. The obtained values for single bubbles can be aggregated into statistical bubble size distributions or fluxes for extrapolation based on diffusion and dissolution models and large scale acoustic surveys. We demonstrate and evaluate the wide baseline stereo measurement model using a controlled test setup with ground truth information. PMID:26690168

  14. Fully automated measurement setup for non-destructive characterization of thermoelectric materials near room temperature.

    PubMed

    Schwyter, E S; Helbling, T; Glatz, W; Hierold, C

    2012-07-01

    A measurement setup is presented that allows for a complete and non-destructive material characterization of electrochemically deposited thermoelectric material. All electrical (Seebeck coefficient α, electrical conductivity σ), thermal (thermal conductivity λ), and thermoelectric (figure of merit ZT) material parameters are determined within a single measurement run. The setup is capable of characterizing individual electrochemically deposited Bi(2+x)Te(3-x) pillars of various size and thickness down to a few 10 μm, embedded in a polymer matrix with a maximum measurement area of 1 × 1 cm(2). The temperature range is limited to an application specific window near room temperature of 10 °C to 70 °C. A maximum thermal flux of 1 W/cm(2) can be applied to the device under test (DUT) by the Peltier element driven heat source and sink. The setup has a highly symmetric design and DUTs can be mounted and dismounted within few seconds. A novel in situ recalibration method for a simple, quick and more accurate calibration of all sensors has been developed. Thermal losses within the setup are analysed and are mathematically considered for each measurement. All random and systematic errors are encountered for by a MATLAB routine, calculating all the target parameters and their uncertainties. The setup provides a measurement accuracy of ±2.34 μV/K for α, ±810.16 S/m for σ, ±0.13 W/mK for λ, and ±0.0075 for ZT at a mean temperature of 42.5 °C for the specifically designed test samples with a pillar diameter of 696 μm and thickness of 134 μm, embedded in a polyethylene terephthalate polymer matrix. PMID:22852715

  15. Integrated automated nanomanipulation and real-time cellular surface imaging for mechanical properties characterization

    NASA Astrophysics Data System (ADS)

    Eslami, Sohrab; Zareian, Ramin; Jalili, Nader

    2012-10-01

    Surface microscopy of individual biological cells is essential for determining the patterns of cell migration to study the tumor formation or metastasis. This paper presents a correlated and effective theoretical and experimental technique to automatically address the biophysical and mechanical properties and acquire live images of biological cells which are of interest in studying cancer. In the theoretical part, a distributed-parameters model as the comprehensive representation of the microcantilever is presented along with a model of the contact force as a function of the indentation depth and mechanical properties of the biological sample. Analysis of the transfer function of the whole system in the frequency domain is carried out to characterize the stiffness and damping coefficients of the sample. In the experimental section, unlike the conventional atomic force microscope techniques basically using the laser for determining the deflection of microcantilever's tip, a piezoresistive microcantilever serving as a force sensor is implemented to produce the appropriate voltage and measure the deflection of the microcantilever. A micromanipulator robotic system is integrated with the MATLAB® and programmed in such a way to automatically control the microcantilever mounted on the tip of the micromanipulator to achieve the topography of biological samples including the human corneal cells. For this purpose, the human primary corneal fibroblasts are extracted and adhered on a sterilized culture dish and prepared to attain their topographical image. The proposed methodology herein allows an approach to obtain 2D quality images of cells being comparatively cost effective and extendable to obtain 3D images of individual cells. The characterized mechanical properties of the human corneal cell are furthermore established by comparing and validating the phase shift of the theoretical and experimental results of the frequency response.

  16. Laser beam welding non-ferrous metals. (Latest citations from METADEX). Published Search

    SciTech Connect

    Not Available

    1994-09-01

    The bibliography contains citations concerning techniques and the evaluation of laser beam welding of non-ferrous metals. Welding parameters, such as incident laser power and welding speed, are reviewed in relation to their characterization of weld microstructure. Weld examination techniques are cited, including macrophotography, light and electron microscopy, and microhardness profiling. (Contains a minimum of 170 citations and includes a subject term index and title list.)

  17. Automated wind load characterization of wind turbine structures by embedded model updating

    NASA Astrophysics Data System (ADS)

    Swartz, R. Andrew; Zimmerman, Andrew T.; Lynch, Jerome P.

    2010-04-01

    The continued development of renewable energy resources is for the nation to limit its carbon footprint and to enjoy independence in energy production. Key to that effort are reliable generators of renewable energy sources that are economically competitive with legacy sources. In the area of wind energy, a major contributor to the cost of implementation is large uncertainty regarding the condition of wind turbines in the field due to lack of information about loading, dynamic response, and fatigue life of the structure expended. Under favorable circumstances, this uncertainty leads to overly conservative designs and maintenance schedules. Under unfavorable circumstances, it leads to inadequate maintenance schedules, damage to electrical systems, or even structural failure. Low-cost wireless sensors can provide more certainty for stakeholders by measuring the dynamic response of the structure to loading, estimating the fatigue state of the structure, and extracting loading information from the structural response without the need of an upwind instrumentation tower. This study presents a method for using wireless sensor networks to estimate the spectral properties of a wind turbine tower loading based on its measured response and some rudimentary knowledge of its structure. Structural parameters are estimated via model-updating in the frequency domain to produce an identification of the system. The updated structural model and the measured output spectra are then used to estimate the input spectra. Laboratory results are presented indicating accurate load characterization.

  18. Automated nondestructive evaluation method for characterizing ceramic and metallic hot gas filters.

    SciTech Connect

    Ellingson, W. A.; Koehl, E. R.; Deemer, C.; Pastilla, P.; Wheeler, B.; Forster, G. A.

    2002-06-03

    In advanced coal-fired power generation, one technology under development to clean up hot gases before their use as fuel for gas turbines is rigid ceramic candle filters. These porous filters are typically 1.5 m long and 60 mm in diameter and are made of various ceramic materials, including clay-bonded SiC. The high costs of downtime in a large utility demands that nondestructive evaluation/characterization (NDE/C) methods be available. At shutdowns, data from such analysis are needed to decide which filters are still usable and which need to be replaced, and if possible, to estimate the remaining lifetimes. Thus our objective was to develop reliable low-cost NDE technology for these filters. Our approach was to develop NDE/C technology, referred to as acousto-ultrasonics (AU), for application to hot gas filters. Lamb waves generated by the AU method were analyzed to derive a stress wave factor (SWF). This technology was tested by comparing SWF data with the measured strength for a variety of rigid ceramic filters and was shown to work on iron-aluminide filters as well but no strength data have been obtained on the iron-aluminides at this time.

  19. 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.

  20. Initial Development in Joining of ODS Alloys Using Friction Stir Welding

    SciTech Connect

    Ren, Weiju; Feng, Zhili

    2007-08-01

    Solid-state welding of oxide-dispersion-strengthened (ODS) alloy MA956 sheets using friction stir welding (FSW) was investigated. Butt weld was successfully produced. The weld and base metals were characterized using optical microscopy, scanning electronic microscopy, transmission electronic microscopy, and energy dispersion x-ray spectrum. Microhardness mapping was also conducted over the weld region. Analyses indicate that the distribution of the strengthening oxides was preserved in the weld. Decrease in microhardness of the weld was observed but was insignificant. The preliminary results seem to confirm the envisioned feasibility of FSW application to ODS alloy joining. For application to Gen IV nuclear reactor heat exchanger, further investigation is suggested.

  1. Characterization of Low Temperature Ferrite/Austenite Transformations in the Heat Affected Zone of 2205 Duplex Stainless Steel Arc Welds

    SciTech Connect

    Palmer, T A; Elmer, J W; Babu, S S; Vitek, J M

    2003-08-20

    Spatially Resolved X-Ray Diffraction (SRXRD) has been used to identify a previously unobserved low temperature ferrite ({delta})/austenite({gamma}) phase transformation in the heat affected zone (HAZ) of 2205 Duplex Stainless Steel (DSS) welds. In this ''ferrite dip'' transformation, the ferrite transforms to austenite during heating to peak temperatures on the order of 750 C, and re-transforms to ferrite during cooling, resulting in a ferrite volume fraction equivalent to that in the base metal. Time Resolved X-Ray Diffraction (TRXRD) and laser dilatometry measurements during Gleeble{reg_sign} thermal simulations are performed in order to verify the existence of this low temperature phase transformation. Thermodynamic and kinetic models for phase transformations, including both local-equilibrium and para-equilibrium diffusion controlled growth, show that diffusion of substitutional alloying elements does not provide a reasonable explanation for the experimental observations. On the other hand, the diffusion of interstitial alloying elements may be rapid enough to explain this behavior. Based on both the experimental and modeling results, two mechanisms for the ''ferrite dip'' transformation, including the formation and decomposition of secondary austenite and an athermal martensitic-type transformation of ferrite to austenite, are considered.

  2. Weld-Bead Shaver

    NASA Technical Reports Server (NTRS)

    Guirguis, Kamal; Price, Daniel S.

    1990-01-01

    Hand-held power tool shaves excess metal from inside circumference of welded duct. Removes excess metal deposited by penetration of tungsten/inert-gas weld or by spatter from electron-beam weld. Produces smooth transition across joint. Easier to use and not prone to overshaving. Also cuts faster, removing 35 in. (89 cm) of weld bead per hour.

  3. Introduction to Welding.

    ERIC Educational Resources Information Center

    Fortney, Clarence; Gregory, Mike

    This curriculum guide provides six units of instruction on basic welding. Addressed in the individual units of instruction are the following topics: employment opportunities for welders, welding safety and first aid, welding tools and equipment, basic metals and metallurgy, basic math and measuring, and procedures for applying for a welding job.…

  4. Vacuum vapor deposition: A spinoff of space welding development

    NASA Technical Reports Server (NTRS)

    Poorman, R. M.

    1991-01-01

    A vapor deposition process has been defined through a spinoff effort of space welding development. In this development for welding in a space environment, a hollow electrode was used to add gas precisely at the welding arc. This provides gas for ionization which carries the welding arc current. During this welding development metal vapor coatings were observed. These coatings are unique in that they are produced by a new process. Some coatings produced and the potential of this new and innovative vapor deposition process are characterized. Advantages over prior art are discussed.

  5. Laser welding in space

    NASA Technical Reports Server (NTRS)

    Kaukler, W. F.; Workman, G. L.

    1991-01-01

    Autogenous welds in 304 stainless steel were performed by Nd-YAG laser heating in a simulated space environment. Simulation consists of welding on the NASA KC-135 aircraft to produce the microgravity and by containing the specimen in a vacuum chamber. Experimental results show that the microgravity welds are stronger, harder in the fusion zone, have deeper penetration and have a rougher surface rippling of the weld pool than one-g welds. To perform laser welding in space, a solar-pumped laser concept that significantly increases the laser conversion efficiency and makes welding viable despite the limited power availability of spacecraft is proposed.

  6. Automated liver lesion characterization using fast kVp switching dual energy computed tomography imaging

    NASA Astrophysics Data System (ADS)

    Santamaria-Pang, Alberto; Dutta, Sandeep; Makrogiannis, Sokratis; Hara, Amy; Pavlicek, William; Silva, Alvin; Thomsen, Brian; Robertson, Scott; Okerlund, Darin; Langan, David A.; Bhotika, Rahul

    2010-03-01

    Hypodense metastases are not always completely distinguishable from benign cysts in the liver using conventional Computed Tomography (CT) imaging, since the two lesion types present with overlapping intensity distributions due to similar composition as well as other factors including beam hardening and patient motion. This problem is extremely challenging for small lesions with diameter less than 1 cm. To accurately characterize such lesions, multiple follow-up CT scans or additional Positron Emission Tomography or Magnetic Resonance Imaging exam are often conducted, and in some cases a biopsy may be required after the initial CT finding. Gemstone Spectral Imaging (GSI) with fast kVp switching enables projection-based material decomposition, offering the opportunity to discriminate tissue types based on their energy-sensitive material attenuation and density. GSI can be used to obtain monochromatic images where beam hardening is reduced or eliminated and the images come inherently pre-registered due to the fast kVp switching acquisition. We present a supervised learning method for discriminating between cysts and hypodense liver metastases using these monochromatic images. Intensity-based statistical features extracted from voxels inside the lesion are used to train optimal linear and nonlinear classifiers. Our algorithm only requires a region of interest within the lesion in order to compute relevant features and perform classification, thus eliminating the need for an accurate segmentation of the lesion. We report classifier performance using M-fold cross-validation on a large lesion database with radiologist-provided lesion location and labels as the reference standard. Our results demonstrate that (a) classification using a single projection-based spectral CT image, i.e., a monochromatic image at a specified keV, outperforms classification using an image-based dual energy CT pair, i.e., low and high kVp images derived from the same fast kVp acquisition and (b

  7. Welding of transparent polymers using femtosecond laser

    NASA Astrophysics Data System (ADS)

    Roth, Gian-Luca; Rung, Stefan; Hellmann, Ralf

    2016-02-01

    Based on nonlinear absorption, we report on laser welding of cycloolefin copolymers without any additional absorption layer employing infrared femtosecond laser. To the best of our knowledge, this is the first report of ultrashort laser welding of this material class, revealing a remarkable high processing speed of 20 mm/s in a single pass mode. Using a 1028 nm laser having a pulse duration of 220 fs at a repetition rate of 571 kHz leads to a welding seam width between 38 and 137 μm, depending on the applied laser average power. The welded joint is characterized by a maximum shear strength of 40 MPa. The experimental results are compared to those reported for femtosecond laser welding of PMMA and to those published for using a Thulium fiber laser.

  8. Applying an intelligent and automated emissions measurement system to characterize the RF environment for supporting wireless technologies

    SciTech Connect

    Keebler, P. F.; Phipps, K. O.

    2006-07-01

    overview of wireless emissions sources, the need for EMC characterization of power and signal cables with exposure to wireless devices, and an intelligent and automated emissions measurement system. Such a system can be used in nuclear power plants to determine the spectral quality of the wireless band, the EMC characterization of power and signal cables, and if wireless technologies can be collocated in plants while reducing the risk of interference with I and C systems. (authors)

  9. Optical Welding Torch

    NASA Technical Reports Server (NTRS)

    Richardson, R. W.

    1987-01-01

    Gas/tungsten-arc welding torch supports electrode at center while enabling viewing of weld area along torch axis. Gas torch accommodates lens and optical fibers, all part of vision system for welding robot. Welding torch includes spoked structure in central bore of optical body. Structure supports welding electrode, carries electric current to it, and takes heat away from it. Spokes formed by drilling six holes 60 degrees apart around center line of torch.

  10. Advanced Welding Applications

    NASA Technical Reports Server (NTRS)

    Ding, Robert J.

    2010-01-01

    Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

  11. 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

  12. Signal Analysis of Gas Tungsten Arc Welds

    NASA Technical Reports Server (NTRS)

    Eagar, T. W.

    1985-01-01

    Gas tungsten arc welding is a process in which the input parameters such as current, voltage and travel speed, can be easily controlled and/or monitored. However, weld quality is not solely a function of these parameters. An adaptive method of observing weld quality is desired to improve weld quality assurance. The use of dynamic electrical properties of the welding arc as a weld quality monitor was studied. The electrical properties of the arc are characterized by the current voltage transfer function. The hardware and software necessary to collect the data at a maximum rate of 45 kHz and to allow the off-line processing of this data are tested. The optimum input current waveform is determined. Bead-on-plate welds to observe such characteristics of the weld as the fundamental frequency of the puddle are studied. Future work is planned to observe changes of the arc response with changes in joint geometry, base metal chemistry, and shielding gas composition are discussed.

  13. Effect of Scratches on Pinch Welds

    SciTech Connect

    Korinko, P

    2005-10-11

    Fill stems for tritium reservoirs have stringent scratch requirements such that any indications that appear to have depth are cause for rework or rejection. A scoping study was undertaken to evaluate the effect of scratches approximately 0.0015 to 0.002 inch deep on the fitness for service and bond quality. The stems were characterized using borescope before and after welding. The four stems were welded with near optimal weld parameters, proof tested, and examined metallographically. The stems were radiographed, proof tested, and examined metallographically. The scratches did not adversely affect (1) the weld integrity based on radiography, (2) the ability to withstand the proof pressure, and (3) the weld quality based on metallographic cross-sections. Based on these limited results at a nominal weld current, the weld process is very robust. It may be able to recover from manufacturing defects and inspection anomalies worse than those expected for typical fill stem manufacturing processes; additional testing specific to each application over a range of weld heats is needed to verify applicability of these results.

  14. 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.

  15. Study on Sensor Design Technique for Real-Time Robotic Welding Tracking System

    NASA Astrophysics Data System (ADS)

    Liu, C. J.; Li, Y. B.; Zhu, J. G.; Ye, S. H.

    2006-10-01

    Based on visual measurement techniques, the real-time robotic welding tracking system achieves real-time adjustment for robotic welding according to the position and shape changes of a workpiece. In system design, the sensor design technique is so important that its performance directly affects the precision and stability of the tracking system. Through initiative visual measurement technology, a camera unit for real-time sampling is built with multiple-strip structured light and a high-performance CMOS image sensor including 1.3 million pixels; to realize real-time data process and transmission, an image process unit is built with FPGA and DSP. Experiments show that the precision of this sensor reaches 0.3mm, and band rate comes up to 10Mbps, which effectively improves robot welding quality.With the development of advanced manufacturing technology, it becomes an inexorable trend to realize the automatic, flexible and intelligent welding product manufacture. With the advantage of interchangeability and reliability, robotic welding can boost productivity, improve work condition, stabilize and guarantee weld quality, and realize welding automation of the short run products [1]. At present, robotic welding has already become the application trend of automatic welding technology. Traditional welding robots are play-back ones, which cannot adapt environment and weld distortion. Especially in the more and more extensive arc-welding course, the deficiency and limitation of play-back welding technology becomes more prominent because of changeable welding condition. It becomes one of the key technology influencing the development of modern robotic welding technology to eliminate or decrease uncertain influence on quality of welding such as changing welding condition etc [2]. Based on visual measuring principle, this text adopts active visual measuring technology, cooperated with high-speed image process and transmission technology to structure a tracking sensor, to realize

  16. Microstructural Characterization of Internal Welding Defects and Their Effect on the Tensile Behavior of FSW Joints of AA2198 Al-Cu-Li Alloy

    NASA Astrophysics Data System (ADS)

    Le Jolu, Thomas; Morgeneyer, Thilo F.; Denquin, Anne; Sennour, Mohamed; Laurent, Anne; Besson, Jacques; Gourgues-Lorenzon, Anne-Françoise

    2014-11-01

    Internal features and defects such as joint line remnant, kissing bond, and those induced by an initial gap between the two parent sheets were investigated in AA2198-T851 friction stir welded joints. They were compared with the parent material and to defect-free welds obtained using a seamless sheet. The cross-weld tensile strength was reduced by the defects by less than 6 pct. The fracture elongation was not significantly affected in view of experimental scatter. Fracture location, however, changed from the thermomechanically affected zone (retreating side) to the defect in the weld nugget for the welds bearing a kissing bond and for some of the gap welds. The kissing bond was shown by EBSD to be an intergranular feature; it fractured under a normal engineering stress close to 260 MPa during an in situ SEM tensile test. Synchrotron tomography after interrupted tensile testing confirmed opening of the kissing bond. For an initial gap of 23 pct of the sheet thickness, intergranular fracture of copper-enriched or oxide-bearing grain boundaries close to the nugget root was evidenced. The stress and strain state of cross-weld specimens loaded under uniaxial tension was assessed using a 3D finite element, multi-material model, determined on the basis of experimental data obtained on the same specimens using digital image correlation.

  17. Microstructural Characterization of Internal Welding Defects and Their Effect on the Tensile Behavior of FSW Joints of AA2198 Al-Cu-Li Alloy

    NASA Astrophysics Data System (ADS)

    Le Jolu, Thomas; Morgeneyer, Thilo F.; Denquin, Anne; Sennour, Mohamed; Laurent, Anne; Besson, Jacques; Gourgues-Lorenzon, Anne-Françoise

    2014-09-01

    Internal features and defects such as joint line remnant, kissing bond, and those induced by an initial gap between the two parent sheets were investigated in AA2198-T851 friction stir welded joints. They were compared with the parent material and to defect-free welds obtained using a seamless sheet. The cross-weld tensile strength was reduced by the defects by less than 6 pct. The fracture elongation was not significantly affected in view of experimental scatter. Fracture location, however, changed from the thermomechanically affected zone (retreating side) to the defect in the weld nugget for the welds bearing a kissing bond and for some of the gap welds. The kissing bond was shown by EBSD to be an intergranular feature; it fractured under a normal engineering stress close to 260 MPa during an in situ SEM tensile test. Synchrotron tomography after interrupted tensile testing confirmed opening of the kissing bond. For an initial gap of 23 pct of the sheet thickness, intergranular fracture of copper-enriched or oxide-bearing grain boundaries close to the nugget root was evidenced. The stress and strain state of cross-weld specimens loaded under uniaxial tension was assessed using a 3D finite element, multi-material model, determined on the basis of experimental data obtained on the same specimens using digital image correlation.

  18. Microstructural and mechanical characterization of CO{sub 2} laser and gas tungsten arc welds of an Al-Li-Cu alloy 2195

    SciTech Connect

    Hou, K.H.; Baeslack, W.A. III; Szabo, A.

    1994-12-31

    Lithium-containing aluminum alloys offer an attractive combination of low density and high strength and stiffness and have been the focus of vigorous research for their promising aerospace applications. To achieve the full potential advantages in using these alloys, the integrity of welded joints, both n the fusion zone and the heat-affected zone, must be ensured. In the present study, Weldalite{sup TM} 049 (designated as alloy 2195) with nominal composition of Al-1.0Li-4.0Cu-0.4Mg0.4Ag-0.14Zr (wt%) was welded autogenously using the gas tungsten-arc (GTA) and CO{sub 2} laser beam (LB) welding processes. The average ultimate tensile strengths for as-welded, 160{degrees}C/16 h-aged, and 190{degrees}C/16 h-aged GTA welds were 296.4 MPa, 304.6 MPa, and 336.8 MPa, and corresponded to joint efficiencies of 61.4%, 48.1% and 56.0%, respectively. Porosity was found occasionally in the laser welds and slightly affected the performance of the aluminum weldments. For laser welds, average ultimate tensile strengths and corresponding joint efficiencies for a-welded, 160{degrees}C/16 h-aged, and 190{degrees}C/16 h-aged weldments were 293.2 MPa (60.8%) 305.9 MPa (48.3%), and 331.0 MPa (55.0%), respectively. Scanning electron fractography revealed that failure of the GTA and LB tensile specimens occurred either within the weld metal or along the fusion boundary. The latter was related to the existence of an equiaxed band along the fusion boundary.

  19. Television Monitoring System for Welding

    NASA Technical Reports Server (NTRS)

    Vallow, K.; Gordon, S.

    1986-01-01

    Welding process in visually inaccessible spots viewed and recorded. Television system enables monitoring of welding in visually inaccessible locations. System assists welding operations and provide video record, used for weld analysis and welder training.

  20. An Automated Method for the Optical Characterization of Dissolved Organic Matter in a Rapidly Suburbanizing Watershed, Southeastern New Hampshire

    NASA Astrophysics Data System (ADS)

    Gettel, G. M.; McDowell, W.; Pisani, O.

    2006-12-01

    Dissolved organic matter (DOM) is exported from watersheds to downstream ecosystems where it can contribute to eutrophication problems by enhancing microbial respiration and lowering oxygen levels. DOM quality affects microbial respiration; however, little is known about how watershed processes affect the quality of DOM export. In order to document temporal and spatial variability in DOM quality at the watershed scale, we are developing a method to automate the optical characterization of DOM in the Lamprey River watershed in southeastern New Hampshire. This method employs a refrigerated autosampler and column heater associated with a Shimadzu high-pressure liquid chromatograph (HPLC) with a photo-diode array (PDA) UV absorbance detector and an in-line Horiba Jobin Yvon Fluoromax 3 fluorometer capable of 3D excitation- emission scans (EEM). One advantage of this method is that the HPLC flow-through cell in the fluorometer reduces inner-filter effects due to its small volume. Furthermore, specific UV absorbance or SUVA can also be calculated because an in-line UV PDA is used. We found that a number of fluorescence indices are related to DOC, DON, or NO3 concentrations throughout the Lamprey River watershed. For example, Fluorescence Index (F.I.), an indicator of autochthonous sources of DOM, is positively correlated with nitrate and negatively correlated with DOC concentrations (R2=0.95; p<0.01; R2=0.86; p<0.05 respectively). The highest F.I. occurred in the highest-population density sub-basin with the highest nitrate concentrations, while the lowest F.I. occurred in the lowest-population density sub-basin with highest DOC concentrations. These results indicate that nitrate may increase within-stream generation of DOC at high- population sites while DOC from low-population, low-nitrate sites is predominately allochthonous. This allows DOM characterization to be performed in conjunction with weekly and monthly monitoring of many water quality parameters and to be

  1. Design and evaluation of a new automated method for the segmentation and characterization of masses on ultrasound images

    NASA Astrophysics Data System (ADS)

    Cui, Jing; Sahiner, Berkman; Chan, Heang-Ping; Nees, Alexis; Paramagul, Chintana; Hadjiiski, Lubomir M.; Zhou, Chuan; Shi, Jiazheng

    2008-03-01

    Segmentation of masses is the first step in most computer-aided diagnosis (CAD) systems for characterization of breast masses as malignant or benign. In this study, we designed an automated method for segmentation of masses on ultrasound (US) images. The method automatically estimated an initial contour based on a manually-identified point approximately at the mass center. A two-stage active contour (AC) method iteratively refined the initial contour and performed self-examination and correction on the segmentation result. To evaluate our method, we compared it with manual segmentation by an experienced radiologists (R1) on a data set of 226 US images containing biopsy-proven masses from 121 patients (44 malignant and 77 benign). Four performance measures were used to evaluate the segmentation accuracy; two measures were related to the overlap between the computer and radiologist segmentation, and two were related to the area difference between the two segmentation results. To compare the difference between the segmentation results by the computer and R1 to inter-observer variation, a second radiologist (R2) also manually segmented all masses. The two overlap measures between the segmentation results by the computer and R1 were 0.87+ 0.16 and 0.73+ 0.17 respectively, indicating a high agreement. However, the segmentation results between two radiologists were more consistent. To evaluate the effect of the segmentation method on classification accuracy, three feature spaces were formed by extracting texture, width-to-height, and posterior shadowing features using the computer segmentation, R1's manual segmentation, and R2's manual segmentation. A linear discriminant analysis classifier using stepwise feature selection was tested and trained by a leave-one-case-out method to characterize the masses as malignant or benign. For case-based classification, the area A z under the test receiver operating characteristic (ROC) curve was 0.90+/-0.03, 0.87+/-0.03 and 0

  2. 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.

  3. 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.

  4. Laser weld jig

    DOEpatents

    Van Blarigan, Peter; Haupt, David L.

    1982-01-01

    A system is provided for welding a workpiece (10, FIG. 1) along a predetermined weld line (12) that may be of irregular shape, which includes the step of forming a lip (32) on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members (34, 36). Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space (17) at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig (24) forming the lip, and with the jig constructed to detachably hold parts (22, 20) to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

  5. Welding and Weldability of Thorium-Doped Iridium Alloys

    SciTech Connect

    David, S.A.; Ohriner, E.K.; King, J.F.

    2000-03-12

    Ir-0.3%W alloys doped with thorium are currently used as post-impact containment material for radioactive fuel in thermoelectric generators that provide stable electrical power for a variety of outer planetary space exploration missions. Welding and weldability of a series of alloys was investigated using arc and laser welding processes. Some of these alloys are prone to severe hot-cracking during welding. Weldability of these alloys was characterized using Sigmajig weldability test. Hot-cracking is influenced to a great extent by the fusion zone microstructure and composition. Thorium content and welding atmosphere were found to be very critical. The weld cracking behavior in these alloys can be controlled by modifying the fusion zone microstructure. Fusion zone microstructure was found to be controlled by welding process, process parameters, and the weld pool shape.

  6. A residual stress study in similar and dissimilar welds

    DOE PAGESBeta

    Eisazadeh, Hamid; Goldak, John A.; Aidun, Daryush K.; Coules, Harry E.; Bunn, Jeffrey R; Achuthan, A.

    2016-04-01

    Residual strain distributions in similar and dissimilar welds were measured using neutron diffraction (ND) method. Then, using three strain components, three-dimensional stress states were calculated. The results were used to determine the effect of the martensitic phase transformation and material properties on residual stress (RS) distribution. It was observed that smaller longitudinal RS was induced in the low carbon steel side of dissimilar weld when compared to its similar weld. Also, it was found that the transverse RS near and within the weld zone (WZ) in dissimilar weld exhibited a distinctive trend, with tensile mode reaching the yield strength ofmore » the base metal (BM). In order to characterize the WZ in dissimilar weld, we deployed optical microscopy, hardness, and energy dispersive X-ray spectroscopy (EDAX). This study not only provides further insight into the RS state in similar and dissimilar welds; it also delivers important consequences of phase transformation in the latter case.« less

  7. Plastic welding techniques based on torsional and circular motion.

    PubMed

    Kising, J

    2001-05-01

    The torsion ultrasonic welding process and the frequency decoupled circular friction process at low frequencies deliver low particle production. In addition, the even, circular movement of the circular welding process over the whole seam area and the freely selectable frequency open up applications in the medical field that cannot be achieved, or can only be achieved with difficulty, by traditional welding processes. The processes are fast and can be process controlled to a fine degree with a facility to be integrated into automation lines. PMID:11521653

  8. Inspection apparatus for evaluating a partially completed weld

    DOEpatents

    Smartt, Herschel B.; Larsen, Eric D.; Johnson, Jonn A.

    2001-01-01

    An inspection apparatus for evaluating a partially completed weld is described and which is utilized in combination with an automated movable welder which moves across a supporting surface, and wherein the inspection apparatus includes a coupling member mounted on the welder; a frame member mounted on the coupling member; an ultrasonic sensor mounted on the frame member and disposed in ultrasonic sound transmitting relation relative to the partially completed weld; and a drive assembly for adjusting the position of the ultrasonic sensor relative to the partially completed weld.

  9. Shielding gas effect on weld characteristics in arc-augmented laser welding process of super austenitic stainless steel

    NASA Astrophysics Data System (ADS)

    Sathiya, P.; Kumar Mishra, Mahendra; Soundararajan, R.; Shanmugarajan, B.

    2013-02-01

    A series of hybrid welding (gas metal arc welding-CO2 laser beam welding) experiments were conducted on AISI 904L super austenitic stainless steel sheet of 5 mm thickness. A detailed study of CO2 Laser-GMAW hybrid welding experiments with different shielding gas mixtures (100% He, 50% He+50% Ar, 50%He+45% Ar+5% O2, and 45% He+45% Ar+10% N2) were carried out and the results are presented. The resultant welds were subjected to detailed mechanical and microstructural characterization. Hardness testing revealed that the hardness values in the fusion zone were higher than the base material irrespective of the parameters. Transverse tensile testing showed that the joint efficiency is 100% with all the shielding gas experimented. Impact energy values of the welds were also found to be higher than the base material and the fractrograph taken in scanning electron microscope (SEM) has shown that the welds exhibited dimple fracture similar to the base material.

  10. HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS

    SciTech Connect

    Tang, Wei; Chen, Gaoqiang; Chen, Jian; Yu, Xinghua; Frederick, David Alan; Feng, Zhili

    2015-01-01

    Reduced-activation ferritic/martensitic (RAFM) steels are an important class of structural materials for fusion reactor internals developed in recent years because of their improved irradiation resistance. However, they can suffer from welding induced property degradations. In this paper, a solid phase joining technology friction stir welding (FSW) was adopted to join a RAFM steel Eurofer 97 and different FSW parameters/heat input were chosen to produce welds. FSW response parameters, joint microstructures and microhardness were investigated to reveal relationships among welding heat input, weld structure characterization and mechanical properties. In general, FSW heat input results in high hardness inside the stir zone mostly due to a martensitic transformation. It is possible to produce friction stir welds similar to but not with exactly the same base metal hardness when using low power input because of other hardening mechanisms. Further, post weld heat treatment (PWHT) is a very effective way to reduce FSW stir zone hardness values.

  11. PDC IC WELD FAILURE EVALUATION AND RESOLUTION

    SciTech Connect

    Korinko, P.; Howard, S.; Maxwell, D.; Fiscus, J.

    2012-04-16

    During final preparations for start of the PDCF Inner Can (IC) qualification effort, welding was performed on an automated weld system known as the PICN. During the initial weld, using a pedigree canister and plug, a weld defect was observed. The defect resulted in a hole in the sidewall of the canister, and it was observed that the plug sidewall had not been consumed. This was a new type of failure not seen during development and production of legacy Bagless Transfer Cans (FB-Line/Hanford). Therefore, a team was assembled to determine the root cause and to determine if the process could be improved. After several brain storming sessions (MS and T, R and D Engineering, PDC Project), an evaluation matrix was established to direct this effort. The matrix identified numerous activities that could be taken and then prioritized those activities. This effort was limited by both time and resources (the number of canisters and plugs available for testing was limited). A discovery process was initiated to evaluate the Vendor's IC fabrication process relative to legacy processes. There were no significant findings, however, some information regarding forging/anneal processes could not be obtained. Evaluations were conducted to compare mechanical properties of the PDC canisters relative to the legacy canisters. Some differences were identified, but mechanical properties were determined to be consistent with legacy materials. A number of process changes were also evaluated. A heat treatment procedure was established that could reduce the magnetic characteristics to levels similar to the legacy materials. An in-situ arc annealing process was developed that resulted in improved weld characteristics for test articles. Also several tack welds configurations were addressed, it was found that increasing the number of tack welds (and changing the sequence) resulted in decreased can to plug gaps and a more stable weld for test articles. Incorporating all of the process improvements

  12. Fusion welding process

    DOEpatents

    Thomas, Kenneth C.; Jones, Eric D.; McBride, Marvin A.

    1983-01-01

    A process for the fusion welding of nickel alloy steel members wherein a ferrite containing pellet is inserted into a cavity in one member and melted by a welding torch. The resulting weld nugget, a fusion of the nickel containing alloy from the members to be welded and the pellet, has a composition which is sufficiently low in nickel content such that ferrite phases occur within the weld nugget, resulting in improved weld properties. The steel alloys encompassed also include alloys containing carbon and manganese, considered nickel equivalents.

  13. Characterization of Mg/Al butt joints welded by gas tungsten arc filling with Zn–29.5Al–0.5Ti filler metal

    SciTech Connect

    Liu, Fei; Wang, Hongyang; Liu, Liming

    2014-04-01

    The multivariate alloying design of a welding joint is used in the Mg to Al welding process. A Zn–29.5Al–0.5Ti alloy is added as filler metal in gas tungsten arc welding of Mg and Al alloy joint based on the analysis of Al and Mg alloy characteristics. The tensile strength, microstructure, and phase constitution of the weld seam are analyzed. The formation of brittle and hard Mg–Al intermetallic compounds is avoided because of the effects of Zn, Al, and Ti. The average tensile strength of the joint is 148 MPa. Al{sub 3}Ti is first precipitated and functions as the nucleus of heterogeneous nucleation during solidification. Moreover, the precipitated Al–MgZn{sub 2} hypoeutectic phase exhibited a feather-like structure, which enhances the property of the Mg–Al dissimilar joint. - Highlights: • Mg alloy AZ31B and Al alloy 6061 are butt welded by fusion welding. • The effect of Ti in filler metal is investigated. • The formation of Mg–Al intermetallic compounds is avoided.

  14. Automated waste canister docking and emplacement using a sensor-based intelligent controller; Yucca Mountain Site Characterization Project

    SciTech Connect

    Drotning, W.D.

    1992-08-01

    A sensor-based intelligent control system is described that utilizes a multiple degree-of-freedom robotic system for the automated remote manipulation and precision docking of large payloads such as waste canisters. Computer vision and ultrasonic proximity sensing are used to control the automated precision docking of a large object with a passive target cavity. Real-time sensor processing and model-based analysis are used to control payload position to a precision of {plus_minus} 0.5 millimeter.

  15. Welding in airplane construction

    NASA Technical Reports Server (NTRS)

    Rechtlich, A; Schrenk, M

    1928-01-01

    The present article attempts to explain the principles for the production of a perfect weld and to throw light on the unexplained problems. Moreover, it is intended to elucidate the possibilities of testing the strength and reliability of welded parts.

  16. 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.

  17. Welding-Current Indicator

    NASA Technical Reports Server (NTRS)

    Hensley, Milton C.; Huston, Steven W.; Kroy, Ralph E.

    1990-01-01

    Light flashes on to indicate high current. Simple, inexpensive display circuit indicates when 3,000-A welding current flows in welding gun. Onset of welding current induces voltage and current in 1,000-turn, 28-gauge copper-wire coil. Single-transistor amplifier amplifies induced current, energizing light-emitting diode (LED) connected to collector of transistor. Light from LED gives simple, direct indication of welding current.

  18. Infrared Thermography For Welding

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Lucky, Brian D.; Spiegel, Lyle B.; Hudyma, Russell M.

    1992-01-01

    Infrared imaging and image-data-processing system shows temperatures of joint during welding and provides data from which rates of heating and cooling determined. Information used to control welding parameters to ensure reliable joints, in materials which microstructures and associated metallurgical and mechanical properties depend strongly on rates of heating and cooling. Applicable to variety of processes, including tungsten/inert-gas welding; plasma, laser, and resistance welding; cutting; and brazing.

  19. Coil Welding Aid

    NASA Technical Reports Server (NTRS)

    Wiesenbach, W. T.; Clark, M. C.

    1983-01-01

    Positioner holds coil inside cylinder during tack welding. Welding aid spaces turns of coil inside cylinder and applies contact pressure while coil is tack-welded to cylinder. Device facilitates fabrication of heat exchangers and other structures by eliminating hand-positioning and clamping of individual coil turns.

  20. Instructional Guidelines. Welding.

    ERIC Educational Resources Information Center

    Fordyce, H. L.; Doshier, Dale

    Using the standards of the American Welding Society and the American Society of Mechanical Engineers, this welding instructional guidelines manual presents a course of study in accordance with the current practices in industry. Intended for use in welding programs now practiced within the Federal Prison System, the phases of the program are…

  1. Welding Course Curriculum.

    ERIC Educational Resources Information Center

    Genits, Joseph C.

    This guide is intended for use in helping students gain a fundamental background on the major aspects of the welding trade. The course emphasis is on mastery of the manipulative skills necessary to develop successful welding techniques and on acquisition of an understanding of the specialized tools and equipment used in welding. The first part…

  2. Penetration in GTA welding

    SciTech Connect

    Heiple, C.R.; Burgardt, P.

    1990-01-01

    The size and shape of the weld bead produced in GTA welding depends on the magnitude and distribution of the energy incident on the workpiece surfaces as well as the dissipation of that energy in the workpiece. The input energy is largely controllable through the welding parameters selected, however the dissipation of that energy in the workpiece is less subject to control. Changes in energy dissipation can produce large changes in weld shape or penetration. Heat transport away from the weld pool is almost entirely by conduction, but heat transport in the weld pool is more complicated. Heat conduction through the liquid is an important component, but heat transport by convection (mass transport) is often the dominant mechanism. Convective heat transport is directional and changes the weld pool shape from that produced by conduction alone. Surface tension gradients are often the dominant forces driving fluid flow in GTA weld pools. These gradients are sensitive functions of weld pool chemistry and the energy input distribution to the weld. Experimental and theoretical work conducted primarily in the past decade has greatly enhanced our understanding of weld pool fluid flow, the forces which drive it, and its effects on weld pool shape. This work is reviewed here. While less common, changes in energy dissipation through the unmelted portion of the workpiece can also affect fusion zone shape or penetration. These effects are also described. 41 refs., 9 figs.

  3. Portable Weld Tester.

    ERIC Educational Resources Information Center

    Eckert, Douglas

    This training manual, which was developed for employees of an automotive plant, is designed to teach trainees to operate a portable weld tester (Miyachi MM-315). In chapter 1, the weld tester's components are illustrated and described, and the procedure for charging its batteries is explained. Chapter 2 illustrates the weld tester's parts,…

  4. Diffusion welding tool

    NASA Technical Reports Server (NTRS)

    Milam, T. B.

    1973-01-01

    Tool allows flat plate diffusion welding to be done in standard brazing furnace. Weld is achieved using high water pressure applied by hand-operated positive-displacement pump. Good welds have been obtained between nickel and nickel-base alloy plates at temperature of 1200 K and water pressure of 13.8 million N/sq m.

  5. Active weld control

    NASA Technical Reports Server (NTRS)

    Powell, Bradley W.; Burroughs, Ivan A.

    1994-01-01

    Through the two phases of this contract, sensors for welding applications and parameter extraction algorithms have been developed. These sensors form the foundation of a weld control system which can provide action weld control through the monitoring of the weld pool and keyhole in a VPPA welding process. Systems of this type offer the potential of quality enhancement and cost reduction (minimization of rework on faulty welds) for high-integrity welding applications. Sensors for preweld and postweld inspection, weld pool monitoring, keyhole/weld wire entry monitoring, and seam tracking were developed. Algorithms for signal extraction were also developed and analyzed to determine their application to an adaptive weld control system. The following sections discuss findings for each of the three sensors developed under this contract: (1) weld profiling sensor; (2) weld pool sensor; and (3) stereo seam tracker/keyhole imaging sensor. Hardened versions of these sensors were designed and built under this contract. A control system, described later, was developed on a multiprocessing/multitasking operating system for maximum power and flexibility. Documentation for sensor mechanical and electrical design is also included as appendices in this report.

  6. 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.

  7. Friction stir welding joint of dissimilar materials between AZ31B magnesium and 6061 aluminum alloys: Microstructure studies and mechanical characterizations

    SciTech Connect

    Mohammadi, J.; Behnamian, Y.; Mostafaei, A.; Izadi, H.; Saeid, T.; Kokabi, A.H.; Gerlich, A.P.

    2015-03-15

    Friction stir welding is an efficient manufacturing method for joining dissimilar alloys, which can dramatically reduce grain sizes and offer high mechanical joint efficiency. Lap FSW joints between dissimilar AZ31B and Al 6061 alloy sheets were made at various tool rotation and travel speeds. Rotation and travel speeds varied between 560–1400 r/min and 16–40 mm/min respectively, where the ratio between these parameters was such that nearly constant pitch distances were applied during welding. X-ray diffraction pattern (XRD), optical microscopy images (OM), electron probe microanalysis (EPMA) and scanning electron microscopy equipped with an energy-dispersive X-ray spectroscopy (SEM-EDS) were used to investigate the microstructures of the joints welded. Intermetallic phases including Al{sub 12}Mg{sub 17} (γ) and Al{sub 3}Mg{sub 2} (β) were detected in the weld zone (WZ). For different tool rotation speeds, the morphology of the microstructure in the stir zone changed significantly with travel speed. Lap shear tensile test results indicated that by simultaneously increasing the tool rotation and travel speeds to 1400 r/min and 40 mm/min, the joint tensile strength and ductility reached a maximum. Microhardness measurements and tensile stress–strain curves indicated that mechanical properties were affected by FSW parameters and mainly depended on the formation of intermetallic compounds in the weld zone. In addition, a debonding failure mode in the Al/Mg dissimilar weld nugget was investigated by SEM and surface fracture studies indicated that the presence of intermetallic compounds in the weld zone controlled the failure mode. XRD analysis of the fracture surface indicated the presence of brittle intermetallic compounds including Al{sub 12}Mg{sub 17} (γ) and Al{sub 3}Mg{sub 2} (β). - Highlights: • Dissimilar Al/Mg joint was obtained by lap friction stir welding technique. • Effect of rotation and travel speeds on the formation of intermetallic

  8. Characterization of the tensile properties of friction stir welded aluminum alloy joints based on axial force, traverse speed, and rotational speed

    NASA Astrophysics Data System (ADS)

    Panda, Biranchi; Garg, A.; Jian, Zhang; Heidarzadeh, Akbar; Gao, Liang

    2016-06-01

    Friction stir welding (FSW) process has gained attention in recent years because of its advantages over the conventional fusion welding process. These advantages include the absence of heat formation in the affected zone and the absence of large distortion, porosity, oxidation, and cracking. Experimental investigations are necessary to understand the physical behavior that causes the high tensile strength of welded joints of different metals and alloys. Existing literature indicates that tensile properties exhibit strong dependence on the rotational speed, traverse speed, and axial force of the tool that was used. Therefore, this study introduces the experimental procedure for measuring tensile properties, namely, ultimate tensile strength (UTS) and tensile elongation of the welded AA 7020 Al alloy. Experimental findings suggest that a welded part with high UTS can be achieved at a lower heat input compared with the high heat input condition. A numerical approach based on genetic programming is employed to produce the functional relationships between tensile properties and the three inputs (rotational speed, traverse speed, and axial force) of the FSW process. The formulated models were validated based on the experimental data, using the statistical metrics. The effect of the three inputs on the tensile properties was investigated using 2D and 3D analyses. A high UTS was achieved, including a rotational speed of 1050 r/min and traverse speed of 95 mm/min. The results also indicate that 8 kN axial force should be set prior to the FSW process.

  9. Method for welding beryllium

    DOEpatents

    Dixon, Raymond D.; Smith, Frank M.; O'Leary, Richard F.

    1997-01-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon.

  10. Explosive welding of pipes

    NASA Astrophysics Data System (ADS)

    Drennov, O.; Burtseva, O.; Kitin, A.

    2006-08-01

    For connection by welding it is suggested to use the explosive welding method. This method is rather new. Nevertheless, it has become commonly used among the technological developments. This method can be advantageous (saving material and physical resources) comparing to its statical analogs (electron-beam welding, argon-arc welding, plasma welding, gas welding, etc.), in particular, in hard-to-reach areas due to their geographic and climatic conditions. The suggestion is to use water as filler. The principle of non-compressibility of liquid under quasi-dynamic loading is used. In one-dimensional gasdynamic and elastic-plastic calculations we determined non-deformed mass of water. Model experiments with pipes having radii R = 57 mm confirmed results of the calculations and the possibility in principle to weld pipes by explosion with use of water as filler.

  11. Optically controlled welding system

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1989-01-01

    An optically controlled welding system (10) wherein a welding torch (12) having through-the-torch viewing capabilities is provided with an optical beam splitter (56) to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder (15) to make the welding torch responsive thereto. Other features includes an actively cooled electrode holder (26) which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm (28) and a weld pool contour detector (14) comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom being characteristic of a penetrated or unpenetrated condition of the weld pool.

  12. Optically controlled welding system

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1988-01-01

    An optically controlled welding system wherein a welding torch having through-the-torch viewing capabilities is provided with an optical beam splitter to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder to make the welding torch responsive thereto. Other features include an actively cooled electrode holder which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm, and a weld pool contour detector comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom, being characteristic of a penetrated or unpenetrated condition of the weld pool.

  13. Capacitive sensor for high resolution weld seam tracking

    SciTech Connect

    Schmitt, D.J.; Novak, J.L.; Akins, J.L.

    1995-05-01

    A non-contact capacitive sensing system has been developed for guiding automated welding equipment along typical v-groove geometries. The Multi-Axis Seam Tracking (MAST) sensor has been designed to produce four electric fields for locating and measuring the v-groove geometry. In this system, the MAST sensor is coupled with a set of signal conditioning electronics making it possible to output four varying voltages proportional to the electric field perturbations. This output is used for motion control purposes by the automated welding platform to guide the weld torch directly over the center of the v-groove. This report discusses the development of this capacitive sensing system. A functional description of the system and MAST sensor response characteristics for typical weld v-groove geometries are provided. The effects of the harsh thermal and electrical noise environments of plasma arc welding on sensor performance are discussed. A comparison of MAST sensor fabrication from glass-epoxy and thick-film ceramic substrates is provided. Finally, results of v-groove tracking experiments on a robotic welding platform are described.

  14. 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.

  15. Robotic Welding Of Injector Manifold

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Shelley, D. Mark

    1992-01-01

    Brief report presents history, up through October 1990, of continuing efforts to convert from manual to robotic gas/tungsten arc welding in fabrication of main injector inlet manifold of main engine of Space Shuttle. Includes photographs of welding machinery, welds, and weld preparations. Of interest to engineers considering establishment of robotic-welding facilities.

  16. Aircraft landing dynamics facility carriage weld test program

    NASA Technical Reports Server (NTRS)

    Lawson, A. G.

    1984-01-01

    A welded tubular structure constructed of low alloy high strength quenched and tempered steel was tested. The consistency of the mechanical strengths and chemical composition and the degree of difficulty of obtaining full strength welds with these steels is characterized. The results of constructing and testing two typical connections which are used in the structure design are reported.

  17. Fusion welding studies using laser on Ti-SS dissimilar combination

    NASA Astrophysics Data System (ADS)

    Shanmugarajan, B.; Padmanabham, G.

    2012-11-01

    Laser welding investigations were carried out on dissimilar Ti-SS combination. The study is aimed to improve the weld strength and ductility by minimizing harmful intermetallics and taking advantage of high cooling rates in laser welding. Results of continuous wave 3.5 kW CO2 laser welding of totally dissimilar combination of Titanium and stainless steel (304) have been discussed. Bead on plate welding experiments were conducted to identify the laser welding parameters using depth of penetration as criteria. The welding of dissimilar combination has been attempted both autogenously and with interlayers such as Vanadium (V) and Tantalum (Ta) in the form of laser cladding as well as strip. Autogenous welds were carried out by varying the laser power, welding speed and position of the laser beam with respect to the joint centre. The resultant welds are characterized by macrostructure analysis, SEM/EDAX and XRD and as welded tensile test in UTM. The autogenous welds have exhibited extensive cracking even when welded at high speeds or by manipulating the beam position with respect to the joint. Similarly Vandaium as interlayer could not achieve crack free joint. A joint with 40 MPa strength could be made with Ta as interlayer. Results and analysis of these variants of laser welded joints are reported and discussed.

  18. Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

    NASA Astrophysics Data System (ADS)

    Vasantharaja, P.; Vasudevan, M.

    2012-02-01

    Low Activation Ferritic-Martensitic steels (LAFM) are chosen as the candidate material for structural components in fusion reactors. The structural components are generally fabricated by welding processes. Activated Tungsten Inert Gas (A-TIG) welding is an emerging process for welding of thicker components. In the present work, attempt was made to develop A-TIG welding technology for LAFM steel plates of 10 mm thick. Activated flux was developed for LAFM steel by carrying out various bead-on-plate TIG welds without flux and with flux. The optimum flux was identified as one which gave maximum depth of penetration at minimum heat input values. With the optimized flux composition, LAFM steel plate of 10 mm thickness was welded in square butt weld joint configuration using double side welding technique. Optical and Scanning Electron Microscopy was used for characterizing the microstructures. Microhardness measurements were made across the weld cross section for as welded and post weld heat treated samples. Tensile and impact toughness properties were determined. The mechanical properties values obtained in A-TIG weld joint were comparable to that obtained in weld joints of LAFM steel made by Electron beam welding process.

  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. Thermal Stir Welding Development at Marshall Space Flight Center

    NASA Technical Reports Server (NTRS)

    Ding, Robert J.

    2008-01-01

    Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

  1. Thermocapillary and arc phenomena in stainless steel welding

    SciTech Connect

    Pierce, S.W.; Olson, D.L.; Burgardt, P.

    1999-02-01

    This investigation characterized the effects of power level and Gaussian heat source size on thermocapillary-induced weld shape and estimated the relative influence of various possible arc phenomena in determining weld shape. Welds made with the CTAW process were compared with similar ones made with a conduction-mode EBW process and the differences were related to arc effects. Evidence of thermocapillary flow was readily apparent in both the GTA welds and the conduction-mode EB welds and was qualitatively similar in both. The similarity between the results obtained with the two processes serves to demonstrate that thermocapillary convection is the dominant factor in heat-to-heat weld shape variability. However, a similar one-to-one correspondence between welds produced with the two processes does not exist. Especially at high power, the EB welds showed stronger thermocapillary convection than the GTA welds. One important arc factor that limits thermocapillary flow in ar welds appears to be an increase in arc size with arc length and arc current. A non-Gaussian arc power distribution in GTAW seems to be most important in limiting the fluid flow. Apparently, the arc power distribution is more nearly rectangular in shape for an argon gas arc. At higher currents, above 200 A, plasma shear force may also be an important contributor to weld shape development. The conduction-mode EB welds demonstrate that thermocapillary flow reversal probably does not occur in welds made with a simple Gaussian heat source. The complex shape behavior is likely a result of an arc effect such as plasma shear.

  2. Welding arc plasma physics

    NASA Technical Reports Server (NTRS)

    Cain, Bruce L.

    1990-01-01

    The problems of weld quality control and weld process dependability continue to be relevant issues in modern metal welding technology. These become especially important for NASA missions which may require the assembly or repair of larger orbiting platforms using automatic welding techniques. To extend present welding technologies for such applications, NASA/MSFC's Materials and Processes Lab is developing physical models of the arc welding process with the goal of providing both a basis for improved design of weld control systems, and a better understanding of how arc welding variables influence final weld properties. The physics of the plasma arc discharge is reasonably well established in terms of transport processes occurring in the arc column itself, although recourse to sophisticated numerical treatments is normally required to obtain quantitative results. Unfortunately the rigor of these numerical computations often obscures the physics of the underlying model due to its inherent complexity. In contrast, this work has focused on a relatively simple physical model of the arc discharge to describe the gross features observed in welding arcs. Emphasis was placed of deriving analytic expressions for the voltage along the arc axis as a function of known or measurable arc parameters. The model retains the essential physics for a straight polarity, diffusion dominated free burning arc in argon, with major simplifications of collisionless sheaths and simple energy balances at the electrodes.

  3. Weld electrode cooling study

    NASA Astrophysics Data System (ADS)

    Masters, Robert C.; Simon, Daniel L.

    1999-03-01

    The U.S. auto/truck industry has been mandated by the Federal government to continuously improve their fleet average gas mileage, measured in miles per gallon. Several techniques are typically used to meet these mandates, one of which is to reduce the overall mass of cars and trucks. To help accomplish this goal, lighter weight sheet metal parts, with smaller weld flanges, have been designed and fabricated. This paper will examine the cooling characteristics of various water cooled weld electrodes and shanks used in resistance spot welding applications. The smaller weld flanges utilized in modern vehicle sheet metal fabrications have increased industry's interest in using one size of weld electrode (1/2 inch diameter) for certain spot welding operations. The welding community wants more data about the cooling characteristics of these 1/2 inch weld electrodes. To hep define the cooling characteristics, an infrared radiometer thermal vision system (TVS) was used to capture images (thermograms) of the heating and cooling cycles of several size combinations of weld electrodes under typical production conditions. Tests results will show why the open ended shanks are more suitable for cooling the weld electrode assembly then closed ended shanks.

  4. VPPA weld model evaluation

    NASA Technical Reports Server (NTRS)

    Mccutcheon, Kimble D.; Gordon, Stephen S.; Thompson, Paul A.

    1992-01-01

    NASA uses the Variable Polarity Plasma Arc Welding (VPPAW) process extensively for fabrication of Space Shuttle External Tanks. This welding process has been in use at NASA since the late 1970's but the physics of the process have never been satisfactorily modeled and understood. In an attempt to advance the level of understanding of VPPAW, Dr. Arthur C. Nunes, Jr., (NASA) has developed a mathematical model of the process. The work described in this report evaluated and used two versions (level-0 and level-1) of Dr. Nunes' model, and a model derived by the University of Alabama at Huntsville (UAH) from Dr. Nunes' level-1 model. Two series of VPPAW experiments were done, using over 400 different combinations of welding parameters. Observations were made of VPPAW process behavior as a function of specific welding parameter changes. Data from these weld experiments was used to evaluate and suggest improvements to Dr. Nunes' model. Experimental data and correlations with the model were used to develop a multi-variable control algorithm for use with a future VPPAW controller. This algorithm is designed to control weld widths (both on the crown and root of the weld) based upon the weld parameters, base metal properties, and real-time observation of the crown width. The algorithm exhibited accuracy comparable to that of the weld width measurements for both aluminum and mild steel welds.

  5. On the hot cracking susceptibility of a semisolid aluminium 6061 weld: Application of a coupled solidification- thermomechanical model

    NASA Astrophysics Data System (ADS)

    Zareie Rajani, H. R.; Phillion, A. B.

    2015-06-01

    A coupled solidification-thermomechanical model is presented that investigates the hot tearing susceptibility of an aluminium 6061 semisolid weld. Two key phenomena are considered: excessive deformation of the semisolid weld, initiating a hot tear, and the ability of the semisolid weld to heal the hot tear by circulation of the molten metal. The model consists of two major modules: weld solidification and thermomechanical analysis. 1) By means of a multi-scale model of solidification, the microstructural evolution of the semisolid weld is simulated in 3D. The semisolid structure, which varies as a function of welding parameters, is composed of solidifying grains and a network of micro liquid channels. The weld solidification module is utilized to obtain the solidification shrinkage. The size of the micro liquid channels is used as an indicator to assess the healing ability of the semisolid weld. 2) Using the finite element method, the mechanical interaction between the weld pool and the base metal is simulated to capture the transient force field deforming the semisolid weld. Thermomechanical stresses and shrinkage stresses are both considered in the analysis; the solidification contractions are extracted from the weld solidification module and applied to the deformation simulation as boundary conditions. Such an analysis enables characterization of the potential for excessive deformation of the weld. The outputs of the model are used to study the effect of welding parameters including welding current and speed, and also welding constraint on the hot cracking susceptibility of an aluminium alloy 6061 semisolid weld.

  6. A low-cost, multiplexable, automated flow cytometry procedure for the characterization of microbial stress dynamics in bioreactors

    PubMed Central

    2013-01-01

    Background Microbial cell population heterogeneity is now recognized as a major source of issues in the development and optimization of bioprocesses. Even if single cell technologies are available for the study of microbial population heterogeneity, only a few of these methods are available in order to study the dynamics of segregation directly in bioreactors. In this context, specific interfaces have been developed in order to connect a flow cytometer directly to a bioreactor for automated analyses. In this work, we propose a simplified version of such an interface and demonstrate its usefulness for multiplexed experiments. Results A low-cost automated flow cytometer has been used in order to monitor the synthesis of a destabilized Green Fluorescent Protein (GFP) under the regulation of the fis promoter and propidium iodide (PI) uptake. The results obtained showed that the dynamics of GFP synthesis are complex and can be attributed to a complex set of biological parameters, i.e. on the one hand the release of protein into the extracellular medium and its uptake modifying the activity of the fis promoter, and on the other hand the stability of the GFP molecule itself, which can be attributed to the protease content and energy status of the cells. In this respect, multiplexed experiments have shown a correlation between heat shock and ATP content and the stability of the reporter molecule. Conclusion This work demonstrates that a simplified version of on-line FC can be used at the process level or in a multiplexed version to investigate the dynamics of complex physiological mechanisms. In this respect, the determination of new on-line parameters derived from automated FC is of primary importance in order to fully integrate the power of FC in dedicated feedback control loops. PMID:24176169

  7. MannDB – A microbial database of automated protein sequence analyses and evidence integration for protein characterization

    PubMed Central

    Zhou, Carol L Ecale; Lam, Marisa W; Smith, Jason R; Zemla, Adam T; Dyer, Matthew D; Kuczmarski, Thomas A; Vitalis, Elizabeth A; Slezak, Thomas R

    2006-01-01

    Background MannDB was created to meet a need for rapid, comprehensive automated protein sequence analyses to support selection of proteins suitable as targets for driving the development of reagents for pathogen or protein toxin detection. Because a large number of open-source tools were needed, it was necessary to produce a software system to scale the computations for whole-proteome analysis. Thus, we built a fully automated system for executing software tools and for storage, integration, and display of automated protein sequence analysis and annotation data. Description MannDB is a relational database that organizes data resulting from fully automated, high-throughput protein-sequence analyses using open-source tools. Types of analyses provided include predictions of cleavage, chemical properties, classification, features, functional assignment, post-translational modifications, motifs, antigenicity, and secondary structure. Proteomes (lists of hypothetical and known proteins) are downloaded and parsed from Genbank and then inserted into MannDB, and annotations from SwissProt are downloaded when identifiers are found in the Genbank entry or when identical sequences are identified. Currently 36 open-source tools are run against MannDB protein sequences either on local systems or by means of batch submission to external servers. In addition, BLAST against protein entries in MvirDB, our database of microbial virulence factors, is performed. A web client browser enables viewing of computational results and downloaded annotations, and a query tool enables structured and free-text search capabilities. When available, links to external databases, including MvirDB, are provided. MannDB contains whole-proteome analyses for at least one representative organism from each category of biological threat organism listed by APHIS, CDC, HHS, NIAID, USDA, USFDA, and WHO. Conclusion MannDB comprises a large number of genomes and comprehensive protein sequence analyses

  8. Cleaning Internal-Weld Splatter

    NASA Technical Reports Server (NTRS)

    Snodgrass, R.

    1982-01-01

    Splattered metal produced by welding can be easily removed from inaccessible areas by method resembling ball milling. Hard steel balls are vibrated inside welded unit so that they "scrub away" excess metal on interior side of weld joint.

  9. Welding and joining: A compilation

    NASA Technical Reports Server (NTRS)

    1975-01-01

    A compilation is presented of NASA-developed technology in welding and joining. Topics discussed include welding equipment, techniques in welding, general bonding, joining techniques, and clamps and holding fixtures.

  10. Computerized adaptive control weld skate with CCTV weld guidance project

    NASA Technical Reports Server (NTRS)

    Wall, W. A.

    1976-01-01

    This report summarizes progress of the automatic computerized weld skate development portion of the Computerized Weld Skate with Closed Circuit Television (CCTV) Arc Guidance Project. The main goal of the project is to develop an automatic welding skate demonstration model equipped with CCTV weld guidance. The three main goals of the overall project are to: (1) develop a demonstration model computerized weld skate system, (2) develop a demonstration model automatic CCTV guidance system, and (3) integrate the two systems into a demonstration model of computerized weld skate with CCTV weld guidance for welding contoured parts.

  11. EVALUATION OF CONSTANT CURRENT WELD CONTROL FOR PINCH WELDING

    SciTech Connect

    Korinko, P; STANLEY, S; HOWARD, H

    2005-10-11

    Modern weld controllers typically use current to control the weld process. SRS uses a legacy voltage control method. This task was undertaken to determine if the improvements in the weld control equipment could be implemented to provide improvements to the process control. The constant current mode of operation will reduce weld variability by about a factor of 4. The constant voltage welds were slightly hotter than the constant current welds of the same nominal current. The control mode did not appear to adversely affect the weld quality, but appropriate current ranges need to be established and a qualification methodology for both welding and shunt calibrations needs to be developed and documented.

  12. Laser Peening of Alloy 22 Welds

    SciTech Connect

    Stevens, D W; Hackel, L A; Lingenfelter, A C

    2002-10-03

    Stress corrosion cracking (SCC) of near-surface Alloy 22 metal can be propagated by yield-point levels (45 ksi) of residual weld tensile stresses. This is a serious concern for welds in the Alloy 22 canister employed in the Yucca Mountain Project (YMP) Waste Package, particularly in closure welds that cannot be stress relieved by conventional heat treating. This work shows that compressive shock waves, driven into a weldment by laser peening, replaces its detrimental tensile stresses of 30-80 ksi with compressive stresses of 2-25 ksi or better that retard SCC. This benefit occurs in the top 1.5 mm (or more) of the material without appreciable heating. It was also found that quenching after solution annealing and shot peening during production of Alloy 22 plate imparts compressive stresses of 35-105 ksi near the surface, a very large buffer against SCC. This means that if seam-welded hollow canisters likewise gain compressive stresses upon post-weld annealing and quenching, and if closure welds are laser peened, all surfaces of the canister would be under compression, thereby precluding SCC of the Alloy 22 canister. Laser peening may plastically deform as much as the top 10% of the metal (about 2 mm out of the 25-mm plate thickness), thereby changing the rate of general corrosion of waste package outer barrier. Long-term corrosion tests of laser peened Alloy 22 welds should be conducted. Present results show that laser peening, currently under development at LLNL using high-energy lasers, induces compressive residual stress on the near surface of the weld. This laser peening process is showing significant retardation of SCC and should be further characterized and assessed to preclude SCC in Alloy 22 canisters.

  13. Ultrasonic Stir Welding

    NASA Technical Reports Server (NTRS)

    Nabors, Sammy

    2015-01-01

    NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.

  14. Welding in Space Workshop

    NASA Technical Reports Server (NTRS)

    Workman, Gary L.

    1990-01-01

    The potential was discussed for welding in space, its advantages and disadvantages, and what type of programs can benefit from the capability. Review of the various presentations and comments made in the course of the workshop suggests several routes to obtaining a better understanding of how welding processes can be used in NASA's initiatives in space. They are as follows: (1) development of a document identifying well processes and equipment requirements applicable to space and lunar environments; (2) more demonstrations of welding particular hardware which are to be used in the above environments, especially for space repair operations; (3) increased awareness among contractors responsible for building space equipment as to the potential for welding operations in space and on other planetary bodies; and (4) continuation of space welding research projects is important to maintain awareness within NASA that welding in space is viable and beneficial.

  15. The effect of laser pulse tailored welding of Inconel 718

    NASA Technical Reports Server (NTRS)

    Mccay, T. Dwayne; Mccay, Mary Helen; Sharp, C. Michael; Womack, Michael G.

    1990-01-01

    Pulse tailored laser welding has been applied to wrought, wrought grain grown, and cast Inconel 718 using a CO2 laser. Prior to welding, the material was characterized metallographically and the solid state transformation regions were identified using Differential Scanning Calorimetry and high temperature x-ray diffraction. Bead on plate welds (restrained and unrestrained) were then produced using a matrix of pulse duty cycles and pulsed average power. Subsequent characterization included heat affected zone width, penetration and underbead width, the presence of cracks, microfissures and porosity, fusion zone curvature, and precipitation and liquated region width. Pedigree welding on three selected processing conditions was shown by microstructural and dye penetrant analysis to produce no microfissures, a result which strongly indicates the viability of pulse tailored welding for microfissure free IN 718.

  16. WELDED JACKETED URANIUM BODY

    DOEpatents

    Gurinsky, D.H.

    1958-08-26

    A fuel element is presented for a neutronic reactor and is comprised of a uranium body, a non-fissionable jacket surrounding sald body, thu jacket including a portion sealed by a weld, and an inclusion in said sealed jacket at said weld of a fiux having a low neutron capture cross-section. The flux is provided by combining chlorine gas and hydrogen in the intense heat of-the arc, in a "Heliarc" welding muthod, to form dry hydrochloric acid gas.

  17. Development and characterization of a novel plug and play liquid chromatography-mass spectrometry (LC-MS) source that automates connections between the capillary trap, column, and emitter.

    PubMed

    Bereman, Michael S; Hsieh, Edward J; Corso, Thomas N; Van Pelt, Colleen K; Maccoss, Michael J

    2013-06-01

    We report the development and characterization of a novel, vendor-neutral ultra-high pressure-compatible (~10,000 p.s.i.) LC-MS source. This device is the first to make automated connections with user-packed capillary traps, columns, and capillary emitters. The source uses plastic rectangular inserts (referred to here as cartridges) where individual components (i.e. trap, column, or emitter) can be exchanged independent of one another in a plug and play manner. Automated robotic connections are made between the three cartridges using linear translation powered by stepper motors to axially compress each cartridge by applying a well controlled constant compression force to each commercial LC fitting. The user has the versatility to tailor the separation (e.g. the length of the column, type of stationary phase, and mode of separation) to the experimental design of interest in a cost-effective manner. The source is described in detail, and several experiments are performed to evaluate the robustness of both the system and the exchange of the individual trap and emitter cartridges. The standard deviation in the retention time of four targeted peptides from a standard digest interlaced with a soluble Caenorhabditis elegans lysate ranged between 3.1 and 5.3 s over 3 days of analyses. Exchange of the emitter cartridge was found to have an insignificant effect on the abundance of various peptides. In addition, the trap cartridge can be replaced with minimal effects on retention time (<20 s). PMID:23422586

  18. Adaption of a fragment analysis technique to an automated high-throughput multicapillary electrophoresis device for the precise qualitative and quantitative characterization of microbial communities.

    PubMed

    Trotha, René; Reichl, Udo; Thies, Frank L; Sperling, Danuta; König, Wolfgang; König, Brigitte

    2002-04-01

    The analysis of microbial communities is of increasing importance in life sciences and bioengineering. Traditional techniques of investigations like culture or cloning methods suffer from many disadvantages. They are unable to give a complete qualitative and quantitative view of the total amount of microorganisms themselves, their interactions among each other and with their environment. Obviously, the determination of static or dynamic balances among microorganisms is of fast growing interest. The generation of species specific and fluorescently labeled 16S ribosomal DNA (rDNA) fragments by the terminal restriction fragment length polymorphism (T-RFLP) technique is a suitable tool to overcome the problems other methods have. For the separation of these fragments polyacrylamide gel sequencers are preferred as compared to capillary sequencers using linear polymers until now because of their higher electrophoretic resolution and therefore sizing accuracy. But modern capillary sequencers, especially multicapillary sequencers, offer an advanced grade of automation and an increased throughput necessary for the investigation of complex communities in long-time studies. Therefore, we adapted a T-RFLP technique to an automated high-throughput multicapillary electrophoresis device (ABI 3100 Genetic Analysis) with regard to a precise qualitative and quantitative characterization of microbial communities. PMID:11981854

  19. Development and Characterization of a Novel Plug and Play Liquid Chromatography-Mass Spectrometry (LC-MS) Source That Automates Connections between the Capillary Trap, Column, and Emitter*

    PubMed Central

    Bereman, Michael S.; Hsieh, Edward J.; Corso, Thomas N.; Van Pelt, Colleen K.; MacCoss, Michael J.

    2013-01-01

    We report the development and characterization of a novel, vendor-neutral ultra-high pressure-compatible (∼10,000 p.s.i.) LC-MS source. This device is the first to make automated connections with user-packed capillary traps, columns, and capillary emitters. The source uses plastic rectangular inserts (referred to here as cartridges) where individual components (i.e. trap, column, or emitter) can be exchanged independent of one another in a plug and play manner. Automated robotic connections are made between the three cartridges using linear translation powered by stepper motors to axially compress each cartridge by applying a well controlled constant compression force to each commercial LC fitting. The user has the versatility to tailor the separation (e.g. the length of the column, type of stationary phase, and mode of separation) to the experimental design of interest in a cost-effective manner. The source is described in detail, and several experiments are performed to evaluate the robustness of both the system and the exchange of the individual trap and emitter cartridges. The standard deviation in the retention time of four targeted peptides from a standard digest interlaced with a soluble Caenorhabditis elegans lysate ranged between 3.1 and 5.3 s over 3 days of analyses. Exchange of the emitter cartridge was found to have an insignificant effect on the abundance of various peptides. In addition, the trap cartridge can be replaced with minimal effects on retention time (<20 s). PMID:23422586

  20. Dual wire welding torch and method

    DOEpatents

    Diez, Fernando Martinez; Stump, Kevin S.; Ludewig, Howard W.; Kilty, Alan L.; Robinson, Matthew M.; Egland, Keith M.

    2009-04-28

    A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

  1. An intelligent approach to welding robot selection

    NASA Astrophysics Data System (ADS)

    Milano, J.; Mauk, S. D.; Flitter, L.; Morris, R.

    1993-10-01

    In a shipyard where multiple stationary and mobile workcells are employed in the fabrication of components of complex sub-assemblies,efficient operation requires an intelligent method of scheduling jobs and selecting workcells based on optimum throughput and cost. The achievement of this global solution requires the successful organization of resource availability,process requirements,and process constraints. The Off-line Planner (OLP) of the Programmable Automated Weld Systemd (PAWS) is capable of advanced modeling of weld processes and environments as well as the generation of complete weld procedures. These capabilities involve the integration of advanced Computer Aided Design (CAD), path planning, and obstacle detection and avoidance techniques as well as the synthesis of complex design and process information. These existing capabilities provide the basis of the functionality required for the successful implementation of an intelligent weld robot selector and material flow planner. Current efforts are focused on robot selection via the dynamic routing of components to the appropriate work cells. It is proposed that this problem is a variant of the “Traveling Salesman Problem” (TSP) that has been proven to belong to a larger set of optimization problems termed nondeterministic polynomial complete (NP complete). In this paper, a heuristic approach utilizing recurrent neural networks is explored as a rapid means of producing a near optimal, if not optimal, bdweld robot selection.

  2. IR Spot Weld Inspect

    SciTech Connect

    Chen, Jian; Feng, Zhili

    2014-01-01

    In automotive industry, destructive inspection of spot welds is still the mandatory quality assurance method due to the lack of efficient non-destructive evaluation (NDE) tools. However, it is costly and time-consuming. Recently at ORNL, a new NDE prototype system for spot weld inspection using infrared (IR) thermography has been developed to address this problem. This software contains all the key functions that ensure the NDE system to work properly: system input/output control, image acquisition, data analysis, weld quality database generation and weld quality prediction, etc.

  3. Robot welding process control

    NASA Technical Reports Server (NTRS)

    Romine, Peter L.

    1991-01-01

    This final report documents the development and installation of software and hardware for Robotic Welding Process Control. Primary emphasis is on serial communications between the CYRO 750 robotic welder, Heurikon minicomputer running Hunter & Ready VRTX, and an IBM PC/AT, for offline programming and control and closed-loop welding control. The requirements for completion of the implementation of the Rocketdyne weld tracking control are discussed. The procedure for downloading programs from the Intergraph, over the network, is discussed. Conclusions are made on the results of this task, and recommendations are made for efficient implementation of communications, weld process control development, and advanced process control procedures using the Heurikon.

  4. IR Spot Weld Inspect

    Energy Science and Technology Software Center (ESTSC)

    2014-01-01

    In automotive industry, destructive inspection of spot welds is still the mandatory quality assurance method due to the lack of efficient non-destructive evaluation (NDE) tools. However, it is costly and time-consuming. Recently at ORNL, a new NDE prototype system for spot weld inspection using infrared (IR) thermography has been developed to address this problem. This software contains all the key functions that ensure the NDE system to work properly: system input/output control, image acquisition, datamore » analysis, weld quality database generation and weld quality prediction, etc.« less

  5. Physics of Fusion Welding

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.

    1986-01-01

    Applicabilities and limitations of three techniques analyzed. NASA technical memorandum discusses physics of electron-beam, gas/ tungsten-arc, and laser-beam welding. From comparison of capabilities and limitations of each technique with regard to various welding conditions and materials, possible to develop criteria for selecting best welding technique in specific application. All three techniques classified as fusion welding; small volume of workpiece melted by intense heat source. Heat source moved along seam, leaving in wake solid metal that joins seam edges together.

  6. Electric arc welding gun

    DOEpatents

    Luttrell, Edward; Turner, Paul W.

    1978-01-01

    This invention relates to improved apparatus for arc welding an interior joint formed by intersecting tubular members. As an example, the invention is well suited for applications where many similar small-diameter vertical lines are to be welded to a long horizontal header. The improved apparatus includes an arc welding gun having a specially designed welding head which is not only very compact but also produces welds that are essentially free from rolled-over solidified metal. The welding head consists of the upper end of the barrel and a reversely extending electrode holder, or tip, which defines an acute angle with the barrel. As used in the above-mentioned example, the gun is positioned to extend upwardly through the vertical member and the joint to be welded, with its welding head disposed within the horizontal header. Depending on the design of the welding head, the barrel then is either rotated or revolved about the axis of the vertical member to cause the electrode to track the joint.

  7. Explosive Welding of Pipes

    NASA Astrophysics Data System (ADS)

    Drennov, Oleg; Drennov, Andrey; Burtseva, Olga

    2013-06-01

    For connection by welding it is suggested to use the explosive welding method. This method is rather new. Nevertheless, it has become commonly used among the technological developments. This method can be advantageous (saving material and physical resources) comparing to its statical analogs (electron-beam welding, argon-arc welding, plasma welding, gas welding, etc.), in particular, in hard-to-reach areas due to their geographic and climatic conditions. Explosive welding of cylindrical surfaces is performed by launching of welded layer along longitudinal axis of construction. During this procedure, it is required to provide reliable resistance against radial convergent strains. The traditional method is application of fillers of pipe cavity, which are dense cylindrical objects having special designs. However, when connecting pipes consecutively in pipelines by explosive welding, removal of the fillers becomes difficult and sometimes impossible. The suggestion is to use water as filler. The principle of non-compressibility of liquid under quasi-dynamic loading is used. In one-dimensional gasdynamic and elastic-plastic calculations we determined non-deformed mass of water (perturbations, which are moving in the axial direction with sound velocity, should not reach the layer end boundaries for 5-7 circulations of shock waves in the radial direction). Linear dimension of the water layer from the zone of pipe coupling along axis in each direction is >= 2R, where R is the internal radius of pipe.

  8. 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.

  9. Automation or De-automation

    NASA Astrophysics Data System (ADS)

    Gorlach, Igor; Wessel, Oliver

    2008-09-01

    In the global automotive industry, for decades, vehicle manufacturers have continually increased the level of automation of production systems in order to be competitive. However, there is a new trend to decrease the level of automation, especially in final car assembly, for reasons of economy and flexibility. In this research, the final car assembly lines at three production sites of Volkswagen are analysed in order to determine the best level of automation for each, in terms of manufacturing costs, productivity, quality and flexibility. The case study is based on the methodology proposed by the Fraunhofer Institute. The results of the analysis indicate that fully automated assembly systems are not necessarily the best option in terms of cost, productivity and quality combined, which is attributed to high complexity of final car assembly systems; some de-automation is therefore recommended. On the other hand, the analysis shows that low automation can result in poor product quality due to reasons related to plant location, such as inadequate workers' skills, motivation, etc. Hence, the automation strategy should be formulated on the basis of analysis of all relevant aspects of the manufacturing process, such as costs, quality, productivity and flexibility in relation to the local context. A more balanced combination of automated and manual assembly operations provides better utilisation of equipment, reduces production costs and improves throughput.

  10. Double-Sided Single-Pass Submerged Arc Welding for 2205 Duplex Stainless Steel

    NASA Astrophysics Data System (ADS)

    Luo, Jian; Yuan, Yi; Wang, Xiaoming; Yao, Zongxiang

    2013-09-01

    The duplex stainless steel (DSS), which combines the characteristics of ferritic steel and austenitic steel, is used widely. The submerged arc welding (SAW) method is usually applied to join thick plates of DSS. However, an effective welding procedure is needed in order to obtain ideal DSS welds with an appropriate proportion of ferrite (δ) and austenite (γ) in the weld zone, particularly in the melted zone and heat-affected zone. This study evaluated the effectiveness of a high efficiency double-sided single-pass (DSSP) SAW joining method for thick DSS plates. The effectiveness of the converse welding procedure, characterizations of weld zone, and mechanical properties of welded joint are analyzed. The results show an increasing appearance and continuous distribution feature of the σ phase in the fusion zone of the leading welded seam. The converse welding procedure promotes the σ phase to precipitate in the fusion zone of leading welded side. The microhardness appears to significantly increase in the center of leading welded side. Ductile fracture mode is observed in the weld zone. A mixture fracture feature appears with a shear lip and tears in the fusion zone near the fusion line. The ductility, plasticity, and microhardness of the joints have a significant relationship with σ phase and heat treatment effect influenced by the converse welding step. An available heat input controlling technology of the DSSP formation method is discussed for SAW of thick DSS plates.

  11. Process automation

    SciTech Connect

    Moser, D.R.

    1986-01-01

    Process automation technology has been pursued in the chemical processing industries and to a very limited extent in nuclear fuel reprocessing. Its effective use has been restricted in the past by the lack of diverse and reliable process instrumentation and the unavailability of sophisticated software designed for process control. The Integrated Equipment Test (IET) facility was developed by the Consolidated Fuel Reprocessing Program (CFRP) in part to demonstrate new concepts for control of advanced nuclear fuel reprocessing plants. A demonstration of fuel reprocessing equipment automation using advanced instrumentation and a modern, microprocessor-based control system is nearing completion in the facility. This facility provides for the synergistic testing of all chemical process features of a prototypical fuel reprocessing plant that can be attained with unirradiated uranium-bearing feed materials. The unique equipment and mission of the IET facility make it an ideal test bed for automation studies. This effort will provide for the demonstration of the plant automation concept and for the development of techniques for similar applications in a full-scale plant. A set of preliminary recommendations for implementing process automation has been compiled. Some of these concepts are not generally recognized or accepted. The automation work now under way in the IET facility should be useful to others in helping avoid costly mistakes because of the underutilization or misapplication of process automation. 6 figs.

  12. Automated Entire Thrombus Density Measurements for Robust and Comprehensive Thrombus Characterization in Patients with Acute Ischemic Stroke

    PubMed Central

    Santos, Emilie M. M.; Niessen, Wiro J.; Yoo, Albert J.; Berkhemer, Olvert A.; Beenen, Ludo F.

    2016-01-01

    Background and Purpose In acute ischemic stroke (AIS) management, CT-based thrombus density has been associated with treatment success. However, currently used thrombus measurements are prone to inter-observer variability and oversimplify the heterogeneous thrombus composition. Our aim was first to introduce an automated method to assess the entire thrombus density and then to compare the measured entire thrombus density with respect to current standard manual measurements. Materials and Method In 135 AIS patients, the density distribution of the entire thrombus was determined. Density distributions were described using medians, interquartile ranges (IQR), kurtosis, and skewedness. Differences between the median of entire thrombus measurements and commonly applied manual measurements using 3 regions of interest were determined using linear regression. Results Density distributions varied considerably with medians ranging from 20.0 to 62.8 HU and IQRs ranging from 9.3 to 55.8 HU. The average median of the thrombus density distributions (43.5 ± 10.2 HU) was lower than the manual assessment (49.6 ± 8.0 HU) (p<0.05). The difference between manual measurements and median density of entire thrombus decreased with increasing density (r = 0.64; p<0.05), revealing relatively higher manual measurements for low density thrombi such that manual density measurement tend overestimates the real thrombus density. Conclusions Automatic measurements of the full thrombus expose a wide variety of thrombi density distribution, which is not grasped with currently used manual measurement. Furthermore, discrimination of low and high density thrombi is improved with the automated method. PMID:26765847

  13. Joining technologies for the 1990s: Welding, brazing, soldering, mechanical, explosive, solid-state, adhesive

    NASA Technical Reports Server (NTRS)

    Buckley, John D. (Editor); Stein, Bland A. (Editor)

    1986-01-01

    A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Society, and Society of Manufacturing Engineers Conference on Welding, Bonding, and Fastening at Langley Research Center, Hampton, VA, on October 23 to 25, 1984 is given. Papers were presented on technology developed in current research programs relevant to welding, bonding, and fastening of structural materials required in fabricating structures and mechanical systems used in the aerospace, hydrospace, and automotive industries. Topics covered in the conference included equipment, hardware and materials used when welding, brazing, and soldering, mechanical fastening, explosive welding, use of unique selected joining techniques, adhesives bonding, and nondestructive evaluation. A concept of the factory of the future was presented, followed by advanced welding techniques, automated equipment for welding, welding in a cryogenic atmosphere, blind fastening, stress corrosion resistant fasteners, fastening equipment, explosive welding of different configurations and materials, solid-state bonding, electron beam welding, new adhesives, effects of cryogenics on adhesives, and new techniques and equipment for adhesive bonding.

  14. A neuro-expert approach for decision-making in welding environment

    NASA Astrophysics Data System (ADS)

    Goel, Vivek

    2000-10-01

    Decision making in welding is very important for achieving a good quality welded joint for the least possible cost. Of particular interest is decision making involving the selection of process, parameters, weld procedure specification, defect analysis and trouble shooting. This research has provided a means of capturing the planning knowledge in a Neuro-Expert System in a form that is capable of learning new information, correcting old information and automating the decision-making process in a welding environment. A strategy is formulated for the representation of knowledge in the form of a neural links and the translation of rules into neural link weights. After training those weights were converted back into rules to find out the inconsistent rules and capture new rules using a new approach. The various job variables affecting the process of welding are identified in detail and a Neuro-Expert system for the selection of process, parameters and weld procedure specification is developed. The neural networks are integrated with an expert system for decision making in welding environment. Apart from providing the initial parameters of welding, the expert system is used to validate the output of the neural network and served as a user-friendly interface for the neural network. Defect Analysis is performed in welding domain by mapping the welding parameters and defect patterns in a neural network. A neural network based approach for representing the knowledge in expert system is utilized for this purpose as the modification and updating of the knowledge was easier.

  15. Feasibility study of in-process weld quality control by means of scanning laser profilometry

    NASA Astrophysics Data System (ADS)

    Jezeršek, Matija; Polajnar, Ivan; Diaci, Janez

    2007-06-01

    We have developed a scanning laser system based on the optical triangulation principle for the shape measurement of fusion weld surfaces. The system integrates a triangulation module consisting of a laser line projector and a digital video camera with a mechanical scanning stage and an industrial computer. The system is small and rugged, suitable for application in industrial environment. The system can sample a weld surface at a rate of up to 30 profiles per second achieving 0.1mm accuracy. Software was developed which analyses the captured weld surface shape in real time determining the characteristic shape parameters (length, width, height, cross section, volume, starting position,...) which are then used for automated classification of the welds into acceptable and unacceptable. The software also detects surface defects such as undercutting, holes or melt splash, etc. The system has been tested in a robotized welding cell for automotive parts in an industrial production facility. Weld classification obtained by the system was compared to an independent classification determined by a trained weld inspector on the basis of visual inspection and to another one determined on the basis of metallographic analysis of the weld. Using the metallographic based classification as the reference we find that the developed weld inspection system can achieve better classification reliability than a trained visual weld inspector.

  16. Automated air-void system characterization of hardened concrete: Helping computers to count air-voids like people count air-voids---Methods for flatbed scanner calibration

    NASA Astrophysics Data System (ADS)

    Peterson, Karl

    Since the discovery in the late 1930s that air entrainment can improve the durability of concrete, it has been important for people to know the quantity, spacial distribution, and size distribution of the air-voids in their concrete mixes in order to ensure a durable final product. The task of air-void system characterization has fallen on the microscopist, who, according to a standard test method laid forth by the American Society of Testing and Materials, must meticulously count or measure about a thousand air-voids per sample as exposed on a cut and polished cross-section of concrete. The equipment used to perform this task has traditionally included a stereomicroscope, a mechanical stage, and a tally counter. Over the past 30 years, with the availability of computers and digital imaging, automated methods have been introduced to perform the same task, but using the same basic equipment. The method described here replaces the microscope and mechanical stage with an ordinary flatbed desktop scanner, and replaces the microscopist and tally counter with a personal computer; two pieces of equipment much more readily available than a microscope with a mechanical stage, and certainly easier to find than a person willing to sit for extended periods of time counting air-voids. Most laboratories that perform air-void system characterization typically have cabinets full of prepared samples with corresponding results from manual operators. Proponents of automated methods often take advantage of this fact by analyzing the same samples and comparing the results. A similar iterative approach is described here where scanned images collected from a significant number of samples are analyzed, the results compared to those of the manual operator, and the settings optimized to best approximate the results of the manual operator. The results of this calibration procedure are compared to an alternative calibration procedure based on the more rigorous digital image accuracy

  17. Toward practical 3D radiography of pipeline girth welds

    NASA Astrophysics Data System (ADS)

    Wassink, Casper; Hol, Martijn; Flikweert, Arjan; van Meer, Philip

    2015-03-01

    Digital radiography has made its way into in-the-field girth weld testing. With recent generations of detectors and x-ray tubes it is possible to reach the image quality desired in standards as well as the speed of inspection desired to be competitive with film radiography and automated ultrasonic testing. This paper will show the application of these technologies in the RTD Rayscan system. The method for achieving an image quality that complies with or even exceeds prevailing industrial standards will be presented, as well as the application on pipeline girth welds with CRA layers. A next step in development will be to also achieve a measurement of weld flaw height to allow for performing an Engineering Critical Assessment on the weld. This will allow for similar acceptance limits as currently used with Automated Ultrasonic Testing of pipeline girth welds. Although a sufficient sizing accuracy was already demonstrated and qualified in the TomoCAR system, testing in some applications is restricted to time limits. The paper will present some experiments that were performed to achieve flaw height approximation within these time limits.

  18. Toward practical 3D radiography of pipeline girth welds

    SciTech Connect

    Wassink, Casper

    2015-03-31

    Digital radiography has made its way into in-the-field girth weld testing. With recent generations of detectors and x-ray tubes it is possible to reach the image quality desired in standards as well as the speed of inspection desired to be competitive with film radiography and automated ultrasonic testing. This paper will show the application of these technologies in the RTD Rayscan system. The method for achieving an image quality that complies with or even exceeds prevailing industrial standards will be presented, as well as the application on pipeline girth welds with CRA layers. A next step in development will be to also achieve a measurement of weld flaw height to allow for performing an Engineering Critical Assessment on the weld. This will allow for similar acceptance limits as currently used with Automated Ultrasonic Testing of pipeline girth welds. Although a sufficient sizing accuracy was already demonstrated and qualified in the TomoCAR system, testing in some applications is restricted to time limits. The paper will present some experiments that were performed to achieve flaw height approximation within these time limits.

  19. New development activities in the field of wet welding

    SciTech Connect

    Szelagowski, P.; Osthus, V.; Petershagen, H.; Pohl, R.; Lafaye, G.

    1995-12-31

    The Wet Welding process has now become an interesting alternative repair process due to its high flexibility, its low investment costs and its high versatility. However, due to the prior bad reputation of the in former times achievable low weldment quality, due to extremely high hardness, high porosity, high hydrogen contamination and in combination with this high cracking susceptibility the wet welding process nowadays requires further activities to improve its reputation and credibility. New acceptance criteria, more detailed information on the achievable weldment quality and especially the development of life prediction data for wet welded components are now required. Advanced testing methods are necessary, additional design criteria are to be developed and achievable weldment quality data are to be included in acknowledged and approved standards and recommendations. Only by the provision of such data the credibility of the process and the problem of quality assurance for wet welded joints can be improved. In two comprehensive projects, sponsored by the European Community under the Thermie Programme, process development and new testing procedures have bene procured and are still under progress to generate the required data and new design criteria for the future application of the wet welding process to main components of offshore structures. The water depths in the range of 50 to 100 msw have been selected for the application of the wet welding process to structural components, as these depths include that range of application in which this process can become competitive to the hyperbaric dry welding process. The international trend to mechanize and automate the hyperbaric welding processes in dry environments can even be completed by the application of a semiautomatic wet welding process, which has already shown very promising results. This process is applicable to mechanized systems (e.g. to a wet robot system).

  20. Improved diffusion welding and roll welding of titanium alloys

    NASA Technical Reports Server (NTRS)

    Holko, K. H.

    1973-01-01

    Auto-vacuum cleaning technique was applied to titanium parts prior to welding. This provides oxide-free welding surfaces. Diffusion welding can be accomplished in as little as five minutes of hot pressing. Roll welding can be accomplished with only ten percent deformation.

  1. Information flow analysis and Petri-net-based modeling for welding flexible manufacturing cell

    NASA Astrophysics Data System (ADS)

    Qiu, T.; Chen, Shanben; Wang, Y. T.; Wu, Lin

    2000-10-01

    Due to the development of advanced manufacturing technology and the introduction of Smart-Manufacturing notion in the field of modern industrial production, welding flexible manufacturing system (WFMS) using robot technology has become the inevitable developing direction on welding automation. In WFMS process, the flexibility for different welding products and the realizing on corresponding welding parameters control are the guarantees for welding quality. Based on a new intelligent arc-welding flexible manufacturing cell (WFMC), the system structure and control policies are studied in this paper. Aiming at the different information flows among every subsystem and central monitoring computer in this WFMC, Petri net theory is introduced into the process of welding manufacturing. With its help, a discrete control model of WFMC has been constructed, in which the system status is regarded as place and the control process is regarded as transition. Moreover, grounded on automation Petri net principle, the judging and utilizing of information obtained from welding sensors are imported into net structure, which extends the traditional Petri net concepts. The control model and policies researched in this paper have established foundation for further intelligent real-time control on WFMC and WFMS.

  2. Automation pilot

    NASA Technical Reports Server (NTRS)

    1983-01-01

    An important concept of the Action Information Management System (AIMS) approach is to evaluate office automation technology in the context of hands on use by technical program managers in the conduct of human acceptance difficulties which may accompany the transition to a significantly changing work environment. The improved productivity and communications which result from application of office automation technology are already well established for general office environments, but benefits unique to NASA are anticipated and these will be explored in detail.

  3. Automated Urinalysis

    NASA Technical Reports Server (NTRS)

    1994-01-01

    Information from NASA Tech Briefs assisted DiaSys Corporation in the development of the R/S 2000 which automates urinalysis, eliminating most manual procedures. An automatic aspirator is inserted into a standard specimen tube, the "Sample" button is pressed, and within three seconds a consistent amount of urine sediment is transferred to a microscope. The instrument speeds up, standardizes, automates and makes urine analysis safer. Additional products based on the same technology are anticipated.

  4. Sorting Titanium Welding Rods

    NASA Technical Reports Server (NTRS)

    Ross, W. D., Jr.; Brown, R. L.

    1985-01-01

    Three types of titanium welding wires identified by their resistance to current flow. Welding-wire tester quickly identifies unknown titaniumalloy wire by touching wire with test probe, and comparing meter response with standard response. Before touching wire, tip of test probe dipped into an electrolyte.

  5. DC arc weld starter

    DOEpatents

    Campiotti, Richard H.; Hopwood, James E.

    1990-01-01

    A system for starting an arc for welding uses three DC power supplies, a high voltage supply for initiating the arc, an intermediate voltage supply for sustaining the arc, and a low voltage welding supply directly connected across the gap after the high voltage supply is disconnected.

  6. Advanced Welding Torch

    NASA Technical Reports Server (NTRS)

    1996-01-01

    In order to more easily join the huge sections of the Space Shuttle external tank, Marshall Space Flight Center initiated development of the existing concept of Variable Polarity Plasma Arc (VPPA) welding. VPPA welding employs a variable current waveform that allows the system to operate for preset time increments in either of two polarity modes for effective joining of light alloys.

  7. Explosive Welding of Pipes

    NASA Astrophysics Data System (ADS)

    Burtseva, Olga

    2007-06-01

    For connection by welding it is suggested to use the explosive welding method. This method is rather new. Nevertheless, it has become commonly used among the technological developments. This method can be advantageous (saving material and physical resources) comparing to its statical analogs (electron-beam welding, argon-arc welding, plasma welding, gas welding, etc.), in particular, in hard-to-reach areas due to their geographic and climatic conditions. The suggestion is to use water as filler. The principle of non-compressibility of liquid under quasi-dynamic loading is used. In one-dimensional gasdynamic and elastic-plastic calculations we determined non-deformed mass of water (perturbations, which are moving in the axial direction with sound velocity, should not reach the layer end boundaries for 5-7 circulations of shock waves in the radial direction). Linear dimension of the water layer from the zone of pipe coupling along axis in each direction is >= 2R, where R is the internal radius of pipe. Model experiments with pipes having radii R = 57 mm confirmed results of the calculations and the possibility in principle to weld pipes by explosion with use of water as filler. Reduction of pipe diameter after dynamic loading and explosive welding was ˜2%.

  8. Welding: Scope and Sequence.

    ERIC Educational Resources Information Center

    Nashville - Davidson County Metropolitan Public Schools, TN.

    Intended for use by all welding instructors in the Metropolitan Nashville Public Schools, this guide provides a sequential listing of course content and scope. A course description provides a brief overview of the content of the courses offered in the welding program. General course objectives are then listed. Outlines of the course content are…

  9. Laser Welding in Space

    NASA Technical Reports Server (NTRS)

    Workman, Gary L.; Kaukler, William F.

    1989-01-01

    Solidification type welding process experiments in conditions of microgravity were performed. The role of convection in such phenomena was examined and convective effects in the small volumes obtained in the laser weld zone were observed. Heat transfer within the weld was affected by acceleration level as indicated by the resulting microstructure changes in low gravity. All experiments were performed such that both high and low gravity welds occurred along the same weld beam, allowing the effects of gravity alone to be examined. Results indicate that laser welding in a space environment is feasible and can be safely performed IVA or EVA. Development of the hardware to perform the experiment in a Hitchhiker-g platform is recomended as the next step. This experiment provides NASA with a capable technology for welding needs in space. The resources required to perform this experiment aboard a Shuttle Hitchhiker-pallet are assessed. Over the four year period 1991 to 1994, it is recommended that the task will require 13.6 manyears and $914,900. In addition to demonstrating the technology and ferreting out the problems encountered, it is suggested that NASA will also have a useful laser materials processing facility for working with both the scientific and the engineering aspects of materials processing in space. Several concepts are also included for long-term optimization of available solar power through solar pumping solid state lasers directly for welding power.

  10. Vocational Preparation Curriculum: Welding.

    ERIC Educational Resources Information Center

    Usoro, Hogan

    Designed to be a workable guide for instructors serving the occupational needs of various categories of disadvantaged and handicapped students, this welding curriculum contains fourteen units of self-paced and self-contained instructional materials. The instructional units cover the following topics: job opportunities in welding, safety rules in…

  11. Welding Tubes In Place

    NASA Technical Reports Server (NTRS)

    Meredith, R.

    1984-01-01

    Special welding equipment joins metal tubes that carry pressurized cyrogenic fluids. Equipment small enough to be used in confined spaces in which such tubes often mounted. Welded joints lighter in weight and more leak-proof than joints made with mechanical fittings.

  12. Fine welding with lasers.

    PubMed

    MacLellan, D

    2008-01-01

    The need for micro joining metallic alloys for surgical instruments, implants and advanced medical devices is driving a rapid increase in the implementation of laser welding technology in research, development and volume production. This article discusses the advantages of this welding method and the types of lasers used in the process. PMID:18557404

  13. Weld-Fill Program

    NASA Technical Reports Server (NTRS)

    Maslakowski, John E.

    1994-01-01

    ROCKFILL is software that calculates key robot weld information. Its easy-to-use menu system enables robot operator to estimate better number of passes, amount of wire, arc time, and amount of heat put into particular weld. Designed to operate on work-cell personal computer of robot and requires no documentation or training. Written in C language.

  14. The effect of welding parameters on penetration in GTA welds

    SciTech Connect

    Shirali, A.A. ); Mills, K.C. )

    1993-07-01

    The effect of various welding parameters on the penetration of GTA welds has been investigated. Increases in welding speed were found to reduce penetration; however, increases in welding current were observed to increase the penetration in high sulfur (HS) casts and decrease penetration in low sulfur (LS) steels. Plots of penetration as a function of increasing linear energy (the heat supplied per unit length of weld) revealed a similar trend with increased penetration in HS casts, but the penetration in LS casts was unaffected by increases in linear energy. These results support the Burgardt-Heiple proposition that changes in welding parameters on penetration can be explained in terms of their effect, sequentially, on the temperature gradient and the Marangoni forces operating in the weld pool. Increases in arc length were found to decrease weld penetration regardless of the sulfur concentration of the steel, and the effects of electrode geometry and welding position on weld penetration were also investigated.

  15. Method for welding beryllium

    DOEpatents

    Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

    1997-04-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. 9 figs.

  16. Welds in thermoplastic composite materials

    NASA Astrophysics Data System (ADS)

    Taylor, N. S.

    Welding methods are reviewed that can be effectively used for joining of thermoplastic composites and continuous-fiber thermoplastics. Attention is given to the use of ultrasonic, vibration, hot-plate, resistance, and induction welding techniques. The welding techniques are shown to provide complementary weld qualities for the range of thermoplastic materials that are of interest to industrial and technological applications.

  17. Alternating-Polarity Arc Welding

    NASA Technical Reports Server (NTRS)

    Schwinghamer, R. J.

    1987-01-01

    Brief reversing polarity of welding current greatly improves quality of welds. NASA technical memorandum recounts progress in art of variable-polarity plasma-arc (VPPA) welding, with emphasis on welding of aluminum-alloy tanks. VPPA welders offer important advantages over conventional single-polarity gas/tungsten arc welders.

  18. Vacuum Gas Tungsten Arc Welding

    NASA Technical Reports Server (NTRS)

    Weeks, J. L.; Todd, D. T.; Wooten, J. R.

    1997-01-01

    A two-year program investigated vacuum gas tungsten arc welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. After a vacuum chamber and GTAW power supply were modified, several difficult-to-weld materials were studied and key parameters developed. Finally, Incoloy 903 weld overlays were produced without microfissures.

  19. Ultrasonic seam welding. Final report

    SciTech Connect

    Darner, G.S.

    1980-06-01

    Ultrasonic seam welding has been evaluated for making continuous seam welds on aluminum and copper-foil conductors. A seam welding system has been designed and fabricated, weldable material combinations have been identified, and the process parameters for welding materials applicable to flat cable production have been established.

  20. Argon Welding Inside A Workpiece

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.

    1988-01-01

    Canopies convert large hollow workpiece into inert-gas welding chamber. Large manifold serves welding chamber for attachment of liner parts in argon atmosphere. Every crevice, opening and passageway provided with argon-rich environment. Weld defects and oxidation dramatically reduced; also welding time reduced.

  1. Solidification of underwater wet welds

    SciTech Connect

    Pope, A.M.; Medeiros, R.C. de; Liu, S.

    1995-12-31

    It is well known that the shape of a weld pool can influence the microstructure and segregation pattern of the final solidified weld metal. Mechanical properties and susceptibility to defects are consequently affected by the solidification mode of the weld. In this work the solidification behavior of weld beads deposited in air and underwater wet welding using rutile electrodes were compared. The welds were deposited by gravity feed, on low carbon, manganese steel plates using similar welding conditions. Macroscopic observation of the weld craters showed that welds deposited in air presented an elliptical weld pool. The underwater wet welds, on the other hand, solidified with a tear drop shape. Although the welds differed in shape, their lengths were approximately the same. Microscopic examinations carried out on transverse, normal and longitudinal sections revealed a coarser columnar grain structure in the underwater welds. These results suggest that the tear-drop shaped pool induced solidification in a preferred orientation with segregation more likely in welds deposited under wet conditions. This change in weld pool geometry can be explained by the surface heat loss conditions that occur in a wet weld: slower when covered by the steam bubble and faster in the region in contact with water behind the pool.

  2. Development of a Fiber Laser Welding Capability for the W76, MC4702 Firing Set

    SciTech Connect

    Samayoa, Jose

    2010-05-12

    Development work to implement a new welding system for a Firing Set is presented. The new system is significant because it represents the first use of fiber laser welding technology at the KCP. The work used Six-Sigma tools for weld characterization and to define process performance. Determinations of workable weld parameters and comparison to existing equipment were completed. Replication of existing waveforms was done utilizing an Arbitrary Pulse Generator (APG), which was used to modulate the fiber laser’s exclusive continuous wave (CW) output. Fiber laser weld process capability for a Firing Set is demonstrated.

  3. Laser-welded V-Cr-Ti alloys: Microstructural and mechanical properties

    SciTech Connect

    Natesan, K.; Smith, D.L.; Sanders, P.G.; Leong, K.H.

    1998-03-01

    A systematic study has been initiated to examine the use of lasers to weld sheet materials of V-Cr-Ti alloys and to characterize the microstructural and mechanical properties of the laser-welded materials. In addition, several post-welding heat treatments are being applied to the welded samples to evaluate their benefits, if any, to the structure and properties of the weldments. Hardness measurements are made across the welded regions of different samples to evaluate differences in the characteristics of various weldments.

  4. Fatigue strength improvement of MIG-welded joint by shot peening

    NASA Astrophysics Data System (ADS)

    Azida Che Lah, Nur; Ali, Aidy

    2011-02-01

    In this study, the effect of controlled shot peening (CSP) treatment on the fatigue strength of an ASTM A516 grade 70 carbon steel MIG-welded joint has been studied quantitatively. Metallurgical modifications, hardness, elemental compositions, and internal discontinuities, such as porosity and inclusions found in treated and untreated fusion welded joints, were characterized. The fatigue results of as-welded and peened skimmed joints were compared. It was observed that the effect of the CSP and skimming processes improved the fatigue life of the fusion weld by 63% on MIG-welded samples.

  5. An automated microfluidic chip system for detection of piscine nodavirus and characterization of its potential carrier in grouper farms.

    PubMed

    Kuo, Hsiao-Che; Wang, Ting-Yu; Hsu, Hao-Hsuan; Lee, Szu-Hsien; Chen, Young-Mao; Tsai, Tieh-Jung; Ou, Ming-Chang; Ku, Hsiao-Tung; Lee, Gwo-Bin; Chen, Tzong-Yueh

    2012-01-01

    Groupers of the Epinephelus spp. are an important aquaculture species of high economic value in the Asia Pacific region. They are susceptible to piscine nodavirus infection, which results in viral nervous necrosis disease. In this study, a rapid and sensitive automated microfluidic chip system was implemented for the detection of piscine nodavirus; this technology has the advantage of requiring small amounts of sample and has been developed and applied for managing grouper fish farms. Epidemiological investigations revealed an extremely high detection rate of piscine nodavirus (89% of fish samples) from 5 different locations in southern Taiwan. In addition, positive samples from the feces of fish-feeding birds indicated that the birds could be carrying the virus between fish farms. In the present study, we successfully introduced this advanced technology that combines engineering and biological approaches to aquaculture. In the future, we believe that this approach will improve fish farm management and aid in reducing the economic loss experienced by fish farmers due to widespread disease outbreaks. PMID:22912690

  6. Grinding Parts For Automatic Welding

    NASA Technical Reports Server (NTRS)

    Burley, Richard K.; Hoult, William S.

    1989-01-01

    Rollers guide grinding tool along prospective welding path. Skatelike fixture holds rotary grinder or file for machining large-diameter rings or ring segments in preparation for welding. Operator grasps handles to push rolling fixture along part. Rollers maintain precise dimensional relationship so grinding wheel cuts precise depth. Fixture-mounted grinder machines surface to quality sufficient for automatic welding; manual welding with attendant variations and distortion not necessary. Developed to enable automatic welding of parts, manual welding of which resulted in weld bead permeated with microscopic fissures.

  7. Pin Tool Geometry Effects in Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Querin, J. A.; Rubisoff, H. A.; Schneider, J. A.

    2009-01-01

    In friction stir welding (FSW) there is significant evidence that material can take one of two different flow paths when being displaced from its original position in front of the pin tool to its final position in the wake of the weld. The geometry of the pin tool, along with the process parameters, plays an important role in dictating the path that the material takes. Each flow path will impart a different thermomechanical history on the material, consequently altering the material microstructure and subsequent weld properties. The intention of this research is to isolate the effect that different pin tool attributes have on the flow paths imparted on the FSWed material. Based on published weld tool geometries, a variety of weld tools were fabricated and used to join AA2219. Results from the tensile properties and microstructural characterization will be presented.

  8. Solidification behavior and structure of Al-Cu alloy welds

    SciTech Connect

    Brooks, J.A.; Li, M.; Yang, N.C.Y.

    1997-09-01

    The microsegregation behavior of electron beam (EB) and gas tungsten arc (GTA) welds of Al-Cu alloys covering a range from 0.19 to 7.74 wt% Cu were characterized for dendrite core concentrations and fraction eutectic solidification. Although a single weld speed of 12.7 mm/sec was used, some differences were observed in the segregation behavior of the two weld types. The microsegregation behavior was also modeled using a finite differences technique considering dendrite tip and eutectic undercooling and solid state diffusion. Fairly good agreement was observed between measured and calculated segregation behavior although differences between the two weld types could not be completely accounted for. The concept of dendrite tip undercooling was used to explain the formation of a single through thickness centerline grain in the higher alloy content GTA welds.

  9. 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.

  10. Calibration Fixture For Welding Robot

    NASA Technical Reports Server (NTRS)

    Holly, Krisztina J.

    1990-01-01

    Compact, lightweight device used in any position or orientation. Calibration fixture designed for use on robotic gas/tungsten-arc welding torch equipped with vision-based seam-tracking system. Through optics in hollow torch cylinder, video camera obtains image of weld, viewing along line of sight coaxial with welding electrode. Attaches to welding-torch cylinder in place of gas cup normally attached in use. By use of longer or shorter extension tube, fixture accommodates welding electrode of unusual length.

  11. 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.

  12. 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.

  13. Effect of Multipass TIG and Activated TIG Welding Process on the Thermo-Mechanical Behavior of 316LN Stainless Steel Weld Joints

    NASA Astrophysics Data System (ADS)

    Ganesh, K. C.; Balasubramanian, K. R.; Vasudevan, M.; Vasantharaja, P.; Chandrasekhar, N.

    2016-04-01

    The primary objective of this work was to develop a finite element model to predict the thermo-mechanical behavior of an activated tungsten inert gas (ATIG)-welded joint. The ATIG-welded joint was fabricated using 10 mm thickness of 316LN stainless steel plates in a single pass. To distinguish the merits of ATIG welding process, it was compared with manual multipass tungsten inert gas (MPTIG)-welded joint. The ATIG-welded joint was fabricated with square butt edge configuration using an activating flux developed in-house. The MPTIG-welded joint was fabricated in thirteen passes with V-groove edge configuration. The finite element model was developed to predict the transient temperature, residual stress, and distortion of the welded joints. Also, microhardness, impact toughness, tensile strength, ferrite measurement, and microstructure were characterized. Since most of the recent publications of ATIG-welded joint was focused on the molten weld pool dynamics, this research work gives an insight on the thermo-mechanical behavior of ATIG-welded joint over MPTIG-welded joint.

  14. Characterization of cysteine related variants in an IgG2 antibody by LC-MS with an automated data analysis approach.

    PubMed

    Zhang, Yuling; Bailey, Robert; Nightlinger, Nancy; Gillespie, Alison; Balland, Alain; Rogers, Richard

    2015-08-01

    In this communication, a high-throughput method for automated data analysis of cysteine-related product quality attributes (PQAs) in IgG2 antibodies is reported. This method leverages recent advances in the relative quantification of PQAs to facilitate the characterization of disulfide variants and free sulfhydryls (SHs) in IgG2 antibodies. The method uses samples labeled with a mass tag (N-ethyl maleimide [NEM]) followed by enzymatic digestion under non-reducing conditions to maintain the cysteine connectivity. The digested IgG2 samples are separated and detected by mass spectrometry (MS) and the resulting peptide map is analyzed in an automated fashion using Pinpoint software (Thermo Scientific). Previous knowledge of IgG2 disulfide structures can be fed into the Pinpoint software to create workbooks for various disulfide linkages and hinge disulfide variants. In addition, the NEM mass tag can be added to the workbooks for targeted analysis of labeled cysteine-containing peptides. The established Pinpoint workbooks are a high-throughput approach to quantify relative abundances of unpaired cysteines and disulfide linkages, including complicated hinge disulfide variants. This approach is especially efficient for comparing large sets of similar samples such as those created in comparability and stability studies or chromatographic fractions. Here, the high throughput method is applied to quantify the relative abundance of hinge disulfide variants and unpaired cysteines in the IgG2 fractions from non-reduced reversed-phase high-performance liquid chromatography (nrRP-HPLC). The LC-MS data analyzed by the Pinpoint workbook suggests that the nrRP-HPLC separated peaks contain hinge disulfide isoforms and free cysteine pairs for each major disulfide isoform structure. PMID:26079266

  15. Functional characterization of naturally expressed G-protein-coupled receptors in mammalian cells using the automated high-throughput pharmacological system HT-PS 100

    NASA Astrophysics Data System (ADS)

    Okun, Ilya; Okun, Alex; Anantharam, Vellareddy; Goldman, Mark E.; Otto, Michael; Kaler, Gregory V.

    1999-04-01

    In studying the molecular mechanics of stimulation of a receptor and mechanisms of the receptor's interaction with ligands, the widely sued approach is to characterize dose- dependent functional responses of stimulation or inhibition of the receptor. Many GPCRs respond to the stimulation by transient changes in cytoplasmic calcium. A time trace of the ligand-evoked 'calcium signal' visualizes the sequence of signaling events taking place after the initial receptor stimulation. It is more important to know how those events depend on the ligand concentration. This type of data provides ligand affinity profiles together with information about mechanisms of the receptor/ligand interaction - competitive, non-competitive antagonism, full or partial stimulation. We have developed an automated system, HT-PS 100, for registering continuous concentration-dependent functional responses in real time at the rate of 2 min per dose-response curve. The flow-through fluidics prepares a concentration gradient of the compound and sequentially mixes it with another reagent, agonist or antagonist, and finally with cells. The resulting 'real time' concentration dependent signal is registered with a fluorescence detector. By monitoring calcium mobilization with Fura-2, we have functionally and mechanistically characterized a variety of G protein-coupled receptors, cholinergic, histaminergic, purinergic, endothelin, and bradykinin, endogenously expressed in different cell lines, SK-N-MC, TE671 and DDT1MF-2.

  16. Microstructure Formation in Dissimilar Metal Welds: Electron Beam Welding of Ti/Ni

    NASA Astrophysics Data System (ADS)

    Chatterjee, Subhradeep; Abinandanan, T. A.; Reddy, G. Madhusudhan; Chattopadhyay, Kamanio

    2016-02-01

    We present results for electron beam welding of a binary Ti/Ni dissimilar metal couple. The difference in physical properties of the base metals and metallurgical features (thermodynamics and kinetics) of the system influence both macroscopic transport and microstructure development in the weld. Microstructures near the fusion interfaces are markedly different from those inside the weld region. At the Ti side, Ti2Ni dendrites are observed to grow toward the fusion interface, while in the Ni side, layered growth of γ-Ni, Ni3Ti, and Ni3Ti + NiTi eutectic is observed. Different morphologies of the latter eutectic constitute the predominant microstructure inside the weld metal region. These results are compared and contrasted with those from laser welding of the same binary couple, and a scheme of solidification is proposed to explain the observations. This highlights notable departures from welding of similar and other dissimilar metals such as a significant asymmetry in heat transport that governs progress of solidification from each side of the couple, and a lack of unique liquidus isotherm characterizing the liquid-solid front.

  17. Gravitational effects on weld pool shape and microstructural evolution during gas tungsten arc and laser beam welding on 304 stainless steel, nickel, and aluminum-4 wt.% copper alloy

    NASA Astrophysics Data System (ADS)

    Kang, Namhyun

    The objective of the present work was to investigate effects of gravitational (acceleration) level and orientation on Ni 200 alloy (99.5% Ni purity), 304 stainless steel, and Al-4 wt.% Cu alloy during gas tungsten arc welding (GTAW) and laser beam welding (LBW). Main characterization was focused on the weld pool shape, microstructure, and solute distribution as a function of gravitational level and orientation. The welds were divided into two classes, i.e., 'stable' and 'unstable' welds, in view of the variation of weld pool shape as a function of gravitational level and orientation. In general, higher arc current and translational GTAW produced more significant effects of gravitational orientation on the weld pool shape than the case of lower arc current and spot welding. Cross-sectional area (CSA) was a secondary factor in determining the stability of weld pool shape. For the 'stable' weld of 304 stainless steel GTAW, the II-U weld showed less convexity in the pool bottom and more depression of the free surface, therefore producing deeper penetration (10--20%) than the case of II-D weld. The II-D weld of 304 stainless steel showed 31% deeper penetration, 28% narrower width, and more hemispherical shape of the weld pool than the case of II-U weld. For GTAW on 304 stainless steel, gravitational level variation from low gravity (LG ≈ 1.2 go) to high gravity (HG ≈ 1.8 go) caused 10% increase in width and 10% decrease in depth while maintaining the overall weld pool volume. Furthermore, LBW on 304 stainless steels showed mostly constant shape of weld pool as a function of gravitational orientation. GTAW on Ni showed similar trends of weld pool shape compared with GTAW on 304 stainless steel, i.e., the weld pool became unstable by showing more penetration in the II-D weld for slower arc translational velocity (V a) and larger weld pool size. However, the Ni weld pool shape had greater stability of the weld pool shape with respect to the gravitational orientation

  18. Mechanical Properties, Microstructure and Crystallographic Texture of Magnesium AZ91-D Alloy Welded by Friction Stir Welding (FSW)

    NASA Astrophysics Data System (ADS)

    Kouadri-Henni, A.; Barrallier, L.

    2014-10-01

    The objective of the study was to characterize the properties of a magnesium alloy welded by friction stir welding. The results led to a better understanding of the relationship between this process and the microstructure and anisotropic properties of alloy materials. Welding principally leads to a large reduction in grain size in welded zones due to the phenomenon of dynamic recrystallization. The most remarkable observation was that crystallographic textures appeared from a base metal without texture in two zones: the thermo-mechanically affected and stir-welded zones. The latter zone has the peculiarity of possessing a marked texture with two components on the basal plane and the pyramidal plane. These characteristics disappeared in the thermo-mechanically affected zone (TMAZ), which had only one component following the basal plane. These modifications have been explained by the nature of the plastic deformation in these zones, which occurs at a moderate temperature in the TMAZ and high temperature in the SWZ.

  19. A fundamental study on the structural integrity of magnesium alloys joined by friction stir welding

    NASA Astrophysics Data System (ADS)

    Rao, Harish Mangebettu

    The goal of this research is to study the factors that influence the physical and mechanical properties of lap-shear joints produced using friction stir welding. This study focuses on understanding the effect of tool geometry and weld process parameters including the tool rotation rate, tool plunge depth and dwell time on the mechanical performance of similar magnesium alloy and dissimilar magnesium to aluminum alloy weld joints. A variety of experimental activities were conducted including tensile and fatigue testing, fracture surface and failure analysis, microstructure characterization, hardness measurements and chemical composition analysis. An investigation on the effect of weld process conditions in friction stir spot welding of magnesium to magnesium produced in a manner that had a large effective sheet thickness and smaller interfacial hook height exhibited superior weld strength. Furthermore, in fatigue testing of friction stir spot welded of magnesium to magnesium alloy, lap-shear welds produced using a triangular tool pin profile exhibited better fatigue life properties compared to lap-shear welds produced using a cylindrical tool pin profile. In friction stir spot welding of dissimilar magnesium to aluminum, formation of intermetallic compounds in the stir zone of the weld had a dominant effect on the weld strength. Lap-shear dissimilar welds with good material mixture and discontinues intermetallic compounds in the stir zone exhibited superior weld strength compared to lap-shear dissimilar welds with continuous formation of intermetallic compounds in the stir zone. The weld structural geometry like the interfacial hook, hook orientation and bond width also played a major role in influencing the weld strength of the dissimilar lap-shear friction stir spot welds. A wide scatter in fatigue test results was observed in friction stir linear welds of aluminum to magnesium alloys. Different modes of failure were observed under fatigue loading including crack

  20. Hybrid Laser-Arc Welding of 10-mm-Thick Cast Martensitic Stainless Steel CA6NM: As-Welded Microstructure and Mechanical Properties

    NASA Astrophysics Data System (ADS)

    Mirakhorli, Fatemeh; Cao, Xinjin; Pham, Xuan-Tan; Wanjara, Priti; Fihey, Jean-Luc

    2016-07-01

    Cast CA6NM martensitic stainless steel plates, 10 mm in thickness, were welded using hybrid laser-arc welding. The effect of different welding speeds on the as-welded joint integrity was characterized in terms of the weld bead geometry, defects, microstructure, hardness, ultimate tensile strength, and impact energy. Significant defects such as porosity, root humping, underfill, and excessive penetration were observed at a low welding speed (0.5 m/min). However, the underfill depth and excessive penetration in the joints manufactured at welding speeds above 0.75 m/min met the specifications of ISO 12932. Characterization of the as-welded microstructure revealed untempered martensite and residual delta ferrite dispersed at prior-austenite grain boundaries in the fusion zone. In addition, four different heat-affected zones in the weldments were differentiated through hardness mapping and inference from the Fe-Cr-Ni ternary phase diagram. The tensile fracture occurred in the base metal for all the samples and fractographic analysis showed that the crack path is within the martensite matrix, along primary delta ferrite-martensite interfaces and within the primary delta ferrite. Additionally, Charpy impact testing demonstrated slightly higher fracture energy values and deeper dimples on the fracture surface of the welds manufactured at higher welding speeds due to grain refinement and/or lower porosity.