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%.

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

Code of Federal Regulations, 2014 CFR

2014-10-01

.... Cylinders closed in by spinning process are not authorized. (b) Authorized steel. Steel used in the.... Cylinders must be manufactured using equipment and processes adequate to ensure that each cylinder produced... seams must be of the butt welded type. Welds must be made by a machine process including automatic feed...

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

Code of Federal Regulations, 2013 CFR

2013-10-01

.... Cylinders closed in by spinning process are not authorized. (b) Authorized steel. Steel used in the.... Cylinders must be manufactured using equipment and processes adequate to ensure that each cylinder produced... seams must be of the butt welded type. Welds must be made by a machine process including automatic feed...

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

Code of Federal Regulations, 2012 CFR

2012-10-01

.... Cylinders closed in by spinning process are not authorized. (b) Authorized steel. Steel used in the.... Cylinders must be manufactured using equipment and processes adequate to ensure that each cylinder produced... seams must be of the butt welded type. Welds must be made by a machine process including automatic feed...

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.

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.

APPARATUS AND METHOD FOR WELDING END CLOSURE TO CONTAINER

DOEpatents

Frantz, C.E.; Correy, T.B.

1959-08-01

A semi-automatic apparatus is described for welding a closure to the open end of a can containing a nuclear fuel slug. An arc is struck at the center of the closure and is shifted to a region near its periphery. Then the assembly of closure, can, and fuel slug is rotated so that the peripheral region of the closure is preheated. Next the arc is shifted to the periphery itself of the closure, and the assembly is rotated so that the closure is welded to the can.

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.

Development of an improved GTA (gas tungsten arc) weld temperature monitor fixture

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hollar, D.L.

1990-05-01

An initial design weld temperature control fixture was implemented into final closure of an electronic assembly in November 1986. Use of this fixture indicated several areas that could be improved. Review of these areas with the process engineer and the weld operator provided the ideas to be incorporated into the new design Phase 2 fixture. Some primary areas of change and improvement included fixture mobility to provide better accessibility to the weld joint area, automatic timed blow cooling of the weld joint, and a feature to assure proper thermocouple placement. The resulting Phase 2 fixture design provided all of themore » essential weld temperature monitoring features in addition to several significant improvements. Technology developed during this project will pave the way to similar process monitoring of other manual gas tungsten arc (GTA) welding applications. 9 figs.« less

Prediction of Weld Penetration in FCAW of HSLA steel using Artificial Neural Networks

NASA Astrophysics Data System (ADS)

Asl, Y. Dadgar; Mostafa, N. B.; Panahizadeh R., V.; Seyedkashi, S. M. H.

2011-01-01

Flux-cored arc welding (FCAW) is a semiautomatic or automatic arc welding process that requires a continuously-fed consumable tubular electrode containing a flux. The main FCAW process parameters affecting the depth of penetration are welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed. Shallow depth of penetration may contribute to failure of a welded structure since penetration determines the stress-carrying capacity of a welded joint. To avoid such occurrences; the welding process parameters influencing the weld penetration must be properly selected to obtain an acceptable weld penetration and hence a high quality joint. Artificial neural networks (ANN), also called neural networks (NN), are computational models used to express complex non-linear relationships between input and output data. In this paper, artificial neural network (ANN) method is used to predict the effects of welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed on weld penetration depth in gas shielded FCAW of a grade of high strength low alloy steel. 32 experimental runs were carried out using the bead-on-plate welding technique. Weld penetrations were measured and on the basis of these 32 sets of experimental data, a feed-forward back-propagation neural network was created. 28 sets of the experiments were used as the training data and the remaining 4 sets were used for the testing phase of the network. The ANN has one hidden layer with eight neurons and is trained after 840 iterations. The comparison between the experimental results and ANN results showed that the trained network could predict the effects of the FCAW process parameters on weld penetration adequately.

Sensor Fusion to Estimate the Depth and Width of the Weld Bead in Real Time in GMAW Processes

PubMed Central

Sampaio, Renato Coral; Vargas, José A. R.

2018-01-01

The arc welding process is widely used in industry but its automatic control is limited by the difficulty in measuring the weld bead geometry and closing the control loop on the arc, which has adverse environmental conditions. To address this problem, this work proposes a system to capture the welding variables and send stimuli to the Gas Metal Arc Welding (GMAW) conventional process with a constant voltage power source, which allows weld bead geometry estimation with an open-loop control. Dynamic models of depth and width estimators of the weld bead are implemented based on the fusion of thermographic data, welding current and welding voltage in a multilayer perceptron neural network. The estimators were trained and validated off-line with data from a novel algorithm developed to extract the features of the infrared image, a laser profilometer was implemented to measure the bead dimensions and an image processing algorithm that measures depth by making a longitudinal cut in the weld bead. These estimators are optimized for embedded devices and real-time processing and were implemented on a Field-Programmable Gate Array (FPGA) device. Experiments to collect data, train and validate the estimators are presented and discussed. The results show that the proposed method is useful in industrial and research environments. PMID:29570698

Sensor Fusion to Estimate the Depth and Width of the Weld Bead in Real Time in GMAW Processes.

PubMed

Bestard, Guillermo Alvarez; Sampaio, Renato Coral; Vargas, José A R; Alfaro, Sadek C Absi

2018-03-23

The arc welding process is widely used in industry but its automatic control is limited by the difficulty in measuring the weld bead geometry and closing the control loop on the arc, which has adverse environmental conditions. To address this problem, this work proposes a system to capture the welding variables and send stimuli to the Gas Metal Arc Welding (GMAW) conventional process with a constant voltage power source, which allows weld bead geometry estimation with an open-loop control. Dynamic models of depth and width estimators of the weld bead are implemented based on the fusion of thermographic data, welding current and welding voltage in a multilayer perceptron neural network. The estimators were trained and validated off-line with data from a novel algorithm developed to extract the features of the infrared image, a laser profilometer was implemented to measure the bead dimensions and an image processing algorithm that measures depth by making a longitudinal cut in the weld bead. These estimators are optimized for embedded devices and real-time processing and were implemented on a Field-Programmable Gate Array (FPGA) device. Experiments to collect data, train and validate the estimators are presented and discussed. The results show that the proposed method is useful in industrial and research environments.

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.

The effects of welding parameters on ultra-violet light emissions, ozone and CrVI formation in MIG welding.

PubMed

Dennis, J H; Mortazavi, S B; French, M J; Hewitt, P J; Redding, C R

1997-01-01

This paper describes the relationships between ultra-violet emission, ozone generation and CrVI production in MIG welding which were measured as a function of shield gas flow rate, welding voltage, electrode stick-out and shield gas composition using an automatic welding rig that permitted MIG welding under reproducible conditions. The experimental results are interpreted in terms of the physico-chemical processes occurring in the micro- and macro-environments of the arc as part of research into process modification to reduce occupational exposure to ozone and CrVI production rates in MIG welding. We believe the techniques described here, and in particular the use of what we have termed u.v.-ozone measurements, will prove useful in further study of ozone generation and CrVI formation and may be applied in the investigation of engineering control of occupational exposure in MIG and other welding process such as Manual Metal Arc (MMA) and Tungsten Inert Gas (TIG).

Automatic arc welding of propulsion system tubing in close proximity to sensitive electronic devices

NASA Technical Reports Server (NTRS)

Lumsden, J. M.; Whittlesey, A. C.

1981-01-01

The planned final assembly of the Galileo spacecraft propulsion system tubing, which involves welding in close proximity to sensitive electronics, raised significant concerns about the effects of electromagnetic coupling of weld energy on CMOS and other sensitive integrated circuits. A test program was established to assess the potential of an orbital arc welder and an RF-induction brazing machine to damage sensitive electronic equipment. Test parameters were varied to assess the effectiveness of typical transient suppression practices such as grounding, bonding, and shielding. A technique was developed to calibrate the hazard levels at the victim-circuit location; this technique is described along with the results and conclusions of the test program.

A Generalized Method for Automatic Downhand and Wirefeed Control of a Welding Robot and Positioner

NASA Technical Reports Server (NTRS)

Fernandez, Ken; Cook, George E.

1988-01-01

A generalized method for controlling a six degree-of-freedom (DOF) robot and a two DOF positioner used for arc welding operations is described. The welding path is defined in the part reference frame, and robot/positioner joint angles of the equivalent eight DOF serial linkage are determined via an iterative solution. Three algorithms are presented: the first solution controls motion of the eight DOF mechanism such that proper torch motion is achieved while minimizing the sum-of-squares of joint displacements; the second algorithm adds two constraint equations to achieve torch control while maintaining part orientation so that welding occurs in the downhand position; and the third algorithm adds the ability to control the proper orientation of a wire feed mechanism used in gas tungsten arc (GTA) welding operations. A verification of these algorithms is given using ROBOSIM, a NASA developed computer graphic simulation software package design for robot systems development.

WELDING METHOD

DOEpatents

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

1959-09-29

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

[Spectra and thermal analysis of the arc in activating flux plasma arc welding].

PubMed

Chai, Guo-Ming; Zhu, Yi-Feng

2010-04-01

In activating flux plasma arc welding the welding arc was analyzed by spectra analysis technique, and the welding arc temperature field was measured by the infrared sensing and computer image technique. The distribution models of welding arc heat flow density of activating flux PAW welding were developed. The composition of welding arc affected by activated flux was studied, and the welding arc temperature field was studied. The results show that the spectral lines of argon atom and ionized argon atom of primary ionization are the main spectra lines of the conventional plasma welding arc. The spectra lines of weld metal are inappreciable in the spectra lines of the conventional plasma welding arc. The gas particle is the main in the conventional plasma welding arc. The conventional plasma welding arc is gas welding arc. The spectra lines of argon atom and ionized argon atom of primary ionization are intensified in the activating flux plasma welding arc, and the spectra lines of Ti, Cr and Fe elements are found in the activating flux plasma welding arc. The welding arc temperature distribution in activating flux plasma arc welding is compact, the outline of the welding arc temperature field is narrow, the range of the welding arc temperature distribution is concentrated, the welding arc radial temperature gradient is large, and the welding arc radial temperature gradient shows normal Gauss distribution.

Pipeline welding goes mechanized

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beeson, R.

1999-11-01

Spread four has bugs in the cornfield--but not to worry. The bug referred to here is a mechanized welding bug, specifically a single welding head, computer-aided gas metal arc (GMAW) system from CRC-Evans Automatic Welding powered by a Miller Electric XMT{reg{underscore}sign} 304 inverter-based welding machine. The bug operator and owner of 32 inverters is Welded Construction, L.P., of Perrysburgh, Ohio. Spread four is a 147-mile stretch of the Alliance Pipeline system (Alliance) cutting through the cornfields of northeast Iowa. While used successfully in Canada and Europe for onshore and offshore pipeline construction for 30 years, this is the first large-scalemore » use of mechanized welding in the US on a cross-country pipeline. On longer, larger-diameter and thicker-wall pipe projects--the Alliance mainline has 1,844 miles of pipe, most of it 36-in. diameter with a 0.622-in. wall thickness--mechanized GMAW offers better productivity than manual shielded metal arc welding (SMAW). In addition, high-strength steels, such as the API 5L Grade X70 pipe used on the Alliance, benefit from the low-hydrogen content of certain solid and tubular wire electrodes.« less

Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes.

PubMed

Pinto-Lopera, Jesús Emilio; S T Motta, José Mauricio; Absi Alfaro, Sadek Crisostomo

2016-09-15

Associated to the weld quality, the weld bead geometry is one of the most important parameters in welding processes. It is a significant requirement in a welding project, especially in automatic welding systems where a specific width, height, or penetration of weld bead is needed. This paper presents a novel technique for real-time measuring of the width and height of weld beads in gas metal arc welding (GMAW) using a single high-speed camera and a long-pass optical filter in a passive vision system. The measuring method is based on digital image processing techniques and the image calibration process is based on projective transformations. The measurement process takes less than 3 milliseconds per image, which allows a transfer rate of more than 300 frames per second. The proposed methodology can be used in any metal transfer mode of a gas metal arc welding process and does not have occlusion problems. The responses of the measurement system, presented here, are in a good agreement with off-line data collected by a common laser-based 3D scanner. Each measurement is compare using a statistical Welch's t-test of the null hypothesis, which, in any case, does not exceed the threshold of significance level α = 0.01, validating the results and the performance of the proposed vision system.

Benefit from NASA

NASA Image and Video Library

1998-12-01

Two companies have successfully commercialized a specialized welding tool developed at the Marshall Space Flight Center (MSFC). Friction stir welding uses the high rotational speed of a tool and the resulting frictional heat created from contact to crush, "stir" together, and forge a bond between two metal alloys. It has had a major drawback, reliance on a single-piece pin tool. The pin is slowly plunged into the joint between two materials to be welded and rotated as high speed. At the end of the weld, the single-piece pin tool is retracted and leaves a "keyhole," something which is unacceptable when welding cylindrical objects such as drums, pipes and storage tanks. Another drawback is the requirement for different-length pin tools when welding materials of varying thickness. An engineer at the MSFC helped design an automatic retractable pin tool that uses a computer-controlled motor to automatically retract the pin into the shoulder of the tool at the end of the weld, preventing keyholes. This design allows the pin angle and length to be adjusted for changes in material thickness and results in a smooth hole closure at the end of the weld. Benefits of friction stir welding, using the MSFC retractable pin tool technology, include the following: The ability to weld a wide range of alloys, including previously unweldable and composite materials; provision of twice the fatigue resistance of fusion welds and no keyholes; minimization of material distortion; no creation of hazards such as welding fumes, radiation, high voltage, liquid metals, or arcing; automatic retraction of the pin at the end of the weld; and maintaining full penetration of the pin.

Real-time seam tracking control system based on line laser visions

NASA Astrophysics Data System (ADS)

Zou, Yanbiao; Wang, Yanbo; Zhou, Weilin; Chen, Xiangzhi

2018-07-01

A set of six-degree-of-freedom robotic welding automatic tracking platform was designed in this study to realize the real-time tracking of weld seams. Moreover, the feature point tracking method and the adaptive fuzzy control algorithm in the welding process were studied and analyzed. A laser vision sensor and its measuring principle were designed and studied, respectively. Before welding, the initial coordinate values of the feature points were obtained using morphological methods. After welding, the target tracking method based on Gaussian kernel was used to extract the real-time feature points of the weld. An adaptive fuzzy controller was designed to input the deviation value of the feature points and the change rate of the deviation into the controller. The quantization factors, scale factor, and weight function were adjusted in real time. The input and output domains, fuzzy rules, and membership functions were constantly updated to generate a series of smooth bias robot voltage. Three groups of experiments were conducted on different types of curve welds in a strong arc and splash noise environment using the welding current of 120 A short-circuit Metal Active Gas (MAG) Arc Welding. The tracking error was less than 0.32 mm and the sensor's metrical frequency can be up to 20 Hz. The end of the torch run smooth during welding. Weld trajectory can be tracked accurately, thereby satisfying the requirements of welding applications.

Weld repair of carbon-moly coke drums without postweld heat treatment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Moore, D.E.

1996-06-01

Investigations to evaluate weld repair of C-{1/2}Mo coke drums without postweld heat treatment (PWHT) are discussed in this paper. These investigations showed that shielded metal-arc welding (SMAW) without PWHT produced heat-affected zones (HAZ) and weld deposits with Charpy V-notch (CVN) impact toughness that exceeded the toughness of ex-service plate material. PWHT de-embrittles strain age-embrittled ex-service plate material. However, warming of drums to 200 F before putting in feed compensates for the omission of the de-embrittling PWHT. Additional testing showed that the de-embrittling PWHT did not significantly improve the fatigue properties of the ex-service plate material. As-welded SMAW repairs were foundmore » to be feasible for coke drums, and repairs have now been in service successfully for up to 2 years. The as-welded SMAW repairs were qualified on the basis of a 300 F preheat using small diameter electrodes for the first pass followed by larger diameter electrodes to temper the HAZ of the first pass. A half-bead technique was not used. Heat input is not precisely controlled as would be required for controlled deposition welding. Following the implementation of SMAW repairs without PWHT, the author extended the work to include as-welded repairs with automatic gas metal-arc welding (GMAW).« less

Retractable Pin Tools for the Friction Stir Welding Process

NASA Technical Reports Server (NTRS)

1998-01-01

Two companies have successfully commercialized a specialized welding tool developed at the Marshall Space Flight Center (MSFC). Friction stir welding uses the high rotational speed of a tool and the resulting frictional heat created from contact to crush, 'stir' together, and forge a bond between two metal alloys. It has had a major drawback, reliance on a single-piece pin tool. The pin is slowly plunged into the joint between two materials to be welded and rotated as high speed. At the end of the weld, the single-piece pin tool is retracted and leaves a 'keyhole,' something which is unacceptable when welding cylindrical objects such as drums, pipes and storage tanks. Another drawback is the requirement for different-length pin tools when welding materials of varying thickness. An engineer at the MSFC helped design an automatic retractable pin tool that uses a computer-controlled motor to automatically retract the pin into the shoulder of the tool at the end of the weld, preventing keyholes. This design allows the pin angle and length to be adjusted for changes in material thickness and results in a smooth hole closure at the end of the weld. Benefits of friction stir welding, using the MSFC retractable pin tool technology, include the following: The ability to weld a wide range of alloys, including previously unweldable and composite materials; provision of twice the fatigue resistance of fusion welds and no keyholes; minimization of material distortion; no creation of hazards such as welding fumes, radiation, high voltage, liquid metals, or arcing; automatic retraction of the pin at the end of the weld; and maintaining full penetration of the pin.

State-of-the-art survey of joinability of materials for OTEC heat exchangers

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beaver, R. J.

1978-12-01

Literature and industrial sources were surveyed to assess, on the basis of apparent economics and reliability, the joinability of both shell-and-tube and compact ocean thermal energy conversion (OTEC) heat exchangers. A no-leak requirement is mandatory to prevent mixing seawater and the ammonia working fluid. The operating temperature range considered is 7 to 28/sup 0/C (45 to 82/sup 0/F). Materials evaluated were aluminum, titanium, copper--nickel, AL-6X austenitic stainless steel, singly and in combination with steel and concrete. Many types of welding and brazing processes, roller expansion, magnaforming, O-ring sealing, and adhesive bonding were considered. The automatic gas tungsten-arc welding process andmore » explosion welding processes are the only two joining processes that now appear to offer the high reliability required of no-leak shell-and-tube heat exchangers. Of these two processes, the gas tungsten-arc welding process appears to be the more economically attractive.« less

Generation rate of carbon monoxide from CO2 arc welding.

PubMed

Ojima, Jun

2013-01-01

CO poisoning has been a serious industrial hazard in Japanese workplaces. Although incomplete combustion is the major cause of CO generation, there is a risk of CO poisoning during some welding operations. The aim of the present study was to evaluate the generation rate of CO from CO2 arc welding under controlled laboratory conditions and estimate the ventilation requirements for the prevention of CO poisoning. Bead on plate welding was carried out with an automatic welding robot on a rolled steel base metal under several conditions. The concentration of emitted CO from the welding was measured by a real-time CO monitor in a well-ventilated laboratory that was free from ambient CO contamination. The generation rate of CO was obtained from the three measurements-the flow rate of the welding exhaust gas, CO concentration in the exhaust gas and the arcing time. Then the ventilation requirement to prevent CO poisoning was calculated. The generation rate of CO was found to be 386-883 ml/min with a solid wire and 331-1,293 ml/min with a flux cored wire respectively. It was found that the CO concentration in a room would be maintained theoretically below the OSHA PEL (50 ppm) providing the ventilation rate in the room was 6.6-25.9 m3/min. The actual ventilation requirement was then estimated to be 6.6-259 m3/min considering incomplete mixing. In order to prevent CO poisoning, some countermeasures against gaseous emission as well as welding fumes should be taken eagerly.

Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes

PubMed Central

Pinto-Lopera, Jesús Emilio; S. T. Motta, José Mauricio; Absi Alfaro, Sadek Crisostomo

2016-01-01

Associated to the weld quality, the weld bead geometry is one of the most important parameters in welding processes. It is a significant requirement in a welding project, especially in automatic welding systems where a specific width, height, or penetration of weld bead is needed. This paper presents a novel technique for real-time measuring of the width and height of weld beads in gas metal arc welding (GMAW) using a single high-speed camera and a long-pass optical filter in a passive vision system. The measuring method is based on digital image processing techniques and the image calibration process is based on projective transformations. The measurement process takes less than 3 milliseconds per image, which allows a transfer rate of more than 300 frames per second. The proposed methodology can be used in any metal transfer mode of a gas metal arc welding process and does not have occlusion problems. The responses of the measurement system, presented here, are in a good agreement with off-line data collected by a common laser-based 3D scanner. Each measurement is compare using a statistical Welch’s t-test of the null hypothesis, which, in any case, does not exceed the threshold of significance level α = 0.01, validating the results and the performance of the proposed vision system. PMID:27649198

Automatic hot wire GTA welding of pipe offers speed and increased deposition

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sykes, I.; Digiacomo, J.

1995-07-01

Heavy-wall pipe welding for the power and petrochemical industry must meet code requirements. Contractors strive to meet these requirements in the most productive way possible. The challenge put to orbital welding equipment manufacturers is to produce pipe welding equipment that cost-effectively produces code-quality welds. Orbital welding equipment using the GTA process has long produced outstanding quality results but has lacked the deposition rate to compete cost effectively with other manual and semiautomatic processes such as SMAW, FCAW and GMAW. In recent years, significant progress has been made with the use of narrow-groove weld joint designs to reduce weld joint volumemore » and improve welding times. Astro Arc Polysoude, an orbital welding equipment manufacturer based in Sun Valley, Calif., and Nantes, France, has combined the hot wire GTAW process with orbital welding equipment using a narrow-groove weld joint design. Field test results show this process and procedure is a good alternative for many heavy-wall-pipe welding applications.« less

Characterizing Shipyard Welding Emissions and Associated Control Options (The National Shipbuilding Research Program)

DTIC Science & Technology

1995-08-01

TRl) Occupational Health and Safety Administration (OSHA) Air Quality Legislation Hexavalent Chromium and the Legislation List-of-list Chemicals and...2.2.7 2.2.8 Shielded Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) Gas Metal Arc Welding (GMAW) Gas Tungsten Arc Welding ( GTAW ) Flux Core Arc... GTAW Welding Processes Advantages and Disadvantages of FCAW Welding Processes Welding Process Comparison Matrix Diagram of SMAW Welding Process

Robotic and automatic welding development at the Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

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

1988-01-01

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

Plasma Processes of Cutting and Welding

DTIC Science & Technology

1976-02-01

TIG process. 2.2.2 Keyhole Welding In plasma arc welding , the term...Cutting 3 3 4 4 4 2.2 Plasma Arc Welding 5 2.2.1 Needle Arc Welding 2.2.2 Keyhole Welding 5 6 3. Applications 8 93.1 Economics 4. Environmental Aspects of...Arc Lengths III. Needle Arc Welding Conditions IV. Keyhole Welding Conditions v. Chemical Analyses of Plates Used - vii - 1. 2. 3. 4. 5. 6. 7. 8.

Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

NASA Astrophysics Data System (ADS)

Stavinoha, Joe N.

The process of producing near net-shape components by material deposition is known as additive manufacturing. All additive manufacturing processes are based on the addition of material with the main driving forces being cost reduction and flexibility in both manufacturing and product design. With wire metal deposition, metal is deposited as beads side-by-side and layer-by-layer in a desired pattern to build a complete component or add features on a part. There are minimal waste products, low consumables, and an efficient use of energy and feedstock associated with additive manufacturing processes. Titanium and titanium alloys are useful engineering materials that possess an extraordinary combination of properties. Some of the properties that make titanium advantageous for structural applications are its high strength-to-weight ratio, low density, low coefficient of thermal expansion, and good corrosion resistance. The most commonly used titanium alloy, Ti-6Al-4V, is typically used in aerospace applications, pressure vessels, aircraft gas turbine disks, cases and compressor blades, and surgical implants. Because of the high material prices associated with titanium alloys, the production of near net-shape components by additive manufacturing is an attractive option for the manufacturing of Ti-6Al-4V alloy components. In this thesis, the manufacturing of cylindrical Ti-6Al-4V alloy specimens by wire metal deposition utilizing the plasma arc welding process was demonstrated. Plasma arc welding is a cost effective additive manufacturing technique when compared to other current additive manufacturing methods such as laser beam welding and electron beam welding. Plasma arc welding is considered a high-energy-density welding processes which is desirable for the successful welding of titanium. Metal deposition was performed using a constant current plasma arc welding power supply, flow-purged welding chamber, argon shielding and orifice gas, ERTi-5 filler metal, and Ti-6Al-4V alloy substrates. Cylindrical weld metal deposits were built by employing an automatic wire feeder, turntable positioner, and vertical torch positioner. A total of four cylindrical weld metal specimens were built with various combinations of essential plasma arc welding process parameters. The temperature of the weld metal deposit was taken with a thermocouple after allowing a specified amount of time to pass before depositing the next weld track. An analytical heat flow model was created that estimated the temperature of the weld metal deposit in relation to the number of tracks deposited. The analytical heat flow model was adjusted to match the experimental data that was obtained and revealed that the rate of production could be increased if the rate of thermal energy losses from the deposit were increased. Cross-sections of the weld metal deposits were examined to observe the effects of thermal energy input on the weld metal macrostructure, microstructure, and grain size. Results from the metallographic inspections revealed an increase in grain size and coarsening of the structure as the number of weld tracks in the deposit increased.

[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.

Method for enhanced control of welding processes

DOEpatents

Sheaffer, Donald A.; Renzi, Ronald F.; Tung, David M.; Schroder, Kevin

2000-01-01

Method and system for producing high quality welds in welding processes, in general, and gas tungsten arc (GTA) welding, in particular by controlling weld penetration. Light emitted from a weld pool is collected from the backside of a workpiece by optical means during welding and transmitted to a digital video camera for further processing, after the emitted light is first passed through a short wavelength pass filter to remove infrared radiation. By filtering out the infrared component of the light emitted from the backside weld pool image, the present invention provides for the accurate determination of the weld pool boundary. Data from the digital camera is fed to an imaging board which focuses on a 100.times.100 pixel portion of the image. The board performs a thresholding operation and provides this information to a digital signal processor to compute the backside weld pool dimensions and area. This information is used by a control system, in a dynamic feedback mode, to automatically adjust appropriate parameters of a welding system, such as the welding current, to control weld penetration and thus, create a uniform weld bead and high quality weld.

Welding Experiments of Aluminum Alloy by Space GHTA Welding at ISS Orbital Pressure

NASA Astrophysics Data System (ADS)

Suita, Yoshikazu; Takai, Daisuke; Sugiyama, Satoshi; Terajima, Noboru; Tsukuda, Yoshiyuki; Fujisawa, Shoichiro; Imagawa, Kichiro

As a feasible welding method in space, the authors previously proposed the space GHTA (Gas Hollow Tungsten Arc) welding process. However, space GHTA welding with a high-frequency device for arc start may cause electromagnetic noise problems for the computer equipment placed on the ISS (International Space Station). Therefore, in this report, welding experiments of space GHTA welding using aluminum alloy with a high-voltage DC device for arc start were carried out at the ISS orbital pressure, 10-5 Pa. It is clear from the experiments using a high-voltage DC device in a high-vacuum condition, that there is a shifting phenomenon in which the spark discharge shifts to either a glow discharge or an arc discharge when starting the arc. Welding projects in space need an arc discharge, so we investigated the effects of welding parameters on the arc formation ratio. As a result, space GHTA welding with a high-voltage DC device can be used for arc start when welding at the ISS orbital pressure.

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.

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.

Effect of laser pulse on alternative current arc discharge during laser-arc hybrid welding of magnesium alloy

NASA Astrophysics Data System (ADS)

Chen, Minghua; Xin, Lijun; Zhou, Qi; He, Lijia; Wu, Fufa

2018-01-01

The coupling effect between a laser and arc plasma was studied in situations in which the laser acts at the positive and negative waveforms of the arc discharge during the laser-arc hybrid welding of magnesium alloy. Using the methods of direct observation, high speed imaging, and spectral analysis, the surface status of weld seams, weld penetration depths, plasma behavior, and spectral characteristics of welding plasma were investigated, respectively. Results show that, as compared with the laser pulse acting at the negative waveform of the arc plasma discharge, a better weld seam formation can be achieved when the laser pulse acts at the positive waveform of the arc discharge. At the same time, the radiation intensity of Mg atoms in the arc plasma increases significantly. However, the weld penetration depth is weaker. The findings show that when the laser pulse is acting at the negative waveform of the arc plasma discharge, the position of the arc plasma discharge on the workpiece can be restrained by the laser action point, which improves the energy density of the welding arc.

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.

Replacement of seam welded hot reheat pipe using narrow groove GTA machine welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Richardson, R.R.; Yanes, J.; Bryant, R.

1995-12-31

Southern California Edison, recognizing a potential safety concern, scrutinized its existing seam welded hot reheat pipe manufactured by the same supplier as that which failed. Alternatives were narrowed to two in dealing with the installed seam welded pipe. The overriding consideration, however, was one of safety. With this in mind, the utility company evaluated replacement of the seam welded hot reheat pipe with seamless pipe or increasing the frequency of its inspection program. Although increased inspection was much costly, pipe replacement was chosen due to potential safety concerns with seam welded pipe even with more frequent inspection. The utility companymore » then proceeded to determine the most effective method to complete this work. Analysis showed machine-made (automatic) gas tungsten arc welds (GTAW) as the method of choice due to cleanliness and superior mechanical properties. In conjunction with this method, the narrow groove (3{degree} bevel) weld joint as opposed to the traditional groove (37 1/2{degree} bevel) was shown to provide significant technical advantages.« less

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

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.

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.

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.

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.

Modeling of plasma and thermo-fluid transport in hybrid welding

NASA Astrophysics Data System (ADS)

Ribic, Brandon D.

Hybrid welding combines a laser beam and electrical arc in order to join metals within a single pass at welding speeds on the order of 1 m min -1. Neither autonomous laser nor arc welding can achieve the weld geometry obtained from hybrid welding for the same process parameters. Depending upon the process parameters, hybrid weld depth and width can each be on the order of 5 mm. The ability to produce a wide weld bead increases gap tolerance for square joints which can reduce machining costs and joint fitting difficulty. The weld geometry and fast welding speed of hybrid welding make it a good choice for application in ship, pipeline, and aerospace welding. Heat transfer and fluid flow influence weld metal mixing, cooling rates, and weld bead geometry. Cooling rate affects weld microstructure and subsequent weld mechanical properties. Fluid flow and heat transfer in the liquid weld pool are affected by laser and arc energy absorption. The laser and arc generate plasmas which can influence arc and laser energy absorption. Metal vapors introduced from the keyhole, a vapor filled cavity formed near the laser focal point, influence arc plasma light emission and energy absorption. However, hybrid welding plasma properties near the opening of the keyhole are not known nor is the influence of arc power and heat source separation understood. A sound understanding of these processes is important to consistently achieving sound weldments. By varying process parameters during welding, it is possible to better understand their influence on temperature profiles, weld metal mixing, cooling rates, and plasma properties. The current literature has shown that important process parameters for hybrid welding include: arc power, laser power, and heat source separation distance. However, their influence on weld temperatures, fluid flow, cooling rates, and plasma properties are not well understood. Modeling has shown to be a successful means of better understanding the influence of 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 heat source separation distance on cooling rates during hybrid welding are not known. (4) Convection during hybrid welding is not well understood despite its importance to weld integrity. (5) The influence of surface active elements on weld geometry, weld pool temperatures, and fluid flow during high power density laser and laser/arc hybrid welding are not known. (6) Although the arc power and heat source separation distance have been experimentally shown to influence arc stability and plasma light emission during hybrid welding, the influence of these parameters on plasma properties is unknown. (7) The electrical conductivity of hybrid welding plasmas is not known, despite its importance to arc stability and weld integrity. In this study, heat transfer and fluid flow are analyzed for laser, gas tungsten arc (GTA), and laser/GTA hybrid welding using an experimentally validated three dimensional phenomenological model. By evaluating arc and laser welding using similar process parameters, a better understanding of the hybrid welding process is expected. The role of arc power and heat source separation distance on weld depth, weld pool centerline cooling rates, and fluid flow profiles during CO2 laser/GTA hybrid welding of 321 stainless steel are analyzed. Laser power is varied for a constant heat source separation distance to evaluate its influence on weld temperatures, weld geometry, and fluid flow during Nd:YAG laser/GTA hybrid welding of A131 structural steel. The influence of oxygen and sulfur on keyhole and weld bead geometry, weld temperatures, and fluid flow are analyzed for high power density Yb doped fiber laser welding of (0.16 %C, 1.46 %Mn) mild steel. Optical emission spectroscopy was performed on GTA, Nd:YAG laser, and Nd:YAG laser/GTA hybrid welding plasmas for welding of 304L stainless steel. Emission spectroscopy provides a means of determining plasma temperatures and species densities using deconvoluted measured spectral intensities, which can then be used to calculate plasma electrical conductivity. In this study, hybrid welding plasma temperatures, species densities, and electrical conductivities were determined using various heat source separation distances and arc currents using an analytical method coupled calculated plasma compositions. As a result of these studies heat transfer by convection was determined to be dominant during hybrid welding of steels. The primary driving forces affecting hybrid welding fluid flow are the surface tension gradient and electromagnetic force. Fiber laser weld depth showed a negligible change when increasing the (0.16 %C, 1.46 %Mn) mild steel sulfur concentration from 0.006 wt% to 0.15 wt%. Increasing the dissolved oxygen content in weld pool from 0.0038 wt% to 0.0257 wt% increased the experimental weld depth from 9.3 mm to 10.8 mm. Calculated partial pressure of carbon monoxide increased from 0.1 atm to 0.75 atm with the 0.0219 wt% increase in dissolved oxygen in the weld metal and may explain the increase in weld depth. Nd:YAG laser/GTA hybrid welding plasma temperatures were calculated to be approximately between 7927 K and 9357 K. Increasing the Nd:YAG laser/GTA hybrid welding heat source separation distance from 4 mm to 6 mm reduced plasma temperatures between 500 K and 900 K. Hybrid welding plasma total electron densities and electrical conductivities were on the order of 1 x 1022 m-3 and 3000 S m-1, respectively.

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.

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.

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.

Interaction of both plasmas in CO2 laser-MAG hybrid welding of carbon steel

NASA Astrophysics Data System (ADS)

Kutsuna, Muneharu; Chen, Liang

2003-03-01

Researches and developments of laser and arc hybrid welding has been curried out since in 1978. Especially, CO2 laser and TIG hybrid welding has been studied for increasing the penetration depth and welding speed. Recently laser and MIG/MAG/Plasma hybrid welding processes have been developed and applied to industries. It was recognized as a new welding process that promote the flexibility of the process for increasing the penetration depth, welding speed and allowable joint gap and improving the quality of the welds. In the present work, CO2 Laser-MAG hybrid welding of carbon steel (SM490) was investigated to make clear the phenomenon and characteristics of hybrid welding process comparing with laser welding and MAG process. The effects of many process parameters such as welding current, arc voltage, welding speed, defocusing distance, laser-to-arc distance on penetration depth, bead shape, spatter, arc stability and plasma formation were investigated in the present work. Especially, the interaction of laser plasma and MAG arc plasma was considered by changing the laser to arc distance (=DLA).

An investigation on capability of hybrid Nd:YAG laser-TIG welding technology for AA2198 Al-Li alloy

NASA Astrophysics Data System (ADS)

Faraji, Amir Hosein; Moradi, Mahmoud; Goodarzi, Massoud; Colucci, Pietro; Maletta, Carmine

2017-09-01

This paper surveys the capability of the hybrid laser-arc welding in comparison with lone laser welding for AA2198 aluminum alloy experimentally. In the present research, a continuous Nd:YAG laser with a maximum power of 2000 W and a 350 A electric arc were used as two combined welding heat sources. In addition to the lone laser welding experiments, two strategies were examined for hybrid welding; the first one was low laser power (100 W) accompanied by high arc energy, and the second one was high laser power (2000 W) with low arc energy. Welding speed and arc current varied in the experiments. The influence of heat input on weld pool geometry was surveyed. The macrosection, microhardness profile and microstructure of the welded joints were studied and compared. The results indicated that in lone laser welding, conduction mode occurred and keyhole was not formed even in low welding speeds and thus the penetration depth was so low. It was also found that the second approach (high laser power accompanied with low arc energy) is superior to the first one (low laser power accompanied with high arc energy) in hybrid laser-arc welding of Al2198, since lower heat input was needed for full penetration weld and as a result a smaller HAZ was created.

Welding of Thin Steel Plates by Hybrid Welding Process Combined TIG Arc with YAG Laser

NASA Astrophysics Data System (ADS)

Kim, Taewon; Suga, Yasuo; Koike, Takashi

TIG arc welding and laser welding are used widely in the world. However, these welding processes have some advantages and problems respectively. In order to improve problems and make use of advantages of the arc welding and the laser welding processes, hybrid welding process combined the TIG arc with the YAG laser was studied. Especially, the suitable welding conditions for thin steel plate welding were investigated to obtain sound weld with beautiful surface and back beads but without weld defects. As a result, it was confirmed that the shot position of the laser beam is very important to obtain sound welds in hybrid welding. Therefore, a new intelligent system to monitor the welding area using vision sensor is constructed. Furthermore, control system to shot the laser beam to a selected position in molten pool, which is formed by TIG arc, is constructed. As a result of welding experiments using these systems, it is confirmed that the hybrid welding process and the control system are effective on the stable welding of thin stainless steel plates.

Narrow groove welding gas diffuser assembly and welding torch

DOEpatents

Rooney, Stephen J.

2001-01-01

A diffuser assembly is provided for narrow groove welding using an automatic gas tungsten arc welding torch. The diffuser assembly includes a manifold adapted for adjustable mounting on the welding torch which is received in a central opening in the manifold. Laterally extending manifold sections communicate with a shield gas inlet such that shield gas supplied to the inlet passes to gas passages of the manifold sections. First and second tapered diffusers are respectively connected to the manifold sections in fluid communication with the gas passages thereof. The diffusers extend downwardly along the torch electrode on opposite sides thereof so as to release shield gas along the length of the electrode and at the distal tip of the electrode. The diffusers are of a transverse width which is on the order of the thickness of the electrode so that the diffusers can, in use, be inserted into a narrow welding groove before and after the electrode in the direction of the weld operation.

Dilution in single pass arc welds

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 efficiencymore » 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.« less

Hybrid Laser-Arc Welding of the High-Strength Shipbuilding Steels: Equipment and Technology

NASA Astrophysics Data System (ADS)

Turichin, G.; Kuznetsov, M.; Tsibulskiy, I.; Firsova, A.

Hybrid laser-arc welding (HLAW) allows getting weld joints with thickness up to 35 mm for one pass, provide good quality formation of joints, minimal thermal deformations, the productivity in 10 times more in comparison with arc welding. In addition, replacement arc welding to the HLAW allows economizing filler materials, shielding gas and consumable electricity more than 4 times. Therefore, HLAW is actually technology for basic engineering branches and especially for shipbuilding. The Institute of Laser and Welding Technologies (ILWT) developed laser and hybrid laser-arc welding technologies for different type of steels and alloys including high-strength shipbuilding steels. Also ILWT produced portal and robotic systems for HLAW process realization. Portal system for hybrid laser-arc welding of panels with dimensions 6x6 m using at the manufacturing of flat curvilinear sections in the shipbuilding is depicted in the article. Results of experimental researches of the hybrid laser-arc welding parameters influence on the formation and mechanical properties of weld joint are described at the publication also. Experimental part was made with using of the portal system.

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.

Three-dimensional modeling of the plasma arc in arc welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 asmore » 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.« less

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.

Contribution For Arc Temperature Affected By Current Increment Ratio At Peak Current In Pulsed Arc

NASA Astrophysics Data System (ADS)

Kano, Ryota; Mitubori, Hironori; Iwao, Toru

2015-11-01

Tungsten Inert Gas (TIG) Welding is one of the high quality welding. However, parameters of the pulsed arc welding are many and complicated. if the welding parameters are not appropriate, the welding pool shape becomes wide and shallow.the convection of driving force contributes to the welding pool shape. However, in the case of changing current waveform as the pulse high frequency TIG welding, the arc temperature does not follow the change of the current. Other result of the calculation, in particular, the arc temperature at the reaching time of peak current is based on these considerations. Thus, the accurate measurement of the temperature at the time is required. Therefore, the objective of this research is the elucidation of contribution for arc temperature affected by current increment ratio at peak current in pulsed arc. It should obtain a detail knowledge of the welding model in pulsed arc. The temperature in the case of increment of the peak current from the base current is measured by using spectroscopy. As a result, when the arc current increases from 100 A to 150 A at 120 ms, the transient response of the temperature didn't occur during increasing current. Thus, during the current rise, it has been verified by measuring. Therefore, the contribution for arc temperature affected by current increment ratio at peak current in pulsed arc was elucidated in order to obtain more knowledge of welding model of pulsed arc.

Metal transfer and V-I transients in GMAW of aluminium

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pandey, S.; Rao, U.R.K.; Aghakhani, M.

1996-12-31

The mode of metal transfer in arc welding significantly affects the positional weldability; particularly the overhead welding, the chemical composition and properties of weld metal, metallurgy of weld metal, weld pool stability, arc stability, spatter losses, and weld bead geometry. The mode of metal transfer is affected mainly by the type of the arc, welding current, electrode polarity, arc voltage, contact tube to plate distance (CTPD)/Stand-off, type and flow rate of the shielding gas, torch angle and alloying elements in GMAW of aluminium and its alloys.

Keyhole behavior and liquid flow in molten pool during laser-arc hybrid welding

NASA Astrophysics Data System (ADS)

Naito, Yasuaki; Katayama, Seiji; Matsunawa, Akira

2003-03-01

Hybrid welding was carried out on Type 304 stainless steel plate under various conditions using YAG laser combined with TIG arc. During arc and laser-arc hybrid welding, arc voltage variation was measured, and arc plasma, laser-induced plume and evaporation spots as well as keyhole behavior and liquid flow in the molten pool were observed through CCD camera and X-ray real-time transmission apparatus. It was consequently found that hybrid welding possessed many features in comparison with YAG laser welding. The deepest weld bead could be produced when the YAG laser beam of high power density was shot on the molten pool made beforehand stably with TIG arc. A keyhole was long and narrow, and its behavior was rather stable inside the molten pool. It was also confirmed that porosity was reduced by the suppression of bubble formation in hybrid welding utilizing a laser of a moderate power density.

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…

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 combustible...

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 combustible...

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 combustible...

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 combustible...

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 combustible...

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.

ARC and Melting Efficiency of Plasma ARC Welds

NASA Technical Reports Server (NTRS)

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

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% for the conditions of the welds. Arc efficiency depends in different ways on voltage and current. The voltage effect dominates. Raising voltage while reducing current increases arc efficiency. Longer, higher voltage arcs are thought to transfer a greater portion of arc power to the workpiece through shield gas convection. Melting efficiency depends upon weld pool shape as well as arc efficiency. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Increased plasma gas flow does the same thing. Higher currents are thought to raise arc pressure and depress liquid at the bottom of the weld pool. More arc power then transfers to the workpiece through increasing plasma gas convection. If the power is held constant, the reduced voltage lowers the arc efficiency, while the pool shape change increases the melting efficiency,

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.

[Investigation of occupational hazards of ultraviolet radiation and protective measures for workers in electric welding].

PubMed

Xu, Yan; Gong, Man-man; Wang, Jiao; He, Li-hua; Wang, Sheng; Du, Wei-wei; Zhang, Long-lian; Lin, Sen; Dong, Xue-mei; Wang, Ru-gang

2012-06-18

To investigate and analyze the occupational hazards of ultraviolet radiation, protective measures and related factors for typical symptoms among workers in electric welding, and to provide basic information for revision of the occupational standards of UV. Questionnaires and physical examinations were used in this investigation. A total of 828 workers from four vehicle manufacturers in Beijing and Guangdong Province were selected. Corresponding analyses were conducted with SPSS 16.0 statistic software. The top three injuries of faces and hands were burning tingling (48.7% & 41.3%), itch of skin (39% & 34.9%) and pigmentation (31.9% & 24.5%).The major injuries of eyes were ophthalmodynia (61.5%) , photophobia and tearing (61.4%), and blurred vision (50.2%). The incidences of facial and hands burning tingling, hands flushing, hands macula and papula were significantly different between the welders and auxiliary workers (P<0.05). The differences of facial and hands burning tingling, flushing, facial disesthesia and anaesthesia, symptoms and signs of eyes were significant in different working years groups (P<0.05). The top three usages of protective measures were welding masks (87.2%), gloves (84.3%) and glasses (65.9%). Except for UV cut cream, the usages of other protective equipments in the auxiliary workers were significantly lower than those in the welders (P<0.05). The logistic regression analysis showed that prolonged exposure to arc welding, using argon arc welding and CO(2) gas shielded arc welding, not wearing welding masks, and not using UV cut cream was significantly associated with the increased risk of face burning tingling, and the ORs were 3.894 (6 h to 8 h), 2.665 (4 h to 6 h), 2.052, 1.765, 1.759, 1.833, respectively; working years might be a protective factor, and the OR was 0.440, respectively. The study suggested that the UV radiation produced during welding operations not only caused harm to welders, but also to the auxiliary workers. Protection should be strengthened,for example, wearing welding masks, glasses, etc. Meanwhile automatic welding machines should be adopted by the factories to reduce the exposure time for workers.

JPRS Report, Science & Technology, USSR: Materials Science

DTIC Science & Technology

1988-03-15

another. It has developed and transferred to design institutes technological schemes of transportation systems for working deep levels at the Sarbay...manuscript received 1 Oct 84, in final version 19 May 86) pp 45-50 [Article by V.V. Shefel, engineer, Energomontazhproyekt Design -Technological...Institute, Moscow] [Abstract] Three variants of automatic argon-arc welding have been developed at the Energomontazh Design -Technological Institute

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. [Statutory Provisions] All welding, cutting, or soldering with arc or flame in all underground areas of a coal mine shall, whenever...

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. [Statutory Provisions] All welding, cutting, or soldering with arc or flame in all underground areas of a coal mine shall, whenever...

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. [Statutory Provisions] All welding, cutting, or soldering with arc or flame in all underground areas of a coal mine shall, whenever...

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. [Statutory Provisions] All welding, cutting, or soldering with arc or flame in all underground areas of a coal mine shall, whenever...

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. [Statutory Provisions] All welding, cutting, or soldering with arc or flame in all underground areas of a coal mine shall, whenever...

Properties of the welded joints of manganese steel made by low-frequency pulsed arc welding

NASA Astrophysics Data System (ADS)

Saraev, Yu. N.; Bezborodov, V. P.; Gladovskii, S. V.; Golikov, N. I.

2017-04-01

The structure, the mechanical properties, the impact toughness, and the fracture mechanisms of the welded joints made of steel 09G2S plates by direct current welding and pulsed arc welding with a modulated arc current in the frequency range 0.25-5.0 Hz are studied. The application of low-frequency pulsed arc welding allowed us to form welded joints with a fine-grained structure in the weld metal and the heat-affected zone and to achieve a higher impact toughness and a longer cyclic fatigue life as compared to the welded joints fabricated by direct current welding. The achieved effect manifests itself over the entire testing range from 20 to-60°C.

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 may...

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 may...

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 may...

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 may...

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 may...

Hybrid laser arc welding: State-of-art review

NASA Astrophysics Data System (ADS)

Acherjee, Bappa

2018-02-01

Hybrid laser arc welding simultaneously utilizes the arc welding and the laser welding, in a common interaction zone. The synergic effects of laser beam and eclectic arc in the same weld pool results in an increase of welding speed and penetration depth along with the enhancement of gap bridging capability and process stability. This paper presents the current status of this hybrid technique in terms of research, developments and applications. Effort is made to present a comprehensive technical know-how about this process through a systematic review of research articles, industrial catalogues, technical notes, etc. In the introductory part of the review, an overview of the hybrid laser arc welding is presented, including operation principle, process requirements, historical developments, benefits and drawbacks of the process. This is followed by a detailed discussion on control parameters those govern the performance of hybrid laser arc welding process. Thereafter, a report of improvements of performance and weld qualities achieved by using hybrid welding process is presented based on review of several research papers. The succeeding sections furnish the examples of industrial applications and the concluding remarks.

Nuclear valve manufacturer selects stainless forgings

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

1976-02-01

Forged type 316 stainless steel components for nuclear valves are described. Automatic plasma arc welding with powder filler alloys is employed for hardfacing. Seat ring forgings are surfaced four-at-a-time with Stellite No. 156 in a sequential manner to minimize heat input to the individual components. After cladding and machining, seat rings are welded into the valve body using a semiautomatic, hot-wire gas tungsten-arc process. Disc faces and guide slots are surfaced with Stellite No. 6. The valve stem is machined from 17-4PH forged bar stock in the H-1100 condition. The heat treatment is specified to minimize pitting under prolonged exposuremore » to wet packing. A 12 rms (0.3 $mu$m) surface finish minimizes tearing of the packing and subsequent leakage. The link and stem pin are SA 564 Grade 660 (in the H-1100 condition) and ASTM A637 Grade 718 respectively. (JRD)« less

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.

Linear Mathematical Model for Seam Tracking with an Arc Sensor in P-GMAW Processes

PubMed Central

Liu, Wenji; Li, Liangyu; Hong, Ying; Yue, Jianfeng

2017-01-01

Arc sensors have been used in seam tracking and widely studied since the 80s and commercial arc sensing products for T and V shaped grooves have been developed. However, it is difficult to use these arc sensors in narrow gap welding because the arc stability and sensing accuracy are not satisfactory. Pulse gas melting arc welding (P-GMAW) has been successfully applied in narrow gap welding and all position welding processes, so it is worthwhile to research P-GMAW arc sensing technology. In this paper, we derived a linear mathematical P-GMAW model for arc sensing, and the assumptions for the model are verified through experiments and finite element methods. Finally, the linear characteristics of the mathematical model were investigated. In torch height changing experiments, uphill experiments, and groove angle changing experiments the P-GMAW arc signals all satisfied the linear rules. In addition, the faster the welding speed, the higher the arc signal sensitivities; the smaller the groove angle, the greater the arc sensitivities. The arc signal variation rate needs to be modified according to the welding power, groove angles, and weaving or rotate speed. PMID:28335425

Linear Mathematical Model for Seam Tracking with an Arc Sensor in P-GMAW Processes.

PubMed

Liu, Wenji; Li, Liangyu; Hong, Ying; Yue, Jianfeng

2017-03-14

Arc sensors have been used in seam tracking and widely studied since the 80s and commercial arc sensing products for T and V shaped grooves have been developed. However, it is difficult to use these arc sensors in narrow gap welding because the arc stability and sensing accuracy are not satisfactory. Pulse gas melting arc welding (P-GMAW) has been successfully applied in narrow gap welding and all position welding processes, so it is worthwhile to research P-GMAW arc sensing technology. In this paper, we derived a linear mathematical P-GMAW model for arc sensing, and the assumptions for the model are verified through experiments and finite element methods. Finally, the linear characteristics of the mathematical model were investigated. In torch height changing experiments, uphill experiments, and groove angle changing experiments the P-GMAW arc signals all satisfied the linear rules. In addition, the faster the welding speed, the higher the arc signal sensitivities; the smaller the groove angle, the greater the arc sensitivities. The arc signal variation rate needs to be modified according to the welding power, groove angles, and weaving or rotate speed.

[Plasma temperature calculation and coupling mechanism analysis of laser-double wire hybrid welding].

PubMed

Zheng, Kai; Li, Huan; Yang, Li-Jun; Gu, Xiao-Yan; Gao, Ying

2013-04-01

The plasma radiation of laser-double wire hybrid welding was collected by using fiber spectrometer, the coupling mechanism of arc with laser was studied through high-speed photography during welding process, and the temperature of hybrid plasma was calculated by using the method of Boltzmann plot. The results indicated that with laser hybrid, luminance was enhanced; radiation intensity became stronger; arc was attracted to the laser point; cross section contracted and arc was more stable. The laser power, welding current and arc-arc distance are important factors that have great influence on electron temperature. Increase in the laser power, amplification of welding current and reduction of arc-arc distance can all result in the rise of temperature.

Process stability during fiber laser-arc hybrid welding of thick steel plates

NASA Astrophysics Data System (ADS)

Bunaziv, Ivan; Frostevarg, Jan; Akselsen, Odd M.; Kaplan, Alexander F. H.

2018-03-01

Thick steel plates are frequently used in shipbuilding, pipelines and other related heavy industries, and are usually joined by arc welding. Deep penetration laser-arc hybrid welding could increase productivity but has not been thoroughly investigated, and is therefore usually limited to applications with medium thickness (5-15 mm) sections. A major concern is process stability, especially when using modern welding consumables such as metal-cored wire and advanced welding equipment. High speed imaging allows direct observation of the process so that process behavior and phenomena can be studied. In this paper, 45 mm thick high strength steel was welded (butt joint double-sided) using the fiber laser-MAG hybrid process utilizing a metal-cored wire without pre-heating. Process stability was monitored under a wide range of welding parameters. It was found that the technique can be used successfully to weld thick sections with appropriate quality when the parameters are optimized. When comparing conventional pulsed and the more advanced cold metal transfer pulse (CMT+P) arc modes, it was found that both can provide high quality welds. CMT+P arc mode can provide more stable droplet transfer over a limited range of travel speeds. At higher travel speeds, an unstable metal transfer mechanism was observed. Comparing leading arc and trailing arc arrangements, the leading arc configuration can provide higher quality welds and more stable processing at longer inter-distances between the heat sources.

Process Stability of Ultrasonic-Wave-Assisted Gas Metal Arc Welding

NASA Astrophysics Data System (ADS)

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

2017-10-01

As a newly developed arc welding method, ultrasonic-wave-assisted arc welding successfully introduced power ultrasound into the arc and weld pool, during which the ultrasonic acts on the top of the arc in the coaxial alignment direction. The advanced process for molten metals can be realized by using an additional ultrasonic field. Compared with the conventional gas metal arc welding (GMAW), the welding arc is compressed, the droplet size is decreased, and the droplet transfer frequency is increased significantly in ultrasonic-wave-assisted GMAW (U-GMAW). However, the stability of the metal transfer has deep influence on the welding quality equally, and the ultrasonic wave effect on the stability of the metal transfer is a phenomenon that is not completely understood. In this article, the stabilities of the short-circuiting transfer process and globular transfer process are studied systematically, and the effect of ultrasonic wave on the metal transfer is analyzed further. The transfer frequency and process stability of the U-GMAW process are much higher than those of the conventional GMAW. Analytical results show that the additional ultrasonic wave is helpful for improving welding stability.

Survey of welding processes.

DOT National Transportation Integrated Search

2003-07-01

The current KYTC SPECIAL PROVISION NO. 4 WELDING STEEL BRIDGES prohibits the use of welding processes other than shielded metal arc welding (SMAW) and submerged arc welding (SAW). Nationally, bridge welding is codified under ANSI/AASHTO/AWS D1....

Blue-Light Hazard From Gas Metal Arc Welding of Aluminum Alloys.

PubMed

Nakashima, Hitoshi; Takahashi, Jyunya; Fujii, Nobuyuki; Okuno, Tsutomu

2017-10-01

The objective was to quantify the blue-light hazard from gas metal arc welding (GMAW) of aluminum alloys. The exposure level is expected to depend on the welding conditions. Therefore, it is important to identify the blue-light hazard under various welding conditions. We experimentally conducted GMAW of aluminum alloys under various welding conditions and measured the spectral radiance of the arcs. The effective blue-light radiance, which the American Conference of Governmental Industrial Hygienists has defined to quantify the exposure level of blue light, was calculated from the measured spectral radiance. The maximum acceptable exposure duration per 10000 s for this effective blue-light radiance was calculated. The effective blue-light radiance measured in this study was in the range of 2.9-20.0 W cm-2·sr. The corresponding maximum acceptable exposure duration per 10000 s was only 5.0-34 s, so it is hazardous to view the welding arc. The effective blue-light radiance was higher at higher welding currents than at lower welding currents, when pulsed welding currents were used rather than steady welding currents, and when magnesium was included in the welding materials. It is very hazardous to view the arcs in GMAW of aluminum alloys. Welders and their helpers should use appropriate eye protection in arc-welding operations. They should also avoid direct light exposure when starting an arc-welding operation. © The Author 2017. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.

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.

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.

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

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.

Improvement of laser keyhole formation with the assistance of arc plasma in the hybrid welding process of magnesium alloy

NASA Astrophysics Data System (ADS)

Liu, Liming; Hao, Xinfeng

2009-11-01

In the previous work, low-power laser/arc hybrid welding technique is used to weld magnesium alloy and high-quality weld joints are obtained. In order to make clear the interactions between low-power laser pulse and arc plasma, the effect of arc plasma on laser pulse is studied in this article. The result shows that the penetration of low-power laser welding with the assistance of TIG arc is more than two times deeper than that of laser welding alone and laser welding transforms from thermal-conduction mode to keyhole mode. The plasma behaviors and spectra during the welding process are studied, and the transition mechanism of laser-welding mode is analyzed in detail. It is also found that with the assistance of arc plasma, the threshold value of average power density to form keyhole welding for YAG laser is only 3.3×10 4 W/cm 2, and the average peak power density is 2.6×10 5 W/cm 2 in the present experiment. Moreover, the distribution of energy density during laser pulse is modulated to improve the formation and stability of laser keyholes.

29 CFR 1915.56 - Arc welding and cutting.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 29 Labor 7 2014-07-01 2014-07-01 false Arc welding and cutting. 1915.56 Section 1915.56 Labor... (CONTINUED) OCCUPATIONAL SAFETY AND HEALTH STANDARDS FOR SHIPYARD EMPLOYMENT Welding, Cutting and Heating § 1915.56 Arc welding and cutting. The provisions of this section shall apply to ship repairing...

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.

Analysis of droplet transfer mode and forming process of weld bead in CO 2 laser-MAG hybrid welding process

NASA Astrophysics Data System (ADS)

Liu, Shuangyu; Liu, Fengde; Zhang, Hong; Shi, Yan

2012-06-01

In this paper, CO 2 laser-metal active gas (MAG) hybrid welding technique is used to weld high strength steel and the optimized process parameters are obtained. Using LD Pumped laser with an emission wavelength of 532 nm to overcome the strong interference from the welding arc, a computer-based system is developed to collect and visualize the waveforms of the electrical welding parameters and metal transfer processes in laser-MAG. The welding electric signals of hybrid welding processes are quantitatively described and analyzed using the ANALYSATOR HANNOVER. The effect of distance between laser and arc ( DLA) on weld bead geometry, forming process of weld shape, electric signals, arc characteristic and droplet transfer behavior is investigated. It is found that arc characteristic, droplet transfer mode and final weld bead geometry are strongly affected by the distance between laser and arc. The weld bead geometry is changed from "cocktail cup" to "cone-shaped" with the increasing DLA. The droplet transfer mode is changed from globular transfer to projected transfer with the increasing DLA. Projected transfer mode is an advantage for the stability of hybrid welding processes.

Investigation of Hot Cracking Behavior in Transverse Mechanically Arc Oscillated Autogenous AA2014 T6 TIG Welds

NASA Astrophysics Data System (ADS)

Biradar, N. S.; Raman, R.

2012-09-01

Hot cracking studies on autogenous AA2014 T6 TIG welds were carried out. Significant cracking was observed during linear and circular welding test (CWT) on 4-mm-thick plates. Weld metal grain structure and amount of liquid distribution during the terminal stages of solidification were the key cause for hot cracking in aluminum welds. Square-wave AC TIG welding with transverse mechanical arc oscillation (TMAO) was employed to study the cracking behavior during linear and CWT. TMAO welds with amplitude = 0.9 mm and frequency = 0.5 Hz showed significant reduction in cracking tendency. The increase in cracking resistance in the arc-oscillated weld was attributed to grain refinement and improved weld bead morphology, which improved the weld metal ductility and uniformity, respectively, of residual tensile stresses that developed during welding. The obtained results were comparable to those of reported favorable results of electromagnetic arc oscillation.

Distribution of Argon Arc Contaminated with Nitrogen as Function of Frequency in Pulsed TIG Welding

NASA Astrophysics Data System (ADS)

Takahashi, Hiroki; Tanaka, Tatsuro; Yamamoto, Shinji; Iwao, Toru

2016-09-01

TIG arc welding is the high-quality and much applicable material joining technology. However, the current has to be small because the cathode melting should be prevented. In this case, the heat input to the welding pool becomes low, then, the welding defect sometimes occurs. The pulsed TIG arc welding is used to improve this disadvantage This welding can be controlled by some current parameters such as frequency However, few report has reported the distribution of argon arc contaminated with nitrogen It is important to prevent the contamination of nitrogen because the melting depth increases in order to prevent the welding defects. In this paper, the distribution of argon arc contaminated as function of frequency with nitrogen in pulsed TIG welding is elucidated. The nitrogen concentration, the radial flow velocity, the arc temperature were calculated using the EMTF simulation when the time reached at the base current. As a result, the nitrogen concentration into the arc became low with increasing the frequency The diffusion coefficient decreased because of the decrement of temperature over 4000 K. In this case, the nitrogen concentration became low near the anode. Therefore, the nitrogen concentration became low because the frequency is high.

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.

Reduction of Residual Stress and Distortion in HY100 and HY130 High Strength Steels During Welding

DTIC Science & Technology

1989-06-01

SMAW), Gas Tungsten Arc Welding ( GTAW ), Gas Metal Arc Welding (GMAW), Submerged Arc Welding (SAW), and Stud Welding (SW) the recommended joint...3.2 4.83 Cr Chromium -(3) 1.5 .55 M0 Molybdium -(3) .40 .40 V Vanadium -(3) .08 T i Titanium -(3) .005 Identifier ABS Class B USX TAG328 Lukens

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.

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…

Welding Experiments of Aluminum Alloy by Space GHTA Welding in the ISS Orbital Pressure

NASA Astrophysics Data System (ADS)

Suita, Yoshikazu; Takai, Daisuke; Sugiyama, Satoshi; Terajima, Noboru; Tsukuda, Yoshiyuki; Fujisawa, Shoichiro; Imagawa, Kichiro

As a feasible welding method in space, the authors have previously proposed the space GHTA (Gas Hollow Tungsten Arc) welding process. The space GHTA welding with high frequency power source for the arc starting may cause the electro-magnetic noise problems of computer equipments placed on the ISS. Therefore, in this paper the welding experiments of aluminum alloy by the space GHTA welding with DC high voltage power source for the arc starting was carried out in the ISS orbital pressure 10-5Pa. It is made clear that there is the shifting phenomenon in which the spark discharge changes to the glow or arc discharge at starting phenomenon of the space GHTA welding in high vacuum condition, and the features of those starting phenomenon are demonstrated. And the space GHTA welding with DC high voltage power source can be used for welding in the ISS orbital pressure.

Dredge Mooring Study Recommended Design, Phase 2 Report

DTIC Science & Technology

1992-05-01

processes are acceptable under this Specification: a. Shielded Metal Arc Welding (SMAW). b. Gas Tungsten-Arc Welding ( GTAW or TIG). c. Gas Metal-Arc...the GTAW process. 11.3.9.3 For welding of stainless steel pipe, the GTAW process shall be used on the root pass of open butt joints welded from one...whichever is greater, from each edge of the weld (t = wall thickness of the thickest part being welded). 11.3.11.5 Postweld heat treatment for chromium

Particulate and gaseous emissions when welding aluminum alloys.

PubMed

Cole, Homer; Epstein, Seymour; Peace, Jon

2007-09-01

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

Significance of the Resonance Condition for Controlling the Seam Position in Laser-assisted TIG Welding

NASA Astrophysics Data System (ADS)

Emde, B.; Huse, M.; Hermsdorf, J.; Kaierle, S.; Wesling, V.; Overmeyer, L.; Kozakov, R.; Uhrlandt, D.

As an energy-preserving variant of laser hybrid welding, laser-assisted arc welding uses laser powers of less than 1 kW. Recent studies have shown that the electrical conductivity of a TIG welding arc changes within the arc in case of a resonant interaction between laser radiation and argon atoms. This paper presents investigations on how to control the position of the arc root on the workpiece by means of the resonant interaction. Furthermore, the influence on the welding result is demonstrated. The welding tests were carried out on a cooled copper plate and steel samples with resonant and non-resonant laser radiation. Moreover, an analysis of the weld seam is presented.

Hybrid/Tandem Laser-Arc Welding of Thick Low Carbon Martensitic Stainless Steel Plates =

NASA Astrophysics Data System (ADS)

Mirakhorli, Fatemeh

High efficiency and long-term life of hydraulic turbines and their assemblies are of utmost importance for the hydropower industry. Usually, hydroelectric turbine components are made of thick-walled low carbon martensitic stainless steels. The assembly of large hydroelectric turbine components has been a great challenge. The use of conventional welding processes involves typical large groove design and multi-pass welding to fill the groove which exposes the weld to a high heat input creating relatively large fusion zone and heat affected zone. The newly-developed hybrid/tandem laser-arc welding technique is believed to offer a highly competitive solution to improve the overall hydro-turbine performance by combining the high energy density and fast welding speed of the laser welding technology with the good gap bridging and feeding ability of the gas metal arc welding process to increase the productivity and reduce the consumable material. The main objective of this research work is to understand different challenges appearing during hybrid laser-arc welding (HLAW) of thick gauge assemblies of low carbon 13%Cr- 4%Ni martensitic stainless steel and find a practical solution by adapting and optimizing this relatively new welding process in order to reduce the number of welding passes necessary to fill the groove gap. The joint integrity was evaluated in terms of microstructure, defects and mechanical properties in both as-welded and post-welded conditions. A special focus was given to the hybrid and tandem laser-arc welding technique for the root pass. Based on the thickness of the low carbon martensitic stainless steel plates, this work is mainly focused on the following two tasks: • Single pass hybrid laser-arc welding of 10-mm thick low carbon martensitic stainless steel. • Multi-pass hybrid/tandem laser-arc welding of 25-mm thick martensitic stainless steel.

Coupling of Laser with Plasma Arc to Facilitate Hybrid Welding of Metallic Materials: A Review

NASA Astrophysics Data System (ADS)

Zhiyong, Li; Srivatsan, T. S.; Yan, LI; Wenzhao, Zhang

2013-02-01

Hybrid laser arc welding combines the advantages of laser welding and arc welding. Ever since its origination in the late 1970s, this technique has gained gradual attention and progressive use due to a combination of high welding speed, better formation of weld bead, gap tolerance, and increased penetration coupled with less distortion. In hybrid laser arc welding, one of the reasons for the observed improvement is an interaction or coupling effect between the plasma arc, laser beam, droplet transfer, and the weld pool. Few researchers have made an attempt to study different aspects of the process to facilitate a better understanding. It is difficult to get a thorough understanding of the process if only certain information in a certain field is provided. In this article, an attempt to analyze the coupling effect of the process was carried out based on a careful review of the research work that has been done which provides useful information from a different prospective.

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.

BMP Report Of Survey Conducted At University Of New Orleans, LA Best Manufacturing Practices

DTIC Science & Technology

2003-01-01

external influences. Several differ- ent technologies have been used to combat this problem. Chromium , cop- per, lead, cadmium, and zinc metals are...SMAW) on AH36 and Stainless Steel • Gas Metal Arc Welding (GMAW) on Stain- less Steel • Gas Tungsten Arc Welding ( GTAW ) on Stainless Steel and...GCRMTC Gulf Coast Region Maritime Technology Center GMAW Gas Metal Arc Welding GTAW Gas Tungsten Arc Welding ISO International Standards Organization

Application of YAG Laser TIG Arc Hybrid Welding to Thin AZ31B Magnesium Alloy Sheet

NASA Astrophysics Data System (ADS)

Kim, Taewon; Kim, Jongcheol; Hasegawa, Yu; Suga, Yasuo

A magnesium alloy is said to be an ecological material with high ability of recycling and lightweight property. Especially, magnesium alloys are in great demand on account of outstanding material property as a structural material. Under these circumstances, research and development of welding process to join magnesium alloy plates are of great significance for wide industrial application of magnesium. In order to use it as a structure material, the welding technology is very important. TIG arc welding process is the most ordinary process to weld magnesium alloy plates. However, since the heat source by the arc welding process affects the magnesium alloy plates, HAZ of welded joint becomes wide and large distortion often occurs. On the other hand, a laser welding process that has small diameter of heat source seems to be one of the possible means to weld magnesium alloy in view of the qualitative improvement. However, the low boiling point of magnesium generates some weld defects, including porosity and solidification cracking. Furthermore, precise edge preparation is very important in butt-welding by the laser welding process, due to the small laser beam diameter. Laser/arc hybrid welding process that combines the laser beam and the arc is an effective welding process in which these two heat sources influence and assist each other. Using the hybrid welding, a synegistic effect is achievable and the disadvantages of the respective processes can be compensated. In this study, YAG laser/TIG arc hybrid welding of thin magnesium alloy (AZ31B) sheets was investigated. First of all, the effect of the irradiation point and the focal position of laser beam on the quality of a weld were discussed in hybrid welding. Then, it was confirmed that a sound weld bead with sufficient penetration is obtained using appropriate welding conditions. Furthermore, it was made clear that the heat absorption efficiency is improved with the hybrid welding process. Finally, the tensile tests of welded joints were performed, and it was confirmed that they have sufficient mechanical properties. As a result of this study, it is confirmed that, if the appropriate welding conditions are selected, sound welded joints of AZ31B magnesium alloy are obtainable by the YAG laser/TIG arc hybrid welding process.

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.

Moisture contamination and welding parameter effects on flux cored arc welding diffusible hydrogen

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kiefer, J.J.

1994-12-31

Gas metal arc (GMAW) and flux cored arc (FCAW) welding are gas shielded semiautomatic processes widely used for achieving high productivity in steel fabrication. Contamination of the shielding has can occur due to poorly maintained gas distribution systems. Moisture entering as a gas contaminant is a source of hydrogen that can cause delayed cold cracking in welds. Limiting heat-affected zone hardness is one method of controlling cracking. Even this is based on some assumptions about the hydrogen levels in the weld. A study was conducted to investigate the effect of shielding gas moisture contamination and welding parameters on the diffusiblemore » hydrogen content of gas shielded flux cored arc welding. The total wire hydrogen of various electrodes was also tested and compared to the diffusible weld hydrogen. An empirical equation has been developed that estimates the diffusible hydrogen in weld metal for gas shielded flux cored arc welding. The equation is suitable for small diameter electrodes and welding parameter ranges commonly used for out-of-position welding. by combining this with the results from the total wire hydrogen tests, it is possible to estimate diffusible hydrogen directly from measured welding parameters, shielding gas dew point, and total hydrogen of the consumable. These equations are also useful for evaluating the effect of welding procedure variations from known baseline conditions.« less

Effect of process parameters on temperature distribution in twin-electrode TIG coupling arc

NASA Astrophysics Data System (ADS)

Zhang, Guangjun; Xiong, Jun; Gao, Hongming; Wu, Lin

2012-10-01

The twin-electrode TIG coupling arc is a new type of welding heat source, which is generated in a single welding torch that has two tungsten electrodes insulated from each other. This paper aims at determining the distribution of temperature for the coupling arc using the Fowler-Milne method under the assumption of local thermodynamic equilibrium. The influences of welding current, arc length, and distance between both electrode tips on temperature distribution of the coupling arc were analyzed. Based on the results, a better understanding of the twin-electrode TIG welding process was obtained.

Transient Response of Arc Temperature and Iron Vapor Concentration Affected by Current Frequency with Iron Vapor in Pulsed Arc

NASA Astrophysics Data System (ADS)

Tanaka, Tatsuro; Maeda, Yoshifumi; Yamamoto, Shinji; Iwao, Toru

2016-10-01

TIG arc welding is chemically a joining technology with melting the metallic material and it can be high quality. However, this welding should not be used in high current to prevent cathode melting. Thus, the heat transfer is poor. Therefore, the deep penetration cannot be obtained and the weld defect sometimes occurs. The pulsed arc welding has been used for the improvement of this defect. The pulsed arc welding can control the heat flux to anode. The convention and driving force in the weld pool are caused by the arc. Therefore, it is important to grasp the distribution of arc temperature. The metal vapor generate from the anode in welding. In addition, the pulsed current increased or decreased periodically. Therefore, the arc is affected by such as a current value and current frequency, the current rate of increment and the metal vapor. In this paper, the transient response of arc temperature and the iron vapor concentration affected by the current frequency with iron vapor in pulsed arc was elucidated by the EMTF (ElectroMagnetic Thermal Fluid) simulation. As a result, the arc temperature and the iron vapor were transient response as the current frequency increase. Thus, the temperature and the electrical conductivity decreased. Therefore, the electrical field increased in order to maintain the current continuity. The current density and electromagnetic force increased at the axial center. In addition, the electronic flow component of the heat flux increased at the axial center because the current density increased. However, the heat conduction component of the heat flux decreased.

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.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray

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. Tomore » 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.« less

Effects of electrode bevel angle on argon arc properties and weld shape

NASA Astrophysics Data System (ADS)

Dong, W. C.; Lu, S. P.; Li, D. Z.; Y Li, Y.

2012-07-01

A numerical modeling of coupled welding arc with weld pool is established using FLUENT software for moving shielded GTA welding to systematically investigate the effects of electrode bevel angle on the argon arc properties as well as the weld shape on SUS304 stainless steel. The calculated results show that the argon arc is constricted and the peak values of heat flux and shear stress on the weld pool decrease with increasing electrode bevel angle, while the radial distribution of heat flux and shear stress varying slightly. The weld shape is controlled by the pool flow patterns driving by the surface tension, gas shear stress, electromagnetic force and buoyancy. The Marangoni convection induced by surface tension plays an important role on weld shapes. All the weld shapes are wide and shallow with low weld metal oxygen content, while the narrow and deep weld shapes form under high weld metal oxygen content, which is related with the oxygen concentration in the shielding gas. The weld depth/width (D/W) ratio increases with increasing electrode bevel angle for high weld metal oxygen content and is not sensitive to the electrode bevel angle under low weld metal oxygen content. The calculated results for the weld shape, weld size and weld D/W ratio agree well with the experimental ones.

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 are significantly affected by thin film coatings on solid wire electrodes for Gas Metal Arc welding. The influences are regarding the stability of the arc, the properties of the weld metal in terms of geometric expression, chemical composition and mechanical properties, the composition of the arc-plasma and the dynamics of the molten metal.

Emissions of chromium (VI) from arc welding.

PubMed

Heung, William; Yun, Myoung-Jin; Chang, Daniel P Y; Green, Peter G; Halm, Chris

2007-02-01

The presence of Cr in the +6 oxidation state (Cr[VI]) is still observed in ambient air samples in California despite steps taken to reduce emissions from plating operations. One known source of emission of Cr(VI) is welding, especially with high Cr-content materials, such as stainless steels. An experimental effort was undertaken to expand and update Cr(VI) emission factors by conducting tests on four types of arc-welding operations: gas-metal arc welding (GMAW), shielded metal arc welding (SMAW), fluxcore arc welding, and pulsed GMAW. Standard American Welding Society hood results were compared with a total enclosure method that permitted isokinetic sampling for particle size-cut measurement, as well as total collection of the aerosol. The fraction of Cr(VI) emitted per unit mass of Cr electrode consumed was determined. Consistent with AP-42 data, initial results indicate that a significant fraction of the total Cr in the aerosol is in the +6 oxidation state. The fraction of Cr(VI) and total aerosol mass produced by the different arc welding methods varies with the type of welding process used. Self-shielded electrodes that do not use a shield gas, for example, SMAW, produce greater amounts of Cr(VI) per unit mass of electrode consumed. The formation of Cr(VI) from standard electrode wires used for welding mild steel was below the method detection limit after eliminating an artifact in the analytical method used.

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.

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.

73rd American Welding Society annual meeting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1992-01-01

The volume includes the abstracts of papers presented at the 73rd American Welding Society Annual Meeting. Detailed summaries are given for 118 technical sessions papers discussing computer and control applications in welding, stainless steel, nickel and nickel alloys, weld metal microstructure, shipbuilding, consumables, structural welding, investigations in arc welding and cutting, arc welding processes, weldability testing, piping and tubing, high energy beam welding processes, welding metallurgy of structural steels, new applications, weld metal behavior, NDT certification, aluminum welding, submerged arc welding, modeling studies, resistance welding, friction welding, and safety and health. The 23rd International AWS Brazing and Soldering Conference wasmore » also held during this meeting. The topics presented in 24 papers included recent developments in soldering technology, brazing of stainless steel, brazing of ceramics and nickel material, filler metal developments for torch brazing, and developments in diffusion and induction brazing.« less

Gas Metal Arc Weld (GMAW) Qualification of 7020-T651 Aluminum

DTIC Science & Technology

2015-11-01

ARL-TR-7515 ● NOV 2015 US Army Research Laboratory Gas Metal Arc Weld (GMAW) Qualification of 7020-T651 Aluminum by John F...Metal Arc Weld (GMAW) Qualification of 7020-T651 Aluminum by John F Chinella Weapons and Materials Research Directorate, ARL Nick Kapustka and...Seth Shira Edison Welding Institute, Columbus, Ohio Approved for public release; distribution is unlimited. ii REPORT

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.

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.

Guidelines in the Choice of Parameters for Hybrid Laser Arc Welding with Fiber Lasers

NASA Astrophysics Data System (ADS)

Eriksson, I.; Powell, J.; Kaplan, A.

Laser arc hybrid welding has been a promising technology for three decades and laser welding in combination with gas metal arc welding (GMAW) has shown that it is an extremely promising technique. On the other hand the process is often considered complicated and difficult to set up correctly. An important factor in setting up the hybrid welding process is an understanding of the GMAW process. It is especially important to understand how the wire feed rate and the arc voltage (the two main parameters) affect the process. In this paper the authors show that laser hybrid welding with a 1 μm laser is similar to ordinary GMAW, and several guidelines are therefore inherited by the laser hybrid process.

Research Progress in Plasma arc welding of Magnesium Alloys and Magnesium Matrix Composites

NASA Astrophysics Data System (ADS)

Hui, Li; Yang, Zou; Yongbo, Li; Lei, Jiao; Ruijun, Hou

2017-11-01

Magnesium alloys and magnesium matrix composites by means of its excellent performance have wide application prospect in electronics, automotive, biotechnology, aerospace field, and welding technology has become a key of restricting its application. This paper describes the welding characteristics of magnesium, the obvious advantages in the application and the domestic and foreign research advance technology of plasma arc welding of magnesium, and summarizes the existing problems and development trends of plasma arc welding technology of magnesium.

Inverter-based GTA welding machines improve fabrication

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sammons, M.

2000-05-01

While known as precision process, many fabricators using the gas tungsten arc welding (GTAW) process fight several common problems that hinder quality, slow production, frustrate the operator and otherwise prevent the process from achieving its full potential. These include a limited ability to tailor the weld bead profile, poor control of the arc direction and arc wandering, poor arc starting, unstable or inconsistent arcs in the AC mode, high-frequency interference with electronics and tungsten contamination. Fortunately, new GTA welding technology--made possible by advances with inverter-based power sources and micro-processor controls--can eliminate common productivity gremlins. Further, new AC/DC inverter-based GTA powermore » sources provide advanced arc shaping capabilities. As a result, many fabricators adopting this new technology have experienced phenomenal production increases, taken on new types of projects and reduced costs. Most importantly, the operators enjoy welding more.« less

Assessing the Impact of Sequencing Practicums for Welding in Agricultural Mechanics

ERIC Educational Resources Information Center

Rose, Malcolm; Pate, Michael L.; Lawver, Rebecca G.; Warnick, Brian K.; Dai, Xin

2015-01-01

This study examined the impact of sequencing practicums for welding on students' ability to perform a 1F (flat position-fillet lap joint) weld on low-carbon steel. Participants were randomly assigned a specific practice sequence of welding for using gas metal arc welding (GMAW) and shielded metal arc welding (SMAW). A total of 71 participants…

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. Copyright © 2015 Elsevier B.V. All rights reserved.

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.

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.

In Process Measurement of Hydrogen in Welding

DTIC Science & Technology

1986-09-01

Specimen Geometry.........40 Figure 4.8 GTAW Diffusible Hydrogen Specimen Geometry .......... 40 Figure 4.9 Schematic of Specimen Outgassing Container for... GTAW ) and gas metal arc welding (GMAW) have the lowest potentials for hydrogen pickup, while -. the flux-cored arc welding (FCAW) and submerged arc...wire during welding which is the major source of hydrogen in GMAW and GTAW . Although the FCAW process was originally considered an intrinsi- cally low

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 bymore » 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.« less

Influence of the Gap Width on the Geometry of the Welded Joint in Hybrid Laser-Arc Welding

NASA Astrophysics Data System (ADS)

Turichin, G.; Tsibulskiy, I.; Kuznetsov, M.; Akhmetov, A.; Mildebrath, M.; Hassel, T.

The aim of this research was the experimental investigation of the influence of the gap width and speed of the welding wire on the changes of the geometry in the welded joint in the hybrid laser-arc welding of shipbuilding steel RS E36. The research was divided into three parts. First, in order to understand the influence of the gap width on the welded joint geometry, experimental research was done using continuous wave fiber laser IPG YLS-15000 with arc rectifier VDU-1500DC. The second part involved study of the geometry of the welded joint and hardness test results. Three macrosections from each welded joint were obtained. Influence of the gap width and welding wire speed on the welded joint geometry was researched in the three lines: in the right side of the plates, middle welded joint and in the root welded joint.

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.

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.

Auto Body Welding 2 (Course Outline), Automotive Body Repair and Refinishing 1: 9033.04.

ERIC Educational Resources Information Center

Dade County Public Schools, Miami, FL.

The 90-hour course is a foundation quinmester course in welding for the auto body repairman. The outline consists of seven blocks of instruction (orientation, 6 hours; auto body oxyacetylene welding, 10 hours; electric arc welding equipment, 6 hours; auto body electric arc welding, 8 hours; position welding, 40 hours; electric spot welders, 16…

An Evaluation of Former Soviet Union Welding Processes on Commercially Pure Titanium

DTIC Science & Technology

2001-12-01

welding (GTAW), gas metal arc welding ( GMAW ), and plasma arc welding (PAW) being the most widely used techniques. Of these, the GTAW process is much...quality welds, is free of the spatter that may occur with GMAW , and can be used with or without filler material, depending on the specific application

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.

Chamber free fusion welding root side purging method and apparatus

NASA Technical Reports Server (NTRS)

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

1993-01-01

A method and apparati are presented for non-chamber root side purging in fusion welding of oxygen reactive metals which require that the molten weld zone and local solid areas of the weld seam remaining at high temperatures be shielded from normal atmosphere to prevent degradation of the welded area. The apparati provide an inert atmosphere to the root side of a weld joint through a porous medium whereby the jet-like thrust of the plasma arc actually draws the continuously supplied inert atmosphere into the path of the molten or high temperature solid weld zone. The porous medium is configured so it can be placed at the borders of the weld seam and substantially parallel to the seam without restricting the view of the root side of the seam. The inert gas is dispersed evenly through the porous media and across the weld seam, at the point of arc penetration and in front of and behind the arc. The apparati can be constructed so as to limit the amount of inert gas flow and can be mobile and travel synchronously with the welding arc.

Chamber free fusion welding root side purging method and apparatus

NASA Technical Reports Server (NTRS)

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

1995-01-01

A method and apparati are presented for non-chamber root side purging in fusion welding of oxygen reactive metals which require that the molten weld zone and local solid areas of the weld seam remaining at high temperatures be shielded from normal atmosphere to prevent degradation of the welded area. The apparati provide an inert atmosphere to the root side of a weld joint through a porous medium whereby the jet-like thrust of the plasma arc actually draws the continuously supplied inert atmosphere into the path of the molten or high temperature solid weld zone. The porous medium is configured so it can be placed at the borders of the weld seam and substantially parallel to the seam without restricting the view of the root side of the seam. The inert gas is dispersed evenly through the porous media and across the weld seam, at the point of arc penetration and in front of and behind the arc. The apparati can be constructed so as to limit the amount of inert gas flow and can be mobile and travel synchronously with the welding arc.

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.

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.

Mechanical Properties of Aluminum-Based Dissimilar Alloy Joints by Power Beams, Arc and FSW Processes

NASA Astrophysics Data System (ADS)

Okubo, Michinori; Kon, Tomokuni; Abe, Nobuyuki

Dissimilar smart joints are useful. In this research, welded quality of dissimilar aluminum alloys of 3 mm thickness by various welding processes and process parameters have been investigated by hardness and tensile tests, and observation of imperfection and microstructure. Base metals used in this study are A1050-H24, A2017-T3, A5083-O, A6061-T6 and A7075-T651. Welding processes used are YAG laser beam, electron beam, metal inert gas arc, tungsten inert gas arc and friction stir welding. The properties of weld zones are affected by welding processes, welding parameters and combination of base metals. Properties of high strength aluminum alloy joints are improved by friction stir welding.

Materials Trends in Marine Construction

DTIC Science & Technology

1990-01-01

purposes. Nickel and 5 chromium are added to increase toughness and both nickel and molybdenum are used to control the response of the alloy to the Q&T...submerged metal arc welding (SAW): 15%; CO shielded gas metal arc welding (GMAW): 30%; with gas tungsten arc welding ( GTAW ) and electroslag welding...ESW) providing the remainder. GMAW is used more for the high strength quenched and tempered steels, while GTAW is used on a limited basis to remelt the

[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.

Theoretical model and experimental investigation of current density boundary condition for welding arc study

NASA Astrophysics Data System (ADS)

Boutaghane, A.; Bouhadef, K.; Valensi, F.; Pellerin, S.; Benkedda, Y.

2011-04-01

This paper presents results of theoretical and experimental investigation of the welding arc in Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW) processes. A theoretical model consisting in simultaneous resolution of the set of conservation equations for mass, momentum, energy and current, Ohm's law and Maxwell equation is used to predict temperatures and current density distribution in argon welding arcs. A current density profile had to be assumed over the surface of the cathode as a boundary condition in order to make the theoretical calculations possible. In stationary GTAW process, this assumption leads to fair agreement with experimental results reported in literature with maximum arc temperatures of ~21 000 K. In contrast to the GTAW process, in GMAW process, the electrode is consumable and non-thermionic, and a realistic boundary condition of the current density is lacking. For establishing this crucial boundary condition which is the current density in the anode melting electrode, an original method is setup to enable the current density to be determined experimentally. High-speed camera (3000 images/s) is used to get geometrical dimensions of the welding wire used as anode. The total area of the melting anode covered by the arc plasma being determined, the current density at the anode surface can be calculated. For a 330 A arc, the current density at the melting anode surface is found to be of 5 × 107 A m-2 for a 1.2 mm diameter welding electrode.

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.

Studies on the Parametric Effects of Plasma Arc Welding of 2205 Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Selva Bharathi, R.; Siva Shanmugam, N.; Murali Kannan, R.; Arungalai Vendan, S.

2018-03-01

This research study attempts to create an optimized parametric window by employing Taguchi algorithm for Plasma Arc Welding (PAW) of 2 mm thick 2205 duplex stainless steel. The parameters considered for experimentation and optimization are the welding current, welding speed and pilot arc length respectively. The experimentation involves the parameters variation and subsequently recording the depth of penetration and bead width. Welding current of 60-70 A, welding speed of 250-300 mm/min and pilot arc length of 1-2 mm are the range between which the parameters are varied. Design of experiments is used for the experimental trials. Back propagation neural network, Genetic algorithm and Taguchi techniques are used for predicting the bead width, depth of penetration and validated with experimentally achieved results which were in good agreement. Additionally, micro-structural characterizations are carried out to examine the weld quality. The extrapolation of these optimized parametric values yield enhanced weld strength with cost and time reduction.

Control of the plume induced during high-power fiber laser welding with a transverse arc

NASA Astrophysics Data System (ADS)

Wu, Shikai; Zou, Jianglin; Xiao, Rongshi; Li, Fei

2015-04-01

In this letter, the addition of the transverse arc into high-power fiber welding is proposed. The effects of the transverse arc on the laser-induced plume, the morphology of the weld, and the stability of the welding process are investigated. The experimental results indicate that, by introducing the transverse arc, the slender plume disappears, the temperature of the plasma plume increases then decreases with the rise in height, the weld width is reduced by around 42%, and the weld depth and the melting area are enhanced by about 28 and 12%, respectively. Moreover, the stability of the welding process is improved remarkably. As concluded from further analysis, the Mie scattering of the incident laser, induced by the particles in the plume, is responsible for the adverse effects induced by the plume. With the addition of the transverse arc, the particles in the plume are gasified and, thus, do not impact the energy transmission of the fiber laser. Consequently, the adverse effects induced by the plume can be significantly suppressed while the laser energy utilization efficiency and the stability of the welding process are improved.

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)

Modeling of the Weld Shape Development During the Autogenous Welding Process by Coupling Welding Arc with Weld Pool

NASA Astrophysics Data System (ADS)

Dong, Wenchao; Lu, Shanping; Li, Dianzhong; Li, Yiyi

2010-10-01

A numerical model of the welding arc is coupled to a model for the heat transfer and fluid flow in the weld pool of a SUS304 stainless steel during a moving GTA welding process. The described model avoids the use of the assumption of the empirical Gaussian boundary conditions, and at the same time, provides reliable boundary conditions to analyze the weld pool. Based on the two-dimensional axisymmetric numerical modeling of the argon arc, the heat flux to workpiece, the input current density, and the plasma drag stress are obtained. The arc temperature contours, the distributions of heat flux, and current density at the anode are in fair agreement with the reported experimental results. Numerical simulation and experimental studies to the weld pool development are carried out for a moving GTA welding on SUS304 stainless steel with different oxygen content from 30 to 220 ppm. The calculated result show that the oxygen can change the Marangoni convection from outward to inward direction on the liquid pool surface and make the wide shallow weld shape become narrow deep one. The calculated result for the weld shape and weld D/W ratio agrees well with the experimental one.

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.

Wire-Guide Manipulator For Automated Welding

NASA Technical Reports Server (NTRS)

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

1994-01-01

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

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…

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…

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.

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.

Process Simulation of Gas Metal Arc Welding Software

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 ofmore » 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

Spectroscopic analysis technique for arc-welding process control

NASA Astrophysics Data System (ADS)

Mirapeix, Jesús; Cobo, Adolfo; Conde, Olga; Quintela, María Ángeles; López-Higuera, José-Miguel

2005-09-01

The spectroscopic analysis of the light emitted by thermal plasmas has found many applications, from chemical analysis to monitoring and control of industrial processes. Particularly, it has been demonstrated that the analysis of the thermal plasma generated during arc or laser welding can supply information about the process and, thus, about the quality of the weld. In some critical applications (e.g. the aerospace sector), an early, real-time detection of defects in the weld seam (oxidation, porosity, lack of penetration, ...) is highly desirable as it can reduce expensive non-destructive testing (NDT). Among others techniques, full spectroscopic analysis of the plasma emission is known to offer rich information about the process itself, but it is also very demanding in terms of real-time implementations. In this paper, we proposed a technique for the analysis of the plasma emission spectrum that is able to detect, in real-time, changes in the process parameters that could lead to the formation of defects in the weld seam. It is based on the estimation of the electronic temperature of the plasma through the analysis of the emission peaks from multiple atomic species. Unlike traditional techniques, which usually involve peak fitting to Voigt functions using the Levenberg-Marquardt recursive method, we employ the LPO (Linear Phase Operator) sub-pixel algorithm to accurately estimate the central wavelength of the peaks (allowing an automatic identification of each atomic species) and cubic-spline interpolation of the noisy data to obtain the intensity and width of the peaks. Experimental tests on TIG-welding using fiber-optic capture of light and a low-cost CCD-based spectrometer, show that some typical defects can be easily detected and identified with this technique, whose typical processing time for multiple peak analysis is less than 20msec. running in a conventional PC.

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.

Sensors control gas metal arc welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

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

1997-04-01

The response time of a trained welder from the time a weld problem is identified to the time action is taken is about one second--especially after a long, uneventful period of welding. This is acceptable for manual welding because it is close to the time it takes for the weld pool to solidify. If human response time were any slower, manual welding would not be possible. However, human response time is too slow to respond to some weld events, such as melting of the contact tube in gas metal arc welding (GMAW), and only automated intelligent control systems can reactmore » fast enough to correct or avoid these problems. Control systems incorporate welding knowledge that enables intelligent decisions to be made about weld quality and, ultimately, to keep welding parameters in the range where only high-quality welds are produced. This article discusses the correlation of electrical signals with contact-tube wear, changes in shielding gas, changes in arc length, and other weld process data.« less

Optimization of hybrid laser arc welding of 42CrMo steel to suppress pore formation

NASA Astrophysics Data System (ADS)

Zhang, Yan; Chen, Genyu; Mao, Shuai; Zhou, Cong; Chen, Fei

2017-06-01

The hybrid laser arc welding (HLAW) of 42CrMo quenched and tempered steel was conducted. The effect of the processing parameters, such as the relative positions of the laser and the arc, the shielding gas flow rate, the defocusing distance, the laser power, the wire feed rate and the welding speed, on the pore formation was analyzed, the morphological characteristics of the pores were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results showed that the majority of the pores were invasive. The pores formed at the leading a laser (LA) welding process were fewer than those at the leading a arc (AL) welding process. Increasing the shielding gas flow rate could also facilitate the reduction of pores. The laser power and the welding speed were two key process parameters to reduce the pores. The flow of the molten pool, the weld cooling rate and the pore escaping rate as a result of different parameters could all affect pore formation. An ideal pore-free weld was obtained for the optimal welding process parameters.

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

2016-12-01

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.

Modeling, simulation and control of pulsed DE-GMA welding process for joining of aluminum to steel

NASA Astrophysics Data System (ADS)

Zhang, Gang; Shi, Yu; Li, Jie; Huang, Jiankang; Fan, Ding

2014-09-01

Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme's feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme further. The beautiful and smooth weld beads are also obtained by this method. Pulsed DE-GMAW can thus be considered as an alternative method for low cost, high efficiency joining of aluminum to steel.

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.

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.

The influence of TIG-Arc physical characteristics on the penetration and weld width under different Ar and He supply conditions

NASA Astrophysics Data System (ADS)

Dai, Hongbin; Shen, Xiuqiang; Wang, Haoran

2018-06-01

In the paper, the 5A03 aluminium alloy was employed to study the influence of TIG arc on the penetration and the weld width. And the split anode method with water-cooled copper plate was used to measure and record the distribution of arc current, under different flow ratio of argon and helium conditions. And a gas supply device controlled by a solenoid valve was employed to obtain the stable TIG welding arc of gas supply alternately at the frequency of 1 Hz and 4 Hz, and then collected the phenomenon of arc alternate by the high-speed camera. The experimental results indicated that the current density at the arc anode center of argon and helium supply alternately with different mixing ratio is lower than that of the pure argon-arc center. Nonetheless, the former is more uniform in current density within 2 mm from the arc center. Furthermore, it presented as a component arc of argon-arc and helium-arc switched, with the condition of argon and helium supply alternately at a frequency of 1 Hz and the arc power density is greater and concentrated, leading to the wider and deeper weld.

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.

Pulsed welding plasma source

NASA Astrophysics Data System (ADS)

Knyaz'kov, A.; Pustovykh, O.; Verevkin, A.; Terekhin, V.; Shachek, A.; Tyasto, A.

2016-04-01

It is shown that in order to form the current pulse of a near rectangular shape, which provides conversion of the welding arc into a dynamic mode, it is rational to connect a forming element made on the basis of an artificial forming line in series to the welding DC circuit. The paper presents a diagram of a pulsed device for welding with a non-consumable electrode in argon which was developed using the forming element. The conversion of the arc into the dynamic mode is illustrated by the current and voltage oscillograms of the arc gap and the dynamic characteristic of the arc within the interval of one pulse generation time in the arc gap. The background current travels in the interpulse interval.

Fast, Nonspattering Inert-Gas Welding

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.

1991-01-01

Proposed welding technique combines best features of metal (other than tungsten)/inert-gas welding, plasma arc welding, and tungsten/inert-gas welding. Advantages include: wire fed to weld joint preheated, therefore fed at high speed without spattering; high-frequency energy does not have to be supplied to workpiece to initiate welding; size of arc gap not critical, power-supply control circuit adjusts voltage across gap to compensate for changes; only low gas-flow rate needed; welding electrode replaced easily as prefabricated assembly; external wire-feeding manipulator not needed; and welding process relatively forgiving of operator error.

An evaluation of welding processes to reduce hexavalent chromium exposures and reduce costs by using better welding techniques.

PubMed

Keane, Michael J

2014-01-01

A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr(6+)) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr(6+) were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr(6+) emissions, and greatly reduce costs relative to SMAW.

An Evaluation of Welding Processes to Reduce Hexavalent Chromium Exposures and Reduce Costs by Using Better Welding Techniques

PubMed Central

Keane, Michael J

2014-01-01

A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr6+) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr6+ were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr6+ emissions, and greatly reduce costs relative to SMAW. PMID:25574138

Electromagnetic characteristic of twin-wire indirect arc welding

NASA Astrophysics Data System (ADS)

Shi, Chuanwei; Zou, Yong; Zou, Zengda; Wu, Dongting

2015-01-01

Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc(TWIA) welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires: one connected to the negative electrode and another to the positive electrode of a direct-current(DC) power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 μN. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.

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.

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.

Effects on the efficiency of activated carbon on exposure to welding fumes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ghosh, D.

1995-02-01

It is the intention of this paper to document that certain types of welding fumes have little or no effect on the effectiveness of the carbon filter air filtration efficiency when directly exposed to a controlled amount of welding fumes for a short-term period. The welding processes studied were restricted to shielded metal arc welding (SMAW), flux cored arc welding (FCAW), gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) processes. Contrary to the SMAW and FCAW processes, the GTAW (or TIG) and the GMAW (or MIG) welding processes do not require the use of flux as partmore » of the overall process. Credit was taken for these processes occurring in inert gas environments and producing minimal amount of smoke. It was concluded that a study involving the SMAW process would also envelop the effects of the TIG and MIG welding processes. The quantity of welding fumes generated during the arc welding process is a function of the particular process, the size and type of electrode, welding machine amperage, and operator proficiency. For this study, the amount of welding for specific testing was equated to the amount of welding normally conducted during plant unit outages. Different welding electrodes were also evaluated, and the subsequent testing was limited to an E7018 electrode which was judged to be representative of all carbon and stainless steel electrodes commonly used at the site. The effect of welding fumes on activated charcoal was tested using a filtration unit complete with prefilters, upstream and downstream high efficiency particulate air (HEPA) filters, and a carbon adsorber section. The complete system was field tested in accordance with ANSI N510 standards prior to exposing the filters and the adsorber bed to welding fumes. The carbon samples were tested at an established laboratory using ASTM D3803-1989 standards.« less

Method and device for reducing overpenetration at the start of plasma arc welds

DOEpatents

Sanders, John M.; Lehmann, John M.; Ryan, Patrick M.

1998-01-01

A shim for improving plasma arc weld quality has ends tapered at about 25.degree. and notches at each end roughly centered over the corner between the tapered ends and main body of the shim. The improved shim allows lower starting plasma arc heat input and reduces the occurrence of sagging, or overpenetration, of the weld.

Design of a robust fuzzy controller for the arc stability of CO(2) welding process using the Taguchi method.

PubMed

Kim, Dongcheol; Rhee, Sehun

2002-01-01

CO(2) welding is a complex process. Weld quality is dependent on arc stability and minimizing the effects of disturbances or changes in the operating condition commonly occurring during the welding process. In order to minimize these effects, a controller can be used. In this study, a fuzzy controller was used in order to stabilize the arc during CO(2) welding. The input variable of the controller was the Mita index. This index estimates quantitatively the arc stability that is influenced by many welding process parameters. Because the welding process is complex, a mathematical model of the Mita index was difficult to derive. Therefore, the parameter settings of the fuzzy controller were determined by performing actual control experiments without using a mathematical model of the controlled process. The solution, the Taguchi method was used to determine the optimal control parameter settings of the fuzzy controller to make the control performance robust and insensitive to the changes in the operating conditions.

Embedded spectroscopic fiber sensor for on-line arc-welding analysis.

PubMed

Mirapeix, Jesús; Cobo, Adolfo; Quintela, Antonio; López-Higuera, José-Miguel

2007-06-01

A new fiber sensor system designed for spectroscopic analysis and on-line quality assurance of arc-welding processes is presented here. Although several different approaches have been considered for the optical capture of plasma emission in arc-welding processes, they tend to be invasive and make use of optical devices such as collimators or photodiodes. The solution proposed here is based on the arrangement of an optical fiber, which is used at the same time as the optical capturing device and also to deliver the optical information to a spectrometer, embedded within an arc-welding torch. It will be demonstrated that, by using the shielding gas as a protection for the fiber end, the plasma light emission is efficiently collected, forming a sensor system completely transparent and noninvasive for the welding operator. The feasibility of the proposed sensor designed to be used as the input optics of a welding quality-assurance system based on plasma spectroscopy will be demonstrated by means of several welding tests.

Numerical Modeling of Fluid Flow, Heat Transfer and Arc-Melt Interaction in Tungsten Inert Gas Welding

NASA Astrophysics Data System (ADS)

Li, Linmin; Li, Baokuan; Liu, Lichao; Motoyama, Yuichi

2017-04-01

The present work develops a multi-region dynamic coupling model for fluid flow, heat transfer and arc-melt interaction in tungsten inert gas (TIG) welding using the dynamic mesh technique. The arc-weld pool unified model is developed on basis of magnetohydrodynamic (MHD) equations and the interface is tracked using the dynamic mesh method. The numerical model for arc is firstly validated by comparing the calculated temperature profiles and essential results with the former experimental data. For weld pool convection solution, the drag, Marangoni, buoyancy and electromagnetic forces are separately validated, and then taken into account. Moreover, the model considering interface deformation is adopted in a stationary TIG welding process with SUS304 stainless steel and the effect of interface deformation is investigated. The depression of weld pool center and the lifting of pool periphery are both predicted. The results show that the weld pool shape calculated with considering the interface deformation is more accurate.

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.

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

Research on High-Strength Steels with an Improved Resistance against Weld Cracking.

DTIC Science & Technology

1984-06-01

rate. The cooling rate is also dependent upon the welding process selected. Gas Tungsten Arc Welding ( GTAW ), Gas Metal Arc Welding (GMAW), and Shielded...displacement (COD) was used to measure the magnitude 45 GTAW , GMAW, SMAW - SAW j ESW APPROXIMATE RANGES FOR WELDING PROCESSES Increased Martensite...following processes when joining metal, in order of decreasing frequency: GMAW, SMAW, GTAW , SAW, FCAW, and Electrogas welding. 0 The various regulatory

Microstructure and Mechanical Properties of Narrow Gap Laser-Arc Hybrid Welded 40 mm Thick Mild Steel.

PubMed

Zhang, Chen; Li, Geng; Gao, Ming; Zeng, XiaoYan

2017-01-26

Both laser-arc hybrid welding and narrow gap welding have potential for the fabrication of thick sections, but their combination has been seldom studied. In this research, 40 mm thick mild steel was welded by narrow gap laser-arc hybrid welding. A weld with smooth layer transition, free of visible defects, was obtained by nine passes at a 6 mm width narrow gap. The lower part of the weld has the lowest mechanical properties because of the lowest amount of acicular ferrite, but its ultimate tensile strength and impact absorbing energy is still 49% and 60% higher than those of base metal, respectively. The microhardness deviation of all filler layers along weld thickness direction is no more than 15 HV 0.2 , indicating that no temper softening appeared during multiple heat cycles. The results provide an alternative technique for improving the efficiency and quality of welding thick sections.

Microstructure and Mechanical Properties of Narrow Gap Laser-Arc Hybrid Welded 40 mm Thick Mild Steel

PubMed Central

Zhang, Chen; Li, Geng; Gao, Ming; Zeng, XiaoYan

2017-01-01

Both laser-arc hybrid welding and narrow gap welding have potential for the fabrication of thick sections, but their combination has been seldom studied. In this research, 40 mm thick mild steel was welded by narrow gap laser-arc hybrid welding. A weld with smooth layer transition, free of visible defects, was obtained by nine passes at a 6 mm width narrow gap. The lower part of the weld has the lowest mechanical properties because of the lowest amount of acicular ferrite, but its ultimate tensile strength and impact absorbing energy is still 49% and 60% higher than those of base metal, respectively. The microhardness deviation of all filler layers along weld thickness direction is no more than 15 HV0.2, indicating that no temper softening appeared during multiple heat cycles. The results provide an alternative technique for improving the efficiency and quality of welding thick sections. PMID:28772469

Gas Metal Arc Welding Parameters Effect on Properties of Tailored Orbital Weld of SS304 and BS1387

NASA Astrophysics Data System (ADS)

Ayof, M. N.; Hussein, N. I. S.; Noh, M. Z. Mohd

2017-09-01

Dissimilar material pipes in a power plant boiler water piping system are used to transmit water at various temperatures, either in extremely high temperature water or room temperature water. In this study, tailored orbital welding of dissimilar material of Stainless Steel (SS) 304 and British Steel (BS) 1387 were performed by Gas Metal Arc Welding (GMAW) with automated fixed nozzle-rotational jig. This study focused on GMAW parameters variation effects on mechanical properties of SS304 and BS1387 dissimilar material tailored orbital welding. The weldment quality was tested by performing non-destructive dye penetrant test. The tensile strength and microhardness were studied to verify the influence of welding parameters variations. Design of Experiment (DOE) was employed to generate process parameter using Response Surface Methodology (RSM) method. Welding parameters that were arc current, arc voltage and travel speed as input response, whilst, tensile strength and microhardness as output response. Results from non-destructive test showed no major defect occurred. The tensile strength and microhardness increased when arc current and voltage increased and travel speed decreased. Microhardness at weldment was higher than base material.

Effect of Compositional Variation in TiO2-Based Flux-Cored Arc Welding Fluxes on the Thermo-physical Properties and Mechanical Behavior of a Weld Zone

NASA Astrophysics Data System (ADS)

Kim, J. B.; Lee, T. H.; Sohn, I.

2018-04-01

The effect of compositional variation in TiO2-based flux-cored arc welding fluxes on viscosity, wettability, and electronegativity was studied. The thermo-physical properties of the retrieved fluxes and their relationship with the mechanical properties of the weld zone, including tensile strength and micro-Vickers hardness, after welding were identified. Microstructural observation under similar welding conditions revealed significant grain coarsening at a corrected optical basicity (Λcorr) of 0.62, resulting in reduced strength and hardness due to greater heat transfer. Welding fluxes containing TiO2-based simple structural units should result in greater heat transfer due to the deficiency in complex [AlO4]5-- and [SiO4]4--based structural units, as identified through spectroscopic analyses using fourier transform infrared spectroscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy. The electronegativity of the retrieved fluxes was also evaluated since higher electronegativity results in greater absorption of electrons in the arc, resulting in arc condensation towards the center direction. Consequently, deeper penetration could be obtained, where the highest electronegativity was identified to be approximately 0.62 of the corrected optical basicity. Thus, both the thermal conductivity and electronegativity of the welding fluxes were identified to determine the heat transfer phenomenon during flux-cored arc welding.

Effect of Compositional Variation in TiO2-Based Flux-Cored Arc Welding Fluxes on the Thermo-physical Properties and Mechanical Behavior of a Weld Zone

NASA Astrophysics Data System (ADS)

Kim, J. B.; Lee, T. H.; Sohn, I.

2018-07-01

The effect of compositional variation in TiO2-based flux-cored arc welding fluxes on viscosity, wettability, and electronegativity was studied. The thermo-physical properties of the retrieved fluxes and their relationship with the mechanical properties of the weld zone, including tensile strength and micro-Vickers hardness, after welding were identified. Microstructural observation under similar welding conditions revealed significant grain coarsening at a corrected optical basicity (Λcorr) of 0.62, resulting in reduced strength and hardness due to greater heat transfer. Welding fluxes containing TiO2-based simple structural units should result in greater heat transfer due to the deficiency in complex [AlO4]5-- and [SiO4]4--based structural units, as identified through spectroscopic analyses using fourier transform infrared spectroscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy. The electronegativity of the retrieved fluxes was also evaluated since higher electronegativity results in greater absorption of electrons in the arc, resulting in arc condensation towards the center direction. Consequently, deeper penetration could be obtained, where the highest electronegativity was identified to be approximately 0.62 of the corrected optical basicity. Thus, both the thermal conductivity and electronegativity of the welding fluxes were identified to determine the heat transfer phenomenon during flux-cored arc welding.

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…

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…

Development of Chromium-Free Welding Consumables for Stainless Steels

DTIC Science & Technology

2009-02-01

FINAL REPORT Development of Chromium -Free Welding Consumables for Stainless Steels SERDP Project WP-1415 FEBRUARY 2009 J.C. Lippold...NUMBER 4. TITLE AND SUBTITLE Development of Chromium -Free Welding Consumables for Stainless Steels 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER...Energy dispersive spectroscopy FGR Fume generation rate GMAW Gas metal arc welding GTAW Gas tungsten arc welding HAZ Heat affected zone LTE Long

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.

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.

A novel pulsed gas metal arc welding system with direct droplet transfer close-loop control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Q.; Li, P.; Zhang, L.

1994-12-31

In pulsed gas metal arc welding (GMAW), a predominant parameter that has to be monitored and controlled in real time for maintaining process stability and ensuring weld quality, is droplet transfer. Based on the close correlation between droplet transfer and arc light radiant flux in GMAW of steel and aluminum, a direct closed-loop droplet transfer control system for pulsed GMAW with arc light sensor has been developed. By sensing the droplet transfer directly via the arc light signal, a pulsed GMAW process with real and exact one-pulse, one-droplet transfer has been achieved. The novel pulsed GMAW machine consists of threemore » parts: a sensing system, a controlling system, and a welding power system. The software used in this control system is capable of data sampling and processing, parameter matching, optimum parameter restoring, and resetting. A novel arc light sensing system has been developed. The sensor is small enough to be clamped to a semiautomatic welding torch. Based on thissensingn system, a closed-loop droplet transfer control system of GMAW of steel and aluminum has been built and a commercial prototype has been made. The system is capable of keeping one-pulse, one-droplet transfer against external interferences. The welding process with this control system has been proved to be stable, quiet, with no spatter, and provide good weld formation.« less

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…

Gas metal arc welding fume generation using pulsed current

DOE Office of Scientific and Technical Information (OSTI.GOV)

Castner, H.R.

1994-12-31

This paper describes a study of the effects of pulsed welding current on the amount of welding fume and ozone produced during gas metal arc welding (GMAW) using a range of welding procedures and pulse parameters. The results reported in this paper show that pulsed current can reduce GMAW fumes compared to steady current. This research also shows that welding parameters need to be properly controlled if pulsed current is to be used to reduce welding fumes. Fume and ozone generation rates were measured during this study for GMAW of mild steel using copper-coated ER70S-3 electrode wire and 95%Ar-5%CO{sub 2}more » and 85%Ar-15%CO{sub 2} shielding gases. Welds were made with both steady current and pulsed current over a wide range of welding parameters. Fume generation rates for steady current were found to be typically between 0.2 g/min and 0.8 g/min which agrees with other researchers. No significant difference was found in the chemical composition of welding fumes from pulsed current compared to the composition of fumes generated by steady current. New technology that can reduce arc welding fumes is of significant interest to a wide range of companies that use arc welding processes and this research should assist these users in evaluating the potential for the application of this technology to their own operations.« less

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.

Evaluating optical hazards from plasma arc cutting.

PubMed

Glassford, Eric; Burr, Gregory

2018-01-01

The Health Hazard Evaluation Program of the National Institute for Occupational Safety and Health evaluated a steel building materials manufacturer. The employer requested the evaluation because of concerns about optical radiation hazards from a plasma arc cutting system and the need to clarify eye protection requirements for plasma operators, other employees, and visitors. The strength of the ultraviolet radiation, visible radiation (light), and infrared radiation generated by the plasma arc cutter was measured at various distances from the source and at different operating amperages. Investigators also observed employees performing the plasma arc cutting. Optical radiation above safe levels for the unprotected eyes in the ultraviolet-C, ultraviolet-B, and visible light ranges were found during plasma arc cutting. In contrast, infrared and ultraviolet-A radiation levels during plasma arc cutting were similar to background levels. The highest non-ionizing radiation exposures occurred when no welding curtains were used. A plasma arc welding curtain in place did not eliminate optical radiation hazards to the plasma arc operator or to nearby employees. In most instances, the measured intensities for visible light, UV-C, and UV-B resulted in welding shade lens numbers that were lower than those stipulated in the OSHA Filter Lenses for Protection Against Radiant Energy table in 29 CFR 1910.133(a)(5). [1] Investigators recommended using a welding curtain that enclosed the plasma arc, posting optical radiation warning signs in the plasma arc cutter area, installing audible or visual warning cues when the plasma arc cutter was operating, and using welding shades that covered the plasma arc cutter operator's face to protect skin from ultraviolet radiation hazards.

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.

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…

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.

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…

Fatigue Microcrack Behavior under the Influence of Surface Residual Stresses.

DTIC Science & Technology

1982-11-01

Stress Surface Crack Opening Displacement Technique * Brine Environment Stress Intensity Weld Microstructure W. *O ABSTRACT (Continue on reverse aide If...discussed. The results of preliminary optical metallography of the microstructural development in three types of welding processes for one inch thick...of Gas-Metal Arc Weld (GMA) 35 14 Macrograph of Extended Electrode Weld (EE) 35 15 Macrograpb of Deep Gas-Tungsten Arc Weld (DTIG) 36 16

Design of cylindrical pipe automatic welding control system based on STM32

NASA Astrophysics Data System (ADS)

Chen, Shuaishuai; Shen, Weicong

2018-04-01

The development of modern economy makes the demand for pipeline construction and construction rapidly increasing, and the pipeline welding has become an important link in pipeline construction. At present, there are still a large number of using of manual welding methods at home and abroad, and field pipe welding especially lacks miniature and portable automatic welding equipment. An automated welding system consists of a control system, which consisting of a lower computer control panel and a host computer operating interface, as well as automatic welding machine mechanisms and welding power systems in coordination with the control system. In this paper, a new control system of automatic pipe welding based on the control panel of the lower computer and the interface of the host computer is proposed, which has many advantages over the traditional automatic welding machine.

Stability evaluation of short-circuiting gas metal arc welding based on ensemble empirical mode decomposition

NASA Astrophysics Data System (ADS)

Huang, Yong; Wang, Kehong; Zhou, Zhilan; Zhou, Xiaoxiao; Fang, Jimi

2017-03-01

The arc of gas metal arc welding (GMAW) contains abundant information about its stability and droplet transition, which can be effectively characterized by extracting the arc electrical signals. In this study, ensemble empirical mode decomposition (EEMD) was used to evaluate the stability of electrical current signals. The welding electrical signals were first decomposed by EEMD, and then transformed to a Hilbert-Huang spectrum and a marginal spectrum. The marginal spectrum is an approximate distribution of amplitude with frequency of signals, and can be described by a marginal index. Analysis of various welding process parameters showed that the marginal index of current signals increased when the welding process was more stable, and vice versa. Thus EEMD combined with the marginal index can effectively uncover the stability and droplet transition of GMAW.

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.

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.

The dynamic effects of metal vapour in gas metal arc welding

NASA Astrophysics Data System (ADS)

Haidar, Jawad

2010-04-01

Numerical simulations for the dynamic effects of metal vapour in gas metal arc welding (GMAW) suggest that vapour from the welding droplet at the tip of the welding wire has a significant influence on the plasma properties. It is found that for the evaporation rates calculated for arcs in pure argon, the dynamic effects of metal vapour markedly cool down the plasma in the central region of the arc, leading to the formation of a low temperature zone centred on the arc axis, in agreement with experimental measurements in the literature. Radiation effects, omitted in this paper, may produce further cooling of the plasma gas. The results highlight major deficiencies in the common approach to modelling the GMAW process and suggest that accurate description of GMAW must include the influence of metal vapour on the plasma.

Real-time GMAW quality classification using an artificial neural network with airborne acoustic signals as inputs

DOE Office of Scientific and Technical Information (OSTI.GOV)

Matteson, A.; Morris, R.; Tate, R.

1993-12-31

The acoustic signal produced by the gas metal arc welding (GMAW) arc contains information about the behavior of the arc column, the molten pool and droplet transfer. It is possible to detect some defect producing conditions from the acoustic signal from the GMAW arc. An intelligent sensor, called the Weld Acoustic Monitor (WAM) has been developed to take advantage of this acoustic information in order to provide real-time quality assessment information for process control. The WAM makes use of an Artificial Neural Network (ANN) to classify the characteristic arc acoustic signals of acceptable and unacceptable welds. The ANN used inmore » the Weld Acoustic Monitor developed its own set of rules for this classification problem by learning a data base of known GMAW acoustic signals.« less

Contributions to study of the stability of the electric welding arc under the action of acoustic pressure

NASA Technical Reports Server (NTRS)

Petru, S.

1974-01-01

During the treatment of an electric welding arc with ultrasonic oscillations, an improvement was found in overall source-arc stability. Theoretical explanations are provided for this phenomenon and formulas of equivalence between the classical arc and the treated arc are derived, taking stability as their criterion. A knowledge of this phenomenon can be useful in extending the applications of ultrasounds to different forms of electric arcs.

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

NASA Technical Reports Server (NTRS)

Talia, George E.

1996-01-01

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

Decreasing biotoxicity of fume particles produced in welding process.

PubMed

Yu, Kuei-Min; Topham, Nathan; Wang, Jun; Kalivoda, Mark; Tseng, Yiider; Wu, Chang-Yu; Lee, Wen-Jhy; Cho, Kuk

2011-01-30

Welding fumes contain heavy metals, such as chromium, manganese, and nickel, which cause respiratory diseases and cancer. In this study, a SiO(2) precursor was evaluated as an additive to the shielding gas in an arc welding process to reduce the biotoxicity caused by welding fume particles. Transmission electron micrographic images show that SiO(2) coats on the surface of welding fume particles and promotes particle agglomeration. Energy dispersive X-ray spectroscopy further shows that the relative amount of silicon in these SiO(2)-coated agglomerates is higher than in baseline agglomerates. In addition, Escherichia coli (E. coli) exposed to different concentrations of pure SiO(2) particles generated from the arc welding process exhibits similar responses, suggesting that SiO(2) does not contribute to welding fume particle toxicity. The trend of E. coli growth in different concentrations of baseline welding fume particle shows the most significant inhibition occurs in higher exposure concentrations. The 50% lethal logarithmic concentrations for E. coli in arc welding particles of baseline, 2%, and 4.2% SiO(2) precursor additives were 823, 1605, and 1800 mg/L, respectively. Taken together, these results suggest that using SiO(2) precursors as an additive to arc welding shielding gas can effectively reduce the biotoxicity of welding fume. Copyright © 2010 Elsevier B.V. All rights reserved.

Effects of alloying element on weld characterization of laser-arc hybrid welding of pure copper

NASA Astrophysics Data System (ADS)

Hao, Kangda; Gong, Mengcheng; Xie, Yong; Gao, Ming; Zeng, Xiaoyan

2018-06-01

Effects of alloying elements of Si and Sn on weld characterizations of laser-arc hybrid welded pure copper (Cu) with thickness of 2 mm was studied in detail by using different wires. The weld microstructure was analyzed, and the mechanical properties (micro-hardness and tensile property), conductivity and corrosion resistance were tested. The results showed that the alloying elements benefit the growth of column grains within weld fusion zone (FZ), increase the ultimate tensile strength (UTS) of the FZ and weld corrosion resistance, and decrease weld conductivity. The mechanisms were discussed according to the results.

The three dimensional distribution of chromium and nickel alloy welding fumes.

PubMed

Mori, T; Matsuda, A; Akashi, S; Ogata, M; Takeoka, K; Yoshinaka, M

1991-08-01

In the present study, the fumes generated from manual metal arc (MMA) and submerged metal arc (SMA) welding of low temperature service steel, and the chromium and nickel percentages in these fumes, were measured at various horizontal distances and vertical heights from the arc in order to obtain a three dimensional distribution. The MMA welding fume concentrations were significantly higher than the SMA welding fume concentrations. The highest fume concentration on the horizontal was shown in the fumes collected directly above the arc. The fume concentration vertically was highest at 50 cm height and reduced by half at 150 cm height. The fume concentration at 250 cm height was scarcely different from that at 150 cm height. The distribution of the chromium concentration vertically was analogous to the fume concentration, and a statistically significant difference in the chromium percentages was not found at the different heights. The nickel concentrations were not statistically significant within the welding processes, but the nickel percentages in the SMA welding fumes were statistically higher than in the MMA welding fumes. The highest nickel concentration on the horizontal was found in the fumes collected directly above the arc. The highest nickel concentration vertically showed in the fume samples collected at 50 cm height, but the greater the height the larger the nickel percentage in the fumes.

Theoretical Foundation for Weld Modeling

NASA Technical Reports Server (NTRS)

Traugott, S.

1986-01-01

Differential equations describe physics of tungsten/inert-gas and plasma-arc welding in aluminum. Report collects and describes necessary theoretical foundation upon which numerical welding model is constructed for tungsten/inert gas or plasma-arc welding in aluminum without keyhole. Governing partial differential equations for flow of heat, metal, and current given, together with boundary conditions relevant to welding process. Numerical estimates for relative importance of various phenomena and required properties of 2219 aluminum included

Thermal Insulation of Wet Shielded Metal Arc Welds

DTIC Science & Technology

1993-06-01

not as versatile as dry underwater welding with respect to the variety of processes that can be performed (i.e., GMAW, GTAW , SMAW). However, since...deposition rate processes are required for underwater welding. Therefore, even in enclosures where GMAW and GTAW could be used, SMAW is the most frequently...welding steel in a dry environment: GMAW. GTAW , SMAW and submerged arc welding. Because of their relatively low metal deposition rates for manual

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…

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

PubMed

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

2006-04-01

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

3D finite element simulation of TIG weld pool

NASA Astrophysics Data System (ADS)

Kong, X.; Asserin, O.; Gounand, S.; Gilles, P.; Bergheau, J. M.; Medale, M.

2012-07-01

The aim of this paper is to propose a three-dimensional weld pool model for the moving gas tungsten arc welding (GTAW) process, in order to understand the main factors that limit the weld quality and improve the productivity, especially with respect to the welding speed. Simulation is a very powerful tool to help in understanding the physical phenomena in the weld process. A 3D finite element model of heat and fluid flow in weld pool considering free surface of the pool and traveling speed has been developed for the GTAW process. Cast3M software is used to compute all the governing equations. The free surface of the weld pool is calculated by minimizing the total surface energy. The combined effects of surface tension gradient, buoyancy force, arc pressure, arc drag force to drive the fluid flow is included in our model. The deformation of the weld pool surface and the welding speed affect fluid flow, heat flow and thus temperature gradients and molten pool dimensions. Welding trials study is presented to compare our numerical results with macrograph of the molten pool.

Investigation on Microstructure and Mechanical Properties of Continuous and Pulsed Current Gas Tungsten Arc Welded alloy 600

NASA Astrophysics Data System (ADS)

Srikanth, A.; Manikandan, M.

2018-02-01

The present study investigates the microstructure and mechanical properties of joints fabricated by Continuous and pulsed current gas tungsten arc welded alloy 600. Welding was done by autogenous mode. The macro examination was carried out to evaluate the welding defects in the weld joints. Optical and Scanning Electron Microscope (SEM) were performed to assess the microstructural changes in the fusion zone. Energy Dispersive Spectroscopy (EDS) analysis was carried to evaluate the microsegregation of alloying elements in the fusion zone. The tensile test was conducted to assess the strength of the weld joints. The results show that no welding defects were observed in the fusion zones of Continuous and Pulsed current Gas Tungsten Arc Welding. The refined microstructure was found in the pulsed current compared to continuous current mode. Microsegregation was not noticed in the weld grain boundary of continuous and pulsed current mode. The pulsed current shows improved mechanical properties compared to the continuous current mode.

Arc and resistance welding and tumours of the endocrine glands: a Swedish case-control study with focus on extremely low frequency magnetic fields.

PubMed

Håkansson, N; Stenlund, C; Gustavsson, P; Johansen, C; Floderus, B

2005-05-01

Mechanisms for potential effects of extremely low frequency (ELF) magnetic fields on carcinogenesis have not been identified. A potential pathway could be an interaction with the endocrine system. To analyse occupational exposure to ELF magnetic fields from welding, and tumours of the endocrine glands. This case-control study was based on a cohort with an increased prevalence of high exposed individuals. A total of 174 incident cases of tumours of the endocrine glands, 1985-94, were identified and data were obtained from 140 (80%) of these cases; 1692 controls frequency matched on sex and age were selected, and information on 1306 (77%) individuals was obtained. A short questionnaire was sent to a work administrator at the workplaces of the cases and controls. The exposure assessment was based on questions about job tasks, exposure to different types of welding, and exposure to solvents. There was an overall increased risk for all tumours of the endocrine glands for individuals who had been welding sometime during the follow up. The increased risk was attributable to arc welding; for resistance welding there was no clear evidence of an association. We found an increased risk for the adrenal glands in relation to arc welding, and for the parathyroid glands in relation to both arc welding and resistance welding. An imprecise increase in risk was also noted for tumours of the pituitary gland for arc welding. No confounding effect was found for solvent exposure, and there was no sign of biological interaction. The increased risks of endocrine gland tumours related to welding might be explained by exposure to high levels of ELF magnetic fields.

Arc and resistance welding and tumours of the endocrine glands: a Swedish case-control study with focus on extremely low frequency magnetic fields

PubMed Central

Hakansson, N; Stenlund, C; Gustavsson, P; Johansen, C; Floderus, B

2005-01-01

Background: Mechanisms for potential effects of extremely low frequency (ELF) magnetic fields on carcinogenesis have not been identified. A potential pathway could be an interaction with the endocrine system. Aims: To analyse occupational exposure to ELF magnetic fields from welding, and tumours of the endocrine glands. Methods: This case-control study was based on a cohort with an increased prevalence of high exposed individuals. A total of 174 incident cases of tumours of the endocrine glands, 1985–94, were identified and data were obtained from 140 (80%) of these cases; 1692 controls frequency matched on sex and age were selected, and information on 1306 (77%) individuals was obtained. A short questionnaire was sent to a work administrator at the workplaces of the cases and controls. The exposure assessment was based on questions about job tasks, exposure to different types of welding, and exposure to solvents. Results: There was an overall increased risk for all tumours of the endocrine glands for individuals who had been welding sometime during the follow up. The increased risk was attributable to arc welding; for resistance welding there was no clear evidence of an association. We found an increased risk for the adrenal glands in relation to arc welding, and for the parathyroid glands in relation to both arc welding and resistance welding. An imprecise increase in risk was also noted for tumours of the pituitary gland for arc welding. No confounding effect was found for solvent exposure, and there was no sign of biological interaction. Conclusion: The increased risks of endocrine gland tumours related to welding might be explained by exposure to high levels of ELF magnetic fields. PMID:15837851

Swirl Ring Improves Performance Of Welding Torch

NASA Technical Reports Server (NTRS)

Mcgee, William F.; Rybicki, Daniel J.

1995-01-01

Plasma-arc welding torch modified to create vortex in plasma gas to focus arc into narrower and denser column. Swirl ring contains four channels with angled exit holes to force gas to swirl as it flows out of torch past tip of electrode. Degradation of electrode and orifice more uniform and need to rotate torch during operation to compensate for asymmetry in arc reduced or eliminated. Used in both keyhole and nonkeyhole welding modes.

Microstructure and fatigue resistance of high strength dual phase steel welded with gas metal arc welding and plasma arc welding processes

NASA Astrophysics Data System (ADS)

Ahiale, Godwin Kwame; Oh, Yong-Jun; Choi, Won-Doo; Lee, Kwang-Bok; Jung, Jae-Gyu; Nam, Soo Woo

2013-09-01

This study presents the microstructure and high cycle fatigue performance of lap shear joints of dual phase steel (DP590) welded using gas metal arc welding (GMAW) and plasma arc welding (PAW) processes. High cycle fatigue tests were conducted on single and double lap joints under a load ratio of 0.1 and a frequency of 20 Hz. In order to establish a basis for comparison, both weldments were fabricated to have the same weld depth in the plate thickness. The PAW specimens exhibited a higher fatigue life, a gentle S-N slope, and a higher fatigue limit than the GMAW specimens. The improvement in the fatigue life of the PAW specimens was primarily attributed to the geometry effect that exhibited lower and wider beads resulting in a lower stress concentration at the weld toe where cracks initiate and propagate. Furthermore, the microstructural constituents in the heat-affected zone (HAZ) of the PAW specimens contributed to the improvement. The higher volume fraction of acicular ferrite in the HAZ beneath the weld toe enhanced the PAW specimen's resistance to fatigue crack growth. The double lap joints displayed a higher fatigue life than the single lap joints without changing the S-N slope.

Signal analysis of voltage noise in welding arcs. [gas tungsten arc welding

NASA Technical Reports Server (NTRS)

Elis, E.; Eagar, T. W.

1982-01-01

Gas tungsten arc welds were made on low alloy steel plates to which intentional defects (discontinuities) were imposed. Disruption of shielding gas, welding over surface films, and tack welds produce changes in what is otherwise a relatively uniform voltage signal. The arc voltage was 15 volts + or - 2 volts with 300 mV ripple noise from the power supply. Changes in this steady noise voltage varied from 50 mV to less than one millivolt depending on the severity and the type of change experienced. In some instances the changes were easily detected by analysis of the signal in real time, while in other cases the signal had to transformed to the frequency domain in order to detect the changes. Discontinuities as small as 1.5 mm in length were detected. The ultimate sensitivity and reproducibility of the technique is still being investigated.

29 CFR 1910.254 - Arc welding and cutting.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 80 volts. (c) Installation of arc welding equipment—(1) General. Installation including power supply... mechanically strong and electrically adequate for the required current. (3) Supply connections and conductors...-carrying capacity of the supply conductors shall be not less than the rated primary current of the welding...

Heat Transfer Affected by Transverse Magnetic Field using 3D Modeling of Arc Plasma

NASA Astrophysics Data System (ADS)

Maeda, Yoshifumi; Tanaka, Tatsuro; Yamamoto, Shinji; Iwao, Toru

2016-10-01

Gas shielded metal arc welding is used to join the various metal because this is the high quality joining technology. Thus, this welding is used for a welding of large buildings such as bridges and LNG tanks. However, the welding defect caused by the heat transfer decrement may occur with increasing the wind velocity. This is because that the convection loss increases because the arc deflects to leeward side with increasing the wind velocity. In order to prevent from the arc deflection, it is used that the transverse magnetic field is applied to the arc. However, the arc deflection occurs with increasing the transverse magnetic field excessively. The energy balance of the arc is changed with increasing the convection loss caused by the arc deflection, and the heat transfer to the anode decreases. Therefore, the analysis including the arc and anode is necessary to elucidate the heat transfer to the anode. In this paper, the heat transfer affected by the transverse magnetic field using 3D modeling of the arc plasma is elucidated. The heat transfer to the anode is calculated by using the EMTF(electromagnetic thermal fluid) simulation with increasing the transverse magnetic field. As a result, the heat transfer decreased with increasing the transverse magnetic field.

Parameter optimization of flux-aided backing-submerged arc welding by using Taguchi method

NASA Astrophysics Data System (ADS)

Pu, Juan; Yu, Shengfu; Li, Yuanyuan

2017-07-01

Flux-aided backing-submerged arc welding has been conducted on D36 steel with thickness of 20 mm. The effects of processing parameters such as welding current, voltage, welding speed and groove angle on welding quality were investigated by Taguchi method. The optimal welding parameters were predicted and the individual importance of each parameter on welding quality was evaluated by examining the signal-to-noise ratio and analysis of variance (ANOVA) results. The importance order of the welding parameters for the welding quality of weld bead was: welding current > welding speed > groove angle > welding voltage. The welding quality of weld bead increased gradually with increasing welding current and welding speed and decreasing groove angle. The optimum values of the welding current, welding speed, groove angle and welding voltage were found to be 1050 A, 27 cm/min, 40∘ and 34 V, respectively.

[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.

Theoretical study of a consumable anode in a gas metal welding arc

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhu, P.; Simpson, S.W.

1996-12-31

A better understanding of the behavior of the metal transfer process in a welding arc is important for further improvement of quality control for gas-metal-arc welding (GMAW). The problems related to the metal transfer are generally complicated because (a) the metal transfer process is strongly coupled with the arc plasma, which is not stable, for example, the length of the arc plasma varies during the formation and detachment of a metal droplet, and (b) the formation of the electrode droplet itself is influenced by energy transfer, the anode-plasma interface, and also the location of the liquid-solid interface inside the anode.more » This paper presents primary results of an investigation of the consumable anode in a gas metal welding arc. The study includes theoretical predictions of the properties related to metal transfer including moving anode temperature profile, welding arc length and arc current as a function of time for various wire feed rates, as well as numerical treatment of droplet formation. The anode temperature profile and the melting rate are analyzed by a metal transfer model which couples a two-dimensional arc model to a one-dimensional anode thermal model. The droplet formation is predicted by a quasi-one-dimensional dynamic model of a pendant drop which accounts for the electromagnet pinch effect, the surface tension, gravitation and the momentum transfer due to wire motion. Comparison between experimental observation and theoretical predictions will also be discussed.« less

Grinding Parts For Automatic Welding

NASA Technical Reports Server (NTRS)

Burley, Richard K.; Hoult, William S.

1989-01-01

Rollers guide grinding tool along prospective welding path. Skatelike fixture holds rotary grinder or file for machining large-diameter rings or ring segments in preparation for welding. Operator grasps handles to push rolling fixture along part. Rollers maintain precise dimensional relationship so grinding wheel cuts precise depth. Fixture-mounted grinder machines surface to quality sufficient for automatic welding; manual welding with attendant variations and distortion not necessary. Developed to enable automatic welding of parts, manual welding of which resulted in weld bead permeated with microscopic fissures.

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... a maximum wall stress of 24,000 p.s.i. in the formula described in paragraph (f)(4) of this section... any case the minimum wall thickness must be such that the wall stress calculated by the formula listed...

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

Code of Federal Regulations, 2010 CFR

2010-10-01

... DOT 4BW cylinder is a welded type steel cylinder with a longitudinal electric-arc welded seam, a water... a maximum wall stress of 24,000 p.s.i. in the formula described in paragraph (f)(4) of this section... any case the minimum wall thickness must be such that the wall stress calculated by the formula listed...

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)…

Design Considerations for Remotely Operated Welding in Space: Task Definition and Visual Weld Monitoring Experiment

DTIC Science & Technology

1993-05-01

processes [48] ................ 91 Figure 4.14 Energy effectiveness comparison between EBW, GMAW , and PAW [48...1 10 Figure 5.2 The spectrum of control modes [76] ................. 112 Figure 5.3 Levels of control for GMAW [26...vehicular activity FTS Flight Telerobotic Servicer GMAW Gas metal arc welding GTAW Gas tungsten arc welding LEO Low-earth orbit NDT Non-destructive test

EB welding of launch vehicles

NASA Astrophysics Data System (ADS)

Szabo, Attila

While large structural components can be electron beam (EB) welded, equipment and operating costs increase with the requisite vacuum chamber's size. Attention is presently given to cost-effective ways of EB welding launch-vehicle assemblies without compromise of weld quality in such alloys as 2219, 2090, Weldalite, and HP9-4-30/20. Weld strengths at both room and cryogenic temperatures that were 50 percent higher than those obtainable for such materials with arc welding have been demonstrated. Fracture toughnesses were also 40-50 percent higher than arc-welded values. Attention is given to EB joint fit-up allowables for 2219-T87 Al alloy.

Heat transfer in GTA welding arcs

NASA Astrophysics Data System (ADS)

Huft, Nathan J.

Heat transfer characteristics of Gas Tungsten Arc Welding (GTAW) arcs with arc currents of 50 to 125 A and arc lengths of 3 to 11 mm were measured experimentally through wet calorimetry. The data collected were used to calculate how much heat reported to the cathode and anode and how much was lost from the arc column. A Visual Basic for Applications (VBA) macro was written to further analyze the data and account for Joule heating within the electrodes and radiation and convection losses from the arc, providing a detailed account of how heat was generated and dissipated within the system. These values were then used to calculate arc efficiencies, arc column voltages, and anode and cathode fall voltages. Trends were noted for variances in the arc column voltage, power dissipated from the arc column, and the total power dissipated by the system with changing arc length. Trends for variances in the anode and cathode fall voltages, total power dissipated, Joule heating within the torches and electrodes with changing arc current were also noted. In addition, the power distribution between the anode and cathode for each combination of arc length and arc current was examined. Keywords: Gas Tungsten Arc Welding, GTAW, anode fall, cathode fall, heat transfer, wet calorimetry

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,…

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.

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.

Vacuum vapor deposition: A spinoff of space welding development

NASA Technical Reports Server (NTRS)

Poorman, R. M.

1991-01-01

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

Automatic welding of stainless steel tubing

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1978-01-01

The use of automatic welding for making girth welds in stainless steel tubing was investigated as well as the reduction in fabrication costs resulting from the elimination of radiographic inspection. Test methodology, materials, and techniques are discussed, and data sheets for individual tests are included. Process variables studied include welding amperes, revolutions per minute, and shielding gas flow. Strip chart recordings, as a definitive method of insuring weld quality, are studied. Test results, determined by both radiographic and visual inspection, are presented and indicate that once optimum welding procedures for specific sizes of tubing are established, and the welding machine operations are certified, then the automatic tube welding process produces good quality welds repeatedly, with a high degree of reliability. Revised specifications for welding tubing using the automatic process and weld visual inspection requirements at the Kennedy Space Center are enumerated.

Health hazard evaluation report HETA 96-0137-2607, Yankee Atomic Electric Company, Rowe, Massachusetts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sylvain, D.C.

1996-10-01

In response to a request from the Health and Safety Supervisor at the Yankee Nuclear Power Station (SIC-4911), Rowe, Massachusetts, an investigation was begun into ozone (10028156) exposure during plasma arc cutting and welding. Welders had reported chest tightness, dry cough, and throat and bronchial irritation. The nuclear power station was in the process of being decommissioned, and workers were dismantling components using welding and cutting methods. Of the operations observed during the site visit, the highest ozone concentrations were generated during plasma arc cutting, followed by metal inert gas (MIG) welding and arc welding. During plasma arc cutting themore » average and peak concentrations exceeded the NIOSH ceiling recommended exposure limit of 0.1 part per million. The author concludes that ozone exposure during plasma arc cutting and MIG welding presented a health hazard to welders. The author recommends that improvements be made in the local exhaust ventilation, that nitrogen-dioxide levels be monitored during hot work, and that many exposed workers wear protective clothing, use ultraviolet blocking lotion, and continue the use appropriate shade of eye protection.« less

Study the Effect of SiO2 Based Flux on Dilution in Submerged Arc Welding

NASA Astrophysics Data System (ADS)

kumar, Aditya; Maheshwari, Sachin

2017-08-01

This paper highlights the method for prediction of dilution in submerged arc welding (SAW). The most important factors of weld bead geometry are governed by the weld dilution which controls the chemical and mechanical properties. Submerged arc welding process is used generally due to its very easy control of process variables, good penetration, high weld quality, and smooth finish. Machining parameters, with suitable weld quality can be achieved with the different composition of the flux in the weld. In the present study Si02-Al2O3-CaO flux system was used. In SiO2 based flux NiO, MnO, MgO were mixed in various proportions. The paper investigates the relationship between the process parameters like voltage, % of flux constituents and dilution with the help of Taguchi’s method. The experiments were designed according to Taguchi L9 orthogonal array, while varying the voltage at two different levels in addition to alloying elements. Then the optimal results conditions were verified by confirmatory experiments.

Welding Penetration Control of Fixed Pipe in TIG Welding Using Fuzzy Inference System

NASA Astrophysics Data System (ADS)

Baskoro, Ario Sunar; Kabutomori, Masashi; Suga, Yasuo

This paper presents a study on welding penetration control of fixed pipe in Tungsten Inert Gas (TIG) welding using fuzzy inference system. The welding penetration control is essential to the production quality welds with a specified geometry. For pipe welding using constant arc current and welding speed, the bead width becomes wider as the circumferential welding of small diameter pipes progresses. Having welded pipe in fixed position, obviously, the excessive arc current yields burn through of metals; in contrary, insufficient arc current produces imperfect welding. In order to avoid these errors and to obtain the uniform weld bead over the entire circumference of the pipe, the welding conditions should be controlled as the welding proceeds. This research studies the intelligent welding process of aluminum alloy pipe 6063S-T5 in fixed position using the AC welding machine. The monitoring system used a charge-coupled device (CCD) camera to monitor backside image of molten pool. The captured image was processed to recognize the edge of molten pool by image processing algorithm. Simulation of welding control using fuzzy inference system was constructed to simulate the welding control process. The simulation result shows that fuzzy controller was suitable for controlling the welding speed and appropriate to be implemented into the welding system. A series of experiments was conducted to evaluate the performance of the fuzzy controller. The experimental results show the effectiveness of the control system that is confirmed by sound welds.

Evaluation Of Four Welding Arc Processes Applied To 6061 Aluminium Alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Benoit, A.; Laboratoire de Genie des Materiaux et Procedes Associes; Paillard, P.

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 producedmore » 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.« less

Occupational asthma due to manual metal-arc welding of special stainless steels.

PubMed

Hannu, T; Piipari, R; Kasurinen, H; Keskinen, H; Tuppurainen, M; Tuomi, T

2005-10-01

Occupational asthma (OA) can be induced by fumes of manual metal-arc welding on stainless steel. In recent years, the use of special stainless steels (SSS) with high chromium content has increased. This study presents two cases of OA caused by manual metal-arc welding on SSS. In both cases, the diagnosis of OA was based on respiratory symptoms, occupational exposure and positive findings in the specific challenge tests. In the first case, a 46-yr-old welder had experienced severe dyspnoea while welding SSS (SMO steel), but not in other situations. Challenge tests with both mild steel and stainless steel using a common electrode were negative. Welding SSS with a special electrode caused a delayed 37% drop in forced expiratory volume in one second (FEV1). In the second case, a 34-yr-old male had started to experience dyspnoea during the past few years, while welding especially SSS (Duplex steel). The workplace peak expiratory flow monitoring was suggestive of OA. Challenge tests with both mild steel and stainless steel using a common electrode did not cause bronchial obstruction. Welding SSS with a special electrode caused a delayed 31% drop in FEV1. In conclusion, exposure to manual metal-arc welding fumes of special stainless steel should be considered as a new cause of occupational asthma.

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…

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…

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…

Effect of Cut Quality on Hybrid Laser Arc Welding of Thick Section Steels

NASA Astrophysics Data System (ADS)

Farrokhi, F.; Nielsen, S. E.; Schmidt, R. H.; Pedersen, S. S.; Kristiansen, M.

From an industrial point of view, in a laser cutting-welding production chain, it is of great importance to know the influence of the attainable laser cut quality on the subsequent hybrid laser arc welding process. Many studies have been carried out in the literature to obtain lower surface roughness values on the laser cut edge. However, in practice, the cost and reliability of the cutting process is crucial and it does not always comply with obtaining the highest surface quality. In this study, a number of experiments on 25 mm steel plates were carried out to evaluate the influence of cut surface quality on the final quality of the subsequent hybrid laser welded joints. The different cut surfaces were obtained by different industrial cutting methods including laser cutting, abrasive water cutting, plasma cutting, and milling. It was found that the mentioned cutting methods could be used as preparation processes for the subsequent hybrid laser arc welding. However, cut quality could determine the choice of process parameters of the following hybrid laser arc welding.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 moltenmore » 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.« less

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.

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. Copyright © 2014 Elsevier B.V. All rights reserved.

Evaluation of the Low Heat Input Process for Weld Repair of Nickel-Base Superalloys

NASA Astrophysics Data System (ADS)

Durocher, J.; Richards, N. L.

2011-10-01

The repair of turbine blades and vanes commonly involves gas tungsten arc welding or an equivalent process, but unfortunately these components are often susceptible to heat-affected zone (HAZ) cracking during the weld repair process. This is a major problem especially in cast alloys due to their coarse-grain size and where the (Al + Ti) contents is in excess of 3-4%; vacuum brazing is also used but mainly on low stress non-rotating components such as vanes. Micro-welding has the potential to deposit small amounts of filler at low heat input levels with minimum HAZ and thus is an attractive process for depositing a quality weld. As with conventional fusion processes, the filler alloy is deposited by the generation of a low power arc between a consumable electrode and the substrate. The low heat input of this process offers unique advantages over more common welding processes such as gas tungsten arc, plasma arc, laser, and electron beam welding. In this study, the low heat input characteristic of micro-welding has been used to simulate weld repair using Inconel (IN) (Inconel and IN are trademarks of INCO Alloys International) 625, Rene (Rene is a trademark of General Electric Company) 41, Nimonic (Nimonic is a trademark of INCO Alloys International) 105 and Inconel 738LC filler alloys, to a cast Inconel 738LC substrate. The effect of micro-welding process parameters on the deposition rate, coating quality, and substrate has been investigated.

Microstructure and corrosion behavior of shielded metal arc-welded dissimilar joints comprising duplex stainless steel and low alloy steel

NASA Astrophysics Data System (ADS)

Srinivasan, P. Bala; Muthupandi, V.; Sivan, V.; Srinivasan, P. Bala; Dietzel, W.

2006-12-01

This work describes the results of an investigation on a dissimilar weld joint comprising a boiler-grade low alloy steel and duplex stainless steel (DSS). Welds produced by shielded metal arc-welding with two different electrodes (an austenitic and a duplex grade) were examined for their microstructural features and properties. The welds were found to have overmatching mechanical properties. Although the general corrosion resistance of the weld metals was good, their pitting resistance was found to be inferior when compared with the DSS base material.

Evaluating the SCC resistance of underwater welds in sodium tetrathionate

DOE Office of Scientific and Technical Information (OSTI.GOV)

White, R.A.; Angeliu, T.M.

1997-12-01

The susceptibility of welds to stress corrosion cracking (SCC) is enhanced by the surface residual tensile stresses generated by the typical welding process. However, underwater plasma transferred arc (PTA) welding has been shown to produce compressive surface residual stresses, an encouraging result if repairs of cracked boiling water reactor (BWR) components are to be made without further endangering them to SCC. This program was designed to verify that underwater PTA welds are resistant to SCC and to determine if underwater PTA welding could mitigate SCC in potentially susceptible welds. This was achieved by exposing various welds on solution annealed (SA)more » and SA + thermally sensitized 304 stainless steel at 25 C in a solution of 1.5 gm/liter of sodium sulfide added to 0.05M sodium tetrathionate, titrated to a pH of 1.25 with H{sub 2}SO{sub 4}. The autogeneous welds were produced using gas tungsten arc (GTA) and plasma transferred arc (PTA) welding under atmospheric conditions, and PTA welding underwater. After 1 hour of sodium tetrathionate exposure, GTA and air PTA welds exhibited SCC while the underwater PTA weld heat affected zones were more resistant. Underwater PTA welds bisecting a GTA weld eliminated the cracking in the GTA weld heat affected zone under certain conditions. The lack of IG cracking in the region influenced by the underwater PTA weld is consistent with the measurement of compressive surface residual stresses inherent to the underwater welding process.« less

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.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lévesque, D.; Rousseau, G.; Monchalin, J.-P.

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 thatmore » 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.« less

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

NASA Astrophysics Data System (ADS)

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

2014-02-01

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.

Experimental Investigation on Acoustic Control Droplet Transfer in Ultrasonic-Wave-Assisted Gas Metal Arc Welding

NASA Astrophysics Data System (ADS)

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

2018-02-01

Ultrasonic-wave-assisted gas metal arc welding (U-GMAW) is a new, advanced arc welding method that uses an ultrasonic wave emitted from an ultrasonic radiator above the arc. However, it remains unclear how the ultrasonic wave affects the metal droplet, hindering further application of U-GMAW. In this paper, an improved U-GMAW system was used and its superiority was experimentally demonstrated. Then a series of experiments were designed and performed to study how the ultrasonic wave affects droplet transfer, including droplet size, velocity, and motion trajectory. The behavior of droplet transfer was observed in high-speed images. The droplet transfer is closely related to the distribution of the acoustic field, determined by the ultrasonic current. Moreover, by analyzing the variably accelerated motion of the droplet, the acoustic control of the droplet transfer was intuitively demonstrated. Finally, U-GMAW was successfully used in vertical-up and overhead welding experiments, showing that U-GMAW is promising for use in welding in all positions.

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.

Novel Approach for Welding Stainless Steel Using Cr-Free Welding Consumables

DTIC Science & Technology

2004-12-31

Breakdown potential ERP Repassivation potential SS Stainless steel SMAW Shielded metal arc welding GTAW Gas tungsten arc welding PEL Permissible...0.1 M NaCl. 14 4. List of Tables Table 1. Details of GTAW procedure. 7 1 5. Acknowledgements The work in this report was...resistance, filler metals matching or exceeding the chromium (Cr) content of the base metal must be used. The Cr content of Types 304 and 308 stainless

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

PubMed

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.

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

Research on the Effect of Welding Speed on the Quality of Welding Seam Based on the Local Dry Underwater Welding

NASA Astrophysics Data System (ADS)

Liu, Lei; Chen, Wu; Wang, Huagang; Ba, Jinyu; Li, Bing

2017-12-01

The repair of nuclear spent fuel pool has a high requirement for the quality of welding, the welding speed directly affects the quality of the weld when local dry automatic underwater welding is used to repair the damaged surface. Under the condition of the same condition, the local dry automatic underwater welding test was carried out under the condition of the same welding condition. Taking the 20cm as the experimental condition, after massive experiments show that when the welding speed is approximately 48cm/min the weld quality is high, meeting the design requirements, based on the double layer shrinkage nozzle chamber of local dry underwater automatic welding.

Hazard of ultraviolet radiation emitted in gas metal arc welding of mild steel.

PubMed

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

2016-09-30

Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema in the workplace. The degree of hazard from UVR exposure depends on the welding method and conditions. Therefore, it is important to identify the UVR levels present under various conditions. We experimentally evaluated the UVR levels emitted in gas metal arc welding (GMAW) of mild steel. We used both a pulsed welding current and a non-pulsed welding current. The shielding gases were 80% Ar + 20% CO 2 and 100% CO 2 . The effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines was used to quantify the UVR hazard. The effective irradiance measured in this study was in the range of 0.51-12.9 mW/cm 2 at a distance of 500 mm from the arc. The maximum allowable exposure times at these levels are only 0.23-5.9 s/day. The following conclusions were made regarding the degree of hazard from UVR exposure during the GMAW of mild steel: (1) It is more hazardous at higher welding currents than at lower welding currents. (2) At higher welding currents, it is more hazardous when 80% Ar + 20% CO 2 is used as a shielding gas than when 100% CO 2 is used. (3) It is more hazardous for pulsed welding currents than for non-pulsed welding currents. (4) It appears to be very hazardous when metal transfer is the spray type. This study demonstrates that unprotected exposure to UVR emitted by the GMAW of mild steel is quite hazardous.

Hazard of ultraviolet radiation emitted in gas metal arc welding of mild steel

PubMed Central

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

2016-01-01

Objectives: Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema in the workplace. The degree of hazard from UVR exposure depends on the welding method and conditions. Therefore, it is important to identify the UVR levels present under various conditions. Methods: We experimentally evaluated the UVR levels emitted in gas metal arc welding (GMAW) of mild steel. We used both a pulsed welding current and a non-pulsed welding current. The shielding gases were 80% Ar + 20% CO2 and 100% CO2. The effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines was used to quantify the UVR hazard. Results: The effective irradiance measured in this study was in the range of 0.51-12.9 mW/cm2 at a distance of 500 mm from the arc. The maximum allowable exposure times at these levels are only 0.23-5.9 s/day. Conclusions: The following conclusions were made regarding the degree of hazard from UVR exposure during the GMAW of mild steel: (1) It is more hazardous at higher welding currents than at lower welding currents. (2) At higher welding currents, it is more hazardous when 80% Ar + 20% CO2 is used as a shielding gas than when 100% CO2 is used. (3) It is more hazardous for pulsed welding currents than for non-pulsed welding currents. (4) It appears to be very hazardous when metal transfer is the spray type. This study demonstrates that unprotected exposure to UVR emitted by the GMAW of mild steel is quite hazardous. PMID:27488036

Inspection of thick welded joints using laser-ultrasonic SAFT.

PubMed

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

2016-07-01

The detection of defects in thick butt joints in the early phase of multi-pass arc welding would be very valuable to reduce cost and time in the necessity of reworking. As a non-contact method, the laser-ultrasonic technique (LUT) has the potential for the automated inspection of welds, ultimately online during manufacturing. In this study, testing has been carried out using LUT combined with the synthetic aperture focusing technique (SAFT) on 25 and 50mm thick butt welded joints of steel both completed and partially welded. EDM slits of 2 or 3mm height were inserted at different depths in the multi-pass welding process to simulate a lack of fusion. Line scans transverse to the weld are performed with the generation and detection laser spots superimposed directly on the surface of the weld bead. A CCD line camera is used to simultaneously acquire the surface profile for correction in the SAFT processing. All artificial defects but also real defects are visualized in the investigated thick butt weld specimens, either completed or partially welded after a given number of passes. The results obtained clearly show the potential of using the LUT with SAFT for the automated inspection of arc welds or hybrid laser-arc welds during manufacturing. Crown Copyright © 2016. Published by Elsevier B.V. All rights reserved.

Comparative Studies on microstructure, mechanical and corrosion behaviour of DMR 249A Steel and its welds

NASA Astrophysics Data System (ADS)

Mohammed, Raffi; Dilkush; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

DMR249A Medium strength (low carbon) Low-alloy steels are used as structural components in naval applications due to its low cost and high availability. An attempt has been made to weld the DMR 249A steel plates of 8mm thickness using shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW). Welds were characterized for metallography to carry out the microstructural changes, mechanical properties were evaluated using vickers hardness tester and universal testing machine. Potentio-dynamic polarization tests were carried out to determine the pitting corrosion behaviour. Constant load type Stress corrosion cracking (SCC) testing was done to observe the cracking tendency of the joints in a 3.5%NaCl solution. Results of the present study established that SMA welds resulted in formation of relatively higher amount of martensite in ferrite matrix when compared to gas tungsten arc welding (GTAW). It is attributed to faster cooling rates achieved due to high thermal efficiency. Improved mechanical properties were observed for the SMA welds and are due to higher amount of martensite. Pitting corrosion and stress corrosion cracking resistance of SMA welds were poor when compared to GTA welds.

Proposed GTA welding specification and acceptance criteria for the MC4163

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kwiatkowski, J.J.

1991-04-12

This specification documents the gas tungsten arc (GTA) welding process and production weld acceptance criteria requirements for the MC4163. This document is written specifically to apply to the welds on the MC4163 and is not to be used as a general gas tungsten arc welding specification. All sections of this specification must be complied with unless specifically exempted in writing. There are a total of five welds with three different joint designs required to fabricate the MC4163. In the order of fabrication they are (1) initiator closure disc, (2) nozzle to case girth welds, two and, (3) nozzle closure discmore » welds, two. This specification will only address the nozzle to case girth welds and the nozzle closure disc welds.« less

Investigation on mechanical properties of welded material under different types of welding filler (shielded metal arc welding)

NASA Astrophysics Data System (ADS)

Tahir, Abdullah Mohd; Lair, Noor Ajian Mohd; Wei, Foo Jun

2018-05-01

The Shielded Metal Arc Welding (SMAW) is (or the Stick welding) defined as a welding process, which melts and joins metals with an arc between a welding filler (electrode rod) and the workpieces. The main objective was to study the mechanical properties of welded metal under different types of welding fillers and current for SMAW. This project utilized the Design of Experiment (DOE) by adopting the Full Factorial Design. The independent variables were the types of welding filler and welding current, whereas the other welding parameters were fixed at the optimum value. The levels for types of welding filler were by the models of welding filler (E6013, E7016 and E7018) used and the levels for welding current were 80A and 90A. The responses were the mechanical properties of welded material, which include tensile strength and hardness. The experiment was analyzed using the two way ANOVA. The results prove that there are significant effects of welding filler types and current levels on the tensile strength and hardness of the welded metal. At the same time, the ANOVA results and interaction plot indicate that there are significant interactions between the welding filler types and the welding current on both the hardness and tensile strength of the welded metals, which has never been reported before. This project found that when the amount of heat input with increase, the mechanical properties such as tensile strength and hardness decrease. The optimum tensile strength for welded metal is produced by the welding filler E7016 and the optimum of hardness of welded metal is produced by the welding filler E7018 at welding current of 80A.

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.

Investigation of the Microstructure of Laser-Arc Hybrid Welded Boron Steel

NASA Astrophysics Data System (ADS)

Son, Seungwoo; Lee, Young Ho; Choi, Dong-Won; Cho, Kuk-Rae; Shin, Seung Man; Lee, Youngseog; Kang, Seong-Hoon; Lee, Zonghoon

2018-05-01

The microstructure of boron steel for automotive driving shaft manufacturing after laser-arc hybrid welding was investigated. Laser-arc hybrid welding technology was applied to 3-mm-thick plates of boron steel, ST35MnB. The temperature distribution of the welding pool was analyzed using the finite element method, and the microstructure of the welded boron steel was characterized using optical microscopy and scanning and transmission electron microscopies. The microstructure of the weld joint was classified into the fusion zone, the heat-affected zone (HAZ), and the base material. At the fusion zone, the bainite grains exist in the martensite matrix and show directionality because of heat input from the welding. The HAZ is composed of smaller grains, and the hardness of the HAZ is greater than that of the fusion zone. We discuss that the measured grain size and the hardness of the HAZ originate from undissolved precipitates that retard the grain growth of austenite.

Assessment of the Biological Effects of Welding Fumes Emitted From Metal Active Gas and Manual Metal Arc Welding in Humans.

PubMed

Dewald, Eva; Gube, Monika; Baumann, Ralf; Bertram, Jens; Kossack, Veronika; Lenz, Klaus; Reisgen, Uwe; Kraus, Thomas; Brand, Peter

2015-08-01

Emissions from a particular welding process, metal inert gas brazing of zinc-coated steel, induce an increase in C-reactive protein. In this study, it was investigated whether inflammatory effects could also be observed for other welding procedures. Twelve male subjects were separately exposed to (1) manual metal arc welding fumes, (2) filtered air, and (3) metal active gas welding fumes for 6 hours. Inflammatory markers were measured in serum before, and directly, 1 and 7 days after exposure. Although C-reactive protein concentrations remained unchanged, neutrophil concentrations increased directly after exposure to manual metal arc welding fumes, and endothelin-1 concentrations increased directly and 24 hours after exposure. After exposure to metal active gas and filtered air, endothelin-1 concentrations decreased. The increase in the concentrations of neutrophils and endothelin-1 may characterize a subclinical inflammatory reaction, whereas the decrease of endothelin-1 may indicate stress reduction.

Exploring infrared sensoring for real time welding defects monitoring in GTAW.

PubMed

Alfaro, Sadek C A; Franco, Fernand Díaz

2010-01-01

This paper presents an evaluation of an infrared sensor for monitoring the welding pool temperature in a Gas Tungsten Arc Welding (GTAW) process. The purpose of the study is to develop a real time system control. It is known that the arc welding pool temperature is related to the weld penetration depth; therefore, by monitoring the temperature, the arc pool temperature and penetration depth are also monitored. Various experiments were performed; in some of them the current was varied and the temperature changes were registered, in others, defects were induced throughout the path of the weld bead for a fixed current. These simulated defects resulted in abrupt changes in the average temperature values, thus providing an indication of the presence of a defect. The data has been registered with an acquisition card. To identify defects in the samples under infrared emissions, the timing series were analyzed through graphics and statistic methods. The selection of this technique demonstrates the potential for infrared emission as a welding monitoring parameter sensor.

Exploring Infrared Sensoring for Real Time Welding Defects Monitoring in GTAW

PubMed Central

Alfaro, Sadek C. A.; Franco, Fernand Díaz

2010-01-01

This paper presents an evaluation of an infrared sensor for monitoring the welding pool temperature in a Gas Tungsten Arc Welding (GTAW) process. The purpose of the study is to develop a real time system control. It is known that the arc welding pool temperature is related to the weld penetration depth; therefore, by monitoring the temperature, the arc pool temperature and penetration depth are also monitored. Various experiments were performed; in some of them the current was varied and the temperature changes were registered, in others, defects were induced throughout the path of the weld bead for a fixed current. These simulated defects resulted in abrupt changes in the average temperature values, thus providing an indication of the presence of a defect. The data has been registered with an acquisition card. To identify defects in the samples under infrared emissions, the timing series were analyzed through graphics and statistic methods. The selection of this technique demonstrates the potential for infrared emission as a welding monitoring parameter sensor. PMID:22219697

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.

Gas tungsten arc welding of aluminum alloys 6XXX. Welding procedure specification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1985-08-01

Procedure WPS-1003 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.035 to 0.516 in.; filler metal is ER4043 (F-23) or ER5356 (F-22); shielding gas is argon.

Personal exposure to metal fume, NO2, and O3 among production welders and non-welders.

PubMed

Schoonover, Todd; Conroy, Lorraine; Lacey, Steven; Plavka, Julie

2011-01-01

The objective of this study was to characterize personal exposures to welding-related metals and gases for production welders and non-welders in a large manufacturing facility. Welding fume metals and irritant gases nitrogen dioxide (NO(2)) and ozone (O(3)) were sampled for thirty-eight workers. Personal exposure air samples for welding fume metals were collected on 37 mm open face cassettes and nitrogen dioxide and ozone exposure samples were collected with diffusive passive samplers. Samples were analyzed for metals using Inductively Coupled Plasma Mass Spectrometry (ICP-MS) and welding fume metal exposure concentrations were defined as the sum of welding-related metals mass per volume of air sampled. Welding fume metal exposures were highly variable among similar types of welding while NO(2) and O(3) exposure were less variable. Welding fume metal exposures were significantly higher 474 μg/m(3) for welders than non-welders 60 μg/m(3) (p=0.001). Welders were exposed to higher concentrations of NO(2) and O(3) than non-welders but the differences were not statistically significant. Welding fume metal exposure concentrations for welders performing gas metal arc welding (GMAW) and shielded metal arc welding (SMAW) were higher than welders performing gas tungsten arc welding (GTAW). Non-welders experienced exposures similar to GTAW welders despite a curtain wall barrier separating welding and non-welding work areas.

Mechanical Characteristics of Welded Joints of Aluminum Alloy 6061 T6 Formed by Arc and Friction Stir Welding

NASA Astrophysics Data System (ADS)

Astarita, A.; Squillace, A.; Nele, L.

2016-01-01

Butt welds formed by arc welding in inert gas with nonconsumable electrode (tungsten inert gas (TIG) welding) and by friction stir welding (FSW) from aluminum alloy AA6061 T6 are studied. Comparative analysis of the structures and mechanical properties of the welded joints is performed using the results of optical and electron microscopy, tensile tests, tests for residual bending ductility, and measurements of microhardness. The changes in the microstructure in different zones and the degrees of degradation of the mechanical properties after the welding are determined. It is shown that the size of the tool for the friction stir welding affects the properties of the welds. Quantitative results showing the relation between the microscopic behavior of the alloy and the welding-induced changes in the microstructure are obtained. Friction stir welding is shown to provide higher properties of the welds.

Automatic, nondestructive test monitors in-process weld quality

NASA Technical Reports Server (NTRS)

Deal, F. C.

1968-01-01

Instrument automatically and nondestructively monitors the quality of welds produced in microresistance welding. It measures the infrared energy generated in the weld as the weld is made and compares this energy with maximum and minimum limits of infrared energy values previously correlated with acceptable weld-strength tolerances.

Effect of Inverter Power Source Characteristics on Welding Stability and Heat Affected Zone Dimensions

NASA Astrophysics Data System (ADS)

Il'yaschenko, D. P.; Chinakhov, D. A.; Mamadaliev, R. A.

2018-01-01

The paper presents results the research in the effect of power sources dynamic characteristics on stability of melting and electrode metal transfer to the weld pool shielded metal arc welding. It is proved that when applying inverter-type welding power sources, heat and mass transfer characteristics change, arc gap short-circuit time and drop generation time are reduced. This leads to reduction of weld pool heat content and contraction of the heat-affected zone by 36% in comparison the same parameters obtained using a diode rectifier.

Integrated optical sensor

DOEpatents

Watkins, Arthur D.; Smartt, Herschel B.; Taylor, Paul L.

1994-01-01

An integrated optical sensor for arc welding having multifunction feedback control. The sensor, comprising generally a CCD camera and diode laser, is positioned behind the arc torch for measuring weld pool position and width, standoff distance, and post-weld centerline cooling rate. Computer process information from this sensor is passed to a controlling computer for use in feedback control loops to aid in the control of the welding process. Weld pool position and width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint. Sensor standoff distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to determine the final metallurgical state of the weld bead and heat affected zone, thereby controlling post-weld mechanical properties.

Integrated optical sensor

DOEpatents

Watkins, A.D.; Smartt, H.B.; Taylor, P.L.

1994-01-04

An integrated optical sensor for arc welding having multifunction feedback control is described. The sensor, comprising generally a CCD camera and diode laser, is positioned behind the arc torch for measuring weld pool position and width, standoff distance, and post-weld centerline cooling rate. Computer process information from this sensor is passed to a controlling computer for use in feedback control loops to aid in the control of the welding process. Weld pool position and width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint. Sensor standoff distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to determine the final metallurgical state of the weld bead and heat affected zone, thereby controlling post-weld mechanical properties. 6 figures.

Pulmonary function abnormalities and airway irritation symptoms of metal fumes exposure on automobile spot welders.

PubMed

Luo, Jiin-Chyuan John; Hsu, Kuang-Hung; Shen, Wu-Shiun

2006-06-01

Spot or resistance welding has been considered less hazardous than other types of welding. Automobile manufacturing is a major industry in Taiwan. Spot and arc welding are common processes in this industry. The respiratory effects on automobile spot welders exposed to metal fumes are investigated. The cohort consisted of 41 male auto-body spot welders, 76 male arc welders, 71 male office workers, and 59 assemblers without welding exposure. Inductivity Coupled Plasma Mass Spectrophotometer (ICP-MS) was applied to detect metals' (zinc, copper, nickel) levels in the post-shift urine samples. Demographic data, work history, smoking status, and respiratory tract irritation symptoms were gathered by a standard self-administered questionnaire. Pulmonary function tests were also performed. There were significantly higher values for average urine metals' (zinc, copper, nickel) levels in spot welders and arc welders than in the non-welding controls. There were 4 out of 23 (17.4%) abnormal forced vital capacity (FVC) among the high-exposed spot welders, 2 out of 18 (11.1%) among the low-exposed spot welders, and 6 out of 130 (4.6%) non-welding-exposed workers. There was a significant linear trend between spot welding exposure and the prevalence of restrictive airway abnormalities (P = 0.036) after adjusting for other factors. There were 9 out of 23 (39.1%) abnormal peak expiratory flow rate (PEFR) among high-exposed spot welders, 5 out of 18 (27.8%) among the low-exposed spot welders, and 28 out of 130 (21.5%) non-welding-exposed workers. There was a borderline significant linear trend between spot welding exposure and the prevalence of obstructive lung function abnormalities (P = 0.084) after adjusting for other factors. There was also a significant dose-response relationship of airway irritation symptoms (cough, phlegm, chronic bronchitis) among the spot welders. Arc welders with high exposure status also had a significant risk of obstructive lung abnormalities (PEFR reduction). There was also a significant dose-response relationship of airway irritation symptoms (cough, phlegm, chest tightness, and chronic bronchitis) among the arc welders. These findings suggest that restrictive and obstructive lung abnormalities, and airway irritation symptoms are associated with spot and arc welding exposures.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Campbell, R.D.; Heiple, C.R.; Sturgill, P.L.

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, andmore » 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.« less

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.

Thomson scattering diagnostics of steady state and pulsed welding processes without and with metal vapor

NASA Astrophysics Data System (ADS)

Kühn-Kauffeldt, M.; Marqués, J.-L.; Schein, J.

2015-01-01

Thomson scattering is applied to measure temperature and density of electrons in the arc plasma of the direct current gas tungsten arc welding (GTAW) process and pulsed gas metal arc welding (GMAW) process. This diagnostic technique allows to determine these plasma parameters independent from the gas composition and heavy particles temperature. The experimental setup is adapted to perform measurements on stationary as well as transient processes. Spatial and temporal electron temperature and density profiles of a pure argon arc in the case of the GTAW process and argon arc with the presence of aluminum metal vapor in the case of the GMAW process were obtained. Additionally the data is used to estimate the concentration of the metal vapor in the GMAW plasma.

A method for predicting optimized processing parameters for surfacing

DOE Office of Scientific and Technical Information (OSTI.GOV)

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

1994-12-31

Welding is used extensively for surfacing applications. To operate a surfacing process efficiently, the variables must be optimized to produce low levels of dilution with the substrate while maintaining high deposition rates. An equation for dilution in terms of the welding variables, thermal efficiency factors, and thermophysical properties of the overlay and substrate was developed by balancing energy and mass terms across the welding arc. To test the validity of the resultant dilution equation, the PAW, GTAW, GMAW, and SAW processes were used to deposit austenitic stainless steel onto carbon steel over a wide range of parameters. Arc efficiency measurementsmore » were conducted using a Seebeck arc welding calorimeter. Melting efficiency was determined based on knowledge of the arc efficiency. Dilution was determined for each set of processing parameters using a quantitative image analysis system. The pertinent equations indicate dilution is a function of arc power (corrected for arc efficiency), filler metal feed rate, melting efficiency, and thermophysical properties of the overlay and substrate. With the aid of the dilution equation, the effect of processing parameters on dilution is presented by a new processing diagram. A new method is proposed for determining dilution from welding variables. Dilution is shown to depend on the arc power, filler metal feed rate, arc and melting efficiency, and the thermophysical properties of the overlay and substrate. Calculated dilution levels were compared with measured values over a large range of processing parameters and good agreement was obtained. The results have been applied to generate a processing diagram which can be used to: (1) predict the maximum deposition rate for a given arc power while maintaining adequate fusion with the substrate, and (2) predict the resultant level of dilution with the substrate.« less

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…

Improving the reliability of inverter-based welding machines

DOE Office of Scientific and Technical Information (OSTI.GOV)

Schiedermayer, M.

1997-02-01

Although inverter-based welding power sources have been available since the late 1980s, many people hesitated to purchase them because of reliability issues. Unfortunately, their hesitancy had a basis, until now. Recent improvements give some inverters a reliability level that approaches that of traditional, transformer-based industrial welding machines, which have a failure rate of about 1%. Acceptance of inverter-based welding machines is important because, for many welding applications, they provide capabilities that solid-state, transformer-based machines cannot deliver. These advantages include enhanced pulsed gas metal arc welding (GMAW-P), lightweight portability, an ultrastable arc, and energy efficiency--all while producing highly aesthetic weld beadsmore » and delivering multiprocess capabilities.« less

Contribution to applications of EBW in instrument techniques

NASA Astrophysics Data System (ADS)

Hrabovsky, Miroslav

1999-07-01

The electron beam welding belongs to so-called physical methods of welding and it is utilized to welding of most materials, that can be arc welded. It is of use there, where one taxing welding technics and structure technologyableless heavily. As a rule, the quality of weld is better than at most first-rate welds being done by inert gas shielded arc welding (WIG, Argoarc). In plant instrumentation, where the limitation of any welded material distortion is of extraordinary importance, this way of welding is significant at welding of thermal-treated Cu-Be alloys, used in measurement technics, structural members from Ti alloys and stainless steels in branches of biomedicine and cryotechnics. This technology positives, especially high weld purity, narrow and deep root penetration, high welding rate, together with low energy consumption, lead to applications and verification of optimum operating mode at welding of frequent materials. In the contribution the results of this proofs of selected welded materials from viewpoint of weld quality, their physical-mechanic properties and microhardness, are presented.

Study of the welding gas influence on a controlled short-arc GMAW process by optical emission spectroscopy

NASA Astrophysics Data System (ADS)

Wilhelm, G.; Gött, G.; Schöpp, H.; Uhrlandt, D.

2010-11-01

The controlled short-arc processes, variants of the gas metal arc welding (GMAW) process, which have recently been developed, are used to reduce the heat input into the workpiece. Such a process with a wire feeding speed which varies periodically, using a steel wire and a steel workpiece to produce bead-on-plate welds has been investigated. As welding gases CO2 and a mixture of Ar and O2 have been used. Depending on the gas, the properties of the plasma change, and as a consequence the weldseams themselves also differ distinctly. Optical emission spectroscopy has been applied to analyse the plasma. The radial profiles of the emission coefficients of an iron line and an argon line or an atomic oxygen line, respectively, have been determined. These profiles indicate the establishment of a metal vapour arc core which has a broader profile under CO2 but is more focused in the centre for argon. The measured iron line emission was near to its norm maximum in the case of CO2. From this fact, temperatures around 8000 K and a metal vapour molar fraction above 75% in the arc centre could be roughly estimated for this case. Estimations of the electrical conductivity and the arc field indicate that the current path must include not only the metal vapour arc core but also outer hot regions dominated by welding gas properties in the case of argon.

FAST TRACK COMMUNICATION: Metal vapour causes a central minimum in arc temperature in gas-metal arc welding through increased radiative emission

NASA Astrophysics Data System (ADS)

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

2010-01-01

A computational model of the argon arc plasma in gas-metal arc welding (GMAW) that includes the influence of metal vapour from the electrode is presented. The occurrence of a central minimum in the radial distributions of temperature and current density is demonstrated. This is in agreement with some recent measurements of arc temperatures in GMAW, but contradicts other measurements and also the predictions of previous models, which do not take metal vapour into account. It is shown that the central minimum is a consequence of the strong radiative emission from the metal vapour. Other effects of the metal vapour, such as the flux of relatively cold vapour from the electrode and the increased electrical conductivity, are found to be less significant. The different effects of metal vapour in gas-tungsten arc welding and GMAW are explained.

Methodology for Estimating Thermal and Neutron Embrittlement of Austenitic Stainless Steel Welds During Service in Light Water Reactors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chopra, O. K.; Rao, A. S.

The effect of thermal aging on the degradation of fracture toughness and Charpy-impact properties of austenitic stainless steel (SS) welds has been characterized at reactor temperatures. The solidification behavior and the distribution and morphology of the ferrite phase in SS welds are described. Thermal aging of the welds results in moderate decreases in Charpy-impact strength and fracture toughness. The upper-shelf Charpy-impact energy of aged welds decreases by 50–80 J/cm2. The decrease in fracture toughness J-R curve, or JIc is relatively small. Thermal aging has minimal effect on the tensile strength. The fracture properties of SS welds are insensitive to fillermore » metal; the welding process has a significant effect. The large variability in the data makes it difficult to establish the effect of the welding process on fracture properties of SS welds. Consequently, the approach used for evaluating thermal and neutron embrittlement of austenitic SS welds relies on establishing a lower-bound fracture toughness J-R curve for unaged and aged, and non-irradiated and irradiated, SS welds. The existing fracture toughness J-R curve data for SS welds have been reviewed and evaluated to define lower-bound J-R curve for submerged arc (SA)/shielded metal arc (SMA)/manual metal arc (MMA) welds and gas tungsten arc (GTA)/tungsten inert gas (TIG) welds in the unaged and aged conditions. At reactor temperatures, the fracture toughness of GTA/TIG welds is a factor of about 2.3 higher than that of SA/SMA/MMA welds. Thermal aging decreases the fracture toughness by about 20%. The potential combined effects of thermal and neutron embrittlement of austenitic SS welds are also described. Lower-bound curves are presented that define the change in coefficient C and exponent n of the power-law J-R curve and the JIc value for SS welds as a function of neutron dose. The potential effects of reactor coolant environment on the fracture toughness of austenitic SS welds are also discussed.« less

Research on Kinematic Trajectory Simulation System of KUKA Arc Welding Robot System

NASA Astrophysics Data System (ADS)

Hu, Min

2017-10-01

In this paper, the simulation trajectory simulation of KUKA arc welding robot system is realized by means of VC platform. It is used to realize the teaching of professional training of welding robot in middle school. It provides teaching resources for the combination of work and study and integration teaching, which enriches the content of course teaching.

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,…

Gas metal arc weldability of 1.5 GPa grade martensitic steels

NASA Astrophysics Data System (ADS)

Hwang, Insung; Yun, Hyeonsang; Kim, Dongcheol; Kang, Munjin; Kim, Young-Min

2018-01-01

The gas metal arc weldability of 1.5 GPa grade martensitic (MART) steel was evaluated using both inverter direct current (DC) and DC pulse power type welders, under conditions of different welding currents, welding speeds, and shielding gasses. By investigating the bead appearance, tensile strength, and arc stability, it was determined that DC pulse power is better than inverter DC power for arc welding of 1.3 mm thick 1.5 GPa grade MART steel. Further, from the results of the weldability for various shielding gases, it was determined that mixed shielding gas is more effective for welding 1.5 GPa grade MART steel than is pure inert gas (Ar) or active (CO2) gas. In the case of pure shielding gas, no sound bead was formed under any conditions. However, when the mixed shielding gas was used, sound and fine beads were obtained.

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.

Ternary gas plasma welding torch

NASA Technical Reports Server (NTRS)

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

1995-01-01

A plasma arc welding torch is discussed. A first plasma gas is directed through the body of the welding torch and out of the body across the tip of a welding electrode disposed at the forward end of the body. A second plasma gas is disposed for flow through a longitudinal bore in the electrode. The second plasma gas enters one end of the electrode and exits the electrode at the tip thereof for co-acting with the electric welding arc to produce the desired weld. A shield gas is directed through the torch body and circulates around the head of the torch adjacent to the electrode tip.

Hybrid Welding of 45 mm High Strength Steel Sections

NASA Astrophysics Data System (ADS)

Bunaziv, Ivan; Frostevarg, Jan; Akselsen, Odd M.; Kaplan, Alexander F.

Thick section welding has significant importance for oil and gas industry in low temperature regions. Arc welding is usually employed providing suitable quality joints with acceptable toughness at low temperatures with very limited productivity compared to modern high power laser systems. Laser-arc hybrid welding (LAHW) can enhance the productivity by several times due to higher penetration depth from laser beam and combined advantages of both heat sources. LAHW was applied to join 45 mm high strength steel with double-sided technique and application of metal cored wire. The process was captured by high speed camera, allowing process observation in order to identify the relation of the process stability on weld imperfections and efficiency. Among the results, it was found that both arc power and presence of a gap increased penetration depth, and that higher welding speeds cause unstable processing and limits penetration depth. Over a wide range of heat inputs, the welds where found to consist of large amounts of fine-grained acicular ferrite in the upper 60-75% part of welds. At the root filler wire mixing was less and cooling faster, and thus found to have bainitic transformation. Toughness of deposited welds provided acceptable toughness at -50 °C with some scattering.

Decomposition of ferrite in commercial superduplex stainless steel weld metals; microstructural transformations above 700 °C

NASA Astrophysics Data System (ADS)

Gregori, A.; Nilsson, J.-O.

2002-04-01

The microstructural stability at temperatures above 700 °C of weld metal of type 29Cr-8Ni-2Mo-0.39N and weld metal of type 25Cr-10Ni-4Mo-0.28N has been compared. Multipass welding was employed using the gas tungsten arc welding technique with a shielding gas of Ar+2 pct N2. The quantitative assessment of the intermetallic phase was performed using automatic image analysis in the light optical microscope (LOM). Detailed microanalysis was also performed using scanning and transmission electron microscopy. A computer program developed by the authors was used to calculate a continuous cooling-temperature (CCT) diagram on the basis of the experimentally determined time-temperature-transformation (TTT) diagram. Thermodynamic calculations for estimating phase stabilities and for interpreting experimental observations were performed. It was found that weld metal of type 29Cr-8Ni-2Mo-0.39N was microstructurally more stable than weld metal of type 25Cr-10Ni-4Mo-0.28N. A lower molybdenum concentration and a higher nitrogen concentration in the former alloy could explain the higher stability with respect to the intermetallic phase. The higher nitrogen concentration also provides a rationale for the higher stability against the formation of secondary austenite in weld metal of type 29Cr-8Ni-2Mo-0.39N. This effect, which is associated with a lower thermodynamic driving force for precipitation of secondary austenite during multipass welding, can be explained by nitrogen-enhanced primary austenite formation.

Effect of Heat Input on Geometry of Austenitic Stainless Steel Weld Bead on Low Carbon Steel

NASA Astrophysics Data System (ADS)

Saha, Manas Kumar; Hazra, Ritesh; Mondal, Ajit; Das, Santanu

2018-05-01

Among different weld cladding processes, gas metal arc welding (GMAW) cladding becomes a cost effective, user friendly, versatile method for protecting the surface of relatively lower grade structural steels from corrosion and/or erosion wear by depositing high grade stainless steels onto them. The quality of cladding largely depends upon the bead geometry of the weldment deposited. Weld bead geometry parameters, like bead width, reinforcement height, depth of penetration, and ratios like reinforcement form factor (RFF) and penetration shape factor (PSF) determine the quality of the weld bead geometry. Various process parameters of gas metal arc welding like heat input, current, voltage, arc travel speed, mode of metal transfer, etc. influence formation of bead geometry. In the current experimental investigation, austenite stainless steel (316) weld beads are formed on low alloy structural steel (E350) by GMAW using 100% CO2 as the shielding gas. Different combinations of current, voltage and arc travel speed are chosen so that heat input increases from 0.35 to 0.75 kJ/mm. Nine number of weld beads are deposited and replicated twice. The observations show that weld bead width increases linearly with increase in heat input, whereas reinforcement height and depth of penetration do not increase with increase in heat input. Regression analysis is done to establish the relationship between heat input and different geometrical parameters of weld bead. The regression models developed agrees well with the experimental data. Within the domain of the present experiment, it is observed that at higher heat input, the weld bead gets wider having little change in penetration and reinforcement; therefore, higher heat input may be recommended for austenitic stainless steel cladding on low alloy steel.

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.

Initial Testing for the Recommendation of Improved Gas Metal Arc Welding Procedures for HY-80 Steel Plate Butt Joints at Norfolk Naval Shipyard

DTIC Science & Technology

2015-12-01

is unlimited 12b. DISTRIBUTION CODE 13. ABSTRACT (maximum 200 words) Hull cut welding proficiency is an essential skill maintained by personnel...at naval shipyards. This thesis explores arc weld theory to develop ideal submarine hull butt joint designs and recommends preliminary testing to...shipboard hull welding applications, theoretically. Butt joint samples were created using HY-80 steel plate so that the following comparisons could

Arc Deflection Length Affected by Transverse Rotating Magnetic Field with Lateral Gas

NASA Astrophysics Data System (ADS)

Shiino, Toru; Ishii, Yoko; Yamamoto, Shinji; Iwao, Toru; High Current Energy Laboratory (HiCEL) Team

2016-10-01

Gas metal arc welding using shielding gas is often used in the welding industry. However, the arc deflection affected by lateral gas is problem because of inappropriate heat transfer. Shielding gas is used in order to prevent the instability affected by the arc deflection. However, the shielding gas causes turbulence, then blowhole of weld defect occurs because the arc affected by the instability is contaminated by the air. Thus, the magnetic field is applied to the arc in order to stabilize the arc using low amount of shielding gas. The method of applying the transverse rotating magnetic field (RMF) to the arc is one of the methods to prevent the arc instability. The RMF drives the arc because of electromagnetic force. The driven arc is considered to be prevented to arc deflection of lateral gas because the arc is restrained by the magnetic field because of the driven arc. In addition, it is assume the RMF prevented to the arc deflection of lateral gas from the multiple directions. In this paper, the arc deflection length affected by the RMF with lateral gas was elucidated in order to know the effect of the RMF for arc stabilization. Specifically, the arc deflection length affected by the magnetic frequency and the magnetic flux density is measured by high speed video camera. As a result, the arc deflection length decreases with increasing magnetic frequency, and the arc deflection length increases with increasing the magnetic flux density.

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 than the case of 304 stainless steel, i.e., higher current boundary and no humping. Regardless of the gravitational level, the ferrite content and the distribution of the solutes (Cr and Ni) remained constant for GTAW on 304 stainless steel. However, for GTAW on Al-4 wt.% Cu alloys, the gravitational orientation changed the weld pool shape associated with convection flows. In summary, gravity influenced the weld pool shape that was associated with convection flows and weld surface deformation for specific welding conditions. The variation of convection flows and weld pool shape played a role in modifying VS and GL. Solidification orientation and morphology were affected because VS and GL were changed as a function of gravity. Studies of gravity on the welding process are expected to play a significant role in the space-station construction and circumferential pipe welding on the earth. (Abstract shortened by UMI.)

The effect of the welding direction on the plasma and metal transfer behavior of CO2 laser+GMAW-P hybrid welding processes

NASA Astrophysics Data System (ADS)

Zhang, Wang; Hua, Xueming; Liao, Wei; Li, Fang; Wang, Min

2014-07-01

During laser-arc hybrid welding, the welding direction exerts direct effects on the plasma properties, the transient behavior of the droplet, the weld pool behavior, and the temperature field. Ultimately, it will affect the welding process and the weld quality. However, the behavior of the CO2 laser+GMAW-P hybrid welding process has not been systematically studied. In this paper, the current-voltage characteristics of different welding processes were analyzed and compared. The dynamics of the droplet transfer, the plasma behavior, and the weld pool behavior were observed by using two high-speed camera systems. Moreover, an optical emission spectroscopy was applied to analyze the plasma temperature and the electron number density. The results indicated that the electrical resistance of the arc plasma reduced in the laser leading mode. For the same pulse duration, the metal transfer mode was the spray type with the laser leading arrangement. The temperature and electron density distribution showed bimodal behavior in the case of arc leading mode, while this phenomenon does not exist in the caser of laser leading mode. The double elliptic-planar distribution which conventional simulation process used was not applicable in the laser leading mode.

Surface preparation effects on GTA weld shape in JBK-75 stainless steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Campbell, R.D.; Robertson, A.M.; Heiple, C.R.

1993-02-01

The results of a study are reported here on the effects of surface preparation on the shape of autogenous gas tungsten arc (GTA) welds in JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface preparation produced substantial changes in the fusion zone shape and welding behavior of this alloy. Increased and more consistent depth of fusion (higher d/w ratios) along with improved arc stability and less arc wander resulted from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any increase in depth of fusion. Abrasive treatments roughen themore » surface, increase the surface area, increase the surface oxide thickness, and entrap oxide. 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. Increased depth of fusion in wire-fed U-groove weld joints also resulted when welding wire with a greater surface oxide thickness was used. Increasing the amount of wire brushing produced even deeper welds. However, a maximum in depth of fusion was observed with further wire brushing, beyond which weld fusion depth decreased.« less

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.

Sensing the gas metal arc welding process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carlson, N.M.; Johnson, J.A.; Smartt, H.B.

1992-01-01

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-bypass 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.

Sensing the gas metal arc welding process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carlson, N.M.; Johnson, J.A.; Smartt, H.B.

1992-10-01

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-bypass 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.

Implementation of an Outer Can Welding System for Savannah River Site FB-Line

DOE Office of Scientific and Technical Information (OSTI.GOV)

Howard, S.R.

2003-03-27

This paper details three phases of testing to confirm use of a Gas Tungsten Arc (GTA) system for closure welding the 3013 outer container used for stabilization/storage of plutonium metals and oxides. The outer container/lid closure joint was originally designed for laser welding, but for this application, the gas tungsten arc (GTA) welding process has been adapted. The testing progressed in three phases: (1) system checkout to evaluate system components for operational readiness, (2) troubleshooting to evaluate high weld failure rates and develop corrective techniques, and (3) pre-installation acceptance testing.

In situ strain and temperature measurement and modelling during arc welding

DOE PAGES

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

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

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.

Numerical analysis of fume formation mechanism in arc welding

NASA Astrophysics Data System (ADS)

Tashiro, Shinichi; Zeniya, Tasuku; Yamamoto, Kentaro; Tanaka, Manabu; Nakata, Kazuhiro; Murphy, Anthony B.; Yamamoto, Eri; Yamazaki, Kei; Suzuki, Keiichi

2010-11-01

In order to clarify the fume formation mechanism in arc welding, a quantitative investigation based on the knowledge of interaction among the electrode, arc and weld pool is indispensable. A fume formation model consisting of a heterogeneous condensation model, a homogeneous nucleation model and a coagulation model has been developed and coupled with the GTA or GMA welding model. A series of processes from evaporation of metal vapour to fume formation from the metal vapour was totally investigated by employing this simulation model. The aim of this paper is to visualize the fume formation process and clarify the fume formation mechanism theoretically through a numerical analysis. Furthermore, the reliability of the simulation model was also evaluated through a comparison of the simulation result with the experimental result. As a result, it was found that the size of the secondary particles consisting of small particles with a size of several tens of nanometres reached 300 nm at maximum and the secondary particle was in a U-shaped chain form in helium GTA welding. Furthermore, it was also clarified that most part of the fume was produced in the downstream region of the arc originating from the metal vapour evaporated mainly from the droplet in argon GMA welding. The fume was constituted by particles with a size of several tens of nanometres and had similar characteristics to that of GTA welding. On the other hand, if the metal transfer becomes unstable and the metal vapour near the droplet diffuses directly towards the surroundings of the arc not getting into the plasma flow, the size of the particles reaches several hundred nanometres.

Welding processes and ocular hazards and protection.

PubMed

Pabley, A S; Keeney, A H

1981-07-01

There are approximately 60 different forms of welding, but only six of these are commonly used. Shielded metal-arc or stick welding, gas metal-arc welding, and oxyacetylene welding are the most frequently used. All produce ultraviolet, visible, and infrared radiation at damaging levels. Conventional glass welding shields contain ultraviolet, visible, and infrared absorbers. Infrared absorbers, however, cause heating and secondary re-radiation. New polycarbonate lenses offer greater impact resistance, and have less tendency to welding spatter. Early abrasion-resistant and reflective coatings on plastics were ineffective. Thin layers of gold with proprietary coatings provide cool reflection and surface resistance. Thermal monitoring of welding indicated that these new shields reduce temperature rises above the ambient by 150% to 175% compared to green glass filter plates without interfering with the welder's vision.

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.

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.

Analysis of plasma characteristics and conductive mechanism of laser assisted pulsed arc welding

NASA Astrophysics Data System (ADS)

Liu, Shuangyu; Chen, Shixian; Wang, Qinghua; Li, Yanqing; Zhang, Hong; Ding, Hongtao

2017-05-01

This study aims to investigate the arc plasma shape and the spectral characteristics during the laser assisted pulsed arc welding process. The arc plasma shape was synchronously observed using a high speed camera, and the emission spectrum of plasma was obtained by spectrometer. The well-known Boltzmann plot method and Stark broadening were used to calculate the electron temperature and density respectively. The conductive mechanism of arc ignition in laser assisted arc hybrid welding was investigated, and it was found that the plasma current moved to the arc anode under the action of electric field. Thus, a significant parabolic channel was formed between the keyhole and the wire tip. This channel became the main method of energy transformation between the arc and the molten pool. The calculation results of plasma resistivity show that the laser plasma has low resistivity as the starting point of conductive channel formation. When the laser pulse duration increases, the intensity of the plasma radiation spectrum and the plasma electron density will increase, and the electron temperature will decrease.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 tomore » re-examine techniques previously discounted, such as wet welding (Anon 1993).« less

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.

Modelling welded material for ultrasonic testing using MINA: Theory and applications

NASA Astrophysics Data System (ADS)

Moysan, J.; Corneloup, G.; Chassignole, B.; Gueudré, C.; Ploix, M. A.

2012-05-01

Austenitic steel multi-pass welds exhibit a heterogeneous and anisotropic structure that causes difficulties in the ultrasonic testing. Increasing the material knowledge is a long term research field for LCND laboratory and EDF Les Renardières in France. A specific model has been developed: the MINA model (Modelling an Isotropy from Notebook of Arc welding). Welded material is described in 2D for flat position arc welding with shielded electrode (SMAW) at a functional scale for UT modeling. The grain growth is the result of three physical phenomena: epitaxial growth, influence of temperature gradient, and competition between the grains. The model uses phenomenological rules to combine these three phenomena. A limited number of parameters is used to make the modelling possible from the information written down in a notebook of arc welding. We present all these principles with 10 years' hindsight. To illustrate the model's use, we present conclusions obtained with two recent applications. In conclusion we give also insights on other research topics around this model : inverse problem using a F.E.M. code simulating the ultrasonic propagation, in position welding, 3D prospects, GTAW.

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…

Characteristics of Extra Narrow Gap Weld of HSLA Steel Welded by Single-Seam per Layer Pulse Current GMA Weld Deposition

NASA Astrophysics Data System (ADS)

Agrawal, B. P.; Ghosh, P. K.

2017-03-01

Butt weld joints are produced using pulse current gas metal arc welding process by employing the technique of centrally laid multi-pass single-seam per layer weld deposition in extra narrow groove of thick HSLA steel plates. The weld joints are prepared by using different combination of pulse parameters. The selection of parameter of pulse current gas metal arc welding is done considering a summarized influence of simultaneously interacting pulse parameters defined by a dimensionless hypothetical factor ϕ. The effect of diverse pulse parameters on the characteristics of weld has been studied. Weld joint is also prepared by using commonly used multi-pass multi-seam per layer weld deposition in conventional groove. The extra narrow gap weld joints have been found much superior to the weld joint prepared by multi-pass multi-seam per layer deposition in conventional groove with respect to its metallurgical characteristics and mechanical properties.

Influence of shielding gas pressure on welding characteristics in CO2 laser-MIG hybrid welding process

NASA Astrophysics Data System (ADS)

Chen, Yanbin; Lei, Zhenglong; Li, Liqun; Wu, Lin

2006-01-01

The droplet transfer behavior and weld characteristics have been investigated under different pressures of shielding gas in CO2 laser and metal inert/active gas (laser-MIG) hybrid welding process. The experimental results indicate that the inherent droplet transfer frequency and stable welding range of conventional MIG arc are changed due to the interaction between CO2 laser beam and MIG arc in laser-MIG hybrid welding process, and the shielding gas pressure has a crucial effect on welding characteristics. When the pressure of shielding gas is low in comparison with MIG welding, the frequency of droplet transfer decreases, and the droplet transfer becomes unstable in laser-MIG hybrid welding. So the penetration depth decreases, which shows the characteristic of unstable hybrid welding. However, when the pressure of shielding gas increases to a critical value, the hybrid welding characteristic is changed from unstable hybrid welding to stable hybrid welding, and the frequency of droplet transfer and the penetration depth increase significantly.

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

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.

Numerical Simulation of Stationary AC Tungsten Inert Gas Welding of Aluminum Plate in Consideration of Oxide Layer Cleaning

NASA Astrophysics Data System (ADS)

Tashiro, Shinichi; Tanaka, Manabu

An unified numerical simulation model of AC TIG welding of the aluminum plate considering energy balance among the electrode, the arc and the base metal and employing an analytical model for calculating cleaning rate of the oxide layer has been developed for investigating heat transport properties and weld pool formation process in AC TIG welding of aluminum plate. As a result of this simulation, it was shown that although the heat flux from the arc onto the base metal increases in EN (Electrode Negative) phase due to the electron condensation, that in EP (Electrode Positive) phase conversely decreases because mainly of cooling caused by the electron emission. Furthermore, the validity of the simulation model was confirmed by comparing to experimental results such as the arc voltage, the area of cleaning zone and the shape of weld pool.

Modelling of fluid flow phenomenon in laser+GMAW hybrid welding of aluminum alloy considering three phase coupling and arc plasma shear stress

NASA Astrophysics Data System (ADS)

Xu, Guoxiang; Li, Pengfei; Cao, Qingnan; Hu, Qingxian; Gu, Xiaoyan; Du, Baoshuai

2018-03-01

The present study aims to develop a unified three dimensional numerical model for fiber laser+GMAW hybrid welding, which is used to study the fluid flow phenomena in hybrid welding of aluminum alloy and the influence of laser power on weld pool dynamic behavior. This model takes into account the coupling of gas, liquid and metal phases. Laser heat input is described using a cone heat source model with changing peak power density, its height being determined based on the keyhole size. Arc heat input is modeled as a double ellipsoid heat source. The arc plasma flow and droplet transfer are simulated through the two simplified models. The temperature and velocity fields for different laser powers are calculated. The computed results are in general agreement with the experimental data. Both the peak and average values of fluid flow velocity during hybrid welding are much higher than those of GMAW. At a low level of laser power, both the arc force and droplet impingement force play a relatively large role on fluid flow in the hybrid welding. Keyhole depth always oscillates within a range. With an increase in laser power, the weld pool behavior becomes more complex. An anti-clockwise vortex is generated and the stability of keyhole depth is improved. Besides, the effects of laser power on different driving forces of fluid flow in weld pool are also discussed.

Plasma effect on weld pool surface reconstruction by shape-from-polarization analysis

DOE Office of Scientific and Technical Information (OSTI.GOV)

Coniglio, N.; Mathieu, A., E-mail: alexandre.mathieu@u-bourgogne.fr; Aubreton, O.

2014-03-31

The polarimetric state of the thermal radiations emitted by the weld metal contains geometric information about the emitting surface. Even though the analysed thermal radiation has a wavelength corresponding to a blind spectral window of the arc plasma, the physical presence of the arc plasma itself interferes with the rays radiated by the weld pool surface before attaining the polarimeter, thus modifying the geometric information transported by the ray. In the present work, the effect of the arc plasma-surrounding zone on the polarimetric state and propagation direction of the radiated ray is analyzed. The interaction with the arc plasma zonemore » induces a drop in ray intensity and a refraction of ray optical path.« less

The humoral immune response of mice exposed to manual metal arc stainless steel-welding fumes.

PubMed

Anderson, Stacey E; Meade, B Jean; Butterworth, Leon F; Munson, Albert E

2007-01-01

Arc welding is one of the most common forms of welding and includes the use of stainless steel electrodes that emit fumes containing chromium and nickel. Epidemological studies suggest a correlation between arc welding and adverse respiratory health effects. Studies evaluating the immunotoxic effects of welding fumes are limited due to the large number of variables associated with welding. This work investigates the immunotoxic effects of welding fumes by analyzing the in vivo and in vitro IgM response to a T-dependent antigen after welding fume exposure. Significant decreases in the total IgM activity/10(6) viable cells and total IgM activity/well were observed in splenocytes exposed to 5 mu g/ml of either total or soluble welding fumes. A significant reduction in the specific IgM activity in lung associated lymph node cells was also observed following four pharyngeal aspirations of 10 mg/kg total or soluble welding fumes to mice. Significant elevations in the absolute lymph node cell numbers for both B- and T-cells including the CD4(+) and CD8(+) subsets were observed. These results demonstrate that exposure to manual metal-stainless steel welding fumes is immunosuppressive in the presence of increased lymphoctye numbers in mice and raises concerns regarding the potential for adverse immunological effects to impact respiratory health in humans.

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.

Weld pool development during GTA and laser beam welding of Type 304 stainless steel; Part I - theoretical analysis

DOE Office of Scientific and Technical Information (OSTI.GOV)

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

1989-12-01

A computational and experimental study was carried out to quantitatively understand the influence of the heat flow and the fluid flow in the transient development of the weld pool during gas tungsten arc (GTA) and laser beam welding of Type 304 stainless steel. Stationary gas tungsten arc and laser beam welds were made on two heats of Type 304 austenitic stainless steels containing 90 ppm sulfur and 240 ppm sulfur. A transient heat transfer model was utilized to simulate the heat flow and fluid flow in the weld pool. In this paper, the results of the heat flow and fluidmore » flow analysis are presented.« less

Evaluation of pitting corrosion resistance of high-alloyed stainless steels welds for FGD plants in Korea

DOE Office of Scientific and Technical Information (OSTI.GOV)

Baek, K.K.; Sung, H.J.; Im, C.S.

1998-12-31

For successful application of high-alloyed stainless steels for Flue Gas Desulfurization (FGD) plants, pitting corrosion resistance of arc welds of N-added 6%Mo austenitic stainless steels (UNS N 08367) and super duplex stainless steels (UNS S 32550) made with various filler metals were evaluated using the Green Death solution. For Gas Tungsten Arc (GTA) and Gas Metal Arc (GMA) welds of N 08367, Critical Pitting Temperature (CPT) of base metal was 65--70 C, whereas weld made by ERNiCrMo-3 filler metal yielded CPT of 50 C. Welds made by ERNiCrMo-10 or ERNiCrMo-4 filler metals showed CPT of 60--65 C and 65--70C, respectively.more » For GTA and GMA welds of S 32550, CPT of welds made by ERNiCrMo-3 was 45--50 C, indicating that the filler metal can provide pitting corrosion resistance matching the S 32550 alloy. Thus, a proper pitting corrosion resistance of weldments of high-alloy stainless steels can be achieved by selecting filler metals having at least +10 higher Pitting Resistance Equivalent Number (PRE{sub N}) value than the base metal regardless of the type of arc welding process. The over-alloyed filler metals would compensate preferential segregation of Cr, MO along the dendrite boundary, which made the dendrite core more susceptible to pitting. Nitrogen addition to the GTA welds of N 08367 made with ERNiCrMo-3 failed to improve pitting corrosion resistance, which was attributed to the precipitation of nitrogen in the weld metal in the form of Nb-nitride.« less

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

NASA Astrophysics Data System (ADS)

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

2010-07-01

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

Numerical analysis of the heat source characteristics of a two-electrode TIG arc

NASA Astrophysics Data System (ADS)

Ogino, Y.; Hirata, Y.; Nomura, K.

2011-06-01

Various kinds of multi-electrode welding processes are used to ensure high productivity in industrial fields such as shipbuilding, automotive manufacturing and pipe fabrication. However, it is difficult to obtain the optimum welding conditions for a specific product, because there are many operating parameters, and because welding phenomena are very complicated. In the present research, the heat source characteristics of a two-electrode TIG arc were numerically investigated using a 3D arc plasma model with a focus on the distance between the two electrodes. The arc plasma shape changed significantly, depending on the electrode spacing. The heat source characteristics, such as the heat input density and the arc pressure distribution, changed significantly when the electrode separation was varied. The maximum arc pressure of the two-electrode TIG arc was much lower than that of a single-electrode TIG. However, the total heat input of the two-electrode TIG arc was nearly constant and was independent of the electrode spacing. These heat source characteristics of the two-electrode TIG arc are useful for controlling the heat input distribution at a low arc pressure. Therefore, these results indicate the possibility of a heat source based on a two-electrode TIG arc that is capable of high heat input at low pressures.

Mixing weld gases offers advantages

NASA Technical Reports Server (NTRS)

May, J. L.; Mendenhall, M. M.

1969-01-01

Argon added to helium during gas tungsten arc cover-pass welding in the horizontal position results in a better controlled wider bead width, increased arc stability, and reduction in heat input. Adequate filler material wetness and penetration pass coverage is possible with only one pass.

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.

Fusion welding experiments under low-gravity conditions using aircraft

NASA Astrophysics Data System (ADS)

Masubuchi, Koichi; Nayama, Michisuke

A series of gas tungsten arc welding experiments under low-gravity conditions created using parabolic flight of aircraft were performed. The materials used were aluminum and 2219 aluminum alloy. Welding was conducted in a small chamber filled with 100 percent argon gas, and the power source was a set of storage batteries. While welding was conducted, CCD image of welding phenomena, welding current, voltage, and the gravity level of the welding table were recorded continuously. It was found that sound welds can be obtained under low-gravity conditions. The bead appearance of the weld bead made under low-gravity conditions was very smooth and flat with no ripple lines which normally exist in welds made on the earth. The observed shape of the arc plasma under low-gravity conditions was larger than that made under normal gravity condition, but the difference was not so significant. Welds made under low-gravity conditions tend to contain more porosity compared with welds made under the earth conditions.

Gas tungsten arc welding of aluminum alloys 6XXX. Welding procedure specification. Supplement 1. Records of procedure qualification tests. [6061 and 6063

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1986-06-01

Procedure WPS-1003 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.035 to 0.516 inch; filler metal is ER4043 (F-23) or ER5356 (F-22); shielding gas is argon.

Gas tungsten arc welding of aluminum alloys 1XXX and 3003 to 3004, 5052 and 5X54. Welding procedure specification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1985-08-01

Procedure WPS-2201 is qualified under Section IX of the ASME Boiler and Pressure Vessel for gas tungsten arc welding of aluminum alloys 1060, 1100, and 3003 (P-21) to 3004, 5052, 5154, and 5454 (P-22), in thickness range 0.062 to 0.5 in.; filler metal is ER5356 (F-22); shielding gas is argon.

Gas tungsten arc welding of aluminum alloys 3004, 5052, and 5X54. Welding procedure specification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1985-08-01

Procedure WPS-1002 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 3004, 5052, 5154, and 5454 (P-22), in thickness range 0.062 to 0.5 in.; filler metal is ER4043 (F-23) for 3004, and ER5356 (F-22) for other alloys; shielding gas is argon.

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. The heat and mass transfer and the issues in joining of dissimilar alloys by the hybrid laser/arc welding process (HLAW) were explicitly explained in details. A finite element model was developed to simulate the heat transfer in HLAW of the aluminum alloys. Two double-ellipsoidal heat source models were considered to describe the heat input of the gas metal arc welding and laser welding processes. An experimental procedure was also developed for joining thick advanced high strength steel plates by using the HLAW, by taking into consideration different butt joint configurations. The geometry of the weld groove was optimized according to the requirements of ballistic test, where the length of the softened heat affected zone should be less than 15.9 mm measured from the weld centerline. Since the main issue in HLAW of the AHSS was the formation of the pores, the possible mechanisms of the pores formation and their mitigation methods during the welding process were investigated. Mitigation methods were proposed to reduce the pores inside in the weld area and the influence of each method on the process stability was investigated by an on-line monitoring system of the HLAW process. The groove angle was optimized for the welding process based on the allowed amount of heat input along the TRICLADRTM interface generated by an explosive welding. The weld was fractured in the heat affected zone of the aluminum side in the tensile test. The microharness was shown that the temperature variation caused minor softening in the heat affected zone satisfying the requirement that the width of the softened heat affected zone in the steel side falls within 15.9 mm far away from the weld centerline. The microstructure analysis showed the presence of tempered martensite at the vicinity of the weld area, which it was a cause of softening in the heat affected zone.

Automatic Welding System of Aluminum Pipe by Monitoring Backside Image of Molten Pool Using Vision Sensor

NASA Astrophysics Data System (ADS)

Baskoro, Ario Sunar; Kabutomori, Masashi; Suga, Yasuo

An automatic welding system using Tungsten Inert Gas (TIG) welding with vision sensor for welding of aluminum pipe was constructed. This research studies the intelligent welding process of aluminum alloy pipe 6063S-T5 in fixed position and moving welding torch with the AC welding machine. The monitoring system consists of a vision sensor using a charge-coupled device (CCD) camera to monitor backside image of molten pool. The captured image was processed to recognize the edge of molten pool by image processing algorithm. Neural network model for welding speed control were constructed to perform the process automatically. From the experimental results it shows the effectiveness of the control system confirmed by good detection of molten pool and sound weld of experimental result.

Contribution for Iron Vapor and Radiation Distribution Affected by Current Frequency of Pulsed Arc

NASA Astrophysics Data System (ADS)

Shimokura, Takuya; Mori, Yusuke; Iwao, Toru; Yumoto, Motoshige

Pulsed GTA welding has been used for improvement of stability, weld speed, and heat input control. However, the temperature and radiation power of the pulsed arc have not been elucidated. Furthermore, arc contamination by metal vapor changes the arc characteristics, e.g. by increasing radiation power. In this case, the metal vapor in pulsed GTA welding changes the distribution of temperature and radiation power as a function of time. This paper presents the relation between metal vapor and radiation power at different pulse frequencies. We calculate the Fe vapor distribution of the pulsed current. Results show that the Fe vapor is transported at fast arc velocity during the peak current period. During the base current period, the Fe vapor concentration is low and distribution is diffuse. The transition of Fe vapor distribution does not follow the pulsed current; the radiation power density distribution differs for high frequencies and low frequencies. In addition, the Fe vapor and radiation distribution are affected by the pulsed arc current frequency.

Welding of gamma titanium aluminide alloys

NASA Technical Reports Server (NTRS)

Smashey, Russell W. (Inventor); Snyder, John H. (Inventor); Kelly, Thomas J. (Inventor); Sheranko, Ronald L. (Inventor)

1998-01-01

An article made of a gamma titanium aluminide alloy is welded, as for example in the weld repair of surface cracks, by removing foreign matter from the area to be welded, first stress relieving the article, cooling the entire article to a welding temperature of from about 1000.degree. F. to about 1400.degree. F., welding a preselected region in an inert atmosphere at the welding temperature, and second stress relieving the article. Welding is preferably accomplished by striking an arc in the preselected region so as to locally melt the alloy in the preselected region, providing a filler metal having the same composition as the gamma titanium aluminide alloy of the article, and feeding the filler metal into the arc so that the filler metal is melted and fused with the article to form a weldment upon solidification.

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.

Models for selecting GMA Welding Parameters for Improving Mechanical Properties of Weld Joints

NASA Astrophysics Data System (ADS)

Srinivasa Rao, P.; Ramachandran, Pragash; Jebaraj, S.

2016-02-01

During the process of Gas Metal Arc (GMAW) welding, the weld joints mechanical properties are influenced by the welding parameters such as welding current and arc voltage. These parameters directly will influence the quality of the weld in terms of mechanical properties. Even small variation in any of the cited parameters may have an important effect on depth of penetration and on joint strength. In this study, S45C Constructional Steel is taken as the base metal to be tested using the parameters wire feed rate, voltage and type of shielding gas. Physical properties considered in the present study are tensile strength and hardness. The testing of weld specimen is carried out as per ASTM Standards. Mathematical models to predict the tensile strength and depth of penetration of weld joint have been developed by regression analysis using the experimental results.

The keyhole region in VPPA welds

NASA Technical Reports Server (NTRS)

Walsh, Daniel W.

1988-01-01

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. The effects of microsegregation and transient weld stress on macrosegregation in the weld tool are examined. In addition the electrical character of straight and reverse polarity portions of the arc cycle were characterized. The results of the former study indicate that alloy 2219 is weldable because large liquid volumes are available during latter stages of weld solidification. Strains in the pool region, acting in conjunction with weld microsegregation can produce macrosegregation great enough to produce radiographic contrast effects in welds. Mechanisms of surface copper enrichment were identified. The latter study has demonstrated that increased heat is delivered to workpieces if the reverse polarity proportion of the weld cycle is increased. Current in the straight polarity portion of the welding cycle increased as the reverse cycle proportion increased. Voltage during reverse polarity segments is large.

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

NASA Technical Reports Server (NTRS)

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

1973-01-01

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

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…

Welding deviation detection algorithm based on extremum of molten pool image contour

NASA Astrophysics Data System (ADS)

Zou, Yong; Jiang, Lipei; Li, Yunhua; Xue, Long; Huang, Junfen; Huang, Jiqiang

2016-01-01

The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding(GMAW) molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels(0.16 mm), and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.

Study of 2219 aluminum alloy using direct current A-TIG welding

NASA Astrophysics Data System (ADS)

Li, Hui; Zou, Jiasheng

2017-07-01

Direct current A-TIG (DCEN A-TIG) welding using special active agent had eliminated the pores and the oxidation of 2219 high-strength aluminum alloy in welding. Addition of AlF3-25% LiF active agent to DCEN A-TIG welding and arc morphology showed a trailing phenomenon. However, the change in arc morphology was not remarkable when AlF3-75% LiF active agent was added. Addition of AlF3-75% LiF active agent can refine the grain size of DCEN A-TIG joint. The mechanical properties of the weld were optimal at 10% AlF3-75% LiF active agent. Compared with AC TIG and AC A-TIG welding, DCEN A-TIG welding yielded better results for 2219 Al alloy.

GTA welding and heat treating of high purity aluminum. [-452/sup 0/F

DOE Office of Scientific and Technical Information (OSTI.GOV)

Voigt, R.C.; Loper, C.R. Jr.

1979-01-01

Gas tungsten arc welding is a suitable way to join high purity aluminum with only small increases in the electrical resistivity at 4.2 K (i.e., -269 C or -452 F) if proper welding procedures are used. High purity aluminum weld zone properties, useful for the design of cryogenic superconducting devices, are now available. The additional electrical resistivity caused by welding is independent of original base metal resistivity and can be decreased significantly by heat treatments as low as 260 C (500 F) for 30 minutes. Tungsten contamination caused from welding is small (on the order of 0.2 ppM) but itmore » is a significant contribution to weld zone resistivity. This suggests that other welding techniques such as laser welding or electron beam welding may be successful alternatives. Additional GTA welding tests for various welding conditions and welding procedures would lead to a greater understanding of the tungsten emission levels during welding. Perturbations during GTA welding such as electrode spitting or electrode contact with the weld metal must be eliminated to successfully weld high purity aluminum. Improper welding techniques causing arc instabilities, for any reason, cause highly resistive welds that must be properly repaired.« less

Gas tungsten arc welder

DOEpatents

Christiansen, D.W.; Brown, W.F.

A welder for automated closure of fuel pins by a gas tungsten arc process in which a rotating length of cladding is positioned adjacent a welding electrode in a sealed enclosure. An independently movable axial grinder is provided in the enclosure for refurbishing the used electrode between welds.

A case of photic retinal injury associated with exposure to plasma arc welding.

PubMed

Choi, Sung-Won; Chun, Ko-I; Lee, Seok-Joon; Rah, Sang-Hoon

2006-12-01

To report of photic retinopathy induced by plasma arc welding, and the OCT (optical coherence tomography) results of damaged retinal lesions. We describe a case report of a 37-year-old male, working in the steel industry, who presented with central scotoma in both eyes. On his first visit, one day after performing plasma arc welding with protective gear at work, his best corrected vision was 0.7 for both eyes. Ophthalmic examination of the fundus showed a round yellow lesion with an approximate size of 300 micrometers superonasal to the fovea of both eyes. On his next visit, one month later, his vision had recovered to 1.0, his symptoms had improved, and the ophthalmoscopic examination of the fundus revealed that the round yellow spots had disappeared from both eyes. To our knowledge, this is the first report of photic retinopathy induced by plasma arc welding, and the OCT (optical coherence tomography) results of damaged retinal lesions have not previously been reported. For these reasons, we report this case.

Automatic Welding of Stainless Steel Tubing

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1978-01-01

To determine if the use of automatic welding would allow reduction of the radiographic inspection requirement, and thereby reduce fabrication costs, a series of welding tests were performed. In these tests an automatic welder was used on stainless steel tubing of 1/2, 3/4, and 1/2 inch diameter size. The optimum parameters were investigated to determine how much variation from optimum in machine settings could be tolerate and still result in a good quality weld. The process variables studied were the welding amperes, the revolutions per minute as a function of the circumferential weld travel speed, and the shielding gas flow. The investigation showed that the close control of process variables in conjunction with a thorough visual inspection of welds can be relied upon as an acceptable quality assurance procedure, thus permitting the radiographic inspection to be reduced by a large percentage when using the automatic process.

The effect of welding parameters on surface quality of AA6351 aluminium alloy

NASA Astrophysics Data System (ADS)

Yacob, S.; MAli, M. A.; Ahsan, Q.; Ariffin, N.; Ali, R.; Arshad, A.; Wahab, M. I. A.; Ismail, S. A.; Roji, NS M.; Din, W. B. W.; Zakaria, M. H.; Abdullah, A.; Yusof, M. I.; Kamarulzaman, K. Z.; Mahyuddin, A.; Hamzah, M. N.; Roslan, R.

2015-12-01

In the present work, the effects of gas metal arc welding-cold metal transfer (GMAW-CMT) parameters on surface roughness are experimentally assessed. The purpose of this study is to develop a better understanding of the effects of welding speed, material thickness and contact tip to work distance on the surface roughness. Experiments are conducted using single pass gas metal arc welding-cold metal transfer (GMAW-CMT) welding technique to join the material. The material used in this experiment was AA6351 aluminum alloy with the thickness of 5mm and 6mm. A Mahr Marsuft XR 20 machine was used to measure the average roughness (Ra) of AA6351 joints. The main and interaction effect analysis was carried out to identify process parameters that affect the surface roughness. The results show that all the input process parameters affect the surface roughness of AA6351 joints. Additionally, the average roughness (Ra) results also show a decreasing trend with increased of welding speed. It is proven that gas metal arc welding-cold metal transfer (GMAW-CMT)welding process has been successful in term of providing weld joint of good surface quality for AA6351 based on the low value surface roughness condition obtained in this setup. The outcome of this experimental shall be valuable for future fabrication process in order to obtained high good quality weld.

Low Speed Control for Automatic Welding

NASA Technical Reports Server (NTRS)

Iceland, W. E.

1982-01-01

Amplifier module allows rotating positioner of automatic welding machine to operate at speeds below normal range. Low speeds are precisely regulated by a servomechanism as are normal-range speeds. Addition of module to standard welding machine makes it unnecessary to purchase new equipment for low-speed welding.

Thermo-mechanical modeling of the gas-tungsten-arc (GTA) welding process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Duncan, D.B.

1980-01-18

A fundamental study of gas-tungsten-arc (GTA) welding was undertaken. This was initiated with a review of the GTA welding process which lead to the decision to focus experimental and analytical efforts on stationary welds on a pure material. Pure nickel was selected for the test material. Temperature, strain, and distortion measurements were made during the formation of spot welds on circular plates. Transient thermal data were obtained with thermocouples, a radiation pyrometer, and from motion pictures. Local strain was observed qualitatively from Moire interference fringe patterns. Distortion during welding was measured with displacement gages and residual distortion with a profilometer.more » Experimental measurements are compared with predictions of thermal and mechanical finite element codes.« less

General Mechanical Repair. Welding. Volume 2. Teacher's Guide.

ERIC Educational Resources Information Center

East Texas State Univ., Commerce. Occupational Curriculum Lab.

Five units on welding are presented in this teacher's guide. The units are the following: introduction to oxyacetylene welding, oxyacetylene welding positions and applications, use of the cutting torch, introduction to shielded metal arc welding, and welding joints and positions. Each instructional unit generally contains eight components:…

Thermal Analysis and Microhardness Mapping in Hybrid Laser Welds in a Structural Steel

DTIC Science & Technology

2003-01-01

conditions. Via the keyhole the laser beam brings about easier ignition of the arc, stabilization of the arc welding process, and penetration of the...with respect to the conventional GMAW or GTAW processes without the need for very close fit-up. This paper will compare an autogenous laser weld to a...UNCLASSIFIED Defense Technical Information Center Compilation Part Notice ADP017864 TITLE: Thermal Analysis and Microhardness Mapping in Hybrid Laser

Exposure to welding fumes increases lung cancer risk among light smokers but not among heavy smokers: evidence from two case-control studies in Montreal.

PubMed

Vallières, Eric; Pintos, Javier; Lavoué, Jérôme; Parent, Marie-Élise; Rachet, Bernard; Siemiatycki, Jack

2012-08-01

We investigated relationships between occupational exposure to gas and arc welding fumes and the risk of lung cancer among workers exposed to these agents throughout the spectrum of industries. Two population-based case-control studies were conducted in Montreal. Study I (1979-1986) included 857 cases and 1066 controls, and Study II (1996-2001) comprised 736 cases and 894 controls. Detailed job histories were obtained by interview and evaluated by an expert team of chemist-hygienists to estimate degree of exposure to approximately 300 substances for each job. Gas and arc welding fumes were among the agents evaluated. We estimated odds ratios (ORs) and 95% confidence intervals (CIs) of lung cancer using logistic regression, adjusting for smoking history and other covariates. The two studies provided similar results, so a pooled analysis was conducted. Among all subjects, no significant association was found between lung cancer and gas welding fumes (OR = 1.1; 95% CI = 0.9-1.4) or arc welding fumes (OR = 1.0; 95% CI = 0.8-1.2). However, when restricting attention to light smokers, there was an increased risk of lung cancer in relation to gas welding fumes (OR = 2.9; 95% CI = 1.7-4.8) and arc welding fumes (OR = 2.3; 95% CI = 1.3-3.8), with even higher OR estimates among workers with the highest cumulative exposures. In conclusion, there was no detectable excess risk of lung cancer due to welding fumes among moderate to heavy smokers; but among light smokers we found an excess risk related to both types of welding fumes.

Exposure to welding fumes increases lung cancer risk among light smokers but not among heavy smokers: evidence from two case–control studies in Montreal

PubMed Central

Vallières, Eric; Pintos, Javier; Lavoué, Jérôme; Parent, Marie-Élise; Rachet, Bernard; Siemiatycki, Jack

2012-01-01

We investigated relationships between occupational exposure to gas and arc welding fumes and the risk of lung cancer among workers exposed to these agents throughout the spectrum of industries. Two population-based case–control studies were conducted in Montreal. Study I (1979–1986) included 857 cases and 1066 controls, and Study II (1996–2001) comprised 736 cases and 894 controls. Detailed job histories were obtained by interview and evaluated by an expert team of chemist–hygienists to estimate degree of exposure to approximately 300 substances for each job. Gas and arc welding fumes were among the agents evaluated. We estimated odds ratios (ORs) and 95% confidence intervals (CIs) of lung cancer using logistic regression, adjusting for smoking history and other covariates. The two studies provided similar results, so a pooled analysis was conducted. Among all subjects, no significant association was found between lung cancer and gas welding fumes (OR = 1.1; 95% CI = 0.9–1.4) or arc welding fumes (OR = 1.0; 95% CI = 0.8–1.2). However, when restricting attention to light smokers, there was an increased risk of lung cancer in relation to gas welding fumes (OR = 2.9; 95% CI = 1.7–4.8) and arc welding fumes (OR = 2.3; 95% CI = 1.3–3.8), with even higher OR estimates among workers with the highest cumulative exposures. In conclusion, there was no detectable excess risk of lung cancer due to welding fumes among moderate to heavy smokers; but among light smokers we found an excess risk related to both types of welding fumes. PMID:23342253

Evolution of Welding-Fume Aerosols with Time and Distance from the Source: A study was conducted on the spatiotemporal variability in welding-fume concentrations for the characterization of first- and second-hand exposure to welding fumes.

PubMed

Cena, L G; Chen, B T; Keane, M J

2016-08-01

Gas metal arc welding fumes were generated from mild-steel plates and measured near the arc (30 cm), representing first-hand exposure of the welder, and farther away from the source (200 cm), representing second-hand exposure of adjacent workers. Measurements were taken during 1-min welding runs and at subsequent 5-min intervals after the welding process was stopped. Number size distributions were measured in real time. Particle mass distributions were measured using a micro-orifice uniform deposition impactor, and total mass concentrations were measured with polytetrafluorothylene filters. Membrane filters were used for collecting morphology samples for electron microscopy. Average mass concentrations measured near the arc were 45 mg/m 3 and 9 mg/m 3 at the farther distance. The discrepancy in concentrations at the two distances was attributed to the presence of spatter particles, which were observed only in the morphology samples near the source. As fumes aged over time, mass concentrations at the farther distance decreased by 31% (6.2 mg/m 3 ) after 5 min and an additional 13% (5.4 mg/m 3 ) after 10 min. Particle number and mass distributions during active welding were similar at both distances, indicating similar exposure patterns for welders and adjacent workers. Exceptions were recorded for particles smaller than 50 nm and larger than 3 μm, where concentrations were higher near the arc, indicating higher exposures of welders. These results were confirmed by microscopy analysis. As residence time increased, number concentrations decreased dramatically. In terms of particle number concentrations, second-hand exposures to welding fumes during active welding may be as high as first-hand exposures.

A model for prediction of fume formation rate in gas metal arc welding (GMAW), globular and spray modes, DC electrode positive.

PubMed

Dennis, J H; Hewitt, P J; Redding, C A; Workman, A D

2001-03-01

Prediction of fume formation rate during metal arc welding and the composition of the fume are of interest to occupational hygienists concerned with risk assessment and to manufacturers of welding consumables. A model for GMAW (DC electrode positive) is described based on the welder determined process parameters (current, wire feed rate and wire composition), on the surface area of molten metal in the arc and on the partial vapour pressures of the component metals of the alloy wire. The model is applicable to globular and spray welding transfer modes but not to dip mode. Metal evaporation from a droplet is evaluated for short time increments and total evaporation obtained by summation over the life of the droplet. The contribution of fume derived from the weld pool and spatter (particles of metal ejected from the arc) is discussed, as are limitations of the model. Calculated droplet temperatures are similar to values determined by other workers. A degree of relationship between predicted and measured fume formation rates is demonstrated but the model does not at this stage provide a reliable predictive tool.

Effect of chronic exposure to welding light on Calabar welders.

PubMed

Davies, K G; Asanga, U; Nku, C O; Osim, E E

2007-01-01

It was generally observed that welders in Calabar, Nigeria did not always wear their protective goggles during welding. Since chronic exposure to welding light can impair vision this study was done to assess the effect of exposure to welding light on ocular function of welders in Calabar, Nigeria. There were 195 subjects comprising 110 welders (test) and 85 control subjects. Both groups were all male and had similar age range. The tests employed were clinical examination for ocular disorders, assessment of visual acuity, and opthalmoscopy. Test questionnaire was also used to record information on length of service, precautionary measures at work place, age and past ocular illnesses. The study also compared incidence of ocular disorders between the two groups of welders (arc and carbide welders). The mean ages of the welders and their control were not significantly different (27.53 +/- 10.0 vs 27.78 +/- 8.5 yrs respectively). There was a significantly [P < 0.01] higher incidence of pingueculum, cataract, allergic conjunctivitis, corneal opacity, and keratoconjunctivitis (arc eye) in welders than in their control subjects. However, visual acuity, incidence of pterygium and glaucoma were similar. Between the two groups of welders, the incidence of pterygium, corneal opacity and keratoconjunctivitis was significantly [P < 0.01] higher in arc welders than carbide welders. The incidence of pingueculum and glaucoma were however, similar. In conclusion, chronic exposure to welding light without adequate precaution may cause ocular disorders. Arc welding is more dangerous to ocular function than carbide welding. Length of service and age are predisposing factors to ocular disorders in the welding business.

Local exhaust ventilation for the control of welding fumes in the construction industry--a literature review.

PubMed

Flynn, Michael R; Susi, Pam

2012-08-01

Arc welding is a common unit operation in the construction industry, where frequent changes in location and welding position make it more difficult to control fume exposures than in industries where fixed locations are the norm. Welders may be exposed to a variety of toxic airborne contaminants including manganese (Mn) and hexavalent chromium (CrVI). Local exhaust ventilation (LEV) is a well-known engineering control for welding fumes but has not been adopted widely in the construction industry. This literature review presents data on the performance of a variety of LEV systems for welding fume control from the construction (five references), shipyard (five references), and other industries. The studies indicate that LEV can reduce fume exposures to total particulate, Mn, and CrVI to levels below currently relevant standards. Field studies suggest that 40-50% or more reduction in exposure is possible with portable or fixed LEV systems relative to natural ventilation but that correct positioning of the hood and adequate exhaust flow rates are essential. Successful implementation of extraction guns for gas metal arc welding (GMAW) and flux core arc welding has been demonstrated, indicating that a successful balance between extraction airflow and shielding gas requirements is possible. Work practices are an important part of achieving successful control of fume exposures; in particular, positioning the hood close to the arc, checking exhaust flow rates, and avoiding the plume. Further research is needed on hood size effects for controlling welding fume with portable LEV systems and identifying and overcoming barriers to LEV use in construction.

Gas tungsten arc welder with electrode grinder

DOEpatents

Christiansen, David W.; Brown, William F.

1984-01-01

A welder for automated closure of fuel pins by a gas tungsten arc process in which a rotating length of cladding is positioned adjacent a welding electrode in a sealed enclosure. An independently movable axial grinder is provided in the enclosure for refurbishing the used electrode between welds.

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.

Multiphysics Modeling and Simulations of Mil A46100 Armor-Grade Martensitic Steel Gas Metal Arc Welding Process

NASA Astrophysics Data System (ADS)

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

2013-10-01

A multiphysics computational model has been developed for the conventional Gas Metal Arc Welding (GMAW) joining process and used to analyze butt-welding of MIL A46100, a prototypical high-hardness armor martensitic steel. The model consists of five distinct modules, each covering a specific aspect of the GMAW process, i.e., (a) dynamics of welding-gun behavior; (b) heat transfer from the electric arc and mass transfer from the electrode to the weld; (c) development of thermal and mechanical fields during the GMAW process; (d) the associated evolution and spatial distribution of the material microstructure throughout the weld region; and (e) the final spatial distribution of the as-welded material properties. To make the newly developed GMAW process model applicable to MIL A46100, the basic physical-metallurgy concepts and principles for this material have to be investigated and properly accounted for/modeled. The newly developed GMAW process model enables establishment of the relationship between the GMAW process parameters (e.g., open circuit voltage, welding current, electrode diameter, electrode-tip/weld distance, filler-metal feed speed, and gun travel speed), workpiece material chemistry, and the spatial distribution of as-welded material microstructure and properties. The predictions of the present GMAW model pertaining to the spatial distribution of the material microstructure and properties within the MIL A46100 weld region are found to be consistent with general expectations and prior observations.

Multi-objective Optimization of Pulsed Gas Metal Arc Welding Process Using Neuro NSGA-II

NASA Astrophysics Data System (ADS)

Pal, Kamal; Pal, Surjya K.

2018-05-01

Weld quality is a critical issue in fabrication industries where products are custom-designed. Multi-objective optimization results number of solutions in the pareto-optimal front. Mathematical regression model based optimization methods are often found to be inadequate for highly non-linear arc welding processes. Thus, various global evolutionary approaches like artificial neural network, genetic algorithm (GA) have been developed. The present work attempts with elitist non-dominated sorting GA (NSGA-II) for optimization of pulsed gas metal arc welding process using back propagation neural network (BPNN) based weld quality feature models. The primary objective to maintain butt joint weld quality is the maximization of tensile strength with minimum plate distortion. BPNN has been used to compute the fitness of each solution after adequate training, whereas NSGA-II algorithm generates the optimum solutions for two conflicting objectives. Welding experiments have been conducted on low carbon steel using response surface methodology. The pareto-optimal front with three ranked solutions after 20th generations was considered as the best without further improvement. The joint strength as well as transverse shrinkage was found to be drastically improved over the design of experimental results as per validated pareto-optimal solutions obtained.

Thermal regulation in multiple-source arc welding involving material transformations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Doumanidis, C.C.

1995-06-01

This article addresses regulation of the thermal field generated during arc welding, as the cause of solidification, heat-affected zone and cooling rate related metallurgical transformations affecting the final microstructure and mechanical properties of various welded materials. This temperature field is described by a dynamic real-time process model, consisting of an analytical composite conduction expression for the solid region, and a lumped-state, double-stream circulation model in the weld pool, integrated with a Gaussian heat input and calibrated experimentally through butt joint GMAW tests on plain steel plates. This model serves as the basis of an in-process thermal control system employing feedbackmore » of part surface temperatures measured by infrared pyrometry; and real-time identification of the model parameters with a multivariable adaptive control strategy. Multiple heat inputs and continuous power distributions are implemented by a single time-multiplexed torch, scanning the weld surface to ensure independent, decoupled control of several thermal characteristics. Their regulation is experimentally obtained in longitudinal GTAW of stainless steel pipes, despite the presence of several geometrical, thermal and process condition disturbances of arc welding.« less

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shen, Z.; Chen, Y.; Haghshenas, M., E-mail: mhaghshe@uwaterloo.ca

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 overmore » 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.« less

Home cage locomotor changes in non-human primates after prolonged welding-fume exposure.

PubMed

Kim, Choong Yong; Sung, Jae Hyuck; Chung, Yong Hyun; Park, Jung Duck; Han, Jeong Hee; Lee, Jong Seong; Heo, Jeong Doo; Yu, Il Je

2013-12-01

To define the relationship between the brain concentration of manganese and neurological signs, such as locomotion, after prolonged welding-fume exposure, cynomolgus monkeys were acclimated for 1 month and then divided into three concentration groups: unexposed, low concentration (31 mg/m(3) total suspended particulate (TSP), 0.9 mg/m(3) of Mn), and high concentration (62 mg/m(3) TSP, 1.95 mg/m(3) of Mn) of TSP. The monkeys were exposed to manual metal-arc stainless steel (MMA-SS) welding fumes for 2 h per day over 8 months in an inhalation chamber system equipped with an automatic fume generator. The home cage locomotor activity and patterns were determined using a camera system over 2-4 consecutive days. After 25 and 32 weeks of exposure, the home cage locomotor activity of the high-concentration primates was found to be 5-6 times higher than that of the unexposed primates, and this increased locomotor activity was maintained for 7 weeks after ceasing the welding-fume exposure, eventually subsiding to three times higher after 13 weeks of recovery. Therefore, the present results, along with our previous observations of a high magnetic resonance imaging (MRI) T1 signal in the globus pallidus and increased blood Mn concentration, indicate that prolonged welding-fume exposure can cause neurobehavioral changes in cynomolgus monkeys.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fazackerley, W.; Gee, R.

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 formulationsmore » 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.« less

Optical sensor for real-time weld defect detection

NASA Astrophysics Data System (ADS)

Ancona, Antonio; Maggipinto, Tommaso; Spagnolo, Vincenzo; Ferrara, Michele; Lugara, Pietro M.

2002-04-01

In this work we present an innovative optical sensor for on- line and non-intrusive welding process monitoring. It is based on the spectroscopic analysis of the optical VIS emission of the welding plasma plume generated in the laser- metal interaction zone. Plasma electron temperature has been measured for different chemical species composing the plume. Temperature signal evolution has been recorded and analyzed during several CO2-laser welding processes, under variable operating conditions. We have developed a suitable software able to real time detect a wide range of weld defects like crater formation, lack of fusion, excessive penetration, seam oxidation. The same spectroscopic approach has been applied for electric arc welding process monitoring. We assembled our optical sensor in a torch for manual Gas Tungsten Arc Welding procedures and tested the prototype in a manufacturing industry production line. Even in this case we found a clear correlation between the signal behavior and the welded joint quality.

Numerical simulation of humping phenomenon in high speed gas metal arc welding

NASA Astrophysics Data System (ADS)

Chen, Ji; Wu, Chuan-Song

2011-06-01

It is of great significance to obtain a thorough understanding of the physical mechanisms responsible for humping bead phenomenon in high speed gas metal arc welding (GMAW) in order to raise welding efficiency. Experiments were conducted to observe the weld pool behaviors in high speed GMAW, and it was found that both the severely deformed weld pool surface and strong backward flowing play a dominant role in humping bead formation. In this study, a mathematical model is developed to quantitatively analyze the forming mechanism of humping beads for high speed GMAW through considering both the momentum and heat content distribution of the backward flowing molten metal inside the weld pool. The transient development of temperature profiles in the weld pool with severe deformation demonstrates the humping bead forming process under some welding conditions. The predicted and measured humping bead dimensions are in agreement.

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…

Clamp and Gas Nozzle for TIG Welding

NASA Technical Reports Server (NTRS)

Gue, G. B.; Goller, H. L.

1982-01-01

Tool that combines clamp with gas nozzle is aid to tungsten/inert-gas (TIG) welding in hard-to-reach spots. Tool holds work to be welded while directing a stream of argon gas at weld joint, providing an oxygen-free environment for tungsten-arc welding.

Welding and Weldability of AZ31B by Gas Tungsten Arc and Laser Beam Welding Processes

NASA Astrophysics Data System (ADS)

Lathabai, S.; Barton, K. J.; Harris, D.; Lloyd, P. G.; Viano, D. M.; McLean, A.

Welding will play an important role in the fabrication of modular lightweight structures based on magnesium alloy die castings, extrusion profiles and wrought products. Minimisation of rejection rates during fabrication requires that satisfactory weldability be established for a particular combination of materials and welding procedures. In this paper, we present the results of a study to quantify the weldability of wrought alloy AZ31B by gas tungsten arc (GTA) and laser beam (LB) welding processes. The susceptibility to weld metal solidification cracking was evaluated using the Circular Patch weldability test. Operating windows of welding parameters for crack-free and porosity-free GTA and LB welding were identified, based on which welding procedures were developed for sheet and plate AZ31B. The microstructure and mechanical properties of welded test plates were assessed, leading to a better understanding of microstructurat development and structure-property relationships in GTA and LB weldments in AZ31B.

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

NASA Astrophysics Data System (ADS)

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

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

Study on the special vision sensor for detecting position error in robot precise TIG welding of some key part of rocket engine

NASA Astrophysics Data System (ADS)

Zhang, Wenzeng; Chen, Nian; Wang, Bin; Cao, Yipeng

2005-01-01

Rocket engine is a hard-core part of aerospace transportation and thrusting system, whose research and development is very important in national defense, aviation and aerospace. A novel vision sensor is developed, which can be used for error detecting in arc length control and seam tracking in precise pulse TIG welding of the extending part of the rocket engine jet tube. The vision sensor has many advantages, such as imaging with high quality, compactness and multiple functions. The optics design, mechanism design and circuit design of the vision sensor have been described in detail. Utilizing the mirror imaging of Tungsten electrode in the weld pool, a novel method is proposed to detect the arc length and seam tracking error of Tungsten electrode to the center line of joint seam from a single weld image. A calculating model of the method is proposed according to the relation of the Tungsten electrode, weld pool, the mirror of Tungsten electrode in weld pool and joint seam. The new methodologies are given to detect the arc length and seam tracking error. Through analyzing the results of the experiments, a system error modifying method based on a linear function is developed to improve the detecting precise of arc length and seam tracking error. Experimental results show that the final precision of the system reaches 0.1 mm in detecting the arc length and the seam tracking error of Tungsten electrode to the center line of joint seam.

Automated Welding System

NASA Technical Reports Server (NTRS)

Bayless, E. O.; Lawless, K. G.; Kurgan, C.; Nunes, A. C.; Graham, B. F.; Hoffman, D.; Jones, C. S.; Shepard, R.

1993-01-01

Fully automated variable-polarity plasma arc VPPA welding system developed at Marshall Space Flight Center. System eliminates defects caused by human error. Integrates many sensors with mathematical model of the weld and computer-controlled welding equipment. Sensors provide real-time information on geometry of weld bead, location of weld joint, and wire-feed entry. Mathematical model relates geometry of weld to critical parameters of welding process.

Evaluation of the AISI 904L Alloy Weld Overlays Obtained by GMAW and Electro-Slag Welding Processes

NASA Astrophysics Data System (ADS)

Jorge, Jorge C. F.; Meira, O. G.; Madalena, F. C. A.; de Souza, L. F. G.; Araujo, L. S.; Mendes, M. C.

2017-05-01

The use of superaustenitic stainless steels (SASS) as an overlay replacement for nickel-based alloys can be an interesting alternative for the oil and gas industries, due to its lower cost, when compared to superalloys. Usually, the deposition is made with several welding passes by using conventional arc welding processes, such as gas tungsten arc welding (GTAW) or gas metal arc welding (GMAW) processes. In this respect, electro-slag welding (ESW), which promotes high heat inputs and low dilution of the welds, can also be attractive for this application, as it provides a higher productivity, once only one layer is needed for the deposition of the minimum thickness required. The present work evaluates the behavior of an AISI 904L SASS weld overlay deposited on a carbon steel ASTM A516 Grade 70 by ESW and GMAW processes. Both as-welded and heat-treated conditions were evaluated and compared. A multipass welding by GMAW process with three layers and 48 passes was performed on 12.5 × 200 × 250 mm steel plates with average welding energy of 1.0 kJ/mm. For ESW process, only one layer was deposited on 50 × 400 × 400 mm steel plates with average welding energy of 11.7 kJ/mm. After welding, a post-weld heat treatment (PWHT) at 620 °C for 10 h was performed in half of the steel plate, in order to allow the comparison between this condition and the as-welded one. For both processes, the austenitic microstructure of the weld deposits was characterized by optical microscopy and scanning electron microscopy with electron backscatter diffraction. A low proportion of secondary phases were observed in all conditions, and the PWHT did not promote significant changes on the hardness profile. Martensite for GMAW process and bainite for ESW process were the microstructural constituents observed at the coarse grain heat-affected zone, due to the different cooling rates. For ESW process, no evidences of partially diluted zones were found. As a consequence of the microstructural findings, the hardness results for ESW were lower than those usually observed for other electric arc welding processes. In addition, specimens subject to bending tests performed in accordance with the current standards used for qualification of welding procedures were approved. These evidences allow the conclusion that the ESW process can provide deposits with high quality despite the high welding energy levels, in order to achieve the desired productivity, being an interesting alternative for AISI 904L weld overlays.

Analysis of thermomechanical states in single-pass GMAW surfaced steel element

NASA Astrophysics Data System (ADS)

Winczek, Jerzy; Gawronska, Elzbieta; Murcinkova, Zuzana; Hatala, Michal; Pavlenko, Slavko; Makles, Krzysztof

2017-03-01

In the paper the model of temperature field, phase changes and stress states calculation during single-pass arc weld surfacing have been presented. In temperature field solution the temperature changes caused by the heat of weld and by electric arc have been taken into consideration. Kinetics of phase changes during heating is limited by temperature values at the beginning and at the end of austenitic transformation, while progress of phase transformations during cooling has been determined on the basis of time-temperature-transformation (TTT) - welding diagram. The analysis of stress state has been presented for S235 steel flat assuming planar section hypothesis and using integral equations of stress equilibrium. It has enabled a clear interpretation of influence of temperature field and phase transformation on stresses caused by surfacing using Gas Metal Arc Welding (GMAW) method.

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…

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…

The nitrogen effect on Type 304L austenitic stainless steel weld metal welded with a GTA (Gas Tungsten Arc) system under ambient and hyperbaric conditions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Okagawa, R.K.

1984-01-01

Small amounts of nitrogen were injected into Type 304L austenitic stainless steel weld metal. This was accomplished by using an Ar-N/sub 2/ shield gas mixture in combination with a controlled argon atmosphere on autogeneous Gas Tungsten Arc (GTA) welds. Weld metal nitrogen as a function of nitrogen shield gas content and applied pressure was examined. Nitrogen shield gas contents above 4% were found to have a major effect on the weld metal microstructure. The base metal nitrogen did not influence the nitrogen solubility reaction or solidification behavior during welding. For Type 304L austenitic stainless steel, a nitrogen coefficient of 13.4more » was determined for the nickel equivalent expression. 63 refs., 19 figs., 4 tabs.« less

Laser Assisted Micro Wire GMAW and Droplet Welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

FUERSCHBACH, PHILLIP W.; LUCK, D. L.; BERTRAM, LEE A.

2002-03-01

Laser beam welding is the principal welding process for the joining of Sandia weapon components because it can provide a small fusion zone with low overall heating. Improved process robustness is desired since laser energy absorption is extremely sensitive to joint variation and filler metal is seldom added. This project investigated the experimental and theoretical advantages of combining a fiber optic delivered Nd:YAG laser with a miniaturized GMAW system. Consistent gas metal arc droplet transfer employing a 0.25 mm diameter wire was only obtained at high currents in the spray transfer mode. Excessive heating of the workpiece in this modemore » was considered an impractical result for most Sandia micro-welding applications. Several additional droplet detachment approaches were investigated and analyzed including pulsed tungsten arc transfer(droplet welding), servo accelerated transfer, servo dip transfer, and electromechanically braked transfer. Experimental observations and rigorous analysis of these approaches indicate that decoupling droplet detachment from the arc melting process is warranted and may someday be practical.« less

Process characteristics of the combination of laser beam- and gas metal arc welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kalla, G.; Neuenhahn, J.; Koerber, C.

1994-12-31

In this presentation, experiences regarding the combination of laser beam-and gas metal arc welding are discussed. The combination of both techniques offers the possibility of using the specific advantages include the deep penetration effect and the concentrated heat input. Additionally, the gas metal arc welding (GMAW) process is characterized by several advantages, such as high thermal efficiency and good gap-bridging ability. Beyond these characteristics, the combination leads to additional advantages concerning process, technique, and quality. Improvement of seam quality and properties are of special note. Adaptation of the GMAW parameters reduces the hardness of the seam weld at increasing weldingmore » speed. This is possible by adapting the efficiency of metal deposition and by the suitable choice of wire material composition. Another advantage is an improvement of surface topology. The surface of the weld seam and the connection to the base material are very smooth. This leads to advantages with regard to the fatigue strength of the seam.« less

Microstructural changes of a thermally aged stainless steel submerged arc weld overlay cladding of nuclear reactor pressure vessels

NASA Astrophysics Data System (ADS)

Takeuchi, T.; Kameda, J.; Nagai, Y.; Toyama, T.; Matsukawa, Y.; Nishiyama, Y.; Onizawa, K.

2012-06-01

The effect of thermal aging on microstructural changes in stainless steel submerged arc weld-overlay cladding of reactor pressure vessels was investigated using atom probe tomography (APT). In as-received materials subjected to post-welding heat treatments (PWHTs), with a subsequent furnace cooling, a slight fluctuation of the Cr concentration was observed due to spinodal decomposition in the δ-ferrite phase but not in the austenitic phase. Thermal aging at 400 °C for 10,000 h caused not only an increase in the amplitude of spinodal decomposition but also the precipitation of G phases with composition ratios of Ni:Si:Mn = 16:7:6 in the δ-ferrite phase. The degree of the spinodal decomposition in the submerged arc weld sample was similar to that in the electroslag weld one reported previously. We also observed a carbide on the γ-austenite and δ-ferrite interface. There were no Cr depleted zones around the carbide.

Effect of Welding Process on Microstructure, Mechanical and Pitting Corrosion Behaviour of 2205 Duplex Stainless Steel Welds

NASA Astrophysics Data System (ADS)

Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

An attempt has been made to weld 2205 Duplex stainless steel of 6mm thick plate using conventional gas tungsten arc welding (GTAW) and activated gas tungsten arc welding (A- GTAW) process using silica powder as activated flux. Present work is aimed at studying the effect of welding process on depth of penetration, width of weld zone of 2205 duplex stainless steel. It also aims to observe the microstructural changes and its effect on mechanical properties and pitting corrosion resistance of 2205 duplex stainless steel welds. Metallography is done to observe the microstructural changes of the welds using image analyzer attached to the optical microscopy. Hardness studies, tensile and ductility bend tests were evaluated for mechanical properties. Potentio-dynamic polarization studies were carried out using a basic GillAC electro-chemical system in 3.5% NaCl solution to observe the pitting corrosion behaviour. Results of the present investigation established that increased depth of penetration and reduction of weld width in a single pass by activated GTAW with the application of SiO2 flux was observed when compared with conventional GTAW process. It may be attributed to the arc constriction effect. Microstructure of the weld zones for both the welds is observed to be having combination of austenite and delta ferrite. Grain boundary austenite (GBA) with Widmanstatten-type austenite (WA) of plate-like feature was nucleated from the grain boundaries in the weld zone of A-GTAW process. Mechanical properties are relatively low in activated GTAW process and are attributed to changes in microstructural morphology of austenite. Improved pitting corrosion resistance was observed for the welds made with A-GTAW process.

Study on mechanical and microstructure behavior of submerged arc welding flux using red mud

NASA Astrophysics Data System (ADS)

Dewangan, Rishi; Pandey, Pankaj K.; Upadhyay, Renu

2018-05-01

This paper emphasis on utilization of Red Mud for preparing submerged arc welding flux and study its mechanical and microstructure behavior. Among the six fluxes prepared in the laboratory, Flux no. 1 (basicity 1.106) found to be best due to its running performance, micro hardness and Brinell hardness. The hardness value (HV) of the fluxes was varying from 165.70 to 217.15 at a load of 1000gm respectively. From the micrograph of welded metal, acicular ferrite found to be optimum which helps in increasing the ductility and hardness of the welded material.

Investigation on microstructure and mechanical properties on pulsed current gas tungsten arc welded super alloy 617

NASA Astrophysics Data System (ADS)

Mageshkumar, K.; Kuppan, P.; Arivazhagan, N.

2017-11-01

The present research work investigates the metallurgical and mechanical properties of weld joint fabricated by alloy 617 by pulsed current gas tungsten arc welding (PCGTAW) technique. Welding was done by ERNiCrCoMo-1 filler wire. Optical and Scanning Electron Microscope (SEM) revealed the fine equiaxed dendritic in the fusion zone. Electron Dispersive Spectroscopy (EDS) demonstrates the presence of Mo-rich secondary phases in the grain boundary regions. Tensile test shows improved mechanical properties compared to the continuous current mode. Bend test didn’t indicate the presence of defects in the weldments.

Improvement of the control of a gas metal arc welding process

NASA Astrophysics Data System (ADS)

Gött, Gregor; Schöpp, Heinz; Hofmann, Frank; Heinz, Gerd

2010-02-01

Up to now, the use of the electrical characteristics for process control is state of the art in gas metal arc welding (GMAW). The aim of the work is the improvement of GMAW processes by using additional information from the arc. Therefore, the emitted light of the arc is analysed spectroscopically and compared with high-speed camera images. With this information, a conclusion about the plasma arc and the droplet formation is reasonable. With the correlation of the spectral and local information of the plasma, a specific control of the power supply can be applied. A corresponding spectral control unit (SCU) is introduced.

Welding procedure specification. Supplement 1. Records of procedure qualification tests. Gas tungsten arc welding of aluminum alloys 3004, 5052, and 5X54

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1986-06-01

Procedure WPS-1002 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 3004, 5052, 5154, and 5454 (P-22), in thickness range 0.062 to 0.5 inches; filler metal is ER4043 (F-23) for 3004, and ER5356 (F-22) for other alloys; shielding gas is argon.

Visualization of hump formation in high-speed gas metal arc welding

NASA Astrophysics Data System (ADS)

Wu, C. S.; Zhong, L. M.; Gao, J. Q.

2009-11-01

The hump bead is a typical weld defect observed in high-speed welding. Its occurrence limits the improvement of welding productivity. Visualization of hump formation during high-speed gas metal arc welding (GMAW) is helpful in the better understanding of the humping phenomena so that effective measures can be taken to suppress or decrease the tendency of hump formation and achieve higher productivity welding. In this study, an experimental system was developed to implement vision-based observation of the weld pool behavior during high-speed GMAW. Considering the weld pool characteristics in high-speed welding, a narrow band-pass and neutral density filter was equipped for the CCD camera, the suitable exposure time was selected and side view orientation of the CCD camera was employed. The events that took place at the rear portion of the weld pools were imaged during the welding processes with and without hump bead formation, respectively. It was found that the variation of the weld pool surface height and the solid-liquid interface at the pool trailing with time shows some useful information to judge whether the humping phenomenon occurs or not.

Hot Forging of a Cladded Component by Automated GMAW Process

NASA Astrophysics Data System (ADS)

Rafiq, Muhammad; Langlois, Laurent; Bigot, Régis

2011-01-01

Weld cladding is employed to improve the service life of engineering components by increasing corrosion and wear resistance and reducing the cost. The acceptable multi-bead cladding layer depends on single bead geometry. Hence, in first step, the relationship between input process parameters and the single bead geometry is studied and in second step a comprehensive study on multi bead clad layer deposition is carried out. This paper highlights an experimental study carried out to get single layer cladding deposited by automated Gas Metal Arc Welding (GMAW) process and to find the possibility of hot forming of the cladded work piece to get the final hot formed improved structure. GMAW is an arc welding process that uses an arc between a consumable electrode and the welding pool with an external shielding gas and the cladding is done by alongside deposition of weld beads. The experiments for single bead were conducted by varying the three main process parameters wire feed rate, arc voltage and welding speed while keeping other parameters like nozzle to work distance, shielding gas and its flow rate and torch angle constant. The effect of bead spacing and torch orientation on the cladding quality of single layer from the results of single bead deposition was studied. Effect of the dilution rate and nominal energy on the cladded layer hot bending quality was also performed at different temperatures.

30 CFR 57.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Ventilation and shielding for welding. 57.14213... welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to persons. (b) All welding operations shall be well-ventilated. ...

30 CFR 57.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Ventilation and shielding for welding. 57.14213... welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to persons. (b) All welding operations shall be well-ventilated. ...

30 CFR 57.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Ventilation and shielding for welding. 57.14213... welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to persons. (b) All welding operations shall be well-ventilated. ...

30 CFR 57.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Ventilation and shielding for welding. 57.14213... welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to persons. (b) All welding operations shall be well-ventilated. ...

30 CFR 57.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Ventilation and shielding for welding. 57.14213... welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to persons. (b) All welding operations shall be well-ventilated. ...

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.

A vision-based weld quality evaluation system

DOE Office of Scientific and Technical Information (OSTI.GOV)

Barnett, R.J.; Cook, G.E.; Strauss, A.M.

1996-12-31

Inspection of the appearance of weld beads is an integral part of the overall welding process. Lack of satisfactory appearance in itself may be sufficient grounds for part rejection or the lack of satisfactory appearance may be used as an indirect indicator of more substantive problems such as poor fusion or subsurface cracks. In all cases the inspection process tends to be both time and labor intensive. The present research uses a video system and appropriate image capture and processing to determine the quality of the weld based upon surface appearance. This relative quality rating was compared to similar ratingsmore » performed by human inspectors and was found to give very good correlation. The system was implemented for the Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW) processes.« less

Heat and metal transfer in gas metal arc welding using argon and helium

DOE Office of Scientific and Technical Information (OSTI.GOV)

Joensson, P.G.; Eagar, T.W.; Szekely, J.

1995-04-01

This article describes a theoretical investigation on the arc parameters and metal transfer in gas metal arc welding (GMAW) of mild steel using argon and helium shielding gases. Major differences in the predicted arc parameters were determined to be due to large differences in thermophysical properties. Various findings from the study include that an arc cannot be struck in a pure helium atmosphere without the assistance of metal vapor, that a strong electromagnetic cathode force affects the fluid flow and heat transfer in the helium arc, providing a possible explanation for the experimentally observed globular transfer mode and that themore » tapering of t electrode in an argon arc is caused by electron condensation on the side of the electrode.« less

Analytical Modeling of Weld Bead Shape in Dry Hyperbaric GMAW Using Ar-He Chamber Gas Mixtures

NASA Astrophysics Data System (ADS)

Azar, Amin S.; Ås, Sigmund K.; Akselsen, Odd M.

2013-03-01

Hyperbaric arc welding is a special application of joining the pipeline steels under seawater. In order to analyze the behavior of the arc under ambient pressure, a model is required to estimate the arc efficiency. A distributed point heat source model was employed. The simulated isotherms were calibrated iteratively to fit the actual bead cross section. Basic gas mixture rules and models were used to calculate the thermal properties of the low-temperature shielding gas under the ambient pressure of 10 bar. Nine bead-on-plate welds were deposited each of which under different Ar-He chamber gas compositions. The well-known correlation between arc efficiency (delivered heat) and the thermal conductivity was established for different gas mixtures. The arc efficiency was considered separately for the transverse and perpendicular heat sources. It was found that assigning single heat efficiency factor for the entire arc, which is usually below unity, causes a noticeable underestimation for the heat transfer in the perpendicular direction and a little overestimation in the transverse direction.

Shielding gas effect on weld characteristics in arc-augmented laser welding process of super austenitic stainless steel

NASA Astrophysics Data System (ADS)

Sathiya, P.; Kumar Mishra, Mahendra; Soundararajan, R.; Shanmugarajan, B.

2013-02-01

A series of hybrid welding (gas metal arc welding-CO2 laser beam welding) experiments were conducted on AISI 904L super austenitic stainless steel sheet of 5 mm thickness. A detailed study of CO2 Laser-GMAW hybrid welding experiments with different shielding gas mixtures (100% He, 50% He+50% Ar, 50%He+45% Ar+5% O2, and 45% He+45% Ar+10% N2) were carried out and the results are presented. The resultant welds were subjected to detailed mechanical and microstructural characterization. Hardness testing revealed that the hardness values in the fusion zone were higher than the base material irrespective of the parameters. Transverse tensile testing showed that the joint efficiency is 100% with all the shielding gas experimented. Impact energy values of the welds were also found to be higher than the base material and the fractrograph taken in scanning electron microscope (SEM) has shown that the welds exhibited dimple fracture similar to the base material.

Microstructures and mechanical properties of bonding layers between low carbon steel and alloy 625 processed by gas tungsten arc welding

NASA Astrophysics Data System (ADS)

Lou, Shuai; Lee, Seul Bi; Nam, Dae-Geun; Choi, Yoon Suk

2017-11-01

A filler metal wire, Alloy 625, was cladded on a plate of a low carbon streel, SS400, by gas tungsten arc welding, and the morphology of the weld bead and resulting dilution ratio were investigated under different welding parameter values (the input current, weld speed and wire feed speed). The wire feed speed was found to be most influential in controlling the dilution ratio of the weld bead, and seemed to limit the influence of other welding parameters. Two extreme welding conditions (with the minimum and maximum dilution ratios) were identified, and the corresponding microstructures, hardness and tensile properties near the bond line were compared between the two cases. The weld bead with the minimum dilution ratio showed superior hardness and tensile properties, while the formation lath martensite (due to relatively fast cooling) affected mechanical properties in the heat affected zone of the base metal with the maximum dilution ratio.

The mechanical properties of high speed GTAW weld and factors of nonlinear multiple regression model under external transverse magnetic field

NASA Astrophysics Data System (ADS)

Lu, Lin; Chang, Yunlong; Li, Yingmin; He, Youyou

2013-05-01

A transverse magnetic field was introduced to the arc plasma in the process of welding stainless steel tubes by high-speed Tungsten Inert Gas Arc Welding (TIG for short) without filler wire. The influence of external magnetic field on welding quality was investigated. 9 sets of parameters were designed by the means of orthogonal experiment. The welding joint tensile strength and form factor of weld were regarded as the main standards of welding quality. A binary quadratic nonlinear regression equation was established with the conditions of magnetic induction and flow rate of Ar gas. The residual standard deviation was calculated to adjust the accuracy of regression model. The results showed that, the regression model was correct and effective in calculating the tensile strength and aspect ratio of weld. Two 3D regression models were designed respectively, and then the impact law of magnetic induction on welding quality was researched.

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.

Self-Aligning Sensor-Mounting Fixture

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.; Mills, Rhonda J.

1991-01-01

Optical welding sensors replaced without realignment. Mounting fixture for optical weld-penetration sensor enables accurate and repeatable alignment. Simple and easy to use. Assembled on welding torch, it holds sensor securely and keeps it pointed toward weld pool. Designed for use on gas/tungsten arc-welding torch, fixture replaces multipiece bracket.

Fluid Flow Phenomena during Welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Wei

2011-01-01

MOLTEN WELD POOLS are dynamic. Liquid in the weld pool in acted on by several strong forces, which can result in high-velocity fluid motion. Fluid flow velocities exceeding 1 m/s (3.3 ft/s) have been observed in gas tungsten arc (GTA) welds under ordinary welding conditions, and higher velocities have been measured in submerged arc welds. Fluid flow is important because it affects weld shape and is related to the formation of a variety of weld defects. Moving liquid transports heat and often dominates heat transport in the weld pool. Because heat transport by mass flow depends on the direction andmore » speed of fluid motion, weld pool shape can differ dramatically from that predicted by conductive heat flow. Temperature gradients are also altered by fluid flow, which can affect weld microstructure. A number of defects in GTA welds have been attributed to fluid flow or changes in fluid flow, including lack of penetration, top bead roughness, humped beads, finger penetration, and undercutting. Instabilities in the liquid film around the keyhole in electron beam and laser welds are responsible for the uneven penetration (spiking) characteristic of these types of welds.« less

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).

Studying heat-affected zone deformations of electric arc welding

NASA Astrophysics Data System (ADS)

Suleimanov, R. I.; Zainagalina, L. Z.; Khabibullin, M. Ya; Zaripova, L. M.; Kovalev, N. O.

2018-03-01

The paper studies the influence of the most common defects in permanent electric arc welds made during the welding butt joints in infield oil pipelines, onto the strength characteristics of the welded pipe material around the heat-affected zone. A specimen of a butt weld with an obvious defect was used as a subject of the study. The changes in the geometric parameters of the weld were measured with the standard means; Rockwell hardness in the heat-affected zone was determined in certain areas with justification for the weld process modes. The cause of softening was found to be an increased width of the hot spot on the one side of the weld, where an enlarged crystalline structure appears as a result of the pipe material recrystallization under the influence of heat. Changes in the geometry of the thermal action area are determined by accumulation of molten filler on the one side of the weld when the welding rate is decreased. Some recommendations are given to prevent destruction of the welded structures and appearance of emergencies in infield oil pipelines.

Applicability of Firecracker Welding to Ship Production

DTIC Science & Technology

1975-07-31

minor arc-outages seemed to coincide with defects in-the weld. For example, careful study of the film permitted orientation of such phenomena with the...Sample Electrode Electrode Voltage Current Frames Length weld covered No. Type diam. in. v A per sec. of film ft. in. Polarity 50 7024 1/4 35 240 128...to snuff out the arc. This was especially evident with the E7016 and E7018 electrodes which have a very fluid slag. The molten metal often caused a

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

DTIC Science & Technology

2014-06-12

distribution is unlimited. Ballistic-Failure Mechanisms in Gas Metal Arc Welds of Mil A46100 Armor-Grade Steel : A Computational Investigation The views...Welds of Mil A46100 Armor-Grade Steel : A Computational Investigation Report Title In our recent work, a multi-physics computational model for 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

Vision-sensing image analysis for GTAW process control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Long, D.D.

1994-11-01

Image analysis of a gas tungsten arc welding (GTAW) process was completed using video images from a charge coupled device (CCD) camera inside a specially designed coaxial (GTAW) electrode holder. Video data was obtained from filtered and unfiltered images, with and without the GTAW arc present, showing weld joint features and locations. Data Translation image processing boards, installed in an IBM PC AT 386 compatible computer, and Media Cybernetics image processing software were used to investigate edge flange weld joint geometry for image analysis.

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.

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.

Simulation of a manual electric-arc welding in a working gas pipeline. 2. Numerical investigation of the temperature-stress distribution in the wall of a gas pipe

NASA Astrophysics Data System (ADS)

Baikov, V. I.; Gishkelyuk, I. A.; Rus', A. M.; Sidorovich, T. V.; Tonkonogov, B. A.

2010-11-01

A numerical simulation of the action of the current experienced by an electric arc and the rate of gas flow in a pipe of a cross-country gas pipeline on the depth of penetration of the electric arc into the wall of this pipe and on the current and residual stresses arising in the pipe material in the process of electric-arc welding of nonthrough cavity-like defects in it has been carried out for gas pipes with walls of different thickness.

Improving the Quality of Welding Seam of Automatic Welding of Buckets Based on TCP

NASA Astrophysics Data System (ADS)

Hu, Min

2018-02-01

Since February 2014, the welding defects of the automatic welding line of buckets have been frequently appeared. The average repair time of each bucket is 26min, which seriously affects the production efficiency and welding quality. We conducted troubleshooting, and found the main reasons for the welding defects of the buckets were the deviations of the center points of the robot tools and the poor quality of the locating welding. We corrected the gripper, welding torch, and accuracy of repeat positioning of robots to control the quality of positioning welding. The welding defect rate of buckets was reduced greatly, ensuring the production efficiency and welding quality.

Reed Valve Regulates Welding Back-Purge Pressure

NASA Technical Reports Server (NTRS)

Coby, J. Ben, Jr.; Weeks, Jack L.

1991-01-01

Simple modification yields welds of better quality. Reed valve halves fluctuations in pressure in back-purge chamber attached to workpiece undergoing keyhole plasma arc welding. Identical to one used in fuel system of two-cycle gasoline engine. Backbead smoother, and weld penetrates more uniformly.

Improved welding of Rene-41

NASA Technical Reports Server (NTRS)

Nunez, S.

1970-01-01

Gas-tungsten arc welding with a filler of Rene-41 produces strong welded joints. When Rene-41 is used, resistance to strain-age cracking is greatly increased by post-weld solution annealing in an inert atmosphere. Mechanical properties of Rene-41 and Hastelloy-W are compared.

Dissimilar Joining of Stainless Steel and 5083 Aluminum Alloy Sheets by Gas Tungsten Arc Welding-Brazing Process

NASA Astrophysics Data System (ADS)

Cheepu, Muralimohan; Srinivas, B.; Abhishek, Nalluri; Ramachandraiah, T.; Karna, Sivaji; Venkateswarlu, D.; Alapati, Suresh; Che, Woo Seong

2018-03-01

The dissimilar joining using gas tungsten arc welding - brazing of 304 stainless steel to 5083 Al alloy had been conducted with the addition of Al-Cu eutectic filler metal. The interface microstructure formation between filler metal and substrates, and spreading of the filler metal were studied. The interface microstructure between filler metal and aluminum alloy characterized that the formation of pores and elongated grains with the initiation of micro cracks. The spreading of the liquid braze filler on stainless steel side packed the edges and appeared as convex shape, whereas a concave shape has been formed on aluminum side. The major compounds formed at the fusion zone interface were determined by using X-ray diffraction techniques and energy-dispersive X-ray spectroscopy analysis. The micro hardness at the weld interfaces found to be higher than the substrates owing to the presence of Fe2Al5 and CuAl2 intermetallic compounds. The maximum tensile strength of the weld joints was about 95 MPa, and the tensile fracture occurred at heat affected zone on weak material of the aluminum side and/or at stainless steel/weld seam interface along intermetallic layer. The interface formation and its effect on mechanical properties of the welds during gas tungsten arc welding-brazing has been discussed.

Virtual welding equipment for simulation of GMAW processes with integration of power source regulation

NASA Astrophysics Data System (ADS)

Reisgen, Uwe; Schleser, Markus; Mokrov, Oleg; Zabirov, Alexander

2011-06-01

A two dimensional transient numerical analysis and computational module for simulation of electrical and thermal characteristics during electrode melting and metal transfer involved in Gas-Metal-Arc-Welding (GMAW) processes is presented. Solution of non-linear transient heat transfer equation is carried out using a control volume finite difference technique. The computational module also includes controlling and regulation algorithms of industrial welding power sources. The simulation results are the current and voltage waveforms, mean voltage drops at different parts of circuit, total electric power, cathode, anode and arc powers and arc length. We describe application of the model for normal process (constant voltage) and for pulsed processes with U/I and I/I-modulation modes. The comparisons with experimental waveforms of current and voltage show that the model predicts current, voltage and electric power with a high accuracy. The model is used in simulation package SimWeld for calculation of heat flux into the work-piece and the weld seam formation. From the calculated heat flux and weld pool sizes, an equivalent volumetric heat source according to Goldak model, can be generated. The method was implemented and investigated with the simulation software SimWeld developed by the ISF at RWTH Aachen University.

Gas metal arc welding in refurbishment of cobalt base superalloys

NASA Astrophysics Data System (ADS)

Shahriary, M. S.; Miladi Gorji, Y.; Kolagar, A. M.

2017-01-01

Refurbishments of superalloys which are used in manufacturing gas turbine hot components usually consists of removing cracks and other defects by blending and then repair welding in order to reconstruct damaged area. In this study, the effects of welding parameters on repair of FSX-414 superalloy, as the most applicable cobalt base superalloy in order to manufacture gas turbine nozzles, by use of Gas Metal Arc Welding (GMAW) technic were investigated. Results then were compared by Gas Tungsten Arc Welding (GTAW). Metallographic and SEM studies of the microstructure of the weld and HAZ showed that there are no noticeable defects in the microstructure by use of GMAW. Also, chemical analysis and morphologies of carbide in both methods are similar. Hardness profile of the GM AW structure then also compared with GTAW and no noticeable difference was observed between the profiles. Also, proper tensile properties, compared with GTAW, can be achieved by use of optimum parameters that can be obtained by examining the current and welding speed. Tensile properties of optimized condition of the GMAW then were compared with GTAW. It was seen that the room and high temperature tensile properties of the GMAW structure is very similar and results confirmed that changing the technic did not have any significant influence on the properties.

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.

Comparison of Tensile Damage Evolution in Ti6A14V Joints Between Laser Beam Welding and Gas Tungsten Arc Welding

NASA Astrophysics Data System (ADS)

Gao, Xiao-Long; Zhang, Lin-Jie; Liu, Jing; Zhang, Jian-Xun

2014-12-01

The present paper studied the evolution of tensile damage in joints welded using laser beam welding (LBW) and gas tungsten arc welding (TIG) under a uniaxial tensile load. The damage evolution in the LBW joints and TIG-welded joints was studied by using digital image correlation (DIC) technology and monitoring changes in Young's modulus during tensile testing. To study the mechanism of void nucleation and growth in the LBW joints and TIG-welded joints, test specimens with various amounts of plastic deformation were analyzed using a scanning electron microscope (SEM). Compared with TIG-welded joints, LBW-welded joints have a finer microstructure and higher microhardness in the fusion zone. The SEM analysis and DIC test results indicated that the critical strain of void nucleation was greater in the LBW-welded joints than in the TIG-welded joints, while the growth rate of voids was lower in the LBW-welded joints than in the TIG-welded joints. Thus, the damage ratio in the LBW joints was lower than that in the TIG-welded joints during tensile testing. This can be due to the coarser martensitic α' and the application of TC-1 welding rods in the TIG-welded joint.

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.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ghomashchi, Reza, E-mail: reza.ghomashchi@adelaide.edu.au; 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.more » 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.« less

Weld arc simulator

DOEpatents

Burr, Melvin J.

1990-01-30

An arc voltage simulator for an arc welder permits the welder response to a variation in arc voltage to be standardized. The simulator uses a linear potentiometer connected to the electrode to provide a simulated arc voltage at the electrode that changes as a function of electrode position.

Development Of Advanced Welding Control System

NASA Technical Reports Server (NTRS)

1990-01-01

Report describes development of next-generation control system for variable-polarity plasma arc (VPPA) welding. When fully developed, system expected to incorporate advanced sensors and adaptive control of position of and current in welding torch.

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.

An integrated optical sensor for GMAW feedback control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Taylor, P.L.; Watkins, A.D.; Larsen, E.D.

1992-08-01

The integrated optical sensor (IOS) is a multifunction feedback control sensor for arc welding, that is computer automated and independent of significant operator interaction. It is based on three major ``off-the-shelf`` components: a charged coupled device (CCD) camera, a diode laser, and a processing computer. The sensor head is compact and lightweight to avoid interference with weld head mobility, hardened to survive the harsh operating environment, and free of specialized cooling and power requirements. The sensor is positioned behind the GMAW torch and measures weld pool position and width, standoff distance, and postweld centerline cooling rate. Weld pool position andmore » width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint, thus allowing compensation for such phenomena as arc blow. Sensor stand off distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to infer the final metallurgical state of the weld bead and heat affected zone, thereby providing a means of controlling post weld mechanical properties.« less

An integrated optical sensor for GMAW feedback control

DOE Office of Scientific and Technical Information (OSTI.GOV)

Taylor, P.L.; Watkins, A.D.; Larsen, E.D.

1992-01-01

The integrated optical sensor (IOS) is a multifunction feedback control sensor for arc welding, that is computer automated and independent of significant operator interaction. It is based on three major off-the-shelf'' components: a charged coupled device (CCD) camera, a diode laser, and a processing computer. The sensor head is compact and lightweight to avoid interference with weld head mobility, hardened to survive the harsh operating environment, and free of specialized cooling and power requirements. The sensor is positioned behind the GMAW torch and measures weld pool position and width, standoff distance, and postweld centerline cooling rate. Weld pool position andmore » width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint, thus allowing compensation for such phenomena as arc blow. Sensor stand off distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to infer the final metallurgical state of the weld bead and heat affected zone, thereby providing a means of controlling post weld mechanical properties.« less

Multiphysics Simulation of Welding-Arc and Nozzle-Arc System: Mathematical-Model, Solution-Methodology and Validation

NASA Astrophysics Data System (ADS)

Pawar, Sumedh; Sharma, Atul

2018-01-01

This work presents mathematical model and solution methodology for a multiphysics engineering problem on arc formation during welding and inside a nozzle. A general-purpose commercial CFD solver ANSYS FLUENT 13.0.0 is used in this work. Arc formation involves strongly coupled gas dynamics and electro-dynamics, simulated by solution of coupled Navier-Stoke equations, Maxwell's equations and radiation heat-transfer equation. Validation of the present numerical methodology is demonstrated with an excellent agreement with the published results. The developed mathematical model and the user defined functions (UDFs) are independent of the geometry and are applicable to any system that involves arc-formation, in 2D axisymmetric coordinates system. The high-pressure flow of SF6 gas in the nozzle-arc system resembles arc chamber of SF6 gas circuit breaker; thus, this methodology can be extended to simulate arcing phenomenon during current interruption.

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. Copyright © 2014 Elsevier Ltd. All rights reserved.

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.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shen Jun; You Guoqiang; Long Siyuan

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 themore » 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.« less

Welding of nickel-base superalloys having a nil-ductility range

NASA Technical Reports Server (NTRS)

Smashey, Russell W. (Inventor); Kelly, Thomas J. (Inventor); Snyder, John H. (Inventor); Sheranko, Ronald L. (Inventor)

1999-01-01

An article made of a nickel-base superalloy having a nil-ductility range from the solidus temperature of the alloy to about 600.degree. F. below the solidus temperature is welded, as for example in the weld repair of surface cracks, by removing foreign matter from the area to be welded, first stress relieving the article, adjusting the temperature of the article to a welding temperature of from about 1800.degree. F. to about 2100.degree. F., welding a preselected area in an inert atmosphere at the welding temperature, and second stress relieving the article. Welding is preferably accomplished by striking an arc in the preselected area so as to locally melt the alloy in the preselected area, providing a filler metal having the same composition as the nickel-based superalloy of the article, and feeding the filler metal into the arc so that the filler metal is melted and fused with the article to form a weldment upon solidification.

Mars Atmosphere Effects on Arc Welds: Phase 1

NASA Technical Reports Server (NTRS)

Courtright, Z. S.

2016-01-01

NASA has been unprecedented in achieving its goals related to space exploration and furthering the understanding of our solar system. In keeping with this trend, NASA's current mission is to land a team of astronauts on Mars and return them safely to Earth. In addition to comprising much of the structure and life support systems that will be brought to Mars for the habitat and vehicle, titanium and aluminum can be found and mined on Mars and may be used when building structures.Where metals are present, there will be a need for welding capabilities. For welds that need to be made quickly and are located far from heavy resistance or solid state welding machinery, there will be a need for basic arc welding. Arc welding has been a major cornerstone of manufacturing throughout the 20th century, and the portability and capability of gas tungsten arc welding (GTAW) will be necessary for repair, manufacturing, and survival on Mars. The two primary concerns for welding on Mars are that the Martian atmosphere contains high levels of carbon dioxide (CO2), and the atmospheric pressure is much lower than it is on Earth. The high levels of CO2 in the Martian atmosphere may dissociate and produce oxygen in the arc and therefore increase the risk of oxidation. For simplification, atmospheric pressure will not be taken into account for this experiment. For survival on Mars during this mission, the life support and water filtration systems must be kept operational at all times. In order to ensure that water filtration systems can be repaired in the event of an emergency, it is very important to have the capability to weld. The Orion capsule and Mars lander must also remain operational throughout the duration of the mission to ensure the safe return of the astronauts on the mission to Mars. A better understanding of welding in a Mars environment is important to ensure that repair welds are possible if the Orion capsule/Mars lander or water filtration system is damaged at any point while on the surface of Mars. The Orion capsule is made primarily of AA2219-T87, and the water filtration system is primarily Ti-6Al-4V, so the effect of the Mars environment on welding those materials must be known to reduce potential mission risk. GTAW is a portable process that can weld a versatile group of metals, so it has many potential applications for welding on Mars. Thus, missions to colonize Mars will depend on the capability to weld a strong, leak-tight joint. Metals are also likely to be used in support structures made of a lightweight and durable material. For this reason, it is important to understand the implications of welding in a Mars environment. A comparison of the Martian and terrestrial atmospheres are provided in table 1. Based on the elemental compositions, simulation of the Martian atmosphere can be made using primarily CO2 gas.

Effect of Welding Processes on the Microstructure, Mechanical Properties and Residual Stresses of Plain 9Cr-1Mo Steel Weld Joints

NASA Astrophysics Data System (ADS)

Nagaraju, S.; Vasantharaja, P.; Brahadees, G.; Vasudevan, M.; Mahadevan, S.

2017-12-01

9Cr-1Mo steel designated as P9 is widely used in the construction of power plants and high-temperature applications. It is chosen for fabricating hexcan fuel subassembly wrapper components of fast breeder reactors. Arc welding processes are generally used for fabricating 9Cr-1Mo steel weld joints. A-TIG welding process is increasingly being adopted by the industries. In the present study, shielded metal arc (SMA), tungsten inert gas (TIG) and A-TIG welding processes are used for fabricating the 9Cr-1Mo steel weld joints of 10 mm thickness. Effect of the above welding processes on the microstructure evolution, mechanical properties and residual stresses of the weld joints has been studied in detail. All the three weld joints exhibited comparable strength and ductility values. 9Cr-1Mo steel weld joint fabricated by SMAW process exhibited lower impact toughness values caused by coarser grain size and inclusions. 9Cr-1Mo steel weld joint fabricated by TIG welding exhibited higher toughness due to finer grain size, while the weld joint fabricated by A-TIG welding process exhibited adequate toughness values. SMA steel weld joint exhibited compressive residual stresses in the weld metal and HAZ, while TIG and A-TIG weld joint exhibited tensile residual stresses in the weld metal and HAZ.

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…

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.

Mathematical Modeling of Optical Radiation Emission as a Function of Welding Power during Gas Shielded Metal Arc Welding.

PubMed

Bauer, Stefan; Janßen, Marco; Schmitz, Martin; Ott, Günter

2017-11-01

Arc welding is accompanied by intense optical radiation emission that can be detrimental not only for the welder himself but also for people working nearby or for passersby. Technological progress advances continuously in the field of joining, so an up-to-date radiation database is necessary. Additionally, many literature irradiance data have been measured for a few welding currents or for parts of the optical spectral region only. Within this paper, a comprehensive study of contemporary metal active gas, metal inert gas, and cold metal transfer welding is presented covering optical radiation emission from 200 up to 2,700 nm by means of (spectro-) radiometric measurements. The investigated welding currents range from 70 to 350 A, reflecting values usually applied in industry. Based upon these new irradiance data, three mathematical models were derived in order to describe optical radiation emission as a function of welding power. The linear, exponential, and sigmoidal emission models depend on the process variant (standard or pulsed) as well as on the welding material (mild and stainless steel, aluminum). In conjunction with the corresponding exposure limit values for incoherent optical radiation maximum permissible exposure durations were calculated as a function of welding power. Typical times are shorter than 1 s for the ultraviolet spectral region and range from 1 to 10 s for visible radiation. For the infrared regime, exposure durations are of the order of minutes to hours. Finally, a validation of the metal active gas emission models was carried out with manual arc welding.

Effects of joint configuration for the arc welding of cast Ti-6Al-4V alloy rods in argon.

PubMed

Taylor, J C; Hondrum, S O; Prasad, A; Brodersen, C A

1998-03-01

Titanium and its alloys are more commonly used in prosthodontics and welding has become the most common modality for their joining. Studies on the welding of titanium and its alloys have not quantified this value, though its importance has been suggested. This study compared the strength and properties of the joint achieved at various butt joint gaps by the arc-welding of cast Ti-6Al-4V alloy tensile bars in an argon atmosphere. Forty of 50 specimens were sectioned and welded at four gaps. All specimens underwent tensile testing to determine ultimate tensile strength and percentage elongation, then oxygen analysis and scanning electron microscopy. As no more than 3 samples in any group of 10 actually fractured in the weld itself, a secondary analysis that involved fracture location was initiated. There were no differences in ultimate tensile strength or percentage elongation between specimens with weld gaps of 0.25, 0.50, 0.75, and 1.00 mm and the as-cast specimens. There were no differences in ultimate tensile strength between specimens fracturing in the weld and those fracturing in the gauge in welded specimens; however, as-cast specimens demonstrated a higher ultimate tensile strength than welded specimens that fractured in the weld. Specimens that fractured in the weld site demonstrated less ductility than those that fractured in the gauge in both welded and as-cast specimens, as confirmed by scanning electron microscopy examination. The weld wire showed an oxygen scavenging effect from the as-cast parent alloy. The effects of the joint gap were not significant, whereas the characteristics of the joint itself were, which displayed slightly lower strength and significantly lower ductility (and thus decreased toughness). The arc-welding of cast titanium alloy in argon atmosphere appears to be a reliable and efficient prosthodontic laboratory modality producing predictable results, although titanium casting and joining procedures must be closely controlled to minimize heat effects and oxygen contamination.

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 learning curve for each student and each Virtual Welding Class'" can be plotted, for an instructor's review or a required third party evaluation.

Selecting Processes to Minimize Hexavalent Chromium from Stainless Steel Welding: Eight welding processes/shielding gas combinations were assessed for generation of hexavalent chromium in stainless steel welding fumes.

PubMed

Keane, M; Siert, A; Stone, S; Chen, B; Slaven, J; Cumpston, A; Antonini, J

2012-09-01

Eight welding processes/shielding gas combinations were assessed for generation of hexavalent chromium (Cr 6+ ) in stainless steel welding fumes. The processes examined were gas metal arc welding (GMAW) (axial spray, short circuit, and pulsed spray modes), flux cored arc welding (FCAW), and shielded metal arc welding (SMAW). The Cr 6+ fractions were measured in the fumes; fume generation rates, Cr 6+ generation rates, and Cr 6+ generation rates per unit mass of welding wire were determined. A limited controlled comparison study was done in a welding shop including SMAW, FCAW, and three GMAW methods. The processes studied were compared for costs, including relative labor costs. Results indicate the Cr 6+ in the fume varied widely, from a low of 2800 to a high of 34,000 ppm. Generation rates of Cr 6+ ranged from 69 to 7800 μg/min, and Cr 6+ generation rates per unit of wire ranged from 1 to 270 μg/g. The results of field study were similar to the findings in the laboratory. The Cr 6+ (ppm) in the fume did not necessarily correlate with the Cr 6+ generation rate. Physical properties were similar for the processes, with mass median aerodynamic diameters ranging from 250 to 336 nm, while the FCAW and SMAW fumes were larger (360 and 670 nm, respectively). The pulsed axial spray method was the best choice of the processes studied based on minimal fume generation, minimal Cr 6+ generation, and cost per weld. This method is usable in any position, has a high metal deposition rate, and is relatively simple to learn and use.

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.

Welding procedure specification. Suppliment 1. Records of procedure qualification tests. Gas tungsten arc welding of aluminum alloys 1XXX and 3003 to 3004, 5052 and 5X54. [1060, 1100, and 3003 to 3004, 5052, 5154, and 5454

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1986-06-01

Procedure WPS-2202 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 1060, 1100, and 3003 (P-21) to 3004, 5052, 5154, and 5454 (P-22), in thickness range 0.062 to 0.062 to 0.5 inch; filler metal is ER5356 (F-22); shielding gas is argon.

Microstructures and Mechanical Properties of 12Cr1MoVG Tube Welded Joints With/Without Post-weld Heat Treatment

NASA Astrophysics Data System (ADS)

Wang, Jingjing; Sun, Jian; Yu, Xinhai; Chen, Guohong; Fu, Qiuhua; Gao, Chao; Tang, Wenming

2017-10-01

Small-caliber, thick-wall 12Cr1MoVG seamless steel tube welded joints were fabricated in this study by gas tungsten arc welding and shielded metal arc welding techniques, then the microstructures, mechanical properties, and residual stress distributions of the joints with or without post-weld heat treatment (PWHT) were compared. The welded joints are mainly composed of bcc ferrite (F), Fe3C, and M7C3 carbides. PWHT did not cause an apparent microstructure evolution in the joints, but promoted granular pearlite decomposition and growth of F grains and carbides, therefore decreasing the yield, tensile strength, and hardness while increasing the impact toughness and elongation of the welded joints. PWHT also released the circumferential residual stress and altered the stress state in the joint from tensile to compressive. Although the mechanical properties and bending performance of the small-caliber, thick-wall 12Cr1MoVG seamless welded joints without PWHT are acceptable, our results show that the joints with PWHT are more reliable.

Predictive value of spectral-domain optical coherence tomography features in assessment of visual prognosis in eyes with acute welding arc maculopathy.

PubMed

Zhang, Chunxia; Dang, Guangfu; Zhao, Tianmei; Wang, DongLin; Su, Yan; Qu, Yi

2018-04-12

To observe spectral-domain optical coherence tomography (SD-OCT) features and to determine whether baseline OCT features can be used as predictors of visual acuity outcome in eyes with acute welding arc maculopathy. This retrospective study enrolled twenty-two eyes of eleven subjects with acute welding arc maculopathy. All subjects were evaluated by SD-OCT at baseline and final visit. The involved parameters included best-corrected visual acuity (BCVA), central macular thickness (CMT), the length of ellipsoid zone (EZ) defects, the greatest linear dimension (GLD) of outer retinal lesions, EZ reflectivity and relative EZ reflectivity (defined as the ratio of EZ reflectivity to retinal pigment epithelium reflectivity on OCT). Acute welding arc maculopathy was presented as abnormal hyperreflectivity, hyporeflectivity and defects of outer retinal layer in fovea on OCT. Compared with baseline, BCVA improved significantly accompanied by decreased GLD of outer retinal lesions and the length of EZ defects at final visit (P = 0.0004, P < 0.0001 and P < 0.0001, respectively). No significant changes were shown on CMT (P = 0.248). In multivariate regression analysis, final BCVA was associated with baseline BCVA and the length of EZ defects (P = 0.012 and P = 0.045, respectively). However, EZ reflectivity and relative EZ reflectivity were not associated with final BCVA (P > 0.05). In conclusion, SD-OCT images clearly reveal morphological changes in outer retinal layer in acute welding arc maculopathy. The baseline BCVA and length of EZ defects are the strongest predictors of final BCVA.

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.

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.

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

Discontinuity Detection in the Shield Metal Arc Welding Process

PubMed Central

Cocota, José Alberto Naves; Garcia, Gabriel Carvalho; da Costa, Adilson Rodrigues; de Lima, Milton Sérgio Fernandes; Rocha, Filipe Augusto Santos; Freitas, Gustavo Medeiros

2017-01-01

This work proposes a new methodology for the detection of discontinuities in the weld bead applied in Shielded Metal Arc Welding (SMAW) processes. The detection system is based on two sensors—a microphone and piezoelectric—that acquire acoustic emissions generated during the welding. The feature vectors extracted from the sensor dataset are used to construct classifier models. The approaches based on Artificial Neural Network (ANN) and Support Vector Machine (SVM) classifiers are able to identify with a high accuracy the three proposed weld bead classes: desirable weld bead, shrinkage cavity and burn through discontinuities. Experimental results illustrate the system’s high accuracy, greater than 90% for each class. A novel Hierarchical Support Vector Machine (HSVM) structure is proposed to make feasible the use of this system in industrial environments. This approach presented 96.6% overall accuracy. Given the simplicity of the equipment involved, this system can be applied in the metal transformation industries. PMID:28489045

Discontinuity Detection in the Shield Metal Arc Welding Process.

PubMed

Cocota, José Alberto Naves; Garcia, Gabriel Carvalho; da Costa, Adilson Rodrigues; de Lima, Milton Sérgio Fernandes; Rocha, Filipe Augusto Santos; Freitas, Gustavo Medeiros

2017-05-10

This work proposes a new methodology for the detection of discontinuities in the weld bead applied in Shielded Metal Arc Welding (SMAW) processes. The detection system is based on two sensors-a microphone and piezoelectric-that acquire acoustic emissions generated during the welding. The feature vectors extracted from the sensor dataset are used to construct classifier models. The approaches based on Artificial Neural Network (ANN) and Support Vector Machine (SVM) classifiers are able to identify with a high accuracy the three proposed weld bead classes: desirable weld bead, shrinkage cavity and burn through discontinuities. Experimental results illustrate the system's high accuracy, greater than 90% for each class. A novel Hierarchical Support Vector Machine (HSVM) structure is proposed to make feasible the use of this system in industrial environments. This approach presented 96.6% overall accuracy. Given the simplicity of the equipment involved, this system can be applied in the metal transformation industries.

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

NASA Astrophysics Data System (ADS)

Muth, T. R.; Yamamoto, Y.; Frederick, D. A.; Contescu, C. I.; Chen, W.; Lim, Y. C.; Peter, W. H.; Feng, Z.

2013-05-01

An investigation was undertaken 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 and 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 for achieving equivalent fusion welding success similar to that seen in wrought titanium produced via the Kroll process.

30 CFR 56.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Ventilation and shielding for welding. 56.14213... Equipment Safety Practices and Operational Procedures § 56.14213 Ventilation and shielding for welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to...

30 CFR 56.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Ventilation and shielding for welding. 56.14213... Equipment Safety Practices and Operational Procedures § 56.14213 Ventilation and shielding for welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to...

30 CFR 56.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Ventilation and shielding for welding. 56.14213... Equipment Safety Practices and Operational Procedures § 56.14213 Ventilation and shielding for welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to...

30 CFR 56.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Ventilation and shielding for welding. 56.14213... Equipment Safety Practices and Operational Procedures § 56.14213 Ventilation and shielding for welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to...

30 CFR 56.14213 - Ventilation and shielding for welding.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Ventilation and shielding for welding. 56.14213... Equipment Safety Practices and Operational Procedures § 56.14213 Ventilation and shielding for welding. (a) Welding operations shall be shielded when performed at locations where arc flash could be hazardous to...

Automatic weld torch guidance control system

NASA Technical Reports Server (NTRS)

Smaith, H. E.; Wall, W. A.; Burns, M. R., Jr.

1982-01-01

A highly reliable, fully digital, closed circuit television optical, type automatic weld seam tracking control system was developed. This automatic tracking equipment is used to reduce weld tooling costs and increase overall automatic welding reliability. The system utilizes a charge injection device digital camera which as 60,512 inidividual pixels as the light sensing elements. Through conventional scanning means, each pixel in the focal plane is sequentially scanned, the light level signal digitized, and an 8-bit word transmitted to scratch pad memory. From memory, the microprocessor performs an analysis of the digital signal and computes the tracking error. Lastly, the corrective signal is transmitted to a cross seam actuator digital drive motor controller to complete the closed loop, feedback, tracking system. This weld seam tracking control system is capable of a tracking accuracy of + or - 0.2 mm, or better. As configured, the system is applicable to square butt, V-groove, and lap joint weldments.

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…

Stability of Full Penetration, Flat Position Weld Pools

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.; Coan, Al. B.

1999-01-01

The dynamics of the dropthrough distance of a full penetration, flat position weld pool is described. Close to incipient root side penetration the dropthrough is metastable, so that a small drop in power can cause a loss of penetration if not followed soon enough by a compensating rise in power. The SPA (Soft Plasma Arc) process with higher pressure on top of the weld pool loses penetration more quickly than the GTA (Gas Tungsten Arc) process. 2195 aluminum-lithium alloy with a lower surface tension loses penetration more quickly than 2219 aluminum alloy. An instance of loss of penetration of a SPA weld in 2195 aluminum-lithium alloy is discussed in the light of the model.

[Determination of fumes and their elements from flux cored arc welding].

PubMed

Matczak, Wanda; Przybylska-Stanisławska, Magdalena

2004-01-01

The aim of this work was to assay the concentration levels and composition of welding fumes, released during flux cored arc welding, to assess exposure of welders. Concentrations and welding fume components, such as iron, manganese, chromium (including the soluble and chromium VI), nickel, copper, calcium, aluminium, barium, and fluorides (including hydrogen fluoride) were determined in the air of six industrial plants (shipyards, mechanical engineering plants and a power station) at the breathing zones of the welders who used 10 types of wires during flux cored arc welding. The following determination methods were used: gravimetry (fumes), AAS (metals), and spectrophotometry (chromium VI, fluorides--including hydrogen fluoride). The results made it possible to determine the relationship between concentrations of welding fume and its elements, and to assess worker's exposure. Time weighted average concentrations of the welding fumes and its elements at the worker's breathing zone were: mg/m3: dust 0.2-24.3; Fe 0.2-6.7; Mn 0.01-1.8; Cr 0.004-0.5 (mainly Cr III); Ca 0.004-2.5; Ni < or = 0.004; Cu < 0.002-0.05; Al < 0.14-0.4; Ba < 0.14; F- 0.07-0.43. The welders using some types of flux cored welding wires worked in conditions harmful to their health owing to the considerably exceeded TLV value for fume and MAC values for manganese, and occasional slightly excessive MAC values for calcium and iron.

Phase structures and morphologies of tempered CA6NM stainless steel welded by hybrid laser-arc process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mirakhorli, F., E-mail: Fatemeh.mirakhorli.1@ens.e

The post-weld tempered microstructure of hybrid laser-arc welded CA6NM, a cast low carbon martensitic stainless steel, was investigated. The microstructural evolutions from the fusion zone to the base metal were characterized in detail using optical microscopy, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), X-ray diffraction (XRD) and microhardness techniques. The fusion zone, in its post-weld tempered condition, consisted of tempered lath martensite, residual delta-ferrite with various morphologies, reversed austenite and chromium carbides. The reversed austenite, which can be detected through both EBSD and XRD techniques, was found to be finely dispersed along the martensite lath boundaries, particularly at triplemore » junctions. Based on the EBSD analysis, the orientation relationship between the reversed austenite and the adjacent martensite laths seemed to follow the Kurdjumov-Sachs (K-S) model. The results also revealed the presence of the reversed austenite in the different regions of the heat affected zone after post-weld tempering. The microindentation hardness distribution was measured, and correlated to the evolution of the corresponding microstructure across the welds. - Highlights: •The EBSD analysis was performed on hybrid laser-arc welded CA6NM. •The FZ consisted of tempered lath martensite, reversed austenite, carbides and δ ferrite after tempering. •The reversed γ was formed along the α′ lath boundaries, particularly at triple junctions.« less