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Sample records for arc welding material

  1. Elements of arc welding

    SciTech Connect

    Not Available

    1993-07-01

    This paper looks at the following arc welding techniques: (1) shielded metal-arc welding; (2) submerged-arc welding; (3) gas metal-arc welding; (4) flux-cored arc welding; (5) electrogas welding; (6) gas tungsten-arc welding; and (7) plasma-arc welding.

  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. Study of issues in difficult-to-weld thick materials by hybrid laser arc welding

    NASA Astrophysics Data System (ADS)

    Mazar Atabaki, Mehdi

    There is a high interest for the high strength-to-weight ratio with good ductility for the welds of advanced alloys. The concern about the welding of thick materials (Advanced high strength steels (AHSS) and 5xxx and 6xxx series of aluminum alloys) has stimulated the development of manufacturing processes to overcome the associated issues. The need to weld the dissimilar materials (AHSS and aluminum alloys) is also required for some specific applications in different industries. Hence, the requirement in the development of a state-of-the-art welding procedure can be helpful to fulfill the constraints. Among the welding methods hybrid laser/arc welding (HLAW) has shown to be an effective method to join thick and difficult-to-weld materials. This process benefits from both advantages of the gas metal arc welding (GMAW) and laser welding processes. The interaction of the arc and laser can help to have enough penetration of weld in thick plates. However, as the welding of dissimilar aluminum alloys and steels is very difficult because of the formation of brittle intermetallics the present work proposed a procedure to effectively join the alloys. The reports showed that the explosively welded aluminum alloys to steels have the highest toughness, and that could be used as an "insert" (TRICLAD) for welding the thick plates of AHSS to aluminum alloys. Therefore, the HLAW of the TRICLAD-Flange side (Aluminum alloy (AA 5456)) to the Web side (Aluminum alloys (AA 6061 and AA 5456)) and the TRICLAD-Flange side (ASTM A516) to the Web side (AHSS) was studied in the present work. However, there are many issues related to HLAW of the dissimilar steels as well as dissimilar aluminum alloys that have to be resolved in order to obtain sound welds. To address the challenges, the most recent welding methods for joining aluminum alloys to steels were studied and the microstructural development, mechanical properties, and on-line monitoring of the welding processes were discussed as well

  4. 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.

  5. Flow Dynamics in Arc Welding

    SciTech Connect

    Lowke, John J.; Tanaka, Manabu

    2008-02-21

    The state of the art for numerical computations has now advanced so that the capability is within sight of calculating weld shapes for any arc current, welding gas, welding material or configuration. Inherent in these calculations is 'flow dynamics' applied to plasma flow in the arc and liquid metal flow in the weld pool. Examples of predictions which are consistent with experiment, are discussed for (1) conventional tungsten inert gas welding, (2) the effect of a fraction of a percent of sulfur in steel, which can increase weld depth by more than a factor of two through changes in the surface tension, (3) the effect of a flux, which can produce increased weld depth due to arc constriction, (4) use of aluminium instead of steel, when the much larger thermal conductivity of aluminium greatly reduces the weld depth and (5) addition of a few percent of hydrogen to argon, which markedly increases weld depth.

  6. Flow Dynamics in Arc Welding

    NASA Astrophysics Data System (ADS)

    Lowke, John J.; Tanaka, Manabu

    2008-02-01

    The state of the art for numerical computations has now advanced so that the capability is within sight of calculating weld shapes for any arc current, welding gas, welding material or configuration. Inherent in these calculations is "flow dynamics" applied to plasma flow in the arc and liquid metal flow in the weld pool. Examples of predictions which are consistent with experiment, are discussed for (1) conventional tungsten inert gas welding (2) the effect of a fraction of a percent of sulfur in steel, which can increase weld depth by more than a factor of two through changes in the surface tension (3) the effect of a flux, which can produce increased weld depth due to arc constriction (4) use of aluminium instead of steel, when the much larger thermal conductivity of aluminium greatly reduces the weld depth and (5) addition of a few percent of hydrogen to argon, which markedly increases weld depth.

  7. 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.

  8. Underwater wet flux-cored arc welding development of stainless steel and nickel-based materials

    SciTech Connect

    Findlan, S.J.; Frederick, G.J.

    1995-12-31

    The inaccessibility and high radiation fields of components in the lower two thirds of a reactor pressure vessel (RPV) has generated the need for an automated underwater wet welding process to address repair applications. Mechanical methods presently employed for this type of repair application produce crevices, which promote concerns of intergranular stress corrosion cracking (IGSCC), crevice corrosion and pitting. To address these concerns, the EPRI Repair and Replacement Applications Center (RRAC) has developed underwater wet flux-cored arc welding (FCAW) technology for the welding of stainless steel and nickel based materials. The benefits of underwater wet welding include: (1) provides a permanent repair; (2) offers crevice-five conditions; (3) reduces future inspection requirements (4) eliminates the potential for ``loose parts`` (5) can be performed in a timely approach. Underwater wet shielded metal arc welding (SMAW) has been successfully used to repair components in radiation areas of the upper section of the RPV, although this process is a manual operation and is impractical for remote applications. The developmental work at the EPRI RRAC is directed towards remote repair applications of nickel-based and stainless steel components, which are inaccessible with normal manual repair techniques, e.g., access hole covers. The flux-cored arc welding process (FCAW) was considered a viable option for underwater development, due to the ease of automation, out of position welding proficiency and self-shielding capabilities.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. Arc Reflector For Welding Ducts

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.

    1990-01-01

    Arc-light reflector for through-the-torch welding vision system designed expressly for use in welding ducts of small diameter. Cylindrical reflector positioned to reflect light diffusely from welding arc onto nearby surface of workpiece for most advantageous viewing along axis of welding torch.

  14. Pulsed Long Arc Welding

    NASA Astrophysics Data System (ADS)

    Krampit, N. Yu

    2016-04-01

    The paper presents a method and an appliance for pulsed arc welding. The method supports dosage of energy required for melting each bead of electrode metal starting from the detachment of a bead. The appliance including a sensor to register bead detachment shows this moment due to the voltage burst in the arc space. Transferred beads of electrode metal are of similar size because of the dosage of energy used for melting each bead, as the consequence, the process is more stable and starting conditions to transfer electrode metal are similar, as the result, a produced weld is improved.

  15. APPARATUS FOR ARC WELDING

    DOEpatents

    Lingafelter, J.W.

    1960-04-01

    An apparatus is described in which a welding arc created between an annular electrode and a workpiece moves under the influence of an electromagnetic field about the electrode in a closed or annular path. This mode of welding is specially suited to the enclosing of nuclear-fuel slugs in a protective casing. For example, a uranium slug is placed in an aluminum can, and an aluminum closure is welded to the open end of the can along a closed or annular path conforming to the periphery of the end closure.

  16. Gas Tungsten Arc Welding. Welding Module 6. Instructor's Guide.

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

    This guide is intended to assist vocational educators in teaching a three-unit module in gas tungsten arc welding. The module has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The basic principles involved in gas tungsten arc welding, supplies, and applications are covered. The materials included…

  17. Ultrasound in arc welding: a review.

    PubMed

    da Cunha, Tiago Vieira; Bohórquez, Carlos Enrique Niño

    2015-02-01

    During the last decade, the introduction of ultrasound techniques in arc welding with the intention of improving the operational performance and technical characteristics of the welding processes have been studied intensively. In this work is presented a broad review of the literature surrounding the utilization of this technique. Firstly, we discuss the use of traditional mechanical transducers to generate ultrasound in arc welding. Furthermore, we describe the various methods and their application in arc-welding processes. After, is presented a recent method of introducing ultrasonic energy in arc welding, which forms a potential alternative to the use of traditional mechanical type transducers. This method was originally developed in the late 1990s and is called arc with ultrasonic excitation of current. Here, the arc acts not only as a thermal source but also as an emission mechanism for ultrasound, acting directly on the weld pool. We presented and discussed various innovative concepts based on this method, which allows the introduction of ultrasonic energy in the arc welding without the need of any auxiliary device of welding. In addition, we also presented the variations of this method reported in the literature. Finally, we have described the respective effects attributed to the use of this method in the welding of different materials using various welding processes.

  18. Ultrasound in arc welding: a review.

    PubMed

    da Cunha, Tiago Vieira; Bohórquez, Carlos Enrique Niño

    2015-02-01

    During the last decade, the introduction of ultrasound techniques in arc welding with the intention of improving the operational performance and technical characteristics of the welding processes have been studied intensively. In this work is presented a broad review of the literature surrounding the utilization of this technique. Firstly, we discuss the use of traditional mechanical transducers to generate ultrasound in arc welding. Furthermore, we describe the various methods and their application in arc-welding processes. After, is presented a recent method of introducing ultrasonic energy in arc welding, which forms a potential alternative to the use of traditional mechanical type transducers. This method was originally developed in the late 1990s and is called arc with ultrasonic excitation of current. Here, the arc acts not only as a thermal source but also as an emission mechanism for ultrasound, acting directly on the weld pool. We presented and discussed various innovative concepts based on this method, which allows the introduction of ultrasonic energy in the arc welding without the need of any auxiliary device of welding. In addition, we also presented the variations of this method reported in the literature. Finally, we have described the respective effects attributed to the use of this method in the welding of different materials using various welding processes. PMID:25455190

  19. Arc Welding-Pipe, 3-25. Military Curriculum Materials for Vocational and Technical Education.

    ERIC Educational Resources Information Center

    Ohio State Univ., Columbus. National Center for Research in Vocational Education.

    This instructor guide and text for a secondary-postsecondary level course in arc welding-pipe comprise one of a number of military-developed curriculum packages selected for adaptation to vocational instruction and curriculum development in a civilian setting. Purpose of the course is to teach students to weld 5-inch mild steel schedule 80 pipe,…

  20. Multihole Arc-Welding Orifice

    NASA Technical Reports Server (NTRS)

    Swaim, Benji D.

    1989-01-01

    Modified orifice for variable-polarity plasma-arc welding directs welding plume so it creates clean, even welds on both Inconel(R) and aluminum alloys. Includes eight holes to relieve back pressure in plasma. Quality of welds on ferrous and nonferrous alloys improved as result.

  1. Gas Metal Arc Welding and Flux-Cored Arc Welding. Teacher Edition. Second Edition.

    ERIC Educational Resources Information Center

    Fortney, Clarence; Gregory, Mike

    These instructional materials are designed to improve instruction in Gas Metal Arc Welding (GMAW) and Flux-Cored Arc Welding (FCAW). The following introductory information is included: use of this publication; competency profile; instructional/task analysis; related academic and workplace skills list; tools, materials, and equipment list; and…

  2. Welding arc length control system

    NASA Technical Reports Server (NTRS)

    Iceland, William F. (Inventor)

    1993-01-01

    The present invention is a welding arc length control system. The system includes, in its broadest aspects, a power source for providing welding current, a power amplification system, a motorized welding torch assembly connected to the power amplification system, a computer, and current pick up means. The computer is connected to the power amplification system for storing and processing arc weld current parameters and non-linear voltage-ampere characteristics. The current pick up means is connected to the power source and to the welding torch assembly for providing weld current data to the computer. Thus, the desired arc length is maintained as the welding current is varied during operation, maintaining consistent weld penetration.

  3. 49 CFR 195.226 - Welding: Arc burns.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding: Arc burns. 195.226 Section 195.226 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.226 Welding: Arc burns. (a) Each arc burn must be repaired. (b) An arc burn...

  4. 49 CFR 195.226 - Welding: Arc burns.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding: Arc burns. 195.226 Section 195.226 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.226 Welding: Arc burns. (a) Each arc burn must be repaired. (b) An arc burn...

  5. 49 CFR 195.226 - Welding: Arc burns.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welding: Arc burns. 195.226 Section 195.226 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.226 Welding: Arc burns. (a) Each arc burn must be repaired. (b) An arc burn...

  6. 49 CFR 195.226 - Welding: Arc burns.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding: Arc burns. 195.226 Section 195.226 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.226 Welding: Arc burns. (a) Each arc burn must be repaired. (b) An arc burn...

  7. 49 CFR 195.226 - Welding: Arc burns.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding: Arc burns. 195.226 Section 195.226 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.226 Welding: Arc burns. (a) Each arc burn must be repaired. (b) An arc burn...

  8. Gas arc constriction for plasma arc welding

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

    A welding torch for plasma arc welding apparatus has an inert gas applied circumferentially about the arc column externally of the constricting nozzle so as to apply a constricting force on the arc after it has exited the nozzle orifice and downstream of the auxiliary shielding gas. The constricting inert gas is supplied to a plenum chamber about the body of the torch and exits through a series of circumferentially disposed orifices in an annular wall forming a closure at the forward end of the constricting gas plenum chamber. The constricting force of the circumferential gas flow about the arc concentrates and focuses the arc column into a more narrow and dense column of energy after exiting the nozzle orifice so that the arc better retains its energy density prior to contacting the workpiece.

  9. Laser Assisted Plasma Arc Welding

    SciTech Connect

    FUERSCHBACH,PHILLIP W.

    1999-10-05

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

  10. Controlling Arc Length in Plasma Welding

    NASA Technical Reports Server (NTRS)

    Iceland, W. F.

    1986-01-01

    Circuit maintains arc length on irregularly shaped workpieces. Length of plasma arc continuously adjusted by control circuit to maintain commanded value. After pilot arc is established, contactor closed and transfers arc to workpiece. Control circuit then half-wave rectifies ac arc voltage to produce dc control signal proportional to arc length. Circuit added to plasma arc welding machines with few wiring changes. Welds made with circuit cleaner and require less rework than welds made without it. Beads smooth and free of inclusions.

  11. Method for defect free keyhole plasma arc welding

    NASA Technical Reports Server (NTRS)

    Harwig, Dennis D. (Inventor); Hunt, James F. (Inventor); Ryan, Patrick M. (Inventor); Fisher, Walter J. (Inventor)

    1993-01-01

    A plasma arc welding process for welding metal of increased thickness with one pass includes operating the plasma arc welding apparatus at a selected plasma gas flow rate, travel speed and arc current, to form a weld having a penetration ratio to weld height to weld width, and maintaining the penetration ratio at less than 0.74. Parameters for the plasma gas flow rate, travel speed and arc current are adjusted to a steady state condition during a start up period and maintained during the steady state condition to complete a weld. During a terminal stopping period, the travel speed is stopped and instantaneously replaced by filler wire which adds material to fill the keyhole that had been formed by the welding process. Parameters are subsequently adjusted during the stopping period to terminate the weld in a sound manner.

  12. Percussive arc welding apparatus

    DOEpatents

    Hollar, Jr., Donald L.

    2002-01-01

    A percussive arc welding apparatus includes a generally cylindrical actuator body having front and rear end portions and defining an internal recess. The front end of the body includes an opening. A solenoid assembly is provided in the rear end portion in the internal recess of the body, and an actuator shaft assembly is provided in the front end portion in the internal recess of the actuator body. The actuator shaft assembly includes a generally cylindrical actuator block having first and second end portions, and an actuator shaft having a front end extending through the opening in the actuator body, and the rear end connected to the first end portion of the actuator block. The second end portion of the actuator block is in operational engagement with the solenoid shaft by a non-rigid connection to reduce the adverse rebound effects of the actuator shaft. A generally transversely extending pin is rigidly secured to the rear end of the shaft. One end of the pin is received in a slot in the nose housing sleeve to prevent rotation of the actuator shaft during operation of the apparatus.

  13. 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.

  14. Redundant Grounding Circuit For Arc Welding

    NASA Technical Reports Server (NTRS)

    Burley, Richard K.

    1988-01-01

    Arc burns at loose ground connections prevented. Protective grounding scheme for arc-welding power supply includes four ground leads to workpiece and circuit that automatically turns off welding current if one or two ground leads becomes disconnected. Prevents burns and inadvertent welding occuring where full welding current passes through single loose ground contact.

  15. Control of arc length during gas metal arc welding

    SciTech Connect

    Madigan, R.B.; Quinn, T.P.

    1994-12-31

    An arc-length control system has been developed for gas metal arc welding (GMAW) under spray transfer welding conditions. The ability to monitor and control arc length during arc welding allows consistent weld characteristics to be maintained and therefore improves weld quality. Arc length control has only been implemented for gas tungsten arc welding (GTAW), where an automatic voltage control (AVC) unit adjusts torch-to-work distance. The system developed here compliments the voltage- and current-sensing techniques commonly used for control of GMAW. The system consists of an arc light intensity sensor (photodiode), a Hall-effect current sensor, a personal computer and software implementing a data interpretation and control algorithms. Arc length was measured using both arc light and arc current signals. Welding current was adjusted to maintain constant arc length. A proportional-integral-derivative (PID) controller was used. Gains were automatically selected based on the desired welding conditions. In performance evaluation welds, arc length varied from 2.5 to 6.5 mm while welding up a sloped workpiece (ramp in CTWD) without the control. Arc length was maintained within 1 mm of the desired (5 mm ) with the control.

  16. Arc Welding Dictionary 2. Project HIRE.

    ERIC Educational Resources Information Center

    Gardner, David C.; And Others

    Designed as supplemental material to on-going instruction in the vocational program, this second of three picture dictionary booklets in the Arc Welding series is intended to assist the learning handicapped student to master the core vocabulary taught in the trade. Intended for individual or small group instruction with minimal supervision, this…

  17. Arc Welding Dictionary 3. Project HIRE.

    ERIC Educational Resources Information Center

    Gardner, David C.; And Others

    Designed as supplemental material to on-going instruction in the vocational program, this third of three picture dictionary booklets in the Arc Welding series is intended to assist the learning handicapped student to master the core vocabulary taught in the trade. Intended for individual or small group instruction with minimal supervision, this…

  18. Arc Welding Dictionary 1. Project HIRE.

    ERIC Educational Resources Information Center

    Gardner, David C.; And Others

    Designed as supplemental material to on-going instruction in the vocational program, this first of three picture dictionary booklets in the Arc Welding series is intended to assist the learning handicapped student to master the core vocabulary taught in the trade. Intended for individual or small group instruction with minimal supervision, this…

  19. Arc Welding Teacher's Manual. Project HIRE.

    ERIC Educational Resources Information Center

    Gardner, David C.; And Others

    Designed as supplemental material to on-going instruction in the vocational program, this teacher's manual to the Arc Welding series is intended to accompany three dictionary booklets (available as CE 024 411, CE 024 412, and CE 024 413) for use by handicapped students to help them master the core vocabulary taught in the trade. Information…

  20. Automatic Control Of Length Of Welding Arc

    NASA Technical Reports Server (NTRS)

    Iceland, William F.

    1991-01-01

    Nonlinear relationships among current, voltage, and length stored in electronic memory. Conceptual microprocessor-based control subsystem maintains constant length of welding arc in gas/tungsten arc-welding system, even when welding current varied. Uses feedback of current and voltage from welding arc. Directs motor to set position of torch according to previously measured relationships among current, voltage, and length of arc. Signal paths marked "calibration" or "welding" used during those processes only. Other signal paths used during both processes. Control subsystem added to existing manual or automatic welding system equipped with automatic voltage control.

  1. Long-Lived Electrode For Arc Welding In Vacuum

    NASA Technical Reports Server (NTRS)

    Weeks, Jack L.; Poorman, Richard M.

    1992-01-01

    Improved electrode for gas/tungsten arc welding in vacuum essentially hollow cylinder along which inert gas flows. Interior of cylinder provides large surface area for emission of electrons to form welding arc. Flow of pressurized inert gas inhibits vaporization of hot electrode material. Both features combine to reduce erosion of electrode. Electrode lasts considerably longer in vacuum than conventional electrode.

  2. Welding arc initiator

    DOEpatents

    Correy, T.B.

    1989-05-09

    An improved inert gas shielded tungsten arc welder is disclosed of the type wherein a tungsten electrode is shielded within a flowing inert gas, and, an arc, following ignition, burns between the energized tungsten electrode and a workpiece. The improvement comprises in combination with the tungsten electrode, a starting laser focused upon the tungsten electrode which to ignite the electrode heats a spot on the energized electrode sufficient for formation of a thermionic arc. Interference problems associated with high frequency starters are thus overcome. 3 figs.

  3. Welding arc initiator

    DOEpatents

    Correy, Thomas B.

    1989-01-01

    An improved inert gas shielded tungsten arc welder is disclosed of the type wherein a tungsten electrode is shielded within a flowing inert gas, and, an arc, following ignition, burns between the energized tungsten electrode and a workpiece. The improvement comprises in combination with the tungsten electrode, a starting laser focused upon the tungsten electrode which to ignite the electrode heats a spot on the energized electrode sufficient for formation of a thermionic arc. Interference problems associated with high frequency starters are thus overcome.

  4. Improvement of Weld Characteristics by Laser-Arc Double-Sided Welding Compared to Single Arc Welding

    NASA Astrophysics Data System (ADS)

    Lei, Zhenglong; Zhang, Kezhao; Hu, Xue; Yang, Yuhe; Chen, Yanbin; Wu, Yichao

    2015-11-01

    The single arc welding and laser-arc double-sided welding (LADSW) processes are investigated by virtue of test welds. The impacts of the laser beam during the LADSW process on the weld characteristics are studied from weld geometry, crystal morphology, and the mechanical properties of the joints. Compared with the single arc welding, the LADSW process improves the energy density and reduces the range of arc action, which together leads to a doubling of weld penetration depth. When penetrated by the laser beam, the liquid metal of the arc welding pool experiences severe fluctuations, leading to a finer grain size in the range of 17-26 μm in the LADSW weld, a reduction of nearly 63% compared to the grains in the single arc weld. The tensile strength and elongation-to-failure of the LADSW weld were increased by nearly 10 and 100% over the single arc welding, respectively.

  5. Preventing Arc Welding From Damaging Electronics

    NASA Technical Reports Server (NTRS)

    Sargent, Noel; Mareen, D.

    1988-01-01

    Shielding technique developed to protect sensitive electronic equipment from damage due to electromagnetic disturbances produced by arc welding. Established acceptable alternative in instances in which electronic equipment cannot be removed prior to arc welding. Guidelines established for open, unshielded welds. Procedure applicable to robotics or computer-aided manufacturing.

  6. Welding arc maculopathy and fluphenazine.

    PubMed Central

    Power, W. J.; Travers, S. P.; Mooney, D. J.

    1991-01-01

    A 45-year-old male patient presented with a bilateral maculopathy following unprotected exposure of less than two minutes' duration to a manual metal arc welding unit. He had been receiving the drug fluphenazine for the previous 10 years for treatment of depression. We believe that the drug fluphenazine, which had accumulated in his retinal pigment epithelium, may have rendered him particularly susceptible to retinal photic damage. Images PMID:1854700

  7. 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.

  8. Dilution in single pass arc welds

    SciTech Connect

    DuPont, J.N.; Marder, A.R.

    1996-06-01

    A study was conducted on dilution of single pass arc welds of type 308 stainless steel filler metal deposited onto A36 carbon steel by the plasma arc welding (PAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), and submerged arc welding (SAW) processes. Knowledge of the arc and melting efficiency was used in a simple energy balance to develop an expression for dilution as a function of welding variables and thermophysical properties of the filler metal and substrate. Comparison of calculated and experimentally determined dilution values shows the approach provides reasonable predictions of dilution when the melting efficiency can be accurately predicted. The conditions under which such accuracy is obtained are discussed. A diagram is developed from the dilution equation which readily reveals the effect of processing parameters on dilution to aid in parameter optimization.

  9. 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.

  10. Influence of the arc plasma parameters on the weld pool profile in TIG welding

    NASA Astrophysics Data System (ADS)

    Toropchin, A.; Frolov, V.; Pipa, A. V.; Kozakov, R.; Uhrlandt, D.

    2014-11-01

    Magneto-hydrodynamic simulations of the arc and fluid simulations of the weld pool can be beneficial in the analysis and further development of arc welding processes and welding machines. However, the appropriate coupling of arc and weld pool simulations needs further improvement. The tungsten inert gas (TIG) welding process is investigated by simulations including the weld pool. Experiments with optical diagnostics are used for the validation. A coupled computational model of the arc and the weld pool is developed using the software ANSYS CFX. The weld pool model considers the forces acting on the motion of the melt inside and on the surface of the pool, such as Marangoni, drag, electromagnetic forces and buoyancy. The experimental work includes analysis of cross-sections of the workpieces, highspeed video images and spectroscopic measurements. Experiments and calculations have been performed for various currents, distances between electrode and workpiece and nozzle diameters. The studies show the significant impact of material properties like surface tension dependence on temperature as well as of the arc structure on the weld pool behaviour and finally the weld seam depth. The experimental weld pool profiles and plasma temperatures are in good agreement with computational results.

  11. Method for controlling gas metal arc welding

    DOEpatents

    Smartt, Herschel B.; Einerson, Carolyn J.; Watkins, Arthur D.

    1989-01-01

    The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections.

  12. Method for controlling gas metal arc welding

    DOEpatents

    Smartt, H.B.; Einerson, C.J.; Watkins, A.D.

    1987-08-10

    The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections. 3 figs., 1 tab.

  13. Melting Efficiency During Plasma Arc Welding

    NASA Technical Reports Server (NTRS)

    McClure, J.C.; Evans, D. M.; Tang, W.; Nunes, A. C.

    1999-01-01

    A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 aluminum. Arc Efficiency was measured calorimetrically and ranged between 48% and 66%. Melting efficiency depends on the weld pool shape. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Higher currents are thought to raise arc pressure and depress the liquid at the bottom of the weld pool causing a more nearly two dimensional heat flow condition.

  14. Neural-Network Modeling Of Arc Welding

    NASA Technical Reports Server (NTRS)

    Anderson, Kristinn; Barnett, Robert J.; Springfield, James F.; Cook, George E.; Strauss, Alvin M.; Bjorgvinsson, Jon B.

    1994-01-01

    Artificial neural networks considered for use in monitoring and controlling gas/tungsten arc-welding processes. Relatively simple network, using 4 welding equipment parameters as inputs, estimates 2 critical weld-bead paramaters within 5 percent. Advantage is computational efficiency.

  15. Grain refinement control in TIG arc welding

    NASA Technical Reports Server (NTRS)

    Iceland, W. F.; Whiffen, E. L. (Inventor)

    1975-01-01

    A method for controlling grain size and weld puddle agitation in a tungsten electrode inert gas welding system to produce fine, even grain size and distribution is disclosed. In the method the frequency of dc welding voltage pulses supplied to the welding electrode is varied over a preselected frequency range and the arc gas voltage is monitored. At some frequency in the preselected range the arc gas voltage will pass through a maximum. By maintaining the operating frequency of the system at this value, maximum weld puddle agitation and fine grain structure are produced.

  16. APPARATUS AND METHOD FOR ARC WELDING

    DOEpatents

    Noland, R.A.; Stone, C.C.

    1960-05-10

    An apparatus and method are given for forming a welding arc which is rotated by a magnetic field very rapidly about an annular electrode so that a weld is produced simultaneously over all points of an annular or closed path. This invention inhibits outgassing from the jacket of a fuel slug which is being welded by adjusting the pressure throughout the welding cycle to establish a balance between the gas pressure within the jacket and that of the atmosphere surrounding the jacket. Furthermore, an improved control of the magnetic field producing rotation of the welding arc is disclosed whereby this rotation is prevented from splashing about the metal being welded as the welding arc makes it molten.

  17. Forming Completely Penetrated Welded T-joints when Pulsed Arc Welding

    NASA Astrophysics Data System (ADS)

    Krampit, N. Yu; Krampit, M. A.; Sapozhkov, A. S.

    2016-04-01

    The paper is focused on revealing the influence of welding parameters on weld formation when pulsed arc welding. As an experimental sample a T-joint over 10 mm was selected. Welding was carried out in flat position, which required no edge preparation but provided mono-directional guaranteed root penetration. The following parameters of welding were subjected to investigation: gap in the joint, wire feed rate and incline angles of the torch along and across the weld axis. Technological recommendations have been made with respect to pulsed arc welding; the cost price of product manufacturing can be reduced on their basis due to reduction of labor input required by machining, lowering consumption of welding materials and electric power.

  18. METHOD OF OBTAINING AN IMPROVED WELD IN INERT ARC WELDING

    DOEpatents

    Correy, T.B.

    1962-12-11

    A method is reported for inert arc welding. An a-c welding current is applied to the workpiece and welding electrode such that the positive portion of each cycle thereof, with the electrode positive, has only sufficient energy to clean the surface of the workpiece and the negative portion of each cycle thereof, with the electrode negative, contains the energy required to weld. (AEC)

  19. Process Simulation of Gas Metal Arc Welding Software

    2005-09-06

    ARCWELDER is a Windows-based application that simulates gas metal arc welding (GMAW) of steel and aluminum. The software simulates the welding process in an accurate and efficient manner, provides menu items for process parameter selection, and includes a graphical user interface with the option to animate the process. The user enters the base and electrode material, open circuit voltage, wire diameter, wire feed speed, welding speed, and standoff distance. The program computes the size andmore » shape of a square-groove or V-groove weld in the flat position. The program also computes the current, arc voltage, arc length, electrode extension, transfer of droplets, heat input, filler metal deposition, base metal dilution, and centerline cooling rate, in English or SI units. The simulation may be used to select welding parameters that lead to desired operation conditions.« less

  20. Process Simulation of Gas Metal Arc Welding Software

    SciTech Connect

    Murray, Paul E.

    2005-09-06

    ARCWELDER is a Windows-based application that simulates gas metal arc welding (GMAW) of steel and aluminum. The software simulates the welding process in an accurate and efficient manner, provides menu items for process parameter selection, and includes a graphical user interface with the option to animate the process. The user enters the base and electrode material, open circuit voltage, wire diameter, wire feed speed, welding speed, and standoff distance. The program computes the size and shape of a square-groove or V-groove weld in the flat position. The program also computes the current, arc voltage, arc length, electrode extension, transfer of droplets, heat input, filler metal deposition, base metal dilution, and centerline cooling rate, in English or SI units. The simulation may be used to select welding parameters that lead to desired operation conditions.

  1. Plasma arc welding repair of space flight hardware

    NASA Technical Reports Server (NTRS)

    Hoffman, David S.

    1993-01-01

    Repair and refurbishment of flight and test hardware can extend the useful life of very expensive components. A technique to weld repair the main combustion chamber of space shuttle main engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloyZ, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloyZ while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

  2. Plasma arc welding repair of space flight hardware

    NASA Technical Reports Server (NTRS)

    Hoffman, David S.

    1993-01-01

    A technique to weld repair the main combustion chamber of Space Shuttle Main Engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloy-Z, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloy-Z while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

  3. Physical characteristics of welding arc ignition process

    NASA Astrophysics Data System (ADS)

    Shi, Linan; Song, Yonglun; Xiao, Tianjiao; Ran, Guowei

    2012-07-01

    The existing research of welding arc mainly focuses on the stable combustion state and the research on the mechanism of welding arc ignition process is quite lack. The tungsten inert gas(TIG) touch arc ignition process is observed via a high speed camera and the high time resolution spectral diagnosis system. The changing phenomenon of main ionized element provided the electrons in the arc ignition is found. The metallic element is the main contributor to provide the electrons at the beginning of the discharging, and then the excitated shielding gas element replaces the function of the metallic element. The electron density during the period of the arc ignition is calculated by the Stark-broadened lines of Hα. Through the discussion with the repeatability in relaxation phenomenon, the statistical regularity in the arc ignition process is analyzed. The similar rules as above are observed through the comparison with the laser-assisted arc ignition experiments and the metal inert gas(MIG) arc ignition experiments. This research is helpful to further understanding on the generation mechanism of welding arc ignition and also has a certain academic and practical significance on enriching the welding physical theoretical foundation and improving the precise monitoring on automatic arc welding process.

  4. Latest MIG, TIG arc-YAG laser hybrid welding systems for various welding products

    NASA Astrophysics Data System (ADS)

    Ishide, Takashi; Tsubota, Shuho; Watanabe, Masao

    2003-03-01

    Laser welding is capable of high-efficiency low-strain welding, and so its applications are started to various products. We have also put the high-power YAG laser of up to 10 kW to practical welding use for various products. On the other hand the weakest point of this laser welding is considered to be strict in the welding gap aiming allowance. In order to solve this problem, we have developed hybrid welding of TIG, MIG arc and YAG laser, taking the most advantages of both the laser and arc welding. Since the electrode is coaxial to the optical axis of the YAG laser in this process, it can be applied to welding of various objects. In the coaxial MIG, TIG-YAG welding, in order to make irradiation positions of the YAG laser beams having been guided in a wire or an electrode focused to the same position, the beam transmitted in fibers is separated to form a space between the separated beams, in which the laser is guided. With this method the beam-irradiating area can be brought near or to the arc-generating point. This enables welding of all directions even for the member of a three-dimensional shape. This time we carried out welding for various materials and have made their welding of up to 1 mm or more in welding groove gap possible. We have realized high-speed 1-pass butt welding of 4m/min in welding speed with the laser power of 3 kW for an aluminum alloy plate of approximately 4 mm thick. For a mild steel plate also we have realized butt welding of 1m/min with 5 kW for 6 mm thick. Further, in welding of stainless steel we have shown its welding possibility, by stabilizing the arc with the YAG laser in the welding atmosphere of pure argon, and shown that this welding is effective in high-efficiency welding of various materials. Here we will report the fundamental welding performances and applications to various objects for the coaxial MIG, TIG-YAG welding we have developed.

  5. Hybrid Laser-Arc Welding Tanks Steels

    NASA Astrophysics Data System (ADS)

    Turichin, G.; Tsibulskiy, I.; Kuznetsov, M.; Akhmetov, A.; Klimova-Korsmik, O.

    2016-04-01

    The results investigate hybrid laser-arc welding of high strength steels using design responsible metallic construction and the highest strength body of vehicles. Welds from modern high strength steels grade Hardox 400, Hardox 450, Armox 600T and AB were created. High power fiber laser LS-15 with output 15 kW and arc rectifier VDU - 1500 DC were used in the experiment. Results of the metallographic research and mechanical tests are presented.

  6. Aligning Plasma-Arc Welding Oscillations

    NASA Technical Reports Server (NTRS)

    Norris, Jeff; Fairley, Mike

    1989-01-01

    Tool aids in alignment of oscillator probe on variable-polarity plasma-arc welding torch. Probe magnetically pulls arc from side to side as it moves along joint. Tensile strength of joint depends on alignment of weld bead and on alignment of probe. Operator installs new tool on front of torch body, levels it with built-in bubble glass, inserts probe in slot on tool, and locks probe in place. Procedure faster and easier and resulting alignment more accurate and repeatable.

  7. Shielded Metal Arc Welding. Welding Module 4. Instructor's Guide.

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

    This guide is intended to assist vocational educators in teaching an eight-unit module in shielded metal arc welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: safety; theory, power sources, and…

  8. Gas Metal Arc Welding. Welding Module 5. Instructor's Guide.

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

    This guide is intended to assist vocational educators in teaching an eight-unit module in gas metal arc welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: safety and testing, gas metal arc…

  9. Laser assisted arc welding for aluminum alloys

    SciTech Connect

    Fuerschbach, P.W.

    2000-01-01

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

  10. 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.

  11. Thermal efficiency of arc welding processes

    SciTech Connect

    DuPont, J.N.; Marder, A.R.

    1995-12-01

    A study was conducted on the arc and melting efficiency of the plasma arc, gas tungsten arc, gas metal arc, and submerged arc welding processes. The results of this work are extended to develop a quantitative method for estimating weld metal dilution in a companion paper. Arc efficiency was determined as a function of current for each process using A36 steel base metal. Melting efficiency was evaluated with variations in arc power and travel speed during deposition of austenitic stainless steel filler metal onto A36 steel substrates. The arc efficiency did not vary significantly within a given process over the range of currents investigated. A semi-empirical relation was developed for the melting efficiency as a function of net arc power and travel speed, which described the experimental data well. An interaction was observed between the arc and melting efficiency. A low arc efficiency factor limits the power delivered to the substrate which, in turn, limits the maximum travel speed for a given set of conditions. High melting efficiency is favored by high arc powers and travel speeds. As a result, a low arc efficiency can limit the maximum obtainable melting efficiency.

  12. ARC length control for plasma welding

    NASA Technical Reports Server (NTRS)

    Iceland, William F. (Inventor)

    1988-01-01

    A control system to be used with a plasma arc welding apparatus is disclosed. The plasma arc welding apparatus includes a plasma arc power supply, a contactor, and an electrode assembly for moving the electrode relative to a work piece. The electrode assembly is raised or lowered by a drive motor. The present apparatus includes a plasma arc adapter connected across the power supply to measure the voltage across the plasma arc. The plasma arc adapter forms a dc output signal input to a differential amplifier. A second input is defined by an adjustable resistor connected to a dc voltage supply to permit operator control. The differential amplifier forms an output difference signal provided to an adder circuit. The adder circuit then connects with a power amplifier which forms the driving signal for the motor. In addition, the motor connects to a tachometor which forms a feedback signal delivered to the adder to provide damping, therby avoiding servo loop overshoot.

  13. Welding torch with arc light reflector

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1986-01-01

    A welding torch arc light reflector is disclosed for welding torches having optical viewing systems. A schematic of a welding torch having an internal coaxial viewing system consisting of a lens which focuses the field of view of the weld scene of the workpiece onto the end of the fiberoptic bundle is provided. The transmitted image of the fiberoptic bundle is provided to a camera lens which focuses it onto a TV sensor array for transmission. To improve the parity of the image of the monitoring system, an arc light reflector is shown fitted to the end of the torch housing or gas cup. The arc light reflector has an internal conical section portion which is polished to serve as a mirror which reflects the bright arc light back onto the darker areas of the weld area and thereby provides a more detailed image for the monitoring system. The novelty of the invention lies in the use of an arc light reflector on welding torches having optical viewing systems.

  14. Materials participation in welded joints manufacturing

    NASA Astrophysics Data System (ADS)

    Ghenghea, L. D.

    2016-08-01

    Management of materials dilution to form a joint with higher features asked by complex metallic structures is a problem that took attention and efforts of welding processes researchers and this communication will give a little contribution presenting some scientific and experimental results of dilution processes studied by Welding Research Group from Iasi, Romania, TCM Department. Liquid state welding processes have a strong dependence related to dilution of base and filler materials, the most important are for automatic joining using welding. The paper presents a review of some scientific works already published and their contributions, results of dilution coefficient evaluation using weighing, graphics and software applied for shielded metal arc welding process. Paper results could be used for welders’ qualification, welding procedure specification and other welding processes researchers’ activities. The results of Welding Research Group from Iasi, Romania, TCM Department, show dilution coefficient values between 20-30 % of base material and 70-80 % of filler material for studied welding process.

  15. Automatic programming of arc welding robots

    NASA Astrophysics Data System (ADS)

    Padmanabhan, Srikanth

    Automatic programming of arc welding robots requires the geometric description of a part from a solid modeling system, expert weld process knowledge and the kinematic arrangement of the robot and positioner automatically. Current commercial solid models are incapable of storing explicitly product and process definitions of weld features. This work presents a paradigm to develop a computer-aided engineering environment that supports complete weld feature information in a solid model and to create an automatic programming system for robotic arc welding. In the first part, welding features are treated as properties or attributes of an object, features which are portions of the object surface--the topological boundary. The structure for representing the features and attributes is a graph called the Welding Attribute Graph (WAGRAPH). The method associates appropriate weld features to geometric primitives, adds welding attributes, and checks the validity of welding specifications. A systematic structure is provided to incorporate welding attributes and coordinate system information in a CSG tree. The specific implementation of this structure using a hybrid solid modeler (IDEAS) and an object-oriented programming paradigm is described. The second part provides a comprehensive methodology to acquire and represent weld process knowledge required for the proper selection of welding schedules. A methodology of knowledge acquisition using statistical methods is proposed. It is shown that these procedures did little to capture the private knowledge of experts (heuristics), but helped in determining general dependencies, and trends. A need was established for building the knowledge-based system using handbook knowledge and to allow the experts further to build the system. A methodology to check the consistency and validity for such knowledge addition is proposed. A mapping shell designed to transform the design features to application specific weld process schedules is described

  16. Sensing the gas metal arc welding process

    NASA Technical Reports Server (NTRS)

    Carlson, N. M.; Johnson, J. A.; Smartt, H. B.; Watkins, A. D.; Larsen, E. D.; Taylor, P. L.; Waddoups, M. A.

    1994-01-01

    Control of gas metal arc welding (GMAW) requires real-time sensing of the process. Three sensing techniques for GMAW are being developed at the Idaho National Engineering Laboratory (INEL). These are (1) noncontacting ultrasonic sensing using a laser/EMAT (electromagnetic acoustic transducer) to detect defects in the solidified weld on a pass-by-pass basis, (2) integrated optical sensing using a CCD camera and a laser stripe to obtain cooling rate and weld bead geometry information, and (3) monitoring fluctuations in digitized welding voltage data to detect the mode of metal droplet transfer and assure that the desired mass input is achieved.

  17. Agricultural Construction Volume I. Arc Welding Project Construction. Instructor's Guide.

    ERIC Educational Resources Information Center

    Brzozowski, Dick; Admire, Myron

    This guide contains instructor's materials for teaching a secondary agricultural construction course consisting of instructional units on arc welding (8 lessons) and project construction (14 lessons). The materials for each unit include student objectives, a list of competencies from which the objectives were derived, suggestions for motivating…

  18. Optical Arc-Length Sensor For TIG Welding

    NASA Technical Reports Server (NTRS)

    Smith, Matthew A.

    1990-01-01

    Proposed subsystem of tungsten/inert-gas (TIG) welding system measures length of welding arc optically. Viewed by video camera, in one of three alternative optical configurations. Length of arc measured instead of inferred from voltage.

  19. What makes an electric welding arc perform its required function

    SciTech Connect

    Correy, T.B.

    1982-09-01

    The physics of direct current and alternating current welding arcs, the heat transfer of direct current welding arcs, the characteristics of dc welding and ac welding power supplies and recommendations for the procurement and maintenance of precision power supplies are discussed. (LCL)

  20. 29 CFR 1910.254 - Arc welding and cutting.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 29 Labor 5 2012-07-01 2012-07-01 false Arc welding and cutting. 1910.254 Section 1910.254 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.254 Arc welding and cutting. (a) General—(1) Equipment selection. Welding equipment shall be chosen for safe application to the work to...

  1. 29 CFR 1910.254 - Arc welding and cutting.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 29 Labor 5 2010-07-01 2010-07-01 false Arc welding and cutting. 1910.254 Section 1910.254 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.254 Arc welding and cutting. (a) General—(1) Equipment selection. Welding equipment shall be chosen for safe application to the work to...

  2. 29 CFR 1910.254 - Arc welding and cutting.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 29 Labor 5 2011-07-01 2011-07-01 false Arc welding and cutting. 1910.254 Section 1910.254 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.254 Arc welding and cutting. (a) General—(1) Equipment selection. Welding equipment shall be chosen for safe application to the work to...

  3. 29 CFR 1910.254 - Arc welding and cutting.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 29 Labor 5 2014-07-01 2014-07-01 false Arc welding and cutting. 1910.254 Section 1910.254 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.254 Arc welding and cutting. (a) General—(1) Equipment selection. Welding equipment shall be chosen for safe application to the work to...

  4. 29 CFR 1910.254 - Arc welding and cutting.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 29 Labor 5 2013-07-01 2013-07-01 false Arc welding and cutting. 1910.254 Section 1910.254 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.254 Arc welding and cutting. (a) General—(1) Equipment selection. Welding equipment shall be chosen for safe application to the work to...

  5. A study of arc force, pool depression and weld penetration during gas tungsten arc welding

    SciTech Connect

    Rokhlin, S.I.; Guu, A.C. . Dept. of Welding Engineering)

    1993-08-01

    Weld pool depression, arc force, weld penetration, and their interrelations have been studied as a function of welding current. Pool depression and welding arc force have been measured simultaneously using a recently developed technique. The authors found quadratic dependence of arc force on current, confirming similar findings in previous studies. Pool depression is essentially zero below a threshold level of current (200 A in this experiment) and then increases quadratically with current. A perfectly linear relation between arc force and pool depression was found in the current range from 200 to 350 A, with pool depression onset at about 0.35 g force (0.34 [center dot] 10[sup [minus]2]N). The total surface tension and gravitational forces were calculated, from the measured surface topography, and found to be about five times that required to balance the arc force at 300 A. Thus electromagnetic and hydrodynamic forces must be taken into account to explain the measured levels of pool depression. The relation between weld penetration and pool depression for different welding currents has been established. Three distinct regimes of weld penetration on weld current were found.

  6. Gas Tungsten Arc Welding and Plasma Arc Cutting. Teacher Edition.

    ERIC Educational Resources Information Center

    Fortney, Clarence; And Others

    This welding curriculum guide treats two topics in detail: the care of tungsten electrodes and the entire concept of contamination control and the hafnium electrode and its importance in dual-air cutting systems that use compressed shop air for plasma arc cutting activities. The guide contains three units of instruction that cover the following…

  7. Sensor control of robot arc welding

    NASA Technical Reports Server (NTRS)

    Sias, F. R., Jr.

    1985-01-01

    A basic problem in the application of robots for welding which is how to guide a torch along a weld seam using sensory information was studied. Improvement of the quality and consistency of certain Gas Tungsten Arc welds on the Space Shuttle Main Engine (SSME) that are too complex geometrically for conventional automation and therefore are done by hand was examined. The particular problems associated with space shuttle main egnine (SSME) manufacturing and weld-seam tracking with an emphasis on computer vision methods were analyzed. Special interface software for the MINC computr are developed which will allow it to be used both as a test system to check out the robot interface software and later as a development tool for further investigation of sensory systems to be incorporated in welding procedures.

  8. Mathematical Model Of Variable-Polarity Plasma Arc Welding

    NASA Technical Reports Server (NTRS)

    Hung, R. J.

    1996-01-01

    Mathematical model of variable-polarity plasma arc (VPPA) welding process developed for use in predicting characteristics of welds and thus serves as guide for selection of process parameters. Parameters include welding electric currents in, and durations of, straight and reverse polarities; rates of flow of plasma and shielding gases; and sizes and relative positions of welding electrode, welding orifice, and workpiece.

  9. Internal Filler-Wire Feed For Arc Welding

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.; Dyer, Gerald E.

    1990-01-01

    Tungsten electrode for gas/tungsten arc welding contains lengthwise channel for feeding filler wire to weld joint. Channel makes it unnecessary to feed wire through guides outside electrode, conserving valuable space near weld and protects wire from deformation by contact with other parts in vicinity of weld. Helpful in robotic or automatic welding.

  10. Thermocapillary and arc phenomena in stainless steel welds

    NASA Astrophysics Data System (ADS)

    Pierce, S. W.

    1993-12-01

    The goal of this paper is to study the effects of power level and distribution on thermocapillary induced weld shape and of arc factors on weld shape. Thermocapillarity is apparent in both conduction mode electron beam welds (EBW) and gas tungsten arc (GTA) welds, particularly in the former. A non-Gaussian arc distribution is suggested to account for the differences between the two welding processes. At higher current levels (200-300 A), plasma shear force also contributes to weld shape development. Evidence suggests that thermocapillary flow reversal is not a factor in normal GTA welds; EBW flow reversal occurs only at high power density levels where the keyhole mode is present.

  11. Cheaper Custom Shielding Cups For Arc Welding

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.

    1992-01-01

    New way of making special-purpose shielding cups for gas/tungsten arc welding from hobby ceramic greatly reduces cost. Pattern machined in plastic. Plaster-of-paris mold made, and liquid ceramic poured into mold. Cost 90 percent less than cup machined from lava rock.

  12. 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.

  13. Submerged arc welding of heavy plate

    NASA Technical Reports Server (NTRS)

    Wilson, R. A.

    1972-01-01

    The submerged arc process is particularly suitable for heavy plate welding because of its ability to combine very high deposit rates along with excellent quality. It does these things without the smoke and spatter often accompanying other processes. It is available today in several forms that are pointed to the fabricators of heavy sections with long, short or round about welds. Tandem arc full automatic equipment is particularly suitable for those long heavy welds where speed and deposit rate are of the first order. An attachment called long stick-out which makes use of the IR drop on long electrode extensions can be included on this equipment to increase deposition rates 50% or more.

  14. [Study on the arc spectral information for welding quality diagnosis].

    PubMed

    Li, Zhi-Yong; Gu, Xiao-Yan; Li, Huan; Yang, Li-Jun

    2009-03-01

    Through collecting the spectral signals of TIG and MIG welding arc with spectrometer, the arc light radiations were analyzed based on the basic theory of plasma physics. The radiation of welding arc distributes over a broad range of frequency, from infrared to ultraviolet. The arc spectrum is composed of line spectra and continuous spectra. Due to the variation of metal density in the welding arc, there is great difference between the welding arc spectra of TIG and MIG in both their intensity and distribution. The MIG welding arc provides more line spectra of metal and the intensity of radiation is greater than TIG. The arc spectrum of TIG welding is stable during the welding process, disturbance factors that cause the spectral variations can be reflected by the spectral line related to the corresponding element entering the welding arc. The arc spectrum of MIG welding will fluctuate severely due to droplet transfer, which produces "noise" in the line spectrum aggregation zone. So for MIG welding, the spectral zone lacking spectral line is suitable for welding quality diagnosis. According to the characteristic of TIG and MIG, special spectral zones were selected for welding quality diagnosis. For TIG welding, the selected zone is in ultraviolet zone (230-300 nm). For MIG welding, the selected zone is in visible zone (570-590 nm). With the basic theory provided for welding quality diagnosis, the integral intensity of spectral signal in the selected zone of welding process with disturbing factor was studied to prove the theory. The results show that the welding quality and disturbance factors can be diagnosed with good signal to noise ratio in the selected spectral zone compared with signal in other spectral zone. The spectral signal can be used for real-time diagnosis of the welding quality.

  15. Inert-Gas Diffuser For Plasma Or Arc Welding

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Spencer, Carl N.; Hosking, Timothy J.

    1994-01-01

    Inert-gas diffuser provides protective gas cover for weld bead as it cools. Follows welding torch, maintaining continuous flow of argon over newly formed joint and prevents it from oxidizing. Helps to ensure welds of consistently high quality. Devised for plasma arc keyhole welding of plates of 0.25-in. or greater thickness, also used in tungsten/inert-gas and other plasma or arc welding processes.

  16. Electrochemical Testing of Gas Tungsten Arc Welded and Reduced Pressure Electron Beam Welded Alloy 22

    SciTech Connect

    Day, S D; Wong, F M G; Gordon, S R; Wong, L L; Rebak, R B

    2003-09-07

    Alloy 22 (N06022) is the material selected for the fabrication of the outer shell of the nuclear waste containers for the Yucca Mountain high-level nuclear waste repository site. A key technical issue in the Yucca Mountain waste package program has been the integrity of container weld joints. The currently selected welding process for fabricating and sealing the containers is the traditional gas tungsten arc welding (GTAW) or TIG method. An appealing faster alternative technique is reduced pressure electron beam (RPEB) welding. Standard electrochemical tests were carried on GTAW and RPEB welds as well as on base metal to determine their relative corrosion behavior in SCW at 90 C (alkaline), 1 M HCl at 60 C (acidic) and 1 M NaCl at 90 C (neutral) solutions. Results show that for all practical purposes, the three tested materials had the electrochemical behavior in the three tested solutions.

  17. Specifics of Mode Parameters Choice Under Twin Arc Welding of Fillet Welds

    NASA Astrophysics Data System (ADS)

    Melnikov, A. U.; Fiveyskiy, A. M.; Sholokhov, M. A.

    2016-04-01

    The present article covers the specifics of mode parameters choice under twin arc welding of fillet welds. The necessity of mode parameters adjustment at the second arc due to heated metal of the first arc was proven. The obtained correction indexes allow us to determine with satisfactory accuracy the mode parameters under given dimensions of weld joint.

  18. 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.

  19. More About Arc-Welding Process for Making Carbon Nanotubes

    NASA Technical Reports Server (NTRS)

    Benavides, Jeanette M.; Leidecker, Henning

    2005-01-01

    High-quality batches of carbon nanotubes are produced at relatively low cost in a modified atmospheric-pressure electric-arc welding process that does not include the use of metal catalysts. What would normally be a welding rod and a weldment are replaced by an amorphous carbon anode rod and a wider, hollow graphite cathode rod. Both electrodes are water-cooled. The cathode is immersed in ice water to about 0.5 cm from the surface. The system is shielded from air by flowing helium during arcing. As the anode is consumed during arcing at 20 to 25 A, it is lowered to maintain it at an approximately constant distance above the cathode. The process causes carbon nanotubes to form on the lowest 5 cm of the anode. The arcing process is continued until the anode has been lowered to a specified height. The nanotube-containing material is then harvested. The additional information contained in the instant report consists mostly of illustrations of carbon nanotubes and a schematic diagram of the arc-welding setup, as modified for the production of carbon nanotubes.

  20. Exposure assessment of aluminum arc welding radiation.

    PubMed

    Peng, Chiung-yu; Lan, Cheng-hang; Juang, Yow-jer; Tsao, Ta-ho; Dai, Yu-tung; Liu, Hung-hsin; Chen, Chiou-jong

    2007-10-01

    The purpose of this study is to evaluate the non-ionizing radiation (NIR) exposure, especially optical radiation levels, and potential health hazard from aluminum arc welding processes based on the American Conference of Governmental Industrial Hygienists (ACGIH) method. The irradiance from the optical radiation emissions can be calculated with various biological effective parameters [i.e., S(lambda), B(lambda), R(lambda)] for NIR hazard assessments. The aluminum arc welding processing scatters bright light with NIR emission including ultraviolet radiation (UVR), visible, and infrared spectra. The UVR effective irradiance (Eeff) has a mean value of 1,100 microW cm at 100 cm distance from the arc spot. The maximum allowance time (tmax) is 2.79 s according to the ACGIH guideline. Blue-light hazard effective irradiance (EBlue) has a mean value of 1840 microW cm (300-700 nm) at 100 cm with a tmax of 5.45 s exposure allowance. Retinal thermal hazard effective calculation shows mean values of 320 mW cm(-2) sr(-1) and 25.4 mW (cm-2) (380-875 nm) for LRetina (spectral radiance) and ERetina (spectral irradiance), respectively. From this study, the NIR measurement from welding optical radiation emissions has been established to evaluate separate types of hazards to the eye and skin simultaneously. The NIR exposure assessment can be applied to other optical emissions from industrial sources. The data from welding assessment strongly suggest employees involved in aluminum welding processing must be fitted with appropriate personal protection devices such as masks and gloves to prevent serious injuries of the skin and eyes upon intense optical exposure.

  1. Arc instability in shallow water wet welding

    SciTech Connect

    Nixon, J.H.; Graham, S.R.B.

    1993-12-31

    A series of wet welding trials, undertaken at Cranfield as part of a larger program, examined the relative stability of the process across a range of shallow water depths. The effect of welder skill, and the use of computer based data logging equipment, was also evaluated. By means of the data logging system, it was confirmed that welding carried out at a depth of 6 meters was markedly more stable than similar welds at 1.5 and 3 meters. Objective effects of welder skill were also noted, most markedly the ability of the skilled welder to operate at lower arc voltages and travel speeds. The use of the computer based data logging and analysis system was of great assistance in the program, and the use of similar equipment is highly recommended.

  2. Plasma arc welding takes on the advanced solid rocket motor

    NASA Astrophysics Data System (ADS)

    Irving, Bob

    1992-12-01

    The general design of the Advanced Solid Rocket Motor (ASRM), developed with the aim of improving the flight safety, reliability, producibility, and performance of the Space Shuttle Motor, is described. The material for the new ASRM will be the more weldable HP-9-4-30 steel; it will be welded by the plasma arc process used in the straight polarity mode. An HP-9-4-25 filler metal will be used to deposit the fill pass and a cap pass; the welding operation will be computer controlled.

  3. Training Materials Sourcebook. Welding, Brazing, and Flame-Cutting. Voc./Tec. Resources Series Number 2.

    ERIC Educational Resources Information Center

    Canadian Commission of Employment and Immigration, Ottawa (Ontario).

    Second in a resource series (see note), this annotated bibliography provides detailed information on training curriculum and instructional materials for welding, brazing, and flame-cutting. The materials are divided into thirty-fie sections by topic and type. Specific topic areas include gas and arc welding; arc welding; oxyacetylene welding and…

  4. Optimization of Gas Metal Arc Welding Process Parameters

    NASA Astrophysics Data System (ADS)

    Kumar, Amit; Khurana, M. K.; Yadav, Pradeep K.

    2016-09-01

    This study presents the application of Taguchi method combined with grey relational analysis to optimize the process parameters of gas metal arc welding (GMAW) of AISI 1020 carbon steels for multiple quality characteristics (bead width, bead height, weld penetration and heat affected zone). An orthogonal array of L9 has been implemented to fabrication of joints. The experiments have been conducted according to the combination of voltage (V), current (A) and welding speed (Ws). The results revealed that the welding speed is most significant process parameter. By analyzing the grey relational grades, optimal parameters are obtained and significant factors are known using ANOVA analysis. The welding parameters such as speed, welding current and voltage have been optimized for material AISI 1020 using GMAW process. To fortify the robustness of experimental design, a confirmation test was performed at selected optimal process parameter setting. Observations from this method may be useful for automotive sub-assemblies, shipbuilding and vessel fabricators and operators to obtain optimal welding conditions.

  5. New materials for welding and surfacing

    NASA Astrophysics Data System (ADS)

    Kozyrev, N. A.; Galevsky, G. V.; Kryukov, R. E.; Titova, D. A.; Shurupov, V. M.

    2016-09-01

    The paper provides description of research into the influence of new materials and technologies on quality parameters of welds and deposited metal carried out in the research and production centre “Welding processes and technologies”. New welding technologies of tanks for northern conditions are considered, as well as technologies of submerged arc welding involving fluxing agents AN - 348, AN - 60, AN - 67, OK.10.71 and carbon-fluorine containing additives; new flux cored wires and surfacing technologies, teaching programs and a trainer for welders are designed.

  6. Gas Tungsten Arc Welding and Plasma Arc Cutting. Teacher Edition [and] Student Edition [and] Student Workbook. Second Edition.

    ERIC Educational Resources Information Center

    Harper, Eddie; Knapp, John

    This packet of instructional materials for a gas tungsten arc welding (GTAW) and plasma arc cutting course is comprised of a teacher edition, student edition, and student workbook. The teacher edition consists of introductory pages and teacher pages. Introductory pages include training and competency profile, state duty/task crosswalk,…

  7. Interactions between laser and arc plasma during laser-arc hybrid welding of magnesium alloy

    NASA Astrophysics Data System (ADS)

    Liu, Liming; Chen, Minghua

    2011-09-01

    This paper presents the results of the investigation on the interactions between laser and arc plasma during laser-arc hybrid welding on magnesium alloy AZ31B using the spectral diagnose technique. By comparably analyzing the variation in plasma information (the shape, the electron temperature and density) of single tungsten inert gas (TIG) welding with the laser-arc hybrid welding, it is found that the laser affects the arc plasma through the keyhole forming on the workpiece. Depending on the welding parameters there are three kinds of interactions taking place between laser and arc plasma.

  8. Thermocapillary and arc phenomena in stainless steel welds

    SciTech Connect

    Pierce, S.W.

    1993-10-01

    Goal was to study effect of power level and distribution on thermocapiilary-induced weld shape and of arc factors on weld shape. Thermocapillarity was apparent in both conduction mode EB welds and GTA welds, particularly in the former. A non-Gaussian arc distribution is suggested for accounting for the differences between the twoss processes. At higher current levels (200--300 A), plasma shear force also contributes to weld shape development. Evidence suggests that thermocapillary flow reversal is not a factor in normal GTA welds; EDB flow reversal occurs only at high power density levels where the keyhole mode is present.

  9. Influence of Specific Features of Twin Arc Welding on Properties of Weld Joints

    NASA Astrophysics Data System (ADS)

    Sholokhov, M. A.; Melnikov, A. U.; Fiveyskiy, A. M.

    2016-04-01

    The present article covers the influence of standard and narrow gap twin arc welding on properties of weld joints from high-strength steels. While analyzing microsections we established that distribution of micro structure and phase terms, as well the distribution of micro-hardness, were more homogeneous under narrow gap twin arc welding.

  10. Electrochemical Testing of Gas Tungsten ARC Welded and Reduced Pressure Electron Beam Welded Alloy 22

    SciTech Connect

    S. Daniel Day; Frank M.G. Wong; Steven R. Gordon; Lana L. Wong; Raul B. Rebak

    2006-05-08

    Alloy 22 (N06022) is the material selected for the fabrication of the outer shell of the nuclear waste containers for the Yucca Mountain high-level nuclear waste repository site. A key technical issue in the waste package program has been the integrity of the container weld joints. The currently selected welding process for fabricating and sealing the containers is the traditional gas tungsten arc welding (GTAW) or TIC method. An appealing faster alternative technique is reduced pressure electron beam (RPEB) welding. It was of interest to compare the corrosion properties of specimens prepared using both types of welding techniques. Standard electrochemical tests were carried on GTAW and RPEB welds as well as on base metal (non-welded) to determine their relative corrosion behavior in simulated concentrated water (SCW) at 90 C (alkaline), 1 M HCI at 60 C (acidic) and 1 M NaCl at 90 C (neutral) solutions. Results show that for all practical purposes, the three tested materials had the same electrochemical behavior in the three tested electrolytes.

  11. Electrochemical Testing of Gas Tungsten Arc Welded and Reduced Pressure Electron Beam Welded Alloy 22

    SciTech Connect

    Day, S D; Wong, F G; Gordon, S R; Wong, L L; Rebak, R B

    2006-02-05

    Alloy 22 (N06022) is the material selected for the fabrication of the outer shell of the nuclear waste containers for the Yucca Mountain high-level nuclear waste repository site. A key technical issue in the waste package program has been the integrity of the container weld joints. The currently selected welding process for fabricating and sealing the containers is the traditional gas tungsten arc welding (GTAW) or TIG method. An appealing faster alternative technique is reduced pressure electron beam (RPEB) welding. It was of interest to compare the corrosion properties of specimens prepared using both types of welding techniques. Standard electrochemical tests were carried on GTAW and RPEB welds as well as on base metal (non-welded) to determine their relative corrosion behavior in simulated concentrated water (SCW) at 90 C (alkaline), 1 M HCl at 60 C (acidic) and 1 M NaCl at 90 C (neutral) solutions. Results show that for all practical purposes, the three tested materials had the same electrochemical behavior in the three tested electrolytes.

  12. Control of Gas Tungsten Arc welding pool shape by trace element addition to the weld pool

    DOEpatents

    Heiple, C.R.; Burgardt, P.

    1984-03-13

    An improved process for Gas Tungsten Arc welding maximizes the depth/width ratio of the weld pool by adding a sufficient amount of a surface active element to insure inward fluid flow, resulting in deep, narrow welds. The process is especially useful to eliminate variable weld penetration and shape in GTA welding of steels and stainless steels, particularly by using a sulfur-doped weld wire in a cold wire feed technique.

  13. Effects of shielding gas hydrogen content on the arc behavior in gas tungsten arc welding

    SciTech Connect

    Onsoien, M.I.; Olson, D.L.; Liu, S.

    1994-12-31

    The primary role of the shielding gas in gas tungsten arc welding (GTAW) is to protect the weld pool and tungsten electrode from the oxygen and nitrogen in the surrounding atmosphere. Traditionally inert gases such as argon and helium have been used, either as pure gases or mixed with each other. However, additions of small amounts of hydrogen have been reported to improve weld bead penetration and enable higher welding speeds to be used. The present work was performed to investigate the effect of small hydrogen additions on the arc behavior in GTAW, and to further the fundamental understanding of the effect of shielding gas on arc characteristics. GTAW bead-on-plate welds were made on 12.5 mm x 150 mm x 75 mm Type 304 stainless steel test coupons. The welding current, voltage, and their variations were continuously monitored during welding. After welding, each test coupon was sectioned and prepared using standard metallographic techniques and etched in Vilella`s etch for macroexamination of the weld bead cross section. Bead width, depth, and cross-sectional area were measured using a LECO image analysator system. The influence of hydrogen content in an argon has tungsten arc was characterized. The electrical behavior of the arc, including the arc resistance, was measured as a function of current and hydrogen content. A better fundamental understanding of arc behavior and energy transfer was achieved using these experimental gas mixes. The results allow the following conclusions to be drawn: (1) Small additions of hydrogen in the argon based shielding gas in gas tungsten arc welding significantly change the weld bead geometry due to changes in the arc column. (2) Selection of the right argon, hydrogen shielding gas mixture to give the optimum arc column characteristics for a given condition can improve weld quality and increase productivity. (3) The resistance of the arc column was found to be an adequate parameter to describe the arc column behavior.

  14. Three-dimensional modeling of the plasma arc in arc welding

    SciTech Connect

    Xu, G.; Tsai, H. L.; Hu, J.

    2008-11-15

    Most previous three-dimensional modeling on gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) focuses on the weld pool dynamics and assumes the two-dimensional axisymmetric Gaussian distributions for plasma arc pressure and heat flux. In this article, a three-dimensional plasma arc model is developed, and the distributions of velocity, pressure, temperature, current density, and magnetic field of the plasma arc are calculated by solving the conservation equations of mass, momentum, and energy, as well as part of the Maxwell's equations. This three-dimensional model can be used to study the nonaxisymmetric plasma arc caused by external perturbations such as an external magnetic field. It also provides more accurate boundary conditions when modeling the weld pool dynamics. The present work lays a foundation for true three-dimensional comprehensive modeling of GTAW and GMAW including the plasma arc, weld pool, and/or electrode.

  15. Ultraviolet radiation emitted by CO(2) arc welding.

    PubMed

    Okuno, T; Ojima, J; Saito, H

    2001-10-01

    The arcs associated with arc welding emit high levels of ultraviolet radiation (UVR), and this often causes acute injuries in the workplace, particularly photokeratoconjunctivitis. It is important to know the level of UVR emitted by arc welding under various conditions, as this information will help in evaluating potential UVR hazards in welding workplaces and taking protective measures against it. In this study, the ACGIH effective irradiance for UVR was measured experimentally for CO(2) arc welding in order to evaluate its UVR hazards. A welding robot was used in the experiment in order to realize reproducible and consistent welding operations. The effective irradiance at 1 m from the arc was in the range 0.28-7.85 W/m(2) (28-785 microW/cm(2)) under the study conditions. The corresponding permissible exposure time per day is only 4-100 s, suggesting that UVR from CO(2) arc welding is actually hazardous for the eye and skin. It was found that the effective irradiance is inversely proportional to the square of the distance from the arc, is strongly dependent on the direction of emission from the arc with a maximum at 50-60 degrees from the plate surface, and tends to increase with welding current.

  16. A unified model of coupled arc plasma and weld pool for double electrodes TIG welding

    NASA Astrophysics Data System (ADS)

    Wang, Xinxin; Fan, Ding; Huang, Jiankang; Huang, Yong

    2014-07-01

    A three-dimensional model containing tungsten electrodes, arc plasma and a weld pool is presented for double electrodes tungsten inert gas welding. The model is validated by available experimental data. The distributions of temperature, velocity and pressure of the coupled arc plasma are investigated. The current density, heat flux and shear stress over the weld pool are highlighted. The weld pool dynamic is described by taking into account buoyance, Lorentz force, surface tension and plasma drag force. The turbulent effect in the weld pool is also considered. It is found that the temperature and velocity distributions of the coupled arc are not rotationally symmetrical. A similar property is also shown by the arc pressure, current density and heat flux at the anode surface. The surface tension gradient is much larger than the plasma drag force and dominates the convective pattern in the weld pool, thus determining the weld penetration. The anodic heat flux and plasma drag force, as well as the surface tension gradient over the weld pool, determine the weld shape and size. In addition, provided the welding current through one electrode increases and that through the other decreases, keeping the total current unchanged, the coupled arc behaviour and weld pool dynamic change significantly, while the weld shape and size show little change. The results demonstrate the necessity of a unified model in the study of the arc plasma and weld pool.

  17. 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.

  18. Shielded Metal Arc Pipe Welding. Teacher Edition. Second Edition.

    ERIC Educational Resources Information Center

    Fortney, Clarence; And Others

    This second edition of the shielded metal arc pipe welding curriculum guide presents both basic and advanced pipe welding skills. All specifications for procedure and welder qualification are presented according to national standards. The standards also include the test position for both groove and fillet pipe welding. The guide contains three…

  19. Gas Contamination In Plasma-Arc-Welded Aluminum

    NASA Technical Reports Server (NTRS)

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

    1992-01-01

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

  20. A Glove Box Enclosed Gas-Tungsten Arc Welding System

    SciTech Connect

    Reevr, E, M; Robino, C.V.

    1999-07-01

    This report describes an inert atmosphere enclosed gas-tungsten arc welding system which has been assembled in support of the MC2730, MC2730A and MC 3500 Radioisotope Thermoelectric Generator (RTG) Enhanced Surveillance Program. One goal of this program is to fabricate welds with microstructures and impurity levels which are similar to production heat source welds previously produced at Los Alamos National Laboratory and the Mound Facility. These welds will subsequently be used for high temperature creep testing as part of the overall component lifetime assessment. In order to maximize the utility of the welding system, means for local control of the arc atmosphere have been incorporated and a wide range of welding environments can easily be evaluated. The gas-tungsten arc welding system used in the assembly is computer controlled, includes two-axis and rotary motion, and can be operated in either continuous or pulsed modes. The system can therefore be used for detailed research studies of welding impurity effects, development of prototype weld schedules, or to mimic a significant range of production-like welding conditions. Fixturing for fabrication of high temperature creep test samples have been designed and constructed, and weld schedules for grip-tab and test welds have been developed. The microstructure of these welds have been evaluated and are consistent with those used during RTG production.

  1. Robotic arc welding is off and running at Caterpillar

    SciTech Connect

    Irving, B.

    2000-04-01

    Many experts have long regarded Caterpillar Inc., Peoria, Ill, as not only the largest but perhaps the wisest user of arc welding technology in the world. So it is no surprise Caterpillar was in on the ground floor when robots were first introduced to arc welding. In the early years, which started almost 20 years ago, there were growing pains. There was a huge amount of research into robotic arc welding at the Caterpillar Manufacturing Development Center in East Peoria, Ill., and developments in advanced robotic systems continue today at the Tech Center in Mossville, Ill. The original spadework has paid off to the extent the company now has several hundred robots in operation throughout its plants worldwide specifically engaged in arc welding. Why all this effort? What was the goal? Howard Ludewig, project manager, welding engineering, answered both questions quickly and to the point: Quality, productivity and environmental impact. There was a time not too many years ago when welders wielding semiautomatic guns performed most of the welding operations in a typical Caterpillar manufacturing plant. Most of the welds were made with flux-cored wire. Today, most of the welders have become robot operators or have moved to other jobs. Robotic arc welding systems now make the welds the welders produced in the past. Nowadays, the welds are made mostly by solid, not flux-cored, wire. Things are quiet. The plant area is clean.

  2. A comparison of the physics of Gas Tungsten Arc Welding (GTAW), Electron Beam Welding (EBW), and Laser Beam Welding (LBW)

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.

    1985-01-01

    The physics governing the applicability and limitations of gas tungsten arc (GTA), electron beam (EB), and laser beam (LB) welding are compared. An appendix on the selection of laser welding systems is included.

  3. Computer Control For Gas/Tungsten-Arc Welding

    NASA Technical Reports Server (NTRS)

    Andersen, Kristinn; Springfield, James F.; Barnett, Robert J.; Cook, George E.

    1994-01-01

    Prototype computer-based feedback control system developed for use in gas/tungsten arc welding. Beyond improving welding technician's moment-to-moment general control of welding process, control system designed to assist technician in selecting appropriate welding-process parameters, and provide better automatic voltage control. Modular for ease of reconfiguration and upgrading. Modularity also reflected in software. Includes rack-mounted computer, based on VME bus, containing Intel 80286 and 80386 processors.

  4. Argon-Hydrogen Shielding Gas Mixtures for Activating Flux-Assisted Gas Tungsten Arc Welding

    NASA Astrophysics Data System (ADS)

    Huang, Her-Yueh

    2010-11-01

    Using activating flux for gas tungsten arc welding (GTAW) to improve penetration capability is a well-established technique. Argon is an inert gas and the one most widely used as a shielding gas for GTAW. For the most austenitic stainless steels, pure argon does not provide adequate weld penetration. Argon-hydrogen mixtures give a more even heat input to the workpiece, increasing the arc voltage, which tends to increase the volume of molten material in the weld pool as well as the weld depth-to-width ratio. Great interest has been shown in the interaction between activating flux and the hydrogen concentration in an argon-based shielding gas. In this study, the weld morphology, the arc profile, the retained delta ferrite content, the angular distortion, and the microstructures were examined. The application of an activating flux combining argon and hydrogen for GTAW is important in the industry. The results of this study are presented here.

  5. PENETRATION AND DEFECT FORMATION IN HIGH CURRENT ARC WELDING

    SciTech Connect

    MENDEZ,P.F.; EAGAR, T.W.

    2003-01-01

    The work performed during the three previous years can be roughly divided into two main categories: (1) development of advanced modeling techniques; and (2) modeling of arc welding process. The work in the first category comprised the development of the Order of Magnitude Scaling (OMS) technique, which is complementary to numerical modeling techniques such as finite elements, but it provides approximate formulas instead of just numerical results. Borrowing concepts from OMS, another modeling technique based on empirical data was also developed. During this stage special software was also developed. The second category comprised the application of OMS to the three main subsystems of arc welding: the weld pool, the arc, and the electrode. For each of these subsystems they found scaling laws and regimes. With this knowledge, they analyzed the generation of weld pool defects during high current arc welding, proposed a mechanistic description of the process, and possible solutions.

  6. 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.

  7. Recent progress on gas tungsten arc welding of vanadium alloys

    SciTech Connect

    Grossbeck, M.L.; King, J.F.; Alexander, D.J.

    1997-08-01

    Emphasis has been placed on welding 6.4 mm plate, primarily by gas tungsten arc (GTA) welding. The weld properties were tested using blunt notch Charpy testing to determine the ductile to brittle transition temperature (DBTT). Erratic results were attributed to hydrogen and oxygen contamination of the welds. An improved gas clean-up system was installed on the welding glove box and the resulting high purity welds had Charpy impact properties similar to those of electron beam welds with similar grain size. A post-weld heat treatment (PWHT) of 950{degrees}C for two hours did not improve the properties of the weld in cases where low concentrations of impurities were attained. Further improvements in the gas clean-up system are needed to control hydrogen contamination.

  8. Effects of relative positioning of energy sources on weld integrity for hybrid laser arc welding

    NASA Astrophysics Data System (ADS)

    Liu, Shuangyu; Li, Yanqing; Liu, Fengde; Zhang, Hong; Ding, Hongtao

    2016-06-01

    This study is concerned with the effects of laser and arc arrangement on weld integrity for the hybrid laser arc welding processes. Experiments were conducted for a high-strength steel using a 4 kW Nd: YAG laser and a metal active gas (MAG) welding facility under two configurations of arc-laser hybrid welding (ALHW) and laser-arc hybrid welding (LAHW). Metallographic analysis and mechanical testing were performed to evaluate the weld integrity in terms of weld bead geometry, microstructure and mechanical properties. The morphology of the weld bead cross-section was studied and the typical macrostructure of the weld beads appeared to be cone-shaped and cocktail cup-shaped under ALHW and LAHW configurations, respectively. The weld integrity attributes of microstructure, phase constituents and microhardness were analyzed for different weld regions. The tensile and impact tests were performed and fracture surface morphology was analyzed by scanning electron microscope. The study showed that ALHW produced joints with a better weld shape and a more uniform microstructure of lath martensite, while LAHW weld had a heterogeneous structure of lath martensite and austenite.

  9. Narrow groove gas tungsten arc welding of ASTM A508 Class 4 steel for improved toughness properties

    SciTech Connect

    Penik, M.A. Jr.

    1997-04-01

    Welding of heavy section steel has traditionally used the automatic submerged arc welding (ASAW) process because of the high deposition rates achievable. However, the properties, particularly fracture toughness, of the weld are often inferior when compared to base material. This project evaluated the use of narrow groove gas tungsten arc welding (GTAW) to improve weld material properties. The welding procedures were developed for ASTM A508 Class 4 base material using a 1% Ni filler material complying to AWS Specification A.23-90-EF3-F3-N. A narrow groove joint preparation was used in conjunction with the GTAW process so competitive fabrication rates could be achieved when compared to the ASAW process. Weld procedures were developed to refine weld substructure to achieve better mechanical properties. Two heaters of weld wire were used to examine the effects of minor filler metal chemistry differences on weld mechanical properties. Extensive metallographic evaluations showed excellent weld quality with a refined microstructure. Chemical analysis of the weld metal showed minimal weld dilution by the base metal. Mechanical testing included bend and tensile tests to ensure weld quality and strength. A Charpy impact energy curve versus temperature and fracture toughness curve versus temperature were developed for each weld wire heat. Results of fracture toughness and Charpy impact testing indicated an improved transition temperature closer to that of the base material properties.

  10. A Compact Gas/Tungsten-Arc Welding Torch

    NASA Technical Reports Server (NTRS)

    Morgen, Gene E.

    1991-01-01

    Compact gas/tungsten-arc welding torch delivers 100-A current, yet used in confined spaces inaccessible to even smallest commercially available torch. Despite its extremely small size, torch contains all usual components and delivers high current.

  11. Time resolved optical spectra from MIG welding arc ignitions

    SciTech Connect

    Eriksen, P.

    1985-03-01

    Optical radiation from MIG (GMAW) welding arc ignitions has been measured with a rapid scan spectrometer. The time resolved spectral measurements reveal a substantial overshoot of ultraviolet radiation during the ignition phase of a 200 A aluminum arc. Calculations which follow the ACGIH guidelines show that, at a welding current of 300 A, the unprotected eye at a distance of 0.5 m may suffer a flash after the reception of radiation from only one ignition.

  12. Comparison on welding mode characteristics of arc heat source for heat input control in hybrid welding of aluminum alloy

    NASA Astrophysics Data System (ADS)

    Song, Moo-Keun; Kim, Jong-Do; Oh, Jae-Hwan

    2015-03-01

    Presently in shipbuilding, transportation and aerospace industries, the potential to apply welding using laser and laser-arc hybrid heat sources is widely under research. This study has the purpose of comparing the weldability depending on the arc mode by varying the welding modes of arc heat sources in applying laser-arc hybrid welding to aluminum alloy and of implementing efficient hybrid welding while controlling heat input. In the experimental study, we found that hybrid welding using CMT mode produced deeper penetration and sounder bead surface than those characteristics produced during only laser welding, with less heat input compared to that required in pulsed arc mode.

  13. Implementation of Submerged Arc Welding Training. Final Report.

    ERIC Educational Resources Information Center

    Bowick, Earl; Todd, John

    A unit on submerged arc welding (SAW) was developed and integrated into the welding program at Seattle Central Community College (Washington) during the period December 1983 through May 1984. During this time, 10 major users of SAW in the area were contacted and mailed questionnaires. Follow up consisted of telephone calls and personal contact as…

  14. Student Arc Welding Noise Exposures in Agricultural Mechanics Laboratories.

    ERIC Educational Resources Information Center

    Miller, Glen M.

    1989-01-01

    A study surveyed noise levels in an agricultural mechanics educational laboratory while students completed common arc welds. It found that the time a student spent in the welding booth posed no threat to hearing. Maximum noise measured was well below the 140 dB(A) impulse level set by the Occupational Safety and Health Administration. (JOW)

  15. Internal Wire Guide For Gas/Tungsten-Arc Welding

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.; Dyer, Gerald E.

    1990-01-01

    Wire kept in shielding gas, preventing oxidation. Guide inside gas cup of gas/tungsten-arc welding torch feeds filler wire to weld pool along line parallel to axis of torch. Eliminates problem of how to place and orient torch to provide clearance for external wire guide.

  16. Electron beam, laser beam and plasma arc welding studies

    NASA Technical Reports Server (NTRS)

    Banas, C. M.

    1974-01-01

    This program was undertaken as an initial step in establishing an evaluation framework which would permit a priori selection of advanced welding processes for specific applications. To this end, a direct comparison of laser beam, electron beam and arc welding of Ti-6Al-4V alloy was undertaken. Ti-6Al-4V was selected for use in view of its established welding characteristics and its importance in aerospace applications.

  17. Mutagenicity of fume particles from metal arc welding on stainless steel in the Salmonella/microsome test.

    PubMed

    Maxild, J; Andersen, M; Kiel, P

    1978-01-01

    Mutagenic activity of fume particles produced by metal arc welding on stainless steel (ss) is demonstrated by using the Salmonella/microsome mutagenicity test described by Ames et al., with strain TA100 (base-pair substitution) and TA98 (frame-shift reversion). Results of a representative but limited selection of processes and materials show that mutagenic activity is a function of process and process parameters. Welding on stainless steel produces particles that are mutagenic, whereas welding on mild steel (ms) produces particles that are not. Manual metal arc (MMA) welding on stainless steel produces particles of higher mutagenic activity than does metal inert gas (MIG) welding, and fume particles produced by MIG welding under short-arc transfer. Further studies of welding fumes (both particles and gases) must be performed to determine process parameters of significance for the mutagenic activity.

  18. 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.

  19. Effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding.

    PubMed

    Xie, Weifeng; Fan, Chenglei; Yang, Chunli; Lin, Sanbao

    2016-03-01

    As a newly developed arc welding method, power ultrasound has been successfully introduced into arc and weld pool during ultrasonic wave-assisted arc welding process. The advanced process for molten metals can be realized by utilizing additional ultrasonic field. Under the action of the acoustic wave, the plasma arc as weld heat source is regulated and its characteristics make an obvious change. Compared with the conventional arc, the ultrasonic wave-assisted arc plasma is bound significantly and becomes brighter. To reveal the dependence of the acoustic binding force on acoustic field parameters, a two-dimensional acoustic field model for ultrasonic wave-assisted arc welding device is established. The influences of the radiator height, the central pore radius, the radiator radius, and curvature radius or depth of concave radiator surface are discussed using the boundary element method. Then the authors analyze the resonant mode by this relationship curve between acoustic radiation power and radiator height. Furthermore, the best acoustic binding ability is obtained by optimizing the geometric parameters of acoustic radiator. In addition, three concave radiator surfaces including spherical cap surface, paraboloid of revolution, and rotating single curved surface are investigated systematically. Finally, both the calculation and experiment suggest that, to obtain the best acoustic binding ability, the ultrasonic wave-assisted arc welding setup should be operated under the first resonant mode using a radiator with a spherical cap surface, a small central pore, a large section radius and an appropriate curvature radius.

  20. Effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding.

    PubMed

    Xie, Weifeng; Fan, Chenglei; Yang, Chunli; Lin, Sanbao

    2016-03-01

    As a newly developed arc welding method, power ultrasound has been successfully introduced into arc and weld pool during ultrasonic wave-assisted arc welding process. The advanced process for molten metals can be realized by utilizing additional ultrasonic field. Under the action of the acoustic wave, the plasma arc as weld heat source is regulated and its characteristics make an obvious change. Compared with the conventional arc, the ultrasonic wave-assisted arc plasma is bound significantly and becomes brighter. To reveal the dependence of the acoustic binding force on acoustic field parameters, a two-dimensional acoustic field model for ultrasonic wave-assisted arc welding device is established. The influences of the radiator height, the central pore radius, the radiator radius, and curvature radius or depth of concave radiator surface are discussed using the boundary element method. Then the authors analyze the resonant mode by this relationship curve between acoustic radiation power and radiator height. Furthermore, the best acoustic binding ability is obtained by optimizing the geometric parameters of acoustic radiator. In addition, three concave radiator surfaces including spherical cap surface, paraboloid of revolution, and rotating single curved surface are investigated systematically. Finally, both the calculation and experiment suggest that, to obtain the best acoustic binding ability, the ultrasonic wave-assisted arc welding setup should be operated under the first resonant mode using a radiator with a spherical cap surface, a small central pore, a large section radius and an appropriate curvature radius. PMID:26558995

  1. Weld pool temperatures of steel S235 while applying a controlled short-circuit gas metal arc welding process and various shielding gases

    NASA Astrophysics Data System (ADS)

    Kozakov, R.; Schöpp, H.; Gött, G.; Sperl, A.; Wilhelm, G.; Uhrlandt, D.

    2013-11-01

    The temperature determination of liquid metals is difficult and depends strongly on the emissivity. However, the surface temperature distribution of the weld pool is an important characteristic of an arc weld process. As an example, short-arc welding of steel with a cold metal transfer (CMT) process is considered. With optical emission spectroscopy in the spectral region between 660 and 840 nm and absolute calibrated high-speed camera images the relation between temperature and emissivity of the weld pool is determined. This method is used to obtain two-dimensional temperature profiles in the pictures. Results are presented for welding materials (wire G3Si1 on base material S235) using different welding CMT processes with CO2 (100%), Corgon 18 (18% CO2 + 82% Ar), VarigonH6 (93.5% Ar + 6.5% H2) and He (100%) as shielding gases. The different gases are used to study their influence on the weld pool temperature.

  2. 30 CFR 75.1106 - Welding, cutting, or soldering with arc or flame underground.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Welding, cutting, or soldering with arc or... Protection § 75.1106 Welding, cutting, or soldering with arc or flame underground. All welding, cutting, or... conducted in fireproof enclosures. Welding, cutting, or soldering with arc or flame in other than...

  3. 30 CFR 75.1106 - Welding, cutting, or soldering with arc or flame underground.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Welding, cutting, or soldering with arc or... Protection § 75.1106 Welding, cutting, or soldering with arc or flame underground. All welding, cutting, or... conducted in fireproof enclosures. Welding, cutting, or soldering with arc or flame in other than...

  4. 30 CFR 75.1106 - Welding, cutting, or soldering with arc or flame underground.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Welding, cutting, or soldering with arc or... Protection § 75.1106 Welding, cutting, or soldering with arc or flame underground. All welding, cutting, or... conducted in fireproof enclosures. Welding, cutting, or soldering with arc or flame in other than...

  5. 30 CFR 75.1106 - Welding, cutting, or soldering with arc or flame underground.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Welding, cutting, or soldering with arc or... Protection § 75.1106 Welding, cutting, or soldering with arc or flame underground. All welding, cutting, or... conducted in fireproof enclosures. Welding, cutting, or soldering with arc or flame in other than...

  6. 30 CFR 75.1106 - Welding, cutting, or soldering with arc or flame underground.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Welding, cutting, or soldering with arc or... Protection § 75.1106 Welding, cutting, or soldering with arc or flame underground. All welding, cutting, or... conducted in fireproof enclosures. Welding, cutting, or soldering with arc or flame in other than...

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

    PubMed

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

    2016-01-01

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

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

    PubMed

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

    2016-01-01

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

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

    PubMed Central

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

    2015-01-01

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

  10. Unique variable polarity plasma arc welding for space shuttle

    NASA Technical Reports Server (NTRS)

    Schwinghamer, R. J.

    1985-01-01

    Since the introduction of the Plasma Arc Torch in 1955 and subsequent to the work at Boeing in the 1960's, significant improvements crucial to success have been made in the Variable Polarity Plasma Arc (VPPA) Process at the Marshall Space Flight Center. Several very important advantages to this process are given, and the genesis of PA welding, the genesis of VPPA welding, special equiment requirements, weld property development, results with other aluminum alloys, and the eventual successful VPPA transition to production operations are discussed.

  11. The variable polarity plasma arc welding process: Characteristics and performance

    NASA Technical Reports Server (NTRS)

    Hung, R. J.; Zhu, G. J.

    1991-01-01

    Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. The power distribution was analyzed for an argon plasma gas flow constituting the fluid in the VPPA Welding Process. The major heat loss at the torch nozzle is convective heat transfer; in the space between the outlet of the nozzle and the workpiece; radiative heat transfer; and in the keyhole in the workpiece, convective heat transfer. The power absorbed at the workpiece produces the molten puddle that solidifies into the weld bead. Crown and root widths, and crown and root heights of the weld bead are predicted. The basis is provided for an algorithm for automatic control of VPPA welding machine parameters to obtain desired weld bead dimensions.

  12. Stud arc welding in a magnetic field - Investigation of the influences on the arc motion

    NASA Astrophysics Data System (ADS)

    Hartz-Behrend, K.; Marqués, J. L.; Forster, G.; Jenicek, A.; Müller, M.; Cramer, H.; Jilg, A.; Soyer, H.; Schein, J.

    2014-11-01

    Stud arc welding is widely used in the construction industry. For welding of studs with a diameter larger than 14 mm a ceramic ferrule is usually necessary in order to protect the weld pool. Disadvantages of using such a ferrule are that more metal is molten than necessary for a high quality welded joint and that the ferrule is a consumable generally thrown away after the welding operation. Investigations show that the ferrule can be omitted when the welding is carried out in a radially symmetric magnetic field within a shielding gas atmosphere. Due to the Lorentz force the arc is laterally shifted so that a very uniform and controlled melting of the stud contact surface as well as of the work piece can be achieved. In this paper a simplified physical model is presented describing how the parameters welding current, flux density of the magnetic field, radius of the arc and mass density of the shielding gas influence the velocity of the arc motion. The resulting equation is subsequently verified by comparing it to optical measurements of the arc motion. The proposed model can be used to optimize the required field distribution for the magnetic field stud welding process.

  13. Spectroscopic measurement of temperatures in pulsed TIG welding arcs

    NASA Astrophysics Data System (ADS)

    Ma, Shuiliang; Gao, Hongming; Zheng, Senmu; Wu, Lin

    2011-10-01

    Time resolved plasma temperatures in a pulsed tungsten-inert-gas (TIG) welding arc have been measured using optical emission spectroscopy. The peak and base pulse-averaged plasma temperatures both decrease with time after the arc ignition, and the plasma temperature decreases during the peak pulse period and increases during the base pulse period when the arc reaches the steady state. The decrease in the plasma temperature is associated with the increase in the cathode surface temperature and the decrease in the arc voltage and vice versa. The importance of the cathode surface temperature on the arc properties has been discussed.

  14. Vacuum Compatibility of Flux-Core Arc Welding (FCAW)

    NASA Astrophysics Data System (ADS)

    Arose, Dana; Denault, Martin; Jurcznski, Stephan

    2010-11-01

    Typically, vacuum chambers are welded together using gas tungsten arc welding (GTAW) or gas metal arc welding (GMAW). This is demonstrated in the vacuum chamber of Princeton Plasma Physics Lab's (PPPL) National Spherical Torus Experiment (NSTX). These processes are slow and apply excess heat to the base metal, which may cause the vacuum chamber to deform beyond designed tolerance. Flux cored arc welding (FCAW) avoids these problems, but may produce an unacceptable amount of outgasing due to the flux shielding. We believe impurities due to outgasing from FCAW will not greatly exceed those found in GTAW and GMAW welding. To test this theory, samples welded together using all three welding processes will be made and baked in a residual gas analyzer (RGA). The GTAW and GMAW welds will be tested to establish a metric for permissible outgasing. By testing samples from all three processes we hope to demonstrate that FCAW does not significantly outgas, and is therefore a viable alternative to GTAW and GMAW. Results from observations will be presented.

  15. Self-clamping arc light reflector for welding torch

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1987-01-01

    This invention is directed to a coaxial extending metal mirror reflector attached to the electrode housing or gas cup on a welding torch. An electric welding torch with an internal viewing system for robotic welding is provded with an annular arc light reflector to reflect light from the arc back onto the workpiece. The reflector has a vertical split or gap in its surrounding wall to permit the adjacent wall ends forming the split to be sprung open slightly to permit the reflector to be removed or slipped onto the torch housing or gas cup. The upper opening of the reflector is slightly smaller than the torch housing or gas cup and therefore, when placed on the torch housing or gas cup has that springiness to cause it to clamp tightly on the housing or gas cup. The split or gap also serves to permit the feed of weld wire through to the weld area,

  16. Optical emission spectroscopy of metal vapor dominated laser-arc hybrid welding plasma

    SciTech Connect

    Ribic, B.; DebRoy, T.; Burgardt, P.

    2011-04-15

    During laser-arc hybrid welding, plasma properties affect the welding process and the weld quality. However, hybrid welding plasmas have not been systematically studied. Here we examine electron temperatures, species densities, and electrical conductivity for laser, arc, and laser-arc hybrid welding using optical emission spectroscopy. The effects of arc currents and heat source separation distances were examined because these parameters significantly affect weld quality. Time-average plasma electron temperatures, electron and ion densities, electrical conductivity, and arc stability decrease with increasing heat source separation distance during hybrid welding. Heat source separation distance affects these properties more significantly than the arc current within the range of currents considered. Improved arc stability and higher electrical conductivity of the hybrid welding plasma result from increased heat flux, electron temperatures, electron density, and metal vapor concentrations relative to arc or laser welding.

  17. Extended electrode technique. [gas metal arc welding of metal plates

    NASA Technical Reports Server (NTRS)

    Schaper, V. D.; Pollack, A.

    1972-01-01

    The extended electrode technique is a unique welding process which utilizes manual gas-metal-arc (GMAW) semi-automatic equipment and close, square butt joints to effectively produce a weld. The technique takes advantage of the resistance heating of the electode extension to effect the root pass. Weldments as large as 72-X30-X2-inch have been fabricated with this technique under normal shipyard welding conditions. Mechanical properties and explosion bulge tests indicate that satisfactory results are obtained with this process. Potential savings of approximately 50 percent can be achieved in flat welding and repair of heavy structural steel members.

  18. 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.

  19. Effect of CO{sub 2} laser irradiation on arc welding

    SciTech Connect

    Abe, Nobuyuki; Agano, Yasuo; Tsukamoto, Masahiro

    1996-12-31

    Combination welding was performed using a CO{sub 2} laser and MIG arc under various conditions to investigate the effectiveness of combining these two welding methods for high speed welding of thick plates. The penetration depth of combination welding was affected by the assist gas flow rate similar to when laser welding is performed at a low welding speed. Penetration was governed by the laser, while the bead width was governed by the arc. Laser-arc combination welding enabled welding of 12mm thick mild steel at a welding speed of 2000 mm/min with proper selection of the assist gas flow rate and root gap.

  20. Differences between Laser and Arc Welding of HSS Steels

    NASA Astrophysics Data System (ADS)

    Němeček, Stanislav; Mužík, Tomáš; Míšek, Michal

    Conventional welding processes often fail to provide adequate joints in high strength steels with multiphase microstructures. One of the promising techniques is laser beam welding: working without filler metal and with sufficient capacity for automotive and transportation industry (where the amount of AHSS steels increases each year, as well as the length of laser welds). The paper compares microstructures and properties of HSS (high strength steel) joints made by MAG (Metal Active Gas) and laser welding. The effects of main welding parameters (heat input, welding speed and others) are studied on multiphase TRIP 900 steel tubes and martensitic sheets DOCOL 1200, advanced materials for seat frames and other automotive components. Whereas the strength of conventional welds is significantly impaired, laser welding leaves strength of the base material nearly unaffected. As the nature of fracture changes during loading and depending on the welding method, failure mechanisms upon cross tension tests have been studied as well.

  1. Comparative study on interactions between laser and arc plasma during laser-GTA welding and laser-GMA welding

    NASA Astrophysics Data System (ADS)

    Chen, Minghua; Xu, Jiannan; Xin, Lijun; Zhao, Zuofu; Wu, Fufa

    2016-10-01

    This paper describes an investigation on differences in interactions between laser and arc plasma during laser-gas tungsten arc (LT) welding and laser-gas metal arc (LM) welding. The characteristics of LT heat source and LM heat source, such as plasma behavior, heat penetration ability and spectral information were comparably studied. Based on the plasma discharge theory, the interactions during plasma discharge were modeled and analyzed. Results show that in both LT and LM welding, coupling discharge between the laser keyhole plasma and arc happens, which strongly enhance the arc. But, the enhancing effect in LT welding is much more sensitive than that in LM welding when parameters are adjusted.

  2. Vaccum Gas Tungsten Arc Welding, phase 1. Technical report, October 1993-March 1995

    SciTech Connect

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

    1995-03-01

    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. T & I--Arc Welding. Kit No. 86. Instructor's Manual [and] Student Learning Activity Guide.

    ERIC Educational Resources Information Center

    Underwood, Earl

    An instructor's manual and student activity guide on arc welding are provided in this set of prevocational education materials which focuses on the vocational area of trade and industry. (This set of materials is one of ninety-two prevocational education sets arranged around a cluster of seven vocational offerings: agriculture, home economics,…

  4. Effects of shielding gas compositions on arc plasma and metal transfer in gas metal arc welding

    SciTech Connect

    Rao, Z. H.; Liao, S. M.; Tsai, H. L.

    2010-02-15

    This article presents the effects of shielding gas compositions on the transient transport phenomena, including the distributions of temperature, flow velocity, current density, and electromagnetic force in the arc and the metal, and arc pressure in gas metal arc welding of mild steel at a constant current input. The shielding gas considered includes pure argon, 75% Ar, 50% Ar, and 25% Ar with the balance of helium. It is found that the shielding gas composition has significant influences on the arc characteristics; droplet formation, detachment, transfer, and impingement onto the workpiece; and weld pool dynamics and weld bead profile. As helium increases in the shielding gas, the droplet size increases but the droplet detachment frequency decreases. For helium-rich gases, the current converges at the workpiece with a 'ring' shape which produces non-Gaussian-like distributions of arc pressure and temperature along the workpiece surface. Detailed explanations to the physics of the very complex but interesting transport phenomena are given.

  5. Hybrid Laser-arc Welding of 17-4 PH Martensitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Liu, Wei; Ma, Junjie; Atabaki, Mehdi Mazar; Pillai, Raju; Kumar, Biju; Vasudevan, Unnikrishnan; Sreshta, Harold; Kovacevic, Radovan

    2015-06-01

    17-4 PH stainless steel has wide applications in severe working conditions due to its combination of good corrosion resistance and high strength. The weldability of 17-4 PH stainless steel is challenging. In this work, hybrid laser-arc welding was developed to weld 17-4 PH stainless steel. This method was chosen based on its advantages, such as deep weld penetration, less filler materials, and high welding speed. The 17-4 PH stainless steel plates with a thickness of 19 mm were successfully welded in a single pass. During the hybrid welding, the 17-4 PH stainless steel was immensely susceptible to porosity and solidification cracking. The porosity was avoided by using nitrogen as the shielding gas. The nitrogen stabilized the keyhole and inhibited the formation of bubbles during welding. Solidification cracking easily occurred along the weld centerline at the root of the hybrid laser-arc welds. The microstructural evolution and the cracking susceptibility of 17-4 PH stainless steel were investigated to remove these centerline cracks. The results showed that the solidification mode of the material changed due to high cooling rate at the root of the weld. The rapid cooling rate caused the transformation from ferrite to austenite during the solidification stage. The solidification cracking was likely formed as a result of this cracking-susceptible microstructure and a high depth/width ratio that led to a high tensile stress concentration. Furthermore, the solidification cracking was prevented by preheating the base metal. It was found that the preheating slowed the cooling rate at the root of the weld, and the ferrite-to-austenite transformation during the solidification stage was suppressed. Delta ferrite formation was observed in the weld bead as well no solidification cracking occurred by optimizing the preheating temperature.

  6. An investigation into underwater wet welding using the flux cored arc welding process

    SciTech Connect

    Brydon, A.M.; Nixon, J.H.

    1995-12-31

    For the last two years, Cranfield has been carrying out a program of process investigations into wet underwater welding (Graham and Nixon 1993, Nixon and Webb 1994), and has demonstrated that it is possible to markedly improve the stability and consistency of the process by using control techniques developed for hyperbaric welding. In the project reported below, an initial evaluation of wet flux cored arc welding was undertaken. Although there continues to be considerable resistance to the use of wet welding on structures in the North Sea, continued pressure to reduce repair and maintenance costs is causing the industry to re-examine techniques previously discounted, such as wet welding (Anon 1993).

  7. Parametric Studies Of Weld Quality Of Tungsten Inert Gas Arc Welding Of Stainless Steel

    SciTech Connect

    Kumar Pal, Pradip; Nandi, Goutam; Ghosh, Nabendu

    2011-01-17

    Effect of current and gas flow rate on quality of weld in tungsten inter gas arc welding of austenitic stainless steel has been studied in the present work through experiments and analyses. Butt welded joints have been made by using several levels of current and gas flow rate. The quality of the weld has been evaluated in terms of ultimate and breaking strengths of the welded specimens. The observed data have been interpreted, discussed and analyzed by using Grey--Taguchi methodology. Optimum parametric setting has been predicted and validated as well.

  8. Parametric Studies Of Weld Quality Of Tungsten Inert Gas Arc Welding Of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Kumar Pal, Pradip; Nandi, Goutam; Ghosh, Nabendu

    2011-01-01

    Effect of current and gas flow rate on quality of weld in tungsten inter gas arc welding of austenitic stainless steel has been studied in the present work through experiments and analyses. Butt welded joints have been made by using several levels of current and gas flow rate. The quality of the weld has been evaluated in terms of ultimate and breaking strengths of the welded specimens. The observed data have been interpreted, discussed and analyzed by using Grey—Taguchi methodology. Optimum parametric setting has been predicted and validated as well.

  9. Analysis of hybrid Nd:Yag laser-MAG arc welding processes

    NASA Astrophysics Data System (ADS)

    Le Guen, E.; Fabbro, R.; Carin, M.; Coste, F.; Le Masson, P.

    2011-10-01

    In the hybrid laser-arc welding process, a laser beam and an electric arc are coupled in order to combine the advantages of both processes: high welding speed, low thermal load and high depth penetration thanks to the laser; less demanding on joint preparation/fit-up, typical of arc welding. Thus the hybrid laser-MIG/MAG (Metal Inert or Active Gas) arc welding has very interesting properties: the improvement of productivity results in higher welding speeds, thicker welded materials, joint fit-up allowance, better stability of molten pool and improvement of joint metallurgical quality. The understanding of the main relevant involved physical processes are therefore necessary if one wants for example elaborate adequate simulations of this process. Also, for an efficient use of this process, it is necessary to precisely understand the complex physical phenomena that govern this welding technique. This paper investigates the analysis of the effect of the main operating parameters for the laser alone, MAG alone and hybrid Laser/MAG welding processes. The use of a high speed video camera allows us to precisely characterize the melt pool 3D geometry such as the measurements of its depression and its length and the phenomena occurring inside the melt pool through keyhole-melt pool-droplet interaction. These experimental results will form a database that is used for the validation of a three-dimensional thermal model of the hybrid welding process for a rather wide range of operating parameters where the 3-D geometry of the melt pool is taken into account.

  10. Manganese in occupational arc welding fumes--aspects on physiochemical properties, with focus on solubility.

    PubMed

    Taube, Fabian

    2013-01-01

    Physicochemical properties, such as particle sizes, composition, and solubility of welding fumes are decisive for the bioaccessibility of manganese and thereby for the manganese cytotoxic and neurotoxic effects arising from various welding fumes. Because of the diverse results within the research on welding fume solubility, this article aims to review and discuss recent literature on physicochemical properties of gas metal arc welding, shielded metal arc welding, and flux-cored arc welding fumes, with focus on solubility properties. This article also presents a short introduction to the literature on arc welding techniques, health effects from manganese, and occupational exposure to manganese among welders. PMID:22997412

  11. Manganese in occupational arc welding fumes--aspects on physiochemical properties, with focus on solubility.

    PubMed

    Taube, Fabian

    2013-01-01

    Physicochemical properties, such as particle sizes, composition, and solubility of welding fumes are decisive for the bioaccessibility of manganese and thereby for the manganese cytotoxic and neurotoxic effects arising from various welding fumes. Because of the diverse results within the research on welding fume solubility, this article aims to review and discuss recent literature on physicochemical properties of gas metal arc welding, shielded metal arc welding, and flux-cored arc welding fumes, with focus on solubility properties. This article also presents a short introduction to the literature on arc welding techniques, health effects from manganese, and occupational exposure to manganese among welders.

  12. Nuclear Technology. Course 28: Welding Inspection. Module 28-2, Shielded Metal Arc and Oxyacetylene Welding.

    ERIC Educational Resources Information Center

    Espy, John; Selleck, Ben

    This second in a series of ten modules for a course titled Welding Inspection describes the key features of the oxyacetylene and shielded metal arc welding process. The apparatus, process techniques, procedures, applications, associated defects, and inspections are presented. The module follows a typical format that includes the following…

  13. The Impact of Teaching Oxy-Fuel Welding on Gas Metal Arc Welding Skills

    ERIC Educational Resources Information Center

    Sgro, Sergio D.; Field, Dennis W.; Freeman, Steven A.

    2008-01-01

    Industrial technology programs around the country must be sensitive to the demands of manufacturing and industry as they continue to replace "vocational" curriculum with high-tech alternatives. This article examines whether or not teaching oxyacetylene welding in the industrial technology classroom is required to learn arc welding processes. The…

  14. Achieving High Strength Joint of Pure Copper Via Laser-Cold Metal Transfer Arc Hybrid Welding

    NASA Astrophysics Data System (ADS)

    Chen, Yulong; Chen, Cong; Gao, Ming; Zeng, Xiaoyan

    2016-06-01

    Fiber laser-cold metal transfer arc hybrid welding of pure copper was studied. Weld porosity was tested by X-ray nondestructive testing. Microstructure and fracture features were observed by scanning electron microscopy. Mechanical properties were evaluated by cross weld tensile test. Full penetrated and continuous welds were obtained by hybrid welding once the laser power reached 2 kW, while they could not be obtained by laser welding alone, even though the laser power reached 5 kW. The ultimate tensile strength (UTS), the yield strength (YS), and the elongation of the best hybrid weld material were up to 227, 201 MPa, and 21.5 pct, respectively. The joint efficiencies in UTS and YS of hybrid weld were up to 84 and 80 pct of the BM, respectively. The fracture location changes from the fusion zone to the heat-affected zone with the increase of laser power. Besides, the mechanisms of process stability and porosity suppression were clarified by laser-arc interaction and pool behavior. The strengthening mechanism was discussed by microstructure characteristics.

  15. 30 CFR 77.1112 - Welding, cutting, or soldering with arc or flame; safeguards.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Welding, cutting, or soldering with arc or... WORK AREAS OF UNDERGROUND COAL MINES Fire Protection § 77.1112 Welding, cutting, or soldering with arc or flame; safeguards. (a) When welding, cutting, or soldering with arc or flame near...

  16. 30 CFR 77.1112 - Welding, cutting, or soldering with arc or flame; safeguards.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Welding, cutting, or soldering with arc or... WORK AREAS OF UNDERGROUND COAL MINES Fire Protection § 77.1112 Welding, cutting, or soldering with arc or flame; safeguards. (a) When welding, cutting, or soldering with arc or flame near...

  17. 30 CFR 77.1112 - Welding, cutting, or soldering with arc or flame; safeguards.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Welding, cutting, or soldering with arc or... WORK AREAS OF UNDERGROUND COAL MINES Fire Protection § 77.1112 Welding, cutting, or soldering with arc or flame; safeguards. (a) When welding, cutting, or soldering with arc or flame near...

  18. 30 CFR 77.1112 - Welding, cutting, or soldering with arc or flame; safeguards.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Welding, cutting, or soldering with arc or... WORK AREAS OF UNDERGROUND COAL MINES Fire Protection § 77.1112 Welding, cutting, or soldering with arc or flame; safeguards. (a) When welding, cutting, or soldering with arc or flame near...

  19. 30 CFR 77.1112 - Welding, cutting, or soldering with arc or flame; safeguards.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Welding, cutting, or soldering with arc or... WORK AREAS OF UNDERGROUND COAL MINES Fire Protection § 77.1112 Welding, cutting, or soldering with arc or flame; safeguards. (a) When welding, cutting, or soldering with arc or flame near...

  20. Systems to Control Molten Metal Transfer in Arc Welding

    NASA Astrophysics Data System (ADS)

    Filonov, A. V.; Kryukov, A. V.; Gusarov, D. E.

    2015-09-01

    The paper analyzes the systems used for controlling molten wire metal droplets during the arc welding process in shielding gases. The variations for implementing the relevant systems are given, with the positive and negative aspects of such implementation taken into account. Electrical systems are currently investigated to the fullest extent possible and implemented in different power sources for pulsed welding arc. Mechanical systems are represented by different types of feeders that provide the pulsed wire feeding process. The feed mechanisms driven by electric motors and electromagnets are analyzed. In addition to the mechanical and electrical systems, the examples of combined control systems are given.

  1. Influence of metal vapour on arc temperatures in gas-metal arc welding: convection versus radiation

    NASA Astrophysics Data System (ADS)

    Murphy, Anthony B.

    2013-06-01

    The presence of metal vapour in gas-metal arc welding has been shown to have two strong effects on the arc plasma: a decrease in temperature throughout the arc, and the formation of a local temperature minimum near the arc axis. These effects have been attributed, on the basis of different computational models, to either the increased radiative emission associated with the presence of metal vapour in the arc plasma, or the influence of the metal vapour influx on convective flow in the arc. This question is investigated using a three-dimensional computational model in which the production and the transport of metal vapour are taken into account self-consistently. Parameters relevant to welding of thin sheets of aluminum are examined. For these conditions, it is found that the first effect (the decrease in temperature throughout the arc) is due to both the increased radiative emission and the influence of the metal vapour influx on flow. The second effect (the local temperature minimum, which in this case occurs just below the wire electrode) is a consequence of the influence of aluminum vapour produced from the wire electrode on flow in the arc. By examining published results and the energy balance in the plasma, it is shown that for welding of steel with higher arc currents, the increased radiative emission can lead to a local temperature minimum at a greater distance from the wire electrode.

  2. Plasma arc welding torch having means for vortexing plasma gas exiting the welding torch

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

    A plasma arc welding torch is described wherein a plasma gas is directed through the body of the welding torch and out of the body across the tip of the welding electrode disposed at the forward end of the body. The plasma gas is provided with a vortexing motion prior to exiting the body by a vortex motion imparting member which is mounted in an orifice housing member and carried in the forward portion of the torch body. The orifice housing member is provided with an orifice of an predetermined diameter through which the electric arc and the plasma gas exits.

  3. Plasma Cutting and Carbon-Arc Cutting. Welding Module 8. Instructor's Guide.

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

    This guide is intended to assist vocational educators in teaching the two units of a module in operating plasma cutting and carbon-arc cutting equipment. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The materials included in the module have been…

  4. Microstructure and Mechanical Properties of Hybrid Welded Joints with Laser and CO2-Shielded Arc

    NASA Astrophysics Data System (ADS)

    Wahba, M.; Mizutani, M.; Katayama, S.

    2016-07-01

    With the objective of reducing the operating costs, argon-rich shielding gas was replaced by 100% CO2 gas in hybrid laser-arc welding of shipbuilding steel. The welding parameters were optimized to obtain buried-arc transfer in order to mitigate spatter formation. Sound butt joints could be successfully produced for plates of 14 and 17 mm thickness in one welding pass. Subsequently, the welded joints were subjected to different tests to evaluate the influence of CO2 shielding gas on the mechanical properties of the welded joints. All tensile-tested specimens failed in the base material, indicating the higher strength of the welded joints. The impact toughness of the welded joints, measured at -20 °C, reached approximately 76% of that of the base material, which was well above the limit set by the relevant standard. The microstructure of the fusion zone consisted of grain boundary ferrite and acicular ferrite uniformly over the plate thickness except for the joint root where the microstructure was chiefly ferrite with an aligned second phase. This resulted in higher hardness in the root region compared with the top and middle parts of the fusion zone.

  5. Heat flow in variable polarity plasma arc welds

    NASA Technical Reports Server (NTRS)

    Abdelmessih, Amanie N.

    1992-01-01

    The space shuttle external tank and the space station Freedom are fabricated by the variable polarity plasma arc (VPPA) welding. Heat sink effects (taper) are observed when there are irregularities in the work-piece configuration especially if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, and in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of the previous, present, and consecutive research studies is to investigate the effect of irregularities in the work-piece configuration and fixture differences on the weld bead geometry with the ultimate objective to compensate automatically for the heat sink effects and achieve a perfect weld.

  6. Immunotoxicology of arc welding fume: worker and experimental animal studies.

    PubMed

    Zeidler-Erdely, Patti C; Erdely, Aaron; Antonini, James M

    2012-01-01

    Arc welding processes generate complex aerosols composed of potentially hazardous metal fumes and gases. Millions of workers worldwide are exposed to welding aerosols daily. A health effect of welding that is of concern to the occupational health community is the development of immune system dysfunction. Increased severity, frequency, and duration of upper and lower respiratory tract infections have been reported among welders. Specifically, multiple studies have observed an excess mortality from pneumonia in welders and workers exposed to metal fumes. Although several welder cohort and experimental animal studies investigating the adverse effects of welding fume exposure on immune function have been performed, the potential mechanisms responsible for these effects are limited. The objective of this report was to review both human and animal studies that have examined the effect of welding fume pulmonary exposure on local and systemic immune responses. PMID:22734811

  7. Immunotoxicology of arc welding fume: worker and experimental animal studies.

    PubMed

    Zeidler-Erdely, Patti C; Erdely, Aaron; Antonini, James M

    2012-01-01

    Arc welding processes generate complex aerosols composed of potentially hazardous metal fumes and gases. Millions of workers worldwide are exposed to welding aerosols daily. A health effect of welding that is of concern to the occupational health community is the development of immune system dysfunction. Increased severity, frequency, and duration of upper and lower respiratory tract infections have been reported among welders. Specifically, multiple studies have observed an excess mortality from pneumonia in welders and workers exposed to metal fumes. Although several welder cohort and experimental animal studies investigating the adverse effects of welding fume exposure on immune function have been performed, the potential mechanisms responsible for these effects are limited. The objective of this report was to review both human and animal studies that have examined the effect of welding fume pulmonary exposure on local and systemic immune responses.

  8. Immunotoxicology of arc welding fume: Worker and experimental animal studies

    PubMed Central

    Zeidler-Erdely, Patti C.; Erdely, Aaron; Antonini, James M.

    2015-01-01

    Arc welding processes generate complex aerosols composed of potentially hazardous metal fumes and gases. Millions of workers worldwide are exposed to welding aerosols daily. A health effect of welding that is of concern to the occupational health community is the development of immune system dysfunction. Increased severity, frequency, and duration of upper and lower respiratory tract infections have been reported among welders. Specifically, multiple studies have observed an excess mortality from pneumonia in welders and workers exposed to metal fumes. Although several welder cohort and experimental animal studies investigating the adverse effects of welding fume exposure on immune function have been performed, the potential mechanisms responsible for these effects are limited. The objective of this report was to review both human and animal studies that have examined the effect of welding fume pulmonary exposure on local and systemic immune responses. PMID:22734811

  9. Simulation of the welding of irradiated materials

    SciTech Connect

    Lin, Hua Tay

    1989-07-01

    Helium was uniformly implanted using the ''tritium trick'' technique to levels of 0.18, 2.5, 27, 105 and 256 atomic part per million (appm) for type 316 stainless steel, and 0.3 and 1 appm for Sandvik HT-9 (12 Cr-1MoVW). Both full penetration as well as partial penetration welds were then produced on control and helium-containing materials using the autogenous gas tungsten arc (GTA) welding process under full constraint conditions. For full penetration welds, both materials were successfully welded when they contained less than 0.3 appm helium. However, welds of both materials, when containing greater than 1 appm helium, were found to develop cracks during cooling of the weld. Transmission and scanning electron microscopy indicated that the HAZ cracking was caused by the growth and coalescence of grain boundary (GB) helium bubbles. This cracking occurred as a result of the combination of high temperatures and high shrinkage tensile stresses. The cracking in the fusion zone was found to result from the precipitation of helium along dendrite interfaces. A model based on the kinetics of diffusive cavity growth is presented to explain the observed results. The model proposes a helium bubble growth mechanism which leads to final intergranular rupture in the heat-affected zone. Results of the present study demonstrate that the use of conventional fusion welding techniques to repair materials degraded by exposure to irradiation environments may be difficult if the irradiation results in the generation of helium equal to or greater than 1 appm.

  10. Heat sink effects in variable polarity plasma arc welding

    NASA Technical Reports Server (NTRS)

    Abdelmessih, Amanie N.

    1991-01-01

    The Space Shuttle External Tank is fabricated by the variable polarity plasma arc (VPPA) welding process. In VPPA welding, a noble gas, usually argon, is directed through an arc to emerge from the torch as a hot plasma jet. This jet is surrounded by a shielding gas, usually helium, to protect the weld from contamination with air. The high velocity, hot plasma jet completely penetrates the workpiece (resembling a line heat source) when operated in the 'keyhole' mode. The metal melts on touching the side of the jet, as the torch travels in the perpendicular direction to the direction of the jet, and melted metal moves around the plasma jet in the keyhole forming a puddle which solidifies behind the jet. Heat sink effects are observed when there are irregularities in the workpiece configuration, especially, if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, i.e., in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of this research is to study the effect of irregularities in workpiece configuration and fixture differences (heat sink effects) on the weld bead geometry with the ultimate objective to compensate for the heat sink effects and achieve a perfect weld. Experiments were performed on different workpiece geometries and compared to approximate models.

  11. Dynamic Electrode Forces in Gas Metal Arc Welding.

    NASA Astrophysics Data System (ADS)

    Jones, Lawrence Anthony

    In gas metal arc welding, a low-voltage electric -arc plasma is maintained between a work-piece and a wire electrode, both of which are melted by the arc. This thesis examines the dynamic forces that affect the detachment of molten metal drops from the consumable wire electrode. Unlike drops falling from a water faucet, the drops in gas metal arc welding experience strong magnetic forces generated by the interaction of the welding current with its own magnetic field. An extensive set of clear high-speed motion images of metal drops detaching from a welding electrode was collected under a wide variety of conditions. The images are used to measure the surface tension of steel as it is found in a gas metal arc welding plasma. Impulse-response oscillations of pendent molten steel drops are also measured. A derivation of the magnetic forces acting on necking drops is performed. Numerical computations of these forces are performed by using shapes fitted to high -speed images of molten steel drops as they are ejected from the electrode by magnetic forces during short-duty -cycle current pulsing. A dynamic model of drop detachment is developed and used to study the competition between the retaining surface tension force and other forces (magnetic, gravitational, and inertial). Simulations performed with this model are compared with extensive measurements of constant-current welding images and with limited measurements of pulsed -current welding images. The comparisons indicate that the experimental magnetic forces are much less potent than the calculated magnetic forces when welding-current transients are not present. A hypothesis is advanced that internal flows are able to develop under the relatively quiescent conditions that exist during drop development in constant -current welding. An apparatus was constructed to axially vibrate the electrode as it is consumed. Experiments using inertial forces to induce drop detachment are shown. Comparisons of experimental

  12. Post-weld Tempered Microstructure and Mechanical Properties of Hybrid Laser-Arc Welded Cast Martensitic Stainless Steel CA6NM

    NASA Astrophysics Data System (ADS)

    Mirakhorli, Fatemeh; Cao, Xinjin; Pham, Xuan-Tan; Wanjara, Priti; Fihey, Jean-Luc

    2016-01-01

    Manufacturing of hydroelectric turbine components involves the assembly of thick-walled stainless steels using conventional multi-pass arc welding processes. By contrast, hybrid laser-arc welding may be an attractive process for assembly of such materials to realize deeper penetration depths, higher production rates, narrower fusion, and heat-affected zones, and lower distortion. In the present work, single-pass hybrid laser-arc welding of 10-mm thick CA6NM, a low carbon martensitic stainless steel, was carried out in the butt joint configuration using a continuous wave fiber laser at its maximum power of 5.2 kW over welding speeds ranging from 0.75 to 1.2 m/minute. The microstructures across the weldment were characterized after post-weld tempering at 873 K (600 °C) for 1 hour. From microscopic examinations, the fusion zone was observed to mainly consist of tempered lath martensite and some residual delta-ferrite. The mechanical properties were evaluated in the post-weld tempered condition and correlated to the microstructures and defects. The ultimate tensile strength and Charpy impact energy values of the fully penetrated welds in the tempered condition were acceptable according to ASTM, ASME, and industrial specifications, which bodes well for the introduction of hybrid laser-arc welding technology for the manufacturing of next generation hydroelectric turbine components.

  13. Numerical investigations of arc behaviour in gas metal arc welding using ANSYS CFX

    NASA Astrophysics Data System (ADS)

    Schnick, M.; Fuessel, U.; Hertel, M.; Spille-Kohoff, A.; Murphy, A. B.

    2011-06-01

    Current numerical models of gas metal arc welding (GMAW) are trying to combine magnetohydrodynamics (MHD) models of the arc and volume of fluid (VoF) models of metal transfer. They neglect vaporization and assume an argon atmosphere for the arc region, as it is common practice for models of gas tungsten arc welding. These models predict temperatures above 20 000 K and a temperature distribution similar to tungsten inert gas (TIG) arcs. However, current spectroscopic temperature measurements in GMAW arcs demonstrate much lower arc temperatures. In contrast to TIG arcs they found a central local minimum of the radial temperature distribution. The paper presents a GMAW arc model that considers metal vapour and which is in a very good agreement with experimentally observed temperatures. Furthermore, the model is able to predict the local central minimum in the radial temperature and the radial electric current density distributions for the first time. The axially symmetric model of the welding torch, the work piece, the wire and the arc (fluid domain) implements MHD as well as turbulent mixing and thermal demixing of metal vapour in argon. The mass fraction of iron vapour obtained from the simulation shows an accumulation in the arc core and another accumulation on the fringes of the arc at 2000 to 5000 K. The demixing effects lead to very low concentrations of iron between these two regions. Sensitive analyses demonstrate the influence of the transport and radiation properties of metal vapour, and the evaporation rate relative to the wire feed. Finally the model predictions are compared with the measuring results of Zielińska et al.

  14. Application of welding science to welding engineering: A lumped parameter gas metal arc welding dynamic process model

    SciTech Connect

    Murray, P.E.; Smartt, H.B.; Johnson, J.A.

    1997-12-31

    We develop a model of the depth of penetration of the weld pool in gas metal arc welding (GMAW) which demonstrates interaction between the arc, filler wire and weld pool. This model is motivated by the observations of Essers and Walter which suggest a relationship between droplet momentum and penetration depth. A model of gas metal arc welding was augmented to include an improved model of mass transfer and a simple model of accelerating droplets in a plasma jet to obtain the mass and momentum of impinging droplets. The force of the droplets and depth of penetration is correlated by a dimensionless linear relation used to predict weld pool depth for a range of values of arc power and contact tip to workpiece distance. Model accuracy is examined by comparing theoretical predictions and experimental measurements of the pool depth obtained from bead on plate welds of carbon steel in an argon rich shielding gas. Moreover, theoretical predictions of pool depth are compared to the results obtained from the heat conduction model due to Christensen et al. which suggest that in some cases the momentum of impinging droplets is a better indicator of the depth of the weld pool and the presence of a deep, narrow penetration.

  15. Plasma-Arc Torch For Welding Ducts In Place

    NASA Technical Reports Server (NTRS)

    Gangl, Kenneth J.; Bayless, Ernest; Looney, Alan

    1991-01-01

    Plasma-arc-welding torch redesigned, more suitable for applications in which moved in circular or other orbits about stationary cylindrical workpieces. Preserves elements of original design critical to performance and endurance, but modifies other elements to decrease overall size of torch. Electrode collet and collet nut installed and removed through hole in top; makes installation and removal easier.

  16. Looking north at uing press of the submerged arc weld ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    Looking north at u-ing press of the submerged arc weld (saw) line of the main pipe mill building, bay 7. - U.S. Steel National Tube Works, Main Pipe Mill Building, Along Monongahela River, McKeesport, Allegheny County, PA

  17. Experimental investigations of the arc MIG-MAG welding

    SciTech Connect

    Pellerin, N.; Zielinska, S.; Briand, F.; Richard, F.

    2006-01-15

    The type of the applied shielding gas has a strong influence on quality of the welding process. In particular, increase of the percentage of carbon dioxide in argon, causes increase of the transition current value from the globular to spray mode of metal transfer. Observations by fast camera allows to better characterize the arc column shape in the different working modes. The spectroscopic diagnostic of the welding arc is also necessary to understand the observed changes in the mode of droplet transfer. The use of an original diagnostic method allows to estimate the temperature and the electronic density distributions in the plasma without hypothesis on its equilibrium state. Results of this work seem to show that the observed effects could be linked to the microstructural modifications of the anode tip during the MIG-MAG welding process as a function of the gas composition, and especially to the existence and disappearance of an insulating oxide 'gangue' at the wire extremity.

  18. Experimental investigations of the arc MIG-MAG welding

    NASA Astrophysics Data System (ADS)

    Pellerin, N.; Zielińska, S.; Pellerin, S.; Valensi, F.; Musioł, K.; de Izarra, Ch.; Briand, F.; Richard, F.

    2006-01-01

    The type of the applied shielding gas has a strong influence on quality of the welding process. In particular, increase of the percentage of carbon dioxide in argon, causes increase of the transition current value from the globular to spray mode of metal transfer. Observations by fast camera allows to better characterize the arc column shape in the different working modes. The spectroscopic diagnostic of the welding arc is also necessary to understand the observed changes in the mode of droplet transfer. The use of an original diagnostic method allows to estimate the temperature and the electronic density distributions in the plasma without hypothesis on its equilibrium state. Results of this work seem to show that the observed effects could be linked to the microstructural modifications of the anode tip during the MIG-MAG welding process as a function of the gas composition, and especially to the existence and disappearance of an insulating oxide "gangue" at the wire extremity.

  19. Influencing the arc and the mechanical properties of the weld metal in GMA-welding processes by additive elements on the wire electrode surface

    NASA Astrophysics Data System (ADS)

    Wesling, V.; Schram, A.; Müller, T.; Treutler, K.

    2016-03-01

    Under the premise of an increasing scarcity of raw materials and increasing demands on construction materials, the mechanical properties of steels and its joints are gaining highly important. In particular high- and highest-strength steels are getting in the focus of the research and the manufacturing industry. To the same extent, the requirements for filler metals are increasing as well. At present, these low-alloy materials are protected by a copper coating (<1μm) against corrosion. In addition, the coating realizes a good ohmic contact and good sliding properties between the welding machine and the wire during the welding process. By exchanging the copper with other elements it should be possible to change the mechanical properties of the weld metal and the arc stability during gas metal arc welding processes and keep the basic functions of the coating nearly untouched. On a laboratory scale solid wire electrodes with coatings of various elements and compounds such as titanium oxide were made and processed with a Gas Metal Arc Welding process. During the processing a different process behavior between the wire electrodes, coated and original, could be observed. The influences ranges from greater/shorter arc-length over increasing/decreasing droplets to larger/smaller arc foot point. Furthermore, the weld metal of the coated electrodes has significantly different mechanical and technological characteristics as the weld metal from the copper coated ground wire. The yield strength and tensile strength can be increased by up to 50%. In addition, the chemical composition of the weld metal was influenced by the application of coatings with layer thicknesses to 15 microns in the lower percentage range (up to about 3%). Another effect of the coating is a modified penetration. The normally occurring “argon finger” can be suppressed or enhanced by the choice of the coating. With the help of the presented studies it will be shown that Gas Metal Arc Welding processes

  20. Arc Welding of Mg Alloys: Oxide Films, Irregular Weld Shape and Liquation Cracking

    NASA Astrophysics Data System (ADS)

    Chai, Xiao

    The use of Mg alloys for vehicle weight reduction has been increasing rapidly worldwide. Gas-metal arc welding (GMAW) has the potential for mass-production welding of Mg alloys. Recently, the University of Wisconsin demonstrated in bead-on-plate GMAW of Mg alloys that severe spatter can be eliminated by using controlled short circuiting (CSC), and severe hydrogen porosity can be eliminated by removing Mg(OH)2. The present study aimed at actual butt and lap welding of Mg alloys by CSC-GMAW and susceptibility of Mg alloys to weld-edge cracking using the circular-patch welding test. Sound welds were made without spatter and hydrogen porosity butt and lap welding of AZ 31 Mg using CSC-GMAW , with butt welds approaching 100% of the base-metal strength. However, three new significant issues were found to occur easily and degrade the weld quality significantly: 1. formation of oxide films inside butt welds, 2. formation of high crowns on butt welds, and 3. formation of fingers from lap welds. The mechanisms of their formation were established, and the methods for their elimination or reduction were demonstrated. Circular-patch welds were made on most widely used Mg casting alloy AZ91, the most widely used Mg wrought alloy AZ31 with three different Mg filler wires AZ31, AZ61 and AZ92. The susceptibility to cracking along the weld edge was predicted and compared against the experimental results. Such a prediction has not been made for welds of Mg alloys before.

  1. Evaluation and monitoring of UVR in Shield Metal ARC Welding processing.

    PubMed

    Peng, Chiung-yu; Liu, Hung-hsin; Chang, Cheng-ping; Shieh, Jeng-yueh; Lan, Cheng-hang

    2007-08-01

    This study established a comprehensive approach to monitoring UVR magnitude from Shield Metal Arc Welding (SMAW) processing and quantified the effective exposure based on measured data. The irradiances from welding UVR were calculated with biological effective parameter (Slambda) for human exposure assessment. The spectral weighting function for UVR measurement and evaluation followed the American Conference of Governmental Industrial Hygienists (ACGIH) guidelines. Arc welding processing scatters bright light with UVR emission over the full UV spectrum (UVA, UVB, and UVC). The worst case of effective irradiance from a 50 cm distance arc spot with a 200 A electric current and an electrode E6011 (4 mm) is 311.0 microW cm(-2) and has the maximum allowance time (Tmax) of 9.6 s. Distance is an important factor affecting the irradiance intensity. The worst case of the effective irradiance values from arc welding at 100, 200, and 300 cm distances are 76.2, 16.6, and 12.1 microW cm(-2) with Tmax of 39.4, 180.7, and 247.9 s, respectively. Protective materials (glove and mask) were demonstrated to protect workers from hazardous UVR exposure. From this study, the methodology of UVR monitoring in SMAW processing was developed and established. It is recommended that welders should be fitted with appropriate protective materials for protection from UVR emission hazards.

  2. Probing Pulsed Current Gas Metal Arc Welding for Modified 9Cr-1Mo Steel

    NASA Astrophysics Data System (ADS)

    Krishnan, S.; Kulkarni, D. V.; De, A.

    2015-04-01

    Modified 9Cr-1Mo steels are commonly welded using gas tungsten arc welding process for its superior control over the rate of heat input and vaporization loss of the key alloying elements although the rate electrode deposition remains restricted. Recent developments in pulsed current gas metal arc welding have significantly improved its ability to enhance the rate of electrode deposition with a controlled heat input rate while its application for welding of modified 9Cr-1Mo steels is scarce. The present work reports a detailed experimental study on the pulsed current gas metal arc welding of modified 9Cr-1Mo steels. The effect of the shielding gas, welding current, and speed on the weld bead profile, microstructure and mechanical properties are examined. The results show that the pulsed current gas metal arc welding with appropriate welding conditions can provide acceptable bead profile and mechanical properties in welds of modified 9Cr-1Mo steels.

  3. Thermal mechanical modeling of gas tungsten arc welding

    SciTech Connect

    Shapiro, A.B.; Mahin, K.W.

    1986-05-01

    Welding problems encountered in development and production activities are typically solved in a ''let's try this'' approach, which can be costly and do not always provide the optimal solution. The Ongoing research at LLNL and Sandia is directed toward improving our basic understanding of what is actually occurring on a phenomenological basis in welding and to apply this knowledge to the development of a general computer-based weld model. Our approach has been to couple a well defined experiment with computer simulation to examine the effects of various moedling assumptions on the computer predictions. The application is confined to the inert gas-tungsten-arc (GTA) process. However, the results give insight into modeling other welding processes (e.g. laser, electron beam).

  4. Additive manufactured Ti-6Al-4V using welding wire: comparison of laser and arc beam deposition and evaluation with respect to aerospace material specifications

    NASA Astrophysics Data System (ADS)

    Brandl, E.; Baufeld, B.; Leyens, C.; Gault, R.

    In this paper, the results of two different wire based additive-layer-manufacturing systems are compared: in one system Ti-6Al4V is deposited by a Nd:YAG laser beam, in the other by an arc beam (tungsten inert gas process). Mechanical properties of the deposits and of plate material are presented and evaluated with respect to aerospace material specifications. The mechanical tests including static tension and high cycle fatigue were performed in as-built, stress-relieved and annealed conditions. Generally, the mechanical properties of the components are competitive to cast and even wrought material properties and can attain properties suitable for space or aerospace applications.

  5. Effects of shielding gas composition on arc profile and molten pool dynamics in gas metal arc welding of steels

    NASA Astrophysics Data System (ADS)

    Wang, L. L.; Lu, F. G.; Wang, H. P.; Murphy, A. B.; Tang, X. H.

    2014-11-01

    In gas metal arc welding, gases of different compositions are used to produce an arc plasma, which heats and melts the workpiece. They also protect the workpiece from the influence of the air during the welding process. This paper models gas metal arc welding (GMAW) processes using an in-house simulation code. It investigates the effects of the gas composition on the temperature distribution in the arc and on the molten pool dynamics in gas metal arc welding of steels. Pure argon, pure CO2 and different mixtures of argon and CO2 are considered in the study. The model is validated by comparing the calculated weld profiles with physical weld measurements. The numerical calculations reveal that gas composition greatly affects the arc temperature profile, heat transfer to the workpiece, and consequently the weld dimension. As the CO2 content in the shielding gas increases, a more constricted arc plasma with higher energy density is generated as a result of the increased current density in the arc centre and increased Lorentz force. The calculation also shows that the heat transferred from the arc to the workpiece increases with increasing CO2 content, resulting in a wider and deeper weld pool and decreased reinforcement height.

  6. Is electric arc welding linked to manganism or Parkinson's disease?

    PubMed

    McMillan, Grant

    2005-01-01

    Manganese and its inorganic compounds are widely used in many industries and have been accepted as occupational neurotoxins that have caused a distinct and disabling clinical entity, manganism, in several types of work, notably where exposure is by way of dust. There is inconclusive and inconsistent evidence that, in these occupations, subclinical neurological effects, detectable only by neurobehavioural studies, may be caused by low doses. This has prompted a re-evaluation of occupational exposure limits. Some countries, including the UK, already demand much higher levels of protection against exposure than 5 years ago. Welding is the most common source of occupational exposure as manganese is an essential component of steel and so its compounds are inevitable components of fume emitted from steel welding processes. There it is found in respirable particles, often as complex oxides (spinels), sometimes within a core protected by a silicon oxide shell - as distinct from the much simpler form of particle formed by disintegration in processes such as mining and ore milling where manganism has been diagnosed convincingly. Millions of workers are at risk of exposure to manganese-containing compounds in fumes from electric arc welding of steel. In recent years it has been asserted that neurological and neurobehavioural disorders may develop consequent to exposure to steel welding fumes and that employment as a welder is associated with the unusually early onset of Parkinson's disease. Causal relationships have been postulated. Welders have been recorded as having been exposed to high levels of manganese-containing fume, especially where they have worked in confined, unventilated spaces, although this appears from limited data to be the exception rather than the rule. Even then the dose received is generally less than in mining or ore crushing. When care is taken to exclude exposures from hardfacing and burning and cutting arc processes, where manganese may form a high

  7. Is electric arc welding linked to manganism or Parkinson's disease?

    PubMed

    McMillan, Grant

    2005-01-01

    Manganese and its inorganic compounds are widely used in many industries and have been accepted as occupational neurotoxins that have caused a distinct and disabling clinical entity, manganism, in several types of work, notably where exposure is by way of dust. There is inconclusive and inconsistent evidence that, in these occupations, subclinical neurological effects, detectable only by neurobehavioural studies, may be caused by low doses. This has prompted a re-evaluation of occupational exposure limits. Some countries, including the UK, already demand much higher levels of protection against exposure than 5 years ago. Welding is the most common source of occupational exposure as manganese is an essential component of steel and so its compounds are inevitable components of fume emitted from steel welding processes. There it is found in respirable particles, often as complex oxides (spinels), sometimes within a core protected by a silicon oxide shell - as distinct from the much simpler form of particle formed by disintegration in processes such as mining and ore milling where manganism has been diagnosed convincingly. Millions of workers are at risk of exposure to manganese-containing compounds in fumes from electric arc welding of steel. In recent years it has been asserted that neurological and neurobehavioural disorders may develop consequent to exposure to steel welding fumes and that employment as a welder is associated with the unusually early onset of Parkinson's disease. Causal relationships have been postulated. Welders have been recorded as having been exposed to high levels of manganese-containing fume, especially where they have worked in confined, unventilated spaces, although this appears from limited data to be the exception rather than the rule. Even then the dose received is generally less than in mining or ore crushing. When care is taken to exclude exposures from hardfacing and burning and cutting arc processes, where manganese may form a high

  8. Liquation Cracking in Arc and Friction-Stir Welding of Mg-Zn Alloys

    NASA Astrophysics Data System (ADS)

    Wagner, Dustin C.; Chai, Xiao; Tang, Xin; Kou, Sindo

    2015-01-01

    As compared to Al alloys, which are known to be susceptible to liquation ( i.e., liquid formation) and liquation-induced cracking, most Mg alloys have a lower eutectic temperature and thus are likely to be even more susceptible. The present study was conducted to study liquation and liquation cracking in Mg alloys during arc welding and friction-stir welding (FSW). Binary Mg-Zn alloys were selected as a model material in view of their very low eutectic temperature of 613 K (340 °C). Mg-Zn alloys with 2, 4, and 6 wt pct of Zn were cast and welded in the as-cast condition by both gas-tungsten arc welding (GTAW) and FSW. A simple test for liquation cracking was developed, which avoided interference by solidification cracking in the nearby fusion zone. Liquation and liquation cracking in GTAW were found to be in the decreasing order of Mg-6Zn, Mg-4Zn, and Mg-2Zn. Liquation cracking occurred in FSW of Mg-6Zn but not Mg-4Zn or Mg-2Zn. Instead of a continuous ribbon-like flash connected to the weld edge, small chips, and powder covered the weld surface of Mg-6Zn. The results from GTAW and FSW were discussed in light of the binary Mg-Zn phase diagram and the curves of temperature vs fraction solid during solidification.

  9. The variable polarity plasma arc welding process: Its application to the Space Shuttle external tank

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

    The technical history of the variable polarity plasma arc (VPPA) welding process being introduced as a partial replacement for the gas shielded tungsten arc process in assembly welding of the space shuttle external tank is described. Interim results of the weld strength qualification studies, and plans for further work on the implementation of the VPPA process are included.

  10. 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…

  11. Friction stir welding tool and process for welding dissimilar materials

    DOEpatents

    Hovanski, Yuri; Grant, Glenn J; Jana, Saumyadeep; Mattlin, Karl F

    2013-05-07

    A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

  12. A unified 3D model for an interaction mechanism of the plasma arc, weld pool and keyhole in plasma arc welding

    NASA Astrophysics Data System (ADS)

    Jian, Xiaoxia; Wu, ChuanSong; Zhang, Guokai; Chen, Ji

    2015-11-01

    A 3D model is developed to perform numerical investigation on the coupled interaction mechanism of the plasma arc, weld pool and keyhole in plasma arc welding. By considering the traveling of the plasma arc along the welding direction, unified governing equations are solved in the whole domain including the torch, plasma arc, keyhole, weld pool and workpiece, which involves different physical mechanisms in different zones. The local thermodynamic equilibrium-diffusion approximation is used to treat the interface between the plasma arc and weld pool, and the volume-of-fluid method is used to track the evolution of the keyhole wall. The interaction effects between the plasma arc, keyhole and weld pool as well as the heat, mass and pressure transport phenomena in the whole welding domain are quantitatively simulated. It is found that when the torch is moving along the joint line, the axis of the keyhole channel tilts backward, and the envelope of molten metal surrounding the keyhole wall inside the weld pool is unsymmetrical relative to the keyhole channel. The plasma arc welding tests are conducted, and the predicted keyhole dimensions and the fusion zone shape are in agreement with the experimentally measured results.

  13. Gas tungsten arc welding in a microgravity environment: Work done on GAS payload G-169

    NASA Technical Reports Server (NTRS)

    Welcher, Blake A.; Kolkailah, Faysal A.; Muir, Arthur H., Jr.

    1987-01-01

    GAS payload G-169 is discussed. G-169 contains a computer-controlled Gas Tungsten Arc Welder. The equipment design, problem analysis, and problem solutions are presented. Analysis of data gathered from other microgravity arc welding and terrestrial Gas Tungsten Arc Welding (GTAW) experiments are discussed in relation to the predicted results for the GTAW to be performed in microgravity with payload G-169.

  14. Gas Metal Arc Welding and Flux-Cored Arc Welding. Third Edition. Teacher Edition [and] Student Edition [and] Student Workbook.

    ERIC Educational Resources Information Center

    Knapp, John; Harper, Eddie

    This packet, containing a teacher's edition, a student edition, and a student workbook, introduces students to high deposition welding and processes for "shielding" a weld. In addition to general information, the teacher edition consists of introductory pages and teacher pages, as well as unit information that corresponds to the materials in the…

  15. Grain refinement control in gas-shielded arc welding of aluminum tubing

    NASA Technical Reports Server (NTRS)

    Iceland, W. F.; Whiffen, E. L.

    1974-01-01

    When sections are being welded, operator varies pulse rate of power supply and simultaneously monitors signal on oscilloscope until rate is found which produces maximum arc gas voltage. Remainder of welding is performed with power supply set at this pulse rate, producing desired maximum weld puddle agitation and fine uniform weld of grain structure.

  16. Physics Of Variable-Polarity Plasma Arc Welding

    NASA Technical Reports Server (NTRS)

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

    1990-01-01

    Report describes experimental study of some of the physical and chemical effects that occur during variable-polarity plasma arc (VPPA) keyhole welding of 2219 aluminum alloy. Comprised three major programs: (1) determination of effects of chemical additions (i.e., impurities) on structure and shape of bead and keyhole; (2) determination of flow in regions surrounding keyhole; (3) development of analog used easily to study flow in keyhole region.

  17. Gas-tungsten arc welding of aluminum alloys

    DOEpatents

    Frye, L.D.

    1982-03-25

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

  18. Gas-tungsten arc welding of aluminum alloys

    DOEpatents

    Frye, Lowell D.

    1984-01-01

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

  19. Welding procedure specification: gas tungsten arc welding of AISI 41XX steels

    SciTech Connect

    Wodtke, C.H.; Frizzell, D.R.

    1985-08-01

    Procedure WPS-126 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of AISI 4130 and 4142 steel (ASTM A519) (P-No: None), 0.438-in. wall pipe; filler metal is AMS 6457, Class 4130 MC (F-, A-No: None).

  20. Welding of Stainless Materials

    NASA Technical Reports Server (NTRS)

    Bull, H; Johnson, Lawrence

    1929-01-01

    It would appear that welds in some stainless steels, heat-treated in some practicable way, will probably be found to have all the resistance to corrosion that is required for aircraft. Certainly these structures are not subjected to the severe conditions that are found in chemical plants.

  1. Aviation Maintenance Technology. Airframe. A204. Aircraft Welding. Instructor Material.

    ERIC Educational Resources Information Center

    Oklahoma State Board of Vocational and Technical Education, Stillwater. Curriculum and Instructional Materials Center.

    This teacher's guide is designed to aid teachers in leading students through a module on aircraft welding on airframes. The module contains four units that cover the following topics: (1) gas welding and cutting; (2) brazing and soldering; (3) shielded metal arc welding; and (4) gas tungsten arc welding. Each unit follows a standardized format…

  2. 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…

  3. In situ strain and temperature measurement and modelling during arc welding

    SciTech Connect

    Chen, Jian; Yu, Xinghua; Miller, Roger G.; Feng, Zhili

    2014-12-26

    In this study, experiments and numerical models were applied to investigate the thermal and mechanical behaviours of materials adjacent to the weld pool during arc welding. In the experiment, a new high temperature strain measurement technique based on digital image correlation (DIC) was developed and applied to measure the in situ strain evolution. In contrast to the conventional DIC method that is vulnerable to the high temperature and intense arc light involved in fusion welding processes, the new technique utilised a special surface preparation method to produce high temperature sustaining speckle patterns required by the DIC algorithm as well as a unique optical illumination and filtering system to suppress the influence of the intense arc light. These efforts made it possible for the first time to measure in situ the strain field 1 mm away from the fusion line. The temperature evolution in the weld and the adjacent regions was simultaneously monitored by an infrared camera. Finally and additionally, a thermal–mechanical finite element model was applied to substantiate the experimental measurement.

  4. In situ strain and temperature measurement and modelling during arc welding

    DOE PAGES

    Chen, Jian; Yu, Xinghua; Miller, Roger G.; Feng, Zhili

    2014-12-26

    In this study, experiments and numerical models were applied to investigate the thermal and mechanical behaviours of materials adjacent to the weld pool during arc welding. In the experiment, a new high temperature strain measurement technique based on digital image correlation (DIC) was developed and applied to measure the in situ strain evolution. In contrast to the conventional DIC method that is vulnerable to the high temperature and intense arc light involved in fusion welding processes, the new technique utilised a special surface preparation method to produce high temperature sustaining speckle patterns required by the DIC algorithm as well asmore » a unique optical illumination and filtering system to suppress the influence of the intense arc light. These efforts made it possible for the first time to measure in situ the strain field 1 mm away from the fusion line. The temperature evolution in the weld and the adjacent regions was simultaneously monitored by an infrared camera. Finally and additionally, a thermal–mechanical finite element model was applied to substantiate the experimental measurement.« less

  5. Influence of Welding Current and Focal Position on the Resonant Absorption of Laser Radiation in a TIG Welding Arc

    NASA Astrophysics Data System (ADS)

    Emde, B.; Huse, M.; Hermsdorf, J.; Kaierle, S.; Wesling, V.; Overmeyer, L.

    The work presents the influence of welding current and focal position on the resonant absorption of diode laser radiation in a TIG welding arc. The laser beam is guided perpendicular to the electrical arc to avoid an interaction with the electrodes. Laser power measurements have shown a reduction of the measured laser power up to 18% after passing the electrical arc. This reduction results from the interaction of argon shielding gas atoms and laser radiation at 810.4 nm and 811.5 nm. The interaction is strongly affected by the adjusted welding current and the adjustment of the laser beam and the electrical arc. Lowering the welding current or shifting the laser beam out of the centerline of the electrical arc reduces the ionization probability. An increased ionization is necessary to decrease the resistance of the electrical arc.

  6. Plasma Arc Welding: How it Works

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur

    2004-01-01

    The physical principles of PAW from basic arcs to keyholing to variable polarity are outlined. A very brief account of the physics of PAW with an eye to the needs of a welder is presented. Understanding is usually (but not always) superior to handbooks and is required (unless dumb luck intervenes) for innovation. And, in any case, all welders by nature desire to know. A bit of history of the rise and fall of the Variable Polarity (VP) PA process in fabrication of the Space Shuttle External Tank is included.

  7. Effects of current on droplet generation and arc plasma in gas metal arc welding

    SciTech Connect

    Hu, J.; Tsai, H. L.

    2006-09-01

    In gas metal arc welding (GMAW), a technology using pulsed currents has been employed to achieve the one-droplet-per-pulse (ODPP) metal transfer mode with the advantages of low average currents, a stable and controllable droplet generation, and reduced spatter. In this paper, a comprehensive model was developed to study the effects of different current profiles on the droplet formation, plasma generation, metal transfer, and weld pool dynamics in GMAW. Five types of welding currents were studied, including two constant currents and three wave form currents. In each type, the transient temperature and velocity distributions of the arc plasma and the molten metal, and the shapes of the droplet and the weld pool were calculated. The results showed that a higher current generates smaller droplets, higher droplet frequency, and higher electromagnetic force that becomes the dominant factor detaching the droplet from the electrode tip. The model has demonstrated that a stable ODPP metal transfer mode can be achieved by choosing a current with proper wave form for given welding conditions.

  8. Shielded Metal Arc Welding and Carbon Arc Cutting--Air. Teacher Edition [and] Student Edition [and] Student Workbook. Third Edition.

    ERIC Educational Resources Information Center

    Harper, Eddie; Knapp, John

    This document contains the teacher and student texts and student workbook for a secondary-level course in shielded metal arc welding (SMAW) and carbon arc cutting that consists of units on the following topics: SMAW safety; SMAW equipment, applications, and techniques; hardfacing; and carbon arc cutting--air. The teacher edition includes the…

  9. Causal Factors of Weld Porosity in Gas Tungsten Arc Welding of Powder Metallurgy Produced Titanium Alloys

    SciTech Connect

    Muth, Thomas R; Yamamoto, Yukinori; Frederick, David Alan; Contescu, Cristian I; Chen, Wei; Lim, Yong Chae; Peter, William H; Feng, Zhili

    2013-01-01

    ORNL undertook an investigation using gas tungsten arc (GTA) welding on consolidated powder metallurgy (PM) titanium (Ti) plate, to identify the causal factors behind observed porosity in fusion welding. Tramp element compounds of sodium and magnesium, residual from the metallothermic reduction of titanium chloride used to produce the titanium, were remnant in the starting powder and were identified as gas forming species. PM-titanium made from revert scrap where sodium and magnesium were absent, showed fusion weld porosity, although to a lesser degree. We show that porosity was attributable to hydrogen from adsorbed water on the surface of the powders prior to consolidation. The removal / minimization of both adsorbed water on the surface of titanium powder and the residues from the reduction process prior to consolidation of titanium powders, are critical to achieve equivalent fusion welding success similar to that seen in wrought titanium produced via the Kroll process.

  10. Keyhole and weld shapes for plasma arc welding under normal and zero gravity

    NASA Technical Reports Server (NTRS)

    Keanini, R. G.; Rubinsky, B.

    1990-01-01

    A first order study of the interfacial (keyhole) shape between a penetrating argon plasma arc jet and a stationary liquid metal weld pool is presented. The interface is determined using the Young-Laplace equation by assuming that the plasma jet behaves as a one-dimensional ideal gas flow and by neglecting flow within the weld pool. The solution for the keyhole shape allows an approximate determination of the liquid-solid metal phase boundary location based on the assumption that the liquid melt is a stagnant thermal boundary layer. Parametric studies examine the effect of plasma mass flow rate, initial plasma enthalpy, liquid metal surface tension, and jet shear on weldment shape under both normal and zero gravity. Among the more important findings of this study is that keyhole and weld geometries are minimally affected by gravity, suggesting that data gathered under gravity can be used in planning in-space welding.

  11. Optimization of Gas Metal Arc Welding (GMAW) Process for Maximum Ballistic Limit in MIL A46100 Steel Welded All-Metal Armor

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.

    2015-01-01

    Our recently developed multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process has been upgraded with respect to its predictive capabilities regarding the process optimization for the attainment of maximum ballistic limit within the weld. The original model consists of six modules, each dedicated to handling a specific aspect of the GMAW process, i.e., (a) electro-dynamics of the welding gun; (b) radiation-/convection-controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler metal consumable electrode to the weld; (c) prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; (d) the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; (e) spatial distribution of the as-welded material mechanical properties; and (f) spatial distribution of the material ballistic limit. In the present work, the model is upgraded through the introduction of the seventh module in recognition of the fact that identification of the optimum GMAW process parameters relative to the attainment of the maximum ballistic limit within the weld region entails the use of advanced optimization and statistical sensitivity analysis methods and tools. The upgraded GMAW process model is next applied to the case of butt welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler metal electrodes made of the same material. The predictions of the upgraded GMAW process model pertaining to the spatial distribution of the material microstructure and ballistic limit-controlling mechanical properties within the MIL A46100 butt weld are found to be consistent with general expectations and prior observations.

  12. Laser guided and stabilized gas metal arc welding processes (LGS-GMA)

    NASA Astrophysics Data System (ADS)

    Hermsdorf, Jörg; Barroi, Alexander; Kaierle, Stefan; Overmeyer, Ludger

    2013-05-01

    The demands of the industry are cheap and fast production of highly sophisticated parts without compromises in product quality. To realize this requirement, we have developed a laser guided and stabilized gas metal arc process (LGS-GMA welding). The new welding process is based on a gas metal arc process using low power laser radiation for stabilization. The laser stabilization of gas metal arcs welding is applied to joint welding and cladding. With only 400 W laser power and a focal spot of 1.6 mm the laser radiation is mainly interacting with the arc plasma in order to guide and stabilize it. In joint welding up to 100% increase in welding speed is possible, at equal penetration depth. The guidance effect also enables the process to weld in challenging situations like different sheet thicknesses. Used for cladding, the enhanced process stability allows low penetration depth with dilutions of only 3%. Coatings with up to 63 HRC were achieved.

  13. Mechanism and Microstructure of Oxide Fluxes for Gas Tungsten Arc Welding of Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Liu, L. M.; Zhang, Z. D.; Song, G.; Wang, L.

    2007-03-01

    Five single oxide fluxes—MgO, CaO, TiO2, MnO2, and Cr2O3—were used to investigate the effect of active flux on the depth/width ratio in AZ31B magnesium alloy. The microstructure and mechanical property of the tungsten inert gas (TIG) welding seam were studied. The oxygen content in the weld seam and the arc images during the TIG welding process were analyzed. A series of emission spectroscopy of weld arc for TIG welding for magnesium with and without flux were developed. The results showed that for the five single oxide fluxes, all can increase the weld penetration effectively and grain size in the weld seam of alternating current tungsten inert gas (ACTIG) welding of the Mg alloy. The oxygen content of the welds made without flux is not very different from those produced with oxide fluxes not considering trapped oxide. However, welds that have the best penetration have a relatively higher oxygen content among those produced with flux. It was found that the arc images with the oxide fluxes were only the enlarged form of the arc images without flux; the arc constriction was not observed. The detection of arc spectroscopy showed that the metal elements in the oxides exist as the neutral atom or the first cation in the weld arc. This finding would influence the arc properties. When TIG simulation was carried out on a plate with flux applied only on one side, the arc image video showed an asymmetric arc, which deviated toward the flux free side. The thermal stability, the dissociation energy, and the electrical conductivity of oxide should be considered when studying the mechanism for increased TIG flux weld penetration.

  14. Artificial Optical Radiation photobiological hazards in arc welding.

    PubMed

    Gourzoulidis, G A; Achtipis, A; Topalis, F V; Kazasidis, M E; Pantelis, D; Markoulis, A; Kappas, C; Bourousis, C A

    2016-08-01

    Occupational Health and Safety (OHS) is associated with crucial social, economic, cultural and technical issues. A highly specialized OHS sector deals with the photobiological hazards from artificial optical radiation (AOR), which is divided into visible light, UV and IR emitted during various activities and which is legally covered by European Directive 2006/25/EC. Among the enormous amount of sources emitting AOR, the most important non-coherent ones to consider for health effects to the whole optical range, are arcs created during metal welding. This survey presents the effort to assess the complicated exposure limits of the Directive in the controlled environment of a welding laboratory. Sensors covering the UV and blue light range were set to measure typical welding procedures reproduced in the laboratory. Initial results, apart from apparently justifying the use of Personal Protective Equipment (PPE) due to even subsecond overexposures measured, also set the basis to evaluate PPE's properties and support an integrated risk assessment of the complex welding environment. These results can also improve workers' and employer's information and training about radiation hazards, which is a crucial OHS demand.

  15. Artificial Optical Radiation photobiological hazards in arc welding.

    PubMed

    Gourzoulidis, G A; Achtipis, A; Topalis, F V; Kazasidis, M E; Pantelis, D; Markoulis, A; Kappas, C; Bourousis, C A

    2016-08-01

    Occupational Health and Safety (OHS) is associated with crucial social, economic, cultural and technical issues. A highly specialized OHS sector deals with the photobiological hazards from artificial optical radiation (AOR), which is divided into visible light, UV and IR emitted during various activities and which is legally covered by European Directive 2006/25/EC. Among the enormous amount of sources emitting AOR, the most important non-coherent ones to consider for health effects to the whole optical range, are arcs created during metal welding. This survey presents the effort to assess the complicated exposure limits of the Directive in the controlled environment of a welding laboratory. Sensors covering the UV and blue light range were set to measure typical welding procedures reproduced in the laboratory. Initial results, apart from apparently justifying the use of Personal Protective Equipment (PPE) due to even subsecond overexposures measured, also set the basis to evaluate PPE's properties and support an integrated risk assessment of the complex welding environment. These results can also improve workers' and employer's information and training about radiation hazards, which is a crucial OHS demand. PMID:27422373

  16. Stainless steel manual metal arc welding fumes in rats.

    PubMed Central

    Kalliomäki, P L; Lakomaa, E; Kalliomäki, K; Kiilunen, M; Kivelä, R; Vaaranen, V

    1983-01-01

    Forty two male Wistar rats were exposed to manual metal arc (MMA) stainless steel (SS) welding fumes generated by an automatic welding device for "nose-only" exposure. The exposure simulated an actual MMA/SS welding environment as closely as possible. For the retention study, the duration of exposure was one hour per workday for one, two, three, of four weeks and for the clearance study four weeks. The retention and clearance of the chromium, nickel, and iron found in MMA/SS welding fumes in the rats' lungs were studied as was the distribution of the metals to other organs. Instrumental neutron activation analysis (INAA) was used for the multi-element chemical activation analyses. The concentrations of chromium and nickel in the blood and the urine were determined by atomic absorption method (AAS). The retention of exogenous iron was determined by a magnetic measuring method. The results indicated that the lungs were the target organs of soluble hexavalent chromates. The half times of lung clearance for Cr, Ni, and Fe were 40 +/- 4 d, 20 +/- d, and 50 +/- 10 d. When the lung clearance curves are compared, the half times of Cr and Fe lung clearance are similar but nickel disappears faster. The distribution and clearance patterns of chromium to other organs differ from those obtained after single intravenous or intratracheal injections of alkaline chromates. PMID:6830723

  17. Stability of a pendant droplet in gas metal arc welding

    SciTech Connect

    Murray, P.E.

    1998-07-01

    The authors develop a model of metal transfer in gas metal arc welding and compute the critical mass of a pendant droplet in order to ascertain the size and frequency of droplets detaching from the consumable metal electrode. These results are used to predict the mode of metal transfer for a range of voltage and current encompassing free flight transfer, and the transition between globular and spray transfer. This model includes an efficient method to compute the stability of a pendant droplet and the location of the liquid bridge connecting the primary droplet and the residual liquid remaining after detachment of the primary droplet.

  18. Development of New Materials and Technologies for Welding and Surfacing at Research and Production Center "Welding Processes and Technologies"

    NASA Astrophysics Data System (ADS)

    Kozyrev, N. A.; Kryukov, R. E.; Galevsky, G. V.; Titov, D. A.; Shurupov, V. M.

    2015-09-01

    The paper provides description of research into the influence of new materials and technologies on quality parameters of welds and added metal carried out at research and production center «Welding processes and technologies». New welding technologies of tanks for northern conditions are considered, as well as technologies of submerged arc welding involving fluxing agents AN - 348, AN - 60, AN - 67, OK. 10.71 and carbon-fluorine containing additives, new flux cored wires and surfacing technologies, teaching programs and a trainer for welders are designed.

  19. Improved Back-Side Purge-Gas Chambers For Plasma Arc Welding

    NASA Technical Reports Server (NTRS)

    Ezell, Kenneth G.; Mcgee, William F.; Rybicki, Daniel J.

    1995-01-01

    Improved chambers for inert-gas purging of back sides of workpieces during plasma arc welding in keyhole (full-penetration) mode based on concept of directing flows of inert gases toward, and concentrating them on, hot weld zones. Tapered chamber concentrates flow of inert gas on plasma arc plume and surrounding metal.

  20. Pulmonary functional impairment from years of arc welding

    SciTech Connect

    Kilburn, K.H.; Warshaw, R.H.

    1989-07-01

    The adverse effects of arc welding on pulmonary function have been previously documented. However, in many of these studies, the effects of welding exposure and smoking were not separated. Also, some studies did not adjust for or ignored the effects of asbestosis on pulmonary function. We assessed the long-term effects of welding on pulmonary function in welders who had no evidence of asbestosis on chest radiographs, and adjusted each individual value for height, age, and years of cigarette smoking. The study consisted of 226 male construction welders who had never worked in shipyards. Forced vital capacity (FVC) and flows were measured by spirometry, chest radiographs were obtained and examined for evidence of asbestosis using, and thoracic gas volume (TGV) was determined by planimetry. The subjects were also administered an occupational and respiratory questionnaire. Data on workers with asbestosis (ILO profusion 1/0 or greater) and pleural abnormalities were excluded. The mean age for the 226 subjects without asbestosis was 45 years, mean height was 175.7 cm, and mean duration of welding was 21.3 years. Pulmonary function measurements are presented as mean percentage of predicted (pop) and adjusted for height, age, and years of smoking. In 151 current cigarette smokers, mean midflows and terminal flows were decreased, FEF25-75 to 93.2 pop and FEF75-85 to 91.2 pop, but FVC, forced expiratory volume in one second (FEV1) and TGV were normal. The 43 nonsmokers also had reductions in flows but normal FVC and TGV. Flows in both groups were significantly (p less than 0.05) below those of the referent group. The regression coefficient was -0.0031 for years of welding and FVC pop, -0.0035 for FEV1 pop, and -0.0080 for midflow pop (FEF25-75) (all significant at p less than 0.05), but the coefficient for FEF75-85 pop was not significant.

  1. Possibilities of Application of Carbon-Fluorine Containing Additions in Submerged-Arc Welding

    NASA Astrophysics Data System (ADS)

    Kozyrev, N. A.; Kryukov, N. E.; Kryukov, R. E.; Igushev, V. F.; Kovalskii, I. I.

    2015-09-01

    The paper provides results of comparative analysis of the effect of carbonaceous components introduced into welding fluxes on molten metal - slag interaction. A positive influence of carbonaceous additives on gas content and mechanical properties of welds is demonstrated. Carbon and fluorine containing additives are emphasized to be promising for automatic submerged arc welding.

  2. UAH mathematical model of the variable polarity plasma ARC welding system calculation

    NASA Technical Reports Server (NTRS)

    Hung, R. J.

    1994-01-01

    Significant advantages of Variable Polarity Plasma Arc (VPPA) welding process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. A mathematical model is presented to analyze the VPPA welding process. Results of the mathematical model were compared with the experimental observation accomplished by the GDI team.

  3. Ballistic-Failure Mechanisms in Gas Metal Arc Welds of Mil A46100 Armor-Grade Steel: A Computational Investigation

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Snipes, J. S.; Galgalikar, R.; Ramaswami, S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.

    2014-09-01

    In our recent work, a multi-physics computational model for the conventional gas metal arc welding (GMAW) joining process was introduced. The model is of a modular type and comprises five modules, each designed to handle a specific aspect of the GMAW process, i.e.: (i) electro-dynamics of the welding-gun; (ii) radiation-/convection-controlled heat transfer from the electric-arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; (iii) prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; (iv) the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and (v) spatial distribution of the as-welded material mechanical properties. In the present work, the GMAW process model has been upgraded with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties controlling the ballistic-limit (i.e., penetration-resistance) of the weld. The model is upgraded through the introduction of the sixth module in the present work in recognition of the fact that in thick steel GMAW weldments, the overall ballistic performance of the armor may become controlled by the (often inferior) ballistic limits of its weld (fusion and heat-affected) zones. To demonstrate the utility of the upgraded GMAW process model, it is next applied to the case of butt-welding of a prototypical high-hardness armor-grade martensitic steel, MIL A46100. The model predictions concerning the spatial distribution of the material microstructure and ballistic-limit-controlling mechanical properties within the MIL A46100 butt-weld are found to be consistent with prior observations and general expectations.

  4. Electrical Evaluation Of Welding Machines Based On The Arc Properties. Application To SMAW, GMAW And GTAW Processes

    NASA Astrophysics Data System (ADS)

    Miguel, V.; Martínez, A.; Manjabacas, M. C.; Coello, J.; Calatayud, A.

    2009-11-01

    In this work, a methodology to obtain the electrical behavior of arc welding equipments is presented. The method is based on the electrical arc fundamentals and it is applied to Shielding Metal Arc Welding and to Gas Metal Arc Welding processes. For the first one, different arc points are achieved by practicing several arc lengths. For MIG process, different arc lengths are made by changing the feel wire velocity. Arc current and voltage are measured for the different arc length in both cases. Finally, a Gas Tungsten Arc Welding equipment has been used to obtain the electrical arc characteristics as a function of arc length. Different considerations about the thermal and electrical principles related to the arc behavior have been made.

  5. 49 CFR 178.61 - Specification 4BW welded steel cylinders with electric-arc welded longitudinal seam.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 4BW cylinder is a welded type steel cylinder with a longitudinal electric-arc welded seam, a water....60, Phosphorus 0.045, Sulfur 0.050. Heads must be hemispherical or ellipsoidal in shape with a...) Hydrostatic test. Cylinders must withstand a hydrostatic test, as follows: (1) The test must be by...

  6. 49 CFR 178.61 - Specification 4BW welded steel cylinders with electric-arc welded longitudinal seam.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 4BW cylinder is a welded type steel cylinder with a longitudinal electric-arc welded seam, a water..., Manganese 0.60, Phosphorus 0.045, Sulfur 0.050. Heads must be hemispherical or ellipsoidal in shape with a...) Hydrostatic test. Cylinders must withstand a hydrostatic test, as follows: (1) The test must be by...

  7. 49 CFR 178.61 - Specification 4BW welded steel cylinders with electric-arc welded longitudinal seam.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 4BW cylinder is a welded type steel cylinder with a longitudinal electric-arc welded seam, a water....60, Phosphorus 0.045, Sulfur 0.050. Heads must be hemispherical or ellipsoidal in shape with a...) Hydrostatic test. Cylinders must withstand a hydrostatic test, as follows: (1) The test must be by...

  8. Underwater plasma-MIG arc welding: Shielding technique and pressure reduction by a centrifugal pump

    SciTech Connect

    Creutz, M.; Mewes, D.; Bartzsch, J.; Draugelates, U.

    1995-12-31

    In comparison to hyperbaric underwater welding in diving chambers, wet welding techniques promise higher flexibility and lower costs. One technique for creating a local dry and pressure reduced welding zone is the use of a centrifugal pump. Results of experimental investigations in combination with a plasma-MIG arc welding system are presented in this paper. Special importance is attached to the local pressure reduction in view of the fact that low pressure, i.e. a high pressure difference between surrounding water and dry welding area, is a good condition for welding but is difficult to be obtained with other shielding systems than pressure chambers. Plasma-MIG welding has been done under water with a good result on the weld quality. Values of the hardness of the joint and the appearance of the weld structure are nearly comparable to atmospheric welds.

  9. Weldability characteristics of shielded metal arc welded high strength quenched and tempered plates

    NASA Astrophysics Data System (ADS)

    Datta, R.; Mukerjee, D.; Jha, S.; Narasimhan, K.; Veeraraghavan, R.

    2002-02-01

    High strength, quench and tempered (Q&T) plates having yield strength of a minimum of 670 MPa and conforming to SA 517 Gr. F specification were successfully developed at Rourkela Steel Plant in plates up to 40 mm thickness. The plates are used extensively for the fabrication of impellers, penstocks, excavators, dumpers, and raw material handling devices, where welding is an important processing step. SA 517 Gr. F plates, characterized by a relatively high carbon equivalent (CE: ˜0.6) and alloyed with Ni, Cr, Mo, Cu, and V, are susceptible to a crack-sensitive microstructure and cold cracking during welding. In view of the above, the present study investigated the weldability properties of 20 mm thick plates using the shielded metal arc welding (SMAW) process. Implant and elastic restraint cracking (ERC) tests were carried out to assess the cold cracking resistance of the weld joint under different welding conditions. Preheat of 100 °C, partial or full rebake, and a heat input of 14.9 to 15.4 KJ/cm resulted in static fatigue limit (SFL) values well in excess of the minimum specified yield strength (MSYS) of 670 MPa and a critical restraint intensity (K cr) value of 34,650 MPa, indicating adequate cold cracking resistance. Lamellar tear tests conducted using full thickness plates at heat input levels ranging from 9.7 to 14.4 KJ/cm and weld restraint loads (WRL) of 510 to 685 MPa showed no incidence of lamellar tear upon visual, ultrasonic, and four-section macroexamination. The weld joint, based on optimized welding parameters, exhibited adequate tensile strength (812.4 MPa) and low temperature impact toughness 88.3 and 63.4 J (9.2 and 6.6 kg-m) at -40 °C for weld metal (WM), and heat-affected zone (HAZ) properties, respectively. The crack tip opening displacement (CTOD) values of WM and HAZ (0.40 and 0.36 mm, respectively) were superior to that of the parent metal (0.29 mm), indicating adequate resistance of weld joint to brittle fracture. It was concluded that

  10. Contribution to arc plasma modeling for welding TIG application

    NASA Astrophysics Data System (ADS)

    Borel, Damien; Delalondre, Clarisse; Carpreau, Jean-Michel; Chéron, B. G.; Boubert, J.-P.

    2014-06-01

    In this paper we present a numerical model that simulates transferred energy by a welding thermal plasma to the weld pool. This energy transfer allows materials melting. The originality of our model is to include the modeling of transition zones and the vaporization of the anode. The cathodic and anodic areas are taken into account in the model by means of heat balance at the gas-solid interfaces. We report the heating and cooling effects they induce on the solid (cathode, anode) and plasma. Code_Saturne® the CFD software developed at EDF R&D is used for this work Comparisons between simulations and measurements of temperature and electron density confirm the model assumptions for TIG welding.

  11. Computational Modeling of Microstructural-Evolution in AISI 1005 Steel During Gas Metal Arc Butt Welding

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Arakere, A.; Yen, C.-F.; Cheeseman, B. A.

    2013-05-01

    A fully coupled (two-way), transient, thermal-mechanical finite-element procedure is developed to model conventional gas metal arc welding (GMAW) butt-joining process. Two-way thermal-mechanical coupling is achieved by making the mechanical material model of the workpiece and the weld temperature-dependent and by allowing the potential work of plastic deformation resulting from large thermal gradients to be dissipated in the form of heat. To account for the heat losses from the weld into the surroundings, heat transfer effects associated with natural convection and radiation to the environment and thermal-heat conduction to the adjacent workpiece material are considered. The procedure is next combined with the basic physical-metallurgy concepts and principles and applied to a prototypical (plain) low-carbon steel (AISI 1005) to predict the distribution of various crystalline phases within the as-welded material microstructure in different fusion zone and heat-affected zone locations, under given GMAW-process parameters. The results obtained are compared with available open-literature experimental data to provide validation/verification for the proposed GMAW modeling effort.

  12. A study of gas flow pattern, undercutting and torch modification in variable polarity plasma arc welding

    NASA Technical Reports Server (NTRS)

    Mcclure, John C.; Hou, Haihui Ron

    1994-01-01

    A study on the plasma and shield gas flow patterns in variable polarity plasma arc (VPPA) welding was undertaken by shadowgraph techniques. Visualization of gas flow under different welding conditions was obtained. Undercutting is often present with aluminum welds. The effects of torch alignment, shield gas flow rate and gas contamination on undercutting were investigated and suggestions made to minimize the defect. A modified shield cup for the welding torch was fabricated which consumes much less shield gas while maintaining the weld quality. The current torch was modified with a trailer flow for Al-Li welding, in which hot cracking is a critical problem. The modification shows improved weldablility on these alloys.

  13. Gas Metal Arc Welding Process Modeling and Prediction of Weld Microstructure in MIL A46100 Armor-Grade Martensitic Steel

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Arakere, A.; Ramaswami, S.; Snipes, J. S.; Yavari, R.; Yen, C.-F.; Cheeseman, B. A.; Montgomery, J. S.

    2013-06-01

    A conventional gas metal arc welding (GMAW) butt-joining process has been modeled using a two-way fully coupled, transient, thermal-mechanical finite-element procedure. To achieve two-way thermal-mechanical coupling, the work of plastic deformation resulting from potentially high thermal stresses is allowed to be dissipated in the form of heat, and the mechanical material model of the workpiece and the weld is made temperature dependent. Heat losses from the deposited filler-metal are accounted for by considering conduction to the adjoining workpieces as well as natural convection and radiation to the surroundings. The newly constructed GMAW process model is then applied, in conjunction with the basic material physical-metallurgy, to a prototypical high-hardness armor martensitic steel (MIL A46100). The main outcome of this procedure is the prediction of the spatial distribution of various crystalline phases within the weld and the heat-affected zone regions, as a function of the GMAW process parameters. The newly developed GMAW process model is validated by comparing its predictions with available open-literature experimental and computational data.

  14. Grain Refinement in Al-Mg-Si Alloy TIG Welds Using Transverse Mechanical Arc Oscillation

    NASA Astrophysics Data System (ADS)

    Biradar, N. S.; Raman, R.

    2012-11-01

    Reduction in grain size in weld fusion zones (FZs) presents the advantages of increased resistance to solidification cracking and improvement in mechanical properties. Transverse mechanical arc oscillation was employed to obtain grain refinement in the weldment during tungsten inert gas welding of Al-Mg-Si alloy. Electron backscattered diffraction analysis was carried out on AA6061-AA4043 filler metal tungsten inert gas welds. Grain size, texture evolution, misorientation distribution, and aspect ratio of weld metal, PMZ, and BM have been observed at fixed arc oscillation amplitude and at three different frequencies levels. Arc oscillation showed grain size reduction and texture formation. Fine-grained arc oscillated welds exhibited better yield and ultimate tensile strengths and significant improvement in percent elongation. The obtained results were attributed to reduction in equivalent circular diameter of grains and increase in number of subgrain network structure of low angle grain boundaries.

  15. The Effect of Yttrium on Ti-5111 Gas Tungsten Arc Welds

    NASA Astrophysics Data System (ADS)

    Neuberger, B. W.; Oberson, P. G.; Ankem, S.

    2011-05-01

    Much interest has developed in the near- α titanium alloy Ti-5Al-1Sn-1V-1Zr-0.8Mo (Ti-5111) for naval applications. When gas tungsten arc welded with filler metal that has the same chemical composition as the base metal, however, the weld FZ tends to be harder and less ductile than the base metal, which may make the weld susceptible to failure. This behavior may be attributed to the presence of oxygen impurities and the large prior- β grain size in the weld. In this investigation, the addition of a small amount of yttrium to the weld filler metal can decrease hardening and increase the ductility of Ti-5111 welds, which is beneficial for weld performance. Microstructural and chemical analyses of unmodified and yttrium-modified Ti-5111 welds are presented along with results from mechanical testing of the welds.

  16. Environmental embrittlement of iron-aluminide alloy FA-129 during gas tungsten arc welding

    SciTech Connect

    Fasching, A.A.; Edwards, G.R.; David, S.A.

    1994-12-31

    Iron aluminides are susceptible to hydrogen cold cracking during gastungsten arc welding (GTAW). Cracking occurs by brittle fracture in the fusion zone, which has been attributed to excessive grain growth during solidification. To further investigate hydrogen cold cracking in iron aluminides and, specifically, to study the effect of base material grain size on fusion zone cracking susceptibility, base materials of varying grain size were GTAW. The specimens for this investigation came from a production-sized vacuum arc remelt (VAR) ingot. The results of this investigation showed that changes in either the base material thermomechanical processing or the common welding parameters could not easily be used to refine the fusion zone grain size. This investigation showed that conventional GTAW produced coarse fusion zone grain structures even in fine-grained base material. The results also revealed that fracture strength decreased only slightly with a decrease in heat input, but exhibited a dramatic decrease as the water vapor content increased. in addition, the unrecrystallized base material showed the greatest susceptibility toward hydrogen cold cracking. Fracture stress versus grain size plots at different levels of water vapor were produced for iron-aluminide alloy FA-129.

  17. Stainless steel submerged arc weld fusion line toughness

    SciTech Connect

    Rosenfield, A.R.; Held, P.R.; Wilkowski, G.M.

    1995-04-01

    This effort evaluated the fracture toughness of austenitic steel submerged-arc weld (SAW) fusion lines. The incentive was to explain why cracks grow into the fusion line in many pipe tests conducted with cracks initially centered in SAWS. The concern was that the fusion line may have a lower toughness than the SAW. It was found that the fusion line, Ji. was greater than the SAW toughness but much less than the base metal. Of greater importance may be that the crack growth resistance (JD-R) of the fusion line appeared to reach a steady-state value, while the SAW had a continually increasing JD-R curve. This explains why the cracks eventually turn to the fusion line in the pipe experiments. A method of incorporating these results would be to use the weld metal J-R curve up to the fusion-line steady-state J value. These results may be more important to LBB analyses than the ASME flaw evaluation procedures, since there is more crack growth with through-wall cracks in LBB analyses than for surface cracks in pipe flaw evaluations.

  18. Influence of Filler Wire Feed Rate in Laser-Arc Hybrid Welding of T-butt Joint in Shipbuilding Steel with Different Optical Setups

    NASA Astrophysics Data System (ADS)

    Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

    In this paper, a study of laser-arc hybrid welding featuring three different process fibres was conducted to build knowledge about process behaviour and discuss potential benefits for improving the weld properties. The welding parameters affect the weld geometry considerably, as an example the increase in welding speed usually decreases the penetration and a larger beam diameter usually widens the weld. The laser hybrid welding system equipped with process fibres with 200, 300 and 600 μm core diameter were used to produce fillet welds. Shipbuilding steel AH36 plates with 8 mm thickness were welded with Hybrid-Laser-Arc-Welding (HLAW) in inversed T configuration, the effects of the filler wire feed rate and the beam positioning distance from the joint plane were investigated. Based on the metallographic cross-sections, the effect of process parameters on the joint geometry was studied. Joints with optimized properties (full penetration, soundness, smooth transition from bead to base material) were produced with 200 μm and 600 μm process fibres, while fiber with 300 μm core diameter produced welds with unacceptable levels of porosity.

  19. A numerical analysis of a stationary gas tungsten welding arc considering various electrode angles

    SciTech Connect

    Lee, S.Y.; Na, S.J.

    1996-09-01

    The influences of parameters such as electrode angle, welding current and arc length on the gas tungsten arc welding process using Ar shielding gas were studied assuming the current density distribution along the cathode surface. Its distribution was assumed to have a Gaussian form, which is characterized by the maximum current density at the electrode tip or the distribution parameter. For determining these two values according to the electrode angle and welding current, the temperature distributions of a 60-deg angle electrode were calculated for 100, 200 and 300 A welding currents and compared with the experimental measurements obtained by previous research. Using these assumed current density distributions as the boundary condition for the current continuity equation, the heat flux and current density on the base plate were calculated for various influencing parameters and compared with the experimental results obtained under the same welding conditions. Furthermore, other transporting phenomena acting on the anode plate, such as arc pressure and shear stress, were calculated.

  20. Improving Processes of Mechanized Pulsed Arc Welding of Low-Frequency Range Variation of Mode Parameters

    NASA Astrophysics Data System (ADS)

    Saraev, Yu N.; Solodskiy, S. A.; Ulyanova, O. V.

    2016-04-01

    A new technology of low-frequency modulation of the arc current in MAG and MIG welding is presented. The technology provides control of thermal and crystallization processes, stabilizes the time of formation and crystallization of the weld pool. Conducting theoretical studies allowed formulating the basic criteria for obtaining strong permanent joints for high-duty structures, providing conditions for more equilibrium structure of the deposited metal and the smaller width of the HAZ. The stabilization of time of the formation and crystallization of the weld pool improves the formation of the weld and increases productivity in welding thin sheet metal.

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

    NASA Technical Reports Server (NTRS)

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

    1989-01-01

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

  2. The Study of Complex (Ti, Zr, Cs) Nanopowder Influencing the Effective Ionization Potential of Arc Discharge When Mma Welding

    NASA Astrophysics Data System (ADS)

    Sapozhkov, S. B.; Burakova, E. M.

    2016-08-01

    Strength is one of the most important characteristics of a weld joint. Mechanical properties of a weld metal can be improved in a variety of ways. One of the possibilities is to add a nanopowder to the weld metal. Authors of the paper suggest changing the production process of MMA welding electrodes via adding nanopowder Ti, Zr, Cs to electrode components through liquid glass. Theoretical research into the nanopowder influence on the effective ionization potential (Ueff) of welding arc discharge is also necessitated. These measures support arcing stability, improve strength of a weld joint, as the consequence, ensure quality enhancing of a weld joint and the structure on the whole.

  3. The influence of arc plasma parameters on the form of a welding pool

    NASA Astrophysics Data System (ADS)

    Frolov, V. Ya.; Toropchin, A. I.

    2015-07-01

    The influence of the Marangoni force on the form of a welding pool has been considered. Results of computer simulation of the processes of welding arc generation with a non-consumable tungsten electrode in inert gas are shown. The experimental results are reported and comparatively analyzed. The calculations were carried out in a package of applied programs at various currents.

  4. The Variable Polarity Plasma Arc Welding Process: Its Application to the Space Shuttle External Tank

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.; Bayless, E. O., Jr.; Wilson, W. A.

    1984-01-01

    This report describes progress in the implementation of the Variable Polarity Plasma Arc Welding (VPPAW) process at the External Tank (ET) assembly facility. Design allowable data has been developed for thicknesses up to 1.00 in. More than 24,000 in. of welding on liquid oxygen and liquid hydrogen cylinders has been made without an internal defect.

  5. Welding arc and plasma studies using real time, multipass holographic interferometry

    NASA Technical Reports Server (NTRS)

    Deason, Vance

    1987-01-01

    Flow visualization of the plasma process in a welding arc is being studied with a multipass Argon ion interferometer. High speed movies at 10,000 frames per/sec are taken. The multipass interferometer and several interferograms of the plasma near the electrode of the welding are given. Digitization of the fringes is currently done by hand.

  6. Description and Preliminary Training Evaluation of an Arc Welding Simulator. Research Report SRR 73-23.

    ERIC Educational Resources Information Center

    Abrams, Macy L.; And Others

    A prototype arc welding training simulator was designed to provide immediate, discriminative feedback and the capacity for concentrated practice. Two randomly selected groups of welding trainees were compared to evaluate the simulator, one group being trained using the simulator and the other using conventional practice. Preliminary data indicated…

  7. [Arc spectrum diagnostic and heat coupling mechanism analysis of double wire pulsed MIG welding].

    PubMed

    Liu, Yong-qiang; Li, Huan; Yang, Li-jun; Zheng, Kai; Gao, Ying

    2015-01-01

    A double wire pulsed MIG welding test system was built in the present paper, in order to analyze the heat-coupling mechanism of double wire pulsed MIG welding, and study are temperature field. Spectroscopic technique was used in diagnostic analysis of the are, plasma radiation was collected by using hollow probe method to obtain the arc plasma optical signal The electron temperature of double wire pulsed MIG welding arc plasma was calculated by using Boltzmann diagram method, the electron temperature distribution was obtained, a comprehensive analysis of the arc was conducted combined with the high speed camera technology and acquisition means of electricity signal. The innovation of this paper is the combination of high-speed camera image information of are and optical signal of arc plasma to analyze the coupling mechanism for dual arc, and a more intuitive analysis for are temperature field was conducted. The test results showed that a push-pull output was achieved and droplet transfer mode was a drop in a pulse in the welding process; Two arcs attracted each other under the action of a magnetic field, and shifted to the center of the arc in welding process, so a new heat center was formed at the geometric center of the double arc, and flowing up phenomenon occurred on the arc; Dual arc electronic temperature showed an inverted V-shaped distribution overall, and at the geometric center of the double arc, the arc electron temperature at 3 mm off the workpiece surface was the highest, which was 16,887.66 K, about 4,900 K higher than the lowest temperature 11,963.63 K. PMID:25993809

  8. [Arc spectrum diagnostic and heat coupling mechanism analysis of double wire pulsed MIG welding].

    PubMed

    Liu, Yong-qiang; Li, Huan; Yang, Li-jun; Zheng, Kai; Gao, Ying

    2015-01-01

    A double wire pulsed MIG welding test system was built in the present paper, in order to analyze the heat-coupling mechanism of double wire pulsed MIG welding, and study are temperature field. Spectroscopic technique was used in diagnostic analysis of the are, plasma radiation was collected by using hollow probe method to obtain the arc plasma optical signal The electron temperature of double wire pulsed MIG welding arc plasma was calculated by using Boltzmann diagram method, the electron temperature distribution was obtained, a comprehensive analysis of the arc was conducted combined with the high speed camera technology and acquisition means of electricity signal. The innovation of this paper is the combination of high-speed camera image information of are and optical signal of arc plasma to analyze the coupling mechanism for dual arc, and a more intuitive analysis for are temperature field was conducted. The test results showed that a push-pull output was achieved and droplet transfer mode was a drop in a pulse in the welding process; Two arcs attracted each other under the action of a magnetic field, and shifted to the center of the arc in welding process, so a new heat center was formed at the geometric center of the double arc, and flowing up phenomenon occurred on the arc; Dual arc electronic temperature showed an inverted V-shaped distribution overall, and at the geometric center of the double arc, the arc electron temperature at 3 mm off the workpiece surface was the highest, which was 16,887.66 K, about 4,900 K higher than the lowest temperature 11,963.63 K.

  9. Temperature field acquisition during gas metal arc welding using thermocouples, thermography and fibre Bragg grating sensors

    NASA Astrophysics Data System (ADS)

    Moreira, P. M. G. P.; Frazão, O.; Tavares, S. M. O.; de Figueiredo, M. A. V.; Restivo, M. T.; Santos, J. L.; de Castro, P. M. S. T.

    2007-03-01

    The paper presents the application of temperature acquisition systems integrating thermocouples, a thermographic camera and fibre Bragg grating (FBG) sensors in gas metal arc welding (GMAW) process, MIG (metal inert gas) welding type. Efficient procedures to use FBG sensors and thermocouples were developed. The paper presents and compares measurements made in welded plates of aluminium alloy 6082-T6. Tests were performed in both plate surfaces and good agreement between the three techniques was found.

  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. ARC+(Registered Trademark) and ARC PC Welding Simulators: Teach Welders with Virtual Interactive 3D Technologies

    NASA Technical Reports Server (NTRS)

    Choquet, Claude

    2011-01-01

    123 Certification Inc., a Montreal based company, has developed an innovative hands-on welding simulator solution to help build the welding workforce in the most simple way. The solution lies in virtual reality technology, which has been fully tested since the early 90's. President and founder of 123 Certification Inc., Mr. Claude Choquet Ing. Msc. IWE. acts as a bridge between the welding and the programming world. Working in these fields for more than 20 years. he has filed 12 patents world-wide for a gesture control platform with leading edge hardware related to simulation. In the summer of 2006. Mr Choquet was proud to be invited to the annual IIW International Weld ing Congress in Quebec City to launch the ARC+ welding simulator. A 100% virtual reality system and web based training center was developed to simulate multi process. multi-materiaL multi-position and multi pass welding. The simulator is intended to train welding students and apprentices in schools or industries. The welding simulator is composed of a real welding e[eetrode holder (SMAW-GTAW) and gun (GMAW-FCAW). a head mounted display (HMD), a 6 degrees of freedom tracking system for interaction between the user's hands and head. as well as external audio speakers. Both guns and HMD are interacting online and simultaneously. The welding simulation is based on the law of physics and empirical results from detailed analysis of a series of welding tests based on industrial applications tested over the last 20 years. The simulation runs in real-time, using a local logic network to determine the quality and shape of the created weld. These results are based on the orientation distance. and speed of the welding torch and depth of penetration. The welding process and resulting weld bc.1d are displayed in a virtual environment with screenplay interactive training modules. For review. weld quality and recorded process values can be displayed and diagnosed after welding. To help in the le.tming process, a

  12. Cathodic cleaning and heat input in variable polarity plasma arc welding of aluminum

    SciTech Connect

    Fuerschbach, P.W.

    1998-02-01

    For variable polarity plasma arc welding (VPPAW) of 1,100 Al, it was found that the net heat input to the aluminum workpiece did not decrease as independent changes in polarity balance enabled the tungsten electrode to become the predominant anode in the alternating current arc. For the thin sheet edge welds made in this study, the independent parameters used to vary the arc current polarity balance were very effective in delivering a wide range of actual arc power polarity balance. The ratio of electrode positive polarity arc energy to the total arc energy ranged from as little as 0.03 to as high as 0.99. Despite this pronounced difference in arc polarity, no significant variation in the average arc efficiency (net heat input/arc energy) of 0.51 was found. Substantial heating of the workpiece during electrode positive polarity was attributed to field type emission of electrons from the low boiling point aluminum cathode. Unlike thermionic emission at the tungsten, field emission electrons do not cool the cathode. While the actual arc efficiency were relatively constant, there were significant differences in the measured heat input, the weld size, and the effectiveness of the cathodic cleaning.

  13. Three-dimensional spectral domain optical coherence tomography in chronic exposure to welding arc.

    PubMed

    Saxena, Sandeep; Mishra, Nibha; Meyer, Carsten H

    2014-01-01

    Three-dimensional spectral domain optical coherence tomography was performed in a 26-year-old man with chronic exposure to welding arc. Advanced macular visualisation provided significant findings of inner segment-ellipsoid zone disruption with the presence of cystoid changes and hyper-reflective material in the area of disruption. The external limiting membrane was intact in both the eyes. C-scan retinal pigment epithelium fit map of the left eye revealed a well-delineated defect whereas the right eye showed a poorly delineated smaller defect. The hyper-reflective material can be hypothesised to originate from the disrupted photoreceptor layer. The hyper-reflective material was more evident in the left eye which could be correlated with more marked diminution of vision and a prominent yellow lesion at the fovea. PMID:24832707

  14. Electrode support for gas arc welding torch having coaxial vision

    NASA Technical Reports Server (NTRS)

    Richardson, Richard W. (Inventor)

    1987-01-01

    An improved electrode mounting structure for a gas tungsten arc welding torch having a coaxial imaging system. The electrode mounting structure includes a support having a central hub and a plurality of spokes which extend from the hub generally radially with respect to the axis of the torch into supporting engagement with the interior walls of the torch. The spaces between the spokes are optical passages for transmission of light to form the image. A tubular collet holder is threadedly engaged at its upper end to the hub and extends downwardly toward the open end of the torch. The collet holder has an inwardly tapering constriction near its lower end. An electrode-retaining, tubular collet is mounted within the collet holder and has a longitudinally split and tapered end seating against the tapered constriction. A spring seats against the upper end of the collet and forces the split end against the tapered constriction to wedge the split end radially inwardly to grip the electrode within the collet.

  15. Evaluation Of Four Welding Arc Processes Applied To 6061 Aluminium Alloy

    SciTech Connect

    Benoit, A.; Paillard, P.; Baudin, T.; Jobez, S.; Castagne, J.-F.

    2011-01-17

    At a time when greenhouse gas emissions must be reduced, the use of the aluminium alloys is expanding, in particular in the transportation industry. In order to extend the possibilities of aluminium assembly design, new Metal Inert Gas (MIG) welding processes have been conceived. They work at lower temperatures than usual arc processes (classic MIG or Tungsten Inert Gas). This study compares four arc welding processes, applied to the 6061 aluminium alloy. These four weld processes have been studied through the metallurgical analysis of the weld beads. Metallography, micro-hardness testings, X Ray radiography have been carried out on the produced weld beads. The processes are classified according to the quality of the beads like geometry of beads, size of the heat affected zone and presence of defects.

  16. Evaluation Of Four Welding Arc Processes Applied To 6061 Aluminium Alloy

    NASA Astrophysics Data System (ADS)

    Benoit, A.; Paillard, P.; Baudin, T.; Jobez, S.; Castagné, J.-F.

    2011-01-01

    At a time when greenhouse gas emissions must be reduced, the use of the aluminium alloys is expanding, in particular in the transportation industry. In order to extend the possibilities of aluminium assembly design, new Metal Inert Gas (MIG) welding processes have been conceived. They work at lower temperatures than usual arc processes (classic MIG or Tungsten Inert Gas). This study compares four arc welding processes, applied to the 6061 aluminium alloy. These four weld processes have been studied through the metallurgical analysis of the weld beads. Metallography, micro-hardness testings, X Ray radiography have been carried out on the produced weld beads. The processes are classified according to the quality of the beads like geometry of beads, size of the heat affected zone and presence of defects.

  17. Use of the Plasma Spectrum RMS Signal for Arc-Welding Diagnostics

    PubMed Central

    Mirapeix, Jesus; Cobo, Adolfo; Fuentes, Jose; Davila, Marta; Etayo, Juan Maria; Lopez-Higuera, Jose-Miguel

    2009-01-01

    A new spectroscopic parameter is used in this paper for on-line arc-welding quality monitoring. Plasma spectroscopy applied to welding diagnostics has typically relied on the estimation of the plasma electronic temperature, as there is a known correlation between this parameter and the quality of the seams. However, the practical use of this parameter gives rise to some uncertainties that could provoke ambiguous results. For an efficient on-line welding monitoring system, it is essential to prevent the appearance of false alarms, as well as to detect all the possible defects. In this regard, we propose the use of the root mean square signal of the welding plasma spectra, as this parameter will be proven to exhibit a good correlation with the quality of the resulting seams. Results corresponding to several arc-welding field tests performed on Inconel and titanium specimens will be discussed and compared to non-destructive evaluation techniques. PMID:22346696

  18. Thorium-232 exposure during tungsten inert gas arc welding and electrode sharpening.

    PubMed

    Saito, Hiroyuki; Hisanaga, Naomi; Okada, Yukiko; Hirai, Shoji; Arito, Heihachiro

    2003-07-01

    To assess the exposure of welders to thorium-232 (232Th) during tungsten inert gas arc (TIG) welding, airborne concentrations of 232Th in the breathing zone of the welder and background levels were measured. The radioactive concentrations were 1.11 x 10(-2) Bq/m3 during TIG welding of aluminum (TIG/Al), 1.78 x 10(-4) Bq/m3 during TIG welding of stainless steel (TIG/SS), and 1.93 x 10(-1) Bq/m3 during electrode sharpening, with 5.82 x 10(-5) Bq/m3 background concentration. Although the annual intake of 232Th estimated using these values did not exceed the annual limit intake (ALI, 1.6 x 10(2) Bq), we recommend reducing 232Th exposure by substituting thoriated electrodes with a thorium-free electrodes, setting up local ventilation systems, and by using respiratory protective equipment. It is also necessary to inform workers that thoriated tungsten electrodes contain radioactive material. PMID:12916759

  19. Preventing Oxidation Near Gas/Tungsten-Arc Welds

    NASA Technical Reports Server (NTRS)

    Reed, K. J.

    1987-01-01

    Auxiliary argon jets create more nearly complete nonoxidizing atmosphere. Pyramid-shaped cup directs stream of additional argon over weld. Gas supplements provided by automatic welding machine so oxidation more completely suppressed.

  20. Interfacial microstructure and properties of copper clad steel produced using friction stir welding versus gas metal arc welding

    SciTech Connect

    Shen, Z.; Chen, Y.; Haghshenas, M.; Nguyen, T.; Galloway, J.; Gerlich, A.P.

    2015-06-15

    A preliminary study compares the feasibility and microstructures of pure copper claddings produced on a pressure vessel A516 Gr. 70 steel plate, using friction stir welding versus gas metal arc welding. A combination of optical and scanning electron microscopy is used to characterize the grain structures in both the copper cladding and heat affected zone in the steel near the fusion line. The friction stir welding technique produces copper cladding with a grain size of around 25 μm, and no evidence of liquid copper penetration into the steel. The gas metal arc welding of copper cladding exhibits grain sizes over 1 mm, and with surface microcracks as well as penetration of liquid copper up to 50 μm into the steel substrate. Transmission electron microscopy reveals that metallurgical bonding is produced in both processes. Increased diffusion of Mn and Si into the copper cladding occurs when using gas metal arc welding, although some nano-pores were detected in the FSW joint interface. - Highlights: • Cladding of steel with pure copper is possible using either FSW or GMAW. • The FSW yielded a finer grain structure in the copper, with no evidence of cracking. • The FSW joint contains some evidence of nano-pores at the interface of the steel/copper. • Copper cladding by GMAW contained surface cracks attributed to high thermal stresses. • The steel adjacent to the fusion line maintained a hardness value below 248 HV.

  1. Effect of stainless steel manual metal arc welding fume on free radical production, DNA damage, and apoptosis induction.

    PubMed

    Antonini, James M; Leonard, Stephen S; Roberts, Jenny R; Solano-Lopez, Claudia; Young, Shih-Houng; Shi, Xianglin; Taylor, Michael D

    2005-11-01

    Questions exist concerning the potential carcinogenic effects after welding fume exposure. Welding processes that use stainless steel (SS) materials can produce fumes that may contain metals (e.g., Cr, Ni) known to be carcinogenic to humans. The objective was to determine the effect of in vitro and in vivo welding fume treatment on free radical generation, DNA damage, cytotoxicity and apoptosis induction, all factors possibly involved with the pathogenesis of lung cancer. SS welding fume was collected during manual metal arc welding (MMA). Elemental analysis indicated that the MMA-SS sample was highly soluble in water, and a majority (87%) of the soluble metal was Cr. Using electron spin resonance (ESR), the SS welding fume had the ability to produce the biologically reactive hydroxyl radical (*OH), likely as a result of the reduction of Cr(VI) to Cr(V). In vitro treatment with the MMA-SS sample caused a concentration-dependent increase in DNA damage and lung macrophage death. In addition, a time-dependent increase in the number of apoptotic cells in lung tissue was observed after in vivo treatment with the welding fume. In summary, a soluble MMA-SS welding fume was found to generate reactive oxygen species and cause DNA damage, lung macrophage cytotoxicity and in vivo lung cell apoptosis. These responses have been shown to be involved in various toxicological and carcinogenic processes. The effects observed appear to be related to the soluble component of the MMA-SS sample that is predominately Cr. A more comprehensive in vivo animal study is ongoing in the laboratory that is continuing these experiments to try to elucidate the potential mechanisms that may be involved with welding fume-induced lung disease.

  2. Weld stresses beyond elastic limit: Materials discontinuity

    NASA Technical Reports Server (NTRS)

    Verderaime, V.

    1989-01-01

    When welded structures depend on properties beyond the elastic limit to qualify their ultimate safety factor, and weld-parent materials abruptly change at the interface, then stress discontinuity is inevitable. The stress concentration is mildly sensitive to material relative strain hardening and acutely sensitive to applied stress fields. Peak stresses occur on the weld surface, at the interface, and dissipate within a 0.01-inch band. When the stress is intense, the weld will always fracture at the interface. The analysis incorporates a classical mechanics model to more sharply define stress spikes within the bandwidth, and suggests a relative material index and Poisson's ratio related to strain hardening. Implications are discussed which are applicable to industries of high performance structures.

  3. Temperature changes in contact lenses in connection with radiation from welding arcs.

    PubMed

    Lövsund, P; Nilsson, S E; Lindh, H; Oberg, P A

    1979-09-01

    Because of reports of risks associated with the use of contact lenses during exposure to welding arcs, the temperature changes in soft contact lenses were recorded in connection with certain types of welding [manual metal arc (MMA) welding, tungsten inert-gas (TIG) welding, and metal inert-gas (MIG) welding], both with free-hanging lenses and lenses applied to the eyes of anesthetized rabbits. A great increase in temperature was noted, especially with MMA welding. At a distance of 0.4 m the temperature of a lens on a rabbit eye rose from about 35 to 50 degrees C within 6 min, whereas the air temperature only increased from 23 to 30 degrees C. The increase was the greatest at the beginning of the welding period. Most of the lenses completely dried out during the experiment, and there would seem to be a potential risk that the lens would adhere to the cornea. One safety glass screen (DIN 10 A) proved effective in preventing the rise in temperature in contact lenses during MMA welding. Even though it is impossible to direct the eyes at the arc for a prolonged period of time, the use of contact lenses in connection with at least certain types of welding is not to be recommended without the use of a suitable safety glass screen (or safety glasses). With regard to the large number of particles in the welding environment, also a risk factor for contact lens wearers, it is doubtful whether even safety glasses or screens are satisfactory unless they fit closely. PMID:20120575

  4. Temperature changes in contact lenses in connection with radiation from welding arcs.

    PubMed

    Lövsund, P; Nilsson, S E; Lindh, H; Oberg, P A

    1979-09-01

    Because of reports of risks associated with the use of contact lenses during exposure to welding arcs, the temperature changes in soft contact lenses were recorded in connection with certain types of welding [manual metal arc (MMA) welding, tungsten inert-gas (TIG) welding, and metal inert-gas (MIG) welding], both with free-hanging lenses and lenses applied to the eyes of anesthetized rabbits. A great increase in temperature was noted, especially with MMA welding. At a distance of 0.4 m the temperature of a lens on a rabbit eye rose from about 35 to 50 degrees C within 6 min, whereas the air temperature only increased from 23 to 30 degrees C. The increase was the greatest at the beginning of the welding period. Most of the lenses completely dried out during the experiment, and there would seem to be a potential risk that the lens would adhere to the cornea. One safety glass screen (DIN 10 A) proved effective in preventing the rise in temperature in contact lenses during MMA welding. Even though it is impossible to direct the eyes at the arc for a prolonged period of time, the use of contact lenses in connection with at least certain types of welding is not to be recommended without the use of a suitable safety glass screen (or safety glasses). With regard to the large number of particles in the welding environment, also a risk factor for contact lens wearers, it is doubtful whether even safety glasses or screens are satisfactory unless they fit closely.

  5. Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

    NASA Technical Reports Server (NTRS)

    Walsh, Daniel W.

    1987-01-01

    The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. This study examined the effects of oxide, halide, and sulfate additions to the weld plate on the keyhole and the weld pool. Changes in both the arc plasma character and the bead morphology were correlated to the chemical environment of the weld. Pool behavior was observed by adding flow markers to actual VPPA welds. A low temperature analog to the welding process was developed. The results of the study indicate that oxygen, even at low partial pressures, can disrupt the stable keyhole and weld pool. The results also indicate that the Marangoni surface tension driven flows dominate the weld pool over the range of welding currents studied.

  6. 29 CFR 1915.56 - Arc welding and cutting.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... generation of an arc, sparks or heat at any point shall cause rejection of the structure as a ground circuit... or cutter to electric shock. (3) When the arc welder or cutter has occasion to leave his work or...

  7. 29 CFR 1915.56 - Arc welding and cutting.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... generation of an arc, sparks or heat at any point shall cause rejection of the structure as a ground circuit... or cutter to electric shock. (3) When the arc welder or cutter has occasion to leave his work or...

  8. 29 CFR 1915.56 - Arc welding and cutting.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... generation of an arc, sparks or heat at any point shall cause rejection of the structure as a ground circuit... or cutter to electric shock. (3) When the arc welder or cutter has occasion to leave his work or...

  9. 29 CFR 1915.56 - Arc welding and cutting.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... generation of an arc, sparks or heat at any point shall cause rejection of the structure as a ground circuit... or cutter to electric shock. (3) When the arc welder or cutter has occasion to leave his work or...

  10. 29 CFR 1915.56 - Arc welding and cutting.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... generation of an arc, sparks or heat at any point shall cause rejection of the structure as a ground circuit... or cutter to electric shock. (3) When the arc welder or cutter has occasion to leave his work or...

  11. 29 CFR 1926.351 - Arc welding and cutting.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... Safety, 49 CFR part 192, Minimum Federal Safety Standards for Gas Pipelines, shall apply. (3) When a... electrical contact exists at all joints. The generation of an arc, sparks, or heat at any point shall cause... may expose the arc welder or cutter to electric shock. (3) When the arc welder or cutter has...

  12. 29 CFR 1926.351 - Arc welding and cutting.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... Safety, 49 CFR part 192, Minimum Federal Safety Standards for Gas Pipelines, shall apply. (3) When a... electrical contact exists at all joints. The generation of an arc, sparks, or heat at any point shall cause... may expose the arc welder or cutter to electric shock. (3) When the arc welder or cutter has...

  13. 29 CFR 1926.351 - Arc welding and cutting.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... Safety, 49 CFR part 192, Minimum Federal Safety Standards for Gas Pipelines, shall apply. (3) When a... electrical contact exists at all joints. The generation of an arc, sparks, or heat at any point shall cause... may expose the arc welder or cutter to electric shock. (3) When the arc welder or cutter has...

  14. 29 CFR 1926.351 - Arc welding and cutting.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... Safety, 49 CFR Part 192, Minimum Federal Safety Standards for Gas Pipelines, shall apply. (3) When a... electrical contact exists at all joints. The generation of an arc, sparks, or heat at any point shall cause... may expose the arc welder or cutter to electric shock. (3) When the arc welder or cutter has...

  15. 29 CFR 1926.351 - Arc welding and cutting.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... Safety, 49 CFR part 192, Minimum Federal Safety Standards for Gas Pipelines, shall apply. (3) When a... electrical contact exists at all joints. The generation of an arc, sparks, or heat at any point shall cause... may expose the arc welder or cutter to electric shock. (3) When the arc welder or cutter has...

  16. Specifics of Pulsed Arc Welding Power Supply Performance Based On A Transistor Switch

    NASA Astrophysics Data System (ADS)

    Krampit, N. Yu; Kust, T. S.; Krampit, M. A.

    2016-08-01

    Specifics of designing a pulsed arc welding power supply device are presented in the paper. Electronic components for managing large current was analyzed. Strengths and shortcomings of power supply circuits based on thyristor, bipolar transistor and MOSFET are outlined. As a base unit for pulsed arc welding was chosen MOSFET transistor, which is easy to manage. Measures to protect a transistor are given. As for the transistor control device is a microcontroller Arduino which has a low cost and adequate performance of the work. Bead transfer principle is to change the voltage on the arc in the formation of beads on the wire end. Microcontroller controls transistor when the arc voltage reaches the threshold voltage. Thus there is a separation and transfer of beads without splashing. Control strategies tested on a real device and presented. The error in the operation of the device is less than 25 us, it can be used controlling drop transfer at high frequencies (up to 1300 Hz).

  17. Sensoring fusion data from the optic and acoustic emissions of electric arcs in the GMAW-S process for welding quality assessment.

    PubMed

    Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

    2012-01-01

    The present study shows the relationship between welding quality and optical-acoustic emissions from electric arcs, during welding runs, in the GMAW-S process. Bead on plate welding tests was carried out with pre-set parameters chosen from manufacturing standards. During the welding runs interferences were induced on the welding path using paint, grease or gas faults. In each welding run arc voltage, welding current, infrared and acoustic emission values were acquired and parameters such as arc power, acoustic peaks rate and infrared radiation rate computed. Data fusion algorithms were developed by assessing known welding quality parameters from arc emissions. These algorithms have showed better responses when they are based on more than just one sensor. Finally, it was concluded that there is a close relation between arc emissions and quality in welding and it can be measured from arc emissions sensing and data fusion algorithms.

  18. Sensoring fusion data from the optic and acoustic emissions of electric arcs in the GMAW-S process for welding quality assessment.

    PubMed

    Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

    2012-01-01

    The present study shows the relationship between welding quality and optical-acoustic emissions from electric arcs, during welding runs, in the GMAW-S process. Bead on plate welding tests was carried out with pre-set parameters chosen from manufacturing standards. During the welding runs interferences were induced on the welding path using paint, grease or gas faults. In each welding run arc voltage, welding current, infrared and acoustic emission values were acquired and parameters such as arc power, acoustic peaks rate and infrared radiation rate computed. Data fusion algorithms were developed by assessing known welding quality parameters from arc emissions. These algorithms have showed better responses when they are based on more than just one sensor. Finally, it was concluded that there is a close relation between arc emissions and quality in welding and it can be measured from arc emissions sensing and data fusion algorithms. PMID:22969330

  19. Sensoring Fusion Data from the Optic and Acoustic Emissions of Electric Arcs in the GMAW-S Process for Welding Quality Assessment

    PubMed Central

    Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

    2012-01-01

    The present study shows the relationship between welding quality and optical-acoustic emissions from electric arcs, during welding runs, in the GMAW-S process. Bead on plate welding tests was carried out with pre-set parameters chosen from manufacturing standards. During the welding runs interferences were induced on the welding path using paint, grease or gas faults. In each welding run arc voltage, welding current, infrared and acoustic emission values were acquired and parameters such as arc power, acoustic peaks rate and infrared radiation rate computed. Data fusion algorithms were developed by assessing known welding quality parameters from arc emissions. These algorithms have showed better responses when they are based on more than just one sensor. Finally, it was concluded that there is a close relation between arc emissions and quality in welding and it can be measured from arc emissions sensing and data fusion algorithms. PMID:22969330

  20. The temporal nature of forces acting on metal drops in gas metal arc welding

    SciTech Connect

    Jones, L.A.; Eagar, T.W.; Lang, J.H.

    1996-12-31

    At moderate and high welding currents, the most important forces in gas metal arc welding acting on the molten electrode are magnetic forces arising from the interaction between the welding current and its own magnetic field. These forces drive the dynamic evolution of the drop and also depend on the instantaneous shape of the drop. In this paper, experimentally observed manifestations of magnetic forces are shown, and a technique for approximating the temporal evolution of these forces from experimentally measured drop shapes is reported. The technique provides quantitative data illustrating the large increase in the magnetic forces as a drop detaches from the electrode.

  1. A Real-Time Optical Profile Sensor For Robot Arc Welding

    NASA Astrophysics Data System (ADS)

    Oomen, G. L.; Verbeek, W. J.

    1984-02-01

    For robot ano automated arc welding a compact 3D vision sensor has been developed. It generates data to correct the preprogrammed welding path. It can find the starting point of toe seam, calculate the seam volume for process control and detect tack welds, all in real-time with submillimeter resolution. Mounted to the robot hand the He-Ne laser-based scanning triangulation sensor takes distance measurements to the workpiece at a 2000/s rate. Preproduction models were tested in operation for the effects of arclight, heat, smoke, spatter ano e.m.i., using various combinations of the welding_ parameters: process (MIG, TIG), mode (short cktg, globular, spray), welding current and voltage, protective gas (He, Ar, CO2) and travel speed. Included in the paper is a discussion of environmental influences and of closed-loop operation.

  2. Real-time sensing and monitoring in robotic gas metal arc welding

    NASA Astrophysics Data System (ADS)

    Wu, C. S.; Gao, J. Q.; Hu, J. K.

    2007-01-01

    A real-time monitoring system is developed for detecting abnormal conditions in robotic gas metal arc welding. The butt-joint test pieces with simulated large gaps are used to intentionally introduce step disturbance of welding conditions. During the welding process, the welding voltage and current signals are sampled and processed on-line to extract the characteristic information reflecting the process quality. After the first statistical processing, it is found that seven statistical parameters (the mean, standard deviation, coefficient of variance and kurtosis of welding voltage; the mean, coefficient of variance and kurtosis of welding current) show variations during the step disturbance. Through the second statistical processing of the means of the welding voltage for subgroups of continuous measurement, the statistical control chart is obtained, and an SPC (statistical process control)-based on-line identifying method is developed. Ten robotic welding experiments are conducted to verify the real-time monitoring system. It is found that the correct identification rates for normal and abnormal welding conditions are 100% and 95%, respectively.

  3. Surface preparation effects on GTA (gas tungsten arc) weld penetration in JBK-75 stainless steel

    SciTech Connect

    Campbell, R.D.; Heiple, C.R.; Sturgill, P.L.; Robertson, A.M.; Jamsay, R.

    1989-01-01

    The results of a study are reported here on the effects of surface preparation on the shape of GTA welds on JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface (weld groove) preparation produced substantial changes in the penetration characteristics and welding behavior of this alloy. Increased and more consistent weld penetration (higher d/w ratios) along with improved arc stability and less arc wander result from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any improvement in penetration. Abrasive treatments roughen the surface, increase the surface area, and increase the surface oxide thickness. The increased weld d/w ratio is attributed to oxygen added to the weld pool from the surface oxide on the base metal. The added oxygen alters the surface-tension driven fluid flow pattern in the weld pool. Similar results were observed with changes in filler wire surface oxide thickness, caused by changes in wire production conditions. 15 refs., 14 figs., 4 tabs.

  4. The effect of baking treatments on E9018-B3 manual metal arc welding consumables

    SciTech Connect

    Fazackerley, W.; Gee, R.

    1996-12-31

    For the comparison and assessment of steel welding consumables, standard tests involving small model welds are widely used to determine diffusible hydrogen contents. The lowest scale normally quoted is less than 5 ml/100 g deposited metal (e.g., BS5135:1984 Scale D). However, due to industry`s demands for lower hydrogen levels for critical applications, it is now proposed to sub-divide this scale at around 2--3 ml/100 g. This has led to further development by consumable manufacturers in order to meet the new specification. Traditionally, reductions in potential hydrogen levels in manual metal arc welding consumables have been achieved by improved flux formulations and silicate binder systems. However, there is little published work on the effect of electrode baking treatments. A development program has been employed to study the effect of baking treatments on E9018-B3 type manual metal arc welding consumables. This type of welding consumable is used extensively in the initial fabrication and in the repair and maintenance of power generation plant, where significant risk of HAZ hydrogen cracking exists. These treatments have been assessed using standard tests for weld metal hydrogen content and weld metal composition.

  5. Retinal burns caused by exposure to MIG-welding arcs: report of two cases.

    PubMed Central

    Brittain, G P

    1988-01-01

    A new generation of arc welder has recently become widely available at a price which is within reach of most amateurs and part-time mechanics, known as the MIG welder (metal-arc inert gas welder). In MIG welding the arc is ensheathed in a stream of inert gas which prevents the molten metal from oxidising. The stream of gas changes the character of the emitted radiation, and it is possible that this type of welder poses a greater threat to sight than previously recognised. Radiation in the ultraviolet range emitted by arc welders is absorbed by the unprotected cornea and lens, giving rise to a keratoconjunctivitis, or 'arc-eye,' which, though intensely painful, is not considered a threat to sight. Radiation in the visible and near infrared spectrum, however, penetrates the eye to be absorbed by the retina and may cause thermal or photochemical damage which may be permanent and sight-threatening. Retinal injuries resulting from exposure to ordinary electric welding arcs have been reported, but such injuries are uncommon. Two cases of retinal burns resulting from exposure to MIG welder emissions which presented on consecutive days to the Leicester Royal Infirmary are presented. This is the first report of such injuries relating specifically to MIG welding. Images PMID:3415950

  6. Retinal burns caused by exposure to MIG-welding arcs: report of two cases.

    PubMed

    Brittain, G P

    1988-08-01

    A new generation of arc welder has recently become widely available at a price which is within reach of most amateurs and part-time mechanics, known as the MIG welder (metal-arc inert gas welder). In MIG welding the arc is ensheathed in a stream of inert gas which prevents the molten metal from oxidising. The stream of gas changes the character of the emitted radiation, and it is possible that this type of welder poses a greater threat to sight than previously recognised. Radiation in the ultraviolet range emitted by arc welders is absorbed by the unprotected cornea and lens, giving rise to a keratoconjunctivitis, or 'arc-eye,' which, though intensely painful, is not considered a threat to sight. Radiation in the visible and near infrared spectrum, however, penetrates the eye to be absorbed by the retina and may cause thermal or photochemical damage which may be permanent and sight-threatening. Retinal injuries resulting from exposure to ordinary electric welding arcs have been reported, but such injuries are uncommon. Two cases of retinal burns resulting from exposure to MIG welder emissions which presented on consecutive days to the Leicester Royal Infirmary are presented. This is the first report of such injuries relating specifically to MIG welding.

  7. Measurement of outgassing rate for GTAW welded SS304 materials

    NASA Astrophysics Data System (ADS)

    Bukhari, Mohsin; Mukherjee, Samiran; Panchal, Paresh; Gangradey, Ranjana; Shukla, Ajit Kumar

    2016-09-01

    Outgassing plays an important role to achieve Ultra High Vacuum (UHV) and to maintaining the required vacuum level of the vessel. For a large size machines like Tokamak, accelerators, space simulation chambers, outgassing from the structural materials and their welding sections need to be checked during the design. Hence studies were carried out for the measurement of outgassing rate for the Gas Tungsten Arc Welding (GTAW) welded SS304 materials at OutGassing Measurement System (OGMS) at IPR Extension Lab. The system consists of two chambers, pumping chamber and sample chamber, made up of 304 grades Stainless Steel pre-air baked at 400 °C. The pumping chamber connected to a turbo molecular pump having pumping speed 240 l/s, backed by a rotary vacuum pump having pumping speed 5m3/hour. Pumping chamber and sample chamber connected through a 100 CF flange having a circular aperture of 5.2 mm diameter. The conductance of aperture is 2.47 l/s. Bare SS304 sample & GTAW welded SS304 samples are prepared with 100mmX50mmX5mm and 95mmX55mmX5mm dimensions respectively. The base outgassing rate of the blank system is 2.34×10-11 mbar l/s-cm2. The calculated outgassing rate is 3.66×10-10 & 4.37×10-10 mbar l/s-cm2 for bare sample & welded sample. From the partial pressure analysis it has been found that hydrogen and nitrogen are in the partial level of 3.35×10-9 & 2.36×10-9 for bare sample and 3.14×10-9 mbar & 2.33×10-9 mbar for welded sample. It has been observed that, the GTAW doesn't have major effect on outgassing rate and one can use welded joint for designing a large vessel welding sections.

  8. Software development to support sensor control of robot arc welding

    NASA Technical Reports Server (NTRS)

    Silas, F. R., Jr.

    1986-01-01

    The development of software for a Digital Equipment Corporation MINC-23 Laboratory Computer to provide functions of a workcell host computer for Space Shuttle Main Engine (SSME) robotic welding is documented. Routines were written to transfer robot programs between the MINC and an Advanced Robotic Cyro 750 welding robot. Other routines provide advanced program editing features while additional software allows communicatin with a remote computer aided design system. Access to special robot functions were provided to allow advanced control of weld seam tracking and process control for future development programs.

  9. Recent progress on gas tungsten arc welding of vanadium alloys

    SciTech Connect

    King, J.F.; Grossbeck, M.L.; Goodwin, G.M.; Alexander, D.J.

    1997-04-01

    This is a progress report on a continuing research project to acquire a fundamental understanding of the metallurgical processes in the welding of vanadium alloys. It also has the goal of developing techniques for welding structural vanadium alloys. The alloy V-4Cr-4Ti is used as a representative alloy of the group; it is also the prime candidate vanadium alloy for the U.S. Fusion Program at the present time. However, other alloys of this class were used in the research as necessary. The present work focuses on recent findings of hydrogen embrittlement found in vanadium alloy welds. It was concluded that the atmosphere in the inert gas glove box was insufficient for welding 6mm thick vanadium alloy plates.

  10. Autogeneous Laser and Hybrid Laser Arc Welding of T-joint Low Alloy Steel with Fiber Laser Systems

    NASA Astrophysics Data System (ADS)

    Unt, A.; Lappalainen, E.; Salminen, A.

    This paper is focused on the welding of low alloy steels S355 and AH36 in thicknesses 6, 8 and 10 mm in T-joint configuration using either autogeneous laser welding or laser-arc hybrid welding (HLAW) with high power fiber lasers. The aim was to obtain understanding of the factors influencing the size of the fillet and weld geometry through methodologically studying effects of laser power, welding speed, beam alignment relative to surface, air gap, focal point position and order of processes (in case of HLAW) and to get a B quality class welds in all thicknesses after parameter optimization.

  11. Numerical Simulation to Study the Effect of Arc Travelling Speed and Welding Sequences on Residual Stresses in Welded Sections of New Ferritic P92 Pipes

    NASA Astrophysics Data System (ADS)

    Wang, Xiaowei; Gong, Jianming; Zhao, Yanping; Wang, Yanfei; Ge, Zhiqiang

    2016-02-01

    New ferritic P92 steel is widely used in modern power plants due to its good combination of mechanical and physical properties. However, cracks are often formed in the welded sections during the fabrication or service. In order to ensure the structure integrity, the effects of residual stresses need to be considered. The objective of this paper is to investigate the influence of arc travelling speed and welding sequences on the residual stresses distribution in the welded sections of P92 pipes by finite element method (FEM). Results show that arc travelling speed and welding sequences have great effects on residual stresses distribution. With the arc travelling speed increasing, the residual stresses increase. Meanwhile, welding sequences of case B present smaller residual stresses and more symmetrical distribution of residual stresses at the weld centre line. Therefore, using slower arc travelling speed and case B welding sequences can be useful to decrease the residual stresses, which provides a reference for optimizing the welding technology and improving the fabrication process of new ferritic P92 welded pipes with small diameter and thick wall.

  12. 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…

  13. Microstructure and mechanical properties of laser-arc hybrid welding joint of GH909 alloy

    NASA Astrophysics Data System (ADS)

    Liu, Ting; Yan, Fei; Liu, Sang; Li, Ruoyang; Wang, Chunming; Hu, Xiyuan

    2016-06-01

    In this paper, laser-arc hybrid welding of 10 mm thick low-thermal-expansion superalloy GH909 components was carried out to obtain a joint with good performance. This investigation was conducted using an optical microscope, scanning electron microscope, energy diffraction spectrum and other methodologies. The results showed that weld joints with a desirable wineglass-shaped weld profile can be obtained employing appropriate process parameters. The different grains in between the upper central seam and the bottom seam were associated with the temperature gradient, the pool's flow and the welding thermal cycle. MC-type carbides and eutectic phases (γ+Laves) were produced at grain boundaries due to the component segregation during the welding process. In addition, γ‧ strengthening phase presented in the interior of grains, which kept a coherent relationship with the matrix. The lowest hardness value occurred in the weld center, which indicated that it was the weakest section in the whole joint. The average tensile strength of the joints reached to 632.90 MPa, nearly 76.84% of the base metal. The fracture analysis revealed that the fracture mode of the joint was ductile fracture and the main reason for joint failure was as a result of the occurrence of porosities produced in the weld during the welding process.

  14. Gas influence on the arc shape in MIG-MAG welding

    NASA Astrophysics Data System (ADS)

    Zielinska, S.; Pellerin, S.; Valensi, F.; Dzierzega, K.; Musiol, K.; de Izarra, Ch.; Briand, F.

    2008-07-01

    Composition of the applied shielding gas has a strong influence on physical properties of the plasma and parameters of the welding process. In particular, increase of the percentage of carbon dioxide in argon results in an increase of the transition current value while changing from the globular to spray mode of metal transfer during the welding process. In order to explain this phenomenon, the MIG/MAG welding arc plasma was investigated for different mixtures of argon and carbon dioxide in the shielding gas. Applying a fast camera, recording distribution of spectral lines of the plasma components, we noticed some phenomena not described yet in the literature. Especially, there is a limit in the percentage of relative concentration CO2/Ar beyond which the arc shape is significantly modified.

  15. A computational investigation of the effectiveness of different shielding gas mixtures for arc welding

    NASA Astrophysics Data System (ADS)

    Murphy, A. B.; Tanaka, M.; Tashiro, S.; Sato, T.; Lowke, J. J.

    2009-06-01

    Tungsten-inert-gas welding arcs are modelled using a two-dimensional axisymmetric computational code. Both electrodes (the tungsten cathode and the metal anode workpiece) and the arc plasma are included self-consistently in the computational domain. The influence of adding helium, hydrogen and nitrogen to the argon shielding gas is investigated. It is found that addition of any of the gases increases the heat flow to and the current density at the anode. The shear stress and the arc pressure at the anode surface are increased by adding hydrogen or nitrogen or up to about 50 mol% helium, but decrease when more helium is added. It is predicted that the effect of adding any of the gases is to increase the depth of the weld pool, in agreement with the experimental evidence. The results are explained by referring to the thermodynamic and transport properties of the gas mixtures.

  16. An investigation of fibrogenic and other toxic effects of arc-welding fume particles deposited in the rat lung.

    PubMed

    Hicks, R; Al-Shamma, K J; Lam, H F; Hewitt, P J

    1983-12-01

    Lung burdens of deposited particles from fumes generated by arc-welding were established in rats by single inhalation exposures, repeated intermittent exposure or by intratracheal injection. Fumes from manual metal arc-welding using flux-coated mild-steel rods (MMA-MS) were compared with those from metal inert-gas welding with stainless steel wire (MIG-SS). After initial rapid clearance of deposited material from the lungs, persistent residual deposits remained. Such residues resulting from single inhalation were small and confined mainly to peribronchial accumulations in macrophage clusters. Deposits remaining after repeated inhalation were larger and more widespread. Intratracheal administration (50 mg) established massive residual deposits, giving nodular accumulations in peribronchial, subpleural and perivascular sites, with substantial alveolar parenchymal involvement. Deposits from both types of fumes contained predominantly iron. Particles from stainless steel also contained chromium, but concentrations of this element were low in deposits from MMA-MS fumes. MMA-MS deposits contained silica, probably amorphous. Long-term studies (up to 450 days) attempted to detect evidence of fibrosis resulting from particle burdens. Low-grade collagen fibre layers developed at margins of MMA-MS nodules. Diffuse reticulin fibre networks occurred within MIG-SS aggregates. Tissue hydroxyproline levels were increased (doubled) in lungs with intratracheal burdens of MMA-MS particles, but no significant increases resulted from MIG-SS. The major lesions were nodular aggregates of particle-laden macrophages with giant-cell formation, and alveolar epithelial thickening with atelectasis.

  17. Method and apparatus for welding precipitation hardenable materials

    DOEpatents

    Murray, Jr., Holt; Harris, Ian D.; Ratka, John O.; Spiegelberg, William D.

    1994-01-01

    A method for welding together members consisting of precipitation age hardened materials includes the steps of selecting a weld filler material that has substantially the same composition as the materials being joined, and an age hardening characteristic temperature age threshold below that of the aging kinetic temperature range of the materials being joined, whereby after welding the members together, the resulting weld and heat affected zone (HAZ) are heat treated at a temperature below that of the kinetic temperature range of the materials joined, for obtaining substantially the same mechanical characteristics for the weld and HAZ, as for the parent material of the members joined.

  18. Method and apparatus for welding precipitation hardenable materials

    DOEpatents

    Murray, H. Jr.; Harris, I.D.; Ratka, J.O.; Spiegelberg, W.D.

    1994-06-28

    A method for welding together members consisting of precipitation age hardened materials includes the steps of selecting a weld filler material that has substantially the same composition as the materials being joined, and an age hardening characteristic temperature age threshold below that of the aging kinetic temperature range of the materials being joined, whereby after welding the members together, the resulting weld and heat affected zone (HAZ) are heat treated at a temperature below that of the kinetic temperature range of the materials joined, for obtaining substantially the same mechanical characteristics for the weld and HAZ, as for the parent material of the members joined. 5 figures.

  19. Nuclear Technology. Course 28: Welding Inspection. Module 28-3, Tungsten Inert Gas (TIG), Metal Inert Gas (MIG) and Submerged Arc Welding.

    ERIC Educational Resources Information Center

    Espy, John

    This third in a series of ten modules for a course titled Welding Inspection presents the apparatus, process techniques, procedures, applications, associated defects, and inspection for the tungsten inert gas, metal inert gas, and submerged arc welding processes. The module follows a typical format that includes the following sections: (1)…

  20. 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

  1. Arc welding quality monitoring by means of near infrared imaging spectroscopy

    NASA Astrophysics Data System (ADS)

    Garcia-Allende, P. B.; Mirapeix, J.; Cobo, A.; Conde, O. M.; Lopez-Higuera, J. M.

    2008-03-01

    The search for an efficient on-line monitoring system focused on the real-time analysis of the welding quality is an active area of research, mainly due to the widespread use of both arc and laser welding processes in relevant industrial scenarios such as aeronautics or nuclear. In this work, an improvement in the performance of a previously designed monitor system is presented. This improvement is accomplished by the employment of a dual spatial-spectral technique, namely imaging spectroscopy. This technique allows the simultaneous determination of the optical spectrum components and the spatial location of an object in a surface. In this way, the spatially characterization of the plasma emitted during a tungsten inert gas (TIG) welding is performed. The main advantage of this technique is that the spectra of all the points in the line of vision are measured at the same time. Not only are all the spectra captured simultaneously, but they are also processed as a batch, allowing the investigation of the welding quality. Moreover, imaging spectroscopy provides the desired real-time operation. To simultaneously acquire the information of both domains, spectral and spatial, a passive Prism-Grating-Prism (PGP) device can be used. In this paper the plasma spectra is captured during the welding test by means of a near infrared imaging spectroscopic system which consists of input optics, an imaging spectrograph and a monochrome camera. Technique features regarding on-line welding quality monitoring are discussed by means of several experimental welding tests.

  2. Experimental and numerical investigations of hybrid laser arc welding of aluminum alloys in the thick T-joint configuration

    NASA Astrophysics Data System (ADS)

    Mazar Atabaki, M.; Nikodinovski, M.; Chenier, P.; Ma, J.; Liu, W.; Kovacevic, R.

    2014-07-01

    In the present investigation, a numerical finite element model was developed to simulate the hybrid laser arc welding of different aluminum alloys, namely 5××× to 6××× series. The numerical simulation has been considered two double-ellipsoidal heat sources for the gas metal arc welding and laser welding. The offset distance of the metal arc welding and laser showed a significant effect on the molten pool geometry, the heat distribution and penetration depth during the welding process. It was confirmed that when the offset distance is within the critical distance the laser and arc share the molten pool and specific amount of penetration and dilution can be achieved. The models and experiments show that the off-distance between the two heat sources and shoulder width have considerable influence on the penetration depth and appearance of the weld beads. The experiments also indicate that the laser power, arc voltage and type of the filler metal can effectively determine the final properties of the bonds, specifically the bead appearance and microhardness of the joints. The experiments verified the numerical simulation as the thermocouples assist to comprehend the amount of heat distribution on the T-joint coupons. The role of the welding parameters on the mechanism of the hybrid laser welding of the aluminum alloys was also discussed.

  3. Gas Metal Arc /GMA/ weld torch proximity control

    NASA Technical Reports Server (NTRS)

    Hawkes, E. D.

    1969-01-01

    Adjustable transducer probe, which is attached to a welding torch and maintains a preset touch-to-work distance, accurately follows irregular surfaces, is less sensitive to heat and static interference, and has more positive response because of electro-mechanical control.

  4. Variable polarity plasma arc welding on the Space Shuttle external tank

    NASA Technical Reports Server (NTRS)

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

    1984-01-01

    Variable polarity plasma arc (VPPA) techniques used at NASA's Marshall Space Flight Center for the fabrication of the Space Shuttle External Tank are presentedd. The high plasma arc jet velocities of 300-2000 m/s are produced by heating the plasma gas as it passes through a constraining orifice, with the plasma arc torch becoming a miniature jet engine. As compared to the GTA jet, the VPPA has the following advantages: (1) less sensitive to contamination, (2) a more symmetrical fusion zone, and (3) greater joint penetration. The VPPA welding system is computerized, operating with a microprocessor, to set welding variables in accordance with set points inputs, including the manipulator and wire feeder, as well as torch control and power supply. Some other VPPA welding technique advantages are: reduction in weld repair costs by elimination of porosity; reduction of joint preparation costs through elimination of the need to scrape or file faying surfaces; reduction in depeaking costs; eventual reduction of the 100 percent-X-ray inspection requirements. The paper includes a series of schematic and block diagrams.

  5. Laser-ultrasonic inspection of hybrid laser-arc welded HSLA-65 steel

    SciTech Connect

    Lévesque, D.; Rousseau, G.; Monchalin, J.-P.; Wanjara, P.; Cao, X.

    2014-02-18

    The hybrid laser-arc welding (HLAW) process is a relatively low heat input joining technology that combines the synergistic qualities of both the high energy density laser beam for deep penetration and the arc for wide fit-up gap tolerance. This process is especially suitable for the shipbuilding industry where thick-gauge section, long steel plates have been widely used in a butt joint configuration. In this study, preliminary exploration was carried out to detect and visualize the welding defects using laser ultrasonics combined with the synthetic aperture focusing technique (SAFT). Results obtained on 9.3 mm thick butt-welded HSLA-65 steel plates indicated that the laser-ultrasonic SAFT inspection technique can successfully detect and visualize the presence of porosity, lack of fusion and internal crack defects. This was further confirmed by X-ray digital radiography and metallography. The results obtained clearly show the potential of using the laser-ultrasonic technology for the automated inspection of hybrid laser-arc welds.

  6. Welded joints integrity analysis and optimization for fiber laser welding of dissimilar materials

    NASA Astrophysics Data System (ADS)

    Ai, Yuewei; Shao, Xinyu; Jiang, Ping; Li, Peigen; Liu, Yang; Liu, Wei

    2016-11-01

    Dissimilar materials welded joints provide many advantages in power, automotive, chemical, and spacecraft industries. The weld bead integrity which is determined by process parameters plays a significant role in the welding quality during the fiber laser welding (FLW) of dissimilar materials. In this paper, an optimization method by taking the integrity of the weld bead and weld area into consideration is proposed for FLW of dissimilar materials, the low carbon steel and stainless steel. The relationships between the weld bead integrity and process parameters are developed by the genetic algorithm optimized back propagation neural network (GA-BPNN). The particle swarm optimization (PSO) algorithm is taken for optimizing the predicted outputs from GA-BPNN for the objective. Through the optimization process, the desired weld bead with good integrity and minimum weld area are obtained and the corresponding microstructure and microhardness are excellent. The mechanical properties of the optimized joints are greatly improved compared with that of the un-optimized welded joints. Moreover, the effects of significant factors are analyzed based on the statistical approach and the laser power (LP) is identified as the most significant factor on the weld bead integrity and weld area. The results indicate that the proposed method is effective for improving the reliability and stability of welded joints in the practical production.

  7. [Inhalation exposure to welding fumes of arc welders in processing Cr-Ni steel in large chemical industry].

    PubMed

    Dyrba, B C; Richter, K H

    1989-05-01

    For clearing up the inhalative load by welding fumes and gases of arc welders in industrial workshops mainly working on Cr-Ni-steels the following welding processes were studied: tungsten inert-gas (TIG), electrode-by-hand (EH), metal inert-gas (MIG), and plasma cutting (plasma). From the total load by welding fumes follows the rank TIG less than EH less than plasma less than MIG. Observing the maximum allowable concentration (MACD) for the total welding fume, no MACD for Cr and Ni was found exceeded. Regarding the welding gases ozone and CO no limit values were exceeded. From the results conclusions were made. PMID:2750235

  8. [Inhalation exposure to welding fumes of arc welders in processing Cr-Ni steel in large chemical industry].

    PubMed

    Dyrba, B C; Richter, K H

    1989-05-01

    For clearing up the inhalative load by welding fumes and gases of arc welders in industrial workshops mainly working on Cr-Ni-steels the following welding processes were studied: tungsten inert-gas (TIG), electrode-by-hand (EH), metal inert-gas (MIG), and plasma cutting (plasma). From the total load by welding fumes follows the rank TIG less than EH less than plasma less than MIG. Observing the maximum allowable concentration (MACD) for the total welding fume, no MACD for Cr and Ni was found exceeded. Regarding the welding gases ozone and CO no limit values were exceeded. From the results conclusions were made.

  9. Computer simulation in the design of local exhaust hoods for shielded metal arc welding.

    PubMed

    Tum Suden, K D; Flynn, M R; Goodman, R

    1990-03-01

    Computer simulations were used to examine competing exhaust hood configurations for shielded metal arc welding. The welder's breathing zone concentration appears to be an inverse linear function of the computer-predicted hood capture efficiency. Hood aspect ratio, hood flow, and the welder's position relative to the hood all have a significant effect on the breathing zone concentration. The height of the hood above the welding surface showed no significant effect in reducing breathing zone concentration. Further examination of breathing zone concentration as a function of capture efficiency is needed before reliable design methods can be developed using this parameter.

  10. [The reconstruction of welding arc 3D electron density distribution based on Stark broadening].

    PubMed

    Zhang, Wang; Hua, Xue-Ming; Pan, Cheng-Gang; Li, Fang; Wang, Min

    2012-10-01

    The three-dimensional electron density is very important for welding arc quality control. In the present paper, Side-on characteristic line profile was collected by a spectrometer, and the lateral experimental data were approximated by a polynomial fitting. By applying an Abel inversion technique, the authors obtained the radial intensity distribution at each wavelength and thus constructed a profile for the radial positions. The Fourier transform was used to separate the Lorentz linear from the spectrum reconstructed, thus got the accurate Stark width. And we calculated the electronic density three-dimensional distribution of the TIG welding are plasma. PMID:23285847

  11. Microstructural developments in neutron-irradiated mild steel submerged-arc weld metal

    NASA Astrophysics Data System (ADS)

    Buswell, J. T.; Bischler, P. J. E.; Fenton, S. T.; Ward, A. E.; Phythian, W. J.

    1993-10-01

    The microstructures of Magnox submerged-arc welds have been characterised to investigate the effects of surveillance and accelerated irradiation at temperatures in the range 190-290°C. The radiation hardening and embrittlement is influenced by the precipitation of Cu from solid solution. Mn has been found in the Cu-rich precipitates, together with an indication of P. The precipitates have structure coherent with the ferrite matrix and maintain a constant mean diameter during extended irradiation. Evidence has been obtained indicating that dislocation loops contribute to a matrix damage component in these welds.

  12. Effect of weld line shape on material flow during friction stir welding of aluminum and steel

    NASA Astrophysics Data System (ADS)

    Yasui, Toshiaki; Ando, Naoyuki; Morinaka, Shinpei; Mizushima, Hiroki; Fukumoto, Masahiro

    2014-08-01

    The effect of weld line shape on material flow during the friction stir welding of aluminum and steel was investigated. The material flow velocity was evaluated with simulated experiments using plasticine as the simulant material. The validity of the simulated experiments was verified by the marker material experiments on aluminum. The circumferential velocity of material around the probe increased with the depth from the weld surface. The effect is significant in cases where the advancing side is located on the outside of curve and those with higher curvature. Thus, there is an influence of weld line shape on material flow.

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

    SciTech Connect

    Ramasamy, S.

    2000-01-01

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

  14. Video Game Device Haptic Interface for Robotic Arc Welding

    SciTech Connect

    Corrie I. Nichol; Milos Manic

    2009-05-01

    Recent advances in technology for video games have made a broad array of haptic feedback devices available at low cost. This paper presents a bi-manual haptic system to enable an operator to weld remotely using the a commercially available haptic feedback video game device for the user interface. The system showed good performance in initial tests, demonstrating the utility of low cost input devices for remote haptic operations.

  15. Spiraling Fermi arcs in Weyl materials

    NASA Astrophysics Data System (ADS)

    Li, Songci; Andreev, Anton

    In Weyl materials the valence and conduction electron bands touch at an even number of isolated points in the Brillouin zone. In the vicinity of these points the electron dispersion is linear and may be described by the massless Dirac equation. This results in nontrivial topology of Berry connection curvature. One of its consequences is the existence of peculiar surface electron states whose Fermi surfaces form arcs connecting projections of the Weyl points onto the surface plane. Band bending near the boundary of the crystal also produces surface states. We show that in Weyl materials band bending near the crystal surface gives rise to spiral structure of energy surfaces of arc states. The corresponding Fermi surface has the shape of a spiral that winds about the projection of the Weyl point onto the surface plane. The direction of the winding is determined by the helicity of the Weyl point and the sign of the band bending potential. For close valleys arc state morphology may be understood in terms of avoided crossing of oppositely winding spirals. This work is supported by the U.S. Department of Energy Office of Science, Basic Energy Sciences under Award Number DE-FG02-07ER46452.

  16. Spiraling Fermi arcs in Weyl materials

    NASA Astrophysics Data System (ADS)

    Li, Songci; Andreev, A. V.

    2015-11-01

    In Weyl materials the valence and conduction electron bands touch at an even number of isolated points in the Brillouin zone. In the vicinity of these points the electron dispersion is linear and may be described by the massless Dirac equation. This results in nontrivial topology of the Berry connection curvature. One of its consequences is the existence of peculiar surface electron states whose Fermi surfaces form arcs connecting projections of the Weyl points onto the surface plane. Band bending near the boundary of the crystal also produces surface states. We show that in Weyl materials band bending near the crystal surface gives rise to a spiral structure of energy surfaces of arc states. The corresponding Fermi surface has the shape of a spiral that winds about the projection of the Weyl point onto the surface plane. The direction of the winding is determined by the helicity of the Weyl point and the sign of the band-bending potential. For close valleys the arc state morphology may be understood in terms of the avoided crossing of oppositely winding spirals.

  17. Diagnostics of metal inert gas and metal active gas welding processes

    NASA Astrophysics Data System (ADS)

    Uhrlandt, D.

    2016-08-01

    The paper gives a review on studies on metal inert gas (MIG) and metal active gas (MAG) welding processes with the focus on diagnostics of the arc, the material transfer, and the temporal process behaviour in welding experiments. Recent findings with respect to an improved understanding of the main mechanisms in the welding arc and the welding process are summarized. This is linked to actual developments in welding arc and welding process modelling where measurements are indispensable for validation. Challenges of forthcoming studies are illustrated by means of methods under development for welding process control as well as remaining open questions with respect to arc-surface interaction and arc power balance.

  18. Parameters optimization of hybrid fiber laser-arc butt welding on 316L stainless steel using Kriging model and GA

    NASA Astrophysics Data System (ADS)

    Gao, Zhongmei; Shao, Xinyu; Jiang, Ping; Cao, Longchao; Zhou, Qi; Yue, Chen; Liu, Yang; Wang, Chunming

    2016-09-01

    It is of great significance to select appropriate welding process parameters for obtaining optimal weld geometry in hybrid laser-arc welding. An integrated optimization approach by combining Kriging model and GA is proposed to optimize process parameters. A four-factor, five-level experiment using Taguchi L25 is conducted considering laser power (P), welding current (A), distance between laser and arc (D) and traveling speed (V). Kriging model is adopted to approximate the relationship between process parameters and weld geometry, namely depth of penetration (DP), bead width (BW) and bead reinforcement (BR). The constructed Kriging model was used for parameters optimization by GA to maximize DP, minimize BW and ensure BR at a desired value. The effects of process parameters on weld geometry are analyzed. Microstructure and micro-hardness are also discussed. Verification experiments demonstrate that the obtained optimum values are in good agreement with experimental results.

  19. Study on Surface Depression of Ti-6Al-4V with Ultrahigh-Frequency Pulsed Gas Tungsten Arc Welding

    NASA Astrophysics Data System (ADS)

    Mingxuan, Yang; Zhou, Yang; Bojin, Qi

    2015-08-01

    Molten pool surface depression was observed with the arc welding process that was caused by arc pressure. It was supposed to have a significant effect on fluid in the molten pool that was important for the microstructure and joint properties. The impact of arc force was recognized as the reason for the surface depression during arc welding. The mathematical distribution of arc force was produced with the exponent and parabola models. Different models showed different concentrations and attenuations. The comparison between them was discussed with the simulation results. The volume of fluid method was picked up with the arc force distribution model. The surface depression was caused by the arc force. The geometry of the surface depression was discussed with liquid metal properties. The welding process was carried out with different pulsed frequencies. The results indicated the forced depression exists in molten pool and the geometry of depression was hugely due to the arc force distribution. The previous work calculated the depression in the center with force balance at one point. The other area of gas shielding was resistant by the reverse gravity from the feedback of liquid metal that was squeezed out. The article discusses the pressure effect with free deformation that allowed resistance of liquid and was easy to compare with different distributions. The curve profiles were studied with the arc force distributions, and exponent model was supposed to be more accurate to the as-weld condition.

  20. Dissimilar Arc Welding of Advanced High-Strength Car-Body Steel Sheets

    NASA Astrophysics Data System (ADS)

    Russo Spena, P.; D'Aiuto, F.; Matteis, P.; Scavino, G.

    2014-11-01

    A widespread usage of new advanced TWIP steel grades for the fabrication of car-body parts is conditional on the employment of appropriate welding methods, especially if dissimilar welding must be performed with other automotive steel grades. Therefore, the microstructural features and the mechanical response of dissimilar butt weld seams of TWIP and 22MnB5 steel sheets after metal-active-gas arc welding are examined. The microstructural and mechanical characterization of the welded joints was carried out by optical metallography, microhardness and tensile testing, and fractographic examination. The heat-affected zone on the TWIP side was fully austenitic and the only detectable effect was grain coarsening, while on the 22MnB5 side it exhibited newly formed martensite and tempered martensite. The welded tensile specimens exhibited a much larger deformation on the TWIP steel side than on the 22MnB5. The fracture generally occurred at the interface between the fusion zone and the heat-affected zones, with the fractures surfaces being predominantly ductile. The ultimate tensile strength of the butt joints was about 25% lower than that of the TWIP steel.

  1. [Impact of introduction of O2 on the welding arc of gas pool coupled activating TIG].

    PubMed

    Huang, Yong; Wang, Yan-Lei; Zhang, Zhi-Guo

    2014-05-01

    In the present paper, Boltzmann plot method was applied to analyze the temperature distributions of the are plasma when the gas pool coupled activating TIG welding was at different coupling degrees with the outer gas being O2. Based on this study of temperature distributions, the changing regularities of are voltage and are appearance were studied. The result shows that compared with traditional TIG welding, the introduction of O2 makes the welding arc constricted slightly, the temperature of the are center build up, and the are voltage increase. When argon being the inner gas, oxygen serving as the outer gas instead of argon makes the are constricted more obviously. When the coupling degree increases from 0 to 2, the temperature of the are center and the are voltage both increase slightly. In the gas pool coupled activating TIG welding the are is constricted not obviously, and the reason why the weld penetration is improved dramatically in the welding of stainless steel is not are constriction. PMID:25095400

  2. REVIEW ARTICLE: Modelling of thermal plasmas for arc welding: the role of the shielding gas properties and of metal vapour

    NASA Astrophysics Data System (ADS)

    Murphy, A. B.; Tanaka, M.; Yamamoto, K.; Tashiro, S.; Sato, T.; Lowke, J. J.

    2009-10-01

    The methods used to model thermal plasmas, including treatments of diffusion in arcs in gas mixtures, are reviewed. The influence of thermophysical properties on the parameters of tungsten-inert-gas (TIG) welding arcs, particularly those that affect the weld pool, is investigated using a two-dimensional model in which the arc, anode and cathode are included self-consistently. The effect of changing each of six thermophysical properties on the characteristics of an argon TIG arc is assessed. The influence of the product of specific heat and mass density is found to be particularly important in determining the arc constriction. By examining the influence of the different properties on the heat flux density, current density and shear stress at the anode, it is concluded that the weld pool depth can be increased by using shielding gases with high specific heat, thermal conductivity and viscosity. The effect of metal vapour on the arc and weld pool properties is assessed. The most important effect of the metal vapour is found to be the increased electrical conductivity at low temperatures, which leads to lower heat flux density and current density at the weld pool, implying a shallower weld pool.

  3. Development of an intelligent system for cooling rate and fill control in GMAW. [Gas Metal Arc Welding (GMAW)

    SciTech Connect

    Einerson, C.J.; Smartt, H.B.; Johnson, J.A.; Taylor, P.L. ); Moore, K.L. )

    1992-01-01

    A control strategy for gas metal arc welding (GMAW) is developed in which the welding system detects certain existing conditions and adjusts the process in accordance to pre-specified rules. This strategy is used to control the reinforcement and weld bead centerline cooling rate during welding. Relationships between heat and mass transfer rates to the base metal and the required electrode speed and welding speed for specific open circuit voltages are taught to a artificial neural network. Control rules are programmed into a fuzzy logic system. TRADITOINAL CONTROL OF THE GMAW PROCESS is based on the use of explicit welding procedures detailing allowable parameter ranges on a pass by pass basis for a given weld. The present work is an exploration of a completely different approach to welding control. In this work the objectives are to produce welds having desired weld bead reinforcements while maintaining the weld bead centerline cooling rate at preselected values. The need for this specific control is related to fabrication requirements for specific types of pressure vessels. The control strategy involves measuring weld joint transverse cross-sectional area ahead of the welding torch and the weld bead centerline cooling rate behind the weld pool, both by means of video (2), calculating the required process parameters necessary to obtain the needed heat and mass transfer rates (in appropriate dimensions) by means of an artificial neural network, and controlling the heat transfer rate by means of a fuzzy logic controller (3). The result is a welding machine that senses the welding conditions and responds to those conditions on the basis of logical rules, as opposed to producing a weld based on a specific procedure.

  4. [Welding arc temperature field measurements based on Boltzmann spectrometry].

    PubMed

    Si, Hong; Hua, Xue-Ming; Zhang, Wang; Li, Fang; Xiao, Xiao

    2012-09-01

    Arc plasma, as non-uniform plasma, has complicated energy and mass transport processes in its internal, so plasma temperature measurement is of great significance. Compared with absolute spectral line intensity method and standard temperature method, Boltzmann plot measuring is more accurate and convenient. Based on the Boltzmann theory, the present paper calculates the temperature distribution of the plasma and analyzes the principle of lines selection by real time scanning the space of the TIG are measurements. PMID:23240385

  5. Source profile derivation for an arc welding shop using time sequenced sampling and PIXE analysis

    NASA Astrophysics Data System (ADS)

    Formenti, P.; Van Den Heever, D. J.; Annegarn, H. J.

    1998-03-01

    Samples of particulate concentration inside a welding shop in Bloemfontein (South Africa) were collected for two weeks during August 1995 using a single stage time sequenced sampler (streaker sampler). Inorganic elemental concentrations (μg/m 3) for 12 < Z < 82 were measured via Particle Induced X-ray Emission (PIXE) irradiation. The main activity of the workers consists in welding of the components during manufacturing of train trucks. For that, metallic rods are melted through electric arc welding to join steel plates. The absence of proper ventilation in the building, due to the closing of doors and windows during winter conditions, results in accumulation of pollutants and in enhanced hazardous conditions for the workers. Analysis of temporal coincidences of elemental concentrations time series formed the basis for extracting the arc welding source profile. Major periodical and episodic contributors to the indoor pollution were qualitatively observed during the sampling period. Due to the hourly time resolution of the sampling, their different time dependence could be identified and isolated. The welding shop activities were found to be characterised by high metal concentrations ([Fe] up to 95 μg/m 3) and variations in the Cu-to-Fe and Mn-to-Fe ratios within 30% over a week period. Cr concentrations up to 7 μg/m 3 were detected over 8-h shift periods. A profile for soil dust in the welding shop air was extracted, and was found to be enriched in Cr, Mn and Fe. This identifies the existence of a secondary source of heavy metal particulate exposure, to which all the workers, not only welders during their shifts, are exposed.

  6. [Calculation and analysis of arc temperature field of pulsed TIG welding based on Fowler-Milne method].

    PubMed

    Xiao, Xiao; Hua, Xue-Ming; Wu, Yi-Xiong; Li, Fang

    2012-09-01

    Pulsed TIG welding is widely used in industry due to its superior properties, and the measurement of arc temperature is important to analysis of welding process. The relationship between particle densities of Ar and temperature was calculated based on the theory of spectrum, the relationship between emission coefficient of spectra line at 794.8 nm and temperature was calculated, arc image of spectra line at 794.8 nm was captured by high speed camera, and both the Abel inversion and Fowler-Milne method were used to calculate the temperature distribution of pulsed TIG welding. PMID:23240389

  7. Abnormal macropore formation during double-sided gas tungsten arc welding of magnesium AZ91D alloy

    SciTech Connect

    Shen Jun You Guoqiang; Long Siyuan; Pan Fusheng

    2008-08-15

    One of the major concerns during gas tungsten arc (GTA) welding of cast magnesium alloys is the presence of large macroporosity in weldments, normally thought to occur from the presence of gas in the castings. In this study, a double-sided GTA welding process was adopted to join wrought magnesium AZ91D alloy plates. Micropores were formed in the weld zone of the first side that was welded, due to precipitation of H{sub 2} as the mushy zone freezes. When the reverse side was welded, the heat generated caused the mushy zone in the initial weld to reform. The micropores in the initial weld then coalesced and expanded to form macropores by means of gas expansion through small holes that are present at the grain boundaries in the partially melted zone. Macropores in the partially melted zone increase with increased heat input, so that when a filler metal is used the macropores are smaller in number and in size.

  8. Microstructure evolution of Al/Mg butt joints welded by gas tungsten arc with Zn filler metal

    SciTech Connect

    Liu Fei; Zhang Zhaodong; Liu Liming

    2012-07-15

    Based on the idea of alloying welding seam, Gas tungsten arc welding method with pure Zn filler metal was chosen to join Mg alloy and Al alloy. The microstructures, phases, element distribution and fracture morphology of welding seams were examined. The results indicate that there was a transitional zone in the width of 80-100 {mu}m between the Mg alloy substrate and fusion zone. The fusion zone was mainly composed of MgZn{sub 2}, Zn-based solid solution and Al-based solid solution. The welding seam presented distinct morphology in different location owning to the quite high cooling rate of the molten pool. The addition of Zn metal could prevent the formation of Mg-Al intermetallics and form the alloyed welding seam during welding. Therefore, the tensile strengths of joints have been significantly improved compared with those of gas tungsten arc welded joints without Zn metal added. Highlights: Black-Right-Pointing-Pointer Mg alloy AZ31B and Al alloy 6061 are welded successfully. Black-Right-Pointing-Pointer Zinc wire is employed as a filler metal to form the alloyed welding seam. Black-Right-Pointing-Pointer An alloyed welding seam is benefit for improving of the joint tensile strength.

  9. Procedure of Calculating the Parameters of the Inter-Pulse Period in Pulsed Arc Welding

    NASA Astrophysics Data System (ADS)

    Krampit, A. G.; Krampit, M. A.

    2016-08-01

    The procedure of calculating the parameters of the inter-pulse period such as current strength, electrode supply speed and time length is presented in the paper. Their importance for the stable arc burning is demonstrated. The authors address to the inter-pulse period parameters, influencing on the temperature of the electrode in the device, where the inter-pulse current is used for heating the electrode. The data of calculations are confirmed in the process of experiments. The appropriate parameters of pulsed arc welding with preheated electrode extension are identified; the stability of the process is tested experimentally: impulse frequency, inter-pulse period, arc voltage during the inter-pulse period, speed of electrode supply, current of the inter-pulse period.

  10. Optimization of Process Parameters of Hybrid Laser-Arc Welding onto 316L Using Ensemble of Metamodels

    NASA Astrophysics Data System (ADS)

    Zhou, Qi; Jiang, Ping; Shao, Xinyu; Gao, Zhongmei; Cao, Longchao; Yue, Chen; Li, Xiongbin

    2016-08-01

    Hybrid laser-arc welding (LAW) provides an effective way to overcome problems commonly encountered during either laser or arc welding such as brittle phase formation, cracking, and porosity. The process parameters of LAW have significant effects on the bead profile and hence the quality of joint. This paper proposes an optimization methodology by combining non-dominated sorting genetic algorithm (NSGA-II) and ensemble of metamodels (EMs) to address multi-objective process parameter optimization in LAW onto 316L. Firstly, Taguchi experimental design is adopted to generate the experimental samples. Secondly, the relationships between process parameters ( i.e., laser power ( P), welding current ( A), distance between laser and arc ( D), and welding speed ( V)) and the bead geometries are fitted using EMs. The comparative results show that the EMs can take advantage of the prediction ability of each stand-alone metamodel and thus decrease the risk of adopting inappropriate metamodels. Then, the NSGA-II is used to facilitate design space exploration. Besides, the main effects and contribution rates of process parameters on bead profile are analyzed. Eventually, the verification experiments of the obtained optima are carried out and compared with the un-optimized weld seam for bead geometries, weld appearances, and welding defects. Results illustrate that the proposed hybrid approach exhibits great capability of improving welding quality in LAW.

  11. 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.

  12. Electrical Arc Ignition Testing of Spacesuit Materials

    NASA Technical Reports Server (NTRS)

    Smith, Sarah; Gallus, Tim; Tapia, Susana; Ball, Elizabeth; Beeson, Harold

    2006-01-01

    A viewgraph presentation on electrical arc ignition testing of spacesuit materials is shown. The topics include: 1) Background; 2) Test Objectives; 3) Test Sample Materials; 4) Test Methods; 5) Scratch Test Objectives; 6) Cotton Scratch Test Video; 7) Scratch Test Results; 8) Entire Date Plot; 9) Closeup Data Plot; 10) Scratch Test Problems; 11) Poke Test Objectives; 12) Poke Test Results; 13) Poke Test Problems; 14) Wire-break Test Objectives; 15) Cotton Wire-Break Test Video; 16) High Speed Cotton Wire-break Test Video; 17) Typical Data Plot; 18) Closeup Data Plot; 19) Wire-break Test Results; 20) Wire-break Tests vs. Scratch Tests; 21) Urethane-coated Nylon; and 22) Moleskin.

  13. Numerical Modeling of Enhanced Nitrogen Dissolution During Gas Tungsten Arc Welding

    SciTech Connect

    Palmer, T A

    2001-08-17

    Nitrogen concentrations far in excess of Sieverts' Law calculations and as high as 0.2 wt.% have been obtained in steel welds during arc welding. Such high concentrations of nitrogen in the weld metal can originate from a variety of sources, depending on the welding operation in question. One such mechanism involves the interaction between the surrounding atmosphere, which is about 80% nitrogen, and the plasma phase above the weld pool. Impingement of the surrounding atmosphere into the arc column, which is primarily composed of an inert shielding gas, can be due, in part, to insufficient shielding of the weld metal. In other cases, nitrogen can be purposefully added to the shielding gas to enhance the microstructural evolution of the weld metal. The mechanisms responsible for enhanced nitrogen concentrations are of significant interest. In both arc melting and welding operations, a plasma phase exists above the liquid metal. This plasma phase, which is composed of a number of different species not normally observed in gas-metal systems, significantly alters the nitrogen absorption reaction in liquid iron and steel. Monatomic nitrogen (N) is considered to be the species responsible for the observed enhancements in the nitrogen concentration. This role for monatomic nitrogen is based on its significantly higher solubility in iron with partial pressures many orders of magnitude less than that for diatomic nitrogen. It has also been proposed that the total amount of nitrogen present in the liquid metal is the balance of two independent processes. Monatomic nitrogen is absorbed through the interface between the arc and the liquid metal. Once a saturation level is reached at any location on the metal surface, nitrogen is then expelled from the surface of the liquid metal. This expulsion of nitrogen from the weld pool surface occurs via a desorption reaction, in which bubbles form at the surface and other heterogeneous nucleation sites in the liquid melt. These bubbles

  14. Hybrid laser-arc welding of galvanized high-strength steels in a gap-free lap-joint configuration

    NASA Astrophysics Data System (ADS)

    Yang, Shanglu

    In order to meet the industry demands for increased fuel efficiency and enhanced mechanical and structural performance of vehicles as well as provided excellent corrosion resistance, more and more galvanized advanced high-strength steels (AHSS) have been used to fabricate automobile parts such as panels, bumpers, and front rails. The automotive industry has shown tremendous interest in using laser welding to join galvanized dual phase steels because of lower heat input and higher welding speed. However, the laser welding process tends to become dramatically unstable in the presence of highly pressurized zinc vapor because of the low boiling point of zinc, around 906°C, compared to higher melting point of steel, over 1500°C. A large number of spatters are produced by expelling the liquid metal from the molten pool by the pressurized zinc vapor. Different weld defects such as blowholes and porosities appear in the welds. So far, limited information has been reported on welding of galvanized high strength dual-phase steels in a gap-free lap joint configuration. There is no open literature on the successful attainment of defect-free welds from the laser or hybrid welding of galvanized high-strength steels. To address the significant industry demand, in this study, different welding techniques and monitoring methods are used to study the features of the welding process of galvanized DP steels in a gap-free lap joint configuration. The current research covers: (i) a feasibility study on the welding of galvanized DP 980 steels in a lap joint configuration using gas tungsten arc welding (GTAW), laser welding, hybrid laser/arc welding with the common molten pool, laser welding with the assistance of GTAW preheating source and hybrid laser-variable polarity gas tungsten arc welding (Laser-VPGTAW) techniques (Chapter 2-4); (ii) a welding process monitoring of the welding techniques including the use of machine vision and acoustic emission technique (Chapter 5); (iii

  15. Influence of deformation on structural-phase state of weld material in St3 steel

    NASA Astrophysics Data System (ADS)

    Smirnov, Alexander; Kozlov, Eduard; Ababkov, Nicolay; Popova, Natalya; Nikonenko, Elena; Ozhiganov, Yevgeniy; Zboykova, Nadezhda; Koneva, Nina

    2016-01-01

    The structural-phase condition of the weld material subjected to the plastic deformation was investigated using the translucent diffraction electron microscopy method. The investigations were carried out near the joint of the weld and the base metal. The seam was done by the method of manual arc welding without artificial defects. The St3 steel was taken as the welded material. Influence of the plastic deformation on morphology, phase composition, defect structure and its parameters of weld metal was revealed. All investigations were done at the distance of 0.5 mm from the joint of the weld and the base metal at the deformation degrees from 0 to 5% and after destruction of a sample. It was established that deformation of the sample did not lead to qualitative changes in the structure (the structure is still presented by ferrite-pearlite mixture) but changed the quantitative parameters of the structure, namely, with the increase of plastic deformation a part of the pearlite component becomes more and more imperfect. In the beginning it turns into the destroyed pearlite then into ferrite, the volume fraction of pearlite is decreased. The polarization of dislocation structure takes place but it doesn't lead to the internal stresses that can destroy the sample.

  16. Study of Radiographic Linear Indications and Subsequent Microstructural Features in Gas Tungsten Arc Welds of Inconel 718

    NASA Technical Reports Server (NTRS)

    Walley, J. L.; Nunes, A. C.; Clounch, J. L.; Russell, C. K.

    2007-01-01

    This study presents examples and considerations for differentiating linear radiographic indications produced by gas tungsten arc welds in a 0.05-in-thick sheet of Inconel 718. A series of welds with different structural features, including the enigma indications and other defect indications such as lack of fusion and penetration, were produced, radiographed, and examined metallographically. The enigma indications were produced by a large columnar grain running along the center of the weld nugget occurring when the weld speed was reduced sufficiently below nominal. Examples of respective indications, including the effect of changing the x-ray source location, are presented as an aid to differentiation. Enigma, nominal, and hot-weld specimens were tensile tested to demonstrate the harmlessness of the enigma indication. Statistical analysis showed that there is no difference between the strengths of these three weld conditions.

  17. [Calculating the stark broadening of welding arc spectra by Fourier transform method].

    PubMed

    Pan, Cheng-Gang; Hua, Xue-Ming; Zhang, Wang; Li, Fang; Xiao, Xiao

    2012-07-01

    It's the most effective and accurate method to calculate the electronic density of plasma by using the Stark width of the plasma spectrum. However, it's difficult to separate Stark width from the composite spectrum linear produced by several mechanisms. In the present paper, Fourier transform was used to separate the Lorentz linear from the spectrum observed, thus to get the accurate Stark width. And we calculated the distribution of the TIG welding arc plasma. This method does not need to measure arc temperature accurately, to measure the width of the plasma spectrum broadened by instrument, and has the function to reject the noise data. The results show that, on the axis, the electron density of TIG welding arc decreases with the distance from tungsten increasing, and changes from 1.21 X 10(17) cm(-3) to 1.58 x 10(17) cm(-3); in the radial, the electron density decreases with the distance from axis increasing, and near the tungsten zone the biggest electronic density is off axis. PMID:23016315

  18. The ultrasonic characteristics of high frequency modulated arc and its application in material processing.

    PubMed

    He, Longbiao; Yang, Ping; Li, Luming; Wu, Minsheng

    2014-12-01

    To solve the difficulty of introducing traditional ultrasonic transducers to welding molten pool, high frequency current is used to modulate plasma arc and ultrasonic wave is excited successfully. The characteristics of the excited ultrasonic field are studied. The results show that the amplitude-frequency response of the ultrasonic emission is flat. The modulating current is the main factor influencing the ultrasonic power and the sound pressure depends on the variation of arc plasma stream force. Experimental study of the welding structure indicates grain refinement by the ultrasonic emission of the modulated arc and the test results showed there should be an energy region for the arc ultrasonic to get best welding joints.

  19. Vacuum Deposition From A Welding Torch

    NASA Technical Reports Server (NTRS)

    Poorman, R. M.

    1993-01-01

    Process derived from arc welding produces films of high quality. Modified gas/tungsten-arc welding process developed for use in outer space. Welding apparatus in process includes hollow tungsten electrode through which inert gas flows so arc struck between electrode and workpiece in vacuum of space. Offers advantages of fast deposition, possibility of applying directional impetus to flow of materials, very low pressure at surface being coated, and inert environment.

  20. Gas motion and heat transfer in a hollow cylinder with applications to arc welding

    NASA Astrophysics Data System (ADS)

    Solana, P.; Kapadia, P.; Dowden, J.

    1999-10-01

    The problem of the steady heat transfer in a hollow cylinder subject to intense heating on its walls is studied and solved analytically. The heat supplied to the inner cylinder wall is supposed to be generated by the action of a laser beam on a gas circulating inside the hollow cylinder, acting as the cathode of an arc-welding device. The inverse problem is also solved and analysed for a variety of heat flux profiles. The analytical solution is compared with former numerical approaches of the inverse problem.

  1. Progress report on a fully automatic Gas Tungsten Arc Welding (GTAW) system development

    SciTech Connect

    Daumeyer, G.J. III

    1994-12-01

    A plan to develop a fully automatic gas tungsten arc welding (GTAW) system that will utilize a vision-sensing computer (which will provide in-process feedback control) is presently in work. Evaluations of different technological aspects and system design requirements continue. This report summaries major activities in the plan`s successful progress. The technological feasibility of producing the fully automated GTAW system has been proven. The goal of this process development project is to provide a production-ready system within the shortest reasonable time frame.

  2. Characteristics comparison of weld metal zones welded to cast and forged steels for piston crown material

    NASA Astrophysics Data System (ADS)

    Moon, Kyung-Man; Kim, Yun-Hae; Lee, Myeong-Hoon; Baek, Tae-Sil

    2015-03-01

    An optimum repair welding for the piston crown which is one of the engine parts exposed to the combustion chamber is considered to be very important to prolong the engine lifetime from an economical point of view. In this study, two types of filler metals such as 1.25Cr-0.5Mo, 0.5Mo were welded with SMAW method and the other two types of filler metals such as Inconel 625 and 718 were welded with GTAW method, respectively, and the used base metals were the cast and forged steels of the piston crown material. The weld metal zones welded with Inconel 625 and 718 filler metals exhibited higher corrosion resistance compared to 1.25Cr-0.5Mo and 0.5Mo filler metals. In particular, the weld metal zone welded with Inconel 718 and 0.5Mo, filler metals indicated the best and worst corrosion resistance, respectively. Consequently, it is suggested that the corrosion resistance of the weld metal zone surely depends on the chemical components of each filler metal and welding method irrespective of the types of piston crown material.

  3. Change of electrical conductivity of Ar welding arc under resonant absorption of laser radiation

    NASA Astrophysics Data System (ADS)

    Kozakov, R.; Emde, B.; Pipa, A. V.; Huse, M.; Uhrlandt, D.; Hermsdorf, J.; Wesling, V.

    2015-03-01

    Experimental investigations of the impact of resonant laser absorption by a tungsten inert gas welding arc in argon are presented. The intensity increase of the arc’s radiation between the laser entrance height and the anode are observed, as well as the variation of arc voltage due to the presence of the laser beam. High-speed camera recordings from different directions combined with absolutely calibrated spectroscopic measurements allow the reconstruction of the three-dimensional emission coefficient profiles without the assumption of axial symmetry. The obtained data are evaluated within the framework of local thermodynamic equilibrium. The local increase in the temperature and conductivity due to the influence of the laser is determined. Changes in the electrical conductivity obtained from the optical measurements coincide well with the measured voltage drop, and show significant redistribution of the current density profile near the anode in particular.

  4. Material property evaluations of bimetallic welds, stainless steel saw fusion lines, and materials affected by dynamic strain aging

    SciTech Connect

    Rudland, D.; Scott, P.; Marschall, C.; Wilkowski, G.

    1997-04-01

    Pipe fracture analyses can often reasonably predict the behavior of flawed piping. However, there are material applications with uncertainties in fracture behavior. This paper summarizes work on three such cases. First, the fracture behavior of bimetallic welds are discussed. The purpose of the study was to determine if current fracture analyses can predict the response of pipe with flaws in bimetallic welds. The weld joined sections of A516 Grade 70 carbon steel to F316 stainless steel. The crack was along the carbon steel base metal to Inconel 182 weld metal fusion line. Material properties from tensile and C(T) specimens were used to predict large pipe response. The major conclusion from the work is that fracture behavior of the weld could be evaluated with reasonable accuracy using properties of the carbon steel pipe and conventional J-estimation analyses. However, results may not be generally true for all bimetallic welds. Second, the toughness of austenitic steel submerged-arc weld (SAW) fusion lines is discussed. During large-scale pipe tests with flaws in the center of the SAW, the crack tended to grow into the fusion line. The fracture toughness of the base metal, the SAW, and the fusion line were determined and compared. The major conclusion reached is that although the fusion line had a higher initiation toughness than the weld metal, the fusion-line J-R curve reached a steady-state value while the SAW J-R curve increased. Last, carbon steel fracture experiments containing circumferential flaws with periods of unstable crack jumps during steady ductile tearing are discussed. These instabilities are believed to be due to dynamic strain aging (DSA). The paper discusses DSA, a screening criteria developed to predict DSA, and the ability of the current J-based methodologies to assess the effect of these crack instabilities. The effect of loading rate on the strength and toughness of several different carbon steel pipes at LWR temperatures is also discussed.

  5. Welding procedure specification. Supplement 1. Records of procedure qualification tests. Gas tungsten arc welding of AISI 41XX steels. [4130 and 4142

    SciTech Connect

    Wodtke, C.H.; Frizzell, D.R.

    1986-06-01

    Procedure WPS-126 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of AISI 4130 and 4142 steel (ASTM A519) (P-No: None), 0.438-inch wall pipe; filler metal is AMS 6457, Class 4130 MC (F-, A-No: None).

  6. Inclusions and Microstructure of Ce-Added Weld Metal Coarse Grain Heat-Affected Zone in Twin-Wire Submerged-Arc Welding

    NASA Astrophysics Data System (ADS)

    Yu, S. F.; Yan, N.; Chen, Y.

    2016-06-01

    In high heat-input multi-pass twin-wire submerged-arc welding, weld metal of previous pass will be affected by the heat input of subsequent one and form coarse-grained heat-affected zone (CGHAZ). This study focused on the effects of welding thermal cycle on the inclusions and microstructure of Ce-alloyed weld metal CGHAZ. According to the study of inclusions and microstructure of weld metal CGHAZ, it was found that the composition and type of the inclusions did not change under the effect of welding thermal cycle. Although the inclusions were coarsened slightly, the promoting ability to acicular ferrite (AF) was not deprived after thermal cycling. There are three types of AF in weld metal CGHAZ, which include oxy-sulfides of Ce inclusions-promoted AF, home-position-precipitated AF, and sympathetic AF. Results showed more than 80% of microstructure was AF, which greatly benefited the mechanical properties of weld metal CGHAZ, even though granular bainite and M-A constituents were generated.

  7. Estimation and control of droplet size and frequency in projected spray mode of a gas metal arc welding (GMAW) process.

    PubMed

    Anzehaee, Mohammad Mousavi; Haeri, Mohammad

    2011-07-01

    New estimators are designed based on the modified force balance model to estimate the detaching droplet size, detached droplet size, and mean value of droplet detachment frequency in a gas metal arc welding process. The proper droplet size for the process to be in the projected spray transfer mode is determined based on the modified force balance model and the designed estimators. Finally, the droplet size and the melting rate are controlled using two proportional-integral (PI) controllers to achieve high weld quality by retaining the transfer mode and generating appropriate signals as inputs of the weld geometry control loop.

  8. Effect of Gas Tungsten Arc Welding Parameters on Hydrogen-Assisted Cracking of Type 321 Stainless Steel

    NASA Astrophysics Data System (ADS)

    Rozenak, Paul; Unigovski, Yaakov; Shneck, Roni

    2016-05-01

    The susceptibility of AISI type 321 stainless steel welded by the gas tungsten arc welding (GTAW) process to hydrogen-assisted cracking (HAC) was studied in a tensile test combined with in situ cathodic charging. Specimen charging causes a decrease in ductility of both the as-received and welded specimens. The mechanical properties of welds depend on welding parameters. For example, the ultimate tensile strength and ductility increase with growing shielding gas (argon) rate. More severe decrease in the ductility was obtained after post-weld heat treatment (PWHT). In welded steels, in addition to discontinuous grain boundary carbides (M23C6) and dense distribution of metal carbides MC ((Ti, Nb)C) precipitated in the matrix, the appearance of delta-ferrite phase was observed. The fracture of sensitized specimens was predominantly intergranular, whereas the as-welded specimens exhibited mainly transgranular regions. High-dislocation density regions and stacking faults were found in delta-ferrite formed after welding. Besides, thin stacking fault plates and epsilon-martensite were found in the austenitic matrix after the cathodic charging.

  9. Effect of Weld Characteristic on Mechanical Strength of Laser-Arc, Hybrid-Welded Al-Mg-Si-Mn Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Zhang, Chen; Gao, Ming; Jiang, Ming; Zeng, Xiaoyan

    2016-08-01

    Laser-arc hybrid welding (LAHW) was employed to improve the tensile properties of the joints of 8-mm-thick Al-Mg-Si-Mn alloy (AA6082) using Al-5Mg filler wire. The weld microstructures were examined by scanning electron microscope, electron backscattered diffraction, and transmission electron microscopy in detail. The LAHW joints with pore-free and high-tensile performances were obtained. The strength enhancement of the fusion zone and heat-affected zone in the LAHW joint was mainly attributed to the grain refinement strengthening and the precipitation strengthening, respectively. The microstructure characteristics were related to the effects of laser-arc interaction on the energy transfer within the molten pool. The arc caused the majority of laser energy to dissipate out of the keyhole, and then it reduced the heat input. The lower heat input refined the grain size, weakened the overaging effect, and thus improved the tensile strength.

  10. Effect of Weld Characteristic on Mechanical Strength of Laser-Arc Hybrid-Welded Al-Mg-Si-Mn Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Zhang, Chen; Gao, Ming; Jiang, Ming; Zeng, Xiaoyan

    2016-11-01

    Laser-arc hybrid welding (LAHW) was employed to improve the tensile properties of the joints of 8-mm-thick Al-Mg-Si-Mn alloy (AA6082) using Al-5Mg filler wire. The weld microstructures were examined by scanning electron microscope, electron backscattered diffraction, and transmission electron microscopy in detail. The LAHW joints with pore-free and high-tensile performances were obtained. The strength enhancement of the fusion zone and heat-affected zone in the LAHW joint was mainly attributed to the grain refinement strengthening and the precipitation strengthening, respectively. The microstructure characteristics were related to the effects of laser-arc interaction on the energy transfer within the molten pool. The arc caused the majority of laser energy to dissipate out of the keyhole, and then it reduced the heat input. The lower heat input refined the grain size, weakened the overaging effect, and thus improved the tensile strength.

  11. The use of an advanced design of power supply control system for wet shielded metal arc welding

    SciTech Connect

    Nixon, J.H.; Webb, D.J.

    1994-12-31

    The work described in this paper was carried out as a direct result of the research reported in an earlier OMAE document. That paper described a series of welding trials which investigated the handling characteristics of a series of wet shielded metal arc welding (SMAW) electrodes, and attempted to establish objective measures of welder skill by the use of parameter measurement techniques. One of the conclusions reached as a result of that work was that a skilled wet SMAW welder was capable of maintaining a much shorter arc length than a less skilled welder, resulting in higher levels of metal transfer efficiency and higher weld heat inputs. Based on this conclusion, it was decided to utilize a highly flexible welding power supply control system (PSCS) developed at Cranfield for welding process research, and to apply it to wet SMAW. Similar control techniques have been suggested by other sources. Using the consumable regarded most favorably in the earlier work, a series of welding trials were undertaken to optimize the various operating parameters which the PSCS could control. Although only a limited series of welding tests were conducted, it is felt that techniques of this type offer sufficient promise that they should be investigated in a larger scale investigation.

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

    NASA Astrophysics Data System (ADS)

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

    2015-12-01

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

  13. Urinary β2 microglobulin in workers exposed to arc welding fumes.

    PubMed

    Aminian, Omid; Eftekhari, Saeid; Mazaheri, Maria; Sharifian, Seyed Akbar; Sadeghniiat-Haghighi, Khosro

    2011-01-01

    Welding is a process in which two or more metals are attached by the use of heat and, in some cases, pressure. Direct exposure and inhalation of welding fumes causes acute and chronic side effects in humans. Kidney damage is one of these important side effects. β(2) microglobulin is an 11.8 kilodalton protein and levels increase in the case of some inflammatory and viral diseases, or kidney malfunction and autoimmune diseases. In this study measurements of β(2) microglobulin were used as a criterion for assessing effects on the kidneys of workers exposed to welding fumes. The study population were electric arc welders in an industrial plant in Tehran, Iran. For control we selected workers who did not have any exposure to welding fumes. Both groups were selected on the basis of a questionnaire and the consideration of criteria for inclusion and exclusion. In the end 50 cases and 50 controls were chosen. A urine sample was collected from all participants and urinary pH was set to between 6-8 using NaOH (1M). Sample transportation to the laboratory complied with the related standards. The samples were assessed using the ORG 5BM kit. For quantitative assessment of β(2) microglobulin we used the Enzyme-linked Immunosorbent Assay (ELISA) method. The ages of the welders ranged from 21 to 48 years (mean=30.5 ± 5.9 yrs) and of controls from 23 to 56 years (mean=31.8 ± 5.9 yrs). Mean employment duration was 7.86 ± 5.01 years (range 2 to 27 years) for welders. Mean β(2) microglobulin level was 0.10 ± 0.096 μg/ml in welders and 0.11 ± 0.06 in controls. This difference was not statistically significant (P=0.381). In conclusion we don't find that exposure to electric arc welding fumes cause a significant change in urinary β(2) microglobulin compared to the control group. PMID:22131246

  14. Arc Jet Testing of Thermal Protection Materials: 3 Case Studies

    NASA Technical Reports Server (NTRS)

    Johnson, Sylvia; Conley, Joe

    2015-01-01

    Arc jet testing is used to simulate entry to test thermal protection materials. This paper discusses the usefulness of arc jet testing for 3 cases. Case 1 is MSL and PICA, Case 2 is Advanced TUFROC, and Case 3 is conformable ablators.

  15. Two-temperature modelling and optical emission spectroscopy of a constant current plasma arc welding process

    NASA Astrophysics Data System (ADS)

    Boselli, M.; Colombo, V.; Ghedini, E.; Gherardi, M.; Sanibondi, P.

    2013-06-01

    In this work, a plasma arc welding process with constant current in the range 25-70 A operating in pure Ar is characterized by means of both thermo-fluid-dynamic modelling under the assumption of local thermodynamic equilibrium (LTE) and two-temperature thermal non-equilibrium modelling (2T), allowing a comparison of the LTE temperature fields with electron and heavy particle temperature fields: thermal non-equilibrium is strongest in the fringes of the arc and upstream the plasma flow even though a temperature difference between electrons and heavy particles is also found in the arc core in the nozzle orifice, due to the high velocity of the gas. Also, excitation temperature of Ar atoms is obtained from optical emission spectroscopy measurements using a new method (called hybrid method) that extends the usability of the Boltzmann plot method to spatial regions where the signal-to-noise ratio of the spectral lines adopted in the calculation is poor. Good agreement is obtained between the modelling predicted electron temperature and the measured excitation temperature in the whole investigated spatial region.

  16. Development and Testing of an Experimental Polysensory Instructional System for Teaching Electric Arc Welding Processes. Report No. 24. Final Report.

    ERIC Educational Resources Information Center

    Sergeant, Harold A.

    The population of the study consisted of 15 high school industrial arts students, 10 freshman and sophomore college students, and 10 adults. A polysensory, self-pacing instructional system was developed which included (1) pretests and post tests, (2) a general instruction book, (3) equipment to practice arc welding, (4) programed instruction…

  17. The Comparative Effect of Sugarcane Juice on the Abrasion-Corrosion Behavior of Fe-Cr-B Electric Arc Sprayed and Fe-Cr-C Weld Coatings

    NASA Astrophysics Data System (ADS)

    Buchanan, Vernon E.

    2012-02-01

    Abrasion-corrosion tests were conducted on two commonly Fe-Cr-C shielded metal arc welding (SMAW) hardfacings used in the sugar industry and an arc sprayed Fe-Cr-based coating. The tests were performed on a modified block-on-ring tester with the coatings sliding against compressed sugarcane fiber in the presence of abrasive slurry. The findings showed that, in the presence of sugarcane juice and sand slurry, the SMAW coatings had similar wear performance while the abrasive wear of the arc-sprayed coating was superior to the SMAW coatings. In the presence of a neutral solution, the material loss from the arc-sprayed coating was similar to that obtained in the sugarcane juice while the SMAW coatings showed a marked decrease; this demonstrated that the arc-sprayed coating was more desirable in an abrasive-corrosion environment. The study also showed that the resistance to material does not follow the expected trend, in which wear resistance increases with increasing hardness.

  18. Manufacturing Challenges Implementing Material Changes for the Super Light Weight External Tank: A Welding Process Perspective

    NASA Technical Reports Server (NTRS)

    Lawless, K.; Jones, C.

    2001-01-01

    A viewgraph presentation gives an overview of the manufacturing challenges in implementing welding material changes for the super lightweight external tank. Details are given on the external tank configuration, the weld purging equipment used, planning the selection of weld filler wire alloy, the initial weld microstructure, the wide panel tensile testing, and the dome cap welding.

  19. Prediction of Welded Joint Strength in Plasma Arc Welding: A Comparative Study Using Back-Propagation and Radial Basis Neural Networks

    NASA Astrophysics Data System (ADS)

    Srinivas, Kadivendi; Vundavilli, Pandu R.; Manzoor Hussain, M.; Saiteja, M.

    2016-09-01

    Welding input parameters such as current, gas flow rate and torch angle play a significant role in determination of qualitative mechanical properties of weld joint. Traditionally, it is necessary to determine the weld input parameters for every new welded product to obtain a quality weld joint which is time consuming. In the present work, the effect of plasma arc welding parameters on mild steel was studied using a neural network approach. To obtain a response equation that governs the input-output relationships, conventional regression analysis was also performed. The experimental data was constructed based on Taguchi design and the training data required for neural networks were randomly generated, by varying the input variables within their respective ranges. The responses were calculated for each combination of input variables by using the response equations obtained through the conventional regression analysis. The performances in Levenberg-Marquardt back propagation neural network and radial basis neural network (RBNN) were compared on various randomly generated test cases, which are different from the training cases. From the results, it is interesting to note that for the above said test cases RBNN analysis gave improved training results compared to that of feed forward back propagation neural network analysis. Also, RBNN analysis proved a pattern of increasing performance as the data points moved away from the initial input values.

  20. Set up an Arc Welding Code with Enthalpy Method in Upwind Scheme

    SciTech Connect

    Ho, J.-E.

    2010-05-21

    In this study, a numerical code with enthalpy method in upwind scheme is proposed to estimate the distribution of thermal stress in the molten pool, which is primarily determined by the type of the input power and travel speed of heating source. To predict the cracker deficit inside the workpiece, a simulated program satisfying the diagonal domination and Scarborough criterion provides a stable iteration. Meantime, an experimental performance, operated by robot arm 'DR-400' to provide a steady and continuous arc welding, was also conducted to verify the simulated result. By surveying the consistence of molten pool bounded by contrast shade and simulated melting contour on the surface of workpiece, the validity of model proposed to predict the thermal cracker has been successfully identified.

  1. 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.

  2. Determinants of occupational exposure to metals by gas metal arc welding and risk management measures: a biomonitoring study.

    PubMed

    Persoons, Renaud; Arnoux, Damien; Monssu, Théodora; Culié, Olivier; Roche, Gaëlle; Duffaud, Béatrice; Chalaye, Denis; Maitre, Anne

    2014-12-01

    Welding fumes contain various toxic metals including chromium (Cr), nickel (Ni) and manganese (Mn). An assessment of the risk to health of local and systemic exposure to welding fumes requires the assessment of both external and internal doses. The aims of this study were to test the relevance in small and medium sized enterprises of a biomonitoring strategy based on urine spot-samples, to characterize the factors influencing the internal doses of metals in gas metal arc welders and to recommend effective risk management measures. 137 welders were recruited and urinary levels of metals were measured by ICP-MS on post-shift samples collected at the end of the working week. Cr, Ni and Mn mean concentrations (respectively 0.43, 1.69 and 0.27 μg/g creatinine) were well below occupational health guidance values, but still higher than background levels observed in the general population, confirming the absorption of metals generated in welding fumes. Both welding parameters (nature of base metal, welding technique) and working conditions (confinement, welding and grinding durations, mechanical ventilation and welding experience) were predictive of occupational exposure. Our results confirm the interest of biomonitoring for assessing health risks and recommending risk management measures for welders. PMID:25223250

  3. Abnormal distribution of microhardness in tungsten inert gas arc butt-welded AZ61 magnesium alloy plates

    SciTech Connect

    Xu Nan; Shen Jun; Xie Weidong; Wang Linzhi; Wang Dan; Min Dong

    2010-07-15

    In this study, the effects of heat input on the distribution of microhardness of tungsten inert gas (TIG) arc welded hot-extruded AZ61 magnesium alloy joints were investigated. The results show that with an increase of heat input, the distributions of microhardness at the top and bottom of the welded joints are different because they are determined by both the effect of grain coarsening and the effect of dispersion strengthening. With an increase of the heat input, the microhardness of the heat-affected zone (HAZ) at the top and bottom of welded joints and the fusion zone (FZ) at the bottom of welded joints decreased gradually, while the microhardness of the FZ at the top of welded joints decreased initially and then increased sharply. The reason for the abnormal distribution of microhardness of the FZ at the top of the welded joints is that this area is close to the heat source during welding and then large numbers of hard {beta}-Mg{sub 17}(Al,Zn){sub 12} particles are precipitated. Hence, in this case, the effect of dispersion strengthening dominated the microhardness.

  4. Determinants of occupational exposure to metals by gas metal arc welding and risk management measures: a biomonitoring study.

    PubMed

    Persoons, Renaud; Arnoux, Damien; Monssu, Théodora; Culié, Olivier; Roche, Gaëlle; Duffaud, Béatrice; Chalaye, Denis; Maitre, Anne

    2014-12-01

    Welding fumes contain various toxic metals including chromium (Cr), nickel (Ni) and manganese (Mn). An assessment of the risk to health of local and systemic exposure to welding fumes requires the assessment of both external and internal doses. The aims of this study were to test the relevance in small and medium sized enterprises of a biomonitoring strategy based on urine spot-samples, to characterize the factors influencing the internal doses of metals in gas metal arc welders and to recommend effective risk management measures. 137 welders were recruited and urinary levels of metals were measured by ICP-MS on post-shift samples collected at the end of the working week. Cr, Ni and Mn mean concentrations (respectively 0.43, 1.69 and 0.27 μg/g creatinine) were well below occupational health guidance values, but still higher than background levels observed in the general population, confirming the absorption of metals generated in welding fumes. Both welding parameters (nature of base metal, welding technique) and working conditions (confinement, welding and grinding durations, mechanical ventilation and welding experience) were predictive of occupational exposure. Our results confirm the interest of biomonitoring for assessing health risks and recommending risk management measures for welders.

  5. Phosphorus free energy change associated with segregation to grain boundaries in submerged-arc welds

    SciTech Connect

    Mendes, C.M.

    1999-10-01

    The segregation of phosphorus from the matrix to grain boundaries has been associated with increased brittleness in carbon-manganese submerged-arc weld metals, with the failure mode on the lower shelf and transition regime changing from cleavage to intergranular failure. The quantification of segregation and hence thermal embrittlement requires the knowledge of the energy decrease for an atom in the matrix moving to a grain boundary, {Delta}G. There is some evidence to suggest that the energy decrease depends on the level of alloying constituents and this paper considers a steel with a 1.46 wt% manganese and 0.08% carbon. The value of {Delta}G was calculated as a function of temperature by measuring grain boundary segregation after annealings at constant temperature in the range 763--873 K. The grain refined and columnar regions of the welds were analyzed separately. The phosphorus grain boundary monolayer coverages observed were smaller than those reported for a PWR steel.

  6. 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…

  7. Pulse thermal processing of functional materials using directed plasma arc

    DOEpatents

    Ott, Ronald D.; Blue, Craig A.; Dudney, Nancy J.; Harper, David C.

    2007-05-22

    A method of thermally processing a material includes exposing the material to at least one pulse of infrared light emitted from a directed plasma arc to thermally process the material, the pulse having a duration of no more than 10 s.

  8. Evolution of weld metal microstructure in shielded metal arc welding of X70 HSLA steel with cellulosic electrodes: A case study

    SciTech Connect

    Ghomashchi, Reza Costin, Walter; Kurji, Rahim

    2015-09-15

    The microstructure of weld joint in X70 line pipe steel resulted from shielded metal arc welding with E6010 cellulosic electrodes is characterized using optical and electron microscopy. A range of ferritic morphologies have been identified ranging from polygonal inter- and intra-prior austenite grains allotriomorphic, idiomorphic ferrites to Widmanstätten, acicular and bainitic ferrites. Electron Backscatter Diffraction (EBSD) analysis using Image Quality (IQ) and Inverse Pole Figure (IPF) maps through superimposition of IQ and IPF maps and measurement of percentages of high and low angle grain boundaries was identified to assist in differentiation of acicular ferrite from Widmanstätten and bainitic ferrite morphologies. In addition two types of pearlitic structures were identified. There was no martensite detected in this weld structure. The morphology, size and chemistry of non-metallic inclusions are also discussed briefly. - Highlights: • Application of EBSD reveals orientation relationships in a range of phases for shielded metal arc welding of HSLA steel. • Nucleation sites of various ferrite morphologies identified • Formation of upper and lower bainite and their morphologies.

  9. Multi-objective optimization of weld geometry in hybrid fiber laser-arc butt welding using Kriging model and NSGA-II

    NASA Astrophysics Data System (ADS)

    Gao, Zhongmei; Shao, Xinyu; Jiang, Ping; Wang, Chunming; Zhou, Qi; Cao, Longchao; Wang, Yilin

    2016-06-01

    An integrated multi-objective optimization approach combining Kriging model and non-dominated sorting genetic algorithm-II (NSGA-II) is proposed to predict and optimize weld geometry in hybrid fiber laser-arc welding on 316L stainless steel in this paper. A four-factor, five-level experiment using Taguchi L25 orthogonal array is conducted considering laser power ( P), welding current ( I), distance between laser and arc ( D) and traveling speed ( V). Kriging models are adopted to approximate the relationship between process parameters and weld geometry, namely depth of penetration (DP), bead width (BW) and bead reinforcement (BR). NSGA-II is used for multi-objective optimization taking the constructed Kriging models as objective functions and generates a set of optimal solutions with pareto-optimal front for outputs. Meanwhile, the main effects and the first-order interactions between process parameters are analyzed. Microstructure is also discussed. Verification experiments demonstrate that the optimum values obtained by the proposed integrated Kriging model and NSGA-II approach are in good agreement with experimental results.

  10. Characteristics and performance of the variable polarity plasma arc welding process used in the Space Shuttle external tank

    NASA Technical Reports Server (NTRS)

    Hung, R. J.; Lee, C. C.; Liu, J. W.

    1990-01-01

    Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. Flow profiles and power distribution of argon plasma gas as a working fluid to produce plasma arc jet in the VPPA welding process was analyzed. Major loss of heat transfer for flow through the nozzle is convective heat transfer; for the plasma jet flow between the outlet of the nozzle and workpiece is radiative heat transfer; and for the flow through the keyhole of the workpiece is convective heat transfer. The majority of the power absorbed by the keyhole of the workpiece is used for melting the solid metal workpiece into a molten metallic puddle. The crown and root widths and the crown and root heights can be predicted. An algorithm for promoting automatic control of flow parameters and the dimensions of the final product of the welding specification to be used for the VPPA Welding System operated at MSFC are provided.

  11. Phenomenology of surface arcs on spacecraft dielectric materials

    NASA Technical Reports Server (NTRS)

    Balmain, K. G.; Gossland, M.; Reeves, R. D.; Kuller, W. G.

    1982-01-01

    For electron beam incidence on large specimens of Kapton thermal blanket material, surface arc discharges are shown to cause damage consisting of punchthrough holes which act as focal points for other types of damage, including subsurface tunnels, blowout holes and surface breakup. Under electron bombardment, dielectric sheet specimens separated by a gap are shown to discharge simultaneously. Teflon specimens which have been brushed or rubbed are shown to exhibit directional guidance of discharge arcs, and this phenomenon has been used to generate straight arcs whose velocities have been measured optically.

  12. Weldability and toughness evaluation of pressure vessel quality steel using the shielded metal arc welding (SMAW) process

    NASA Astrophysics Data System (ADS)

    Datta, R.; Mukerjee, D.; Mishra, S.

    1998-12-01

    The present study was carried out to assess the weldability properties of ASTM A 537 Cl. 1 pressure-vessel quality steel using the shielded metal arc welding (SMAW) process. Implant and elastic restraint cracking (ERC) tests were conducted under different welding conditions to determine the cold cracking susceptibility of the steel. The static fatigue limit values determined for the implant test indicate adequate resistance to cold cracking even with unbaked electrodes. The ERC test, however, established the necessity to rebake the electrodes before use. Lamellar tearing tests carried out using full-thickness plates under three welding conditions showed no incidence of lamellar tearing upon visual examination, ultrasonic inspection, and four-section macroexamination. Lamellar tearing tests were repeated using machined plates, such that the central segregated band located at the midthickness of the plate corresponded to the heat-affected zone (HAZ) of the weld. Only in one (no rebake, heat input: 14.2 kj cm-1, weld restraint load: 42 kg mm-2) of the eight samples tested was lamellar tearing observed. This was probably accentuated due to the combined effects of the presence of localized pockets of a hard phase (bainite) and a high hydrogen level (unbaked electrodes) in the weld joint. Optimal welding conditions were formulated based on the above tests. The weld joint was subjected to extensive tests and found to exhibit excellent strength (tensile strength: 56.8 kg mm-2, or 557 MPa), and low temperature impact toughness (7.4 and 4.5 kg-m at-20 °C for weld metal, WM, and HAZ) properties. Crack tip opening displacement tests carried out for the WM and HAZ resulted in δm values 0.36 and 0.27 mm, respectively, which indicates adequate resistance to brittle fracture.

  13. Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive.

    PubMed

    Topham, Nathan; Wang, Jun; Kalivoda, Mark; Huang, Joyce; Yu, Kuei-Min; Hsu, Yu-Mei; Wu, Chang-Yu; Oh, Sewon; Cho, Kuk; Paulson, Kathleen

    2012-03-01

    Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 μg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium. PMID:22104317

  14. Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive.

    PubMed

    Topham, Nathan; Wang, Jun; Kalivoda, Mark; Huang, Joyce; Yu, Kuei-Min; Hsu, Yu-Mei; Wu, Chang-Yu; Oh, Sewon; Cho, Kuk; Paulson, Kathleen

    2012-03-01

    Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 μg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium.

  15. The Effect of Constant and Pulsed Current Gas Tungsten Arc Welding on Joint Properties of 2205 Duplex Stainless Steel to 316L Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Neissi, R.; Shamanian, M.; Hajihashemi, M.

    2016-05-01

    In this study, dissimilar 316L austenitic stainless steel/2205 duplex stainless steel (DSS) joints were fabricated by constant and pulsed current gas tungsten arc welding process using ER2209 DSS as a filler metal. Microstructures and joint properties were characterized using optical and electron scanning microscopy, tensile, Charpy V-notch impact and micro-hardness tests, and cyclic polarization measurements. Microstructural observations confirmed the presence of chromium nitride and delta ferrite in the heat-affected zone of DSS and 316L, respectively. In addition, there was some deviation in the austenite/ferrite ratio of the surface welding pass in comparison to the root welding pass. Besides having lower pitting potential, welded joints produced by constant current gas tungsten arc welding process, consisted of some brittle sigma phase precipitates, which resulted in some impact energy reduction. The tensile tests showed high tensile strength for the weld joints in which all the specimens were broken in 316L base metal.

  16. Study of the effect of low-power pulse laser on arc plasma and magnesium alloy target in hybrid welding by spectral diagnosis technique

    NASA Astrophysics Data System (ADS)

    Liu, Liming; Hao, Xinfeng

    2008-10-01

    In order to study the effect of laser pulses on arc plasma and target metal in the hybrid welding process, the spectra of the plasmas in the welding process of magnesium alloys are analysed in this paper. The acquisition system of plasma spectra is set up and the spectral lines of welding plasma are acquired. Compared with tungsten-inert gas (TIG) welding, the intensities of the spectral lines of magnesium increase sharply while those of Ar decrease for strong evaporation and ionization of magnesium alloys in low-power laser/arc hybrid welding. The electron temperature and density are estimated by the Boltzmann plot method and the Stark broadening effect. The result shows that the electron temperature of arc plasma in the hybrid welding process is much lower than that in TIG welding, especially in the laser beam-affected zone. In contrast, the electron density of the plasma is enhanced. The influences of laser parameters on electron temperature are also studied. The changes in electron temperature and density indicate that the effect of laser pulse on the target metal is the dominant factor influencing the electron temperature and density in low-power laser/arc hybrid welding.

  17. Virtual Welded-Joint Design Integrating Advanced Materials and Processing Technologies

    SciTech Connect

    Yang, Z.; Dong, P.; Liu, S.; Babu, S.; Olson, G.; DebRoy, T.

    2005-04-15

    The primary goal of this project is to increase the fatigue life of a welded-joint by 10 times and to reduce energy use by 25% through product performance and productivity improvements using an integrated modeling approach. The fatigue strength of a welded-joint is currently the bottleneck to design high performance and lightweight welded structures using advanced materials such as high strength steels. In order to achieve high fatigue strength in a welded-joint it is necessary to manage the weld bead shape for lower stress concentration, produce preferable residual stress distribution, and obtain the desired microstructure for improved material toughness and strength. This is a systems challenge that requires the optimization of the welding process, the welding consumable, the base material, as well as the structure design. The concept of virtual welded-joint design has been proposed and established in this project. The goal of virtual welded-joint design is to develop a thorough procedure to predict the relationship of welding process, microstructure, property, residual stress, and the ultimate weld fatigue strength by a systematic modeling approach. The systematic approach combines five sub-models: weld thermal-fluid model, weld microstructure model, weld material property model, weld residual stress model, and weld fatigue model. The systematic approach is thus based on interdisciplinary applied sciences including heat transfer, computational fluid dynamics, materials science, engineering mechanics, and material fracture mechanics. The sub-models are based on existing models with further development. The results from modeling have been validated with critical experiments. The systematic modeling approach has been used to design high fatigue resistant welds considering the combined effects of weld bead geometry, residual stress, microstructure, and material property. In particular, a special welding wire has been developed in this project to introduce

  18. 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.

  19. The ultrasonic characteristics of high frequency modulated arc and its application in material processing.

    PubMed

    He, Longbiao; Yang, Ping; Li, Luming; Wu, Minsheng

    2014-12-01

    To solve the difficulty of introducing traditional ultrasonic transducers to welding molten pool, high frequency current is used to modulate plasma arc and ultrasonic wave is excited successfully. The characteristics of the excited ultrasonic field are studied. The results show that the amplitude-frequency response of the ultrasonic emission is flat. The modulating current is the main factor influencing the ultrasonic power and the sound pressure depends on the variation of arc plasma stream force. Experimental study of the welding structure indicates grain refinement by the ultrasonic emission of the modulated arc and the test results showed there should be an energy region for the arc ultrasonic to get best welding joints. PMID:25001053

  20. The distinctive feature of weld joints structure by adding the nanomodifying to the weld pool

    NASA Astrophysics Data System (ADS)

    Shlyakhova, Galina; Danilov, Vladimir; Kuznetsov, Maxim; Zernin, Evgeny; Kartashov, Evgeny

    2015-10-01

    The experimental studies were carried on for the test samples of welds of the steel 12X18H10T; the results are presented. The effect produced by the nanostructured modifying powders added to the weld pool on the quality of weld joints was examined. The weld joints were obtained by arc welding in argon atmosphere using consumable electrode. Due to the weld pool modification, the dendrite size was found to decrease and a more equilibrium microstructure would form in the weld material.

  1. Laser Transmission Welding of CFRTP Using Filler Material

    NASA Astrophysics Data System (ADS)

    Berger, Stefan; Schmidt, Michael

    In the automotive industry the increasing environmental awareness is reflected through consistent lightweight construction. Especially the use of carbon fiber reinforced thermoplastics (CFRTP) plays an increasingly important role. Accordingto the material substitution, the demand for adequate joining technologies is growing. Therefore, laser transmission welding with filler material provides a way to combine two opaque joining partners by using process specific advantages of the laser transmission welding process. After introducing the new processing variant and the used experimental setup, this paper investigates the process itselfand conditions for a stable process. The influence of the used process parameters on weld quality and process stability is characterized by tensile shear tests. The successfully performed joining of PA 6 CF 42 organic sheets using natural PA 6 as filler material underlines the potential of the described joining method for lightweight design and other industrial applications.

  2. Investigation in the use of plasma arc welding and alternative feedstock delivery method in additive manufacture

    NASA Astrophysics Data System (ADS)

    Alhuzaim, Abdullah F.

    The work conducted for this thesis was to investigate the use of plasma arc welding (PAW) and steel shot as a means of additive manufacturing. A robotic PAW system and automatic shot feeder were used to manufacture linear walls approximately 100 mm long by 7 mm wide and 20 mm tall. The walls were built, layer-by-layer, on plain carbon steel substrate by adding individual 2.5 mm diameter plain carbon steel shot. Each layer was built, shot-by-shot, using a pulse of arc current to form a molten pool on the deposit into which each shot was deposited and melted. The deposition rate, a measure of productivity, was approximately 50 g/hour. Three walls were built using the same conditions except for the deposit preheat temperature prior to adding each new layer. The deposit preheat temperature was controlled by allowing the deposit to cool after each layer for an amount of time called the inter-layer wait time. The walls were sectioned and grain size and hardness distribution were measured as a function of wall height. The results indicated that, for all specimens, deposit grain size increased and hardness decreased as wall height increased. Furthermore, average grain size decreased and hardness increased as interlayer wait time increased. An analytical heat flow model was developed to study the influence of interlayer wait time on deposit temperature and therefore grain size and hardness. The results of the model indicated that as wall height increased, the rate of deposit heat removal by conduction to the substrate decreased leading to a higher preheat temperature after a fixed interlayer wait time causing grain size to increase as wall height increased. However, the model results also show that as wall height increased, the deposit surface area from which heat energy is lost via convection and radiation increased. The model also demonstrated that the use of a means of forced convection to rapidly remove heat from the deposit could be an effective way to boost

  3. 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.

  4. Numerical and experimental study of the weld joints formation in welding foam materials

    SciTech Connect

    Bezginov, Roman O. E-mail: rakrekt@mail.ru; Krektuleva, Raisa A. E-mail: rakrekt@mail.ru; Mishin, Mikhail A. E-mail: rakrekt@mail.ru; Cherepanov, Oleg I. Cherepanov, Roman O.

    2014-11-14

    A numerical analysis of fusion welding of steel- and aluminum-based foam materials is carried out. The schemes of the structured and stochastic pore distribution are considered. The research results were used to conduct the experiments which confirmed the reliability of the numerical calculations.

  5. Effect of Post-Weld Heat Treatment on Mechanical and Electrochemical Properties of Gas Metal Arc-Welded 316L (X2CrNiMo 17-13-2) Stainless Steel

    NASA Astrophysics Data System (ADS)

    Muhammad, F.; Ahmad, A.; Farooq, A.; Haider, W.

    2016-08-01

    In the present research work, corrosion behavior of post-weld heat-treated (PWHT) AISI 316L (X2CrNiMo 17-13-2) specimens joined by gas metal arc welding is compared with as-welded samples by using potentiodynamic polarization technique. Welded samples were PWHT at 1323 K for 480 s and quenched. Mechanical properties, corrosion behavior and microstructures of as-welded and PWHT specimens were investigated. Microstructural studies have shown grain size refinement after PWHT. Ultimate tensile strength and yield strength were found maximum for PWHT samples. Bend test have shown that PWHT imparted ductility in welded sample. Fractographic analysis has evidenced ductile behavior for samples. Potentiodynamic polarization test was carried out in a solution composed of 1 M H2SO4 and 1 N NaCl. Corrosion rate of weld region was 127.6 mpy, but after PWHT, it was decreased to 13.12 mpy.

  6. Effect of Post-Weld Heat Treatment on Mechanical and Electrochemical Properties of Gas Metal Arc-Welded 316L (X2CrNiMo 17-13-2) Stainless Steel

    NASA Astrophysics Data System (ADS)

    Muhammad, F.; Ahmad, A.; Farooq, A.; Haider, W.

    2016-10-01

    In the present research work, corrosion behavior of post-weld heat-treated (PWHT) AISI 316L (X2CrNiMo 17-13-2) specimens joined by gas metal arc welding is compared with as-welded samples by using potentiodynamic polarization technique. Welded samples were PWHT at 1323 K for 480 s and quenched. Mechanical properties, corrosion behavior and microstructures of as-welded and PWHT specimens were investigated. Microstructural studies have shown grain size refinement after PWHT. Ultimate tensile strength and yield strength were found maximum for PWHT samples. Bend test have shown that PWHT imparted ductility in welded sample. Fractographic analysis has evidenced ductile behavior for samples. Potentiodynamic polarization test was carried out in a solution composed of 1 M H2SO4 and 1 N NaCl. Corrosion rate of weld region was 127.6 mpy, but after PWHT, it was decreased to 13.12 mpy.

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

    PubMed

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

    2014-09-01

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

  8. Fracture properties of a neutron-irradiated stainless steel submerged arc weld cladding overlay

    SciTech Connect

    Corwin, W.R.; Berggren, R.G.; Nanstad, R.K.

    1984-01-01

    The ability of stainless steel cladding to increase the resistance of an operating nuclear reactor pressure vessel to extension of surface flaws depends greatly on the properties of the irradiated cladding. Therefore, weld overlay cladding irradiated at temperatures and fluences relevant to power reactor operation was examined. The cladding was applied to a pressure vessel steel plate by the submerged arc, single-wire, oscillating-electrode method. Three layers of cladding provided a thickness adequate for fabrication of test specimens. The first layer was type 309, and the upper two layers were type 308 stainless steel. The type 309 was diluted considerably by excessive melting of the base plate. Specimens were taken from near the base plate-cladding interface and also from the upper layers. Charpy V-notch and tensile specimens were irradiated at 288/sup 0/C to a fluence of 2 x 10/sup 23/ neutrons/m/sup 2/ (>1 MeV). 10 refs., 16 figs., 4 tabs.

  9. 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

  10. In-Situ Phase Mapping and Direct Observations of Phase Transformations During Arc Welding of 1045 Steel

    SciTech Connect

    Elmer, J; Palmer, T

    2005-09-13

    In-situ Spatially Resolved X-Ray Diffraction (SRXRD) experiments were performed during gas tungsten arc (GTA) welding of AISI 1045 C-Mn steel. Ferrite ({alpha}) and austenite ({gamma}) phases were identified and quantified in the weld heat-affected zone (HAZ) from the real time x-ray diffraction data. The results were compiled along with weld temperatures calculated using a coupled thermal fluids weld model to create a phase map of the HAZ. This map shows the {alpha} {yields} {gamma} transformation taking place during weld heating and the reverse {gamma} {yields} {alpha} transformation taking place during weld cooling. Superheating is required to complete the {alpha} {yields} {gamma} phase transformation, and the amount of superheat above the A3 temperature was shown to vary with distance from the centerline of the weld. Superheat values as high as 250 C above the A3 temperature were observed at heating rates of 80 C/s. The SRXRD experiments also revealed details about the {gamma} phase not observable by conventional techniques, showing that {gamma} is present with two distinct lattice parameters as a result of inhomogeneous distribution of carbon and manganese in the starting pearlitic/ferritic microstructure. During cooling, the reverse {gamma} {yields} {alpha} phase transformation was shown to depend on the HAZ location. In the fine grained region of the HAZ, at distances greater than 2 mm from the fusion line, the {gamma} {yields} {alpha} transformation begins near the A3 temperature and ends near the A1 temperature. In this region of the HAZ where the cooling rates are below 40 C/s, the transformation occurs by nucleation and growth of pearlite. For HAZ locations closer to the fusion line, undercoolings of 200 C or more below the A1 temperature are required to complete the {gamma} {yields} {alpha} transformation. In this region of the HAZ, grain growth coupled with cooling rates in excess of 50 C/s causes the transformation to occur by a bainitic mechanism.

  11. 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…

  12. Fundamental Study of Material Flow in Friction Stir Welds

    NASA Technical Reports Server (NTRS)

    Reynolds, Anthony P.

    1999-01-01

    The presented research project consists of two major parts. First, the material flow in solid-state, friction stir, butt-welds as been investigated using a marker insert technique. Changes in material flow due to welding parameter as well as tool geometry variations have been examined for different materials. The method provides a semi-quantitative, three-dimensional view of the material transport in the welded zone. Second, a FSW process model has been developed. The fully coupled model is based on fluid mechanics; the solid-state material transport during welding is treated as a laminar, viscous flow of a non-Newtonian fluid past a rotating circular cylinder. The heat necessary for the material softening is generated by deformation of the material. As a first step, a two-dimensional model, which contains only the pin of the FSW tool, has been created to test the suitability of the modeling approach and to perform parametric studies of the boundary conditions. The material flow visualization experiments agree very well with the predicted flow field. Accordingly, material within the pin diameter is transported only in the rotation direction around the pin. Due to the simplifying assumptions inherent in the 2-D model, other experimental data such as forces on the pin, torque, and weld energy cannot be directly used for validation. However, the 2-D model predicts the same trends as shown in the experiments. The model also predicts a deviation from the "normal" material flow at certain combinations of welding parameters, suggesting a possible mechanism for the occurrence of some typical FSW defects. The next step has been the development of a three-dimensional process model. The simplified FSW tool has been designed as a flat shoulder rotating on the top of the workpiece and a rotating, cylindrical pin, which extends throughout the total height of the flow domain. The thermal boundary conditions at the tool and at the contact area to the backing plate have been varied

  13. Imaging The Leading Edge Of A Weld

    NASA Technical Reports Server (NTRS)

    Mcgee, William F.; Rybicki, Daniel J.

    1994-01-01

    Proposed optical system integrated into plasma arc welding torch provides image of leading edge of weld pool and welding-arc-initiation point. Welding torch aligned better with joint. System includes coherent bundle of optical fibers and transparent cup.

  14. Improvement of localised corrosion resistance of AISI 2205 Duplex Stainless Steel joints made by gas metal arc welding under electromagnetic interaction of low intensity

    NASA Astrophysics Data System (ADS)

    García-Rentería, M. A.; López-Morelos, V. H.; García-Hernández, R.; Dzib-Pérez, L.; García-Ochoa, E. M.; González-Sánchez, J.

    2014-12-01

    The resistance to localised corrosion of AISI 2205 duplex stainless steel plates joined by Gas Metal Arc Welding (GMAW) under the effect of electromagnetic interaction of low intensity (EMILI) was evaluated with sensitive electrochemical methods. Welds were made using two shielding gas mixtures: 98% Ar + 2% O2 (M1) and 97% Ar + 3% N2 (M2). Plates were welded under EMILI using the M1 gas with constant welding parameters. The modified microstructural evolution in the high temperature heat affected zone and at the fusion zone induced by application of EMILI during welding is associated with the increase of resistance to localised corrosion of the welded joints. Joints made by GMAW using the shielding gas M2 without the application of magnetic field presented high resistance to general corrosion but high susceptibility to undergo localised attack.

  15. Laser micro welding of copper and aluminium using filler materials

    NASA Astrophysics Data System (ADS)

    Esser, Gerd; Mys, Ihor; Schmidt, Michael H.

    2004-10-01

    The most evident trend in electronics production is towards miniaturization. Regarding the materials involved, another trend can be observed: intelligent combinations of different materials. One example is the combination of copper and aluminium. Copper is the material of choice for electronic packaging applications due to its superior electrical and thermal conductivity. On the other hand, aluminium offers technical and economical advantages with respect to cost and component weight -- still providing thermal and electrical properties acceptable for numerous applications. Especially for high volume products, the best solution often seems to be a combination of both materials. This fact raises the question of joining copper and aluminium. With respect to miniaturization laser micro welding is a very promising joining technique. Unfortunately, the metallurgical incompatibility of copper and aluminium easily results in the formation of brittle intermetallic phases and segregations during laser welding, thus generating an unacceptable quality of the joints. This paper presents investigations on enhancing the quality during laser micro welding of copper and aluminium for applications in electronics production. In order to eliminate the formation of brittle intermetallic phases, the addition of a filter material in form of a foil has been investigated. It can be shown that the addition of pure metals such as nickel and especially silver significantly reduces the occurrence of brittle phases in the joining area and therefore leads to an increase in welding quality. The proper control of the volume fractions of copper, aluminium and filler material in the melting zone helps to avoid materials segregation and reduces residual stress, consequently leading to a reduction of crack affinity and a stabilization of the mechanical and electrical properties.

  16. Evaluation of human exposure to complex waveform magnetic fields generated by arc-welding equipment according to European safety standards.

    PubMed

    Zoppetti, Nicola; Bogi, Andrea; Pinto, Iole; Andreuccetti, Daniele

    2015-02-01

    In this paper, a procedure is described for the assessment of human exposure to magnetic fields with complex waveforms generated by arc-welding equipment. The work moves from the analysis of relevant guidelines and technical standards, underlining their strengths and their limits. Then, the procedure is described with particular attention to the techniques used to treat complex waveform fields. Finally, the procedure is applied to concrete cases encountered in the workplace. The discussion of the results highlights the critical points in the procedure, as well as those related to the evolution of the technical and exposure standards.

  17. Effect of Load Range on Probabilistic Fatigue Crack Growth Resistance in Flux Cored Arc Welded Api 2w GR. Steel

    NASA Astrophysics Data System (ADS)

    Kim, Seon-Jin; Sohn, Sang-Hoon; Sohn, Hye-Jeong

    The aim of this paper is to investigate the effects of the load range on the spatial variation of fatigue crack growth resistance in three different zones, WM, HAZ and BM for flux cored arc welded API 2W Gr. 50 steel using the stochastic model based on reliability theory. Experimental fatigue crack growth tests were performed on ASTM standard CT specimens. The results indicates that the load range has strong dependency on probabilistic fatigue crack growth for the three different zones WM, HAZ and BM, and also the spatial variation of fatigue crack growth resistance.

  18. Evaluation of human exposure to complex waveform magnetic fields generated by arc-welding equipment according to European safety standards.

    PubMed

    Zoppetti, Nicola; Bogi, Andrea; Pinto, Iole; Andreuccetti, Daniele

    2015-02-01

    In this paper, a procedure is described for the assessment of human exposure to magnetic fields with complex waveforms generated by arc-welding equipment. The work moves from the analysis of relevant guidelines and technical standards, underlining their strengths and their limits. Then, the procedure is described with particular attention to the techniques used to treat complex waveform fields. Finally, the procedure is applied to concrete cases encountered in the workplace. The discussion of the results highlights the critical points in the procedure, as well as those related to the evolution of the technical and exposure standards. PMID:24936022

  19. Arc Plasma Synthesis of Nanostructured Materials: Techniques and Innovations

    SciTech Connect

    Das, A. K.; Bhoraskar, S. V.; Kakati, M.; Karmakar, Soumen

    2008-10-23

    Arc plasma aided synthesis of nanostructured materials has the potential of producing complex nano phase structures in bulk quantities. Successful implementation of this potential capability to industrial scale nano generation needs establishment of a plasma parameter control regime in terms of plasma gas, flow pattern, pressure, local temperature and the plasma fields to obtain the desired nano phase structures. However, there is a need to design innovative in situ experiments for generation of an extensive database and subsequently to correlate plasma parameters to the size, shape and phase of the generated nanostructures. The present paper reviews the various approaches utilized in the field of arc plasma nanosynthesis in general and in the authors' laboratories in particular. Simple plasma diagnostics and monitoring schemes have been used in conjunction with nano materials characterization tools to explore the possibility of controlling the size, shape, yield and phase composition of the arc generated nanostructures through plasma control. Case studies related to synthesis of AlN, Al2O3, TiO2, ZrO2, ZnO), magnetic (e.g. {gamma}-Fe2O3, Fe3O4) and single elemental materials (e.g. carbon nanotubes) are presented.

  20. Weldability Characteristics of Sintered Hot-Forged AISI 4135 Steel Produced through P/M Route by Using Pulsed Current Gas Tungsten Arc Welding

    NASA Astrophysics Data System (ADS)

    Joseph, Joby; Muthukumaran, S.; Pandey, K. S.

    2016-01-01

    Present investigation is an attempt to study the weldability characteristics of sintered hot-forged plates of AISI 4135 steel produced through powder metallurgy (P/M) route using matching filler materials of ER80S B2. Compacts of homogeneously blended elemental powders corresponding to the above steel were prepared on a universal testing machine (UTM) by taking pre-weighed powder blend with a suitable die, punch and bottom insert assembly. Indigenously developed ceramic coating was applied on the entire surface of the compacts in order to protect them from oxidation during sintering. Sintered preforms were hot forged to flat, approximately rectangular plates, welded by pulsed current gas tungsten arc welding (PCGTAW) processes with aforementioned filler materials. Microstructural, tensile and hardness evaluations revealed that PCGTAW process with low heat input could produce weldments of good quality with almost nil defects. It was established that PCGTAW joints possess improved tensile properties compared to the base metal and it was mainly attributed to lower heat input, resulting in finer fusion zone grains and higher fusion zone hardness. Thus, the present investigation opens a new and demanding field in research.

  1. Arc voltage measurements of the hyperbaric MIG process

    SciTech Connect

    Huismann, G.; Hoffmeister, H.

    1996-12-01

    As a vital part of the MIG process, the arc controls the stability of the process, the melting of the filler wire and the base material. In order to control and describe the arc behavior, it is necessary to know the voltage- current- arc length relations, or the arc characteristics. Knowledge of arc characteristics is necessary for control of the MIG process and further automation of welding systems, in particular, at hyperbaric welding. In literature, information on arc characteristics for hyperbaric open arc pulsed process is not available so far. Therefore, in the present work, arc characteristics were measured for a pressure range of 1 to 16 bar. In measuring arc voltages and arc lengths of MIG arcs, specific problems are encountered as compared to TIG arcs where the distance between the electrode and work piece can be taken as the arc length and the ohmic voltage drop in the tungsten electrode is low. The movement of the electrode in the MIG process and the deformation of the molten wire end together with weld pool fluctuations are providing a complex system. For determining the arc characteristics certain simplifications are thus required which have been applied in this work. This paper presents a new concept on measuring arc lengths and voltages in the open MIG arc.

  2. Numerical investigation of the effects of iron oxidation reactions on the fume formation mechanism in arc welding

    NASA Astrophysics Data System (ADS)

    Sanibondi, Paolo

    2015-09-01

    Fume formation during arc welding has been modelled using a stochastic approach taking into account iron oxidation reactions. The model includes the nucleation and condensation of Fe and FeO vapours, the reaction of gaseous O2 and O on the nanoparticle surface, the coagulation of the nanoparticles including a sintering time as a function of temperature and composition, assuming chemical equilibrium for species in the gaseous phase. Results suggest that fumes generated in gas metal arc welding with oxidizing shielding mixtures are composed of aggregates of primary particles that are nucleated from gas-phase FeO and further oxidized to Fe3O4 and Fe2O3 in the liquid and solid phase, respectively. The composition of the fumes at the end of the formation process depends on the relative initial concentration of Fe and O2 species in the gas mixture and on the diameter of the primary particles that compose the aggregates: as the oxidation reactions are driven by deposition of oxygen on nanoparticle surface, the oxidation of larger particles is slower than that of smaller particles because of their lower surface to volume ratio. Solid-state diffusion is limiting the oxidation process at temperatures lower than 1500 K, inducing the formation of not fully oxidized particles composed of Fe3O4.

  3. Multifocal electroretinogram and Optical Coherence tomography spectral-domain in arc welding macular injury: a case report

    PubMed Central

    2011-01-01

    Background the purpose of this study was to report a binocular photic retinal injury induced by plasma arc welding and the follow-up after treatment with vitamin supplements for a month. In our study, we used different diagnostic tools such as fluorescein angiography (FA), optical coherence tomography (OCT) and multifocal electroretinogram (mfERG). Case presentation in the first visit after five days from arc welding injury in the left eye (LE) the visual acuity was 0.9 and 1.0 in the right eye (RE). FA was normal in both eyes. OCT in the left eye showed normal profile and normal reflectivity and one month later, a hyperreflectivity appeared in the external limiting membrane (ELM). The mfERG signal in the LE was 102.30 nV/deg2 five days after the injury and 112.62 nV/deg2 after one month and in the RE respectively 142.70 nV/deg2 and 159.46 nV/deg2. Conclusions in cases of retinal photo injury it is important for the ophthalmologist to evaluate tests such as OCT and the mfERG in the diagnosis and follow-up of the patient because the recovery of visual acuity cannot exclude the persistence of phototoxic damage charged to the complex inner-outer segment of photoreceptors. PMID:22208163

  4. Submerged Arc Stainless Steel Strip Cladding—Effect of Post-Weld Heat Treatment on Thermal Fatigue Resistance

    NASA Astrophysics Data System (ADS)

    Kuo, I. C.; Chou, C. P.; Tseng, C. F.; Lee, I. K.

    2009-03-01

    Two types of martensitic stainless steel strips, PFB-132 and PFB-131S, were deposited on SS41 carbon steel substrate by a three-pass submerged arc cladding process. The effects of post-weld heat treatment (PWHT) on thermal fatigue resistance and hardness were evaluated by thermal fatigue and hardness testing, respectively. The weld metal microstructure was investigated by utilizing optical microscopy, scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS) and transmission electron microscopy (TEM). Results showed that, by increasing the PWHT temperature, hardness decreased but there was a simultaneous improvement in weldment thermal fatigue resistance. During tempering, carbide, such as (Fe, Cr)23C6, precipitated in the weld metals and molybdenum appeared to promote (Fe, Cr, Mo)23C6 formation. The precipitates of (Fe, Cr, Mo)23C6 revealed a face-centered cubic (FCC) structure with fine grains distributed in the microstructure, thereby effectively increasing thermal fatigue resistance. However, by adding nickel, the AC1 temperature decreased, causing a negative effect on thermal fatigue resistance.

  5. Analysis of effect of temperature gradients on surface-tension phenomena in gas-tungsten-arc welds

    SciTech Connect

    Lee, H.A.; Chien, P.S.J.

    1982-10-01

    Fluid motion directed by surface tension is considered as a contributor to heat penetration in a weld pool. The potential phenomena at the gas-liquid interface were analyzed, and the dependence of surface motion on temperature in the gas-tungsten-arc (GTA) welding process was examined. An existing heat-transfer model was used and was able to predict weld size to +- 50% of the actual value. A momentum-transfer equation was derived by considering the contribution of Lorentz force. The momentum boundary condition was developed and was able to predict the Marangoni effect. The magnitude of surface-tension-driven force is comparable to the gravitational force on one gram. An empirical approach was proposed to couple heat-transfer and momentum-transfer phenomena. A dimensional analysis identified the pertinent dimensionless groups as Reynolds, Weber, Froude, Peclet, and Power numbers and a dimensionless velocity. A simplified form of the correction was developed by combining dimensionless groups to yield a correlation with the Bond, Prandtl, and modified power numbers. Future experimental work was proposed to test the functionality of the dimensionless groups.

  6. Microstructure formation in partially melted zone during gas tungsten arc welding of AZ91 Mg cast alloy

    SciTech Connect

    Zhu Tianping Chen, Zhan W.; Gao Wei

    2008-11-15

    During gas tungsten arc (GTA) welding of AZ91 Mg cast alloy, constitutional liquid forms locally in the original interdendritic regions in the partially melted zone (PMZ). The PMZ re-solidification behaviour has not been well understood. In this study, the gradual change of the re-solidification microstructure within PMZ from base metal side to weld metal side was characterised. High cooling rate experiments using Gleeble thermal simulator were also conducted to understand the morphological change of the {alpha}-Mg/{beta}-Mg{sub 17}Al{sub 12} phase interface formed during re-solidification after partial melting. It was found that the original partially divorced eutectic structure has become a more regular eutectic phase in most of the PMZ, although close to the fusion boundary the re-solidified eutectic is again a divorced one. Proceeding the eutectic re-solidification, if the degree of partial melting is sufficiently high, {alpha}-Mg re-solidified with a cellular growth, resulting in a serrated interface between {alpha}-Mg and {alpha}-Mg/{beta}-Mg{sub 17}Al{sub 12} in the weld sample and between {alpha}-Mg and {beta}-Mg{sub 17}Al{sub 12} (fully divorced eutectic) in Gleeble samples. The morphological changes affected by the peak temperature and cooling rate are also explained.

  7. 49 CFR 178.61 - Specification 4BW welded steel cylinders with electric-arc welded longitudinal seam.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ..., adequate to prevent leakage. (4) Closure of fittings, boss or pads must be adequate to prevent leakage. (i... a maximum wall stress of 24,000 p.s.i. in the formula described in paragraph (f)(4) of this section.... (3) Longitudinal seams in shells must conform to the following: (i) Longitudinal electric-arc...

  8. 49 CFR 178.61 - Specification 4BW welded steel cylinders with electric-arc welded longitudinal seam.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ..., adequate to prevent leakage. (4) Closure of fittings, boss or pads must be adequate to prevent leakage. (i... a maximum wall stress of 24,000 p.s.i. in the formula described in paragraph (f)(4) of this section.... (3) Longitudinal seams in shells must conform to the following: (i) Longitudinal electric-arc...

  9. Remote automatic plasma arc-closure welding of a dry-storage canister for spent nuclear fuel and high-level radioactive waste

    SciTech Connect

    Sprecace, R.P.; Blankenship, W.P.

    1982-12-31

    A carbon steel storage canister has been designed for the dry encapsulation of spent nuclear fuel assemblies or of logs of vitrified high level radioactive waste. The canister design is in conformance with the requirements of the ASME Code, Section III, Division 1 for a Class 3 vessel. The canisters will be loaded and sealed as part of a completely remote process sequence to be performed in the hot bay of an experimental encapsulation facility at the Nevada Test Site. The final closure to be made is a full penetration butt weld between the canister body, a 12.75-in O.D. x 0.25-in wall pipe, and a mating semiellipsoidal closure lid. Due to a combination of design, application and facility constraints, the closure weld must be made in the 2G position (canister vertical). The plasma arc welding system is described, and the final welding procedure is described and discussed in detail. Several aspects and results of the procedure development activity, which are of both specific and general interest, are highlighted; these include: The critical welding torch features which must be exactly controlled to permit reproducible energy input to, and gas stream interaction with, the weld puddle. A comparison of results using automatic arc voltage control with those obtained using a mechanically fixed initial arc gap. The optimization of a keyhole initiation procedure. A comparison of results using an autogenous keyhole closure procedure with those obtained using a filler metal addition. The sensitivity of the welding process and procedure to variations in joint configuration and dimensions and to variations in base metal chemistry. Finally, the advantages and disadvantages of the plasma arc process for this application are summarized from the current viewpoint, and the applicability of this process to other similar applications is briefly indicated.

  10. Modeling of plasma and thermo-fluid transport in hybrid welding

    NASA Astrophysics Data System (ADS)

    Ribic, Brandon D.

    processes parameters on heat transfer, fluid flow, and plasma characteristics for arc and laser welding. However, numerical modeling of laser/GTA hybrid welding is just beginning. Arc and laser welding plasmas have been previously analyzed successfully using optical emission spectroscopy in order to better understand arc and laser plasma properties as a function of plasma radius. Variation of hybrid welding plasma properties with radial distance is not known. Since plasma properties can affect arc and laser energy absorption and weld integrity, a better understanding of the change in hybrid welding plasma properties as a function of plasma radius is important and necessary. Material composition influences welding plasma properties, arc and laser energy absorption, heat transfer, and fluid flow. The presence of surface active elements such as oxygen and sulfur can affect weld pool fluid flow and bead geometry depending upon the significance of heat transfer by convection. Easily vaporized and ionized alloying elements can influence arc plasma characteristics and arc energy absorption. The effects of surface active elements on heat transfer and fluid flow are well understood in the case of arc and conduction mode laser welding. However, the influence of surface active elements on heat transfer and fluid flow during keyhole mode laser welding and laser/arc hybrid welding are not well known. Modeling has been used to successfully analyze the influence of surface active elements during arc and conduction mode laser welding in the past and offers promise in the case of laser/arc hybrid welding. A critical review of the literature revealed several important areas for further research and unanswered questions. (1) The understanding of heat transfer and fluid flow during hybrid welding is still beginning and further research is necessary. (2) Why hybrid welding weld bead width is greater than that of laser or arc welding is not well understood. (3) The influence of arc power and

  11. Glass-ceramic materials from electric arc furnace dust.

    PubMed

    Kavouras, P; Kehagias, T; Tsilika, I; Kaimakamis, G; Chrissafis, K; Kokkou, S; Papadopoulos, D; Karakostas, Th

    2007-01-31

    Electric arc furnace dust (EAFD) was vitrified with SiO2, Na2CO3 and CaCO3 powders in an electric furnace at ambient atmosphere. Vitreous products were transformed into glass-ceramic materials by two-stage heat treatment, at temperatures determined by differential thermal analysis. Both vitreous and glass-ceramic materials were chemically stable. Wollastonite (CaSiO3) was separated from the parent matrix as the dominant crystalline phase, verified by X-ray diffraction analysis and energy dispersive spectrometry. Transmission electron microscopy revealed that wollastonite crystallizes mainly in its monoclinic form. Knoop microhardness was measured with the static indentation test method in all initial vitreous products and the microhardness values were in the region of 5.0-5.5 GPa. Devitrification resulted in glass-ceramic materials with microhardness values strongly dependent on the morphology and orientation of the separated crystal phase.

  12. Structural and mechanical properties of welded joints of reduced activation martensitic steels

    NASA Astrophysics Data System (ADS)

    Filacchioni, G.; Montanari, R.; Tata, M. E.; Pilloni, L.

    2002-12-01

    Gas tungsten arc welding and electron beam welding methods were used to realise welding pools on plates of reduced activation martensitic steels. Structural and mechanical features of these simulated joints have been investigated in as-welded and post-welding heat-treated conditions. The research allowed to assess how each welding technique affects the original mechanical properties of materials and to find suitable post-welding heat treatments. This paper reports results from experimental activities on BATMAN II and F82H mod. steels carried out in the frame of the European Blanket Project - Structural Materials Program.

  13. Design of a vision sensor for monitoring microplasma arc welding of metal bellows

    NASA Astrophysics Data System (ADS)

    Zhang, Wenzeng

    2005-02-01

    Metal bellows is one of important components for mechanical sealing. Because the seam is very thin, and its spatial position is strictly limited, it is very difficult to observe the welding seam in order to control the variables of welding in real-time, the welding quality can not usually be guaranteed under the traditional technology. A novel approach is proposed, which is able to provide an amplificatory and clear image of the micro-plasma welding seam observed from better perspective, then output the image to computer and process it so that the variables of welding can be controlled in real-time. A special optical sensor has been designed and realized according to the approach. The principle and main technologies of the sensor is described in detail. The results of applying the system in practice approved the approach is successful. The welding quality of the inner circle of metal bellows, as well as the working condition of welder has been improved after the system is applied.

  14. Student Material for Competency-Based Education Curriculum for Welding.

    ERIC Educational Resources Information Center

    Associated Educational Consultants, Inc., Pittsburgh, PA.

    This student welding competency-based education curriculum consists of six units dealing with general areas related to trade occupations and nine units covering specific aspects of working with welding equipment and performing welding operations. Topics covered in the first six units are welding opportunities, human relations, safety, basic…

  15. Virtual Welded - Joint Design Integrating Advanced Materials and Processing Technology

    SciTech Connect

    Yang, Zhishang; Ludewig, Howard W.; Babu, S. Suresh

    2005-06-30

    Virtual Welede-Joint Design, a systematic modeling approach, has been developed in this project to predict the relationship of welding process, microstructure, properties, residual stress, and the ultimate weld fatique strength. This systematic modeling approach was applied in the welding of high strength steel. A special welding wire was developed in this project to introduce compressive residual stress at weld toe. The results from both modeling and experiments demonstrated that more than 10x fatique life improvement can be acheived in high strength steel welds by the combination of compressive residual stress from the special welding wire and the desired weld bead shape from a unique welding process. The results indicate a technology breakthrough in the design of lightweight and high fatique performance welded structures using high strength steels.

  16. Welding in space and the construction of space vehicles by welding; Proceedings of the Conference, New Carrollton, MD, Sept. 24-26, 1991

    NASA Technical Reports Server (NTRS)

    1991-01-01

    The present conference discusses such topics in spacecraft welding as the NASA Long Duration Exposure Facility's evidence on material properties degradation, EVA/telerobotic construction techniques, welding of the superfluid helium on-orbit transfer flight demonstration tanks and hardware, electron-beam welding of aerospace vehicles, variable-polarity plasma arc keyhole welding of Al, aircraft experiments of low-gravity fusion welding, flash-butt welding of Al alloys, and a computer-aided handbook for space welding fabrication. Also discussed are the welded nozzle extension for Ariane launch vehicles, the existence of on-orbit cold-welding, structural materials performance in long-term space service, high-strength lightweight alloys, steels, and heat-resistant alloys for aerospace welded structures, the NASA-Goddard satellite repair program, and the uses of explosion welding and cutting in aerospace engineering.

  17. Welding in space and the construction of space vehicles by welding; Proceedings of the Conference, New Carrollton, MD, Sept. 24-26, 1991

    NASA Astrophysics Data System (ADS)

    The present conference discusses such topics in spacecraft welding as the NASA Long Duration Exposure Facility's evidence on material properties degradation, EVA/telerobotic construction techniques, welding of the superfluid helium on-orbit transfer flight demonstration tanks and hardware, electron-beam welding of aerospace vehicles, variable-polarity plasma arc keyhole welding of Al, aircraft experiments of low-gravity fusion welding, flash-butt welding of Al alloys, and a computer-aided handbook for space welding fabrication. Also discussed are the welded nozzle extension for Ariane launch vehicles, the existence of on-orbit cold-welding, structural materials performance in long-term space service, high-strength lightweight alloys, steels, and heat-resistant alloys for aerospace welded structures, the NASA-Goddard satellite repair program, and the uses of explosion welding and cutting in aerospace engineering.

  18. Saturated permeability measurements on pumice and welded-tuffaceous materials

    SciTech Connect

    Reda, D.C.; Hadley, G.R.

    1985-12-31

    An experimental apparatus was designed and built to allow water-saturated permeabilities as low as 10{sup -18} m{sup 2} to be measured on cores of diameter 5 cm and length 10 cm under steady-state flow conditions. This same apparatus can also be utilized in a transient (pressure-decay) mode in order to measure permeabilities several orders of magnitude lower than the steady-state limit. Tests were conducted on samples of pumice, fractured welded tuff, and welded tuff, representing a permeability range of seven orders of magnitude. Based on present measurements and calculations, the following results were obtained: Liquid-saturated permeability of the pumice core from Mount St. Helens was 2.76 x 10{sup -12} m{sup 2}; the corresponding Ergun constant was 4.43 x 10{sup 11} kg/m{sup 4}. The ultimate compressive strength of this material was found to be greater than 1.8 MPa, but less than 3.6 MPa; liquid-saturated permeability of the unfractured welded-tuff core was 5.6 x 10{sup -19} m{sup 2}; liquid-saturated permeability for the fractured welded-tuff core was found to decay to 2 x 10{sup -18} m{sup 2} after long-time-scale exposures to continuous-flow and applied-load conditions, independent of the initial fracture state (open vs closed); with an initially closed (naturally existing) fracture, core permeability decreased by a factor of about 2 over a 200-h test period; with an initially open fracture, core permeability decreased by a factor of about 4 under the influence of a comparable load-time history to that experienced in the natural-fracture test; final core permeability was found to be reduced by an order of magnitude from its initial level during a total 700-h test period; and the final effective hydraulic fracture aperture was calculated to be 10{sup -6} m for both tests on the fractured welded-tuff core; the final effective fracture permeability was calculated to be 10{sup -13} m{sup 2}, five orders of magnitude greater than the matrix-material prmeability

  19. CLOSURE WELDING RADIOACTIVE MATERIALS CONTAINERS AT THE DEPARTMENT OF ENERGY (DOE) HANFORD SITE

    SciTech Connect

    CANNELL, G.R.

    2006-09-01

    The Department of Energy's (DOE) responsibility for the disposition of radioactive materials has given rise to several unique welding applications. Many of these materials require packaging into containers for either Interim or long-term storage. It is not uncommon that final container fabrication, i.e., closure welding, is performed with these materials already placed into the container. Closure welding is typically performed remote to the container, and routine post-weld testing and nondestructive examination (NDE) are often times not feasible. Fluor Hanford has packaged many such materials in recent years as park of the Site's cleanup mission. In lieu of post-weld testing and NDE, the Fluor-Hanford approach has been to establish weld quality through ''upfront'' development and qualification of welding parameters, and then ensure parameter compliance during welding. This approach requires a rigor not usually afforded to typical welding development activities, and may involve statistical analysis and extensive testing, including burst, drop, sensitive leak testing, etc. This paper provides an instructive review of the development and qualification activities associated with the closure of radioactive materials containers, including a brief report on activities for closure welding research reactor, spent nuclear fuel (SNF) overpacks at the Hanford Site.

  20. Repair welding of fusion reactor components

    SciTech Connect

    Chin, B.A.

    1993-05-15

    Experiments have shown that irradiated Type 316 stainless steel is susceptible to heat-affected-zone (HAZ) cracking upon cooling when welded using the gas tungsten arc (GTA) process under lateral constraint. The cracking has been hypothesized to be caused by stress-assisted helium bubble growth and rupture at grain boundaries. This study utilized an experimental welding setup which enabled different compressive stresses to be applied to the plates during welding. Autogenous GTA welds were produced in Type 316 stainless steel doped with 256 appm helium. The application of a compressive stress, 55 MPa, during welding suppressed the previously observed catastrophic cracking. Detailed examinations conducted after welding showed a dramatic change in helium bubble morphology. Grain boundary bubble growth along directions parallel to the weld was suppressed. Results suggest that stress-modified welding techniques may be used to suppress or eliminate helium-induced cracking during joining of irradiated materials.

  1. Study on laser welding of stainless steel/copper dissimilar materials

    NASA Astrophysics Data System (ADS)

    Besnea, D.; Dontu, O.; Avram, M.; Spânu, A.; Rizescu, C.; Pascu, T.

    2016-08-01

    In this paper stainless steel/copper laser welding was investigated by controlling the processing parameters like welding speed and laser power. Welding the dissimilar materials of stainless steel and copper presents a series of problems. Differences in the physical properties of the two metals, including the melting point, thermal conductivity and thermal dilatation are the main reasons for obtaining an inappropriate laser welding bead. Particularly, the laser welding process of copper is complex because of the very high reflectivity of cooper and in almost situations it requires a specific surface pre-treatment. The main objective of the study conducted in this work was to laser weld a structure used in pressure measuring and control equipments. In order to satisfy the conditions imposed by the sensor manufacturer, the difficulty of obtaining flawless joints was represented by the very small dimensions of the parts to be welded especially of the elastic spiral thickness made of steel.

  2. High Temperature Corrosion studies on Pulsed Current Gas Tungsten Arc Welded Alloy C-276 in Molten Salt Environment

    NASA Astrophysics Data System (ADS)

    Manikandan, M.; Arivarasu, M.; Arivazhagan, N.; Puneeth, T.; Sivakumar, N.; Murugan, B. Arul; Sathishkumar, M.; Sivalingam, S.

    2016-09-01

    Alloy C-276 is widely used in the power plant environment due to high strength and corrosion in highly aggressive environment. The investigation on high- temperature corrosion resistance of the alloy C-276 PCGTA weldment is necessary for prolonged service lifetime of the components used in corrosive environments. Investigation has been carried out on Pulsed Current Gas Tungsten Arc Welding by autogenous and different filler wires (ERNiCrMo-3 and ERNiCrMo-4) under molten state of K2SO4-60% NaCl environment at 675oC under cyclic condition. Thermogravimetric technique was used to establish the kinetics of corrosion. Weight gained in the molten salt reveals a steady-state parabolic rate law while the kinetics with salt deposits displays multi-stage growth rates. PCGTA ERNiCrMo-3 shows the higher parabolic constant compared to others. The scale formed on the weldment samples upon hot corrosion was characterized by using X-ray diffraction, SEM and EDAX analysis to understand the degradation mechanisms. From the results of the experiment the major phases are identified as Cr2O3, Fe2O3, and NiCr2O4. The result showed that weld fabricated by ERNiCrMo-3 found to be more prone to degradation than base metal and ERNiCrMo-4 filler wire due to higher segregation of alloying element of Mo and W in the weldment

  3. Gas Shielding Technology for Welding and Brazing

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur J.; Gradl, Paul R.

    2012-01-01

    Welding is a common method that allows two metallic materials to be joined together with high structural integrity. When joints need to be leak-tight, light-weight, or free of contaminant-trapping seams or surface asperities, welding tends to be specified. There are many welding techniques, each with its own advantages and disadvantages. Some of these techniques include Forge Welding, Gas Tungsten Arc Welding, Friction Stir Welding, and Laser Beam Welding to name a few. Whichever technique is used, the objective is a structural joint that meets the requirements of a particular component or assembly. A key practice in producing quality welds is the use of shielding gas. This article discusses various weld techniques, quality of the welds, and importance of shielding gas in each of those techniques. Metallic bonds, or joints, are produced when metals are put into intimate contact. In the solid-state "blacksmith welding" process, now called Forge Welding (FOW), the site to be joined is pounded into intimate contact. The surfaces to be joined usually need to be heated to make it easier to deform the metal. The surfaces are sprinkled with a flux to melt surface oxides and given a concave shape so that surface contamination can be squeezed out of the joint as the surfaces are pounded together; otherwise the surface contamination would be trapped in the joint and would weaken the weld. In solid-state welding processes surface oxides or other contamination are typically squeezed out of the joint in "flash."

  4. Factors Affecting the Capture Efficiency of a Fume Extraction Torch for Gas Metal Arc Welding.

    PubMed

    Bonthoux, Francis

    2016-07-01

    Welding fumes are classified as Group 2B 'possibly carcinogenic' and this prompts to the implementation of local exhaust ventilation (LEV). The fume extraction torch with LEV integrated into the tool is the most attractive solution but its capture efficiency is often disappointing in practice. This study assesses the main parameters affecting fume capture efficiency namely the extraction flow rate, the positioning of the suction openings on the torch, the angle of inclination of the torch to the workpiece during welding, the metal transfer modes, and the welding deposition rate. The theoretical velocity induced by suction, estimated from the extraction flow rate and the position of the suction openings, is the main parameter affecting effectiveness of the device. This is the design parameter and its value should never be <0.25 m s(-1) The angle of the torch relative to the workpiece also has a great deal of influence. To improve efficiency, work station layouts need to favour positions where the torch is held with angles closer to perpendicular (<15°). Welding with high deposition rates (>1.1g s(-1)) and spray transfer leads to low capture efficiency if induced velocities are <0.5 m s(-1) The results of the study can be used in the design of integrated on-torch extraction systems and provide information for fixing system objectives. PMID:27074798

  5. Factors Affecting the Capture Efficiency of a Fume Extraction Torch for Gas Metal Arc Welding.

    PubMed

    Bonthoux, Francis

    2016-07-01

    Welding fumes are classified as Group 2B 'possibly carcinogenic' and this prompts to the implementation of local exhaust ventilation (LEV). The fume extraction torch with LEV integrated into the tool is the most attractive solution but its capture efficiency is often disappointing in practice. This study assesses the main parameters affecting fume capture efficiency namely the extraction flow rate, the positioning of the suction openings on the torch, the angle of inclination of the torch to the workpiece during welding, the metal transfer modes, and the welding deposition rate. The theoretical velocity induced by suction, estimated from the extraction flow rate and the position of the suction openings, is the main parameter affecting effectiveness of the device. This is the design parameter and its value should never be <0.25 m s(-1) The angle of the torch relative to the workpiece also has a great deal of influence. To improve efficiency, work station layouts need to favour positions where the torch is held with angles closer to perpendicular (<15°). Welding with high deposition rates (>1.1g s(-1)) and spray transfer leads to low capture efficiency if induced velocities are <0.5 m s(-1) The results of the study can be used in the design of integrated on-torch extraction systems and provide information for fixing system objectives.

  6. Factors Affecting the Capture Efficiency of a Fume Extraction Torch for Gas Metal Arc Welding

    PubMed Central

    Bonthoux, Francis

    2016-01-01

    Welding fumes are classified as Group 2B ‘possibly carcinogenic’ and this prompts to the implementation of local exhaust ventilation (LEV). The fume extraction torch with LEV integrated into the tool is the most attractive solution but its capture efficiency is often disappointing in practice. This study assesses the main parameters affecting fume capture efficiency namely the extraction flow rate, the positioning of the suction openings on the torch, the angle of inclination of the torch to the workpiece during welding, the metal transfer modes, and the welding deposition rate. The theoretical velocity induced by suction, estimated from the extraction flow rate and the position of the suction openings, is the main parameter affecting effectiveness of the device. This is the design parameter and its value should never be <0.25 m s−1. The angle of the torch relative to the workpiece also has a great deal of influence. To improve efficiency, work station layouts need to favour positions where the torch is held with angles closer to perpendicular (<15°). Welding with high deposition rates (>1.1g s−1) and spray transfer leads to low capture efficiency if induced velocities are <0.5 m s−1. The results of the study can be used in the design of integrated on-torch extraction systems and provide information for fixing system objectives. PMID:27074798

  7. INERT GAS SHIELD FOR WELDING

    DOEpatents

    Jones, S.O.; Daly, F.V.

    1958-10-14

    S>An inert gas shield is presented for arc-welding materials such as zirconium that tend to oxidize rapidly in air. The device comprises a rectangular metal box into which the welding electrode is introduced through a rubber diaphragm to provide flexibility. The front of the box is provided with a wlndow having a small hole through which flller metal is introduced. The box is supplied with an inert gas to exclude the atmosphere, and with cooling water to promote the solidification of the weld while in tbe inert atmosphere. A separate water-cooled copper backing bar is provided underneath the joint to be welded to contain the melt-through at the root of the joint, shielding the root of the joint with its own supply of inert gas and cooling the deposited weld metal. This device facilitates the welding of large workpieces of zirconium frequently encountered in reactor construction.

  8. Experimental Study of the Influence of Gassing Material on Blow Open Force and Arc Motion

    NASA Astrophysics Data System (ADS)

    Li, Xingwen; Chen, Degui; Liu, Hongwu; Shi, Zongqian; Wang, Jianhua

    2007-12-01

    The study of arc behavior is important to understand the dynamic phenomena concerning the interruption process in a variety of switching devices. This paper is devoted to investigate the influence of gassing material on blow open force and arc motion. To one double-breaker model, measuring the arc current, voltage and force acting on the moving conductor, the characteristics of the ratio of the emerging blow open force over arc power FB/(ui) could be obtained. With the help of a 2-D optical fiber measurement system, to one arc chamber model, arc motion behavior was measured, too. It is demonstrated that, with the action of gassing material, FB/(ui) will increase 2.5 times, and the arc will enter the splitter plates much easier.

  9. Influence of the Tool Shoulder Contact Conditions on the Material Flow During Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Doude, Haley R.; Schneider, Judy A.; Nunes, Arthur C.

    2014-09-01

    Friction stir welding (FSWing) is a solid-state joining process of special interest in joining alloys that are traditionally difficult to fusion weld. In order to optimize the process, various numeric modeling approaches have been pursued. Of importance to furthering modeling efforts is a better understanding of the contact conditions between the workpiece and the weld tool. Both theoretical and experimental studies indicate the contact conditions between the workpiece and weld tool are unknown, possibly varying during the FSW process. To provide insight into the contact conditions, this study characterizes the material flow in the FSW nugget by embedding a lead (Pb) wire that melted at the FSWing temperature of aluminum alloy 2195. The Pb trace provided evidence of changes in material flow characteristics which were attributed to changes in the contact conditions between the weld tool and workpiece, as driven by temperature, as the tool travels the length of a weld seam.

  10. Direct Observations of Austenite, Bainite and Martensite Formation During Arc Welding of 1045 Steel using Time Resolved X-Ray Diffraction

    SciTech Connect

    Elmer, J; Palmer, T; Babu, S; Zhang, W; DebRoy, T

    2004-02-17

    In-situ Time Resolved X-Ray Diffraction (TRXRD) experiments were performed during stationary gas tungsten arc (GTA) welding of AISI 1045 C-Mn steel. These synchrotron-based experiments tracked, in real time, phase transformations in the heat-affected zone of the weld under rapid heating and cooling conditions. The diffraction patterns were recorded at 100 ms intervals, and were later analyzed using diffraction peak profile analysis to determine the relative fraction of ferrite ({alpha}) and austenite ({gamma}) phases in each diffraction pattern. Lattice parameters and diffraction peak widths were also measured throughout the heating and cooling cycle of the weld, providing additional information about the phases that were formed. The experimental results were coupled with a thermofluid weld model to calculate the weld temperatures, allowing time-temperature transformation kinetics of the {alpha} {yields} {gamma} phase transformation to be evaluated. During heating, complete austenitization was observed in the heat affected zone of the weld and the kinetics of the {alpha} {yields} {gamma} phase transformation were modeled using a Johnson-Mehl-Avrami (JMA) approach. The results from the 1045 steel weld were compared to those of a 1005 low carbon steel from a previous study. Differences in austenitization rates of the two steels were attributed to differences in the base metal microstructures, particularly the relative amounts of pearlite and the extent of the allotriomorphic ferrite phase. During weld cooling, the austenite transformed to a mixture of bainite and martensite. In situ diffraction was able to distinguish between these two non-equilibrium phases based on differences in their lattice parameters and their transformation rates, resulting in the first real time x-ray diffraction observations of bainite and martensite formation made during welding.

  11. Relation between biomarkers in exhaled breath condensate and internal exposure to metals from gas metal arc welding.

    PubMed

    Hoffmeyer, Frank; Raulf-Heimsoth, Monika; Weiss, Tobias; Lehnert, Martin; Gawrych, Katarzyna; Kendzia, Benjamin; Harth, Volker; Henry, Jana; Pesch, Beate; Brüning, Thomas

    2012-06-01

    Concerning possible harmful components of welding fumes, besides gases and quantitative aspects of the respirable welding fumes, particle-inherent metal toxicity has to be considered.The objective of this study was to investigate the effect markers leukotriene B4 (LTB4),prostaglandin E2 (PGE2) and 8-isoprostane (8-Iso PGF2α) as well as the acid–base balance(pH) in exhaled breath condensate (EBC) of 43 full-time gas metal arc welders (20 smokers) in relation to welding fume exposure. We observed different patterns of iron, chromium and nickel in respirable welding fumes and EBC. Welders with undetectable chromium in EBC(group A, n = 24) presented high iron and nickel concentrations. In this group, higher 8-isoPGF2α and LTB4 concentrations could be revealed compared to welders with detectable chromium and low levels of both iron and nickel in EBC (group B): 8-iso PGF2α443.3 pg mL−1 versus 247.2 pg mL−1; p = 0.001 and LTB4 30.5 pg mL−1 versus 17.3 pgmL−1; p = 0.016. EBC-pH was more acid in samples of group B (6.52 versus 6.82; p = 0.011).Overall, effect markers in welders were associated with iron concentrations in EBC according to smoking habits--non-smokers/smokers: LTB4 (rs = 0.48; p = 0.02/rs = 0.21; p = 0.37),PGE2 (rs = 0.15; p = 0.59/rs = 0.47; p = 0.07), 8-iso PGF2α (rs = 0.18; p = 0.54/rs = 0.59;p = 0.06). Sampling of EBC in occupational research provides a matrix for the simultaneous monitoring of metal exposure and effects on target level. Our results suggest irritative effects in the airways of healthy welders. Further studies are necessary to assess whether these individual results might be used to identify welders at elevated risk for developing a respiratory disease. PMID:22622358

  12. Influence of vibrational treatment on thermomechanical response of material under conditions identical to friction stir welding

    SciTech Connect

    Konovalenko, Ivan S.; Konovalenko, Igor S. Kolubaev, Evgeniy A.; Dmitriev, Andrey I.; Psakhie, Sergey G.

    2015-10-27

    A molecular dynamics model was constructed to describe material loading on the atomic scale by the mode identical to friction stir welding. It was shown that additional vibration applied to the tool during the loading mode provides specified intensity values and continuous thermomechanical action during welding. An increase in additional vibration intensity causes an increase both in the force acting on the workpiece from the rotating tool and in temperature within the welded area.

  13. Fluor Hanford Nuclear Material Stabilization Project Welding Manual

    SciTech Connect

    BERKEY, J.R.

    2000-10-20

    The purpose of this section of the welding manual is to: (1) Provide a general description of the major responsibilities of the organizations involved with welding. (2) Provide general guidance concerning the application of codes related to welding. This manual contains requirements for welding for all Fluor Hanford (FH) welding operators working on the W460 Project, in the Plutonium Finishing Plant (PFP) at the U. S. Department of Energy (DOE) Hanford facilities. These procedures and any additional requirements for these joining processes can be used by all FH welding operators that are qualified. The Welding Procedure Specifications (WPS) found in this document were established from Procedure Qualification Records (PQR) qualified by FH specifically for the W460 Project. PQRs are permanent records of the initial testing and qualification program and are used to backup, and support, the WPS. The identification numbers of the supporting PQR(s) are recorded on each WPS. All PQRs are permanently stored under the supervision of the Fluor Hanford Welding Engineer (FHWE). New PQRs and WPSs will continue to be developed as necessary. The qualification of welders, welding operators and welding procedures will be performed for FH under supervision and concurrent of the FHWE. All new welding procedures to be entered in this manual or welder personnel to be added to the welder qualification database, shall be approved by the FHWE.

  14. Effect of Some Overlay Welding Regime With Longitudinal Magnetic Field on Hardness, Phase Composition And Welded Layer Wear By Arc Method With Flux Metal Wire

    NASA Astrophysics Data System (ADS)

    Nosov, D. G.; Peremitko, V. V.; Barashkin, M. H.

    2016-08-01

    The paper defines the range of overlay welding current, frequencies and induction of a longitudinal magnetic field that enhance the wear resistance of welded layer additing the flux. The conditions of their mutual influence on the process of structure formation are stated as well as the mathematical models linking the overlay welding current, frequency and induction of a longitudinal magnetic field with hardness, wear resistance and phase composition of the welded layer, the use of which will allow to determine the welding modes to provide the necessary properties of the weld metal.

  15. 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.

  16. THE NEED FOR A NEW JOINING TECHNOLOGY FOR THE CLOSURE WELDING OF RADIOACTIVE MATERIALS CONTAINERS

    SciTech Connect

    CANNELL GR; HILL BE; GRANT GJ

    2008-10-29

    One of the activities associated with cleanup throughout the Department of Energy (DOE) complex is packaging radioactive materials into storage containers. Much of this work will be performed in high-radiation environments requiring fully remote operations, for which existing, proven systems do not currently exist. These conditions demand a process that is capable of producing acceptable (defect-free) welds on a consistent basis; the need to perform weld repair, under fully-remote operations, can be extremely costly and time consuming. Current closure welding technology (fusion welding) is not well suited for this application and will present risk to cleanup cost and schedule. To address this risk, Fluor and the Pacific Northwest National Laboratory (PNNL), are proposing that a new and emerging joining technology, Friction Stir Welding (FSW), be considered for this work. FSW technology has been demonstrated in other industries (aerospace and marine) to produce near flaw-free welds on a consistent basis. FSW is judged capable of providing the needed performance for fully-remote closure welding of containers for radioactive materials for the following reasons: FSW is a solid-state process; material is not melted. As such, FSW does not produce the type of defects associated with fusion welding, e.g., solidification-induced porosity, cracking, distortion due to weld shrinkage, and residual stress. In addition, because FSW is a low-heat input process, material properties (mechanical, corrosion and environmental) are preserved and not degraded as can occur with 'high-heat' fusion welding processes. When compared to fusion processes, FSW produces extremely high weld quality. FSW is performed using machine-tool technology. The equipment is simple and robust and well-suited for high radiation, fully-remote operations compared to the relatively complex equipment associated with the fusion-welding processes. Additionally, for standard wall thicknesses of radioactive materials

  17. 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.

  18. Automatic orbital GTAW welding: Highest quality welds for tomorrow's high-performance systems

    NASA Technical Reports Server (NTRS)

    Henon, B. K.

    1985-01-01

    Automatic orbital gas tungsten arc welding (GTAW) or TIG welding is certain to play an increasingly prominent role in tomorrow's technology. The welds are of the highest quality and the repeatability of automatic weldings is vastly superior to that of manual welding. Since less heat is applied to the weld during automatic welding than manual welding, there is less change in the metallurgical properties of the parent material. The possibility of accurate control and the cleanliness of the automatic GTAW welding process make it highly suitable to the welding of the more exotic and expensive materials which are now widely used in the aerospace and hydrospace industries. Titanium, stainless steel, Inconel, and Incoloy, as well as, aluminum can all be welded to the highest quality specifications automatically. Automatic orbital GTAW equipment is available for the fusion butt welding of tube-to-tube, as well as, tube to autobuttweld fittings. The same equipment can also be used for the fusion butt welding of up to 6 inch pipe with a wall thickness of up to 0.154 inches.

  19. Structure/property relationships in multipass GMA welding of beryllium.

    SciTech Connect

    Hochanadel, P. W.; Hults, W. L.; Thoma, D. J.; Dave, V. R.; Kelly, A. M.; Pappin, P. A.; Cola, M. J.; Burgardt, P.

    2001-01-01

    Beryllium is an interesting metal that has a strength to weight ratio six times that of steel. Because of its unique mechanical properties, beryllium is used in aerospace applications such as satellites. In addition, beryllium is also used in x-ray windows because it is nearly transparent to x-rays. Joining of beryllium has been studied for decades (Ref.l). Typically joining processes include braze-welding (either with gas tungsten arc or gas metal arc), soldering, brazing, and electron beam welding. Cracking which resulted from electron beam welding was recently studied to provide structure/property relationships in autogenous welds (Ref. 2). Braze-welding utilizes a welding arc to melt filler, and only a small amount of base metal is melted and incorporated into the weld pool. Very little has been done to characterize the braze-weld in terms of the structure/property relationships, especially with reference to multipass welding. Thus, this investigation was undertaken to evaluate the effects of multiple passes on microstructure, weld metal composition, and resulting material properties for beryllium welded with aluminum-silicon filler metal.

  20. A rotating two-phase gas/liquid flow for pressure reduction in underwater plasma arc welding

    SciTech Connect

    Steinkamp, H.; Creutz, M.; Mewes, D.; Bartzsch, J.

    1994-12-31

    Plasma arc welding processes are used in off-shore industry for the construction and maintenance in the wet surrounding of underwater structures and pipelines. In greater water depth the density of the plasma gas increase because of the greater hydrostatic pressure. This causes an increase of the conductive heat losses to the wet surrounding. To keep up the energy flux to the workpiece a pressure reduction is favorable against the surrounding. To keep up the energy flux to the workpiece a pressure reduction is favorable against the surrounding. The plasma arc has to burn in a locally dry area. This requirement can be fulfilled by a rotating disc placed above the workpiece. In the gap between the lower end of the cylinder and the workpiece a rotating two-phase flow is maintained. The flow around the rotating disc is experimentally investigated. The rotating disc is placed above the surface of the workpiece which is simulated by a flat plate. Water is forced out of the cylinder due to centrifugal forces set up by the rotating disc and flat plate. The velocity distribution in the flow is measured by Laser-Doppler-Anemometry. The phase distribution in the two-phase flow in the gap is measured by local electrical probes. The static pressure in the gaseous atmosphere is reduced in comparison to the hydrostatic pressure of the surrounding water. The pressure reduction is given by the void fraction, the phase distribution and the volume flow rates of both phases in the gap as well as by the speed of revolution and the design of the disc and the work surface. Apart from the investigations on the fluid dynamics, the method to reduce the pressure was technically proved. Experiments were carried out under water with a plasma MIG welder.

  1. 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.…

  2. Welding. FOS: Fundamentals of Service.

    ERIC Educational Resources Information Center

    John Deere Co., Moline, IL.

    This manual on modern gas and arc welding is one of a series of power mechanics texts and visual aids on the servicing of automotive and off-the-road agricultural and construction equipment. Materials provide basic information with illustrations for use by vocational students and teachers as well as shop servicemen and laymen. The eight sections…

  3. [New welding processes and health effects of welding].

    PubMed

    La Vecchia, G Marina; Maestrelli, Piero

    2011-01-01

    This paper describes some of the recent developments in the control technology to enhance capability of Pulse Gas Metal Arc Welding. Friction Stir Welding (FSW) processing has been also considered. FSW is a new solid-state joining technique. Heat generated by friction at the rotating tool softens the material being welded. FSW can be considered a green and energy-efficient technique without deleterious fumes, gas, radiation, and noise. Application of new welding processes is limited and studies on health effects in exposed workers are lacking. Acute and chronic health effects of conventional welding have been described. Metal fume fever and cross-shift decline of lung function are the main acute respiratory effects. Skin and eyes may be affected by heat, electricity and UV radiations. Chronic effects on respiratory system include chronic bronchitis, a benign pneumoconiosis (siderosis), asthma, and a possible increase in the incidence of lung cancer. Pulmonary infections are increased in terms of severity, duration, and frequency among welders.

  4. Thick SS316 materials TIG welding development activities towards advanced fusion reactor vacuum vessel applications

    NASA Astrophysics Data System (ADS)

    Kumar, B. Ramesh; Gangradey, R.

    2012-11-01

    Advanced fusion reactors like ITER and up coming Indian DEMO devices are having challenges in terms of their materials design and fabrication procedures. The operation of these devices is having various loads like structural, thermo-mechanical and neutron irradiation effects on major systems like vacuum vessel, divertor, magnets and blanket modules. The concept of double wall vacuum vessel (VV) is proposed in view of protecting of major reactor subsystems like super conducting magnets, diagnostic systems and other critical components from high energy 14 MeV neutrons generated from fusion plasma produced by D-T reactions. The double walled vacuum vessel is used in combination with pressurized water circulation and some special grade borated steel blocks to shield these high energy neutrons effectively. The fabrication of sub components in VV are mainly used with high thickness SS materials in range of 20 mm- 60 mm of various grades based on the required protocols. The structural components of double wall vacuum vessel uses various parts like shields, ribs, shells and diagnostic vacuum ports. These components are to be developed with various welding techniques like TIG welding, Narrow gap TIG welding, Laser welding, Hybrid TIG laser welding, Electron beam welding based on requirement. In the present paper the samples of 20 mm and 40 mm thick SS 316 materials are developed with TIG welding process and their mechanical properties characterization with Tensile, Bend tests and Impact tests are carried out. In addition Vickers hardness tests and microstructural properties of Base metal, Heat Affected Zone (HAZ) and Weld Zone are done. TIG welding application with high thick SS materials in connection with vacuum vessel requirements and involved criticalities towards welding process are highlighted.

  5. 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…

  6. Effect of B2O3 containing fluxes on the microstructure and mechanical properties in submerged arc welded mild steel plates

    NASA Astrophysics Data System (ADS)

    Gupta, P.; Roy, J.; Rai, R. N.; Prasada Rao, A. K.; Saha, S. C.

    2016-02-01

    This paper represents a study on the effect of B2O3 additions in fluxes on the microstructure and mechanical properties of the weld metal formed during Submerged Arc Welding of Mild Steel plates. Five fluxes with about 2.5, 5, 7.5, 10 and 12.5% B2O3 were used with a low carbon electrode. Welding process parameters were kept constant for all the conditions. The microstructure of weld metal for each flux consisted mainly of acicular ferrite, polygonal ferrite, grain boundary ferrites and equiaxed pearlite. It was noted that the Vicker's hardness value was a function of boron content and shows a mixed trend. Impact Energy and Tensile Strength were increased with the increase in boron content in welds this can be attributed to relation with the higher acicular ferrite percentage. However an optimum level of toughness and tensile strength was available with 7.5% and 5% of B2O3 respectively. A qualitative comparison has also be done with fresh flux by means of full metallography and mechanically.

  7. Pressure Resistance Welding of High Temperature Metallic Materials

    SciTech Connect

    Larry Zirker; Craig Tyler

    2010-08-01

    Engineers from the Idaho National Laboratory (INL) have demonstrated an innovative method for seal or pinch welding stainless steel tubing. Sometimes a tube has fuel or contamination that must be contained, or the tube needs to be shortened or cut for handling, and the tube needs to have a guaranteed sealed weld that is both quick and easy. This technique was demonstrated in a laboratory using a resistance welding system with specially designed electrodes to ensure a tube end is seal welded or if a long tube is to be shortened, the severed ends are seal welded. The unique electrodes design is integral to achieving the sealed ends. This process could readily be adapted for robotic--remote handling or for contact handling in a glovebox or hood.

  8. Evaluation of erythemal UV effective irradiance from UV lamp exposure and the application in shield metal arc welding processing.

    PubMed

    Chang, Cheng-Ping; Liu, Hung-Hsin; Peng, Chiung-Yu; Fang, Hsin-Yu; Tsao, Ta-Ho; Lan, Cheng-Hang

    2008-04-01

    Ultraviolet radiation (UVR) exposure is known to cause potential effects such as erythema in skin. For UV-induced erythema (sunburn), the action spectrum from the Commission Internationale de l'Eclairage, International Commission on Illumination (CIE) was adopted. Erythemal UV effects from UVR lamp exposure were investigated with commercial spectroradiometry devices in this research. Three kinds of portable UV germicidal lamps with broadband UVA (BB UVA, 350-400 nm), broadband UVB (BB UVB, 280-350 nm), and narrowband UVC (NB UVC, 254 nm) wavelengths served as the UVR emission sources. An action spectrum expresses the effectiveness of radiation for assessing the hazard of UVR in the erythemal action spectrum from 250-400 nm. The UV Index (UVI) is an irradiance scale computed by multiplying the CIE erythemal irradiance integral in milliwatts per square meter by 0.04 m mW. A comprehensive approach to detecting erythemal UVR magnitude was developed to monitor the effective exposure from UV lamps. The erythemal UVR measurement was established and the exposure assessment was applied to monitor erythemal UVR magnitude from shield metal arc welding (SMAW) processing. From this study, the erythemal UVR exposures were assessed and evaluated with environmental solar simulation of the UVI exposure.

  9. Charpy toughness and tensile properties of a neutron irradiated stainless steel submerged-arc weld cladding overlay

    SciTech Connect

    Corwin, W.R.; Berggren, R.G.; Nanstad, R.K.

    1984-01-01

    The possibility of stainless steel cladding increasing the resistance of an operating nuclear reactor pressure vessel to extension of surface flaws is highly dependent upon the irradiated properties of the cladding. Therefore, weld overlay cladding irradiated at temperatures and fluences relevant to power reactor operation was examined. The cladding was applied to a pressure vessel steel plate by the submerged-arc, single-wire, oscillating electrode method. Three layers of cladding were applied to provide a cladding thickness adequate for fabrication of test specimens. The first layer was type 309, and the upper two layers were type 308 stainless steel. There was considerable dilution of the type 309 in the first layer of cladding as a result of excessive melting of the base plate. Specimens for the irradiation study were taken from near the base plate/cladding interface and also from the upper layers of cladding. Charpy V-notch and tensile specimens were irradiated at 288/sup 0/C to neutron fluences of 2 x 10/sup 23/ n/m/sup 2/ (E > 1 MeV). When irradiated, both types 308 and 309 cladding showed a 5 to 40% increase in yield strength accompanied by a slight increase in ductility in the temperature range from 25 to 288/sup 0/C. All cladding exhibited ductile-to-brittle transition behavior during impact testing.

  10. Evaluation of erythemal UV effective irradiance from UV lamp exposure and the application in shield metal arc welding processing.

    PubMed

    Chang, Cheng-Ping; Liu, Hung-Hsin; Peng, Chiung-Yu; Fang, Hsin-Yu; Tsao, Ta-Ho; Lan, Cheng-Hang

    2008-04-01

    Ultraviolet radiation (UVR) exposure is known to cause potential effects such as erythema in skin. For UV-induced erythema (sunburn), the action spectrum from the Commission Internationale de l'Eclairage, International Commission on Illumination (CIE) was adopted. Erythemal UV effects from UVR lamp exposure were investigated with commercial spectroradiometry devices in this research. Three kinds of portable UV germicidal lamps with broadband UVA (BB UVA, 350-400 nm), broadband UVB (BB UVB, 280-350 nm), and narrowband UVC (NB UVC, 254 nm) wavelengths served as the UVR emission sources. An action spectrum expresses the effectiveness of radiation for assessing the hazard of UVR in the erythemal action spectrum from 250-400 nm. The UV Index (UVI) is an irradiance scale computed by multiplying the CIE erythemal irradiance integral in milliwatts per square meter by 0.04 m mW. A comprehensive approach to detecting erythemal UVR magnitude was developed to monitor the effective exposure from UV lamps. The erythemal UVR measurement was established and the exposure assessment was applied to monitor erythemal UVR magnitude from shield metal arc welding (SMAW) processing. From this study, the erythemal UVR exposures were assessed and evaluated with environmental solar simulation of the UVI exposure. PMID:18332723

  11. Pressure Resistance Welding of High Temperature Metallic Materials

    SciTech Connect

    N. Jerred; L. Zirker; I. Charit; J. Cole; M. Frary; D. Butt; M. Meyer; K. L. Murty

    2010-10-01

    Pressure Resistance Welding (PRW) is a solid state joining process used for various high temperature metallic materials (Oxide dispersion strengthened alloys of MA957, MA754; martensitic alloy HT-9, tungsten etc.) for advanced nuclear reactor applications. A new PRW machine has been installed at the Center for Advanced Energy Studies (CAES) in Idaho Falls for conducting joining research for nuclear applications. The key emphasis has been on understanding processing-microstructure-property relationships. Initial studies have shown that sound joints can be made between dissimilar materials such as MA957 alloy cladding tubes and HT-9 end plugs, and MA754 and HT-9 coupons. Limited burst testing of MA957/HT-9 joints carried out at various pressures up to 400oC has shown encouraging results in that the joint regions do not develop any cracking. Similar joint strength observations have also been made by performing simple bend tests. Detailed microstructural studies using SEM/EBSD tools and fatigue crack growth studies of MA754/HT-9 joints are ongoing.

  12. Monitoring Weld Penetration Optically From Within Torch

    NASA Technical Reports Server (NTRS)

    Smith, Matthew A.; Gilbert, Jeffrey L.; Linsacum, Deron L.; Gutlow, David A.

    1993-01-01

    Photodetector or optical fiber leading to photodetector mounted inside gas/tungsten arc welding torch to monitor arc light reflected from oscillating surface of weld pool. Proposed optical monitoring components preserve compact profile of welding torch, maintained in fixed aim at weld-pool position at end of welding torch, and protected against bumping external objects.

  13. The effects of laser welding parameters on the microstructure of ferritic and duplex stainless steels welds

    NASA Astrophysics Data System (ADS)

    Pekkarinen, J.; Kujanpää, V.

    This study is focused to determine empirically, which microstructural changes occur in ferritic and duplex stainless steels when heat input is controlled by welding parameters. Test welds were done autogenously bead-on-plate without shielding gas using 5 kW fiber laser. For comparison, some gas tungsten arc welds were made. Used test material were 1.4016 (AISI 430) and 1.4003 (low-carbon ferritic) type steels in ferritic steels group and 1.4162 (low-alloyed duplex, LDX2101) and 1.4462 (AISI 2205) type steels in duplex steels group. Microstructural changes in welds were identified and examined using optical metallographic methods.

  14. Repair welding of fusion reactor components. Second year technical report

    SciTech Connect

    Chin, B.A.

    1993-05-15

    Experiments have shown that irradiated Type 316 stainless steel is susceptible to heat-affected-zone (HAZ) cracking upon cooling when welded using the gas tungsten arc (GTA) process under lateral constraint. The cracking has been hypothesized to be caused by stress-assisted helium bubble growth and rupture at grain boundaries. This study utilized an experimental welding setup which enabled different compressive stresses to be applied to the plates during welding. Autogenous GTA welds were produced in Type 316 stainless steel doped with 256 appm helium. The application of a compressive stress, 55 MPa, during welding suppressed the previously observed catastrophic cracking. Detailed examinations conducted after welding showed a dramatic change in helium bubble morphology. Grain boundary bubble growth along directions parallel to the weld was suppressed. Results suggest that stress-modified welding techniques may be used to suppress or eliminate helium-induced cracking during joining of irradiated materials.

  15. A Study on the Welding Characteristics of Tailor Welded Blank Metal Sheets Using GTAW and Laser Welding

    NASA Astrophysics Data System (ADS)

    Thasanaraphan, Pornsak

    In this study, a computational and experimental effort was carried out to qualitatively understand the weld pool shape, distortion and residual stress for continuous laser welding and manual pulsed gas metal arc welding. For all the welding simulations given in this dissertation, a welding specific finite element package, SYSWELD, is used. This research focuses on the welding behavior observed in light-weight metal structures known as the tailor-welded blanks, TWBs. They are a combination of two or more metal sheets with different thickness and/or different materials that are welded together in a single plane prior to forming, e.g., stamping. They made from the low carbon steel. As laser welding experiment results show, the weld pool shape at the top and bottom surface, is strongly influenced by surface tension, giving it a characteristic hourglass shape. In order to simulate the hourglass shape, a new volumetric heat source model was developed to predict the transient temperature profile and weld pool shape, including the effect of surface tension. Tailor welded blanks with different thicknesses were examined in the laser welding process. All major physical phenomena such as thermal conduction, heat radiation and convection heat losses are taken into account in the model development as well as temperature-dependant thermal and mechanical material properties. The model is validated for the case of butt joint welding of cold rolled steel sheets. The results of the numerical simulations provide temperature distributions representing the shape of the molten pool, distortion and residual stress with varying laser beam power and welding speed. It is demonstrated that the finite element simulation results are in good agreement with the experiment results. This includes the weld pool shape and sheet metal distortion. While there is no experimental data to compare directly with residual stress results, the distorted shape provides an indirect measure of the welding

  16. Military Curriculum Materials for Vocational and Technical Education. Welding High and Low Pressure Lines, 3-26.

    ERIC Educational Resources Information Center

    Ohio State Univ., Columbus. National Center for Research in Vocational Education.

    This short course in welding high and low pressure lines was adapted from military curriculum materials for use in vocational education. The course is designed to teach safety requirements for work with high and low pressure pipelines; pipe welding requirements and specifications; special pipeline repair welding applications; layout of pipe…

  17. 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.

  18. Coaxial hybrid CO2-MIG welding system and its application in welding of aluminum alloys

    NASA Astrophysics Data System (ADS)

    Zhang, Xudong; Chen, Wuzhu; Shuang, Yuanqing; Wang, Kangjian

    2005-01-01

    Hybrid laser-arc welding is becoming one of the most significant laser welding technologies in industry due to its higher welding efficiency, higher tolerance to gaps between plates, and adjustment of composition and microstructure of the weld metal. Comparing with common off axis hybrid laser-arc welding, coaxially combined laser beam and arc can provide a symmetrical circular thermal source on the workpiece surface, which is convenient for 3-D welding. This paper introduces a coaxial hybrid CO2 laser-pulsed MIG welding system and conducts experiments of welding Al-Mg alloy plates under different welding conditions. The basic physical phenomena during welding are observed and the weld bead shape (penetration depth, weld width) are measured. The results show that hybrid laser-MIG can stabilize the arc, remarkably increase the total welding efficiency and improve the quality of weld bead formation. In addition, process and control techniques for hybrid laser-MIG welding are also proposed.

  19. Residual stresses in weld overlay tubes: A finite element study

    SciTech Connect

    Taljat, B.; Zacharia, T.; Wang, X.L.; Keiser, J.R.; Feng, Z.; Jirinec, M.J.

    1997-01-03

    Residual stresses and strains in a tube with circumferential weld overlay were analyzed by the finite element (FE) method. The objective of this work was to develop and verify a FE model, to determine the magnitude and distribution of residual stresses in the weld overlay tube, and to evaluate the significance of two contributing factors to residual stress: (1) difference in material properties between tube and weld material, and (2) thermal gradients in the weld. An axisymmetric FE model was developed to simulate the circumferential two-layer welding process of alloy 625 overlay on SA210 tube. The first layer was modeled as a gas metal arc welding process with filler metal, whereas the autogenous gas tungsten arc welding process was modeled for the second layer. Neutron diffraction technique was used to experimentally determine residual elastic strains in the weld overlay tube. Comparison with the FE results shows overall good agreement. Both the experimental and FE results show high compressive stresses at the inside tube surface and high tensile stresses in the weld overlay. This suggests that weld overlay may be used to relieve tensile or produce compressive stresses at the inside tube surface, which is significant for applications where crack initiation is found at the root pass of the joining weld.

  20. Preliminary assessment of the fracture behavior of weld material in full-thickness clad beams

    SciTech Connect

    Keeney, J.A.; Bass, B.R.; McAfee, W.J.; Iskander, S.K.

    1994-10-01

    This report describes a testing program that utilizes full-thickness clad beam specimens to quantify fracture toughness for shallow cracks in material for which metallurgical conditions are prototypic of those found in reactor pressure vessels (RPVs). The beam specimens are fabricated from a section of an RPV wall (removed from a canceled nuclear plant) that includes weld, plate, and clad material. Metallurgical factors potentially influencing fracture toughness for shallow cracks in the beam specimens include material gradients due to welding and cladding applications, as well as material inhomogeneities in welded regions due to reheating in multiple weld passes. A summary of the testing program includes a description of the specimen geometry, material properties, the testing procedure, and the experimental results form three specimens. The yield strength of the weld material was determined to be 36% higher than the yield strength of the base material. An irradiation-induced increase in yield strength of the weld material could result in a yield stress that exceeds the upper limit where code curves are valid. The high yield strength for prototypic weld material may have implications for RPV structural integrity assessments. Analyses of the test data are discussed, including comparisons of measured displacements with finite-element analysis results, applications of toughness estimation techniques, and interpretations of constraint conditions implied by stress-based constraint methodologies. Metallurgical conditions in the region of the cladding heat-affected zone are proposed as a possible explanation for the lower-bound fracture toughness measured with one of the shallow-crack clad beam specimens. Fracture toughness data from the three clad beam specimens are compared with other shallow- and deep-crack uniaxial beam and cruciform data generated previously from A 533 Grade B plate material.

  1. Control of exposure to hexavalent chromium and ozone in gas metal arc welding of stainless steels by use of a secondary shield gas.

    PubMed

    Dennis, John H; French, Michael J; Hewitt, Peter J; Mortazavi, Seyed B; Redding, Christopher A J

    2002-01-01

    Previous work has demonstrated that the shield gas composition in gas metal arc welding can have a considerable effect on hexavalent chromium [Cr(VI)] concentration in the fume and on ozone concentrations near the arc. Normally a single shield gas is used. This paper describes a double shroud torch that allows used of concentric shield gases of different compositions. A solid stainless steel wire was used for welding. The double shroud torch used secondary shield gases containing small amounts of the reducing agents NO and C2H4. The Cr(VI) concentration in the fume and ozone concentration at a fixed point relative to the arc were measured and compared with results when using a single shield gas. Use of the reducing agents in secondary shielding using the double shroud torch was found to offer advantages for ozone concentration reduction compared with use in a conventional torch, but this was not found to be an advantage for reducing Cr(VI) concentrations.

  2. Gravitational effects on carbon nano-materials synthesized by arc in water.

    PubMed

    Kawanami, Osamu; Sano, Noriaki

    2009-04-01

    The "arc-in-liquid" method is a simple and inexpensive technique for the synthesis of carbon nanotubes and related nano-materials. In this paper, we report on the synthesis of carbon nanotubes by means of the arc-in-water method under microgravity and normal gravity conditions. The heat of convection and two-phase flow caused by the arc plasma are suppressed under microgravity, so the heat and fluid flow are stabilized under such conditions and a single huge bubble is generated around the electrodes. From the images captured during the experiment of the arc-in-liquid method, it can be observed that the bubble contained a layer of water vapor at the gas-liquid interface under microgravity conditions, and this layer blocked the carbon vapor reaching the liquid phase. Owing to this unique phenomenon, it was determined that the synthesis of carbon nanotubes by the arc-in-water method is strongly affected by gravity.

  3. FRACTURE STRENGTH OF DIFFERENT SOLDERED AND WELDED ORTHODONTIC JOINING CONFIGURATIONS WITH AND WITHOUT FILLING MATERIAL

    PubMed Central

    Bock, Jens Johannes; Bailly, Jacqueline; Gernhardt, Christian Ralf; Fuhrmann, Robert Andreas Werner

    2008-01-01

    The aim of this study was to compare the mechanical strength of different joints made by conventional brazing, TIG and laser welding with and without filling material. Five standardized joining configurations of orthodontic wire in spring hard quality were used: round, cross, 3 mm length, 9 mm length and 7 mm to orthodontic band. The joints were made by five different methods: brazing, tungsten inert gas (TIG) and laser welding with and without filling material. For the original orthodontic wire and for each kind of joint configuration or connecting method 10 specimens were carefully produced, totalizing 240. The fracture strengths were measured with a universal testing machine (Zwick 005). Data were analyzed by ANOVA (p=0.05) and Bonferroni post hoc test (p=0.05). In all cases, brazing joints were ruptured on a low level of fracture strength (186-407 N). Significant differences between brazing and TIG or laser welding (p<0.05, Bonferroni post hoc test) were found in each joint configuration. The highest fracture strength means were observed for laser welding with filling material and 3 mm joint length (998 N). Using filling materials, there was a clear tendency to higher mean values of fracture strength in TIG and laser welding. However, statistically significant differences were found only in the 9-mm long joints (p<0.05, Bonferroni post hoc test). In conclusion, the fracture strength of welded joints was positively influenced by the additional use of filling material. TIG welding was comparable to laser welding except for the impossibility of joining orthodontic wire with orthodontic band. PMID:19089229

  4. Fracture strength of different soldered and welded orthodontic joining configurations with and without filling material.

    PubMed

    Bock, Jens Johannes; Bailly, Jacqueline; Gernhardt, Christian Ralf; Fuhrmann, Robert Andreas Werner

    2008-01-01

    The aim of this study was to compare the mechanical strength of different joints made by conventional brazing, TIG and laser welding with and without filling material. Five standardized joining configurations of orthodontic wire in spring hard quality were used: round, cross, 3 mm length, 9 mm length and 7 mm to orthodontic band. The joints were made by five different methods: brazing, tungsten inert gas (TIG) and laser welding with and without filling material. For the original orthodontic wire and for each kind of joint configuration or connecting method 10 specimens were carefully produced, totalizing 240. The fracture strengths were measured with a universal testing machine (Zwick 005). Data were analyzed by ANOVA (p=0.05) and Bonferroni post hoc test (p=0.05). In all cases, brazing joints were ruptured on a low level of fracture strength (186-407 N). Significant differences between brazing and TIG or laser welding (p<0.05, Bonferroni post hoc test) were found in each joint configuration. The highest fracture strength means were observed for laser welding with filling material and 3 mm joint length (998 N). Using filling materials, there was a clear tendency to higher mean values of fracture strength in TIG and laser welding. However, statistically significant differences were found only in the 9-mm long joints (p<0.05, Bonferroni post hoc test). In conclusion, the fracture strength of welded joints was positively influenced by the additional use of filling material. TIG welding was comparable to laser welding except for the impossibility of joining orthodontic wire with orthodontic band. PMID:19089229

  5. Size Distribution and Estimated Respiratory Deposition of Total Chromium, Hexavalent Chromium, Manganese, and Nickel in Gas Metal Arc Welding Fume Aerosols

    PubMed Central

    Cena, Lorenzo G.; Chisholm, William P.; Keane, Michael J.; Cumpston, Amy; Chen, Bean T.

    2016-01-01

    A laboratory study was conducted to determine the mass of total Cr, Cr(VI), Mn, and Ni in 15 size fractions for mild and stainless steel gas-metal arc welding (GMAW) fumes. Samples were collected using a nano multi orifice uniform deposition impactor (MOUDI) with polyvinyl chloride filters on each stage. The filters were analyzed by inductively coupled plasma mass spectrometry (ICP-MS) and ion chromatography. Limits of detection (LODs) and quantitation (LOQs) were experimentally calculated and percent recoveries were measured from spiked metals in solution and dry, certified welding-fume reference material. The fraction of Cr(VI) in total Cr was estimated by calculating the ratio of Cr(VI) to total Cr mass for each particle size range. Expected, regional deposition of each metal was estimated according to respiratory-deposition models. The weight percent (standard deviation) of Mn in mild steel fumes was 9.2% (6.8%). For stainless steel fumes, the weight percentages were 8.4% (5.4%) for total Cr, 12.2% (6.5%) for Mn, 2.1% (1.5%) for Ni and 0.5% (0.4%) for Cr(VI). All metals presented a fraction between 0.04 and 0.6 μm. Total Cr and Ni presented an additional fraction <0.03 μm. On average 6% of the Cr was found in the Cr(VI) valence state. There was no statistical difference between the smallest and largest mean Cr(VI) to total Cr mass ratio (p-value D 0.19), hence our analysis does not show that particle size affects the contribution of Cr(VI) to total Cr. The predicted total respiratory deposition for the metal particles was ∼25%. The sites of principal deposition were the head airways (7–10%) and the alveolar region (11–14%). Estimated Cr(VI) deposition was highest in the alveolar region (14%). PMID:26848207

  6. Fracture Behaviour of Type 304LN Stainless Steel and its Welds

    SciTech Connect

    Dubey, J.S.; Chakravartty, J.K.; Singh, P.K.; Banerjee, S.

    2006-07-01

    SA312 type 304LN stainless steel material, having closer control over impurities and inclusion content, is the intended piping material in the Advanced Heavy Water Reactors. Deformation, fatigue and fracture behaviour of this material and its weldments have been characterized at ambient temperature and at 558 K. The details of the fractographic investigations and stretch zone width measurements are also discussed. The base metals shows high initiation toughness (>500 kJ/m{sup 2}) and large tearing modulus at ambient and operating temperatures. Shielded Metal Arc Welding (SMAW) weld metal shows much much reduced initiation toughness and tearing resistance in comparison to base metal and Gas Tungsten Arc Welding (GTAW) welds. This is attributed to larger density of second phase inclusions in the SMAW weld metal. SZW measurements give a good alternate estimate of the toughness of the materials. Fatigue crack growth rate in SMAW weld metal was found to be comparable to base metal at higher load ratios. (authors)

  7. Spinarc gas tungsten arc torch holder

    NASA Technical Reports Server (NTRS)

    Brace, D. F.; Crockett, J. L.

    1970-01-01

    Semiautomatic welding torch enables operator to control arc length, torch angle, and spring tension when welding small diameter aluminum tubing. Tungsten is preset for the weld to make arc initiation easier and to eliminate searching for the joint through a dark welding lens.

  8. Process modeling and parameter optimization using radial basis function neural network and genetic algorithm for laser welding of dissimilar materials

    NASA Astrophysics Data System (ADS)

    Ai, Yuewei; Shao, Xinyu; Jiang, Ping; Li, Peigen; Liu, Yang; Yue, Chen

    2015-11-01

    The welded joints of dissimilar materials have been widely used in automotive, ship and space industries. The joint quality is often evaluated by weld seam geometry, microstructures and mechanical properties. To obtain the desired weld seam geometry and improve the quality of welded joints, this paper proposes a process modeling and parameter optimization method to obtain the weld seam with minimum width and desired depth of penetration for laser butt welding of dissimilar materials. During the process, Taguchi experiments are conducted on the laser welding of the low carbon steel (Q235) and stainless steel (SUS301L-HT). The experimental results are used to develop the radial basis function neural network model, and the process parameters are optimized by genetic algorithm. The proposed method is validated by a confirmation experiment. Simultaneously, the microstructures and mechanical properties of the weld seam generated from optimal process parameters are further studied by optical microscopy and tensile strength test. Compared with the unoptimized weld seam, the welding defects are eliminated in the optimized weld seam and the mechanical properties are improved. The results show that the proposed method is effective and reliable for improving the quality of welded joints in practical production.

  9. Multiple pass and multiple layer friction stir welding and material enhancement processes

    DOEpatents

    Feng, Zhili [Knoxville, TN; David, Stan A [Knoxville, TN; Frederick, David Alan [Harriman, TN

    2010-07-27

    Processes for friction stir welding, typically for comparatively thick plate materials using multiple passes and multiple layers of a friction stir welding tool. In some embodiments a first portion of a fabrication preform and a second portion of the fabrication preform are placed adjacent to each other to form a joint, and there may be a groove adjacent the joint. The joint is welded and then, where a groove exists, a filler may be disposed in the groove, and the seams between the filler and the first and second portions of the fabrication preform may be friction stir welded. In some embodiments two portions of a fabrication preform are abutted to form a joint, where the joint may, for example, be a lap joint, a bevel joint or a butt joint. In some embodiments a plurality of passes of a friction stir welding tool may be used, with some passes welding from one side of a fabrication preform and other passes welding from the other side of the fabrication preform.

  10. Application of friction welding in petroleum and chemical engineering

    SciTech Connect

    Dzhabarov, R.D.; Fataliev, N.S.; Tkachev, Yu.A.; Timofeev, V.I.; Abdullaev, V.G.

    1995-05-01

    Welding, as a technological process, is widely practiced in modern engineering. Resistance or arc welding is most common, but these techniques are increasingly giving way to friction welding which has several advantages, namely higher labor productivity and better quality, possibility of joining diverse and poorly weldable metals and alloys, dispensing with high-grade welding materials and highly skilled welders, ecological cleanness of the process, etc. The major criterion of efficient application of friction welding is its use in large-scale manufacture of a specific equipment, whereupon the cost of the machine is recovered in a short period. That is why friction welding with creation and fabrication of specific machines was adopted by the petroleum machinery manufacture (manufacture of geological prospecting and drill pipes, pump rods of the welded design, and gate valves of high-pressure Christmas trees). By applying friction welding for the manufacture of geological prospecting and drill pipes in place of resistance butt welding, accidents during drilling due to failure of the welded joints were prevented totally. Application of friction welding for making pump rods of the welded design (with welded nipples and heads) made it possible to save costly high-strength and corrosion-resistance alloy steel to the extent of 90%. Use of friction welding in the manufacture of high-pressure gate valves with welded flanges simplifies the valve-making technology and improves the reliability of the welded joints, even at temperatures as low as -60{degrees}C. In particular, cast gate valve bodies with friction-welded side flanges were tested before their breakdown. The welded joints of the branch pipes, even though they were sharpened to reduce wall thickness, did not fail, which shows high reliability of the gate valve bodies of the welded design.

  11. 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.

  12. 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.

  13. In situ synthesis and hardness of TiC/Ti5Si3 composites on Ti-5Al-2.5Sn substrates by gas tungsten arc welding

    NASA Astrophysics Data System (ADS)

    Yan, Wen-qing; Dai, Le; Gui, Chi-bin

    2013-03-01

    TiC/Ti5Si3 composites were fabricated on Ti-5Al-2.5Sn substrates by gas tungsten arc welding (GTAW). Identification of the phases was performed using X-ray diffraction (XRD). The microstructures were analyzed using scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectrometry (EDS) and optical microscopy (OM). The Vickers hardness was measured with a micro-hardness tester. The TiC/Ti5Si3 composites were obtained in a double-layer track, and the Vickers hardness of the track increased by two to three times compared with the Ti-5Al-2.5Sn substrate.

  14. Numerical simulation of MIG type arc welding induced residual stresses and distortions in thin sheets of S235 steel

    NASA Astrophysics Data System (ADS)

    Sakri, A.; Guidara, M.; Elhalouani, F.

    2010-11-01

    This paper investigates distortions and residual stresses which are induced in butt joint of thin plates using Metal Inert Gas welding. In fact, a distribution of heat flux is implemented in finite element simulation of the welding process. Thermo-elastic-plastic finite element methods are applied to modelling the thermal and mechanical behaviour of the welded plate during the welding process. Prediction of temperature variations and heat affected zone as well as longitudinal and transverse shrinkage, angular distortion, and residual stress are obtained. Comparisons are made between numerical and experimental results on out-of-plane displacements of steel assembly.

  15. Advanced fusion welding processes, solid state joining and a successful marriage. [production of aerospace structures

    NASA Technical Reports Server (NTRS)

    Miller, F. R.

    1972-01-01

    Joining processes for aerospace systems combine fusion welding and solid state joining during production of metal structures. Detailed characteristics of electron beam welding, plasma arc welding, diffusion welding, inertia welding and weldbond processes are discussed.

  16. Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Arakere, G.; Yalavarthy, H. V.; He, T.; Yen, C.-F.; Cheeseman, B. A.

    2010-07-01

    A concise yet a fairly comprehensive overview of the friction stir welding (FSW) process is provided. This is followed by a computational investigation in which FSW behavior of a prototypical solution-strengthened and strain-hardened aluminum alloy, AA5083-H131, is modeled using a fully coupled thermo-mechanical finite-element procedure developed in our prior study. Particular attention is given to proper modeling of the welding work-piece material behavior during the FSW process. Specifically, competition and interactions between plastic-deformation and dynamic-recrystallization processes are considered to properly account for the material-microstructure evolution in the weld nugget zone. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results.

  17. Fibrogenic potential of welding fumes.

    PubMed

    Stern, R M; Pigott, G H; Abraham, J L

    1983-02-01

    A search of 3600 indexed pathology cases has disclosed pulmonary fibrosis in 29 welders. Scanning electron microscopy of biopsy material revealed macrophages laden with inorganic particulates which have characteristics compatible with welding aerosols. In order to establish a possible relationship between fibrotic reaction and welding-fume exposure, the fibrogenic potential fo some 11 different welding fumes and metallic aerosols, considered to be reference standard surrogates for the commonly used welding technologies and applications responsible for 70% of welders exposure, were screened using the Rat Peritoneal Macrophage in vitro bioassay. Only one class of fumes, that from the manual metal arc welding of stainless steel, showed distinct fibrogenic potential. This fume is, however, not common to more than four or five of the heretofore 90 cases of pulmonary fibrosis reported among welders. Thus, although insoluble Cr(VI) is probably the active fibrogen in stainless steel fumes, an etiological factor common to all fibrogenic welding exposures must be sought. It is tentatively proposed to be NO2, a potential experimental in vivo fibrogen copiously produced by certain welding processes and ubiquitous at low concentrations in the welding environment.

  18. Innovative Tools Advance Revolutionary Weld Technique

    NASA Technical Reports Server (NTRS)

    2009-01-01

    The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe

  19. Study of gas tungsten arc welding procedures for tantalum alloy T-111 (Ta-8 W-2Hf) plate

    NASA Technical Reports Server (NTRS)

    Gold, R. E.; Kesterson, R. L.

    1973-01-01

    Methods of eliminating or reducing underbread cracking in multipass GTA welds in thick T-111 plate were studied. Single V butt welds prepared using experimental filler metal compositions and standard weld procedures resulted in only moderate success in reducing underbread cracking. Subsequent procedural changes incorporating manual welding, slower weld speeds, and three or fewer fill passes resulted in crack-free single V welds only when the filler metal was free of hafnium. The double V joint design with successive fill passes on opposite sides of the joint produced excellent welds. The quality of each weld was determined metallographically since the cracking, when present, was very slight and undetectable using standard NDT techniques. Tensile and bend tests were performed on selected weldments. The inherent filler metal strength and the joint geometry determined the strength of the weldment. Hardness and electron beam microprobe traverses were made on selected specimens with the result that significant filler metal-base metal dilution as well as hafnium segregation was detected. A tentative explanation of T-111 plate underbread cracking is presented based on the intrinsic effects of hafnium in the weldment.

  20. Graphite and ablative material response to CO2 laser, carbon-arc, and xenon-arc radiation

    NASA Technical Reports Server (NTRS)

    Brewer, W. D.

    1976-01-01

    The behavior was investigated of graphite and several charring ablators in a variety of high-radiative heat-flux environments. A commercial-grade graphite and nine state-of-the-art charring ablators were subjected to various radiative environments produced by a CO2 laser and a carbon arc. Graphite was also tested in xenon-arc radiation. Heat-flux levels ranged from 10 to 47 MW/sq m. Tests were conducted in air, nitrogen, helium, and a CO2-N2 mixture which simulated the Venus atmosphere. The experimental results were compared with theoretical results obtained with a one-dimensional charring-ablator analysis and a two-dimensional subliming-ablator analysis. Neither the graphite nor the charring ablators showed significant differences in appearance or microstructure after testing in the different radiative environments. The performance of phenolic nylon and graphite was predicted satisfactorily with existing analyses and published material property data. Good agreement between experimental and analytical results was obtained by using sublimation parameters from a chemical nonequilibrium analysis of graphite sublimation. Some charring ablators performed reasonably well and could withstand radiative fluxes of the level encountered in certain planetary entries. Other materials showed excessive surface recession and/or large amounts of cracking and spalling, and appear to be unsuitable for severe radiative environments.