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Sample records for beam welded joints

  1. Tracking on the joint during the electron beam welding

    NASA Astrophysics Data System (ADS)

    Braverman, V.; Bogdanov, V.; Belozertsev, V.; Uspenskiy, N.

    2016-11-01

    In the article the description of device, which provides automatic positioning of electron beam relative to joint of welded parts during welding, is given. Extremum seeking based on synchronous detection of sensor signal (X-ray or secondary emission) is realized in the device. Measurements are made when beam goes out of the channel following the welding direction. The application of synchronous detection is possible due to the fact that during joint scanning with electron beam harmonics, carrying data about beam position relative to the joint appear in the joint sensor signal spectrum.

  2. Apparatus for maintaining aligment of a shrinking weld joint in an electron-beam welding operation

    DOEpatents

    Trent, J.B.; Murphy, J.L.

    1980-01-03

    The invention is directed to an apparatus for automatically maintaining a shrinking weld joint in alignement with an electron beam during an electron-beam multipass-welding operation. The apparatus utilizes a bias means for continually urging a workpiece-supporting face plate away from a carriage mounted base that rotatably supports the face plate. The extent of displacement of the face plate away from the base in indicative of the shrinkage occuring in the weld joint area. This displacement is measured and is used to move the base on the carriage a distance equal to one-half the displacement for aligning the weld joint with the electron beam during each welding pass.

  3. Apparatus for maintaining alignment of a shrinking weld joint in an electron-beam welding operation

    DOEpatents

    Trent, Jett B.; Murphy, Jimmy L.

    1981-01-01

    The present invention is directed to an apparatus for automatically maintaining a shrinking weld joint in alignment with an electron beam during an electron-beam multipass-welding operation. The apparatus utilizes a biasing device for continually urging a workpiece-supporting face plate away from a carriage mounted base that rotatably supports the face plate. The extent of displacement of the face plate away from the base is indicative of the shrinkage occuring in the weld joint area. This displacement is measured and is used to move the base on the carriage a distance equal to one-half the displacement for aligning the weld joint with the electron beam during each welding pass.

  4. Laser Beam Oscillation Strategies for Fillet Welds in Lap Joints

    NASA Astrophysics Data System (ADS)

    Müller, Alexander; Goecke, Sven-F.; Sievi, Pravin; Albert, Florian; Rethmeier, Michael

    Laser beam oscillation opens up new possibilities of influencing the welding process in terms of compensation of tolerances and reduction of process emissions that occur in industrial applications, such as in body-in-white manufacturing. The approaches are to adapt the melt pool width in order to generate sufficient melt volume or to influence melt pool dynamics, e.g. for a better degassing. Welding results are highly dependent on the natural frequency of the melt pool, the used spot diameter and the oscillation speed of the laser beam. The conducted investigations with an oscillated 300 μm laser spot show that oscillation strategies, which are adjusted to the joining situation improve welding result for zero-gap welding as well as for bridging gaps to approximately 0.8 mm. However, a complex set of parameters has to be considered in order to generate proper welding results. This work puts emphasize on introducing them.

  5. Characteristics of Laser Beam and Friction Stir Welded AISI 409M Ferritic Stainless Steel Joints

    NASA Astrophysics Data System (ADS)

    Lakshminarayanan, A. K.; Balasubramanian, V.

    2012-04-01

    This article presents the comparative evaluation of microstructural features and mechanical properties of friction stir welded (solid-state) and laser beam welded (high energy density fusion welding) AISI 409M grade ferritic stainless steel joints. Optical microscopy, microhardness testing, transverse tensile, and impact tests were performed. The coarse ferrite grains in the base material were changed to fine grains consisting duplex structure of ferrite and martensite due to the rapid cooling rate and high strain induced by severe plastic deformation caused by frictional stirring. On the other hand, columnar dendritic grain structure was observed in fusion zone of laser beam welded joints. Tensile testing indicates overmatching of the weld metal relative to the base metal irrespective of the welding processes used. The LBW joint exhibited superior impact toughness compared to the FSW joint.

  6. The investigation of ultrasonic mechanical forging influence on the structure and mechanical properties of VT23 welded joints by methods of laser and electron beam welding

    NASA Astrophysics Data System (ADS)

    Smirnova, A. S.; Pochivalov, Yu. I.; Panin, V. E.; Orishich, A. M.; Malikov, A. G.; Fomin, V. M.

    2016-11-01

    The structure and mechanical properties of welded joints of VT23 titanium alloy received by methods of laser and electron beam welding with subsequent thermomechanical treatment (TMP1 and TMP2) including ultrasonic mechanical forging are investigated. X-ray structure analysis, scanning electron and transmission electron microscopy have revealed the features of phase structure, microstructure and fractography of welded joints after electron beam and laser welding with subsequent ultrasonic mechanical forging. Application of ultrasonic mechanical forging of welded joints produced by electron beam and laser welding has allowed increasing fatigue life of samples of welded joints after laser welding from 6369 to 19 569 cycles and from 54 616 cycles to 77 126 cycles for electron beam welding. Thus, the application of ultrasonic mechanical forging can significantly raise fatigue and mechanical characteristics of welded connections.

  7. 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.

  8. Qualification of electron-beam welded joints between copper and stainless steel for cryogenic application

    NASA Astrophysics Data System (ADS)

    Lusch, C.; Borsch, M.; Heidt, C.; Magginetti, N.; Sas, J.; Weiss, K.-P.; Grohmann, S.

    2015-12-01

    Joints between copper and stainless steel are commonly applied in cryogenic systems. A relatively new and increasingly important method to combine these materials is electron-beam (EB) welding. Typically, welds in cryogenic applications need to withstand a temperature range from 300K down to 4K, and pressures of several MPa. However, few data are available for classifying EB welds between OFHC copper and 316L stainless steel. A broad test program was conducted in order to qualify this kind of weld. The experiments started with the measurement of the hardness in the weld area. To verify the leak-tightness of the joints, integral helium leak tests at operating pressures of 16 MPa were carried out at room- and at liquid nitrogen temperature. The tests were followed by destructive tensile tests at room temperature, at liquid nitrogen and at liquid helium temperatures, yielding information on the yield strength and the ultimate tensile strength of the welds at these temperatures. Moreover, nondestructive tensile tests up to the yield strength, i.e. the range in which the weld can be stressed during operation, were performed. Also, the behavior of the weld upon temperature fluctuations between room- and liquid nitrogen temperature was tested. The results of the qualification indicate that EB welded joints between OFHC copper and 316L stainless steel are reliable and present an interesting alternative to other technologies such as vacuum brazing or friction welding.

  9. Effect of Nd:YAG laser beam welding on weld morphology and mechanical properties of Ti-6Al-4V butt joints and T-joints

    NASA Astrophysics Data System (ADS)

    Kashaev, Nikolai; Ventzke, Volker; Fomichev, Vadim; Fomin, Fedor; Riekehr, Stefan

    2016-11-01

    A Nd:YAG single-sided laser beam welding process study for Ti-6Al-4V butt joints and T-joints was performed to investigate joining techniques with regard to the process-weld morphology relationship. An alloy compatible filler wire was used to avoid underfills and undercuts. The quality of the butt joints and T-joints was characterized in terms of weld morphology, microstructure and mechanical properties. Joints with regular shapes, without visible cracks, pores, and geometrical defects were achieved. Tensile tests revealed high joint integrity in terms of strength and ductility for both the butt joint and T-joint geometries. Both the butt joints and T-joints showed base material levels of strength. The mechanical performance of T-joints was also investigated using pull-out tests. The performance of the T-joints in such tests was sensitive to the shape and morphology of the welds. Fracture always occurred in the weld without any plastic deformation in the base material outside the weld.

  10. Microstructure evolution of electron beam welded Ti{sub 3}Al-Nb joint

    SciTech Connect

    Feng Jicai; Wu Huiqiang . E-mail: huiqiang_wu@hit.edu.cn; He Jingshan; Zhang Bingang

    2005-02-15

    The microstructure evolution characterization in high containing Nb, low Al titanium aluminide alloy of electron beam welded joints was investigated by means of OM, SEM, XRD, TEM and microhardness analysis. The results indicated that the microstructure of the weld metal made with electron beam under the welding conditions employed in this work was predominantly metastable, retaining ordered {beta} phase (namely B2 phase), and was independent of the welding parameters but independent of the size and the orientation of the weld solidification structures. As the heat input is decreased, the cellular structure zone is significantly reduced, and then the crystallizing morphology of fusion zone presented dendritically columnar structure. There existed grain growth coarsening in heat affected zone (HAZ) for insufficient polygonization. Both fusion zone (FZ) and the HAZ had higher microhardness than the base metal.

  11. Dual beam Nd:YAG laser welding: influence of lubricants to lap joint welding of steel sheets

    NASA Astrophysics Data System (ADS)

    Geiger, M.; Merklein, M.; Otto, A.; Blankl, A.

    2007-05-01

    Laser welding is applied in large-volume production since the late eighties and has revolutionized the possibilities of designing and engineering products. Nevertheless, problems appear during application because the operational conditions in industrial environments fluctuate and can influence the welding process negatively. Contaminations, like lubricants and organic solids, are an example of changing conditions in laser beam welding. If a lap joint is welded, these materials have to be removed from the sheets, otherwise pores and surface failures may appear due to keyhole instabilities induced by uncontrolled outgassing. One possibility for solving this problem is the use of two separate laser beams. For producing these two beams several systems are available for all different kind of lasers. A bifocal optic is such a solution for an Nd:YAG laser. By using this system, the laser beam is divided after collimation with a prism. Afterwards the two beams are focussed with a lens to the surface of the sheet and two single spots are produced. If the distance between the two spots is low, one common, elliptical keyhole is created. With this system two different welding strategies are possible. The spots can be oriented parallel or normal to the feed direction. For stabilizing the laser welding of contaminated steel sheets the parallel arrangement is better, because the amount of contamination is nearly the same as in single spot welding but the total volume of the keyhole is greater and so pressure variations due to uncontrolled evaporation of contaminations are lower. In order to prove this theory and to determine the exact effects some investigations were made at the Chair of Manufacturing Technology of the University of Erlangen-Nuremberg. A 4 kW Nd:YAG laser with a beam parameter product of 25 mm*mrad and a focal distance of 200 mm was used to weld two 1 mm DC04 steel sheets together with a lap joint. Between the sheets a deep drawing lubricant, Castrol FST 6, was

  12. Modification of Structure and Strength Properties of Permanent Joints Under Laser Beam Welding with Application of Nanopowder Modifiers

    NASA Astrophysics Data System (ADS)

    Cherepanov, A. N.; Orishich, A. M.; Malikov, A. G.; Ovcharenko, V. E.

    2016-08-01

    In the paper we present the results of experimental study of specially prepared nanosize metal-ceramic compositions impact upon structure, microhardness and mechanical properties of permanent joints produced by laser-beam welding of steel and titanium alloy plates.

  13. Numerical study of electron beam welded butt joints with the GTN model

    NASA Astrophysics Data System (ADS)

    Tu, Haoyun; Schmauder, Siegfried; Weber, Ulrich

    2012-08-01

    The fracture behavior of S355NL electron beam welded steel joints is investigated experimentally and numerically. The simulation of crack propagation in an electron beam welded steel joint was performed with the Gurson-Tvergaard-Needleman (GTN) damage model. A parameter study of the GTN model was adopted which reveals the influence of parameters on the material behavior of notched round and compact tension specimens. Based on the combined method of metallographic investigations and numerical calibration, the GTN parameters were fixed. The same parameters were used to predict the ductile fracture of compact tension specimens with the initial crack located at different locations. Good match can be found between the numerical and experimental results in the form of force versus Crack Opening Displacement as well as fracture resistance curves.

  14. Experimental and simulation study on the microstructure of TA15 titanium alloy laser beam welded joints

    NASA Astrophysics Data System (ADS)

    Zhan, Xiaohong; Peng, Qingyu; Wei, Yanhong; Ou, Wenmin

    2017-09-01

    Laser beam welding technique offers obvious advantages over other fusion welding processes in terms of joining titanium alloy. The microstructure of welded seam and heat affected zone resulted from diverse welding speeds and laser powers were investigated after simulating welding heat treatment. The analysis of the thermal transport properties successfully explained the morphology. Optimal process parameters were obtained. The simulation results were consistent with the corresponding experimental observations.

  15. Microstructures and Mechanical Properties of Weld Metal and Heat-Affected Zone of Electron Beam-Welded Joints of HG785D Steel

    NASA Astrophysics Data System (ADS)

    Zhang, Qiang; Han, Jianmin; Tan, Caiwang; Yang, Zhiyong; Wang, Junqiang

    2016-12-01

    Vacuum electron beam welding (EBW) process was employed to butt weld 10-mm-thick HG785D high-strength steels. The penetration into the steel was adjusted by beam current. Microstructures at weld metal and heat-affected zone (HAZ) regions were comparatively observed. Mechanical properties of the EBWed joints including Vickers hardness, tensile and Charpy impact tests were evaluated. The results indicated that microstructures at the weld metal consisted of coarse lath martensite and a small amount of acicular martensite, while that in the HAZ was tempered sorbite and martensite. The grain size in the weld metal was found to be larger than that in the HAZ, and its proportion in weld metal was higher. The hardness in the weld metal was higher than the HAZ and base metal. The tensile strength and impact toughness in the HAZ was higher than that in the weld metal. All the behaviors were related to microstructure evolution caused by higher cooling rates and state of base metal. The fracture surfaces of tensile and impact tests on the optimized joint were characterized by uniform and ductile dimples. The results differed significantly from that obtained using arc welding process.

  16. Laser beam welding of any metal.

    SciTech Connect

    Leong, K. H.

    1998-10-01

    The effect of a metal's thermophysical properties on its weldability are examined. The thermal conductivity, melting point, absorptivity and thermal diffusivity of the metal and the laser beam focused diameter and welding speed influence the minimum beam irradiance required for melting and welding. Beam diameter, surface tension and viscosity of the molten metal affect weld pool stability and weld quality. Lower surface tension and viscosity increases weld pool instability. With larger beam diameters causing wider welds, dropout also increases. Effects of focused beam diameter and joint fitup on weldability are also examined. Small beam diameters are sensitive to beam coupling problems in relation to fitup precision in addition to beam alignment to the seam. Welding parameters for mitigating weld pool instability and increasing weld quality are derived from the above considerations. Guidelines are presented for the tailoring of welding parameters to achieve good welds. Weldability problems can also be anticipated from the properties of a metal.

  17. Shimmed electron beam welding process

    DOEpatents

    Feng, Ganjiang; Nowak, Daniel Anthony; Murphy, John Thomas

    2002-01-01

    A modified electron beam welding process effects welding of joints between superalloy materials by inserting a weldable shim in the joint and heating the superalloy materials with an electron beam. The process insures a full penetration of joints with a consistent percentage of filler material and thereby improves fatigue life of the joint by three to four times as compared with the prior art. The process also allows variable shim thickness and joint fit-up gaps to provide increased flexibility for manufacturing when joining complex airfoil structures and the like.

  18. Properties of Welded Joints from Alloy Zr - 2.5 % Nb after Electron-Beam Local Thermocycling

    NASA Astrophysics Data System (ADS)

    Semenov, A. N.; Plyshevskii, M. I.; Melyukov, V. V.; Korepanov, A. G.; Rassoshkina, N. S.; Uvarov, A. A.

    2014-03-01

    Modes of electron-beam local thermocycling treatment of welded joints of ∅ 88 × 4 mm pipes from alloy É125 (Zr - 2.5 % Nb) are tested. The structure of the welds is studied. The characteristics of mechanical properties are determined under tension and static and dynamic bending. The corrosion resistance is determined in long-term tests in an autoclave with water at 285 °C and in fast tests in an autoclave at 360 °C for 336 h in accordance with the International Standard.

  19. Monitoring of Varying Joint Gap Width During Laser Beam Welding by a Dual Vision and Spectroscopic Sensing System

    NASA Astrophysics Data System (ADS)

    Nilsen, Morgan; Sikström, Fredrik; Christiansson, Anna-Karin; Ancona, Antonio

    A vision and spectroscopic system for estimation of the joint gap width in autogenous laser beam butt welding is presented. Variations in joint gap width can introduce imperfections in the butt joint seam, which in turn influence fatigue life and structural integrity. The aim of the monitoring approach explored here is to acquire sufficiently robust process data to be used to guide post inspection activities and/or to enable feedback control for a decreased process variability. The dual-sensing approach includes a calibrated CMOS camera and a miniature spectrometer integrated with a laser beam tool. The camera system includes LED illumination and matching optical filters and captures images of the area in front of the melt pool in order to estimate the joint gap width from the information in the image. The intensity of different spectral lines acquired by the spectrometer has been investigated and the correlation between the intensity of representative lines and the joint gap width has been studied. Welding experiments have been conducted using a 6 kW fiber laser. Results from both systems are promising, the camera system is able to give good estimations of the joint gap width, and good correlations between the signal from the spectrometer and the joint gap width have been found. However, developments of the camera setup and vision algorithm can further improve the joint gap estimations and more experimental work is needed in order to evaluate the robustness of the systems.

  20. Effect of a copper filler metal on the microstructure and mechanical properties of electron beam welded titanium-stainless steel joint

    SciTech Connect

    Wang, Ting; Zhang, Binggang; Feng, Jicai; Tang, Qi

    2012-11-15

    Cracking in an electron beam weld of titanium to stainless steel occurred during the cooling process because of internal thermal stress. Using a copper filler metal, a crack free joint was obtained, which had a tensile strength of 310 MPa. To determine the reasons for cracking in the Ti/Fe joint and the function of the copper filler metal on the improvement of the cracking resistance of the Ti/Cu/Fe joint, the microstructures of the joints were studied by optical microscopy, scanning electron microscopy and X-ray diffraction. The cracking susceptibilities of the joints were evaluated with microhardness tests on the cross-sections. In addition, microindentation tests were used to compare the brittleness of the intermetallics in the welds. The results showed that the Ti/Fe joint was characterized by continuously distributed brittle intermetallics such as TiFe and TiFe(Cr){sub 2} with high hardness ({approx} 1200 HV). For the Ti/Cu/Fe joint, most of the weld consisted of a soft solid solution of copper with dispersed TiFe intermetallics. The transition region between the weld and the titanium alloy was made up of a relatively soft Ti-Cu intermetallic layer with a lower hardness ({approx} 500 HV). The formation of soft phases reduced the cracking susceptibility of the joint. - Highlights: Black-Right-Pointing-Pointer Electron beam welded Ti/Fe joint cracked for the brittleness and residual stress. Black-Right-Pointing-Pointer Electron beam welded Ti/Cu/Fe joint with tensile strength of 310 MPa was obtained. Black-Right-Pointing-Pointer Cu diluted Ti and Fe contents in weld and separated the TiFe{sub 2} into individual blocks. Black-Right-Pointing-Pointer Interfacial hard Ti-Fe compounds were replaced by soft Ti-Cu compounds in the weld. Black-Right-Pointing-Pointer A large amount of solid solution of copper formed in the weld.

  1. Investigations on Laser Beam Welding of Different Dissimilar Joints of Steel and Aluminum Alloys for Automotive Lightweight Construction

    NASA Astrophysics Data System (ADS)

    Seffer, Oliver; Pfeifer, Ronny; Springer, André; Kaierle, Stefan

    Due to the enormous potential of weight saving, and the consequential reduction of pollutant emissions, the use of hybrid components made of steel and aluminum alloys is increasing steadily, especially concerning automotive lightweight construction. However, thermal joining of steel and aluminum is still being researched, due to a limited solubility of the binary system of iron and aluminum causing the formation of hard and brittle intermetallic phases, which decrease the strength and the formability of the dissimilar seam. The presented results show the investigation of laser beam welding for joining different dissimilar hybrid components of the steel materials HX220LAD+Z100, 22MnB5+AS150 and 1.4301, as well as the aluminum alloy AA6016-T4 as a lap joint. Among other things, the influences of the energy per unit length, the material grade, the sheet thickness t, the weld type (lap weld, fillet weld) and the arrangement of the base materials in a lap joint (aluminum-sided irradiation, steel-sided irradiation) on the achievable strengths are analyzed. The characterization of the dissimilar joints includes tensile shear tests and metallographic analyses, depending on the energy per unit length.

  2. Characterization of lap joints laser beam welding of thin AA 2024 sheets with Yb:YAG disk-laser

    NASA Astrophysics Data System (ADS)

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

    2012-06-01

    Lap joints obtained by overlapping two plates are widely diffused in aerospace industry. Nevertheless, because of natural aging, adhesively bonded and riveted aircraft lap joints may be affected by cracks from rivets, voids or corrosion. Friction stir welding has been proposed as a valid alternative, although large heat affected zones are produced both in the top and the bottom plate due to the pin diameter. Interest has therefore been shown in studying laser lap welding as the laser beam has been proved to be competitive since it allows to concentrate the thermal input and increases productivity and quality. Some challenges arise as a consequence of aluminum low absorptance and high thermal conductivity; furthermore, issues are due to metallurgical challenges such as both micro and macro porosity formation and softening in the fused zone. Welding of AA 2024 thin sheets in a lap joint configuration is discussed in this paper: tests are carried out using a recently developed Trumpf TruDisk 2002 Yb:YAG disk-laser with high beam quality which allows to produce beads with low plates distortion and better penetration. The influence of the processing parameters is discussed considering the fused zone extent and the bead shape. The porosity content as well as the morphological features of the beads have been examined.

  3. Microstructure and Mechanical Properties of Pulsed Laser Beam Welded Ti-2Al-1.5Mn Titanium Alloy Joints

    NASA Astrophysics Data System (ADS)

    Fang, Xiuyang; Liu, Hong; Zhang, Jianxun

    2014-06-01

    The microstructure and mechanical properties in the pulsed laser beam welded joints of Ti-2Al-1.5Mn titanium alloy thin sheet were investigated in this study. The results show that the original α + β-phases and the transformed α + α'-phases are found in the partially transformed heat-affected zone (HAZ) together with the remaining β-phase, and the microhardness gradually enhances in the region as the result of the increase of α'-phase. The martensitic α'-phase and the remaining β-phase are detected in the fully transformed HAZ and the fusion zone (FZ), and the highest microhardness is found in these regions in virtue of the dominant α'-phase structure. The fine α'-phase appeared in the FZ results in higher average microhardness at high welding speed. Moreover, similar to the results of microhardness test, the tensile test results mean that the HAZ and FZ are stronger than the base metal (BM). Therefore, pulsed laser beam welding is feasible for joining thin sheet of Ti-2Al-1.5Mn titanium alloy.

  4. Electron Beam Welding of Gear Wheels by Splitted Beam

    NASA Astrophysics Data System (ADS)

    Dřímal, Daniel

    2014-06-01

    This contribution deals with the issue of electron beam welding of high-accurate gear wheels composed of a spur gearing and fluted shaft joined with a face weld for automotive industry. Both parts made of the high-strength low-alloy steel are welded in the condition after final machining and heat treatment, performed by case hardening, whereas it is required that the run-out in the critical point of weldment after welding, i. e. after the final operation, would be 0.04 mm max.. In case of common welding procedure, cracks were formed in the weld, initiated by spiking in the weld root. Crack formation was prevented by the use of an interlocking joint with a rounded recess and suitable welding parameters, eliminating crack initiation by spiking in the weld root. Minimisation of the welding distortions was achieved by the application of tack welding with simultaneous splitting of one beam into two parts in the opposite sections of circumferential face weld attained on the principle of a new system of controlled deflection with digital scanning of the beam. This welding procedure assured that the weldment temperature after welding would not be higher than 400 °C. Thus, this procedure allowed achieving the final run-outs in the critical point of gearwheels within the maximum range up to 0.04 mm, which is acceptable for the given application. Accurate optical measurements did not reveal any changes in the teeth dimensions.

  5. The structure and properties of filler metal-free laser beam welded joints in steel S700MC subjected to TMCP

    NASA Astrophysics Data System (ADS)

    Górka, Jacek; Stano, Sebastian

    2016-12-01

    The research-related tests aimed to determine the effect of filer-metal free laser beam welding on the structure and properties of 10 mm thick steel S700MC subjected to the Thermo-Mechanical Control Process (TMCP). The nondestructive tests revealed that the welded joints represented quality level B according to the requirements of standard 13919-1. The destructive tests revealed that the joints were characterised by tensile strength being by approximately 5% lower than that of the base material. The tests of thin foils performed using a high-resolution scanning transmission electron microscope revealed that filler metal-free welding led to the increased amount of alloying microagents (Ti and Nb) in the weld (particularly near fusion line) in comparison with welding performed using a filler metal. The significant content of hardening phases in the welds during cooling resulted in considerable precipitation hardening through finedispersive (Ti,Nb)(C,N) type precipitates (several nm in size) leading to the deterioration of plastic properties. The destructive tests revealed that the joints were characterised by tensile strength being by approximately 5% lower than that of the base material. The increase in the concentration of microagents responsible for steel hardening (Ti and Nb) also contributed to the decrease in weld toughness being below the allowed value of 25 J/cm2.

  6. Ultrasonic Welding of Hybrid Joints

    NASA Astrophysics Data System (ADS)

    Wagner, Guntram; Balle, Frank; Eifler, Dietmar

    2012-03-01

    A central research field of the Institute of Materials Science and Engineering at the University of Kaiserslautern (WKK), Germany, is the realization of innovative hybrid joints by ultrasonic metal welding. This article gives an overview of suitable ultrasonic welding systems as well as of essential machine and material parameters, which influence the quality of the welds. Besides the ultrasonic welding of dissimilar metals such as Al to Cu or Al to steels, the welds between newly developed materials like aluminum foam sandwiches or flat flexible cables also can be realized. Moreover, the joining of glass and ceramic to sheet metals is a point of interest at the WKK. By using the ultrasonic metal welding process, it is possible to realize metal/glass welds with tensile shear strengths of 50 MPa. For metal/ceramic joints, the shear strengths values up to 150 MPa were measured. Finally, selected results about the occurring bonding mechanisms will be discussed.

  7. Microstructures and Mechanical Properties of Electron Beam-Welded Titanium-Steel Joints with Vanadium, Nickel, Copper and Silver Filler Metals

    NASA Astrophysics Data System (ADS)

    Wang, Ting; Zhang, Binggang; Wang, Houqin; Feng, Jicai

    2014-04-01

    Electron beam welding experiments of titanium alloy to stainless steel with V, Ni, Cu and Ag filler metals were carried out. The interfacial microstructures of the joints were examined by optical microscopy, scanning electron microscopy, and x-ray diffraction analysis. Mechanical properties of the joints were evaluated according to tensile strength and microhardness. The results showed that all the filler metals were helpful to restrain the Ti-Fe intermetallics formed in the Ti/Fe joint. The welds with different filler metals were all characterized by solid solution and interfacial intermetallics. And the type of solid solution and interfacial intermetallics were depended on the metallurgical reactions between the filler metals and base metals. The interfacial intermetallics were Fe2Ti + Ni3Ti + NiTi2, TiFe, Ti2Ag, and Cu2Ti + CuTi + CuTi2 in the joints welded with Ni, V, Ag, and Cu filler metals, respectively. The tensile strengths of the joints were primarily determined by the hardness of the interfacial intermetallics. The highest tensile strength was obtained in the joint welded with silver filler metal, which is about 310 MPa.

  8. Effects of Welding Processes and Post-Weld Aging Treatment on Fatigue Behavior of AA2219 Aluminium Alloy Joints

    NASA Astrophysics Data System (ADS)

    Malarvizhi, S.; Balasubramanian, V.

    2011-04-01

    AA2219 aluminium alloy square butt joints without filler metal addition were fabricated using gas tungsten arc welding (GTAW), electron beam welding (EBW), and friction stir welding (FSW) processes. The fabricated joints were post-weld aged at 175 °C for 12 h. The effect of three welding processes and post-weld aging (PWA) treatment on the fatigue properties is reported. Transverse tensile properties of the welded joints were evaluated. Microstructure analysis was also carried out using optical and electron microscopes. It was found that the post-weld aged FSW joints showed superior fatigue performance compared to EBW and GTAW joints. This was mainly due to the formation of very fine, dynamically recrystallized grains and uniform distribution of fine precipitates in the weld region.

  9. RHIC Beam Tube-to-Flange Weld Evaluation

    SciTech Connect

    Kane, S.; Farland, A.; Sabatini, R.; Warburton, K.

    1995-10-04

    Leaks and questionable penetration were found in some autogenous machine welded joints between the RHIC beam tube and flange located in the interconnect region. This investigation found the leaks were caused by hot cracking resulting from complications in welding low-sulfur, low-ferrite stainless steel. The marginal penetration is attributed to the joint design and low sulfur content of the beam tube. Both problems are corrected using the same welding machine with specific electrode placement relative to the joint, and the addition of hydrogen to the shield gas. Repairs only should be accomplished with the addition of filler metal.

  10. Laser welding beam quality calibration

    SciTech Connect

    Foulk, L.R.

    1997-06-01

    The relationship of beam quality and weld depth of penetration was studied to attempt to better quantify the operation of CO{sub 2} laser beam welders. Equipment to measure laser beam quality was obtained. The equipment was calibrated using standard apertures. To relate weld penetration and beam quality measurements, it was necessary to force changes in the CO{sub 2} laser welder`s operation. The chosen experimental variables were laser gas mixture and the use of a group of focusing lenses that had been used in production.

  11. Thermal treatment of dissimilar steels' welded joints

    NASA Astrophysics Data System (ADS)

    Nikulina, A. A.; Denisova, A. S.; Gradusov, I. N.; Ryabinkina, P. A.; Rushkovets, M. V.

    2016-04-01

    In this paper combinations of chrome-nickel steel and high-carbon steel, produced by flash butt welding after heat treatment, are investigated. Light and electron microscopic studies show that the welded joints after heat treatment have a complex structure consisting of several phases as initial welded joints. A martensite structure in welded joints after thermal treatment at 300... 800 °C has been found.

  12. Double-sided laser beam welded T-joints for aluminum-lithium alloy aircraft fuselage panels: Effects of filler elements on microstructure and mechanical properties

    NASA Astrophysics Data System (ADS)

    Han, Bing; Tao, Wang; Chen, Yanbin; Li, Hao

    2017-08-01

    In the current work, T-joints consisting of 2.0 mm thick 2060-T8/2099-T83 aluminum-lithium alloys for aircraft fuselage panels have been fabricated by double-sided fiber laser beam welding with different filler wires. A new type wire CW3 (Al-6.2Cu-5.4Si) was studied and compared with conventional wire AA4047 (Al-12Si) mainly on microstructure and mechanical properties. It was found that the main combined function of Al-6.2%Cu-5.4%Si in CW3 resulted in considerable improvements especially on intergranular strength, hot cracking susceptibility and hoop tensile properties. Typical non-dendritic equiaxed zone (EQZ) was observed along welds' fusion boundary. Hot cracks and fractures during the load were always located within the EQZ, however, this typical zone could be restrained by CW3, effectively. Furthermore, changing of the main intergranular precipitated phase within the EQZ from T phase by AA4047 to T2 phase by CW3 also resulted in developments on microscopic intergranular reinforcement and macroscopic hoop tensile properties. In addition, bridging caused by richer substructure dendrites within CW3 weld's columnar zone resulted in much lower hot cracking susceptibility of the whole weld than AA4047.

  13. Strength of Welded Aircraft Joints

    NASA Technical Reports Server (NTRS)

    Brueggeman, W C

    1937-01-01

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

  14. Hybrid welding of hollow section beams for a telescopic lifter

    NASA Astrophysics Data System (ADS)

    Jernstroem, Petteri

    2003-03-01

    Modern lifting equipment is normally constructed using hollow section beams in a telescopic arrangement. Telescopic lifters are used in a variety number of applications including e.g. construction and building maintenance. Also rescue sector is one large application field. It is very important in such applications to use a lightweight and stable beam construction, which gives a high degree of flexibility in working high and width. To ensure a high weld quality of hollow section beams, high efficiency and minimal distortion, a welding process with a high power density is needed. The alternatives, in practice, which fulfill these requirements, are laser welding and hybrid welding. In this paper, the use of hybrid welding process (combination of CO2 laser welding and GMAW) in welding of hollow section beam structure is presented. Compared to laser welding, hybrid welding allows wider joint tolerances, which enables joints to be prepared and fit-up less accurately, aving time and manufacturing costs. A prerequisite for quality and effective use of hybrid welding is, however, a complete understanding of the process and its capabilities, which must be taken into account during both product design and manufacture.

  15. A critical review of laser beam welding

    NASA Astrophysics Data System (ADS)

    Martukanitz, Richard P.

    2005-03-01

    The use of lasers for welding has exhibited tremendous growth over the last decade for improving efficiency and reducing costs in a broad range of industries. Much of these successes are based on the development and availability of enabling technologies, which include improvements in process understanding, enhancements in laser sources and systems, and continued development and progression in process technology for laser beam welding of macro and micro components. The development of accurate numerical simulation techniques has provided an unprecedented opportunity to view the transient nature of laser processing. Advancements in laser source technology include the introduction of higher-power Nd:YAG lasers, utilizing diode pumped rods or disks, and fiber lasers, both providing the capability for fiber optic beam delivery. Although CO2 laser systems continue to dominate thick section welding, this influence will be challenged by emerging source technologies, namely high power fiber lasers. One of the most promising advances in laser process technology is laser-arc hybrid welding, which is seeing considerable interest worldwide and is currently being evaluated for various applications within heavy industry and manufacturing. The benefit of hybrid welding is the synergistic effect of improved processing rates and joint accommodation over either of the processes viewed separately. Other processing methods are also being developed to increase the utility of laser beam welding for industry, such as the use of dual beams and beam manipulation. The continued advancement in process knowledge is seen as a key element for facilitating the development of new processes and encouraging the acceptance of new source technology.

  16. Experimental Characterization of Electron Beam Welded SAE 5137H Thick Steel Plate

    NASA Astrophysics Data System (ADS)

    Kattire, Prakash; Bhawar, Valmik; Thakare, Sandeep; Patil, Sachin; Mane, Santosh; Singh, Rajkumar, Dr.

    2017-09-01

    Electron beam welding is known for its narrow weld zone with high depth to width ratio, less heat affected zone, less distortion and contamination. Electron beam welding is fusion welding process, where high velocity electrons impinge on material joint to be welded and kinetic energy of this electron is transformed into heat upon impact to fuse the material. In the present work electron beam welding of 60 mm thick SAE 5137H steel is studied. Mechanical and metallurgical properties of electron beam welded joint of SAE 5137H were evaluated. Mechanical properties are analysed by tensile, impact and hardness test. Metallurgical properties are investigated through optical and scanning electron microscope. The hardness traverse across weld zone shows HV 370-380, about 18% increase in the tensile strength and very low toughness of weld joint compared to parent metal. Microstructural observation shows equiaxed dendrite in the fusion zone and partial grain refinement was found in the HAZ.

  17. Polyimide weld bonding for titanium alloy joints

    NASA Technical Reports Server (NTRS)

    Vaughan, R. W.; Kurland, R. M.

    1974-01-01

    Two weld bonding processes were developed for joining titanium alloy; one process utilizes a weld-through technique and the other a capillary-flow technique. The adhesive used for the weld-through process is similar to the P4/A5F system. A new polyimide laminating resin, BFBI/BMPM, was used in the capillary-flow process. Static property information was generated for weld-bonded joints over the temperature range of 219 K (-65 F) to 561 K (+550 F) and fatigue strength information was generated at room temperature. Significant improvement in fatigue strength was demonstrated for weld-bonded joints over spot-welded joints. A demonstration was made of the applicability of the weld-through weld-bonding process for fabricating stringer stiffened skin panels.

  18. Laser beam welding of thermoplastics

    NASA Astrophysics Data System (ADS)

    Russek, Ulrich A.; Palmen, A.; Staub, H.; Poehler, J.; Wenzlau, C.; Otto, G.; Poggel, M.; Koeppe, A.; Kind, H.

    2003-07-01

    Current product development showing an ever shrinking physical volume is asking for new, reliable joining technologies. Laser beam technologies conceal innovative solutions to overcome limitations of conventional joining technologies. Laser beam welding of thermoplastics offers several process technical advantages. The joining energy is fed contact-less into the joining area, avoiding mechanical stress and thermal load to the joining partners. The energy is supplied spatially (seam width on the order of 100 μm) and timely (interaction time on the order of ms) very well defined. Different process strategies are possible leading to flexibility, product adapted irradiation, short process times and high quality weld seams as well as to high integration abilities and automation potentials. During the joining process no vibration, no thermal stress, no particle release takes place. Therefore, destruction of mechanically and electronically highly sensitive components, such as microelectronics, is avoided. The work place pollution is neglectable compared to other joining technologies, such as gluing (fume) or ultrasonic welding (noise, pieces of fluff). Not only micro-components can be welded in a reproducible way but also macro-components while obtaining a hermetic sealing with good optical appearance. In this publication firstly, an overview concerning process technical basis, aspects and challenges is given. Next, results concerning laser penetration welding of polymers using high power diode lasers are presented, while comparing contour and simultaneous welding by experimental results and the on-line process monitoring.

  19. Influence of Surface Roughness in Electron Beam Welding

    NASA Astrophysics Data System (ADS)

    Wiednig, C.; Stiefler, F.; Enzinger, N.

    2016-03-01

    The requirements of welded components are rising continuously through increasing demands in engineering. But in engineering not only the quality of welds is important also an economic and timesaving production is crucial. Especially in welding of large cross sections economization potential is existing and significant. Beside the welding technique itself the joint preparation is a major part of work. Electron beam welding has some major advantages in this area. Due the high energy density a very short welding time as well as a small heat affected zone can be achieved. Furthermore the joint preparation can be held simple. Nevertheless, a careful machining and cleaning of the joint surfaces is recommended in literature. In addition to geometric tolerances a specific surface roughness should be kept. These statements are quite general and unspecific. In this contribution a systematic investigation on the influence of joint preparation on the joint properties is presented. By performing several welding experiments with different surface roughness this study provides empirical conclusions. Beside the microscopic investigation of different cross sections and mechanical tests of the welded samples also the process stability during welding was reviewed.

  20. Mechanical properties and microstructure of F-82H welded joints using CO{sub 2} laser beam

    SciTech Connect

    Yamanouchi, N.; Shiba, K.

    1996-10-01

    The laser welding of F-82H was successfully conducted. The heat affected zone of the welding, was about 21 mm width. It was quite adequate to make small specimens, such as SS-3 type sheet tensile specimen.

  1. Ultrasonic velocity testing of steel pipeline welded joints

    NASA Astrophysics Data System (ADS)

    Carreón, Hector

    2017-04-01

    In general the ultrasonic techniques have been used to determine the mechanical properties of materials on based of their relationship with metallurgical characteristics. In this research work, the relationship between ultrasonic velocity and phased array and the microstructure of steel pipeline welded joints is investigated. Measurements of ultrasonic wave velocity were made as a function of the location across the weld. Hardness measurements were performated in an attempt to correlate with ultrasonic response. In addition, the coarse and dendritic grain structure of the weld material is extreme and unpredictably anisotropic. Thus, due to the acoustic anisotropy of the crystal itself weld material of studied joints is anisotropic, too. Such structure is no longer direction-independent to the ultrasonic wave propagation; therefore, the ultrasonic beam deflects and redirects and the wave front becomes distorted. Thus, the use of conventional ultrasonic testing techniques using fixed beam angles is very limited and the application of conventional ultrasonic phased array techniques becomes desirable.

  2. Materials participation in welded joints manufacturing

    NASA Astrophysics Data System (ADS)

    Ghenghea, L. D.

    2016-08-01

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

  3. Joint tracking and adaptive robotic welding using vision sensing of the weld joint geometry

    SciTech Connect

    Agapakis, J.E.; Katz, J.M.; Koifman, M.; Epstein, G.N.; Friedman, J.M.; Eyring, D.O.; Rutishauser, H.J.

    1986-11-01

    An approach to the vision-guidance of welding robots and the in-process adjustment of welding conditions is presented. The implementation of a complete vision-guided adaptive robotic welding system is described. The vision-guided adaptive welding system described here has been used to track and weld a wide variety of test and production parts ranging in size from 1.6-mm (1/16-in.) sheet steel to 19.1-mm (3/4-in.) steel plate. Both conventional joint types, including square butt, lap, and V-groove, and special types, such as a multipass square butt submerged arc weld with pre-welded root passes or the axle joints were welded. Various welding procedures, such as GMA welding with a variety of shielding gases and submerged arc welding, have also been used.

  4. Welding of Mo-Based Alloy Using Electron Beam and Laser-GTAW Hybrid Welding Techniques

    NASA Astrophysics Data System (ADS)

    Chatterjee, Anjan; Kumar, Santosh; Tewari, Raghvendra; Dey, Gautam Kumar

    2016-03-01

    In the current study, welding of TZM (molybdenum-based alloy) plates in square-butt configuration was carried out using electron beam and laser-GTAW hybrid power sources. Microstructures of weld joint containing three zones—parent metal, heat-affected zone, and fusion zone—were clearly identified when examined through optical and scanning electron microscopy. The weld joints were found to be sound with very wide fusion and heat-affected zones. The microstructure of the fusion zone was coarse-grained. as-solidified microstructure, while the microstructure of heat-affected zone was the recrystallized microstructure with reduction in grain size as distance from the fusion line increased. Microhardness profile using Vickers hardness tester was obtained across the weld region, and the tensile properties of the weld joints were evaluated by performing room temperature tensile test and fracture was examined using scanning electron microscope. Joint coefficient of the weld joints were ~40 to 45 pct of that of the parent metals with nonmeasurable tensile ductility with predominantly transgranular mode of fracture indicating weakness along the grain boundary. Detailed orientation imaging and transmission electron microscopy were carried out to understand the most dominating factor in introducing weld joint brittleness.

  5. Laser Beam Submerged Arc Hybrid Welding

    NASA Astrophysics Data System (ADS)

    Reisgen, Uwe; Olschok, Simon; Mavany, Michael; Jakobs, Stefan

    The laser beam submerged arc hybrid welding method originates from the knowledge that, with increasing penetration depth, the laser beam process has a tendency to pore formation in the lower weld regions. The combination with the energy efficient submerged arc process improves the degassing and reduces the tendency to pore formation. The high deposition rate of the SA process in combination with the laser beam process offers, providing the appropriate choice of weld preparation, the possibility of welding plates with a thickness larger than 20 mm in a single pass, and also of welding thicker plates with the double sided single pass technique.

  6. Laser Beam Submerged Arc Hybrid Welding

    NASA Astrophysics Data System (ADS)

    Reisgen, Uwe; Olschok, Simon; Jakobs, Stefan; Schleser, Markus; Mokrov, Oleg; Rossiter, Eduardo

    The laser beam-submerged arc hybrid welding method originates from the knowledge that, with increasing penetration depth, the laser beam process has a tendency to pore formation in the lower weld regions. The coupling with the energy-efficient submerged-arc process improves degassing and reduces the tendency to pore formation. The high deposition rate of the SA process in combination with the laser beam process offers, providing the appropriate choice of weld preparation, the possibility of welding plates with a thickness larger than 20° mm in a single pass, and also of welding thicker plates with the double-sided single pass technique.

  7. Structural and mechanical properties of welded joints of reduced activation martensitic steels

    NASA Astrophysics Data System (ADS)

    Filacchioni, G.; Montanari, R.; Tata, M. E.; Pilloni, L.

    2002-12-01

    Gas tungsten arc welding and electron beam welding methods were used to realise welding pools on plates of reduced activation martensitic steels. Structural and mechanical features of these simulated joints have been investigated in as-welded and post-welding heat-treated conditions. The research allowed to assess how each welding technique affects the original mechanical properties of materials and to find suitable post-welding heat treatments. This paper reports results from experimental activities on BATMAN II and F82H mod. steels carried out in the frame of the European Blanket Project - Structural Materials Program.

  8. Laser Welding of Alumina Ceramic Substrates with Two Fixed Beams

    NASA Astrophysics Data System (ADS)

    Sedore, Blake William Clark

    Laser welding was investigated as a potential joining technology for alumina ceramic substrates. The objective of this study was to develop a method to preheat the ceramic using a single defocused laser beam prior to welding. Engineering ceramics are employed in a variety of systems and environments due to their unique properties. Joining technologies must be developed to facilitate the manufacture of complex or large ceramic components. Laser welding is advantageous as it forms joints rapidly, and does not introduce intermediate materials to form the bond, which can have deleterious effects. The Laser Machining System (LMS) at Queen's University was adapted for this study. A defocused far-infrared (FIR) laser beam was positioned to overlay a focused near-infrared (NIR) laser beam; the defocused FIR beam preheated the ceramic substrate and the focused NIR beam formed the weld. A finite element model was developed in COMSOL MultiPhysics to simulate the preheating processes and to develop a preheating protocol. The protocol was implemented using the FIR beam and adjusted to achieve preheating temperatures of 1450, 1525, and 1600°C. Welds were performed on 1 mm thick alumina plates using the preheating protocols and NIR beam powers of 25, 50, and 75 W. Weld speed was held constant throughout the study at 0.5 mm/s. The preheating protocols were successful at achieving near-constant preheating temperatures, with standard deviations below 32 degrees. Partially penetrating welds were formed with the NIR beam at 25 W, and fully penetrating welds at 50 and 75 W. Large pores were present in the 25 W and 50 W welds. Minimal porosity was observed in the welds formed at 75 W. All of the welded plates experienced a transverse fracture that extended perpendicular to weld, and a longitudinal fracture extending parallel to the weld. This study shows that a fixed defocused laser beam can successfully preheat alumina substrates to the high temperatures required for welding; however

  9. 18. DETAIL VIEW OF A TYPICAL WELDED JOINT BETWEEN THE ...

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

    18. DETAIL VIEW OF A TYPICAL WELDED JOINT BETWEEN THE MAIN GIRDER AND THE FLOOR BEAM, SHOWING THE ATTACHMENT OF A LATERAL BRACING MEMBER AT THIS POINT, SOUTH GIRDER, PANEL 5, LOOKING SOUTH-SOUTHWEST Ryan & Wieskamp - Benton Street Bridge, Spanning Iowa River at Benton Street, Iowa City, Johnson County, IA

  10. 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.

  11. Comparison of the physics of Gas Tungsten Arc Welding (GTAW), Electron Beam Welding (EBW), and Laser Beam Welding (LBW)

    SciTech Connect

    Nunes, A.C. Jr.

    1985-08-01

    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.

  12. Numerical Modeling of Weld Joint Corrosion

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

    A numerical model is presented in this work that predicts the corrosion rate of weld joint. The model is able to track moving boundary of the corroding constituent of weld joint. The corrosion rates obtained from the model are compared with those estimated from mixed potential theory and two experimental techniques, namely immersion test and constant potential polarization test. The corrosion rate predicted using the model is within 10% of the estimate from the mixed potential theory, within 20% of that got from the immersion experiment and within 10% of that got from the constant potential polarization experiment for weld joint.

  13. Electron beam welding produces improved duplex crack arrest specimens

    SciTech Connect

    King, J.F.; Hudson, J.D.

    1988-01-01

    The crack arrest toughness, K/sub Ia/, is generally determined using a monolithic compact type specimen which contains a brittle weld bead to act as a crack initiation site. To test at higher temperatures and toughnesses, electron beam (EB) welded duplex specimens were fabricated. These specimens required the joining of hardened 4340 steel, which acts as the crack initiator, to A533 grade B class 1 steel base material and submerged arc welds in this base metal. The successful fabrication of these specimens required the development of an EB welding procedure with a very narrow heat-affected zone (HAZ). A technique was also developed to eliminate the porosity which was always present in the EB welds through the submerged arc weld deposit region of the joint. The technique involved remelting the joint surface of the A533 steel containing the submerged arc weld to a controlled depth using an oscillated electron beam. This remelt in vacuum reduced the gaseous constituents to low levels and prevented porosity from forming in the deep penetration EB welds between this surface and the 4340 steel.

  14. Definition of Beam Diameter for Electron Beam Welding

    SciTech Connect

    Burgardt, Paul; Pierce, Stanley W.; Dvornak, Matthew John

    2016-03-11

    It is useful to characterize the dimensions of the electron beam during process development for electron beam welding applications. Analysis of the behavior of electron beam welds is simplest when a single number can be assigned to the beam properties that describes the size of the beam spot; this value we generically call the “beam diameter”. This approach has worked well for most applications and electron beam welding machines with the weld dimensions (width and depth) correlating well with the beam diameter. However, in recent weld development for a refractory alloy, Ta-10W, welded with a low voltage electron beam machine (LVEB), it was found that the weld dimensions (weld penetration and weld width) did not correlate well with the beam diameter and especially with the experimentally determined sharp focus point. These data suggest that the presently used definition of beam diameter may not be optimal for all applications. The possible reasons for this discrepancy and a suggested possible alternative diameter definition is the subject of this paper.

  15. Plasma charge current for controlling and monitoring electron beam welding with beam oscillation.

    PubMed

    Trushnikov, Dmitriy; Belenkiy, Vladimir; Shchavlev, Valeriy; Piskunov, Anatoliy; Abdullin, Aleksandr; Mladenov, Georgy

    2012-12-14

    Electron beam welding (EBW) shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which substantially limits the operation speed of these systems and has a negative effect on weld joint quality. The purpose of this study is to develop a method for operational control of the electron beam focus during welding in the deep penetration mode. The method uses the plasma charge current signal as an additional informational parameter. This parameter allows identification of the electron beam focus regime in electron-beam welding without application of additional low-frequency scanning of focus. It can be used for working out operational electron beam control methods focusing exactly on the welding. In addition, use of this parameter allows one to observe the shape of the keyhole during the welding process.

  16. Plasma Charge Current for Controlling and Monitoring Electron Beam Welding with Beam Oscillation

    PubMed Central

    Trushnikov, Dmitriy; Belenkiy, Vladimir; Shchavlev, Valeriy; Piskunov, Anatoliy; Abdullin, Aleksandr; Mladenov, Georgy

    2012-01-01

    Electron beam welding (EBW) shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which substantially limits the operation speed of these systems and has a negative effect on weld joint quality. The purpose of this study is to develop a method for operational control of the electron beam focus during welding in the deep penetration mode. The method uses the plasma charge current signal as an additional informational parameter. This parameter allows identification of the electron beam focus regime in electron-beam welding without application of additional low-frequency scanning of focus. It can be used for working out operational electron beam control methods focusing exactly on the welding. In addition, use of this parameter allows one to observe the shape of the keyhole during the welding process. PMID:23242276

  17. 46 CFR 56.30-5 - Welded joints.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 2 2011-10-01 2011-10-01 false Welded joints. 56.30-5 Section 56.30-5 Shipping COAST... Selection and Limitations of Piping Joints § 56.30-5 Welded joints. (a) General. Welded joints may be used..., then: (1) The backing rings shall be removed and the inside of the joint ground smooth, or (2)...

  18. 46 CFR 56.30-5 - Welded joints.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 2 2012-10-01 2012-10-01 false Welded joints. 56.30-5 Section 56.30-5 Shipping COAST... Selection and Limitations of Piping Joints § 56.30-5 Welded joints. (a) General. Welded joints may be used..., then: (1) The backing rings shall be removed and the inside of the joint ground smooth, or (2)...

  19. 46 CFR 56.30-5 - Welded joints.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 2 2010-10-01 2010-10-01 false Welded joints. 56.30-5 Section 56.30-5 Shipping COAST... Selection and Limitations of Piping Joints § 56.30-5 Welded joints. (a) General. Welded joints may be used..., then: (1) The backing rings shall be removed and the inside of the joint ground smooth, or (2)...

  20. 46 CFR 56.30-5 - Welded joints.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 46 Shipping 2 2014-10-01 2014-10-01 false Welded joints. 56.30-5 Section 56.30-5 Shipping COAST... Selection and Limitations of Piping Joints § 56.30-5 Welded joints. (a) General. Welded joints may be used..., then: (1) The backing rings shall be removed and the inside of the joint ground smooth, or (2)...

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

    NASA Technical Reports Server (NTRS)

    Looney, Alan

    1991-01-01

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

  2. The effects of welded joint characteristics on its properties in HDPE thermal fusion welding

    NASA Astrophysics Data System (ADS)

    Dai, Hongbin; Peng, Jun

    2017-05-01

    In this paper, PE100 pipes with the diameter of 200 mm and the thickness of 11.9 mm were used as material. The welded joints were obtained in different welding pressures with the optimal welding temperature of 220∘C. Reheating process on the welded joints with the temperature of 130∘C was carried out. The joints exhibited X-type, and the cause of X-type joints was discussed. The temperature field in the forming process of welded joints was measured, and tensile and bending tests on welded joints were carried out. The fracture surface of welded joints was observed by scanning electron microscopy (SEM), and crystallinity calculation was taken by X-ray diffraction (XRD). The mechanism of X-type weld profile effects on welded joints properties was analyzed. It was concluded that the mechanical properties of welded joints decrease with the reduced X distance between lines.

  3. Technical note: Preliminary results on underwater laser beam welding of steels

    SciTech Connect

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

    1994-07-01

    An investigation is underway at The University of Aberdeen using a high-power carbon dioxide laser for direct underwater butt joint welding of steels to assess the quality of welds compared to in-air laser welds. This preliminary work forms part of a general study of the application of laser beam welding and cutting within the offshore oil and gas industry. To this end, the feasibility of laser beam welding in both direct wet conditions and in dry hyperbaric conditions is being explored. Considerable advantages may lie in the remote direct wet repair of pipelines and structural members in terms of convenience, low cost and freedom from diver intervention. The laser beam welding mechanism, being fundamentally different from arc welding processes, may be able to overcome the normal problems of weld embrittlement and porosity when wet welding is attempted. In the current work, the primary concern is with the butt joint welding of steel plate without a filler metal. This technical note provides a comparison of underwater and in-air weld characteristics for fully penetrating butt joint welds, and provides an insight into the propagation characteristics of a high-power beam in water. The effect of increasing water depth is also investigated.

  4. High Power Laser Beam Welding of Thick-walled Ferromagnetic Steels with Electromagnetic Weld Pool Support

    NASA Astrophysics Data System (ADS)

    Fritzsche, André; Avilov, Vjaceslav; Gumenyuk, Andrey; Hilgenberg, Kai; Rethmeier, Michael

    The development of modern high power laser systems allows single pass welding of thick-walled components with minimal distortion. Besides the high demands on the joint preparation, the hydrostatic pressure in the melt pool increases with higher plate thicknesses. Reaching or exceeding the Laplace pressure, drop-out or melt sagging are caused. A contactless electromagnetic weld support system was used for laser beam welding of thick ferromagnetic steel plates compensating these effects. An oscillating magnetic field induces eddy currents in the weld pool which generate Lorentz forces counteracting the gravity forces. Hysteresis effects of ferromagnetic steels are considered as well as the loss of magnetization in zones exceeding the Curie temperature. These phenomena reduce the effective Lorentz forces within the weld pool. The successful compensation of the hydrostatic pressure was demonstrated on up to 20 mm thick plates of duplex and mild steel by a variation of the electromagnetic power level and the oscillation frequency.

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

    SciTech Connect

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

    2003-09-07

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

  6. 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.

  7. Real-time measurement of electron beam weld penetration in uranium by acoustic emission monitoring

    SciTech Connect

    Whittaker, J.W.; Murphy, J.L.

    1991-07-01

    High quality electron beam (EB) welds are required in uranium test articles. Acoustic emission (AE) techniques are under development with the goal of measuring weld penetration in real-time. One technique, based on Average Signal Level (ASL) measurement was used to record weld AE signatures. Characteristic AE signatures were recorded for bead-on-plate (BOP) and butt joint (BJ) welds made under varied welding conditions. AE waveforms were sampled to determine what microscopic AE behavior led to the observed macroscopic signature features. Deformation twinning and weld expulsion are two of the main sources of emission. AE behavior was correlated with weld penetration as measured by standard metallographic techniques. The ASL value was found to increase approximately linearly with weld penetration in BJ welds. These results form the basis for a real-time monitoring technique for weld penetration. 5 refs.

  8. Lap Joints of 6061 Al Alloys by Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Tashkandi, M. A.

    2017-06-01

    Lap joints of 6061 aluminium alloys were obtained using friction stir welding. The welding parameters used are: rotational speed, welding speed and pin Length. There were two levels of each factor involved. Rotational speed levels were 900 and 1120 rpm, welding speed levels were 1 and 1.5 mm/sec and pin length levels were 4.5 and 5.5 mm. Successful lap joints were produced for the different combinations of the above welding parameters. The joints quality tested under tensile testing and the microstructure of the welding zone were studied. Fracture mostly occurred in the base metal for most lap-shear welded joints. The exception was joints with welding parameters as follows: rotational speed 900 rpm, the welding speed 1.5 mm/sec and pin length 4.5 mm. In this case, the fracture occurred in the welding zone.

  9. Low Distortion Welded Joints for NCSX

    SciTech Connect

    M. Denault, M Viola, W. England

    2009-02-19

    The National Compact Stellarator Experiment (NCSX) required precise positioning of the field coils in order to generate suitable magnetic fields. A set of three modular field coils were assembled to form the Half Field-Period Assemblies (HPA). Final assembly of the HPA required a welded shear plate to join individual coils in the nose region due to the geometric limitations and the strength constraints. Each of the modular coil windings was wound on a stainless steel alloy (Stellalloy) casting. The alloy is similar to austenitic 316 stainless steel. During the initial welding trials, severe distortion, of approximately 1/16", was observed in the joint caused by weld shrinkage. The distortion was well outside the requirements of the design. Solutions were attempted through several simultaneous routes. The joint design was modified, welding processes were changed, and specialized heat reduction techniques were utilized. A final joint design was selected to reduce the amount of weld material needed to be deposited, while maintaining adequate penetration and strength. Several welding processes and techniques using Miller Axcess equipment were utilized that significantly reduced heat input. The final assembly of the HPA was successful. Distortion was controlled to 0.012", well within the acceptable design tolerance range of 0.020" over a 3.5 foot length.

  10. Electron beam weld development on a Filter Pack Assembly. Final report

    SciTech Connect

    Dereskiewicz, J.P.

    1994-06-01

    A continuous electron beam welding procedure was developed to replace the manual gas tungsten arc welding procedure on the Filter Pack Assembly. A statistical study was used to evaluate the feasibility of electron beam welding 6061-T6 aluminum covers to A356 cast weldments throughout the joint tolerance range specified on product drawings. Peak temperature exposures were not high enough to degrade the heat sensitive electrical components inside the cast weldment. Actual weldments with alodine coating on the weld joint area were successfully cleaned using a nonmetallic fiberglass brush cleaning method.

  11. Numerical simulation of heat transfer and fluid flow during double-sided laser beam welding of T-joints for aluminum aircraft fuselage panels

    NASA Astrophysics Data System (ADS)

    Yang, Zhibin; Tao, Wang; Li, Liqun; Chen, Yanbin; Shi, Chunyuan

    2017-06-01

    In comparison with conventional laser beam welding, double-sided laser beam welding has two laser heat sources simultaneously and symmetrically loaded from both sides makes it to be a more complicated coupled heat transport and fluid flow process. In this work, in order to understand the heat transfer and fluid flow, a three-dimensional model was developed and validated with the experimental results. The temperature field, fluid flow field, and keyhole characteristic were calculated using the developed model by FLUENT software. Calculated results indicated that the temperature and fluid flow fields were bilateral symmetry along the stringer center, and the molten pool maximum length was located near the keyhole intersection position. The skin side had higher temperature and faster cooling speed. Several characteristic flow patterns in the weld pool cross section, including the vortexes flows near the keyhole opening position, the convection flows above the keyhole intersection location, the regularity downward flows at the molten pool bottom. And in the lengthwise section, a distinct vortex flow below the keyhole, and the liquid metal behind the keyhole first flowed to near the molten pool maximum length location and then to the molten pool surface. Perpendicular to and along welding direction the keyhole liquid metal flowed to the weld molten pool surface and around the keyhole, respectively. The special temperature fields and fluid flow patterns were closely related to the effects of the double sides' laser energy coupling and enhancement. The calculated weld pool geometry basically in good agreement with the experimental results indicated that the developed model was validity and reasonable.

  12. Photosensors used to maintain welding electrode-to-joint alignment

    NASA Technical Reports Server (NTRS)

    Bowen, J. B.

    1965-01-01

    Photosensors maintain electrode-to-joint alignment in automatic precision arc welding. They detect the presence and relative position of a joint to be welded and actuate a servomechanism to guide the welding head accordingly thus permitting alignment for more than straight line or true circle joints.

  13. Advanced tests of wet welded joints

    SciTech Connect

    Pachniuk, I.; Petershagen, H.; Pohl, R.; Szelagowski, P.; Drews, O.

    1994-12-31

    Wet Welding has in former times only been applied to secondary structural components. Nowadays wet welding has become an upcoming repair process due to high process flexibility, its low investment costs and its high versatility. Even the quality of the wet welded joints has been improved remarkably due to intensive and concentrated development activities. However, especially in the North Sea regions owners of offshore structures and classifying authorities still hesitate to recognize the process as a reliable alternative to dry hyperbaric welding repair methods. It therefore requires further activities especially in the field of data development for life prediction of such repaired components. Advanced testing methods are necessary, additional design criteria are to be developed and achievable weldment quality data are to be included in acknowledged and approved standards and recommendations to improve the credibility of the process and to solve the problem of quality assurance for wet welded joints. A comprehensive project, sponsored by the European Community under the Thermie Programme, is in progress to develop new testing procedures to generate the required data and design criteria for the future application of the wet welding process to main components of offshore structures. It is the aim of the project to establish additional fitness for purpose data for this process.

  14. Stabilization of a Laser Welding Process Against Focal Shift Effects using Beam Manipulation

    NASA Astrophysics Data System (ADS)

    Thiel, C.; Weber, R.; Johannsen, J.; Graf, T.

    Two measures to enhance welding process stability with respect to a varying focal position are presented and discussed with regards to possible effects of laser power efficiency increase. Spatial beam movement was caused by a deflecting mirror and proved to create a welding process with a higher constancy in welding depth when changing focal position. A larger cross sectional area of the weld seam was measured showing increased laser absorption when compared to a static beam. Sinusoidal laser power modulation was tested for varying focus positions and proves to induce a deeper weld seam at moderately increased cross sectional areas. The power modulated welding process is dominated by the influence of melt dynamics which can be guided by choosing suitable modulation parameters. Both systems can be used to stabilize the welding process against loss of joint area or loss of connection which may occur due to focal shift in high brightness laser beam optics.

  15. Effect of Beam Oscillation on Microstructure and Mechanical Properties of AISI 316L Electron Beam Welds

    NASA Astrophysics Data System (ADS)

    Kar, Jyotirmaya; Roy, Sanat Kumar; Roy, Gour Gopal

    2017-04-01

    The properties of electron beam-welded AISI 316L stainless steel butt joints prepared with and without beam oscillation were evaluated by microstructural analysis, mechanical testing like microhardness measurements, tensile tests at room and elevated temperature 973 K (700 °C), three-point bend, and Charpy impact tests. All joints, irrespective of being prepared with or without beam oscillation, were found to be defect free. Welds produced by beam oscillation exhibited narrower fusion zone (FZ) with lathy ferrite morphology, while the weld without beam oscillation was characterized by wider FZ and skeletal ferrite morphology. During tensile tests at room and elevated temperature 973 K (700 °C), all samples fractured in the base metal (BM) and showed almost the same tensile properties as that of the BM. However, the notch tensile tests at room temperature demonstrated higher strength for joints prepared with the oscillating beam. Besides, face and root bend tests, as well as Charpy impact tests, showed higher bending strength and notch toughness, respectively, for joints prepared with beam oscillation.

  16. Effect of Beam Oscillation on Microstructure and Mechanical Properties of AISI 316L Electron Beam Welds

    NASA Astrophysics Data System (ADS)

    Kar, Jyotirmaya; Roy, Sanat Kumar; Roy, Gour Gopal

    2017-02-01

    The properties of electron beam-welded AISI 316L stainless steel butt joints prepared with and without beam oscillation were evaluated by microstructural analysis, mechanical testing like microhardness measurements, tensile tests at room and elevated temperature 973 K (700 °C), three-point bend, and Charpy impact tests. All joints, irrespective of being prepared with or without beam oscillation, were found to be defect free. Welds produced by beam oscillation exhibited narrower fusion zone (FZ) with lathy ferrite morphology, while the weld without beam oscillation was characterized by wider FZ and skeletal ferrite morphology. During tensile tests at room and elevated temperature 973 K (700 °C), all samples fractured in the base metal (BM) and showed almost the same tensile properties as that of the BM. However, the notch tensile tests at room temperature demonstrated higher strength for joints prepared with the oscillating beam. Besides, face and root bend tests, as well as Charpy impact tests, showed higher bending strength and notch toughness, respectively, for joints prepared with beam oscillation.

  17. The technology and welding joint properties of hybrid laser-tig welding on thick plate

    NASA Astrophysics Data System (ADS)

    Shenghai, Zhang; Yifu, Shen; Huijuan, Qiu

    2013-06-01

    The technologies of autogenous laser welding and hybrid laser-TIG welding are used on thick plate of high strength lower alloy structural steel 10CrNiMnMoV in this article. The unique advantages of hybrid laser-TIG welding is summarized by comparing and analyzing the process parameters and welding joints of autogenous laser welding laser welding and hybrid laser-TIG welding. With the optimal process parameters of hybrid welding, the good welding joint without visible flaws can be obtained and its mechanical properties are tested according to industry standards. The results show that the hybrid welding technology has certain advantages and possibility in welding thick plates. It can reduce the demands of laser power, and it is significant for lowering the aspect ratio of weld during hybrid welding, so the gas in the molten pool can rise and escape easily while welding thick plates. Therefore, the pores forming tendency decreases. At the same time, hybrid welding enhances welding speed, and optimizes the energy input. The transition and grain size of the microstructure of hybrid welding joint is better and its hardness is higher than base material. Furthermore, its tensile strength and impact toughness is as good as base material. Consequently, the hybrid welding joint can meet the industry needs completely.

  18. Effect of Multi-repair Welding on Fatigue Performance of Aluminum Alloy Profile Welded Joint

    NASA Astrophysics Data System (ADS)

    Diao, You-De; Shi, Chun-Yuan; Tian, Hong-Lei

    2016-05-01

    Aluminum alloy profile has been widely used in the manufacture of the rail vehicles. But it's necessary for the repair welding of the welded joints to be conducted because some defects exist in the weld such as porosity, inclusions and incomplete penetrations in the welding processes. In this paper, the influence of the multi-repair welding of 6005A aluminum alloy profile butt welded joints on the fatigue performance are investigated based on the results of fatigue tests. The parameters of curves and the fatigue strength of the welded joints are calculated, and Goodman fatigue limit diagram is also obtained. The results show that fatigue strength of aluminum alloy profile butt welded joints, in condition of 107 cycle life, meet the standard requirement for the as-welded, repair welded state one time or two times respectively.

  19. Electron Beam Welding to Join Gamma Titanium Aluminide Articles

    NASA Technical Reports Server (NTRS)

    Kelly, Thomas Joseph (Inventor)

    2008-01-01

    A method is provided for welding two gamma titanium aluminide articles together. The method includes preheating the two articles to a welding temperature of from about 1700 F to about 2100 F, thereafter electron beam welding the two articles together at the welding temperature and in a welding vacuum to form a welded structure, and thereafter annealing the welded structure at an annealing temperature of from about 1800 F to about 2200 F, to form a joined structure.

  20. Inductive Preheating in Laser Beam Welding of Multimaterial Joints of 22MnB5 and AA6016

    NASA Astrophysics Data System (ADS)

    Kügler, H.; Vollertsen, F.

    Inductive preheating is well known as possibility to heat ferromagnetic materials. In brazing preheating causes an improvement of wetting quality, e.g. smaller wetting angles and longer wetting lengths. In this paper inductive preheating is used to support a laser beam hybrid joining process. Aluminum AA6016 is molten in order to wet the surface of AlSi- coated steel 22MnB5. Investigations on the influence of preheating on wetting characteristics and intermetallic phase seam formation were carried out. Strength values up to 230 MPa have been measured in tensile shear tests. Fraction zone occurs in the aluminum base material indicating uncritical thickness of the intermetallic phase seam at the interface.

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

    SciTech Connect

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

    2006-02-05

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

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

    SciTech Connect

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

    2006-05-08

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

  3. Joint strength of laser-welded titanium.

    PubMed

    Liu, J; Watanabe, I; Yoshida, K; Atsuta, M

    2002-03-01

    The objective of this study was to examine the joint strength of titanium laser-welding using several levels of laser output energy [current (A)]. Cast titanium plates (0.5 x 3.0 x 40 and 1.0 x 3.0 x 40 mm(3)) were prepared and perpendicularly cut at the center of the plate. After the cut halves were fixed in a jig, they were laser-welded using a Nd: YAG laser at several levels of output energy in increments of 30A from 180 to 300A. The penetration depths of laser to titanium were measured under various conditions for output energy, pulse duration, and spot diameter to determine the appropriate conditions for these parameters. Based on the correlation between the results obtained for penetration depth and the size of the specimens (thickness: 0.5 and 1.0 mm, width: 3.0 mm), the pulse duration and spot diameter employed in this study were 10 ms and 1.0 mm, respectively. Three laser pulses (spot diameter: 1.0 mm) were applied from one side to weld the entire joint width (3.0 mm) of the specimens. Uncut specimens served as the non-welded control specimens. Tensile testing was conducted at a crosshead speed of 2 mm/min and a gage length of 10 mm. The breaking force (N) was recorded, and the data (n=5) were statistically analyzed. For the 0.5 mm thick specimens, the breaking force of the specimens laser-welded at currents of 240, 270, and 300A were not statistically (P>0.05) different from the non-welded control specimens. There were no significant differences in breaking force among the 1.0mm thick specimens laser-welded at currents of 270 and 300A, and the non-welded control specimens. Under appropriate conditions, joint strengths similar to the strength of the non-welded parent metal were achieved.

  4. Comparison of single-beam and dual-beam laser welding of Ti-22Al-25Nb/TA15 dissimilar titanium alloys

    NASA Astrophysics Data System (ADS)

    Shen, Junqi; Li, Bo; Hu, Shengsun; Zhang, Hao; Bu, Xianzheng

    2017-08-01

    Laser beam welding (LBW) was used to join Ti-22Al-25Nb/TA15 dissimilar titanium alloys. The microstructure and mechanical properties of the welded joints under single and dual beam welding were analyzed and compared. In the mode of single laser beam, the fusion zone only consisted of B2 phase because of existence of β-phase stabilizer and rapid cooling rate of LBW. However, O phase was formed in the fusion zone while applying dual-beam laser welding due to decrease of the cooling rate. The microhardness distribution of the welded joint in dual-beam welding mode was consistent with that in single mode, but the hardness of the weld under dual laser beam was higher than that of single laser beam. In room-temperature tensile tests, the fractures all occurred in the weld, but the morphology exhibited a quasi-cleavage feature in single mode while the morphology was dimple fracture in the mode of dual laser beam. The tensile strength and elongation were both increased under dual-beam laser welding compared with those under single-beam laser welding.

  5. Onorbit electron beam welding experiment definition

    NASA Technical Reports Server (NTRS)

    1989-01-01

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

  6. Non-Vacuum Electron Beam Welding

    SciTech Connect

    Hershcovitch, Ady

    2007-01-31

    Original objectives of CRADA number BNL-01-03 between BNL and Acceleron, Inc., were to further develop the Plasma Window concept (a BNL invention covered by US Patent number 5,578,831), mate the Plasma Window to an existing electron beam welder to perform in-air electron beam welding, and mount the novel nonvacuum electron beam welder on a robot arm. Except for the last objective, all other goals were met or exceeded. Plasma Window design and operation was enhanced during the project, and it was successfully mated to a conventional4 kW electron beam welder. Unprecedented high quality non-vacuum electron beam . welding was demonstrated. Additionally, a new invention the Plasma Shield (US Patent number 7,075,030) that chemically and thermally shields a target object was set forth. Great interest in the new technology was shown by a number of industries and three arcs were sold for experimental use. However, the welding industry requested demonstration of high speed welding, which requires 100 kW electron beam welders. The cost of such a welder involved the need for additional funding. Therefore, some of the effort was directed towards Plasma Shield development. Although relatively a small portion of the R&D effort was spent on the Plasma Shield, some very encouraging results were obtained. Inair Plasma Shield was demonstrated. With only a partial shield, enhanced vacuum separation and cleaner welds were realized. And, electron beam propagation in atmosphere improved by a factor of about 3. Benefits to industry are the introduction of two new technologies. BNL benefited from licensing fee cash, from partial payment for employee salary, and from a new patent In addition to financial benefits, a new technology for physics studies was developed. Recommendations for future work are to develop an under-water plasma shield, perform welding with high-power electron beam:s, carry out other plasma shielded electron beam and laser processes. Potential benefits from further R

  7. Narrow gap laser welding

    DOEpatents

    Milewski, John O.; Sklar, Edward

    1998-01-01

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

  8. Narrow gap laser welding

    DOEpatents

    Milewski, J.O.; Sklar, E.

    1998-06-02

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

  9. Electron beam welder X-rays its own welds

    NASA Technical Reports Server (NTRS)

    Roden, W. A.

    1967-01-01

    Beam of an electron beam welder X rays its own welds, enabling rapid weld quality checks to be made without removing the work from the vacuum chamber. A tungsten target produces X rays when hit by the beam. They are directed at the weld specimen and recorded on polaroid film.

  10. Beam/seam alignment control for electron beam welding

    DOEpatents

    Burkhardt, Jr., James H.; Henry, J. James; Davenport, Clyde M.

    1980-01-01

    This invention relates to a dynamic beam/seam alignment control system for electron beam welds utilizing video apparatus. The system includes automatic control of workpiece illumination, near infrared illumination of the workpiece to limit the range of illumination and camera sensitivity adjustment, curve fitting of seam position data to obtain an accurate measure of beam/seam alignment, and automatic beam detection and calculation of the threshold beam level from the peak beam level of the preceding video line to locate the beam or seam edges.

  11. Adaptive tracking of weld joints using active contour model in arc-welding processes

    NASA Astrophysics Data System (ADS)

    Kim, Jaeseon; Koh, Kyoungchul; Cho, Hyungsuck

    2001-02-01

    12 This paper presents a vision processing scheme to automatic weld joint tracking in robotic arc welding process. Particular attention is concentrated on its robustness against various optical disturbances, such as arc glares and weld spatters radiating from the melted weld pool. Underlying the developed vision processing is a kind of model-based pattern searching, which is necessarily accompanied by two separate stages of modeling and tracking. In the modeling stage, a syntactic approach is adopted to identify unknown weld joint structure. The joint profile identified in the modeling stage is used as a starting point for successive tracking of variations in the geometry of weld joint during welding, which is automatically achieved by an active contour model technology following feature- based template matching. The performance of the developed scheme is investigated through a series of practical welding experiments.

  12. New technique of skin embedded wire double-sided laser beam welding

    NASA Astrophysics Data System (ADS)

    Han, Bing; Tao, Wang; Chen, Yanbin

    2017-06-01

    In the aircraft industry, double-sided laser beam welding is an approved method for producing skin-stringer T-joints on aircraft fuselage panels. As for the welding of new generation aluminum-lithium alloys, however, this technique is limited because of high hot cracking susceptibility and strengthening elements' uneven distributions within weld. In the present study, a new technique of skin embedded wire double-sided laser beam welding (LBW) has been developed to fabricate T-joints consisting of 2.0 mm thick 2060-T8/2099-T83 aluminum-lithium alloys using eutectic alloy AA4047 filler wire. Necessary dimension parameters of the novel groove were reasonably designed for achieving crack-free welds. Comparisons were made between the new technique welded T-joint and conventional T-joint mainly on microstructure, hot crack, elements distribution features and mechanical properties within weld. Excellent crack-free microstructure, uniform distribution of silicon and superior tensile properties within weld were found in the new skin embedded wire double-sided LBW T-joints.

  13. Numerical simulation of electron beam welding with beam oscillations

    NASA Astrophysics Data System (ADS)

    Trushnikov, D. N.; Permyakov, G. L.

    2017-02-01

    This research examines the process of electron-beam welding in a keyhole mode with the use of beam oscillations. We study the impact of various beam oscillations and their parameters on the shape of the keyhole, the flow of heat and mass transfer processes and weld parameters to develop methodological recommendations. A numerical three-dimensional mathematical model of electron beam welding is presented. The model was developed on the basis of a heat conduction equation and a Navier-Stokes equation taking into account phase transitions at the interface of a solid and liquid phase and thermocapillary convection (Marangoni effect). The shape of the keyhole is determined based on experimental data on the parameters of the secondary signal by using the method of a synchronous accumulation. Calculations of thermal and hydrodynamic processes were carried out based on a computer cluster, using a simulation package COMSOL Multiphysics.

  14. Laser beam welding of aluminum die casting with reduced pore formation

    SciTech Connect

    Rehbein, D.H.; Decker, I.; Wohlfahrt, H.

    1994-12-31

    Laser beam welding is already well treated within the laboratory, but there is still a minor industrial application because of the lack of reliability of the process due to violent fluctuations of the plasma formation above and melt flow turbulence around the welding key-hole. An even greater challenge is the welding of die cast aluminum since the high hydrogen content dissolved within the material during the casting process is responsible for a strong pore formation of the weld and a rather unsteady welding process. During the last 10 years, intensive research work has been executed by the research institute of the authors in order to increase the weldability of die-case aluminum by optimization of the casting process. The casting process has been optimized in such a way that as few gases as possible can penetrate into the castings. The porosity of the welds has been reduced to a level comparable to that of high-quality joints of wrought material. The weld quality achieved by electron beam welding is excellent. The range of possible welding speeds and the necessary laser power depending on the wall thickness and the chosen optical arrangement are quantified. Die casting of aluminum is a manufacturing operation of high productivity. However, it s not suited for production of hollow structures. A combination with a highly productive welding technique such as laser beam welding is now available, and one may expect it to be of reasonable economic benefit in the future.

  15. 49 CFR 195.216 - Welding: Miter joints.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding: Miter joints. 195.216 Section 195.216 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.216 Welding: Miter joints. A miter joint is not permitted (not...

  16. 49 CFR 195.216 - Welding: Miter joints.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding: Miter joints. 195.216 Section 195.216 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.216 Welding: Miter joints. A miter joint is not permitted (not...

  17. 49 CFR 195.216 - Welding: Miter joints.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding: Miter joints. 195.216 Section 195.216 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.216 Welding: Miter joints. A miter joint is not permitted (not...

  18. 49 CFR 195.216 - Welding: Miter joints.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welding: Miter joints. 195.216 Section 195.216 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.216 Welding: Miter joints. A miter joint is not permitted (not...

  19. 49 CFR 195.216 - Welding: Miter joints.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding: Miter joints. 195.216 Section 195.216 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.216 Welding: Miter joints. A miter joint is not permitted (not...

  20. Effect of weld schedule variation on the weldability and durability of AHSS spot weld joints

    NASA Astrophysics Data System (ADS)

    Weishaupt, Eric Raymond

    Tensile strength testing and high cycle fatigue testing of advanced high strength steel spot welded shear lap joints were performed for the various weld conditions. The materials used in this study were DP 980, DP 780 and TRIP 780. The microstructure and microhardness of the shear lap joints were examined in an effort to identify the effect of microstructural changes on the strength and fatigue durability of the spot weld specimens. The occurrence of interfacial failure was recorded for the differing weld processes. Several weld schedules were examined and used to produce shear lap spot weld joints, specifically varying the squeeze force and the average current. The weld force used to produce a spot weld does not have a significant effect on the fracture mode of the specimen given the average current is constant. The average current used to produce a spot weld has a significant effect on the fracture mode of the spot weld for several squeeze forces. Interfacial failure of spot welded TRIP 780 can be mitigated using a certain range of currents when welding. This appears to come as a tradeoff for sacrificing the strength of the joint. Higher values of weld strength were obtainable; however, welds that failed with higher strengths also experienced interfacial failure. A fracture mechanics approach to estimating the high cycle fatigue life of the shear lap specimen is also proposed and represents a conservative estimate of the shear lap specimen durability.

  1. Virtual Welded - Joint Design Integrating Advanced Materials and Processing Technology

    SciTech Connect

    Yang, Zhishang; Ludewig, Howard W.; Babu, S. Suresh

    2005-06-30

    Virtual Welede-Joint Design, a systematic modeling approach, has been developed in this project to predict the relationship of welding process, microstructure, properties, residual stress, and the ultimate weld fatique strength. This systematic modeling approach was applied in the welding of high strength steel. A special welding wire was developed in this project to introduce compressive residual stress at weld toe. The results from both modeling and experiments demonstrated that more than 10x fatique life improvement can be acheived in high strength steel welds by the combination of compressive residual stress from the special welding wire and the desired weld bead shape from a unique welding process. The results indicate a technology breakthrough in the design of lightweight and high fatique performance welded structures using high strength steels.

  2. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2016-11-01

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

  4. Evaluation of Laser Braze-welded Dissimilar Al-Cu Joints

    NASA Astrophysics Data System (ADS)

    Schmalen, Pascal; Plapper, Peter

    The thermal joining of Aluminum and Copper is a promising technology towards automotive battery manufacturing. The dissimilar metals Al-Cu are difficult to weld due to their different physicochemical characteristics and the formation of intermetallic compounds (IMC), which have reduced mechanical and electric properties. There is a critical thickness of the IMCs where the favored mechanical properties of the base material can be preserved. The laser braze welding principle uses a position and power oscillated laser-beam to reduce the energy input and the intermixture of both materials and therefore achieves minimized IMCs thickness. The evaluation of the weld seam is important to improve the joint performance and enhance the welding process. This paper is focused on the characterization and quantification of the IMCs. Mechanical, electrical and metallurgical methods are presented and performed on Al1050 and SF-Cu joints and precise weld criteria are developed.

  5. Seam-Tracking for Friction Stir Welded Lap Joints

    NASA Astrophysics Data System (ADS)

    Fleming, Paul A.; Hendricks, Christopher E.; Cook, George E.; Wilkes, D. M.; Strauss, Alvin M.; Lammlein, David H.

    2010-11-01

    This article presents a method for automatic seam-tracking in friction stir welding (FSW) of lap joints. In this method, tracking is accomplished by weaving the FSW tool back-and-forth perpendicular to the direction of travel during welding and monitoring force and torque signals. Research demonstrates the ability of this method to automatically track weld seam positions. Additionally, tensile and S-bend test result comparisons demonstrate that weaving most likely does not reduce weld quality. Finally, benefits of this weave-based method to FSW of lap joints are discussed and methods for incorporating it into existing friction stir welding control algorithms (such as axial load control) are examined.

  6. Frictional properties of jointed welded tuff

    SciTech Connect

    Teufel, L.W.

    1981-07-01

    The results of the experiments on simulated joints in welded tuff from the Grouse Canyon Member of the Belted Range Tuff warrant the following conclusions: (1) The coefficient of friction of the joints is independent of normal stress at a given sliding velocity. (2) The coefficient of friction increases with both increasing time of stationary contact and decreasing sliding velocity. (3) Time and velocity dependence of friction is due to an increase in the real area of contact on the sliding surface, caused by asperity creep. (4) Joints in water-saturated tuff show a greater time and velocity dependence of friction than those in dehydrated tuff. (5) The enhanced time and velocity dependence of friction with water saturation is a result of increased creep at asperity contacts, which is in turn due to a reduction in the surface indentation hardness by hydrolytic weakening and/or stress corrosion cracking.

  7. Verifying root fusion in electron-beam welds

    NASA Technical Reports Server (NTRS)

    Becker, F. L.; Doctor, S.; Kleint, R. E.

    1980-01-01

    Ultrasonic equipment and x-y recorder indicate where back side of joint is properly welded. Wire waveguide placed in groove at root of joint to be welded is fused when joint is adequately penetrated. Ultransonic signal moving down waveguide is reflected where guide is melted. Change in reflected-signal arrival time with change in weld-head position is nearly constant unless joint is incompletely penetrated. Method permits determination of penetration depth in preweld samples without opening vacuum chamber and sectioning weld. Technique is particularly valuable when back side of joint is inaccessible.

  8. Verifying root fusion in electron-beam welds

    NASA Technical Reports Server (NTRS)

    Becker, F. L.; Doctor, S.; Kleint, R. E.

    1980-01-01

    Ultrasonic equipment and x-y recorder indicate where back side of joint is properly welded. Wire waveguide placed in groove at root of joint to be welded is fused when joint is adequately penetrated. Ultransonic signal moving down waveguide is reflected where guide is melted. Change in reflected-signal arrival time with change in weld-head position is nearly constant unless joint is incompletely penetrated. Method permits determination of penetration depth in preweld samples without opening vacuum chamber and sectioning weld. Technique is particularly valuable when back side of joint is inaccessible.

  9. Yield detection in aluminum welded joints using photostress

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  10. Relation between hardness and ultrasonic velocity on pipeline steel welded joints

    NASA Astrophysics Data System (ADS)

    Carreón, H.; Barrera, G.; Natividad, C.; Salazar, M.; Contreras, A.

    2016-04-01

    In general, the ultrasonic techniques have been used to determine the mechanical properties of materials based on their relationship with metallurgical characteristics. In this research work, the relationship between ultrasonic wave velocity, hardness and the microstructure of steel pipeline welded joints is investigated. Measurements of ultrasonic wave velocity were made as a function of the location across the weld. Hardness measurements were performed in an attempt to correlate with ultrasonic response. In addition, the coarse and dendritic grain structure of the weld material is extreme and unpredictably anisotropic. Thus, due to the acoustic anisotropy of the crystal, weld material of studied joints is anisotropic too. Such structure is no longer direction-independent to the ultrasonic wave propagation; therefore, the ultrasonic beam deflects and redirects and the wave front becomes distorted. Thus, the use of conventional ultrasonic testing techniques using fixed beam angles is very limited and the application of conventional ultrasonic phased array techniques becomes desirable. This technique is proposed to assist pipeline operators in estimating the hardness through ultrasonic measures to evaluate the susceptibility to stress sulphide cracking and hydrogen-induced cracking due to hard spots in steel pipeline welded joints in service. Sound wave velocity and hardness measurements have been carried out on a steel welded joint. For each section of the welding, weld bead, fusion zone, heat affected zone and base metal were found to correspond particular values of the ultrasound velocity. These results were correlated with electron microscopy observations of the microstructure and sectorial scan view of welded joints by ultrasonic phased array.

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

    NASA Astrophysics Data System (ADS)

    Florea, Radu Stefanel

    This comprehensive study is the first to quantify the fatigue performance, failure loads, and microstructure of resistance spot welding (RSW) in 6061-T6 aluminum (Al) alloy according to welding parameters and process sensitivity. The extensive experimental, theoretical and simulated analyses will provide a framework to optimize the welding of lightweight structures for more fuel-efficient automotive and military applications. The research was executed in four primary components. The first section involved using electron back scatter diffraction (EBSD) scanning, tensile testing, laser beam profilometry (LBP) measurements, and optical microscopy(OM) images to experimentally investigate failure loads and deformation of the Al-alloy resistance spot welded joints. Three welding conditions, as well as nugget and microstructure characteristics, were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that increasing the applied welding current deepened the weld imprints. The EBSD scans revealed the strong dependency between the grain sizes and orientation function on the process parameters. For the second section, the fatigue behavior of the RSW'ed joints was experimentally investigated. The process optimization included consideration of the forces, currents, and times for both the main weld and post-heating. Load control cyclic tests were conducted on single weld lap-shear joint coupons to characterize the fatigue behavior in spot welded specimens. Results demonstrate that welding parameters do indeed significantly affect the microstructure and fatigue performance for these welds. The third section comprised residual strains of resistance spot welded joints measured in three different directions, denoted as in-plane longitudinal, in-plane transversal, and normal, and captured on the fusion zone, heat affected zone

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

    SciTech Connect

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

    2001-06-12

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

  13. Properties of welded joints in laser welding of aeronautic aluminum-lithium alloys

    NASA Astrophysics Data System (ADS)

    Malikov, A. G.; Orishich, A. M.

    2017-01-01

    The work presents the experimental investigation of the laser welding of the aluminum-lithium alloys (system Al-Mg-Li) and aluminum alloy (system Al-Cu-Li) doped with Sc. The influence of the nano-structuring of the surface layer welded joint by the cold plastic deformation method on the strength properties of the welded joint is determined. It is founded that, regarding the deformation degree over the thickness, the varying value of the welded joint strength is different for these aluminum alloys.

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

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

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

  15. Tensile and Impact Toughness Properties of Gas Tungsten Arc Welded and Friction Stir Welded Interstitial Free Steel Joints

    NASA Astrophysics Data System (ADS)

    Lakshminarayanan, A. K.; Balasubramanian, V.

    2011-02-01

    Welded regions of interstitial free (IF) steel grades in the vicinity of weld center exhibits larger grains because of the prevailing thermal conditions during weld metal solidification. This often causes inferior weld mechanical properties. In the present study, tensile properties, charpy impact toughness, microhardness, microstructure, lowest hardness distribution profile, and fracture surface morphology of the gas tungsten arc welded (GTAW) and friction stir welded joints were evaluated, and the results are compared. From this investigation, it is found that friction stir welded joint of IF steel showed superior tensile and impact properties compared with GTAW joint, and this is mainly due to the formation of very fine, equiaxed microstructure in the weld zone.

  16. Single Pass Laser Welding with Multiple Spots to Join Four Sheets in a Butt-joint Configuration

    NASA Astrophysics Data System (ADS)

    Kristiansen, Morten; Hansen, Klaus Schütt; Langbak, Andreas; Johansen, Sebastian Blegebrønd; Krempin, Simon Borup; Hornum, Mattias Døssing

    Laser keyhole welding is widely used in industry due to its large welding depth and low heat input. For some industrial cases it is necessary to widen the beam to cover the joint configuration, which instead results in a lower intensity and surface conduction welds. The introduction of the high-power single mode fiber laser makes it possible to deal with this problem, because the beam can be shaped into a pre-defined pattern of multiple spots shaped to the actual joint configuration. The intensity of each spot is sufficient to make a keyhole. A case with four sheets in a butt-joint configuration is used to demonstrate the principle of how to design a spot pattern which ensures weld quality in case of a single pass laser weld.

  17. Improvement of ultrasonic characteristics in butt-welded joint of austenitic stainless steel using magnetic stirring method

    SciTech Connect

    Tanosaki, M.; Yoshikawa, K.; Arakawa, T.

    1995-08-01

    Magnetic Stirring Method of Tungsten Inert Gas(TIG) Welding are applied to butt-welded joint of austenitic stainless steel. The purpose of this method is to refine the welded structure and to improve the ultrasonic characteristics. In the conventional method of ultrasonic test in austenitic stainless steel weldments, dendritic solidification structure of weldment prevents smooth ultrasonic beam transmission. The tests are performed in three welding conditions; One is conventional TIG welding (without magnetic stirring), the other two are TIG welding using magnetic stirring method. Each test piece is evaluated by observing macro structure of cross section and by several ultrasonic tests examining pulse amplitudes, beam path length and proceeding beam direction. The detectability of artificial notches in weldment is also investigated and compared.

  18. An inelastic analysis of a welded aluminum joint

    NASA Technical Reports Server (NTRS)

    Vaughan, R. E.

    1994-01-01

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

  19. Effects of beam configurations on wire melting and transfer behaviors in dual beam laser welding with filler wire

    NASA Astrophysics Data System (ADS)

    Ma, Guolong; Li, Liqun; Chen, Yanbin

    2017-06-01

    Butt joints of 2 mm thick stainless steel with 0.5 mm gap were fabricated by dual beam laser welding with filler wire technique. The wire melting and transfer behaviors with different beam configurations were investigated detailedly in a stable liquid bridge mode and an unstable droplet mode. A high speed video system assisted by a high pulse diode laser as an illumination source was utilized to record the process in real time. The difference of welding stability between single and dual beam laser welding with filler wire was also compartively studied. In liquid bridge transfer mode, the results indicated that the transfer process and welding stability were disturbed in the form of "broken-reformed" liquid bridge in tandem configuration, while improved by stabilizing the molten pool dynamics with a proper fluid pattern in side-by-side configuration, compared to sigle beam laser welding with filler wire. The droplet transfer period and critical radius were studied in droplet transfer mode. The transfer stability of side-by-side configuration with the minium transfer period and critical droplet size was better than the other two configurations. This was attributed to that the action direction and good stability of the resultant force which were beneficial to transfer process in this case. The side-by-side configuration showed obvious superiority on improving welding stability in both transfer modes. An acceptable weld bead was successfully generated even in undesirable droplet transfer mode under the present conditions.

  20. Mechanical behavior study of laser welded joints for DP steel

    NASA Astrophysics Data System (ADS)

    Yan, Qi

    2008-03-01

    Advanced High Strength Steels (AHSS) are gaining considerable market shares in the automotive industry. The development and application of Dual Phase (DP) steel is just a consistent step towards high-strength steel grades with improved mechanical behavior. Tailor welded blanks with DP steel are promoted in the application of Body-In-White (BIW) structure by the automotive industry. A tailor welded blank consists of several flat sheets that are laser welded together before stamping. Applied cases of tailor welded blanks of high strength steels on the automotive structural parts are investigated in this paper. The mechanical behavior of laser welded joints for DP steel is studied. Microstructure of laser welded joints for DP steel was observed by SEM. Martensite in the weld seam explains the higher strength of welded joints than the base metal. Results show that the strain safety tolerance of laser welded seam for high strength steel can meet the requirement of automobile parts for stamping if the location of laser welded seam is designed reasonably.

  1. 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.

  2. Design of a welded joint for robotic, on-orbit assembly of space trusses

    NASA Technical Reports Server (NTRS)

    Rule, William K.

    1992-01-01

    In the future, some spacecraft will be so large that they must be assembled on-orbit. These spacecraft will be used for such tasks as manned missions to Mars or used as orbiting platforms for monitoring the Earth or observing the universe. Some large spacecraft will probably consist of planar truss structures to which will be attached special purpose, self-contained modules. The modules will most likely be taken to orbit fully outfitted and ready for use in heavy-lift launch vehicles. The truss members will also similarly be taken to orbit, but most unassembled. The truss structures will need to be assembled robotically because of the high costs and risks of extra-vehicular activities. Some missions will involve very large loads. To date, very few structures of any kind have been constructed in space. Two relatively simple trusses were assembled in the Space Shuttle bay in late 1985. Here the development of a design of a welded joint for on-orbit, robotic truss assembly is described. Mechanical joints for this application have been considered previously. Welded joints have the advantage of allowing the truss members to carry fluids for active cooling or other purposes. In addition, welded joints can be made more efficient structurally than mechanical joints. Also, welded joints require little maintenance (will not shake loose), and have no slop which would cause the structure to shudder under load reversal. The disadvantages of welded joints are that a more sophisticated assembly robot is required, weld flaws may be difficult to detect on-orbit, the welding process is hazardous, and welding introduces contamination to the environment. In addition, welded joints provide less structural damping than do mechanical joints. Welding on-orbit was first investigated aboard a Soyuz-6 mission in 1969 and then during a Skylab electron beam welding experiment in 1973. A hand held electron beam welding apparatus is currently being prepared for use on the MIR space station

  3. Numerical modeling of electron-beam welding of dissimilar metals

    NASA Astrophysics Data System (ADS)

    Krektuleva, R. A.; Cherepanov, O. I.; Cherepanov, R. O.

    2016-11-01

    This paper is devoted to numerical modeling of heat transfer processes and estimation of thermal stresses in weld seams created by electron beam welding of heterogeneous metals. The mathematical model is based on a system of equations that includes the Lagrange's variational equation of theory of plasticity and variational equation of M. Biot's principle to simulate the heat transfer processes. The two-dimensional problems (plane strain and plane stress) are considered for estimation of thermal stresses in welds considering differences of mechanical properties of welded materials. The model is developed for simulation of temperature fields and stresses during electron beam welding.

  4. Fatigue Behavior and Damage Monitoring of Ultrasonic Welded Hybrid Joints

    NASA Astrophysics Data System (ADS)

    Huxhold, Stefan; Balle, Frank; Wagner, Guntram; Eifler, Dietmar

    The need of hybrid joints especially for joints between light metals and CFRP-composites is strongly increased in the last years. Ultrasonic metal welding is one promising technology to join aluminum alloys to carbon fiber reinforced polymers (CFRP). These hybrid joints can be realized by thermal softening and mechanical replacing the polymer out of the welding zone as a result of the ultrasonic shear oscillation. This allows a direct contact between the aluminum and the carbon fibers. Due to the electrical conductivity of the carbon fibers and the realized metal/fiber contact it is possible to use the hybrid joints as their own fatigue damage sensor and to describe the actual fatigue state of the welds. Additionally to standard experimental data, the change in the electrical resistivity can be monitored during the fatigue tests. Load-increase as well as constant amplitude tests of ultrasonically welded aluminum/CFRP-joints will be presented and discussed.

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

    NASA Astrophysics Data System (ADS)

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

    2016-05-01

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

  6. Finite Element Modeling for the Structural Analysis of Al-Cu Laser Beam Welding

    NASA Astrophysics Data System (ADS)

    Hartel, Udo; Ilin, Alexander; Bantel, Christoph; Gibmeier, Jens; Michailov, Vesselin

    Laser beam welding of aluminum and copper (Al-Cu) materials is a cost efficient joining technology to produce e.g. connector elements for battery modules. Distortion low connections can be achieved, which have electrical favorable properties. Numerical simulation of the laser beam welding process of Al-Cu dissimilar materials can provide further insight into principal process mechanisms and mechanical response of the joint parts. In this paper a methodology is introduced to investigate the structural behavior of Al-Cu joints in overlap joint with respect to welding distortions and residual stresses. First the material model of the homogeneous base materials are validated. Next, a generic material model approach is used to simulate the structural behavior of heterogeneous Al-Cu connections.

  7. Study on laser welding of austenitic stainless steel by varying incident angle of pulsed laser beam

    NASA Astrophysics Data System (ADS)

    Kumar, Nikhil; Mukherjee, Manidipto; Bandyopadhyay, Asish

    2017-09-01

    In the present work, AISI 304 stainless steel sheets are laser welded in butt joint configuration using a robotic control 600 W pulsed Nd:YAG laser system. The objective of the work is of twofold. Firstly, the study aims to find out the effect of incident angle on the weld pool geometry, microstructure and tensile property of the welded joints. Secondly, a set of experiments are conducted, according to response surface design, to investigate the effects of process parameters, namely, incident angle of laser beam, laser power and welding speed, on ultimate tensile strength by developing a second order polynomial equation. Study with three different incident angle of laser beam 89.7 deg, 85.5 deg and 83 deg has been presented in this work. It is observed that the weld pool geometry has been significantly altered with the deviation in incident angle. The weld pool shape at the top surface has been altered from semispherical or nearly spherical shape to tear drop shape with decrease in incident angle. Simultaneously, planer, fine columnar dendritic and coarse columnar dendritic structures have been observed at 89.7 deg, 85.5 deg and 83 deg incident angle respectively. Weld metals with 85.5 deg incident angle has higher fraction of carbide and δ-ferrite precipitation in the austenitic matrix compared to other weld conditions. Hence, weld metal of 85.5 deg incident angle achieved higher micro-hardness of ∼280 HV and tensile strength of 579.26 MPa followed by 89.7 deg and 83 deg incident angle welds. Furthermore, the predicted maximum value of ultimate tensile strength of 580.50 MPa has been achieved for 85.95 deg incident angle using the developed equation where other two optimum parameter settings have been obtained as laser power of 455.52 W and welding speed of 4.95 mm/s. This observation has been satisfactorily validated by three confirmatory tests.

  8. Welding method combining laser welding and MIG welding

    SciTech Connect

    Hamasaki, M.

    1985-03-26

    Welding of deep penetration is obtained in a sustrate by a method which comprises first melting the joint portion of the substrates by MIG welding and then focusing a laser beam in the bottom surface of a crater formed in consequence of the MIG welding thereby effecting laser welding of the crater.

  9. Reduced heat input keyhole welding through improved joint design

    NASA Technical Reports Server (NTRS)

    Sanders, John M. (Inventor); Harwig, Dennis D. (Inventor)

    1993-01-01

    An improved high energy density welding method for reducing input keyhole welding prepares the weld joint (8) between two edges (10, 14) of at least one member by separating the edges (10, 14) of the member (12, 16) with a controllable gap (22) by a projecting portion (24) selectively positioned on one edge (10, 14) of the member (12, 16). The projecting portion (24) closely abuts the other edge of the member for maintaining the controlled distance (d) of the controllable gap (22) to enhance the welding method.

  10. Laser beam welding of 5182 aluminum alloys sheet.

    SciTech Connect

    Leong, K. H.; Sabo, K. R.; Altshuller, B.; Wilkinson, T. L.; Albright, C. E.; Technology Development; Alcan International Limited; Reynolds Metals Co.; Ohio State Univ.

    1999-06-01

    Conditions were determined for consistent coupling of a CO{sub 2} laser beam to weld 5182 aluminum alloy sheet. Full penetration butt and bead-on-plate welds on 0.8 and 1.8 mm sheets were performed. Process conditions examined included beam mode, spot size and irradiance, shielding gas flow, and edge quality and fitup. The observed weld quality variations with the different process parameters were consistent with physical phenomena and a threshold irradiance model. Optimal conditions were determined for obtaining consistent welds on 5182 alloy sheets. Formability and tensile tests were performed on the welded samples. All test failures occurred in the fusion zone. Reduction in formability and tensile strength of the welded samples are discussed with respect to weld profiles and process parameters.

  11. Method of beam welding metallic parts together and apparatus for doing same

    DOEpatents

    Lewandowski, E.F.; Cassidy, D.A.; Sommer, R.G.

    1985-11-29

    This method provides for temporarily clamping a metallic piece to one side of a metallic plate while leaving the opposite side of the plate exposed, and providing a heat conductive heat sink body configured to engage the adjacent portions of such one side of the plate and the piece at all regions proximate to but not at the interface between these components. The exposed side of such plate is then subjected to an electron welding beam, in exact registry with but opposite to the piece. The electron welding beam is supplied with adequate energy for penetrating through the plate, across the interface, and into the piece, whereby the electron welding beam produces molten material from both the plate and the piece in the region of the interface. The molten material flows into any interstices that may exist in the interface, and upon cooling solidifies to provide a welded joint between the plate and piece, where the interface was, virtually without any interstices. The heat sink material prevents the molten material from extrucing beyond what was the interface, to provide a clean welded joint. The heat sink body also mechanically holds the plate and piece together prior to the actual welding.

  12. Method of beam welding metallic parts together and apparatus for doing same

    DOEpatents

    Lewandowski, Edward F.; Cassidy, Dale A.; Sommer, Robert G.

    1987-01-01

    The disclosed method provides for temporarily clamping a metallic piece to one side of a metallic plate while leaving the opposite side of the plate exposed, and providing a heat conductive heat sink body configured to engage the adjacent portions of such one side of the plate and the piece at all regions proximate to but not at the interface between these components. Such exposed side of such plate is then subjected to an electron welding beam, in exact registry with but opposite to the piece. The electron welding beam is supplied with adequate energy for penetrating through the plate, across the interface, and into the piece, whereby the electron welding beam produces molten material from both the plate and the piece in the region of the interface. The molten material flows into any interstices that may exist in the interface, and upon cooling solidifies to provide a welded joint between the plate and piece, where the interface was, virtually without any interstices. The heat sink material prevents the molten material from extruding beyond what was the interface, to provide a clean welded joint. The heat sink body also mechanically holds the plate and piece together prior to the actual welding.

  13. Interactions of fibroblasts with soldered and laser-welded joints.

    PubMed

    Solmi, R; Martini, D; Zanarini, M; Isaza Penco, S; Rimondini, L; Carinci, P; Borea, G; Ruggeri, A

    2004-02-01

    Relatively little is known about the biocompatibility of the soldered or laser-welded joints of dental appliances. We investigated the reaction of human gingival fibroblasts cultured in vitro in direct contact with samples of soldered and laser-welded joints from orthodontic lingual arches. Contrast phase light microscopy was used to evaluate cell adhesion, morphology and proliferation after 6 and 24h and after 7 and 16 days. Scanning electron microscopy (SEM) was performed at 16 days. Our in vitro findings provide evidence that laser-welded orthodontic appliances have superior fibroblast biocompatibility.

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

    SciTech Connect

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

    2010-07-15

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

  15. Residual stress distribution depending on welding sequence in multi-pass welded joints with x-shaped groove

    SciTech Connect

    Mochizuki, Masahito; Hayashi, Makoto; Hattori, Toshio

    2000-02-01

    Residual stress in a large-diameter multi-pass butt-welded pipe joint was calculated for various welding pass sequences by thermal elastic-plastic analysis using the finite element method. The pipe joint used had an X-shaped groove, and the sequences of welding passes were changed. The distribution of residual stress depends on the welding pass sequences. The mechanism that produces residual stress in the welded pipe joint was studied in detail by using a simple prediction model. An optimum welding sequence for preventing stress-corrosion cracking was determined from the residual stress distribution.

  16. Spatter Formation in Laser Welding with Beam Oscillation

    NASA Astrophysics Data System (ADS)

    Schweier, M.; Heins, J. F.; Haubold, M. W.; Zaeh, M. F.

    The investigation presented in this paper aims on a quantitative analysis of spatter formation in laser beam welding with superposed beam oscillation. After a discussion of design space limitations, which result from the scanner dynamics and theoretical considerations on the welding process itself, an optimal experimental design is created. By the use of high speed camera imaging, spatters were captured during statistically designed welding experiments and correlations between the number of spatters and the welding parameters have been derived. To evaluate the spatter characteristics in the high speed videos, a state space approach was applied, which is based on automated image data processing.

  17. Effect of Post-Welding Heat Treatment on Mechanical Properties of Joints of Steel P92 Formed by Submerged Arc Welding

    NASA Astrophysics Data System (ADS)

    Mohyla, P.; Foldynová, K.

    2014-07-01

    Results of mechanical tests and metallographic studies of welded joints of steel P92 obtained by submerged arc welding are presented. The effect of the post-welding heat treatment on the mechanical properties of the welds is described.

  18. Diffractive beam shaping for enhanced laser polymer welding

    NASA Astrophysics Data System (ADS)

    Rauschenberger, J.; Vogler, D.; Raab, C.; Gubler, U.

    2015-03-01

    Laser welding of polymers increasingly finds application in a large number of industries such as medical technology, automotive, consumer electronics, textiles or packaging. More and more, it replaces other welding technologies for polymers, e. g. hot-plate, vibration or ultrasonic welding. At the same rate, demands on the quality of the weld, the flexibility of the production system and on processing speed have increased. Traditionally, diode lasers were employed for plastic welding with flat-top beam profiles. With the advent of fiber lasers with excellent beam quality, the possibility to modify and optimize the beam profile by beam-shaping elements has opened. Diffractive optical elements (DOE) can play a crucial role in optimizing the laser intensity profile towards the optimal M-shape beam for enhanced weld seam quality. We present results on significantly improved weld seam width constancy and enlarged process windows compared to Gaussian or flat-top beam profiles. Configurations in which the laser beam diameter and shape can be adapted and optimized without changing or aligning the laser, fiber-optic cable or optical head are shown.

  19. GTAW penetration based on electrode tip location versus weld joint center line. [Gas Tungsten Arc Welding (GTAW)

    SciTech Connect

    Daumeyer, G.J. III.

    1992-11-01

    Gas Tungsten Arc Welding (GTAW) is often the chosen process for final enclosure welds of heat sensitive electrical and electronic product. GTAW is used to produce welds that satisfy design requirements (usually a penetration requirement) and not expose the product to such high heat that would cause unwanted damage. An important variable in the GTAW process is the location of the Electrode tip over the weld joint center line. This study shows the tolerance of positional location over a narrow scope. Using coupons which represent the W88 container weld joint geometry, penetration vs. electrode tip positional location (offset) is investigated. Results indicate a positional location tolerance of [plus minus] 0.008 in. is acceptable. Several different major components (MCS) supporting various weapons programs require low heat input GTA welds. The electrode tip positional location tolerance is determined by each MC's weld joint tolerances and heat sensitivity. For this short study, the weld joint geometry of a container weld was used. These coupons were welded with the specified weld schedule and one additional weld schedule in order to show the relationship based on both travel speed and gap. Multiple coupon welds were made to eliminate error in the results. Within the scope of this research, a positional tolerance of [plus minus] 0.008 in. of the electrode center over the weld joint center is required. For other MCs this tolerance may be tighter or more relaxed depending upon the specific considerations.

  20. Portable power tool machines weld joints in field

    NASA Technical Reports Server (NTRS)

    Spier, R. A.

    1966-01-01

    Portable routing machine for cutting precise weld joints required by nonstandard pipe sections used in the field for transfer of cryogenic fluids. This tool is adaptable for various sizes of pipes and has a selection of router bits for different joint configurations.

  1. Strength of Welded Joints in Tubular Members for Aircraft

    NASA Technical Reports Server (NTRS)

    Whittemore, H L; Brueggeman, W C

    1931-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-12-01

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

  3. Weld-Bead Shaver

    NASA Technical Reports Server (NTRS)

    Guirguis, Kamal; Price, Daniel S.

    1990-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1993-01-01

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

  5. [The effects of different welding wires on the mechanical properties of laser welding joints].

    PubMed

    Huang, Qing-feng; Zhang, Jian-zhong; Jiang, Wei-dong; Li, Quan; Yu, Jin-xing

    2006-08-01

    To evaluate the mechanical properties and microstructure of laser-welded joints with different welding wires for clinical use of welding wire. The standard tensile test and three-point bending test rods were made from Co-Cr and Ni-Cr alloy, and were laser-welded with different welding wire (commercially welding wire and casting wire). Then the tensile rods were tested for the ultimate tensile strength (UTS), and the bending rods for the ultimate bending strength (UBS). The results was analyzed by one-way ANOVA. The tensile fracture surface were examined by scanning electron microscopy (SEM). Metallurgical analysis were also performed on polished longitudinal sectioned samples. For Co-Cr alloy, the UTS of casting wire group and commercially welding wire group was respectively (606.40+/-82.53)MPa and (693.61+/-47.68)MPa; the UBS was respectively (997.95+/-88.89)MPa and (1160.76+/-91.59)MPa. ANOVA showed a significant difference of UTS and UBS between the two groups at the 0.05 level (P<0.05). For Ni-Cr alloy, the UTS of casting wire group and commercially welding wire group was respectively (558.14+/-46.75)MPa and (582.32+/-35.43)MPa; the UBS was respectively (1084.75+/-46.02)MPa and (1078.29+/-36.25)MPa. There was no significant difference between the two groups (P>0.05). SEM and metallurgical examination showed the welded zone exhibiting more cracks in the casting wire group than in the commercially welding wire group. It would be advisable to work with commercially welding wire for the joints that need better strength.

  6. Microfissuring in Electron-Beam-Welded Nickel Alloy

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr

    1985-01-01

    Mathematical model developed for microfissuring of commercial nickel alloy during electron-beam welding. Number of measured microfissures per unit length of weld plotted against excess power calculated by computer model. Excess power that above level likely to produce microfissures. In agreement with model, measured microfissures increase at rate of 4.5 per inch (1.8 per centimeter) per excess kilowatt.

  7. Solder joint failure localization of welded joint based on acoustic emission beamforming.

    PubMed

    Liu, Xiandong; Xiao, Denghong; Shan, Yingchun; Pan, Qiang; He, Tian; Gao, Yong

    2017-02-01

    A localization approach of welded joint damage is proposed based on acoustic emission (AE) beamforming. In this method, a uniform line array is introduced to detect the AE signal of welded joints in specified area. In order to investigate the influence of fillet and crimping commonly existing in a welded plate structure during the AE wave propagation process, the finite element method (FEM) is applied to simulate the behavior of AE wave in the specimen. The simulation localization results indicate that the proposed localization approach can effectively localize AE sources although there exist the fillet and crimping, and it is also validated by the pencil-lead-broken test on rectangular steel tube with welded joints. Finally, the proposed method is adopted to localize the failure of solder joint in operation vibration condition. The proposed method is successful to localize the compact AE source caused by the cracked joint based on wavelet packet transform.

  8. 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.

  9. Relaxation behavior of polyethylene welded joints

    NASA Astrophysics Data System (ADS)

    Demchenko, Valeriy; Iurzhenko, Maksym; Shadrin, Andriy; Galchun, Anatoliy

    2017-04-01

    The paper presents results of the investigation of structure relaxation and thermal properties of PE-80 and PE-100 polyethylene hot-tool butt welds. It was found that a weld with the re-crystallized crystalline structure is formed during the welding of dissimilar types of polyethylene. It is shown that within a long period (1 year) the relaxation occurs not only in amorphous but also in the crystalline phase (crystalline α-form transforms into mixed αβ-form), with respective changes in polyethylene properties.

  10. Quantitative metal magnetic memory reliability modeling for welded joints

    NASA Astrophysics Data System (ADS)

    Xing, Haiyan; Dang, Yongbin; Wang, Ben; Leng, Jiancheng

    2016-03-01

    Metal magnetic memory(MMM) testing has been widely used to detect welded joints. However, load levels, environmental magnetic field, and measurement noises make the MMM data dispersive and bring difficulty to quantitative evaluation. In order to promote the development of quantitative MMM reliability assessment, a new MMM model is presented for welded joints. Steel Q235 welded specimens are tested along the longitudinal and horizontal lines by TSC-2M-8 instrument in the tensile fatigue experiments. The X-ray testing is carried out synchronously to verify the MMM results. It is found that MMM testing can detect the hidden crack earlier than X-ray testing. Moreover, the MMM gradient vector sum K vs is sensitive to the damage degree, especially at early and hidden damage stages. Considering the dispersion of MMM data, the K vs statistical law is investigated, which shows that K vs obeys Gaussian distribution. So K vs is the suitable MMM parameter to establish reliability model of welded joints. At last, the original quantitative MMM reliability model is first presented based on the improved stress strength interference theory. It is shown that the reliability degree R gradually decreases with the decreasing of the residual life ratio T, and the maximal error between prediction reliability degree R 1 and verification reliability degree R 2 is 9.15%. This presented method provides a novel tool of reliability testing and evaluating in practical engineering for welded joints.

  11. The Effect of Welding Energy on the Microstructural and Mechanical Properties of Ultrasonic-Welded Copper Joints

    PubMed Central

    Yang, Jingwei; Cao, Biao; Lu, Qinghua

    2017-01-01

    The effects of welding energy on the mechanical and microstructural characteristics of ultrasonic-welded pure copper plates were investigated. Complex dynamic recrystallization and grain growth occurred inside the weld zone during ultrasonic welding. At a low welding energy, a thin band of straight weld interfaces was observed and had an ultra-fine grain structure. With an increase in welding energy, the weld interface progressively changed from flat to sinusoidal, and eventually turned into a convoluted wavy pattern, bearing similarities to shear instabilities, as observed in fluid dynamics. The lap shear load of the joints initially increased and then remained stable as the welding energy increased. The tensile characteristics of the joints significantly depended on the development of plastic deformation at the interface. The influence of the microstructure on the hardness was also discussed. PMID:28772553

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

  13. The electron beam welding of dissimilar materials - case study

    NASA Astrophysics Data System (ADS)

    Munteanu, A.

    2016-11-01

    The modalities to realize the welding workpieces are multiple. The electron beam welding is one of them. One can weld two different types of materials that give the possibility to reduce the cost of workpiece, if the active part is realised of rich materials welded on components with inferior phisico-mecanical characteristics. The procedure provides great flexibility to the product designs through efficient use of each type of material. So this aspects lead to the necessity to join dissimilar metals. Different tables are given in the specific literature regarding the possible combination. Conflicts may arise by the compromises required for to the optimum heat control of the two dissimilar materials used. But nowadays, more and more frequently are meet the welding of dissimilar metals, thus, the objective of this article is to provide information regarding the particular case of welding between stainless steel and copper without the filler material use.

  14. Design consideration for wet welded joints

    SciTech Connect

    Szelagowski, P.; Osthus, V.; Petershagen, H.; Pohl, R.; Lafaye, G.

    1996-12-01

    Wet welding has become a joining technique that under certain circumstances can provide results which cannot be distinguished between wet or dry production and the achievable mechanical quality is comparable to dry atmospheric welds. Wet welding is not a process which can be applied easily and which can be properly handled by untrained diver welders. Wet welding is more than any other kind of welding process or procedure a joining technique that requires the full job-concentration and -knowledge of an excellent trained and skilled diver welder throughout the whole production time, who is 100% identifying himself with his task. Furthermore he must be fully aware of the production requirements and possible metallurgical/environmental reactions and outcomes. He must be able to be fully concentrated on the process performance throughout his total work shift. In short: he must be an outstanding expert in his field. The following paper will highlight these subjects and show the necessity of their exact observation to achieve excellent quality in wet welding.

  15. Tensile strength of simulated and welded butt joints in W-Cu composite sheet

    NASA Technical Reports Server (NTRS)

    Moore, Thomas J.; Watson, Gordon K.

    1994-01-01

    The weldability of W-Cu composite sheet was investigated using simulated and welded joints. The welded joints were produced in a vacuum hot press. Tensile test results showed that simulated joints can provide strength and failure mode data which can be used in joint design for actual weldments. Although all of the welded joints had flaws, a number of these joints were as strong as the W-Cu composite base material.

  16. Selection of optimal welding condition for GTA pulse welding in root-pass of V-groove butt joint

    NASA Astrophysics Data System (ADS)

    Yun, Seok-Chul; Kim, Jae-Woong

    2010-12-01

    In the manufacture of high-quality welds or pipeline, a full-penetration weld has to be made along the weld joint. Therefore, root-pass welding is very important, and its conditions have to be selected carefully. In this study, an experimental method for the selection of optimal welding conditions is proposed for gas tungsten arc (GTA) pulse welding in the root pass which is done along the V-grooved butt-weld joint. This method uses response surface analysis in which the width and height of back bead are chosen as quality variables of the weld. The overall desirability function, which is the combined desirability function for the two quality variables, is used as the objective function to obtain the optimal welding conditions. In our experiments, the target values of back bead width and height are 4 mm and zero, respectively, for a V-grooved butt-weld joint of a 7-mm-thick steel plate. The optimal welding conditions could determine the back bead profile (bead width and height) as 4.012 mm and 0.02 mm. From a series of welding tests, it was revealed that a uniform and full-penetration weld bead can be obtained by adopting the optimal welding conditions determined according to the proposed method.

  17. Effect of soft root weld layer on fracture toughness of under-matched weld joints on Q+T steel

    SciTech Connect

    Rak, I.; Gliha, V.; Praunseis, Z.; Kocak, M.

    1996-12-01

    Welding of quenched and tempered (Q+T) high strength low alloyed steels can cause weld strength undermatching to satisfy the toughness requirements for the weld deposit. Cost of pre-heating of these steels can be saved if one can prove that use of soft electrodes for root passes do not endanger the overall quality of the joint. By welding of 40 mm thick Q+T structural steel (grade HT 80), over-matched condition had appeared in the root area of the X-groove weld despite of welding consumable which would give entire weld under-matched properties. This is the effect of weld metal alloying by elements from base material. So, the weld joint is not protected against cold cracking especially in the root region, therefore, a high preheating should be used to reduce the possibility of this phenomenon. In this work soft (lower strength) filler metal was used for first two and four root passes of X-joint. In this case root area was also alloyed by elements from base material and obtained mis-matching factor M was higher than it was expected. So, one homogeneous and two non homogeneous weld joints (with two and four soft passes) were considered. Mechanical properties of weld joints were measured by round tensile bars taken from different parts of the weld. The under-matching factor of weld joint with two and four soft root passes was around 0.80--0.90 in the soft root layer. It was expected that uneven strength distribution along the fatigue crack tip line would affect fracture initiation behavior of all three different weld joints. The metallographical post-test sectioning has revealed the initiation points mainly at the lowest weld metal strength.

  18. Laser beam welding of aluminum alloy 5754-O using a 3 kW Nd:YAG laser and fiber optic beam delivery

    SciTech Connect

    Martukanitz, R.P.; Altshuller, B.

    1996-12-31

    A program was conducted to evaluate laser beam welding of aluminum alloy 5754-O using a 3.0 kW Nd:YAG laser and fiber optic beam delivery. The alloy and laser system were chosen based on consideration for potential applications in the automotive industry. Process parameters were developed for producing autogenous, square-butt welds in 1.6 mm thickness. Metallographic analyses, mechanical property testing, and post weld formability testing were conducted to characterize joints produced under these conditions. Results of these evaluations indicate that the 3.0 kW Nd:YAG laser provides adequate power density and beam quality for welding of this thickness. Enhanced absorption associated with the Nd:YAG laser is believed to be responsible for improved stability of the weld pool and increased weld consistency. Results of tensile tests of the Nd:YAG laser beam welds provided over 90 percent of base metal strength and measurements of post process formability of the welds yielded approximately 70 percent of base metal formability.

  19. Analysis of continuous beams with joint slip

    Treesearch

    L. A. Soltis

    1981-01-01

    A computer analysis with user guidelines to analyze partially continuous multi-span beams is presented. Partial continuity is due to rotational slip which occurs at spliced joints at the supports of continuous beams such as floor joists. Beam properties, loads, and joint slip are input; internal forces, reactions, and deflections are output.

  20. Mechanical properties of a dissimilar aluminum alloy joint welded by hybrid laser-MIG welding

    NASA Astrophysics Data System (ADS)

    Wang, Qiuying; Chen, Hui; Zhu, Zongtao; Cui, Yunlong

    2017-07-01

    Two dissimilar Al alloys, 5083-H111 and 6005A-T6, were joined by hybrid laser-MIG welding method. Mechanical properties of the welded joint were investigated and compared. The results show that the tensile strength of the dissimilar joint is 219.8 MPa, 11.7% higher than that of 6005A-T5 joint. After statistical analysis of the fatigue data, the P-S-N curves of the dissimilar joint were obtained. The mean fatigue strength at Nf = 107 of the dissimilar joint is 112.5 MPa. The fatigue strength at Nf = 107 of the dissimilar joint for a given 10% probability of failure, at a confidence level of 95%, is 101.4 MPa. The fatigue strength at Nf = 107 of the dissimilar joint is almost same as that of the 6005A-T6 joint. In welded structure designing, different P-S-N curves should be chosen according to the different service conditions and reliability requirements.

  1. Mechanical Properties of Laser Beam Welded Ultra-high Strength Chromium Steel with Martensitic Microstructure

    NASA Astrophysics Data System (ADS)

    Dahmen, Martin; Janzen, Vitalij; Lindner, Stefan; Wagener, Rainer

    A new class of steels is going to be introduced into sheet manufacturing. Stainless ferritic and martensitic steels open up opportunities for sheet metal fabrication including hot stamping. A strength of up to 2 GPa at a fracture strain of 15% can be attained. Welding of these materials became apparently a challenge. Energy-reduced welding methods with in-situ heat treatment are required in order to ensure the delicate and complex heat control. Laser beam welding is the joining technique of choice to supply minimum heat input to the fusion process and to apply an efficient heat control. For two application cases, production of tailored blanks in as-rolled condition and welding in assembly in hot stamped conditions, welding processes have been developed. The welding suitability is shown in metallurgical investigations of the welds. Crash tests based on the KSII concept as well as fatigue tests prove the applicability of the joining method. For the case of assembly also joining with deep drawing and manganese boron steel was taken into consideration. The strength of the joint is determined by the weaker partner but can benefit from its ductility.

  2. Effect of welding method on joint strength of laser-welded gold alloy.

    PubMed

    Watanabe, Ikuya; Liu, Jie; Atsuta, Mitsuru; Okabe, Toru

    2003-08-01

    To examine the effect of welding method and heat treatment on the strength of laser-welded gold alloy with age-hardenability at intraoral temperature. Cast gold alloy plates (0.5 x 3.0 x 20 mm3) were prepared and cut perpendicular to the 3.0 mm surface of the plate. After the cut halves were fixed in a jig, they were laser-welded using a Nd: YAG laser. Three laser pulses were applied from one side (single-welded) or both sides (double-welded) to weld the entire joint width of the specimens. Three different heat treatments were given the specimens: solution treatment at 700 degrees C for 5 minute (ST), aging at 250 degrees C for 15 minute after ST (HA), and aging at 37 degrees C for 3 day after ST (IA). As-cast specimens were also reserved. Uncut specimens served as non-welded control specimens. Tensile testing was conducted at a crosshead speed of 2 mm/minute and a gauge length of 10 mm. The breaking stress (Bs: MPa) was recorded, and the data (n = 5 per group) were statistically analyzed. In the control groups, the Bs values of the IA were not significantly different (P > 0.05) from those of the HA specimens. The laser-welded IA specimens showed significantly greater (P < 0.05) Bs values compared to the solution-treated and as-cast specimens. The double-welded specimens showed significantly greater Bs values compared to the single-welded specimens after any heat treatment.

  3. Underwater cladding with laser beam and plasma arc welding

    SciTech Connect

    White, R.A.; Fusaro, R.; Jones, M.G.; Solomon, H.D.; Milian-Rodriguez, R.R.

    1997-01-01

    Two welding processes, plasma arc (transferred arc) (PTA) and laser beam, were investigated to apply cladding to austenitic stainless steels and Inconel 600. These processes have long been used to apply cladding layers , but the novel feature being reported here is that these cladding layers were applied underwater, with a water pressure equivalent to 24 m (80 ft). Being able to apply the cladding underwater is very important for many applications, including the construction of off-shore oil platforms and the repair of nuclear reactors. In the latter case, being able to weld underwater eliminates the need for draining the reactor and removing the fuel. Welding underwater in reactors presents numerous challenges, but the ability to weld without having to drain the reactor and remove the fuel provides a huge cost savings. Welding underwater in reactors must be done remotely, but because of the radioactive corrosion products and neutron activation of the steels, remote welding would also be required even if the reactor is drained and the fuel removed. In fact, without the shielding of the water, the remote welding required if the reactor is drained might be even more difficult than that required with underwater welds. Furthermore, as shall be shown, the underwater welds that the authors have made were of high quality and exhibit compressive rather than tensile residual stresses.

  4. Thermoacoustic method for relaxation of residual stresses in welded joints

    SciTech Connect

    Koshovyi, V.V.; Pakhn`o, M.I.; Tsykhan, O.I.

    1995-01-01

    We propose a thermoacoustic method for the relaxation of residual stresses in welded joints, present a block diagram of a generator of local thermoacoustic pulses designed for implementation of this method, and describe our experiment aimed at relaxation of residual tensile stresses.

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

    NASA Astrophysics Data System (ADS)

    Kolubaev, E. A.

    2015-02-01

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

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

    SciTech Connect

    Elangovan, K.; Balasubramanian, V.

    2008-09-15

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

  7. First samples of Ti and Nb tubes explosion welding joint with stainless steel for ILC 1.8 K cryomodule

    NASA Astrophysics Data System (ADS)

    Sabirov, B. M.; Budagov, J. A.; Shirkov, G. D.

    2013-07-01

    The world first samples of Ti and Nb tubes joint with stainless steel ones by an explosion welding by the JINR-VNIIEF-FNAL-INFN cooperation were manufactured in the frame of ILC R&D programe. An applying methods of relaxation of residual tensions (after explosion and electron beam welding), macro- and microanalyses of welding seam and cryogenic tests of the samples produced manifest the achievement of high mechanic strength (≈250 MPa/share) of welding seam, solidity and leak absence on 10-10 l atm/s level at 1.8 K. The explosion welding technology and methods introducing to industrial manufacturing of the 4-th generation of cryomodule of TESLA TYPE DESIGN can exclude the Ti—communications, connect the Nb—cavity with stainless steel vessel and reduce significantly the accelerator cost.

  8. Influence of control parameters on the joint tracking performance of a coaxial weld vision system

    NASA Technical Reports Server (NTRS)

    Gangl, K. J.; Weeks, J. L.

    1985-01-01

    The first phase of a series of evaluations of a vision-based welding control sensor for the Space Shuttle Main Engine Robotic Welding System is described. The robotic welding system is presently under development at the Marshall Space Flight Center. This evaluation determines the standard control response parameters necessary for proper trajectory of the welding torch along the joint.

  9. Virtual Welded-Joint Design Integrating Advanced Materials and Processing Technologies

    SciTech Connect

    Yang, Z.; Dong, P.; Liu, S.; Babu, S.; Olson, G.; DebRoy, T.

    2005-04-15

    The primary goal of this project is to increase the fatigue life of a welded-joint by 10 times and to reduce energy use by 25% through product performance and productivity improvements using an integrated modeling approach. The fatigue strength of a welded-joint is currently the bottleneck to design high performance and lightweight welded structures using advanced materials such as high strength steels. In order to achieve high fatigue strength in a welded-joint it is necessary to manage the weld bead shape for lower stress concentration, produce preferable residual stress distribution, and obtain the desired microstructure for improved material toughness and strength. This is a systems challenge that requires the optimization of the welding process, the welding consumable, the base material, as well as the structure design. The concept of virtual welded-joint design has been proposed and established in this project. The goal of virtual welded-joint design is to develop a thorough procedure to predict the relationship of welding process, microstructure, property, residual stress, and the ultimate weld fatigue strength by a systematic modeling approach. The systematic approach combines five sub-models: weld thermal-fluid model, weld microstructure model, weld material property model, weld residual stress model, and weld fatigue model. The systematic approach is thus based on interdisciplinary applied sciences including heat transfer, computational fluid dynamics, materials science, engineering mechanics, and material fracture mechanics. The sub-models are based on existing models with further development. The results from modeling have been validated with critical experiments. The systematic modeling approach has been used to design high fatigue resistant welds considering the combined effects of weld bead geometry, residual stress, microstructure, and material property. In particular, a special welding wire has been developed in this project to introduce

  10. Nuclear Technology. Course 28: Welding Inspection. Module 28-4, Weld Joint Verification.

    ERIC Educational Resources Information Center

    Espy, John

    This fourth in a series of ten modules for a course titled Welding Inspection discusses the nomenclature, symbols, and the purposes of most common joint designs, preparations, and fit-ups. The module follows a typical format that includes the following sections: (1) introduction, (2) module prerequisites, (3) objectives, (4) notes to…

  11. Mechanical characteristics of welded joints between different stainless steels grades

    NASA Astrophysics Data System (ADS)

    Topolska, S.; Łabanowski, J.

    2017-08-01

    Investigation of mechanical characteristics of welded joints is one of the most important tasks that allow determining their functional properties. Due to the very high, still rising, cost of some stainless steels it is justified, on economic grounds, welding austenitic stainless steel with steels that are corrosion-resistant like duplex ones. According to forecasts the price of corrosion resistant steels stil can increase by 26 ÷ 30%. For technical reasons welded joints require appropriate mechanical properties such as: tensile strength, bending, ductility, toughness, and resistance to aggressive media. Such joints are applied in the construction of chemical tankers, apparatus and chemical plants and power steam stations. Using the proper binder makes possible the welds directly between the elements of austenitic stainless steels and duplex ones. It causes that such joits behave satisfactorily in service in such areas like maritime constructions and steam and chemical plants. These steels have high mechanical properties such as: the yield strength, the tensile strength and the ductility as well as the resistance to general corrosion media. They are resistant to both pitting and stress corrosions. The relatively low cost of production of duplex steels, in comparison with standard austenitic steels, is inter alia, the result of a reduced amount of scarce and expensive Nickel, which is seen as a further advantage of these steels.

  12. Automated thresholding in radiographic image for welded joints

    NASA Astrophysics Data System (ADS)

    Yazid, Haniza; Arof, Hamzah; Yazid, Hafizal

    2012-03-01

    Automated detection of welding defects in radiographic images becomes non-trivial when uneven illumination, contrast and noise are present. In this paper, a new surface thresholding method is introduced to detect defects in radiographic images of welding joints. In the first stage, several image processing techniques namely fuzzy c means clustering, region filling, mean filtering, edge detection, Otsu's thresholding and morphological operations method are utilised to locate the area in which defects might exist. This is followed by the implementation of inverse surface thresholding with partial differential equation to locate isolated areas that represent the defects in the second stage. The proposed method obtained a promising result with high precision.

  13. Control system architecture for robotic welding of tubular joints

    SciTech Connect

    Madsen, O.; Holm, H.; Lauridsen, J.K.

    1996-12-31

    This paper presents the architecture of a geometry model and sensor based control system for robotic welding of tubular joints. The functional architecture of the system is described with the main emphasis on the overall mode of operation of the system. Furthermore, it is described how measurements of the physical seam profile are used to update a reference geometry model, and how welding control variables are generated based on the updated reference geometry. Finally, it is illustrated how the use of a reference geometry can improve the flexibility and robustness of the system.

  14. GTAW penetration based on electrode tip location versus weld joint center line

    SciTech Connect

    Daumeyer, G.J. III

    1992-11-01

    Gas Tungsten Arc Welding (GTAW) is often the chosen process for final enclosure welds of heat sensitive electrical and electronic product. GTAW is used to produce welds that satisfy design requirements (usually a penetration requirement) and not expose the product to such high heat that would cause unwanted damage. An important variable in the GTAW process is the location of the Electrode tip over the weld joint center line. This study shows the tolerance of positional location over a narrow scope. Using coupons which represent the W88 container weld joint geometry, penetration vs. electrode tip positional location (offset) is investigated. Results indicate a positional location tolerance of {plus_minus} 0.008 in. is acceptable. Several different major components (MCS) supporting various weapons programs require low heat input GTA welds. The electrode tip positional location tolerance is determined by each MC`s weld joint tolerances and heat sensitivity. For this short study, the weld joint geometry of a container weld was used. These coupons were welded with the specified weld schedule and one additional weld schedule in order to show the relationship based on both travel speed and gap. Multiple coupon welds were made to eliminate error in the results. Within the scope of this research, a positional tolerance of {plus_minus} 0.008 in. of the electrode center over the weld joint center is required. For other MCs this tolerance may be tighter or more relaxed depending upon the specific considerations.

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

    PubMed

    Villegas, Irene F; Palardy, Genevieve

    2016-02-11

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

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

    NASA Astrophysics Data System (ADS)

    Shoja Razavi, Reza

    2016-08-01

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

  17. Residual stress in laser welded dissimilar steel tube-to-tube joints

    SciTech Connect

    Sun, Zheng . Lab. of Production Engineering)

    1993-09-01

    Austenitic-ferritic dissimilar steel joints are widely used in power generation systems. Their utilization has proved to be efficient in terms of satisfactory properties and the economics. These types of joints have usually been produced using conventional welding processes, such as tungsten inert gas (TIG) welding. With the rapid development of high power lasers, laser welding has received considerable attention. Laser welding offers many advantages over conventional welding processes, e.g. low heat input, small heat-affected zone (HAZ), small distortion, and welding in an exact and reproducible manner. Residual stress distribution in laser welds may also differ from those made by conventional welding processes due to its special features. Residual stress, particularly tensile residual stress in the weld, can be very important factor in controlling the quality and service life of the welded structure. The formation of tensile residual stress in the weld may result in the initiation of fatigue cracking, stress corrosion cracking or other types of fractures. It is useful, therefore, to understand the distribution of residual stress in austenitic-ferritic laser welds, and thus evaluate the quality of the joints. Although residual stress distribution in the welded joints has been extensively investigated, little data are available for the residual stress distribution in laser welds. The aim of the work was to examine residual stress distribution along laser welds of dissimilar steel tube-to-tube joints, which were made by both autogeneous welding and welding with filler wire. The results were also compared with the joints made by plasma arc and TIG welding.

  18. A Study of Microstructure and Mechanical Properties of Thick Welded Joints of a Cr - Mo Steel

    NASA Astrophysics Data System (ADS)

    Lee, I. Kon; Chien, Yi Cheng

    2015-07-01

    The effect of stress-relieving tempering on the mechanical properties of a welded joint of a high-strength low-alloy steel SAE 4130 (0.3% C - 1% Cr - 0.25% Mo) obtained by multipass arc welding with nonconsumable electrode is studied. The steel is quenched and tempered before the welding. An optimum tempering mode providing a good combination of the characteristics of strength, ductility and toughness of the welded joint is suggested.

  19. Particulate electron beam weld emission hazards in space

    NASA Technical Reports Server (NTRS)

    Bunton, Patrick H.

    1996-01-01

    The electron-beam welding process is well adapted to function in the environment of space. The Soviets were the first to demonstrate welding in space in the mid-1980's. Under the auspices of the International Space Welding Experiment (ISWE), an on-orbit test of a Ukrainian designed electron-beam welder (the Universal Hand Tool or 'UHT') is scheduled for October of 1997. The potential for sustained presence in space with the development of the international space station raises the possibility of the need for construction and repair in space. While welding is not scheduled to be used in the assembly of the space station, repair of damage from orbiting debris or meteorites is a potential need. Furthermore, safe and successful welding in the space environment may open new avenues for design and construction. The safety issue has been raised with regard to hot particle emissions (spatter) sometimes observed from the weld during operations. On earth the hot particles pose no particular hazard, but in space there exists the possibility for burn-through of the space suit which could be potentially lethal. Contamination of the payload bay by emitted particles could also be a problem.

  20. Microstructure and Failure Analysis of Flash Butt Welded HSLA 590CL Steel Joints in Wheel Rims

    NASA Astrophysics Data System (ADS)

    Lu, Ping; Xu, Zhixin; Shu, Yang; Ma, Feng

    2016-11-01

    The aim of the present investigation was to evaluate the microstructures, mechanical properties and failure behavior of flash butt welded high strength low alloy 590CL steel joints. Acicular ferrite, Widmanstatten ferrite and granular bainite were observed in the weld. The micro-hardness values of the welded joints varied between 250 HV and 310 HV. The tensile strength of the welded joints met the strength standard of the wheel steel. The Charpy V-notch impact absorbing energy of the welded joints was higher than the base metal, and the impact fracture of the welded joints was composed of shearing and equiaxed dimples. The fracture mode of the wheel rim in the flaring and expanding process was brittle fracture and ductile fracture, respectively. A limited deviation was found in the terminal of the crack for the wheel in the flaring process. A transition from the weld to the Heat Affected Zone was observed for the wheel in the expanding process.

  1. Microstructure and Failure Analysis of Flash Butt Welded HSLA 590CL Steel Joints in Wheel Rims

    NASA Astrophysics Data System (ADS)

    Lu, Ping; Xu, Zhixin; Shu, Yang; Ma, Feng

    2017-02-01

    The aim of the present investigation was to evaluate the microstructures, mechanical properties and failure behavior of flash butt welded high strength low alloy 590CL steel joints. Acicular ferrite, Widmanstatten ferrite and granular bainite were observed in the weld. The micro-hardness values of the welded joints varied between 250 HV and 310 HV. The tensile strength of the welded joints met the strength standard of the wheel steel. The Charpy V-notch impact absorbing energy of the welded joints was higher than the base metal, and the impact fracture of the welded joints was composed of shearing and equiaxed dimples. The fracture mode of the wheel rim in the flaring and expanding process was brittle fracture and ductile fracture, respectively. A limited deviation was found in the terminal of the crack for the wheel in the flaring process. A transition from the weld to the Heat Affected Zone was observed for the wheel in the expanding process.

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

    SciTech Connect

    Elmer, J W

    2009-01-23

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

  3. Structure of Ti-6Al-4V nanostructured titanium alloy joint obtained by resistance spot welding

    SciTech Connect

    Klimenov, V. A.; Kurgan, K. A.; Chumaevskii, A. V.; Gnyusov, S. F.

    2016-01-15

    The structure of weld joints of the titanium alloy Ti-6Al-4V in the initial ultrafine-grained state, obtained by resistance spot welding, is studied using the optical and scanning electron microscopy method and the X-ray structure analysis. The carried out studies show the relationship of the metal structure in the weld zone with main joint zones. The structure in the core zone and the heat affected zone is represented by finely dispersed grains of needle-shaped martensite, differently oriented in these zones. The change in the microhardness in the longitudinal section of the weld joint clearly correlates with structural changes during welding.

  4. Microstructure and Hardness Profiles of Bifocal Laser-Welded DP-HSLA Steel Overlap Joints

    NASA Astrophysics Data System (ADS)

    Grajcar, A.; Matter, P.; Stano, S.; Wilk, Z.; Różański, M.

    2017-04-01

    The article presents results related to the bifocal laser welding of overlap joints made of HSLA and DP high-strength steels. The joints were made using a disk laser and a head enabling the 50-50% distribution of laser power. The effects of the laser welding rates and the distance between laser spots on morphological features and hardness profiles were analyzed. It was established that the positioning of beams at angles of 0° or 90° determined the hardness of the individual zones of the joints, without causing significant differences in microstructures of the steels. Microstructural features were inspected using scanning electron microscopy. Both steels revealed primarily martensitic-bainitic microstructures in the fusion zone and in the heat-affected zone. Mixed multiphase microstructures were revealed in the inter-critical heat-affected zone of the joint. The research involved the determination of parameters making it possible to reduce the hardness of joints and prevent the formation of the soft zone in the dual-phase steel.

  5. Microstructure and Hardness Profiles of Bifocal Laser-Welded DP-HSLA Steel Overlap Joints

    NASA Astrophysics Data System (ADS)

    Grajcar, A.; Matter, P.; Stano, S.; Wilk, Z.; Różański, M.

    2017-03-01

    The article presents results related to the bifocal laser welding of overlap joints made of HSLA and DP high-strength steels. The joints were made using a disk laser and a head enabling the 50-50% distribution of laser power. The effects of the laser welding rates and the distance between laser spots on morphological features and hardness profiles were analyzed. It was established that the positioning of beams at angles of 0° or 90° determined the hardness of the individual zones of the joints, without causing significant differences in microstructures of the steels. Microstructural features were inspected using scanning electron microscopy. Both steels revealed primarily martensitic-bainitic microstructures in the fusion zone and in the heat-affected zone. Mixed multiphase microstructures were revealed in the inter-critical heat-affected zone of the joint. The research involved the determination of parameters making it possible to reduce the hardness of joints and prevent the formation of the soft zone in the dual-phase steel.

  6. Potential for Fabric Damage by Welding Electron Beam

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.; Nunes, Arthur C., Jr.

    1998-01-01

    Welding electron beam effects on Nextel AF-62 ceramic fabric enable a preliminary, tentative interpretation of electron beam fabric damage. Static surface charging does not protect fabric from beam penetration, but penetration occurs only after a delay time. The delay time is thought to be that required for the buildup of outgassing products at the fabric surface to a point where arcing occurs. Extra long delays are noted when the gun is close enough to the surface to be shut off by outgassing emissions. Penetration at long distances is limited by beam attenuation from electronic collisions with the chamber atmosphere.

  7. Filler-wire positioner for electron beam welding

    NASA Technical Reports Server (NTRS)

    Beaupre, W. M.; Fueg, L. B.; Phillips, J. A.

    1970-01-01

    Miniaturized positioner is installed in any electron beam vacuum chamber for use with wire feed applications requiring filler wire. Horizontal and vertical control of the positioner is maintained from a console while chamber is under vacuum. Device permits more positive positioning of welding filler wire.

  8. Investigation on edge joints of Inconel 625 sheets processed with laser welding

    NASA Astrophysics Data System (ADS)

    Caiazzo, F.; Alfieri, V.; Cardaropoli, F.; Sergi, V.

    2017-08-01

    Laser welding of Inconel 625 edge joint beads in square groove configuration was investigated. The use of different weld geometries in new aerospace solutions explains research on edge joints. A structured plan was carried out in order to characterize the process defining the influence of laser power and welding speed and to study possible interactions among the governing factors. As weld pool protection is crucial in order to obtain sound joints when processing superalloys, a special glove box for gas supply was designed to upgrade the welding head. Welded joints were characterized referring to bead profile, microstructure and X-rays. It was found that heat input plays an important role as it affects welding stability, porosity content and bead shape. Results suggest operating with low values of heat input to reduce porosity and guarantee stable bead conformation. Furthermore, a decrease in the grain size has been observed as a consequence of decreasing heat input.

  9. Tensile Properties of Under-Matched Weld Joints for 950 MPa Steel.

    NASA Astrophysics Data System (ADS)

    Yamamoto, Kouji; Arakawa, Toshiaki; Akazawa, Nobuki; Yamamoto, Kousei; Matsuo, Hiroki; Nakagara, Kiyoyuki; Suita, Yoshikazu

    In welding of 950 MPa-class high tensile strength steel, preheating is crucial in order to avoid cold cracks, which, however, eventually increases welding deformations. One way to decrease welding deformations is lowering preheating temperature by using under-matched weld metal. Toyota and others clarify that although breaking elongation can decrease due to plastic constraint effect under certain conditions, static tensile of under-matched weld joints is comparable to that of base metal. However, there has still been no report about joint static tensile of under-matched weld joints applied to 950 MPa-class high tensile strength steel. In this study, we aim to research tensile strength and fatigue strength of under-matched weld joints applied to 950 MPa-class high tensile steel.

  10. Choice of Heat Treatment Regimes for Welded Joints of Preliminarily Mechanically Hardened Steels

    NASA Astrophysics Data System (ADS)

    Mazukhina, E. A.; Priymak, E. Yu.; Gryzunov, V. I.; Firsova, N. V.

    2015-05-01

    Results of an evaluation of the possibility of the use of electrically welded cold-drawn pipe billets from steels 09GSF and 22GYu for making drill pipes with welded-on tool joint are presented. The structure and properties of friction-welded joints are studied in the initial condition and after annealing. The effect of the annealing on the strength characteristics of the joints is considered. The results of the study are used to recommend the steel for the production of a pilot batch of drill pipes with welded-on tool joints and field testing.

  11. Metallurgy and deformation of electron beam welded similar titanium alloys

    NASA Astrophysics Data System (ADS)

    Pasang, T.; Sabol, J. C.; Misiolek, W. Z.; Mitchell, R.; Short, A. B.; Littlefair, G.

    2012-04-01

    Butt welded joins were produced between commercially pure titanium and various titanium alloys using an electron beam welding technique. The materials used represent commercially pure grade, α-β alloy and β alloy. They were CP Ti, Ti-6Al-4V (Ti64) and Ti-5Al-5V-5Mo-3Cr (Ti5553), respectively. Grains were largest in the FZs of the different weldments, decreasing in size towards the heat affected zones (HAZs) and base metals. Hardness measurements taken across the traverse cross-sections of the weldments were constant from base metal-to-weld-to-base metal for CP Ti/CP Ti and Ti64/Ti64 welds, while the FZ of Ti5553/Ti5553 had a lower hardness compared with the base metal. During tensile testing the CP Ti/CP Ti weldments fractured at the base metal, whereas both the Ti64/Ti64 and Ti5553/Ti5553 broke at the weld zones. Fracture surface analysis suggested microvoid coalescence as the failure mechanism. The compositional analysis showed a relatively uniform distribution of solute elements from base metal-to-weld-to-base metal. CP Ti has always been known for its excellent weldability, Ti64 has good weldability and, preliminary results indicated that Ti5553 alloy is also weldable.

  12. Approach for laser beam welding under hyperbaric conditions

    SciTech Connect

    Franz, T.; Schubert, E.; Sepold, G.

    1995-12-31

    A new approach for welding under hyperbaric conditions can be the application of laser beams. Welding experiments have been performed with CVO{sub 2} and Nd:YAG lasers at elevated pressures. Deep penetration welding with CO{sub 2} laser radiation ({lambda} = 10,6 {micro}m) is not possible at elevated pressure, since the appearing metal vapor plume shields the surface. The results of trials done with a Nd:YAG laser ({lambda} = 1,06 {micro}m) show that it is possible to perform deep penetration welding up to an overpressure of 2 to 3 bar today. At higher pressures heat conduction welding can be performed. This pressure level can be extended by influencing the metal vapor plume. Nd:YAG laser radiation can be transmitted through optical fibers and therefore easily be guided below sea level. This has led to the development of a mobile Nd:YAG laser system which consists of a containerized Nd:YAG laser source, a fiber for beam transmission and a working head which is capable to be remotely controlled and operated at a pressure of up to 10 bar.

  13. Development of a high power electron beam welding gun with replaceable high voltage feed-through insulators

    SciTech Connect

    Saha, T.K; Mascarenhas, M.; Kandaswamy, E.

    2014-07-01

    Ceramic to metal sealed feed-through insulators are commonly used in electron beam welding gun. The above feed-through insulators are susceptible to failure, as the brazing joints in them are not always very strong. Failure in one of these feed-through could render the complete gun unusable. This problem has already been faced in BARC, which led to the development of the electron gun with replaceable feed through insulators. A 24 kW Electron Beam Welding (EBW) gun with indigenous designed replaceable insulators is fabricated in BARC. Emphasis during the design of the gun had been to reduce the use of imported components to zero. This paper describes the design and fabrication of this gun and reports various simulations and tests performed. Beam trajectory of the gun is numerically computed and presented. Weld passes were carried out on stainless steel plates show satisfactory penetrations. (author)

  14. Development of laser beam welding transverse-varestraint test for assessment of solidification cracking susceptibility in laser welds

    NASA Astrophysics Data System (ADS)

    Chun, Eun-Joon; Baba, Hayato; Nishimoto, Kazutoshi; Saida, Kazuyoshi

    2015-05-01

    In order to quantitatively evaluate the solidification cracking susceptibility in laser welds of type 310S stainless steel, a transverse-Varestraint testing system using a laser beam welding apparatus was newly constructed. The timing-synchronization between the laser oscillator, welding robot and hydraulic pressure devices was established by employing high-speed camera observations together with electrical signal control among the three components. Moreover, the yoke-drop time measured by the camera was used to prevent underestimation of the crack length. The laser beam melt-run welding used a variable welding speed from 10.0 to 40.0 mm/s, while the gas tungsten arc welding varied the welding speed from 1.67 to 5.00 mm/s. As the welding speed increased from 1.67 to 40.0mm/s, the solidification brittle temperature range of type 310S stainless steel welds was reduced from 146 to 120 K. It follows that employing the laser beam welding process mitigates the solidification cracking susceptibility for type 310S stainless steel welds.

  15. The influence of radiation on the properties of welds and joints

    NASA Astrophysics Data System (ADS)

    Tavassoli, A. A.

    1988-07-01

    The effect of radiation on mechanical properties of candidate structural materials for the first wall and breeder blanket of fusion reactors is reviewed. The emphasis is placed on austenitic stainless steel type 316L and its weld metals; design parameters considered are similar to those currently specified for the Next European Torus, namely, irradiation doses ≤15 dpa, temperatures ≤ 400°C, number of pulse cycles ≈10 5 and hold times ≤15 mn. The effect of irradiation on other materials, including austenitic stainless steel Type 304L, weld metal Type 308L and ferritic/martensitic steels (9-12% Cr-Mo), as well as other service conditions such as temperatures as high as 550°C are also briefly discussed. The data collected and presented in this review are those usually measured before and after irradiation, through tensile, impact toughness, fracture toughness, fatigue, creep-fatigue and fatigue crack propagation testing. In each case the influence of irradiation parameters on the observed changes are discussed and relative conclusions are drawn. The most important observation made is the lack of medium dose irradiation data on the weld metal and in particular on the electron beam welded joints.

  16. Role of beam absorption in plasma during laser welding

    SciTech Connect

    SEMAK,V.V.; STEELE,R.J.; FUERSCHBACH,PHILLIP W.; DAMKROGER,BRIAN K.

    2000-05-15

    The relationship between beam focus position and penetration depth in CW laser welding was studied numerically and experimentally for different welding conditions. Calculations were performed using a transient hydrodynamic model that incorporates the effect of evaporation recoil pressure and the associated melt expulsion. The simulation results are compared with measurements made on a series of test welds obtained using a 1650 W CO{sub 2} laser. The simulations predict, and the experiments confirm, that maximum penetration occurs with a specific location of the beam focus, with respect to the original sample surface, and that this relationship depends on the processing conditions. In particular, beam absorption in the plasma has a significant effect on the relationship between penetration and focus position. When the process parameters result in strong beam absorption in the keyhole plasma, the maximum penetration will occur when the laser focus is at or above the sample surface. In a case of weak absorption however, the penetration depth reaches its maximum value when the beam focus is located below the sample surface. In all cases, the numerical results are in good agreement with the experimental measurements.

  17. Analysis of Formation and Interfacial WC Dissolution Behavior of WC-Co/Invar Laser-TIG Welded Joints

    NASA Astrophysics Data System (ADS)

    Xu, P. Q.; Ren, J. W.; Zhang, P. L.; Gong, H. Y.; Yang, S. L.

    2013-02-01

    During the valve fabrication, hard metal is welded to stainless steel or invar alloy for sealing purposes because of its good heat resistance operating at 500 °C. However, WC (tungsten carbide) dissolution in weld pool softens the hard metal and decreases mechanical properties near the hard metal/weld interface. In order to analyze the WC dissolution in welded joint, joining of hard metal and invar alloy was carried out using laser-tungsten inert gas hybrid welding method. Microstructures of the weld region, chemical composition were investigated using optical microscope, scanning electron microscopy, and EDAX, respectively. Mechanical properties such as microhardness and four-point bend strength test were performed. Larger and smaller WC dissolution and WC dissolution through transition layer based on thermo-dynamics were discussed. The results thus indicate that WC dissolution led to cellular microstructure, columnar crystal, and transition layer under the effect of laser beam and tungsten arc. WC dissolution was affected by metal ions Fe+, Ni+, Co+ exchange in W-M-C system, and WC grain growth was driven by forces caused by laser beam and tungsten arc in larger WC, smaller WC, and liquid Fe, Ni systems.

  18. Weld cracking in corner joints by submerged-arc welding with high heat input

    SciTech Connect

    Wada, T.; Satoshi, I.; Terasaki, T.

    1995-12-31

    One-pass submerged arc welding (SAW) with high heat input is widely employed in Japan for the comer seam of box-shaped columns with a plate thickness of up to 70mm. The welding efficiency of one-pass SAW is several times higher than that of multipass welding. However, an internal crack similar to lamellar tearing occasionally occurs in the center-thickness position of the flange plate. ne mechanism of this crack and appropriate countermeasures to cracking were studied. It was found that this cracking was a kind of hydrogen induced cracking(HIC), and that the dominant material factors of this cracking were an elongated manganese sulfide (MnS) in the center segregation band, and martensite-austenite constituents (M-A) around MnS formed by intercritical heat affection of one-pass SAW. Drying of the flux was the most effective countermeasure in the welding conditions. As a groove for the one-pass SAW comer joint, a bevel groove was preferable to a V groove to prevent cracking. These effects were also clarified by the finite differential method(FDM) for the diffusion of hydrogen. As countermeasures in the production of steel plates, addition of Ca, soft reduction in continuous casting, and application of thermo-mechanical-control-process (TMCP) were effective.

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

    SciTech Connect

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

    2014-12-30

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

  20. Effect of Welding Current on the Structure and Properties of Resistance Spot Welded Dissimilar (Austenitic Stainless Steel and Low Carbon Steel) Metal Joints

    NASA Astrophysics Data System (ADS)

    Shawon, M. R. A.; Gulshan, F.; Kurny, A. S. W.

    2015-04-01

    1.5 mm thick sheet metal coupons of austenitic stainless steel and plain low carbon steel were welded by resistance spot welding technique. The effects of welding current in the range 3-9 kA on the structure and mechanical properties of welded joint were investigated. The structure was studied by macroscopic, microscopic and scanning electron microscopy techniques. Mechanical properties were determined by tensile testing and microhardness measurements. Asymmetrical shape weld nugget was found to have formed in the welded joint which increased in size with an increase in welding current. The fusion zone showed cast structure with coarse columnar grain and dendritic with excess delta ferrite in austenitic matrix. Microhardness of the weld nugget was maximum because of martensite formation. An increase in welding current also increased tensile strength of the weld coupon. An attempt has also been made to relate the mode of fracture with the welding current.

  1. Electron microscopy and microanalysis of steel weld joints after long time exposures at high temperatures

    NASA Astrophysics Data System (ADS)

    Jandová, D.; Kasl, J.; Rek, A.

    2010-02-01

    The structural changes of three trial weld joints of creep resistant modified 9Cr-1Mo steels and low alloyed chromium steel after post-weld heat treatment and long-term creep tests were investigated. Smooth cross-weld specimens ruptured in different zones of the weld joints as a result of different structural changes taking place during creep exposures. The microstructure of the weld joint is heterogeneous and consequently microstructural development can be different in the weld metal, the heat affected zone, and the base material. Precipitation reactions, nucleation and growth of some particles and dissolution of others, affect the strengthening of the matrix, recovery at high temperatures, and the resulting creep resistance. Therefore, a detailed study of secondary phase's development in individual zones of weld joints can elucidate mechanism of cracks propagation in specific regions and the causes of creep failure. Type I and II fractures in the weld metal and Type IV fractures in the fine prior austenite grain heat affected zones occurred after creep tests at temperatures ranging from 525 to 625 °C and under stresses from 40 to 240 MPa. An extended metallographic study of the weld joints was carried out using scanning and transmission electron microscopy, energy-dispersive and wave-dispersive X-ray microanalysis. Carbon extraction replicas and thin foils were prepared from individual weld joint regions and quantitative evaluation of dislocation substructure and particles of secondary phases has been performed.

  2. The use of ion beam cleaning to obtain high quality cold welds with minimal deformation

    NASA Technical Reports Server (NTRS)

    Sater, B. L.; Moore, T. J.

    1978-01-01

    A variation of cold welding is described which utilizes an ion beam to clean mating surfaces prior to joining in a vacuum environment. High quality solid state welds were produced with minimal deformation.

  3. Laser-based welding of 17-4 PH martensitic stainless steel in a tubular butt joint configuration with a built-in backing bar

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

    Laser-based welding of thick 17-4 precipitation hardening (PH) martensitic stainless steel (SS) plates in a tubular butt joint configuration with a built-in backing bar is very challenging because the porosity and cracks are easily generated in the welds. The backing bar blocked the keyhole opening at the bottom surface through which the entrapped gas could escape, and the keyhole was unstable and collapsed overtime in a deep partially penetrated welding conditions resulting in the formation of pores easily. Moreover, the fast cooling rate prompted the ferrite transform to austenite which induced cracking. Two-pass welding procedure was developed to join 17-4 PH martensitic SS. The laser welding assisted by a filler wire, as the first pass, was used to weld the groove shoulder. The added filler wire could absorb a part of the laser beam energy; resulting in the decreased weld depth-to-width ratio and relieved intensive restraint at the weld root. A hybrid laser-arc welding or a gas metal arc welding (GMAW) was used to fill the groove as the second pass. Nitrogen was introduced to stabilize the keyhole and mitigate the porosity. Preheating was used to decrease the cooling rate and mitigate the cracking during laser-based welding of 17-4 PH martensitic SS plates.

  4. Effect of stress concentration on the fatigue strength of A7N01S-T5 welded joints

    NASA Astrophysics Data System (ADS)

    Zhang, Mingyue; Gou, Guoqing; Hang, Zongqiu; Chen, Hui

    2017-07-01

    Stress concentration is a key factor that affects the fatigue strength of welded joints. In this study, the fatigue strengths of butt joints with and without the weld reinforcement were tested to quantify the effect of stress concentration. The fatigue strength of the welded joints was measured with a high-frequency fatigue machine. The P-S-N curves were drawn under different confidence levels and failure probabilities. The results show that butt joints with the weld reinforcement have much lower fatigue strength than joints without the weld reinforcement. Therefore, stress concentration introduced by the weld reinforcement should be controlled.

  5. About Abnormal Grain Growth in Joints Obtained by Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Mironov, S. Yu.

    2015-05-01

    Some special features of abnormal grain growth in welded joints of aluminum alloys formed by fiction stir welding (FSW) are studied. The microstructure and the texture of the alloys are determined after welding and annealing at 400, 450 and 500°C for different times. The abnormal grain growth is shown to depend much on the macroscopic inhomogeneity of the structure inside the weld.

  6. Butt weld of aluminum alloy plates 6063 and LY12 by laser beam

    NASA Astrophysics Data System (ADS)

    Xia, Jin'an; Cheng, Zhaogu; Xu, Guoliang; Li, Xianqin

    2000-02-01

    By means of a transverse flow 5 kW CO2 laser with low- order mode laser beam output, 1 - 4 mm thick aluminum alloy plates 6063 and LY12 were successfully butt welded. The result shows that the butt weldability and the weld quality of the aluminum alloy plates are mainly dependent on incident laser power density, laser beam defocused distance and shielding gas. The relationship between the weld quality of the aluminum alloy plates and the welding parameters is discussed. The macrostructure and microstructure of the welded seams are analyzed. The mechanical properties of the welded seams are discussed.

  7. Characteristics of microstructure and fatigue resistance of hybrid fiber laser-MIG welded Al-Mg alloy joints

    NASA Astrophysics Data System (ADS)

    Yan, Shaohua; Nie, Yuan; Zhu, Zongtao; Chen, Hui; Gou, Guoqing; Yu, Jinpeng; Wang, Guiguo

    2014-04-01

    In this study, the microstructures, mechanical properties and fatigue strengths of the hybrid laser-MIG welded joints were investigated. The detailed microstructures of the hybrid welded joints were carried out using OM and TEM. The causes of the strengths loss of the hybrid welded joints were studied from aspects of solute strengthening, precipitates hardening, and grain boundary strengthening. The fatigue strengths of the hybrid welded joints, MIG welded joints, and base metals were investigated. The results showed that the fatigue strength of the hybrid welded joints was better than that of the MIG welded joint. The conditional fatigue strength (Nf > 107) of the hybrid welded joints could reach up to 84.6% of the base metal's conditional fatigue strength (130 MPa). The fatigue fracture surfaces were examined by SEM, and the result showed that the main reason for the decrease of the fatigue strength was porosity.

  8. Grinding assembly, grinding apparatus, weld joint defect repair system, and methods

    DOEpatents

    Larsen, Eric D.; Watkins, Arthur D.; Bitsoi, Rodney J.; Pace, David P.

    2005-09-27

    A grinding assembly for grinding a weld joint of a workpiece includes a grinder apparatus, a grinder apparatus includes a grinding wheel configured to grind the weld joint, a member configured to receive the grinding wheel, the member being configured to be removably attached to the grinder apparatus, and a sensor assembly configured to detect a contact between the grinding wheel and the workpiece. The grinding assembly also includes a processing circuitry in communication with the grinder apparatus and configured to control operations of the grinder apparatus, the processing circuitry configured to receive weld defect information of the weld joint from an inspection assembly to create a contour grinding profile to grind the weld joint in a predetermined shape based on the received weld defect information, and a manipulator having an end configured to carry the grinder apparatus, the manipulator further configured to operate in multiple dimensions.

  9. Effect of strength mismatch on fracture toughness of HSLA steel weld joints

    SciTech Connect

    Rak, I.; Gliha, V.; Gubeljak, N.; Praunseis, Z.; Kocak, M.

    1995-12-31

    The purpose of this experimental work is to present the results of measured toughness and strength on mismatched weld joints made on HSLA steel grade HT 80. In the determined over and undermatched weld joints the local mismatching in the through thickness direction was found by hardness measurement. It seems that local mismatch because of WM low toughness has controlled the fracture behavior of weld metal and HAZ in both cases instead of the global one. Direct local CTOD({delta}{sub 5}) technique is found to be particular useful for the determination of fracture toughness values on mismatched weld joints.

  10. Butt Welding of 2205/X65 Bimetallic Sheet and Study on the Inhomogeneity of the Properties of the Welded Joint

    NASA Astrophysics Data System (ADS)

    Gou, Ning-Nian; Zhang, Jian-Xun; Wang, Jian-Long; Bi, Zong-Yue

    2017-03-01

    The explosively welded 2205 duplex stainless steel/X65 pipe steel bimetallic sheets were butt jointed by multilayer and multi-pass welding (gas tungsten arc welding for the flyer and gas metal arc welding for the transition and parent layers of the bimetallic sheets). The microstructure and mechanical properties of the welded joint were investigated. The results showed that in the thickness direction, microstructure and mechanical properties of the welded joint exhibited obvious inhomogeneity. The microstructures of parent filler layers consisted of acicular ferrite, widmanstatten ferrite, and a small amount of blocky ferrite. The microstructure of the transition layer and flyer layer consisted of both austenite and ferrite structures; however, the transition layer of weld had a higher volume fraction of austenite. The results of the microhardness test showed that in both weld metal (WM) and heat-affected zone (HAZ) of the parent filler layers, the average hardness decreased with the increasing (from parent filler layer 1 to parent filler layer 3) welding heat input. The results of hardness test also indicated that the hardness of the WM and the HAZ for the flyer and transition layers was equivalent. The tensile test combined with Digital Specklegram Processing Technology demonstrated that the fracturing of the welded joint started at the HAZ of the flyer, and then the fracture grew toward the base metal of the parent flyer near the parent HAZ. The stratified impact test at -5 °C showed that the WM and HAZ of the flyer exhibited lower impact toughness, and the fracture mode was ductile and brittle mixed fracture.

  11. Butt Welding of 2205/X65 Bimetallic Sheet and Study on the Inhomogeneity of the Properties of the Welded Joint

    NASA Astrophysics Data System (ADS)

    Gou, Ning-Nian; Zhang, Jian-Xun; Wang, Jian-Long; Bi, Zong-Yue

    2017-04-01

    The explosively welded 2205 duplex stainless steel/X65 pipe steel bimetallic sheets were butt jointed by multilayer and multi-pass welding (gas tungsten arc welding for the flyer and gas metal arc welding for the transition and parent layers of the bimetallic sheets). The microstructure and mechanical properties of the welded joint were investigated. The results showed that in the thickness direction, microstructure and mechanical properties of the welded joint exhibited obvious inhomogeneity. The microstructures of parent filler layers consisted of acicular ferrite, widmanstatten ferrite, and a small amount of blocky ferrite. The microstructure of the transition layer and flyer layer consisted of both austenite and ferrite structures; however, the transition layer of weld had a higher volume fraction of austenite. The results of the microhardness test showed that in both weld metal (WM) and heat-affected zone (HAZ) of the parent filler layers, the average hardness decreased with the increasing (from parent filler layer 1 to parent filler layer 3) welding heat input. The results of hardness test also indicated that the hardness of the WM and the HAZ for the flyer and transition layers was equivalent. The tensile test combined with Digital Specklegram Processing Technology demonstrated that the fracturing of the welded joint started at the HAZ of the flyer, and then the fracture grew toward the base metal of the parent flyer near the parent HAZ. The stratified impact test at -5 °C showed that the WM and HAZ of the flyer exhibited lower impact toughness, and the fracture mode was ductile and brittle mixed fracture.

  12. Determining joint penetration in GTAW with vision sensing of weld face geometry

    SciTech Connect

    Zhang, Y.M.; Wu, L.; Chen, D.H. ); Walcott, B.L. )

    1993-10-01

    Many studies have been conducted into the control of weld joint penetration utilizing a weld-face sensor. In this paper, a weld-face vision-based strategy is presented. The strategy employs a structured-light three-dimensional vision sensor to measure the weld-face geometric parameters of the cross-section of full joint penetration welds in real-time. The principle behind this strategy depends on the relationship between the root surface weld width and the measured weld-face parameters. In order to obtain this relationship, the geometric description of the cross-section of full penetration welds is studied and a new geometric parameter, called the average depression depth, is presented. Experiments are performed to acquire the data for weld-face and root-surface geometric parameters. The experiments are arranged according to the application case in order to ensure the validity of the resulting relationship. Through statistical analysis of the experimental data, a linear relationship is obtained. By this relationship, the root-surface weld width can be sufficiently represented by the weld-face average depression depth. Thus, it is feasible to control the full penetration state (the root-surface weld width) based on the measurement and control of the weld-face parameters.

  13. Structure and Corrosion Resistance of Welded Joints of Alloy 1151 in Marine Atmosphere

    NASA Astrophysics Data System (ADS)

    Bakulo, A. V.; Yakushin, B. F.; Puchkov, Yu. A.

    2017-07-01

    The corrosion behavior of joints formed by TIG and IMIG welding from clad sheets of heat-hardenable aluminum alloy 1151 of the Al - Cu - Mg system is studied. The corrosion tests are performed in an aqueous solution of NaCl in a salt-spray chamber. The welded joints are subjected to a metallographic analysis.

  14. 46 CFR 154.524 - Piping joints: Welded and screwed couplings.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 5 2011-10-01 2011-10-01 false Piping joints: Welded and screwed couplings. 154.524... Equipment Cargo and Process Piping Systems § 154.524 Piping joints: Welded and screwed couplings. Pipe... warmer. (d) Screwed couplings are allowed for instrumentation and control piping that meets §...

  15. 46 CFR 154.524 - Piping joints: Welded and screwed couplings.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 5 2012-10-01 2012-10-01 false Piping joints: Welded and screwed couplings. 154.524... Equipment Cargo and Process Piping Systems § 154.524 Piping joints: Welded and screwed couplings. Pipe... warmer. (d) Screwed couplings are allowed for instrumentation and control piping that meets §...

  16. 46 CFR 154.524 - Piping joints: Welded and screwed couplings.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 46 Shipping 5 2013-10-01 2013-10-01 false Piping joints: Welded and screwed couplings. 154.524... Equipment Cargo and Process Piping Systems § 154.524 Piping joints: Welded and screwed couplings. Pipe... warmer. (d) Screwed couplings are allowed for instrumentation and control piping that meets §...

  17. 46 CFR 154.524 - Piping joints: Welded and screwed couplings.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 5 2010-10-01 2010-10-01 false Piping joints: Welded and screwed couplings. 154.524... Equipment Cargo and Process Piping Systems § 154.524 Piping joints: Welded and screwed couplings. Pipe... warmer. (d) Screwed couplings are allowed for instrumentation and control piping that meets §...

  18. 46 CFR 154.524 - Piping joints: Welded and screwed couplings.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 46 Shipping 5 2014-10-01 2014-10-01 false Piping joints: Welded and screwed couplings. 154.524... Equipment Cargo and Process Piping Systems § 154.524 Piping joints: Welded and screwed couplings. Pipe... warmer. (d) Screwed couplings are allowed for instrumentation and control piping that meets §...

  19. Effect of the rotational speed of on the surface quality of 6061 Al-alloy welded joint using friction stir welding

    NASA Astrophysics Data System (ADS)

    Feng, T. T.; Zhang, X. H.; Fan, G. J.; Xu, L. F.

    2017-06-01

    The rotational speed of the stir-welding head is an important technological parameter in friction stir welding (FSW) process. For investigating the effect of the rotational speed of the stir-welding head on the surface quality of the welded joint, in this study, the weld tests were conducted under different rotational speeds (in which the welding speed was fixed), and then the effects were analyzed using the heat-fluid analysis model established. The test results revealed that cracks or grooves could be observed on the welded joint at small rotational speeds; with the increase of rotational speed, the weld surface became bright and clean; as the rotational speed further increased, the surface of the welded joint may be over burnt. Through analysis, it can be observed that appropriate increasing the rotational speed of the stir-welding joint increased the heat input in welding; meanwhile, fewer materials participated in the formation of weld, the material’s flowability was improved, and the resistance that impeded the advance of the stir-welding needle was reduced, thereby improving the quality of the welded joint.

  20. Effect of Multipass TIG and Activated TIG Welding Process on the Thermo-Mechanical Behavior of 316LN Stainless Steel Weld Joints

    NASA Astrophysics Data System (ADS)

    Ganesh, K. C.; Balasubramanian, K. R.; Vasudevan, M.; Vasantharaja, P.; Chandrasekhar, N.

    2016-04-01

    The primary objective of this work was to develop a finite element model to predict the thermo-mechanical behavior of an activated tungsten inert gas (ATIG)-welded joint. The ATIG-welded joint was fabricated using 10 mm thickness of 316LN stainless steel plates in a single pass. To distinguish the merits of ATIG welding process, it was compared with manual multipass tungsten inert gas (MPTIG)-welded joint. The ATIG-welded joint was fabricated with square butt edge configuration using an activating flux developed in-house. The MPTIG-welded joint was fabricated in thirteen passes with V-groove edge configuration. The finite element model was developed to predict the transient temperature, residual stress, and distortion of the welded joints. Also, microhardness, impact toughness, tensile strength, ferrite measurement, and microstructure were characterized. Since most of the recent publications of ATIG-welded joint was focused on the molten weld pool dynamics, this research work gives an insight on the thermo-mechanical behavior of ATIG-welded joint over MPTIG-welded joint.

  1. Reasons for superior mechanical and corrosion properties of 2219 aluminum alloy electron beam welds

    SciTech Connect

    Koteswara Rao, S.R. . E-mail: sajjarkr@yahoo.com; Madhusudhan Reddy, G.; Srinivasa Rao, K.; Kamaraj, M.; Prasad Rao, K.

    2005-11-15

    Electron beam welds of aluminum alloy 2219 offer much higher strength compared to gas tungsten arc welds of the same alloy and the reasons for this have not been fully explored. In this study both types of welds were made and mechanical properties were evaluated by tensile testing and pitting corrosion resistance by potentio dynamic polarization tests. It is shown that electron beam welds exhibit superior mechanical and corrosion properties. The weld metals have been characterized by scanning electron microscopy; transmission electron microscopy and electron probe micro analysis. Presence of partially disintegrated precipitates in the weld metal, finer micro porosity and uniform distribution of copper in the matrix were found to be the reasons for superior properties of electron beam welds apart from the fine equiaxed grain structure. Transmission electron micrographs of the heat affected zones revealed the precipitate disintegration and over aging in gas tungsten arc welds.

  2. Surface-active element effects on the shape of GTA, laser, and electron-beam welds

    SciTech Connect

    Heiple, C.R.; Roper, J.R.; Stagner, R.T.; Aden, R.J.

    1983-03-01

    Laser and electron-beam welds were passed across selenium-doped zones in 21-6-9 stainless steel. The depth/width (d/w) ratio of a defocused laser weld with a weld pool shape similar to a GTA weld increased by over 200% in a zone where 66 ppm selenium had been added. Smaller increases were observed in selenium-doped zones for a moderately defocused electron beam weld with a higher d/w ratio in undoped base metal. When laser or electron beam weld penetration was by a keyhole mechanism, no change in d/w ratio occurred in selenium-doped zones. The results confirm the surface-tension-driven fluid-flow model for the effect of minor elements on GTA weld pool shape. Other experimental evidence bearing on the effect of minor elements on GTA weld penetration is summarized.

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

    NASA Astrophysics Data System (ADS)

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

    1997-12-01

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

  4. The Diagnostic Method of Inner Parts of Welded Joints at Nuclear Power Plant

    NASA Astrophysics Data System (ADS)

    Bednarova, O.; Janovec, J.

    2010-06-01

    There is no possibility to check any inner part at real welded joint at nuclear power station (NPS) during operation because any destructive test cannot be used. In practice there is checked surface of weld. There are used four methodical instructions for the check of real welds: 1. The visual inspection, 2. The measurement of hardness, 3. The chemical composition checking and 4. The microstructure replica analysis. It is necessary to know how these information of weld surface are in accordance with characteristics of inner parts of weld. If there is not any difference between surface weld microstructure and internal weld microstructure of experimental weld it is supposed to that there is not any difference in other measured properties of welds. If is changed structural characteristics of microstructure, it is changed also hardness, chemical analysis etc. It was observed that the microstructure of real welds is almost the same with simulated weld and also the surface microstructure of experimental weld is in accordance with microstructure of inner parts of this weld. It can be supposed extension of lifetime of NPS if there is not any difference between replicas microstructure taken after six year operation of NPS and microstructure of inner parts of simulated weld is almost the same with surface microstructure.

  5. The Diagnostic Method of Inner Parts of Welded Joints at Nuclear Power Plant

    SciTech Connect

    Bednarova, O.; Janovec, J.

    2010-06-22

    There is no possibility to check any inner part at real welded joint at nuclear power station (NPS) during operation because any destructive test cannot be used. In practice there is checked surface of weld. There are used four methodical instructions for the check of real welds: 1. The visual inspection, 2. The measurement of hardness, 3. The chemical composition checking and 4. The microstructure replica analysis. It is necessary to know how these information of weld surface are in accordance with characteristics of inner parts of weld. If there is not any difference between surface weld microstructure and internal weld microstructure of experimental weld it is supposed to that there is not any difference in other measured properties of welds. If is changed structural characteristics of microstructure, it is changed also hardness, chemical analysis etc. It was observed that the microstructure of real welds is almost the same with simulated weld and also the surface microstructure of experimental weld is in accordance with microstructure of inner parts of this weld. It can be supposed extension of lifetime of NPS if there is not any difference between replicas microstructure taken after six year operation of NPS and microstructure of inner parts of simulated weld is almost the same with surface microstructure.

  6. Application of thermal methods for characterization of steel welded joints

    NASA Astrophysics Data System (ADS)

    Galietti, U.; Palumbo, D.

    2010-06-01

    Despite the large number of proposals in the field of fatigue prediction of welded joints, a globally accepted and unified theory, which applies easily to any load condition, does not exist. Real life components, indeed, differ in geometry and/or type of load from the structural design for which they are regarded by Standards, so that a lot of precautionary safety factors are used that lead to an underestimation of the actual fatigue life of joints. Infrared thermography has a great potential in this field, both from structural and thermomechanical points of view. It enables a full field stress analysis with a sufficient spatial resolution so that the complexity of the stress state at the weld toe and its time evolution are taken into account, emphasizing anomalies that may predict structural failure. A new methods for evaluation fatigue limit damage is presented in this paper and in particular interesting results derived from analysis of the evolution of thermoelastic signal phase. Variations in the value of signal phase indicate a not elastic behaviour and plastic dissipation in the material.

  7. Corrosion fracture resistance of welded joints in 16GMYuCh steel

    SciTech Connect

    Steklov, O.I.; Efimenko, L.A.; Khakimov, A.M.; Paul', A.I.; Pushkina, O.A.

    1986-01-01

    This paper studies the effect of combined welding of thick-wall gas and oil chemical equipment consisting of welding the weld root by automatic submerged-arc welding and electrosag welding (ESW) with the control of thermal cycles (CWC) of the main joint, on the corrosion resistance of welded joints in low-alloy normalized 16GMYuCh steel 50 mm thick. The chemical composition of the steel, % 0.16 C; 1.05 Mn; 0.25 Si; 0.42 Mo; 0.14 Ni; 0.1 Cu; 0.11 Cr; 0.049 Al; 0.032 S; 0.019 P. The authors determined the effect of cooling rate in the temperature range of diffusion transformation of austenite on the corrosion resistance of the weld zone. Attention was then given to the corrosion resistance of the welded joints produced by conventional ESW welding and ESW with CWC. The investigations show that the corrosion resistance of the parent metal is lower than that of the welded joints.

  8. Dissimilar Al/steel friction stir welding lap joints for automotive applications

    NASA Astrophysics Data System (ADS)

    Campanella, D.; Spena, P. Russo; Buffa, G.; Fratini, L.

    2016-10-01

    A widespread usage of aluminum alloys for the fabrication of car-body parts is conditional on the employment of appropriate welding methods, especially if dissimilar welding must be performed with automotive steel grades. Dissimilar welding of aluminum alloys and steel grades poses some issues concerning the formation of brittle intermetallic compounds, difference in physical and chemical properties of the parent metals, and poor wetting behavior of aluminum. Friction stir welding is considered to be a reasonable solution to obtain sound aluminum/steel joints. A study on the join quality of dissimilar lap joints of steel and aluminum alloy sheets after friction stir welding is proposed here. A low carbon steel is joined with AA6016 aluminum alloy to study preliminarily the feasibility to assembly car-body parts. The joints, welded with tool rotation and feed rate varying in a wide range, have been studied from a visual examination and microstructural point of view. Optical microscopy has been used to characterize the microstructure of the examined sheets in as-received and welded conditions. Micro-hardness measurements have been carried out to quantitatively analyze the local hardness of the welded joints. Set welding process parameters are identified to assemble without the presence of macroscopic defects the examined steel and aluminum welded parts.

  9. Towards the problem of forming full strength welded joints on aluminum alloy sheets. Part II: AA7475

    NASA Astrophysics Data System (ADS)

    Kalashnikova, Tatiana; Tarasov, Sergey; Eliseev, Alexander; Fortuna, Anastasiya

    2016-11-01

    The microstructural evolution in welded joint zones obtained both by friction stir welding and ultrasonic- assisted friction stir welding on dispersion hardened 7475 aluminum alloy has been examined together with the analysis of mechanical strength and microhardness. It was established that ultrasonic-assisted friction stir provided leveled microhardness profiles across the weld zones as well as higher joint strength as compared to those of standard friction stir welding.

  10. Effect of welding process on the microstructure and properties of dissimilar weld joints between low alloy steel and duplex stainless steel

    NASA Astrophysics Data System (ADS)

    Wang, Jing; Lu, Min-xu; Zhang, Lei; Chang, Wei; Xu, Li-ning; Hu, Li-hua

    2012-06-01

    To obtain high-quality dissimilar weld joints, the processes of metal inert gas (MIG) welding and tungsten inert gas (TIG) welding for duplex stainless steel (DSS) and low alloy steel were compared in this paper. The microstructure and corrosion morphology of dissimilar weld joints were observed by scanning electron microscopy (SEM); the chemical compositions in different zones were detected by energy-dispersive spectroscopy (EDS); the mechanical properties were measured by microhardness test, tensile test, and impact test; the corrosion behavior was evaluated by polarization curves. Obvious concentration gradients of Ni and Cr exist between the fusion boundary and the type II boundary, where the hardness is much higher. The impact toughness of weld metal by MIG welding is higher than that by TIG welding. The corrosion current density of TIG weld metal is higher than that of MIG weld metal in a 3.5wt% NaCl solution. Galvanic corrosion happens between low alloy steel and weld metal, revealing the weakness of low alloy steel in industrial service. The quality of joints produced by MIG welding is better than that by TIG welding in mechanical performance and corrosion resistance. MIG welding with the filler metal ER2009 is the suitable welding process for dissimilar metals jointing between UNS S31803 duplex stainless steel and low alloy steel in practical application.

  11. Evaluation of weld porosity in laser beam seam welds: optimizing continuous wave and square wave modulated processes.

    SciTech Connect

    Ellison, Chad M.; Perricone, Matthew; Faraone, Kevin M. (Honeywell FM&T, Kansas City, MO); Roach, Robert Allen; Norris, Jerome T.

    2007-02-01

    Nd:YAG laser joining is a high energy density (HED) process that can produce high-speed, low-heat input welds with a high depth-to-width aspect ratio. This is optimized by formation of a ''keyhole'' in the weld pool resulting from high vapor pressures associated with laser interaction with the metallic substrate. It is generally accepted that pores form in HED welds due to the instability and frequent collapse of the keyhole. In order to maintain an open keyhole, weld pool forces must be balanced such that vapor pressure and weld pool inertia forces are in equilibrium. Travel speed and laser beam power largely control the way these forces are balanced, as well as welding mode (Continuous Wave or Square Wave) and shielding gas type. A study into the phenomenon of weld pool porosity in 304L stainless steel was conducted to better understand and predict how welding parameters impact the weld pool dynamics that lead to pore formation. This work is intended to aid in development and verification of a finite element computer model of weld pool fluid flow dynamics being developed in parallel efforts and assist in weld development activities for the W76 and future RRW programs.

  12. Influences of post weld heat treatment on tensile properties of friction stir welded AA2519-T87 aluminium alloy joints

    NASA Astrophysics Data System (ADS)

    Sabari, S. Sree; Balasubramanian, V.; Malarvizhi, S.; Reddy, G. Madusudhan

    2015-12-01

    AA 2519-T87 is an aluminium alloy that principally contains Cu as an alloying element and is a new grade of Al-Cu alloy system. This material is a potential candidate for light combat military vehicles. Fusion welding of this alloy leads to hot cracking, porosity and alloy segregation in the weld metal region. Friction stir welding (FSW) is a solid state joining process which can overcome the above mentioned problems. However, the FSW of age hardenable aluminium alloys results in poor tensile properties in the as-welded condition (AW). Hence, post weld heat treatment (PWHT) is used to enhance deteriorated tensile properties of FSW joints. In this work, the effect of PWHT, namely artificial ageing (AA) and solution treatment (ST) followed by ageing (STA) on the microstructure, tensile properties and microhardness were systematically investigated. The microstructural features of the weld joints were characterised using an optical microscope (OM), scanning electron microscope (SEM) and transmission electron microscope (TEM). The tensile strength and microhardness of the joints were correlated with the grain size, precipitate size, shape and its distribution. From the investigation, it was found that STA treatment is beneficial in enhancing the tensile strength of the FSW joints of AA2519-T87 alloy and this is mainly due to the presence of fine and densely distributed precipitates in the stir zone.

  13. Effect of Welding Consumables on Fatigue Performance of Shielded Metal Arc Welded High Strength, Q&T Steel Joints

    NASA Astrophysics Data System (ADS)

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

    2009-02-01

    Quenched and Tempered (Q&T) steels are widely used in the construction of military vehicles due to their high strength-to-weight ratio and high hardness. These steels are prone to hydrogen-induced cracking in the heat affected zone (HAZ) after welding. The use of austenitic stainless steel consumables to weld the above steel was the only remedy because of higher solubility for hydrogen in austenitic phase. Recent studies proved that high nickel steel and low hydrogen ferritic steel consumables can be used to weld Q&T steels, which can give very low hydrogen levels in the weld deposits. In this investigation an attempt has been made to study the effect of welding consumables on high cycle fatigue properties of high strength, Q&T steel joints. Three different consumables namely (i) austenitic stainless steel, (ii) low hydrogen ferritic steel, and (iii) high nickel steel have been used to fabricate the joints by shielded metal arc (SMAW) welding process. The joints fabricated using low hydrogen ferritic steel electrodes showed superior fatigue properties than other joints.

  14. Tensile properties of a titanium modified austenitic stainless steel and the weld joints after neutron irradiation

    SciTech Connect

    Shiba, Kiyoyuki; Ioka, Ikuo; Jitsukawa, Shiro; Hamada, Shozo; Hishinuma, Atkinichi; Robertson, J.P.

    1999-10-01

    Tensile specimens of a titanium modified austenitic stainless steel and its weldments fabricated with Tungsten Inert Gas (TIG) and Electron Beam (EB) welding techniques were irradiated to a peak dose of 19 dpa and a peak helium level of 250 appm in the temperature range between 200 and 400 C in spectrally tailored capsules in the Oak Ridge Research Reactor (ORR) and the High Flux Isotope Reactor (HFIR). The He/dpa ratio of about 13 appm/dpa is similar to the typical helium/.dpa ratio of a fusion reactor environment. The tensile tests were carried out at the irradiation temperature in vacuum. The irradiation caused an increase in yield stress to levels between 670 and 800 MPa depending on the irradiation temperature. Total elongation was reduced to less than 10%, however the specimens failed in a ductile manner. The results were compared with those of the specimens irradiated using irradiation capsules producing larger amount of He. Although the He/dpa ratio affected the microstructural change, the impact on the post irradiation tensile behavior was rather small not only for base metal specimens but also for the weld joint and the weld metal specimens.

  15. Tensile properties of a titanium modified austenitic stainless steel and the weld joints after neutron irradiation

    SciTech Connect

    Shiba, K.; Ioka, I.; Jitsukawa, S.; Hamada, A.; Hishinuma, A.

    1996-10-01

    Tensile specimens of a titanium modified austenitic stainless steel and its weldments fabricated with Tungsten Inert Gas (TIG) and Electron Beam (EB) welding techniques were irradiated to a peak dose of 19 dpa and a peak helium level of 250 appm in the temperature range between 200 and 400{degrees}C in spectrally tailored capsules in the Oak Ridge Research Reactor (ORR) and the High Flux Isotope Reactor (HFIR). The He/dpa ratio of about 13 appm/dpa is similar to the typical helium/dpa ratio of a fusion reactor environment. The tensile tests were carried out at the irradiation temperature in vacuum. The irradiation caused an increase in yield stress to levels between 670 and 800 MPa depending on the irradiation temperature. Total elongation was reduced to less than 10%, however the specimens failed in a ductile manner. The results were compared with those of the specimens irradiated using irradiation capsules producing larger amount of He. Although the He/dpa ratio affected the microstructural change, the impact on the post irradiation tensile behavior was rather small for not only base metal specimens but also for the weld joint and the weld metal specimens.

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

  17. The Effect of Ultrasonic Peening Treatment on Fatigue Performance of Welded Joints

    PubMed Central

    Zhao, Xiaohui; Wang, Mingyi; Zhang, Zhiqiang; Liu, Yu

    2016-01-01

    Ultrasonic peening treatment (UPT) as a method of severe plastic deformation was used to treat cruciform welded joints of Q345 steel. The application of UPT achieves material surface nanocrystallization of the peening zone, reduces stress concentration, and produces residual compressive stresses at the welded toe. Micro-structure, hardness, stress relief, S-N curve, and the fatigue fracture mechanism of cruciform welded joint of Q345 steel, both before and after UPT, were analyzed in detail. The main results show that: stress concentration and residual tensile stress are the main reasons to reduce fatigue strength of cruciform welded joints. The fatigue life of cruciform welded joints is improved for surface hardening, compressive stress, and grain refinement by UPT. Residual compressive stress caused by UPT is released with the increase of fatigue life. A very significant fatigue strength improvement happens when UPT is replenished repeatedly after a certain number of cycles. PMID:28773589

  18. Investigation on the Effect of Friction Welding Parameters on Impact Strength in Dissimilar Joints

    NASA Astrophysics Data System (ADS)

    Shanjeevi, C.; Arputhabalan, J. Jeswin; Dutta, Rohan; Pradeep

    2017-05-01

    Due to increase in demand of joining dissimilar material combinations in applications such as cryogenic fluids, power generation industries and reactor cooling systems, the solid state welding is most suitable in the current scenario. In this study, the experiment is undergone to evaluate the impact strength on the friction welded joint of copper and AISI 430 ferritic stainless steel material in the weld interface. The experiment is conducted by varying the input parameters such as friction pressure, upset pressure, burn-off length and rotational speed using Taguchi’s L9 orthogonal array. The welded joints were examined under scanning electron microscopy (SEM) and type of failure mode is discussed.

  19. Electron beam welding of 6061-T6 covers to A356-T6 machined cast housings: Final report

    SciTech Connect

    Miller, G.P.

    1988-03-01

    An electron beam welding process was developed to replace the manual gas tungsten arc welding process for welding 6061-T6 aluminum covers to the A356-T6 cast aluminum machined housing for a Filter Pack Assembly. Design change recommendations must be incorporated prior to implementation of the electron beam welding process. 3 refs., 9 figs., 5 tabs.

  20. Precipitation of Niobium Boride Phases at the Base Metal/Weld Metal Interface in Dissimilar Weld Joints

    NASA Astrophysics Data System (ADS)

    Výrostková, Anna; Kepič, Ján; Homolová, Viera; Falat, Ladislav

    2015-07-01

    In this work, the analysis of failure mechanism in the heat affected zone is described in dissimilar weld joints between advanced martensitic steel T92 and Ni-base weld metal. The joints were treated with two different post-weld heat treatments and tested. For the creep, tensile, and Charpy impact tests, the samples with interfacially located notch were used. Moreover long term aging at 625 °C was applied before the tensile and notch toughness tests. Decohesion fractures ran along carbides at the T92 BM/WM interfaces in case of the modified PWHT, whereas type IV cracking was the prevailing failure mechanism after the classical PWHT in the creep test. In the notch tensile and Charpy impact tests, with the notch at T92 base metal/weld metal interface, fractures ran along the interface with a hard phase on the fracture surface along with the ductile dimple and brittle quasi-cleavage fracture. The phase identified as niobium boride (either NbB and/or Nb3B2) was produced during welding at the end of the solidification process. It was found in the welds regardless of the post-weld heat treatment and long-term aging.

  1. Predicting mesoscale microstructural evolution in electron beam welding

    DOE PAGES

    Rodgers, Theron M.; Madison, Jonathan D.; Tikare, Veena; ...

    2016-03-16

    Using the kinetic Monte Carlo simulator, Stochastic Parallel PARticle Kinetic Simulator, from Sandia National Laboratories, a user routine has been developed to simulate mesoscale predictions of a grain structure near a moving heat source. Here, we demonstrate the use of this user routine to produce voxelized, synthetic, three-dimensional microstructures for electron-beam welding by comparing them with experimentally produced microstructures. When simulation input parameters are matched to experimental process parameters, qualitative and quantitative agreement for both grain size and grain morphology are achieved. The method is capable of simulating both single- and multipass welds. As a result, the simulations provide anmore » opportunity for not only accelerated design but also the integration of simulation and experiments in design such that simulations can receive parameter bounds from experiments and, in turn, provide predictions of a resultant microstructure.« less

  2. Predicting Mesoscale Microstructural Evolution in Electron Beam Welding

    NASA Astrophysics Data System (ADS)

    Rodgers, T. M.; Madison, J. D.; Tikare, V.; Maguire, M. C.

    2016-05-01

    Using the kinetic Monte Carlo simulator, Stochastic Parallel PARticle Kinetic Simulator, from Sandia National Laboratories, a user routine has been developed to simulate mesoscale predictions of a grain structure near a moving heat source. Here, we demonstrate the use of this user routine to produce voxelized, synthetic, three-dimensional microstructures for electron-beam welding by comparing them with experimentally produced microstructures. When simulation input parameters are matched to experimental process parameters, qualitative and quantitative agreement for both grain size and grain morphology are achieved. The method is capable of simulating both single- and multipass welds. The simulations provide an opportunity for not only accelerated design but also the integration of simulation and experiments in design such that simulations can receive parameter bounds from experiments and, in turn, provide predictions of a resultant microstructure.

  3. Predicting mesoscale microstructural evolution in electron beam welding

    SciTech Connect

    Rodgers, Theron M.; Madison, Jonathan D.; Tikare, Veena; Maguire, Michael C.

    2016-03-16

    Using the kinetic Monte Carlo simulator, Stochastic Parallel PARticle Kinetic Simulator, from Sandia National Laboratories, a user routine has been developed to simulate mesoscale predictions of a grain structure near a moving heat source. Here, we demonstrate the use of this user routine to produce voxelized, synthetic, three-dimensional microstructures for electron-beam welding by comparing them with experimentally produced microstructures. When simulation input parameters are matched to experimental process parameters, qualitative and quantitative agreement for both grain size and grain morphology are achieved. The method is capable of simulating both single- and multipass welds. As a result, the simulations provide an opportunity for not only accelerated design but also the integration of simulation and experiments in design such that simulations can receive parameter bounds from experiments and, in turn, provide predictions of a resultant microstructure.

  4. Microstructure and properties of weld joint during 10 kW laser welding with surface-active element sulfur

    NASA Astrophysics Data System (ADS)

    Li, Shichun; Deng, Zhaohui; Deng, Hui; Xu, Wei

    2017-12-01

    The present work has been focused on the effects of surface-active element sulfur on welding properties during 10 kW high power laser welding of 304 stainless steel thick plate. Molten pool behavior, morphology feature of sulfide inclusions, metallographic structures, XRD patterns, microhardness, potentiodynamic polarization curves and pitted surface have been investigated and discussed. The results indicated that the added sulfur powder improved the weld depth by increasing molten metal fluidity, elongating molten pool and promoting heat transmission. The observed sulfide inclusions had small particle size of 0.65 μm in average and were distributed sparsely in weld joint. The WWS (weld joint with sulfur powder) had higher δ-ferrite content and finer grain size than the WWOS (weld joint without sulfur powder) and BM (base metal) due to the effects of sulfide inclusions on crystallizing process. The preferred orientations of γ-austenite along the (200) and (220) directions were promoted both in WWS and WWOS. Fine grain size and high δ-ferrite content led to high microhardness. The WWS had the highest microhardness among all the specimens. The WWOS and BM had a similar corrosion resistance. By comprehensive comparison, the WWS had a relative lower corrosion resistance than others, since sulfide inclusions in WWS not only had some benefits but also had some bad effects on corrosion property.

  5. Integrity of Polymethylmethacrylate (PMMA) Chemically Welded Joints Examined

    NASA Technical Reports Server (NTRS)

    Lerch, Bradley A.; Thesken, John C.; Bunnell, Charles T.; Kurta, Carol E.; Sydenstricker, Mike

    2005-01-01

    NASA Glenn Research Center s Capillary Flow Experiments (CFE) program is developing experiment payloads to explore fluid interfaces in microgravity on the International Space Station. The information to be gained from the CFE is relevant to the design of fluid-bearing systems in which capillary forces predominate, for example in the passive positioning of liquids in spacecraft fuel tanks. To achieve the science goals of CFE, Glenn researchers constructed several types of experiment vessels. One type of vessel, known as the interior corner flow (ICF), will be used to determine important transients for low-gravity liquid management in a two-phase system. Each vessel has a cylindrical fluid reservoir connected to each end of the test chamber by internal transport tubes, each with a quarter-turn shutoff valve (see the following photograph). These multipiece vessels are made from polymethylmethacrylate (PMMA) because of its excellent optical properties (i.e., the fluids can be observed easily in the vessel). Because of the complexity of certain vessels, the test chamber had to be manufactured in pieces and welded chemically. Some past experience with adhesive bonded plastic showed that the experiment fluid degraded the adhesive to the point of failure. Therefore, it was necessary to see if the fluid also degraded the chemically welded PMMA joints.

  6. Ground Base Skylab Electron Beam Welds in Tantalum

    NASA Technical Reports Server (NTRS)

    2004-01-01

    Comparison of ground-based (left) and Skylab (right) electron beam welds in pure tantalum (Ta) (10X magnification). Residual votices left behind in the ground-based sample after the electron beam passed were frozen into the grain structure. These occurred because of the rapid cooling rate at the high temperature. Although the thermal characteristics and electron beam travel speeds were comparable for the skylab sample, the residual vortices were erased in the grain structure. This may have been due to the fact that final grain size of the solidified material was smaller in the Skylab sample compared to the ground-based sample. The Skylab sample was processed in the M512 Materials Processing Facility (MPF) during Skylab SL-2 Mission. Principal Investigator was Richard Poorman.

  7. Fiber laser welding of austenitic steel and commercially pure copper butt joint

    NASA Astrophysics Data System (ADS)

    Kuryntsev, S. V.; Morushkin, A. E.; Gilmutdinov, A. Kh.

    2017-03-01

    The fiber laser welding of austenitic stainless steel and commercially pure copper in butt joint configuration without filler or intermediate material is presented. In order to melt stainless steel directly and melt copper via heat conduction a defocused laser beam was used with an offset to stainless steel. During mechanical tests the weld seam was more durable than heat affected zone of copper so samples without defects could be obtained. Three process variants of offset of the laser beam were applied. The following tests were conducted: tensile test of weldment, intermediate layer microhardness, optical metallography, study of the chemical composition of the intermediate layer, fractography. Measurements of electrical resistivity coefficients of stainless steel, copper and copper-stainless steel weldment were made, which can be interpreted or recalculated as the thermal conductivity coefficient. It shows that electrical resistivity coefficient of cooper-stainless steel weldment higher than that of stainless steel. The width of intermediate layer between stainless steel and commercially pure copper was 41-53 μm, microhardness was 128-170 HV0.01.

  8. Influences of process parameters on tensile strength of friction stir welded cast A319 aluminium alloy joints

    NASA Astrophysics Data System (ADS)

    Jayaraman, M.; Sivasubramanian, R.; Balasubramanian, V.; Babu, S.

    2009-04-01

    Fusion welding of cast A319 (Al-Si-Cu) alloy will lead to many problems including porosity, micro-fissuring, and hot cracking. Friction Stir Welding (FSW) can be used to weld A319 alloy without these defects. In this investigation, an attempt has been made to study the effect of FSW process parameters on the tensile strength of A319 alloy welded joints. Joints were made using different combinations of tool rotation speed, welding speed, and axial force, each at four levels. The quality of weld zone was analyzed using macrostructure and microstructure analysis. Tensile strength of the joints were evaluated and correlated with the weld zone microstructure. The joint fabricated with a 1200 rpm tool rotation speed, 40 mm/min welding speed, and 4 kN axial force showed superior tensile strength compared with the other joints.

  9. Effect of welding parameters on the mechanical and microstructural properties of friction stir welded AA- 2014 joints

    NASA Astrophysics Data System (ADS)

    Khan, R.; Bhatty, M. B.; Iqbal, F.; Zaigham, H.; Salam, I.

    2016-08-01

    In this study, the effect of processing parameters on the mechanical and microstructural properties of aluminum AA2014-T6 joints produced by friction stir welding was analyzed. Friction stir welding was carried out on a milling machine. Different samples were produced by varying the tool rotational rates (700, 1000 rpm) and travel speeds (45-105 mm/min). Tensile tests performed at room temperature were used to evaluate the mechanical properties of the joints. In order to analyze the microstructural evolution of the material, the welds’ cross-sections were observed under optical microscope. The results shows that the resulting microstructure is free of defects and tensile strength of the welded joints is upto 75% of the base metal strength.

  10. Microsegregation in high-molybdenum austenitic stainless steel laser beam and gas tungsten arc welds

    SciTech Connect

    Kujanpaeae, V.P.; David, S.A.

    1986-01-01

    An austenitic stainless steel with 6% molybdenum (thickness 6 mm) was welded using laser beam (LB) and gas tungsten arc (GTA) processes at various welding speeds. Depending on the welding speed the primary dendrite spacing ranged from 12 to 17 ..mu..m and from 2 to 7 ..mu..m for the GTA and LB welds, respectively. Extensive segregation of molybdenum was observed in the GTA welds. The segregation ratio for molybdenum, C/sub ID//C/sub D/, was found to be 1.9 in the GTA weld, and 1.2 in the LB weld. Distribution of iron, chromium and nickel was found nearly uniform in both welds. A recovered microstructure was observed after a post-weld annealing heat treatment. Annealing had a profound effect on the molybdenum segregation ratio in the laser weld. The critical pitting temperature (CPT) determined by a standard test was 55/sup 0/C for welds made using both processes, whereas it was 75/sup 0/C for the base metal. Upon homogenization the CPT of the laser beam weld increased to the base metal value, while that of the gas tungsten arc weld remained at 60/sup 0/C.

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

  12. Experimental study of hot cracking at circular welding joints of 42CrMo steel

    NASA Astrophysics Data System (ADS)

    Zhang, Yan; Chen, Genyu; Chen, Binghua; Wang, Jinhai; Zhou, Cong

    2017-12-01

    The hot cracking at circular welding joints of quenched and tempered 42CrMo steel were studied. The flow of the molten pool and the solidification process of weld were observed with a high-speed video camera. The information on the variations in the weld temperature was collected using an infrared (IR) thermal imaging system. The metallurgical factors of hot cracking were analyzed via metallographic microscope and scanning electron microscope (SEM). The result shows that leading laser laser-metal active gas (MAG) hybrid welding process has a smaller solid-liquid boundary movement rate (VSL) and a smaller solid-liquid boundary temperature gradient (GSL) compared with leading arc laser-MAG hybrid welding process and laser welding process. Additionally, the metal in the molten pool has superior permeability while flowing toward the dendritic roots and can compensate for the inner-dendritic pressure balance. Therefore, leading laser laser-MAG hybrid welding process has the lowest hot cracking susceptibility.

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

    NASA Astrophysics Data System (ADS)

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

    2016-07-01

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

  14. Fatigue Behavior of Friction Stir-Welded Joints Repaired by Grinding

    NASA Astrophysics Data System (ADS)

    Vidal, C.; Infante, V.

    2014-04-01

    Fatigue is undoubtedly the most important design criterion in aeronautic structures. Although friction stir-welded joints are characterized by a high mechanical performance, they can enclose some defects, especially in their root. These defects along with the relatively low residual stresses of the friction stir-welding thermomechanical cycle can turn into primary sources of crack initiation. In this context, this article deals with the fatigue behavior of friction stir-welded joints subjected to surface smoothing by grinding improvement technique. The 4-mm-thick aluminum alloy 2024-T351 was used in this study. The fatigue strength of the base material, joints in the as-welded condition, and the sound and defective friction stir-welded joints improved by grinding were investigated in detail. The tests were carried out with a constant amplitude loading and with a stress ratio of R = 0. The fatigue results show that an improvement in fatigue behavior was obtained in the joints repaired by superficial grinding technique. The weld grinding technique is better especially for lower loads and increases the high cycle fatigue strength. The fatigue strength of the improved welded joints was higher than that of the base material.

  15. 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.

  16. Investigation of Fatigue Crack Propagation in Spot-Welded Joints Based on Fracture Mechanics Approach

    NASA Astrophysics Data System (ADS)

    Hassanifard, S.; Bonab, M. A. Mohtadi; Jabbari, Gh.

    2013-01-01

    In this paper, fatigue crack propagation life of resistance spot welds in tensile-shear specimens is investigated based on the calculation of stress intensity factors and J-integral using three-dimensional finite element method. For comparison, experimental works on 5083-O aluminum alloy spot-welded joints have been carried out to verify the numerical predictions of fatigue crack propagation of welded joints. A lot of analyses have been performed to obtain stress intensity factors and J-integral in tensile-shear specimens of spot-welded joints by using commercial software ANSYS. These gathered data have been formulated by using statistical software SPSS. The results of fatigue propagation life and predicted fatigue crack path revealed very good agreement with the experimental fatigue test data and photograph of cross-section of the fatigued spot-weld specimens.

  17. Effects of activating fluxes on the weld penetration and corrosion resistant property of laser welded joint of ferritic stainless steel

    NASA Astrophysics Data System (ADS)

    Wang, Yonghui; Hu, Shengsun; Shen, Junqi

    2015-10-01

    This study was based on the ferritic stainless steel SUS430. Under the parallel welding conditions, the critical penetration power values (CPPV) of 3mm steel plates with different surface-coating activating fluxes were tested. Results showed that, after coating with activating fluxes, such as ZrO2, CaCO3, CaF2 and CaO, the CPPV could reduce 100~250 W, which indicating the increases of the weld penetrations (WP). Nevertheless, the variation range of WP with or without activating fluxes was less than 16.7%. Compared with single-component ones, a multi-component activating flux composed of 50% ZrO2, 12.09% CaCO3, 10.43% CaO, and 27.49% MgO was testified to be much more efficient, the WP of which was about 2.3-fold of that without any activating fluxes. Furthermore, a FeCl3 spot corrosion experiment was carried out with samples cut from weld zone to test the effects of different activating fluxes on the corrosion resistant (CR) property of the laser welded joints. It was found that all kinds of activating fluxes could improve the CR of the welded joints. And, it was interesting to find that the effect of the mixed activating fluxes was inferior to those single-component ones. Among all the activating fluxes, the single-component of CaCO3 seemed to be the best in resisting corrosion. By means of Energy Dispersive Spectrometer (EDS) testing, it was found that the use of activating fluxes could effectively restrain the loss of Cr element of weld zone in the process of laser welding, thus greatly improving the CR of welded joints.

  18. Structure and Mechanical Properties of Welded Joints of Gas Transmission Pipes

    NASA Astrophysics Data System (ADS)

    Khotinov, V. A.; Farber, V. M.; Morozova, A. N.; Valov, M. A.; Sharipov, G. A.

    2014-09-01

    Astudy is made of the structure and mechanical properties of welded joints of pipes of strength class K60 produced by three different manufacturers. A detailed analysis of the microstructure of the central weld, heat-affected zone, and base metal is performed with a scanning electron microscope by the method of electron back-scattered diffraction.

  19. Electrical resistance determination of actual contact area of cold welded metal joints

    NASA Technical Reports Server (NTRS)

    Hordon, M. J.

    1970-01-01

    Method measures the area of the bonded zone of a compression weld by observing the electrical resistance of the weld zone while the load changes from full compression until the joint ruptures under tension. The ratio of bonding force to maximum tensile load varies considerably.

  20. Beam profile analysis for the C{ampersand}MS B231 electron beam welding machines

    SciTech Connect

    Elmer, J. W.; Teruya, A.T.; Gauthier, M.

    1997-06-12

    The electron beams produced by two different welders were examined using computer assisted tomographic (CT) analysis. The machines used are Hamilton Standard welders with 150 kV/50mA maximum. One machine uses a ribbon filament while the other uses a hairpin filament. The objective of this study was to characterize the beam power distribution on each machine to see if weld parameters could easily be transferred between machines. Beam focus, voltage, and current settings were pre-selected to duplicate the welding conditions used in LLNL program applications. The results show that the actual beam currents measured by Faraday cup are 5 to 10% higher for the first machine and 30% lower for the second. The CT analysis of the beam shapes shows that the hairpin filament welder produces an elliptical beam shape in the sharp focus condition that defocuses to a diamond shape. The ribbon filament welder produced less of an elliptical beam shape in the sharp focus condition, but when defocused, acquires an elliptical shape. CT analysis of the effects of defocus on the peak power density shows that the hairpin filament drops in peak power density much more quickly than the ribbon filament for a given amount of defocus. Furthermore, it was more difficult to find and repeat the sharp focus condition for the hairpin filament, particularly at higher beam currents.

  1. Numerical simulation of the effect of constraints on welding deformations and residual stresses in a pipe flange joint

    NASA Astrophysics Data System (ADS)

    Abid, Muhammad; Siddique, Muhammad

    2005-09-01

    This paper presents a detailed three-dimensional finite element (FE) study to investigate the effect of mechanical constraints on welding distortions and residual stresses in a pipe-flange joint. The FE model of a pipe-flange joint is subjected to sequentially couple nonlinear transient thermo-mechanical analysis to simulate complex welding phenomena. Single-pass gas metal arc welding for single 'V' butt-weld joint geometry of a 100 mm diameter pipe with compatible weld-neck ANSI flange class #300 of low carbon steel is simulated. Two tack-welds at 90° and 270° from the weld start position are modelled. Four different constraint conditions representing the welding of unassembled joints, welding of assembled joints, welding of assembled joints with reflective symmetry and welding of perfectly constrained joints are analysed. To model the constraints and boundary conditions more realistically contact pairs are used between the matching surfaces of different structural components. Basic FE models are validated with experimental data for temperature distribution and deformations. Predicted welding distortions and residual stresses are compared and discussed in detail. From the results, axial displacement and tilt of the flange face are found to be strongly dependant on the constraint conditions. Minimum axial distortion on the flange face is found for rigidly clamped flanges. However, residual stresses have a weak dependence on the constraints set.

  2. Electron beam welding of heavy-section 3 Cr-1. 5 Mo alloy

    SciTech Connect

    King, J.F.; David, S.A.; Sims, J.E.; Nasreldin, A.M.

    1986-01-01

    Electron beam welding is a process that could have advantages for the fabrication of heavy-section steel components such as pressure vessels. The penetrating ability of the beam produces welds with high depth-to-width ratios at relatively high travel speeds, making it possible to weld thick section with one or two passes without filler metals and other consumables. This paper describes a study that was undertaken to investigate the feasibility of using a high-power electron beam welding machine to weld heavy-section steel of 3 Cr-1.5 Mo-0.1 V alloy. Single-pass welds were made in 102-mm thick (4 in.) plates of this alloy. The main emphasis of this work was concentrated on determining the mechanical properties of the resulting weldment, characterizing the microstructure of the various weldment regions, and comparing these results with those from other welding processes. All characterization testing showed that the electron beam weldment in 3 Cr-1.5 Mo-0.1 V steel had excellent properties either matching or exceeding those of the base metal and weld metal from submerged arc welding and shielded metal arc welding processes.

  3. Characterization of electron-beam weld processes in uranium by acoustic emission monitoring

    SciTech Connect

    Whittaker, J.W.; Murphy, J.L.

    1989-08-19

    Work was begun to characterize electron-beam (EB) welding of uranium by use of acoustic emission (AE) monitoring at the Oak Ridge Y-12 Plant. One specific objective was to determine if a correlation existed between weld penetration and an AE parameter(s). AE monitoring techniques were developed which allowed detection and recording of AE information during welding. Initial results from bead-on-plate welds of uranium imply that the AE signal varies during different processes: weld initiation, process stabilization, steady-state weld formation, weld cessation, and material cool-down. A correlation was developed between the AE ''average signal level'' (ASL) parameter and weld penetration which implies that penetration can be predicted from a given measured ASL level. 1 ref., 7 figs., 1 tab.

  4. Electron beam welding of heavy-section 3Cr-1. 5 Mo alloy

    SciTech Connect

    King, J.F.; David, S.A.; Sims, J.E.; Nasreldin, A.M.

    1986-07-01

    Welding of thick-section steels is a common practice in the fabrication of energy systems. Components such as pressure vessels are large and must be economically fabricated with high integrity. The fabrication cost is strongly influenced by the speed at which these large components can be welded. Conventional welding processes, such as shielded metal arc (SMAW) and submerged arc (SAW), are time-consuming and expensive. Hence, there is a great need to reduce welding time and the tonnage of weld metal deposited. Electron beam welding (EBW) is a process that could be used to achieve dramatic reduction in the welding time and, hence, the cost. It has several attractive characteristics for the welding of thick sections.

  5. TEM Observation of Martensite Layer at the Weld Interface of an A508III to Inconel 82 Dissimilar Metal Weld Joint

    NASA Astrophysics Data System (ADS)

    Chen, Z. R.; Lu, Y. H.

    2015-12-01

    A lenticular martensite layer at the weld interface in an A508III/Inconel 82 dissimilar metal weld (DMW) joint was studied by TEM. The martensite/weld metal boundary was observed as the fusion boundary. There was a K-S orientation relationship between martensite and weld metal. The formation of the martensite was mainly determined by the distribution of alloy elements. The martensite was responsible for the hardness peak in the DMW.

  6. 46 CFR 56.30-5 - Welded joints.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... in accordance with part 57 of this subchapter. (b) Butt welds—general. Butt welds may be made with or... types of butt welding end preparations are shown in ASME B16.25 (incorporated by reference; see 46 CFR...

  7. Microstructure and Fatigue Properties of Laser Welded DP590 Dual-Phase Steel Joints

    NASA Astrophysics Data System (ADS)

    Xie, Chaojie; Yang, Shanglei; Liu, Haobo; Zhang, Qi; Cao, Yaming; Wang, Yuan

    2017-08-01

    In this paper, cold-rolled DP590 dual-phase steel sheets with 1.5 mm thickness were butt-welded by a fiber laser, and the evolution and effect on microhardness, tensile property and fatigue property of the welded joint microstructure were studied. The results showed that the base metal is composed of ferrite and martensite, with the martensite dispersed in the ferrite matrix in an island manner. The microstructure of the weld zone was lath-shaped martensite that can be refined further by increasing the welding speed, while the heat-affected zone was composed of ferrite and tempered martensite. The microhardness increased with increasing welding speed, and the hardness reached its highest value—393.8 HV—when the welding speed was 5 m/min. Static tensile fracture of the welded joints always occurred in the base metal, and the elongation at break was more than 16%. The conditional fatigue limits of the base metal and the weld joints were 354.2 and 233.6 MPa, respectively, under tension-tension fatigue tests with a stress rate of 0.1. After observation of the fatigue fracture morphology, it was evident that the fatigue crack of the base metal had sprouted into the surface pits and that its expansion would be accelerated under the action of a secondary crack. The fatigue source of the welded joint was generated in the weld zone and expanded along the martensite, forming a large number of fatigue striations. Transient breaking, which occurred in the heat-affected zone of the joint as a result of the formation of a large number of dimples, reflected the obvious characteristics of ductile fracture.

  8. Use of coatings for protection of welded joints of steels, their structure and properties

    NASA Astrophysics Data System (ADS)

    Bezborodov, V. P.; Saraev, Yu N.

    2017-05-01

    The paper studies the structure and demonstrates the efficiency of application of eutectic nickel coatings for protection of welded joints of the 10G2S-type steels from corrosive action. It increases simultaneously with the increase of eutectic content and chemical compounds along the grain boundaries of the γ-solid solution based on nickel. The refinement of the coatings’ structure and the reduction of their heterogeneity allow enhancing the protective properties and resistance of welded joints to corrosion.

  9. Multi-Response Optimization of Friction-Stir-Welded AA1100 Aluminum Alloy Joints

    NASA Astrophysics Data System (ADS)

    Rajakumar, S.; Balasubramanian, V.

    2012-06-01

    AA1100 aluminum alloy has gathered wide acceptance in the fabrication of light weight structures. Friction stir welding process (FSW) is an emerging solid state joining process in which the material that is being welded does not melt and recast. The process and tool parameters of FSW play a major role in deciding the joint characteristics. In this research, the relationships between the FSW parameters (rotational speed, welding speed, axial force, shoulder diameter, pin diameter, and tool hardness) and the responses (tensile strength, hardness, and corrosion rate) were established. The optimal welding conditions to maximize the tensile strength and minimize the corrosion rate were identified for AA1100 aluminum alloy and reported here.

  10. X-ray online detection for laser welding T-joint of Al-Li alloy

    NASA Astrophysics Data System (ADS)

    Zhan, Xiaohong; Bu, Xing; Qin, Tao; Yu, Haisong; Chen, Jie; Wei, Yanhong

    2017-05-01

    In order to detect weld defects in laser welding T-joint of Al-Li alloy, a real-time X-ray image system is set up for quality inspection. Experiments on real-time radiography procedure of the weldment are conducted by using this system. Twin fillet welding seam radiographic arrangement is designed according to the structural characteristics of the weldment. The critical parameters including magnification times, focal length, tube current and tube voltage are studied to acquire high quality weld images. Through the theoretical and data analysis, optimum parameters are settled and expected digital images are captured, which is conductive to automatic defect detection.

  11. Effect of Friction Welding Condition on Joining Phenomena and Tensile Strength of Friction Welded joint between Pure Copper and Low Carbon Steel

    NASA Astrophysics Data System (ADS)

    Kimura, Masaaki; Kusaka, Masahiro; Kaizu, Koichi; Fuji, Akiyoshi

    This paper describes the effect of the friction welding condition on the joining phenomena and tensile strength of friction welded joint between pure copper (OFC) and low carbon steel (LCS). When the joint was made at friction pressure of 30 MPa with friction speed of 27.5 s-1, OFC transferred to the half radius region of the weld interface on the LCS side, and then transferred toward the entire weld interface. The temperatures at the centerline, half radius and periphery portions on the weld interface of the LCS side were almost the same after the initial peak. When the joint was made at a friction time of 2.4 s, i.e. the friction torque was close to the initial peak, that had obtained approximately 40% joint efficiency and fractured from the weld interface with a little OFC adhering to the weld interface on the LCS side. The joint efficiency increased with increasing forge pressure, and it reached approximately 80% at a forge pressure of 180 MPa. This joint fractured at the softened OFC region adjacent to the weld interface. On the other hand, OFC transferred to the peripheral region of the weld interface on the LCS side when the joint was made at friction pressure of 90 MPa with friction speed of 27.5 s-1. However, OFC transfer was not obtained at the central region because the temperature at the periphery portion was higher than that of the other portions. The joint efficiency increased with increasing friction time, and it obtained approximately 74% at a friction time of 1.2 s. Moreover, all joints fractured between the OFC side and the weld interface, although the joints were made with higher forge pressure. To obtain higher joint efficiency and fracture in the OFC side, the joint should be made with low friction pressure and high forge pressure, and with the friction time at which the friction torque reaches the initial peak.

  12. Numerical model of the plasma formation at electron beam welding

    SciTech Connect

    Trushnikov, D. N.; Mladenov, G. M.

    2015-01-07

    The model of plasma formation in the keyhole in liquid metal as well as above the electron beam welding zone is described. The model is based on solution of two equations for the density of electrons and the mean electron energy. The mass transfer of heavy plasma particles (neutral atoms, excited atoms, and ions) is taken into account in the analysis by the diffusion equation for a multicomponent mixture. The electrostatic field is calculated using the Poisson equation. Thermionic electron emission is calculated for the keyhole wall. The ionization intensity of the vapors due to beam electrons and high-energy secondary and backscattered electrons is calibrated using the plasma parameters when there is no polarized collector electrode above the welding zone. The calculated data are in good agreement with experimental data. Results for the plasma parameters for excitation of a non-independent discharge are given. It is shown that there is a need to take into account the effect of a strong electric field near the keyhole walls on electron emission (the Schottky effect) in the calculation of the current for a non-independent discharge (hot cathode gas discharge). The calculated electron drift velocities are much bigger than the velocity at which current instabilities arise. This confirms the hypothesis for ion-acoustic instabilities, observed experimentally in previous research.

  13. The Effect of Weld Profile and Geometries of Butt Weld Joints on Fatigue Life Under Cyclic Tensile Loading

    NASA Astrophysics Data System (ADS)

    Al-Mukhtar, A. M.; Biermann, H.; Hübner, P.; Henkel, S.

    2011-11-01

    The fatigue life of welded joint was calculated based on numerical integration of simple Paris' law and a reliable solution of the stress intensity factor (SIF). The initial crack length ( a i) was assumed to be equal to 0.1 mm in case of weld toe. This length was satisfactory for different butt joints geometries. The comparisons with the available data from standards and literature were demonstrated. It was shown numerically that the machining of weld reinforcements will increase the fatigue life. The increase of plate thickness decreases the fatigue strength (FAT) and the number of cycles to failure when using the proportional scaling of crack length. The validation processes of the current calculations have been shown. Therefore, it can be concluded that it will prevent the unnecessary waste of time consumed to carry out the experiments.

  14. Influence of Material Model on Prediction Accuracy of Welding Residual Stress in an Austenitic Stainless Steel Multi-pass Butt-Welded Joint

    NASA Astrophysics Data System (ADS)

    Deng, Dean; Zhang, Chaohua; Pu, Xiaowei; Liang, Wei

    2017-03-01

    Both experimental method and numerical simulation technology were employed to investigate welding residual stress distribution in a SUS304 steel multi-pass butt-welded joint in the current study. The main objective is to clarify the influence of strain hardening model and the yield strength of weld metal on prediction accuracy of welding residual stress. In the experiment, a SUS304 steel butt-welded joint with 17 passes was fabricated, and the welding residual stresses on both the upper and bottom surfaces of the middle cross section were measured. Meanwhile, based on ABAQUS Code, an advanced computational approach considering different plastic models as well as annealing effect was developed to simulate welding residual stress. In the simulations, the perfect plastic model, the isotropic strain hardening model, the kinematic strain hardening model and the mixed isotropic-kinematic strain hardening model were employed to calculate the welding residual stress distributions in the multi-pass butt-welded joint. In all plastic models with the consideration of strain hardening, the annealing effect was also taken into account. In addition, the influence of the yield strength of weld metal on the simulation result of residual stress was also investigated numerically. The conclusions drawn by this work will be helpful in predicting welding residual stresses of austenitic stainless steel welded structures used in nuclear power plants.

  15. Influence of Material Model on Prediction Accuracy of Welding Residual Stress in an Austenitic Stainless Steel Multi-pass Butt-Welded Joint

    NASA Astrophysics Data System (ADS)

    Deng, Dean; Zhang, Chaohua; Pu, Xiaowei; Liang, Wei

    2017-04-01

    Both experimental method and numerical simulation technology were employed to investigate welding residual stress distribution in a SUS304 steel multi-pass butt-welded joint in the current study. The main objective is to clarify the influence of strain hardening model and the yield strength of weld metal on prediction accuracy of welding residual stress. In the experiment, a SUS304 steel butt-welded joint with 17 passes was fabricated, and the welding residual stresses on both the upper and bottom surfaces of the middle cross section were measured. Meanwhile, based on ABAQUS Code, an advanced computational approach considering different plastic models as well as annealing effect was developed to simulate welding residual stress. In the simulations, the perfect plastic model, the isotropic strain hardening model, the kinematic strain hardening model and the mixed isotropic-kinematic strain hardening model were employed to calculate the welding residual stress distributions in the multi-pass butt-welded joint. In all plastic models with the consideration of strain hardening, the annealing effect was also taken into account. In addition, the influence of the yield strength of weld metal on the simulation result of residual stress was also investigated numerically. The conclusions drawn by this work will be helpful in predicting welding residual stresses of austenitic stainless steel welded structures used in nuclear power plants.

  16. Microstructure and Mechanical Properties of Resistance Spot Welding Joints of Carbonitrided Low-Carbon Steels

    NASA Astrophysics Data System (ADS)

    Taweejun, Nipon; Poapongsakorn, Piyamon; Kanchanomai, Chaosuan

    2017-04-01

    Carbonitrided low-carbon steels are resistance welded in various engineering components. However, there are no reports on the microstructure and mechanical properties of their resistance spot welding (RSW) joints. Therefore, various carbonitridings were performed on the low-carbon steel sheets, and then various RSWs were applied to these carbonitrided sheets. The metallurgical and mechanical properties of the welding joint were investigated and discussed. The peak load and failure energy increased with the increases of welding current and fusion zone (FZ) size. At 11 kA welding current, the carbonitrided steel joint had the failure energy of 16 J, i.e., approximately 84 pct of untreated steel joint. FZ of carbonitrided steel joint consisted of ferrite, Widmanstatten ferrite, and untempered martensite, i.e., the solid-state transformation products, while the microstructure at the outer surfaces consisted of untempered martensite and retained austenite. The surface hardening of carbonitrided steel after RSW could be maintained, i.e., approximately 810 HV. The results can be applied to carbonitriding and RSW to achieve a good welding joint.

  17. Microstructural Characteristics and Mechanical Properties of 7050-T7451 Aluminum Alloy Friction Stir-Welded Joints

    NASA Astrophysics Data System (ADS)

    Zhou, L.; Wang, T.; Zhou, W. L.; Li, Z. Y.; Huang, Y. X.; Feng, J. C.

    2016-06-01

    The ultra-high-strength Al-Zn-Mg-Cu alloy, 7050-T7451, was friction stir welded at a constant tool rotation speed of 600 rpm. Defect-free welds were successfully obtained at a welding speed of 100 mm/min, but lack-of-penetration defect was formed at a welding speed of 400 mm/min. The as-received material was mainly composed of coarse-deformed grains with some fine recrystallized grains. Fine equiaxed, dynamic, recrystallized grains were developed in the stir zone, and elongated grains were formed in the thermomechanically affected zone with dynamic recovered subgrains. Grain sizes in different regions of friction stir-welded joints varied depending on the welding speed. The sizes and distributions of precipitates changed in different regions of the joint, and wider precipitation free zone was developed in the heat-affected zone compared to that in the base material. Hardness of the heat-affected zone was obviously lower than that of the base material, and the softening region width was related to the welding speed. The tensile strength of the defect-free joints increased with the increasing welding speed, while the lack-of-penetration defect greatly reduced the tensile strength. The tensile fracture path was significantly influenced by the position and orientation of lack-of-penetration defect.

  18. Joint strength in high speed friction stir spot welded DP 980 steel

    SciTech Connect

    Saunders, Nathan; Miles, Michael; Hartman, Trent; Hovanski, Yuri; Hong, Sung Tae; Steel, Russell

    2014-05-01

    High speed friction stir spot welding was applied to 1.2 mm thick DP 980 steel sheets under different welding conditions, using PCBN tools. The range of vertical feed rates used during welding was 2.5 mm – 102 mm per minute, while the range of spindle speeds was 2500 – 6000 rpm. Extended testing was carried out for five different sets of welding conditions, until tool failure. These welding conditions resulted in vertical welding loads of 3.6 – 8.2 kN and lap shear tension failure loads of 8.9 – 11.1 kN. PCBN tools were shown, in the best case, to provide lap shear tension fracture loads at or above 9 kN for 900 spot welds, after which tool failure caused a rapid drop in joint strength. Joint strength was shown to be strongly correlated to bond area, which was measured from weld cross sections. Failure modes of the tested joints were a function of bond area and softening that occurred in the heat-affected zone.

  19. Development of phased array ultrasonic testing in lieu of radiography for testing complete joint penetration (CJP) welds

    NASA Astrophysics Data System (ADS)

    Haldipur, P.; Boone, Shane D.

    2014-04-01

    The past decade has seen new, emerging innovation of Ultrasonic Testing (UT). Specifically, multiple manufacturers have produced Phased Array Ultrasonic Testing (PAUT) systems. The PAUT systems embed a matrix of multiple (some up to 128) single transducers into one probe used for scanning elastic materials. Simultaneously exciting multiple transducers offers distinct advantages; depending on the sequencing of transducer excitation, the ultrasonic beam could be steered within the material and multiple beams help develop extra dimensional data to assist with visualization of possible flaws including the discontinuity size, shape and location. Unfortunately, there has not been broad acceptance of PAUT in the bridge fabrication industry because it is currently not a recognized inspection technology in AWS D1.5. One situation in which the technology would excel would be inspection of Complete Joint Penetration (CJP) butt welds. Currently, AWS D1.5 required CJP welds subjected to tensile or reversal stresses only be inspected by Radiographic Testing (RT). However, discontinuities normally seen by RT can also be seen with PAUT. Until specification language is adopted into D1.5, there will continue to be hesitancy to use PAUT for the inspection of CJP butt welds. Developmental work must first be performed to develop the acceptance criteria and the specification language. The developmental work from the inspections carried out on butt-weld specimens and transition butt-weld specimens are presented in this paper. Specific scan plans were developed using the ES-Beam simulation software for each of the test specimens. In depth analysis of PAUT data obtained to determine exact location and sizing information of the defects was performed. The results also present the comparison of results from PAUT to those obtained using conventional UT and radiography.

  20. Nickel aluminide-copper backing for butt joint welding

    SciTech Connect

    Raghavan, S.; Muszynski, M.; Chin, B.A.; Nagarajan, S.

    1996-12-31

    Single-side full penetration welding is the primary welding process in shipbuilding. This process requires the use of a backing to support the molten metal. Conventionally, copper has been used as the backing material in the shop and ceramic tiles for jobs on the field. However, copper has shown to contaminate the weld and produce adverse effects and ceramics have shown to produce porosities in the weld. A new backing with an intermetallic layer (NiAl) on the copper surface has been fabricated. The results indicate that this backing could alleviate the contamination problems and produce quality welds.

  1. Vibrational Energy Flows in Beam Networks with Compliant and Dissipative Joints

    NASA Astrophysics Data System (ADS)

    Beshara, M.; Keane, A. J.

    1997-06-01

    Many structures and machines are made up from components (rods, beams and plates) which are joined together by welds, bolts or rivets. The mechanical behaviour of such built-up systems is greatly affected by the properties of their joints which are usually compliant and dissipative.In this work, a general solution for the vibrational energy flows through a plane network of beams is sought, based on the receptance approach. The joints between any two elements are assumed to act at discrete points and are modelled by three sets of springs and dashpots, thus being compliant and non-conservative in all the three degrees of freedom relevant to this case. The beams are assumed to be slender and elastic, and the deflections at the joint are assumed to be small, so that conventional linear beam theory may be used in the analysis. The aim of this study is to give greater insight into the problem of non-conservative coupling, which has not been extensively discussed in the literature. Interest is focused on the effect of damping in the joints on the magnitudes of energy flows between, and energy levels in, each beam. Variations in the energy flows through a compliant joint between two beams with changes in their coupling angle are also discussed. Numerical examples which illustrate these various ideas are presented.

  2. Air boring and nonvacuum electron beam welding with a plasma window

    SciTech Connect

    Hershcovitch, Ady

    2005-05-15

    The plasma window is a novel apparatus that utilizes a stabilized plasma arc as interface between vacuum and atmosphere or pressurized targets without solid material. Additionally, the plasma has a lensing effect on charged particles. This feature enables beam focusing to very small spot sizes and overcoming beam dispersion due to scattering by atmospheric atoms and molecules. Recently, the plasma window was mated to a conventional electron beam welder. And, electron beam welding in atmosphere was accomplished with electron beams of unprecedented low power and energy. Weld quality for the nonvacuum plasma window electron beam welding approached the quality of in-vacuum electron beam welding, without the use of helium as process gas. Weld widths were independent of stand-off distance for up to 5 cm, which along with visual observations suggest that pinched beam propagation might have been achieved with 6-25 mA, 90-150 KeV electron beams. That may explain the better than expected welding results. By comparison previously demonstrated self-pinched propagation used kA MeV electron beams.

  3. Microstructural Characteristics of a Stainless Steel/Copper Dissimilar Joint Made by Laser Welding

    NASA Astrophysics Data System (ADS)

    Chen, Shuhai; Huang, Jihua; Xia, Jun; Zhang, Hua; Zhao, Xingke

    2013-08-01

    The microstructures and its formation mechanism of a stainless steel/copper dissimilar joint by laser welding were investigated. It was found that the two modes of joining, i.e., welding-brazing and fusion welding, depend on different processing parameters. In the welding-brazing mode, the interface between copper and the fusion zone has scraggy morphology because the molten pool is frozen by solid copper with high thermal conductivity. The interdiffusion of elements occurs in the neighborhood of the interface, which leads to the metallurgy bond of the mode. In the fusion welding mode, the liquid phase in the fusion zone undergoes not only primary but also secondary liquid separation due to the high cooling rate and high supercooling level of laser welding. Some microcracks generated in the fusion zone by thermal stress mismatch are healed by liquid copper filling.

  4. Role of heat equation in lap joint for welding process

    NASA Astrophysics Data System (ADS)

    Kumar, P.; Rohit, Sooraj

    2017-07-01

    Welding is predominantly used in industrial purposes and growth in their industry, which gives exact welding and more efficient. The major advantage of using this welding technique at initial stage it takes very low heat to weld the portion and gives a good result of low distortion in modules. In this context, two dissimilar metals copper and nickel are chosen for analysis in tungsten inert gas welding (TIG) in which length is 300 mm and breadth is 100 mm thickness 15 mm welded at room temperature a welded portion zone is formed simulation analysis has done on CATIA® and ANSYS®and MATLAB® code is generated for calculating temperatures at each node to calculate temperature at each node a new technique is used tri-diagonal matrix algorithm is used (TDMA) Steady state one dimension heat is calculated results compared between simulation analysis and analytical analysis temperature at each node is calculated both the temperatures are equal with error.

  5. Nonlinear dynamic characteristic analysis of jointed beam with clearance

    NASA Astrophysics Data System (ADS)

    Zhang, Jing; Guo, Hong-Wei; Liu, Rong-Qiang; Wu, Juan; Kou, Zi-Ming; Deng, Zong-Quan

    2016-12-01

    The impact and elasticity of discontinuous beams with clearance frequently affect the dynamic response of structures used in space missions. This study investigates the dynamic response of jointed beams which are the periodic units of deployable structures. The vibration process of jointed beams includes free-play and impact stages. A method for the dynamic analysis of jointed beams with clearance is proposed based on mode superposition and instantaneous static deformation. Transfer matrix, which expresses the relationship of the responses before and after the impact of jointed beams, is derived to calculate the response of the jointed beams after a critical position. The dynamic responses of jointed beams are then simulated. The effects of various parameters on the displacement and velocity of beams are investigated.

  6. CHARACTERIZATION OF Pro-Beam LOW VOLTAGE ELECTRON BEAM WELDING MACHINE

    SciTech Connect

    Burgardt, Paul; Pierce, Stanley W.

    2015-02-18

    The purpose of this paper is to present and discuss data related to the performance of a newly acquired low voltage electron beam welding machine. The machine was made by Pro-Beam AG &Co. KGaA of Germany. This machine was recently installed at LANL in building SM -39; a companion machine was installed in the production facility. The PB machine is substantially different than the EBW machines typically used at LANL and therefore, it is important to understand its characteristics as well as possible. Our basic purpose in this paper is to present basic machine performance data and to compare those with similar results from the existing EBW machines. It is hoped that this data will provide a historical record of this machine’s characteristics as well as possibly being helpful for transferring welding processes from the old EBW machines to the PB machine or comparable machines that may be purchased in the future.

  7. Comparison of joint designs for laser welding of cast metal plates and wrought wires.

    PubMed

    Takayama, Yasuko; Nomoto, Rie; Nakajima, Hiroyuki; Ohkubo, Chikahiro

    2013-01-01

    The purpose of the present study was to compare joint designs for the laser welding of cast metal plates and wrought wire, and to evaluate the welded area internally using X-ray micro-focus computerized tomography (micro-CT). Cast metal plates (Ti, Co-Cr) and wrought wires (Ti, Co-Cr) were welded using similar metals. The specimens were welded using four joint designs in which the wrought wires and the parent metals were welded directly (two designs) or the wrought wires were welded to the groove of the parent metal from one or both sides (n = 5). The porosity and gap in the welded area were evaluated by micro-CT, and the maximum tensile load of the welded specimens was measured with a universal testing machine. An element analysis was conducted using an electron probe X-ray microanalyzer. The statistical analysis of the results was performed using Bonferroni's multiple comparisons (α = 0.05). The results included that all the specimens fractured at the wrought wire when subjected to tensile testing, although there were specimens that exhibited gaps due to the joint design. The wrought wires were affected by laser irradiation and observed to melt together and onto the filler metal. Both Mo and Sn elements found in the wrought wire were detected in the filler metal of the Ti specimens, and Ni was detected in the filler metal of the Co-Cr specimens. The four joint designs simulating the designs used clinically were confirmed to have adequate joint strength provided by laser welding.

  8. Microstructure of friction stir welded joints of 2017A aluminium alloy sheets.

    PubMed

    Mroczka, K; Dutkiewicz, J; Pietras, A

    2010-03-01

    The present study examines a friction stir welded 2017A aluminium alloy. Transmission electron microscope investigations of the weld nugget revealed the average grain size of 5 microm, moderate density of dislocations as well as the presence of nanometric precipitates located mostly in grains interiors. Scanning electron microscope observations of fractures showed the presence of ductile fracture in the region of the weld nugget with brittle precipitates in the lower part. The microhardness analysis performed on the cross-section of the joints showed fairly small changes; however, after the artificial ageing process an increase in hardness was observed. The change of the joint hardness subject to the ageing process indicates partial supersaturation in the material during friction stir welding and higher precipitation hardening of the joint.

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

    NASA Technical Reports Server (NTRS)

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

    1972-01-01

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

  10. Microstructure and Mechanical Properties of Laser-Welded Joints of Ti-22Al-25Nb/TA15 Dissimilar Titanium Alloys

    NASA Astrophysics Data System (ADS)

    Li, Dalong; Hu, Shengsun; Shen, Junqi; Zhang, Hao; Bu, Xianzheng

    2016-05-01

    Laser beam welding (LBW) was applied to join 1-mm-thick dissimilar titanium alloys, Ti-22Al-25Nb (at.%) and TA15, and the microstructure and mechanical properties of the welded joints were systematically analyzed. Defect-free joints were obtained, and the fusion zone mainly consisted of B2 and martensitic α' phases because of the uneven distribution of the β phase stabilizer and rapid cooling rate of LBW. The phase compositions of the heat-affected zone varied with the different thermal cycles during the welding process. The different microstructures of the dissimilar titanium alloys led to an unsymmetrical hardness profile, with the welded seam exhibiting the lowest value of 271 HV. In room-temperature tensile tests, the fractures all occurred preferentially in the fusion zone. The strengths of the joints were close to those of the base metal but with prominently decreasing ductility. In tensile tests performed at 550 °C, all the joints fractured in the TA15 base metal, and the strength and plasticity of the welds were equivalent to those of the TA15 base metal.

  11. A Study of Microstructure and Mechanical Properties of Grade 91 Steel A-TIG Weld Joint

    NASA Astrophysics Data System (ADS)

    Arivazhagan, B.; Vasudevan, M.

    2013-12-01

    In the present study, A-TIG welding was carried out on grade 91 steel plates of size 220 × 110 × 10 mm using the in-house developed activated flux to produce butt-joints. The room-temperature impact toughness of the A-TIG as-welded joint was low due to the presence of untempered martensite matrix despite the low microinclusion density caused by activated flux and also low δ-ferrite (<0.5 %) content. Toughness after postweld heat treatment (PWHT) at 760 °C-2 h was 20 J as against the required value of 47 J as per the specification EN: 1557:1997. However, there was a significant improvement in impact toughness after PWHT at 760 °C for 3 h. The improvement in toughness was attributed to softening of martensite matrix caused by precipitation of carbides due to tempering reactions. The precipitates are of type M23C6, and they are observed at grain boundary as well as within the grains. The A-TIG-processed grade 91 steel weld joint was found to meet the toughness requirements after PWHT at 760 °C-3 h. Observations of fracture surfaces using SEM revealed that the as-welded joint failed by brittle fracture, whereas post-weld heat-treated weld joints failed by decohesive rupture mode.

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

    NASA Astrophysics Data System (ADS)

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

    2015-09-01

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

  13. Effect of joint design and welding type on the flexural strength and weld penetration of Ti-6Al-4V alloy bars.

    PubMed

    Simamoto Júnior, Paulo Cézar; Resende Novais, Veridiana; Rodrigues Machado, Asbel; Soares, Carlos José; Araújo Raposo, Luís Henrique

    2015-05-01

    Framework longevity is a key factor for the success of complete-arch prostheses and commonly depends on the welding methods. However, no consensus has been reached on the joint design and welding type for improving framework resistance. The purpose of this study was to assess the effect of different joint designs and welding methods with tungsten inert gas (TIG) or laser to join titanium alloy bars (Ti-6Al-4V). Seventy titanium alloy bar specimens were prepared (3.18 mm in diameter × 40.0 mm in length) and divided into 7 groups (n=10): the C-control group consisting of intact specimens without joints and the remaining 6 groups consisting of specimens sectioned perpendicular to the long-axis and rejoined using an I-, X30-, or X45-shaped joint design with TIG welding (TI, TX30, and TX45) or laser welding (LI, LX30, and LX45). The specimens were tested with 3-point bending. The fracture surfaces were first evaluated with stereomicroscopy to measure the weld penetration area and then analyzed with scanning electron microscopy (SEM). The data were statistically analyzed with 2-way ANOVA and the Tukey post hoc test, 1-way ANOVA and the Dunnett test, and the Pearson correlation test (α=.05). Specimens from the X30 and X45 groups showed higher flexural strength (P<.05) and welded area (P<.05) than specimens from the I groups, regardless of the welding type. TIG welded groups showed significantly higher flexural strength than the laser groups (P<.05), regardless of the joint design. TIG welding also resulted in higher welded areas than laser welding for the I-shaped specimens. No significant differences were found for the weld penetration area in the X45 group, either for laser or TIG welding. SEM analysis showed more pores at the fracture surfaces of the laser specimens. Fracture surfaces indicative of regions of increased ductility were detected for the TIG specimens. TIG welding resulted in higher flexural strength for the joined titanium specimens than laser welding

  14. Tensile strength and corrosion resistance of brazed and laser-welded cobalt-chromium alloy joints.

    PubMed

    Zupancic, Rok; Legat, Andraz; Funduk, Nenad

    2006-10-01

    The longevity of prosthodontic restorations is often limited due to the mechanical or corrosive failure occurring at the sites where segments of a metal framework are joined together. The purpose of this study was to determine which joining method offers the best properties to cobalt-chromium alloy frameworks. Brazed and 2 types of laser-welded joints were compared for their mechanical and corrosion characteristics. Sixty-eight cylindrical cobalt-chromium dental alloy specimens, 35 mm long and 2 mm in diameter, were cast. Sixteen specimens were selected for electrochemical measurements in an artificial saliva solution and divided into 4 groups (n=4). In the intact group, the specimens were left as cast. The specimens of the remaining 3 groups were sectioned at the center, perpendicular to the long-axis, and were subsequently rejoined by brazing (brazing group) or laser welding using an X- or I-shaped joint design (X laser and I laser groups, respectively). Another 16 specimens were selected for electrochemical measurements in a more acidic artificial saliva solution. These specimens were also divided into 4 groups (n=4) as described above. Electrochemical impedance spectroscopy and potentiodynamic polarization were used to assess corrosion potentials, breakdown potentials, corrosion current densities, total impedances at lowest frequency, and polarization charge-transfer resistances. The remaining 36 specimens were used for tensile testing. They were divided into 3 groups in which specimen pairs (n=6) were joined by brazing or laser welding to form 70-mm-long cylindrical rods. The tensile strength (MPa) was measured using a universal testing machine. Differences between groups were analyzed using 1-way analysis of variance (alpha=.05). The fracture surfaces and corrosion defects were examined with a scanning electron microscope. The average tensile strength of brazed joints was 792 MPa and was significantly greater (P<.05) than the tensile strength of both types of

  15. Electron beam welding of aircraft structures. [joining of titanium alloy wing structures on F-14 aircraft

    NASA Technical Reports Server (NTRS)

    Witt, R. H.

    1972-01-01

    Requirements for advanced aircraft have led to more extensive use of titanium alloys and the resultant search for joining processes which can produce lightweight, high strength airframe structures efficiently. As a result, electron beam welding has been investigated. The following F-14A components are now being EB welded in production and are mainly annealed Ti-6Al-4V except for the upper wing cover which is annealed Ti-6Al-6V-2Sn: F-14A wing center section box, and F-14A lower and upper wing covers joined to wing pivot fitting assemblies. Criteria for selection of welding processes, the EB welding facility, development work on EB welding titanium alloys, and F-14A production and sliding seal electron beam welding are reported.

  16. The Influence of Modes of Deposition of Coatings on the Corrosion Resistance of Welded Joints of Steels in Acidic Media;

    NASA Astrophysics Data System (ADS)

    Saraev, Yu N.; Bezborodov, V. P.; Selivanov, Y. V.

    2016-08-01

    In this work, effect of welding on corrosion of welded joints of austenitic steel 12KH18N10T. It is shown that the use of pulsed - arc welding steel 12KH18N10T allows you to create a protective coating with dispersed structure with less thermal impact on the zone of the welded joint. Coating is of such structure allows 1.5 to 6 times to reduce the corrosion rate of welded joints of steel 12KH18N10T in active chemical environments. Pulse the process of deposition of coatings on welded joint of steels can be effectively used for the protection against corrosion in the repair of equipment of chemical industry. The results obtained can be recommended for use when welding a protective corrosion - resistant coatings on working surfaces of equipment of chemical productions.

  17. Effect of Activated Flux on the Microstructure, Mechanical Properties, and Residual Stresses of Modified 9Cr-1Mo Steel Weld Joints

    NASA Astrophysics Data System (ADS)

    Maduraimuthu, V.; Vasudevan, M.; Muthupandi, V.; Bhaduri, A. K.; Jayakumar, T.

    2012-02-01

    A novel variant of tungsten inert gas (TIG) welding called activated-TIG (A-TIG) welding, which uses a thin layer of activated flux coating applied on the joint area prior to welding, is known to enhance the depth of penetration during autogenous TIG welding and overcomes the limitation associated with TIG welding of modified 9Cr-1Mo steels. Therefore, it is necessary to develop a specific activated flux for enhancing the depth of penetration during autogeneous TIG welding of modified 9Cr-1Mo steel. In the current work, activated flux composition is optimized to achieve 6 mm depth of penetration in single-pass TIG welding at minimum heat input possible. Then square butt weld joints are made for 6-mm-thick and 10-mm-thick plates using the optimized flux. The effect of flux on the microstructure, mechanical properties, and residual stresses of the A-TIG weld joint is studied by comparing it with that of the weld joints made by conventional multipass TIG welding process using matching filler wire. Welded microstructure in the A-TIG weld joint is coarser because of the higher peak temperature in A-TIG welding process compared with that of multipass TIG weld joint made by a conventional TIG welding process. Transverse strength properties of the modified 9Cr-1Mo steel weld produced by A-TIG welding exceeded the minimum specified strength values of the base materials. The average toughness values of A-TIG weld joints are lower compared with that of the base metal and multipass weld joints due to the presence of δ-ferrite and inclusions in the weld metal caused by the flux. Compressive residual stresses are observed in the fusion zone of A-TIG weld joint, whereas tensile residual stresses are observed in the multipass TIG weld joint.

  18. Laser Beam Welding of Ultra-high Strength Chromium Steel with Martensitic Microstructure

    NASA Astrophysics Data System (ADS)

    Dahmen, Martin; Janzen, Vitalij; Lindner, Stefan; Wagener, Rainer

    A new class of steels is going to be introduced into sheet manufacturing. Stainless ferritic and martensitic steels open up opportunities for sheet metal fabrication including hot stamping. Strengths of up to 2 GPa at fracture elongations of 15% can be attained through this. Welding of these materials, as a result, became a challenge. Energy-reduced welding methods with in-situ heat treatment are required in order to ensure the delicate and complex heat control. Laser beam welding is the joining technique of choice to supply minimum heat input to the fusion process and to apply efficient heat control. For two application cases, tailored blank production in as-rolled condition and welding during assembly in hot stamped condition, welding processes have been developed. The welding suitability is shown through metallurgical investigations of the welds. Crash tests based on the KS-II concept as well as fatigue tests prove the applicability of the joining method.

  19. Gas Shielding Technology for Welding and Brazing

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur J.; Gradl, Paul R.

    2012-01-01

    Welding is a common method that allows two metallic materials to be joined together with high structural integrity. When joints need to be leak-tight, light-weight, or free of contaminant-trapping seams or surface asperities, welding tends to be specified. There are many welding techniques, each with its own advantages and disadvantages. Some of these techniques include Forge Welding, Gas Tungsten Arc Welding, Friction Stir Welding, and Laser Beam Welding to name a few. Whichever technique is used, the objective is a structural joint that meets the requirements of a particular component or assembly. A key practice in producing quality welds is the use of shielding gas. This article discusses various weld techniques, quality of the welds, and importance of shielding gas in each of those techniques. Metallic bonds, or joints, are produced when metals are put into intimate contact. In the solid-state "blacksmith welding" process, now called Forge Welding (FOW), the site to be joined is pounded into intimate contact. The surfaces to be joined usually need to be heated to make it easier to deform the metal. The surfaces are sprinkled with a flux to melt surface oxides and given a concave shape so that surface contamination can be squeezed out of the joint as the surfaces are pounded together; otherwise the surface contamination would be trapped in the joint and would weaken the weld. In solid-state welding processes surface oxides or other contamination are typically squeezed out of the joint in "flash."

  20. Experimental and numerical studies on the issues in laser welding of light-weight alloys in a zero-gap lap joint configuration

    NASA Astrophysics Data System (ADS)

    Harooni, Masoud

    current study a non-destructive evaluation method based on spectroscopy is proposed to detect the presence of pores in the lap joint of laser welded AZ31B magnesium alloy. The electron temperature that is calculated by the Boltzmann plot method is correlated to the presence of pores in the weld bead. A separate series of experiments was performed to evaluate the effect of an oxide coating layer on the dynamic behavior of the molten pool in the laser welding of an AZ31B magnesium alloy in a zero-gap lap joint configuration. A high speed CCD camera assisted with a green laser as an illumination source was selected to record the weld pool dynamics. Another technique used in this study was two-pass laser welding process to join AZ31B magnesium sheet in a zero-gap, lap-shear configuration. Two groups of samples including one pass laser welding (OPLW) and two pass laser welding (TPLW) were studied. In the two pass laser welding procedure, the first pass is performed by a defocused laser beam on the top of the two overlapped sheets in order to preheat the faying surface prior to laser welding, while the second pass is applied to melt and eventually weld the samples. Tensile and microhardness tests were used to measure the mechanical properties of the laser welded samples. A spectrometer was also used in real-time to correlate pore formation with calculated electron temperature using the Boltzmann plot method. The results of calculated electron temperature confirmed the previous results in earlier chapter. Magnesium and aluminum are two alloys which are used in different industries mainly due to their light weight. The main use of these two alloys is in automotive industry. Since different parts of the automobiles can be manufactured with each of these two alloys, it is essential to evaluate the joining feasibility of dissimilar metals such as aluminum to magnesium. A 4 kW fiber laser is used to join AZ31B magnesium alloy to AA 6014 using an overlap joint configuration. Two

  1. Effect of Temperature on Microstructure and Fracture Mechanisms in Friction Stir Welded Al6061 Joints

    NASA Astrophysics Data System (ADS)

    Dorbane, A.; Ayoub, G.; Mansoor, B.; Hamade, R. F.; Imad, A.

    2017-05-01

    Aluminum and its alloys are widely used in different industries due to such attractive properties as adequate strength, ductility, and low density. It is desirable to characterize welds of aluminum alloys obtained using "friction stir welding" at high temperatures. Al-to-Al (both 6061-T6) butt joints are produced by friction stir welding at tool rotation speed of 1600 rpm and four levels of tool advancing speeds: 250, 500, 750, and 1000 mm/min. Microstructural properties of the different welds are investigated. Observed are noticeable differences in microstructure characteristics between the various weld zones. Mechanical properties of these welded joints are characterized under tensile tests at temperatures of 25, 100, 200, and 300 °C, at a constant strain rate of 10-3/s. The optimum microstructural and mechanical properties were obtained for the samples FS welded with 1600 rpm tool rotation speed at 1000 mm/min tool advancing speed. The studied welds exhibited yield strength, ultimate tensile strength, and strain to failure with values inferior of those of the base material. Observations of postmortem samples revealed that in the temperature range of 25-200 °C the locus of failure originates at the region between the thermo-mechanically affected zone and the heat-affected zones. However, at higher temperatures (300 °C), the failure occurs in the stir zone. A change in the crack initiation mechanism with temperature is suggested to explain this observation.

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

    SciTech Connect

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

    2007-10-01

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

  3. Mechanical and structural characteristics of commercially pure grade 2 Ti welds and solder joints.

    PubMed

    Anselm Wiskott, H W; Doumas, T; Scherrer, S S; Belser, U C; Susz, C

    2001-08-01

    This study aimed at determining whether data previously gathered for a laser welds and IR brazings using a Au-Pd alloy were applicable to titanium joints. As to its resistance under fatigue loading, Au-Pd alloy had shown a poor response to pre-ceramic laser welding and post-ceramic brazing. The present study was designed to assess the mechanical resistance, the microstructure and the elemental diffusion of laser welded, electric arch welded and brazed joints using commercially pure titanium as substrate metal. Mechanical resistance was determined by determining the joints' ultimate tensile strength and their resistance to fatigue loading. Elemental diffusion to and from the joints was assessed using microprobe tracings. Optical micrographs of the joints were also obtained and evaluated. Under monotonic tensile stress, three groups emerged: (1) the GTAW and the native (i.e. as received) substrate, (2) the annealed substrate and the laser welds and (3) the brazed joints. Under fatigue stress, the order was: first the native and annealed substrate, second the brazings and laser welds, third the GTAW joints. No Au-filler brazing withstood the applied fatigue loading. The micrographs showed various patterns, an absence of HAZ cracking and several occurrences of Widmanstätten structures. Elemental diffusion to and from the Ti substrate was substantial in the Ti filler brazings and virtually nil in the Au-based brazings. Under fatigue stress application, the titanium-based brazings as well as the laser- and electric arc welds performed equally well if not better than a previously tested AuPd alloy. There was a definite increase in grain size with increased heat application. However, no feature of the microstructures observed or the elemental analysis could be correlated with the specimen's resistance to fatigue stress application. Copyright 2001 Kluwer Academic Publishers

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

    NASA Astrophysics Data System (ADS)

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

    2015-04-01

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

  5. Automation of the electron-beam welding process

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

  6. Structure and properties of fixed joints formed by ultrasonic-assisted friction-stir welding

    SciTech Connect

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

    2015-10-27

    This paper deals with structure and properties of aluminum alloy 7475 and its joints obtained by friction stir welding including under ultrasonic action. Microhardness measurements show that ultrasonic action increases strength properties of the joints. Optical and transmission electron microscopy reveals that this effect is related to the precipitation of tertiary coherent S-and T-phase particles.

  7. Corrosion Behavior of MIG Brazed and MIG Welded Joints of Automotive DP600-GI Steel Sheet

    NASA Astrophysics Data System (ADS)

    Basak, Sushovan; Das, Hrishikesh; Pal, Tapan Kumar; Shome, Mahadev

    2016-12-01

    Galvanized dual-phase steel sheets are extensively used by the auto industry for their corrosion resistance property. Welding by the metal inert gas (MIG) process causes degradation of the steel in the vicinity of the joint due to excessive zinc evaporation. In order to minimize Zn loss, the MIG brazing process has been tried out in lap joint configuration over a heat input range of 136-204 J mm-1. The amount of zinc loss, intermetallic formation and corrosion properties in the joint area has been evaluated for both MIG brazing and MIG welding. Corrosion rate of 21 mm year-1 has been reduced to 2 mm year-1 by adopting MIGB in place MIGW. Impedance study has shown that the corrosion mechanism in base metal, MIG brazed and MIG welded joints is dominated by charge transfer, diffusion and mixed mode control processes, respectively.

  8. Design of a welded joint for robotic, on-orbit assembly of space trusses

    NASA Technical Reports Server (NTRS)

    Rule, W. K.; Thomas, F. P.

    1992-01-01

    A preliminary design for a weldable truss joint for on-orbit assembly of large space structures is described. The joint was designed for ease of assembly, for structural efficiency, and to allow passage of fluid (for active cooling or other purposes) along the member through the joint. The truss members were assumed to consist of graphite/epoxy tubes to which were bonded 2219-T87 aluminum alloy end fittings for welding on-orbit to truss nodes of the same alloy. A modified form of gas tungsten arc welding was assumed to be the welding process. The joint was designed to withstand the thermal and structural loading associated with a 120-ft diameter tetrahedral truss intended as an aerobrake for a mission to Mars.

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

    DOE PAGES

    Lim, Yong Chae; Squires, Lile; Pan, Tsung-Yu; ...

    2014-12-30

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

  10. Effects of Pulse Parameters on Weld Microstructure and Mechanical Properties of Extra Pulse Current Aided Laser Welded 2219 Aluminum Alloy Joints.

    PubMed

    Zhang, Xinge; Li, Liqun; Chen, Yanbin; Yang, Zhaojun; Chen, Yanli; Guo, Xinjian

    2017-09-15

    In order to expand the application range of laser welding and improve weld quality, an extra pulse current was used to aid laser-welded 2219 aluminum alloy, and the effects of pulse current parameters on the weld microstructure and mechanical properties were investigated. The effect mechanisms of the pulse current interactions with the weld pool were evaluated. The results indicated that the coarse dendritic structure in the weld zone changed to a fine equiaxed structure using an extra pulse current, and the pulse parameters, including medium peak current, relatively high pulse frequency, and low pulse duty ratio benefited to improving the weld structure. The effect mechanisms of the pulse current were mainly ascribed to the magnetic pinch effect, thermal effect, and electromigration effect caused by the pulse current. The effect of the pulse parameters on the mechanical properties of welded joints were consistent with that of the weld microstructure. The tensile strength and elongation of the optimal pulse current-aided laser-welded joint increased by 16.4% and 105%, respectively, compared with autogenous laser welding.

  11. Effects of Pulse Parameters on Weld Microstructure and Mechanical Properties of Extra Pulse Current Aided Laser Welded 2219 Aluminum Alloy Joints

    PubMed Central

    Zhang, Xinge; Li, Liqun; Chen, Yanbin; Yang, Zhaojun; Chen, Yanli; Guo, Xinjian

    2017-01-01

    In order to expand the application range of laser welding and improve weld quality, an extra pulse current was used to aid laser-welded 2219 aluminum alloy, and the effects of pulse current parameters on the weld microstructure and mechanical properties were investigated. The effect mechanisms of the pulse current interactions with the weld pool were evaluated. The results indicated that the coarse dendritic structure in the weld zone changed to a fine equiaxed structure using an extra pulse current, and the pulse parameters, including medium peak current, relatively high pulse frequency, and low pulse duty ratio benefited to improving the weld structure. The effect mechanisms of the pulse current were mainly ascribed to the magnetic pinch effect, thermal effect, and electromigration effect caused by the pulse current. The effect of the pulse parameters on the mechanical properties of welded joints were consistent with that of the weld microstructure. The tensile strength and elongation of the optimal pulse current-aided laser-welded joint increased by 16.4% and 105%, respectively, compared with autogenous laser welding. PMID:28914825

  12. Fracture toughness of low activation ferritic steel (JLF-1) weld joint at room temperature

    NASA Astrophysics Data System (ADS)

    Nishimura, A.; Inoue, N.; Muroga, T.

    1998-10-01

    A low activation ferritic steel has been developed for a candidate of a structural material of nuclear fusion reactors. Since welding must be performed when the support structures are constructed, fracture toughness of the weld joint has to be characterized as well as the base metal in an engineering sense. In this report, 25 mm thick plates of JLF-1, which contains 9% Cr and 2% W, are butt-welded by a tungsten inert gas (TIG) procedure, and the fracture toughness of the base plate and the weld metal is investigated at room temperature using 1T and 0.5T CT specimens. The base metal reveals high fracture toughness of about 430 kJ/m 2. However, the weld metal showed unstable big pop-ins. One sample fractured in a nearly elastic condition and another sample showed a toughness of over 400 kJ/m 2.

  13. Weld joints inspection using multisource data and image fusion

    NASA Astrophysics Data System (ADS)

    Chady, T.; Sikora, R.; Szwagiel, M.; Szydłowski, M.; Waszczuk, P.; Grochowalska, B.; Grzywacz, B.; Misztal, L.

    2017-02-01

    The novel concept of comprehensive weld inspection with use of three sources of data (radiogram image, image composed of laser profilometer 3D data, CCD camera image) and weld images fusion is presented in the paper. The algorithms of data processing aimed at detection and visualization of weld flaws are roughly described. The special attention was paid at presentation and explanation of algorithm for aligning and spatial correction of images composed of data delivered by three independent sources. The results yielded by proposed algorithms for preprocessing of weld images, weld detection, feature extraction, shape extraction, shape matching, filtering, distortion correction, etc. are illustrated with several figures included in the paper. The concise description of designed and implemented laboratory stands is included in the paper too.

  14. Determination of Some Parameters for Fatigue Life in Welded Joints Using Fracture Mechanics Method

    NASA Astrophysics Data System (ADS)

    Al-Mukhtar, A. M.; Biermann, H.; Hübner, P.; Henkel, S.

    2010-12-01

    In this work, the parameters stress intensity factor (SIF), initial and final crack lengths ( a i and a f), crack growth parameters ( C and m), and fatigue strength (FAT) are investigated. The determination of initial crack length seems to be the most serious factor in fatigue life and strength calculations for welded joints. A fracture mechanics approach was used in these calculations based on SIF which was calculated with the finite element method (FEM). The weld toe crack was determined to be equal to 0.1 mm, whereas the weld root crack's length was varied depending on the degree of the weld penetration. These initial crack length values are applicable for all types of joints which have the same crack phenomenon. As based on the above calculated parameters, the new limits of FAT for new geometries which are not listed yet in recommendations can be calculated according to the current approach.

  15. 9. DETAIL VIEW OF BOTTOM CHORD/FLOOR BEAM/IBAR PIN CONNECTION. WELDED ...

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

    9. DETAIL VIEW OF BOTTOM CHORD/FLOOR BEAM/I-BAR PIN CONNECTION. WELDED PLATE AT PIN CONNECTION IS 20TH CENTURY REVISION. - Bucks County Bridge No. 313, Spanning Delaware Canal at Letchworth Avenue, Yardley, Bucks County, PA

  16. Evaluation of a method to shield a welding electron beam from magnetic interference

    NASA Technical Reports Server (NTRS)

    Wall, W. A.

    1976-01-01

    It is known that electron beams are easily deflected by magnetic and electrostatic fields. Therefore, to prevent weld defects, stray electromagnetic fields are avoided in electron beam welding chambers if at all possible. The successful results of tests conducted at MSFC to evaluate a simple magnetic shield made from steel tubing are reported. Tests indicate that this shield was up to 85 percent effective in reducing magnetic effects on the electron beam of a welding machine. In addition, residual magnetic fields within the shield were so nearly uniform that the net effect on the beam alignment was negligible. It is concluded that the shield, with the addition of a tungsten liner, could be used in production welding.

  17. Galvanic Corrosion Behavior of Microwave Welded and Post-weld Heat-Treated Inconel-718 Joints

    NASA Astrophysics Data System (ADS)

    Bansal, Amit; Sharma, Apurbba Kumar; Kumar, Pradeep

    2017-05-01

    In the present study, corrosion behavior of microwave welded Inconel-718 at various conditions was investigated. Welding of Inconel-718 in 980 °C solution-treated condition was performed using microwave hybrid heating technique. The microwave welds were subjected to post-heat treatment for improving its microstructure and mechanical properties by solubilizing the Nb-enriched Laves phase. The microstructural features of the fabricated welds at various conditions were investigated through scanning electron microscopy. The electrochemical testing results revealed that Inconel-718 welds were galvanic corroded when they were anodically polarized in 3.5 wt.% NaCl solution at 28 °C. The difference in the corrosion potentials between the base metal (BM) and fusion zone (FZ) in an Inconel-718 weld was the main factor for galvanic corrosion. The highest corrosion was occurred in the as-welded/aged weldments, followed by 980 °C solution-treated and aged weldments, as-welded specimen, and 1080 °C solution-treated and aged (1080STA) weldments. The least galvanic corrosion was occurred in the 1080STA specimens due to almost uniform microstructure developed in the weldment after the treatment. Thus, it was possible to minimize the galvanic corrosion in the microwave welded Inconel-718 by 1080STA treatment which resulted in reducing the difference in corrosion potentials between the BM and the FZ.

  18. Evaluation of joint interface of friction stir welding between dissimilar metals using HTS-SQUID gradiometer

    NASA Astrophysics Data System (ADS)

    Mashiko, Y.; Hatsukade, Y.; Yasui, T.; Takenaka, H.; Todaka, Y.; Fukumoto, M.; Tanaka, S.

    2010-11-01

    In this study, we investigated conductive properties of joint interfaces of friction stir welding (FSW) between dissimilar metals, stainless steel SUS304 and aluminum A6063, using a SQUID nondestructive evaluation (NDE) system. With current injection method, the current maps above the FSW specimens jointed under various conditions were measured by a HTS-SQUID gradiometer. The conductivities of the joint interfaces, which were estimated from the current maps, differed between the joint conditions. By destructive tests using optical microscope, large voids were observed on the joint interfaces with low welding speed that generated excess heating. In case of one specimen, which was welded with welding speed of 500 and 200 mm/min, the conductivity of the former was higher than that of the latter, although the inside voids in the respective regions were not much different. From these results, it is suggested that the current maps were influenced not only by the conductivity of the joint interface but also by inside voids. By hardness test on the SUS boards near the interfaces, only the SUS jointed with 200 mm/min was about half softer than its matrix.

  19. Eutectic structures in friction spot welding joint of aluminum alloy to copper

    NASA Astrophysics Data System (ADS)

    Shen, Junjun; Suhuddin, Uceu F. H.; Cardillo, Maria E. B.; dos Santos, Jorge F.

    2014-05-01

    A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl2 eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

  20. Eutectic structures in friction spot welding joint of aluminum alloy to copper

    SciTech Connect

    Shen, Junjun Suhuddin, Uceu F. H.; Cardillo, Maria E. B.; Santos, Jorge F. dos

    2014-05-12

    A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl{sub 2} eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

  1. Parametric optimisation and microstructural analysis on high power Yb-fibre laser welding of Ti-6Al-4V

    NASA Astrophysics Data System (ADS)

    Ahn, J.; Chen, L.; Davies, C. M.; Dear, J. P.

    2016-11-01

    In this work thin sheets of Ti-6Al-4V were full penetration welded using a 5 kW fibre laser in order to evaluate the effectiveness of high power fibre laser as a welding processing tool for welding Ti-6Al-4V with the requirements of the aircraft industry and to determine the effect of welding parameters including laser power, welding speed and beam focal position on the weld microstructure, bead profile and weld quality. It involved establishing an understanding of the influence of welding parameters on microstructural change, welding defects, and the characteristics of heat affected zone (HAZ) and weld metal (WM) of fibre laser welded joints. The optimum range of welding parameters which produced welds without cracking and porosity were identified. The influence of the welding parameters on the weld joint heterogeneity was characterised by conducting detailed microstructural analysis.

  2. Optimizing friction stir welding parameters to maximize tensile strength of AA2219 aluminum alloy joints

    NASA Astrophysics Data System (ADS)

    Babu, S.; Elangovan, K.; Balasubramanian, V.; Balasubramanian, M.

    2009-04-01

    AA2219 aluminium alloy (Al-Cu-Mn alloy) has gathered wide acceptance in the fabrication of lightweight structures requiring a high strength-to-weight ratio and good corrosion resistance. In contrast to the fusion welding processes that are routinely used for joining structural aluminium alloys, the friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force etc., and the tool pin profile play a major role in determining the joint strength. An attempt has been made here to develop a mathematical model to predict the tensile strength of friction stir welded AA2219 aluminium alloy by incorporating FSW process parameters. A central composite design with four factors and five levels has been used to minimize the number of experimental conditions. The response surface method (RSM) has been used to develop the model. The developed mathematical model has been optimized using the Hooke and Jeeves search technique to maximize the tensile strength of the friction stir welded AA2219 aluminium alloy joints.

  3. Gravitational effects on the weld pool shape and microstructural evolution during gas tungsten arc and laser beam welding of 304 stainless steel and Al-4 wt% Cu alloy.

    PubMed

    Kang, Namhyun; Singh, Jogender; Kulkarni, Anil K

    2004-11-01

    Effects of gravitational acceleration were investigated on the weld pool shape and microstructural evolution for 304 stainless steel and Al-4wt% Cu alloy. Effects of welding heat source were investigated by using laser beam welding (LBW) and gas tungsten arc welding (GTAW). As the gravitational level was increased from low gravity (LG approximately 1.2 g) to high gravity (HG approximately 1.8 g) using a NASA KC-135 aircraft, the weld pool shape for 304 stainless steel was influenced considerably during GTAW. However, insignificant change in the microstructure and solute distribution was observed at gravitational levels between LG and HG. The GTAW on Al-4 wt% Cu alloy was used to investigate the effect of gravitational orientation on the weld solidification behavior. Gravitational orientation was manipulated by varying the welding direction with respect to gravity vector; that is, by welding upward opposing gravity ( ||-U) and downward with gravity ( ||-D) on a vertical weld piece and welding perpendicular to gravity (perpendicular) on a horizontal weld piece. Under the same welding conditions, a larger primary dendrite spacing in the ||-U weld was observed near the weld pool surface and the fusion boundary than in the case of perpendicular or ||-D welds. The ||-D weld exhibited different solidification morphology and abnormal S shape of solidification rate curve during its growth. For 304 stainless steel GTAW, significant effects of gravitational orientation were observed on the weld pool shape that was associated with weld surface morphology and convection flow. However, the weld pool shape for LBW was mostly constant with respect to the gravitational orientation.

  4. Structure and Properties of Thick-Walled Joints of Alloy 1570s Prepared by Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Velichko, O. V.; Ivanov, S. Yu.; Karkhin, V. A.; Lopota, V. A.; Makhin, I. D.

    2016-09-01

    The microstructure and mechanical properties of thick-walled joints of Al - Mg - Sc alloy 1570S, prepared by friction stir welding are studied. Joint microstructural and mechanical inhomogeneity are revealed.

  5. Room temperature mechanical properties of electron beam welded zircaloy-4 sheet

    DOE PAGES

    Parga, C. J.; Rooyen, I. J.; Coryell, B. D.; ...

    2017-11-04

    Room temperature mechanical properties of electron beam welded and plain Zircaloy-4 sheet (1.6mm thick) have been measured and compared. Various welding parameters were utilized to join sheet material. Electron beam welded specimens and as-received sheet specimens show comparable mechanical properties. Zr-4 sheet displays anisotropy; tensile properties measured for transverse display higher elastic modulus, yield strength, reduction of area and slightly lower ductility than for the longitudinal (rolling direction). Higher welding power increases the alloy’s hardness, elastic modulus and yield strength, with a corresponding decrease in tensile strength and ductility. The hardness measured at weld is comparable to the parent metalmore » hardness. Hardness at heat-affected-zone is slightly higher. Electron microscopic examination shows distinct microstructure morphology and grain size at the weld zone, HAZ and parent metal. A correlation between welding parameters, mechanical properties and microstructural features was established for electron beam welded Zircaloy-4 sheet material.« less

  6. 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…

  7. 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…

  8. Structure formation and properties of a copper-aluminum joint produced by ultrasound-assisted explosive welding

    NASA Astrophysics Data System (ADS)

    Kuz'min, E. V.; Peev, A. P.; Kuz'min, S. V.; Lysak, V. I.

    2017-08-01

    The effect of ultrasound-assisted explosive welding on the structure formation and the properties of copper-aluminum joints is studied. Ultrasound-assisted explosive welding improves the quality of formed copper-aluminum joints, i.e., enhances their strength and significantly reduces the amount of fused metal over the entire weldability range. It is shown that ultrasound-assisted explosive welding can noticeably extend the weldability range of the copper-aluminum pair to obtain equal-in-strength joints with minimum structural heterogeneity in the wide welding range.

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

    NASA Astrophysics Data System (ADS)

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

    2008-04-01

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

  10. Laser beam welding of new ultra-high strength and supra-ductile steels

    NASA Astrophysics Data System (ADS)

    Dahmen, Martin

    2015-03-01

    Ultra-high strength and supra-ductile are entering fields of new applications. Those materials are excellent candidates for modern light-weight construction and functional integration. As ultra-high strength steels the stainless martensitic grade 1.4034 and the bainitic steel UNS 53835 are investigated. For the supra-ductile steels stand two high austenitic steels with 18 and 28 % manganese. As there are no processing windows an approach from the metallurgical base on is required. Adjusting the weld microstructure the Q+P and the QT steels require weld heat treatment. The HSD steel is weldable without. Due to their applications the ultra-high strength steels are welded in as-rolled and strengthened condition. Also the reaction of the weld on hot stamping is reflected for the martensitic grades. The supra-ductile steels are welded as solution annealed and work hardened by 50%. The results show the general suitability for laser beam welding.

  11. Effect of Welding Parameters on Microstructure, Thermal, and Mechanical Properties of Friction-Stir Welded Joints of AA7075-T6 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Lotfi, Amir Hossein; Nourouzi, Salman

    2014-06-01

    A high-strength Al-Zn-Mg-Cu alloy AA7075-T6 was friction-stir welded with various process parameter combinations incorporating the design of the experiment to investigate the effect of welding parameters on the microstructure and mechanical properties. A three-factors, five-level central composition design (CCD) has been used to minimize the number of experimental conditions. The friction-stir welding parameters have significant influence on the heat input and temperature profile, which in turn regulates the microstructural and mechanical properties of the joints. The weld thermal cycles and transverse distribution of microhardness of the weld joints were measured, and the tensile properties were tested. The fracture surfaces of tensile specimens were observed by a scanning electron microscope (SEM), and the formation of friction-stir processing zone has been analyzed macroscopically. Also, an equation was derived to predict the final microhardness and tensile properties of the joints, and statistical tools are used to develop the relationships. The results show that the peak temperature during welding of all the joints was up to 713 K (440 °C), which indicates the key role of the tool shoulder diameter in deciding the maximum temperature. From this investigation, it was found that the joint fabricated at a rotational speed of 1050 rpm, welding speed of 100 mm/min, and shoulder diameter of 14 mm exhibited higher mechanical properties compared to the other fabricated joints.

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

    SciTech Connect

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

    2015-01-15

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

  15. A Water-Drop Method of Hardening of the Welded Joints of Drill Pipes

    NASA Astrophysics Data System (ADS)

    Maisuradze, M. V.; Yudin, Yu. V.; Eismondt, Yu. G.

    2015-09-01

    A combined computational and experimental technique is developed for implementing a scientifically based approach to the selection of a technology of heat hardening of welded joints of drill pipes made of steel 25KhGM with the use of water-drop quenching. The basic service characteristics of the water-drop cooling device are presented. An analytic model that relates the parameters of the water-drop quenching device (standard size and number of jets in device, pressure of fed water, distance from the jet nozzle to the cooled surface) to the properties of the welded joint is proposed. With the new technique the construction of a quenching device may be developed and the technology of heat treatment of the welded joints of drill pipes optimized in order to increase the level of mechanical properties.

  16. A Fundamental Study of Laser Beam Welding Aluminum-Lithium Alloy 2195 for Cryogenic Tank Applications

    NASA Technical Reports Server (NTRS)

    Martukanitz, R. P.; Jan. R.

    1996-01-01

    Based on the potential for decreasing costs of joining stiffeners to skin by laser beam welding, a fundamental research program was conducted to address the impediments identified during an initial study involving laser beam welding of aluminum-lithium alloys. Initial objectives of the program were the identification of governing mechanism responsible for process related porosity while establishing a multivariant relationship between process parameters and fusion zone geometry for laser beam welds of alloy 2195. A three-level fractional factorial experiment was conducted to establish quantitative relationships between primary laser beam processing parameters and critical weld attributes. Although process consistency appeared high for welds produced during partial completion of this study, numerous cracks on the top-surface of the welds were discovered during visual inspection and necessitated additional investigations concerning weld cracking. Two experiments were conducted to assess the effect of filler alloy additions on crack sensitivity: the first experiment was used to ascertain the effects of various filler alloys on cracking and the second experiment involved modification to process parameters for increasing filler metal dilution. Results indicated that filler alloys 4047 and 4145 showed promise for eliminating cracking.

  17. Prediction of the Properties of Heat-Affected Zone of Welded Joints of Sheets from Aluminum Alloys with Structured Surface

    NASA Astrophysics Data System (ADS)

    Mikhailov, V. G.

    2016-05-01

    Welded joints of light structured sheets from aluminum alloy EN AW-6181-T4 (DIN EN 515) of the Al - Si - Mg system are studied. The welding is performed in an argon environment with a short arc by the method of cold metal transfer (CMT®). The results of the study are used in an amended Leblond model for describing the variation of the properties of the heat-affected zone of welded joints of structured sheets.

  18. Experimental Investigation on Friction Stir Welding of Cryorolled AA2219 Aluminum Alloy Joints

    NASA Astrophysics Data System (ADS)

    Babu, K. Kamal; Panneerselvam, K.; Sathiya, P.; Haq, A. Noorul; Sundarrajan, S.; Mastanaiah, P.; Murthy, C. V. Srinivasa

    2017-07-01

    In this paper, experimental investigation on cryorolled aluminum AA2219-T87 plate by using friction stir welding (FSW) process is carried out. AA2219-T87 plates with a size of 200×100×22.4 mm were rolled and reduced to 12.2mm thickness (more than 45% of reduction in total thickness of the base material) at cryogenic temperature (operating temperature range -90--30∘C). The cryorolled (CR) plates have reduced grain size, improved hardness and increased corrosion resistance property compared with the uncryorolled AA2219-T87 plates. FSW joints of cryorolled AA2219-T87 plates were prepared using cylindrical threaded FSW tool pin profile. Mechanical and metallurgical behaviors of friction stir welded joints were analyzed and the effects of the FSW process parameters are discussed in this paper. The variation of microhardness in the FSW joint regions were correlated with the microstructure of FSW joints. Cryorolled plate and FSW joints were tested for corrosion resistance using potentiodynamic polarization test. FSW joints shows better result during the corrosion resistance analysis compared to base AA2219-T87. The X-ray diffraction (XRD) test results showed that fine α-Al grains with eutectic phase (Al2Cu) were present in the weld nugget (WN). The large clusters of strengthening precipitates were reduced in size and merged with the weld nugget portion.

  19. Fracture Behaviour of Nickel-Titanium Laser Welded Joints

    NASA Astrophysics Data System (ADS)

    Maletta, C.; Falvo, A.; Furgiuele, F.; Barbieri, G.; Brandizzi, M.

    2009-08-01

    In this study, the effects of Nd:YAG laser welding on the fracture behavior of Ni-rich nickel-titanium sheets are analyzed by experimental investigations. The welding was carried out in open air conditions by using a special shielding/clamping system to avoid the chemical contamination of the molten zone and the formation of hot cracks. Mechanical tests of standard dog bone-shaped and single edge crack specimens were carried out to measure the stress-strain response and the fracture resistance of both the base and the welded materials. Furthermore, scanning electron microscopy observations of the fracture surfaces were carried out in order to better understand the failure mechanisms. Finally, systematic comparative studies between base and laser-welded materials were carried out.

  20. Investigation of welding crack in micro laser welded NiTiNb shape memory alloy and Ti6Al4V alloy dissimilar metals joints

    NASA Astrophysics Data System (ADS)

    Yuhua, Chen; Yuqing, Mao; Weiwei, Lu; Peng, He

    2017-06-01

    Dissimilar metals of NiTiNb shape memory alloy and Ti6Al4V alloy with a same thickness of 0.2 mm were joined by micro laser welding. The effect of laser power on crack sensitivity of the weld was investigated. The results show that full penetrated welds are obtained when the laser power of 7.2 W is used, many cracks are observed in the weld. With increasing the laser power to 12 W, the number of all cracks and cracking width first increase and then decrease. By XRD analysis, three different kinds of Ti2Ni, NbNi3 and AlNbTi2 intermetallic compounds are found in the weld. According to the formation enthalpy and binary phase diagram, brittle Ti2Ni phase with more contents is existed in the weld due to final solidification, and which is the main reason of crack formation along with large stress concentration. Moreover, the welding cracks like the weld center longitudinal solidification cracks, weld metal toe transversal liquid cracks, heat-affected-zone hot cracks and crater cracks are classified in the laser welded joints. A brittle cleavage fracture with cleavage planes and river patterns in the joints is presented from the fracture surface.

  1. Weld Bead Size, Microstructure and Corrosion Behavior of Zirconium Alloys Joints Welded by Pulsed Laser Spot Welding

    NASA Astrophysics Data System (ADS)

    Cai, Chuang; Li, Liqun; Tao, Wang; Peng, Genchen; Wang, Xian

    2016-09-01

    Pulsed laser spot welding of intersection points of zirconium alloys straps was performed. Weld bead size, microstructure and the corrosion behavior of weld bead were investigated. With the increasing laser peak power or number of shots, the weld width of the beads increased, the protrusion decreased and the dimple increased with further increase in heat input. The fusion zone consisted of a mixture of αZr and residual βZr phases. After annealing treatment, βNb and Zr(Fe, Nb)2 second phase particles were precipitated inter- and intragranular of αZr grains adequately. The oxide thickness of annealed weld bead was about 3.90 μm, decreased by about 18.1% relative to the 4.76 μm of as-welded specimen corroded at 400 °C and 10.3 MPa for 20 days. The corrosion resistance of annealed specimen was better than that of as-welded specimen, since the second phase particles exerted better corrosion resistance, and the content of Nb in βZr and the fraction of βZr decreased after the annealing treatment.

  2. Laser beam welding of AZ31B-H24 magnesium alloy.

    SciTech Connect

    Leong, K. H.

    1998-09-29

    The laser beam weldability of AZ31B magnesium alloy was examined with high power CW CO{sub 2} and pulsed Nd:YAG lasers. The low viscosity and surface tension of the melt pool make magnesium more difficult to weld than steel. Welding parameters necessary to obtain good welds were determined for both CW CO{sub 2} and pulsed Nd:YAG lasers. The weldability of the magnesium alloy was significantly better with the Nd:YAG laser. The cause of this improvement was attributed to the higher absorption of the Nd:YAG beam. A lower threshold beam irradiance was required for welding, and a more stable weldpool was obtained.

  3. Signal acquisition and scale calibration for beam power density distribution of electron beam welding

    NASA Astrophysics Data System (ADS)

    Peng, Yong; Li, Hongqiang; Shen, Chunlong; Guo, Shun; Zhou, Qi; Wang, Kehong

    2017-06-01

    The power density distribution of electron beam welding (EBW) is a key factor to reflect the beam quality. The beam quality test system was designed for the actual beam power density distribution of high-voltage EBW. After the analysis of characteristics and phase relationship between the deflection control signal and the acquisition signal, the Post-Trigger mode was proposed for the signal acquisition meanwhile the same external clock source was shared by the control signal and the sampling clock. The power density distribution of beam cross-section was reconstructed using one-dimensional signal that was processed by median filtering, twice signal segmentation and spatial scale calibration. The diameter of beam cross-section was defined by amplitude method and integral method respectively. The measured diameter of integral definition is bigger than that of amplitude definition, but for the ideal distribution the former is smaller than the latter. The measured distribution without symmetrical shape is not concentrated compared to Gaussian distribution.

  4. Modeling and analysis of novel laser weld joint designs using optical ray tracing.

    SciTech Connect

    Milewski, J. O.

    2002-01-01

    Reflection of laser energy presents challenges in material processing that can lead to process inefficiency or process instability. Understanding the fundamentals of non-imaging optics and the reflective propagation of laser energy can allow process and weld joint designs to take advantage of these reflections to enhance process efficiency or mitigate detrimental effects. Optical ray tracing may be used within a 3D computer model to evaluate novel joint and fixture designs for laser welding that take advantage of the reflective propagation of laser energy. This modeling work extends that of previous studies by the author and provides comparison with experimental studies performed on highly reflective metals. Practical examples are discussed.

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

  6. A self-organizing fuzzy control approach to arc sensor for weld joint tracking in gas metal arc welding of butt joints

    SciTech Connect

    Na, S.J. ); Kim, J.W.

    1993-02-01

    For the artificial intelligence (AI) approach to automatic control, the fuzzy rule-based control schemes have been successfully applied to the control of complex processes. The arc welding process is one of the processes due to the fact that it possesses complex and nonlinear characteristics such as a moving distributed heat source, a current path and metal transfer. One possible solution to the design of an effective controller suitable for such a process is to use the fuzzy control scheme. The fuzzy rule-based control can easily realize the heuristic rules obtained from human experiences that cannot be expressed in mathematical form. In this study, an arc sensor, which utilizes the electrical signal obtained from the welding arc itself, was developed for CO[sub 2] gas metal arc welding of butt joints using the fuzzy set theory. A simple fuzzy controller without any adaptation was implemented for the weld joint tracking. A set of fixed rules, which was designed based upon the experiments, and a self-organizing fuzzy controller, which could improve the control rules automatically, were examined. Through a series of experiments, the performance and learning action of the proposed self-organizing fuzzy controller were assessed.

  7. Welded Joint Integrity Analysis: Relative Criticality of Weld Defect and Remote Deformation

    DTIC Science & Technology

    1988-12-09

    and the weld was made using short arc welding. The butt welded plate is 0.1875 inch (. 4762 cm) thick, 192 inches (488 cm) long and 24 inches (61 cm...195 (1976). 4. ASTM Metals Handbook Vol. 10, Failure Analysis, ASTM (1978). 5. Rice, J. R., "A Path Independent Integral and the Approximate Analysis of...Mechanics - 13th Conference. ASTM STP 743, 269-287 (1981). 10. Matic, P. and Jolles, M. I., "Fracture Mechanics. Strain Energy Density and Critical Issues

  8. Joint shear strength of FRP reinforced concrete beam-column joints

    NASA Astrophysics Data System (ADS)

    Saravanan, Jagadeesan; Kumaran, Ganapathy

    2011-03-01

    An assessment of the joint shear strength of exterior concrete beam-column joints reinforced internally with Glass Fibre Reinforced Polymer (GFRP) reinforcements under monotonically increasing load on beams keeping constant load on columns is carried out in this study. Totally eighteen numbers of specimens are cast and tested for different parametric conditions like beam longitudinal reinforcement ratio, concrete strength, column reinforcement ratio, joint aspect ratio and influence of the joint stirrups at the joint. Also finite element analysis is performed to simulate the behaviour of the beam-column joints under various parametric conditions. Based on this study, a modified design equation is proposed for assessing the joint shear strength of the GFRP reinforced beam-column specimens based on the experimental results and the review of the prevailing design equations.

  9. Experimental characterization of fatigue strength in butt welded joint considering the geometry and the effect of cooling rate of the weld

    NASA Astrophysics Data System (ADS)

    Arzola, Nelson; Hernández, Edgar

    2017-05-01

    In this work the experimental characterization of fatigue strength in butt welded joints considering the geometry and the post-weld cooling cycle was performed. ASTM A-36 structural steel was used as the base metal for the shielded metal arc welding process, with welding electrode E6013. Two experimental factors were established: weld bead geometry and the post-weld cooling rate. Two levels for each factor, the welding reinforcement (1 and 3 mm), and the rate of cooling, slow (quiet air) and fast (immersion in water) are evaluated respectively. For the uniaxial fatigue tests, 8 samples were selected for each treatment for a total of 32 specimens. The mechanical and fractomechanical properties of fusion zone, heat affected zone and base metal in relation to the analysis of failure mechanisms were analysed. The fatigue crack growth rates were estimated based on the counting of microstrations. Furthermore, experimental tests, such as uniaxial tension, microindentation hardness, Charpy impact and metallographic analysis, were made to know the influence of the experimental factors in the fatigue strength. On this research, about the 78.13% of the samples obtained a resistance higher than the recommended one by class FAT 100. The results showed that the geometry of the joint is the factor of greatest influence on fatigue strength for butt welded joints; the greater the weld reinforcement the lower the fatigue strength of the joint. Although it is also important to consider other geometric factors of less impact as it is the weld toe radius and the welding chord width.

  10. High power laser welding of thick steel plates in a horizontal butt joint configuration

    NASA Astrophysics Data System (ADS)

    Atabaki, M. Mazar; Yazdian, N.; Ma, J.; Kovacevic, R.

    2016-09-01

    In this investigation, two laser-based welding techniques, autogenous laser welding (ALW) and laser welding assisted with a cold wire (LWACW), were applied to join thick plates of a structural steel (A36) in a horizontal narrow gap butt joint configuration. The main practical parameters including welding method and laser power were varied to get the sound weld with a requirement to achieve a full penetration with the reinforcement at the back side of weld in just one pass. The weld-bead shape, cross-section and mechanical properties were evaluated by profilometer, micro-hardness test and optical microscope. In order to investigate the stability of laser-induced plasma plume, the emitted optical spectra was detected and analyzed by the spectroscopy analysis. It was found that at the laser power of 7 kW a fully penetrated weld with a convex back side of weld could be obtained by the LWACW. The microstructural examinations showed that for the ALW the acicular ferrite and for the LWACW the pearlite were formed in the heat affected zone (HAZ). The prediction of microstructure based on continuous cooling transformation (CCT) diagram and cooling curves obtained by thermocouple measurement were in good agreement with each other. According to the plasma ionization values obtained from the spectroscopy analysis the plume for both processes was recognized as dominated weakly ionized plasma including the main vaporized elemental composition. At the optimum welding condition (LWACW at the laser power of 7 kW) the fluctuation of the electron temperature was reduced. The spectroscopy analysis demonstrated that at the higher laser power more of the elemental compositions such as Mn and Fe were evaporated.

  11. SRF test facility for the superconducting LINAC ``RAON'' — RRR property and e-beam welding

    NASA Astrophysics Data System (ADS)

    Jung, Yoochul; Hyun, Myungook; Joo, Jongdae; Joung, Mijoung

    2015-02-01

    Equipment, such as a vacuum furnace, high pressure rinse (HPR), eddy current test (ECT) and buffered chemical polishing (BCP), are installed in the superconducting radio frequency (SRF) test facility. Three different sizes of cryostats (diameters of 600 mm for a quarter wave resonator (QWR), 900 mm for a half wave resonator (HWR), and 1200 mm for single spoke resonator 1&2 (SSR 1&2)) for vertical RF tests are installed for testing cavities. We confirmed that as-received niobium sheets (ASTM B393, RRR300) good electrical properties because they showed average residual resistance ratio (RRR) values higher than 300. However, serious RRR degradation occurred after joining two pieces of Nb by e-beam welding because the average RRR values of the samples were ˜179, which was only ˜60% of as-received RRR value. From various e-beam welding experiments in which the welding current and a speed at a fixed welding voltage were changed, we confirmed that good welding results were obtained at a 53 mA welding current and a 20-mm/s welding speed at a fixed welding voltage of 150 kV.

  12. Structure and Microhardness of Cu-Ta Joints Produced by Explosive Welding

    PubMed Central

    Maliutina, Iu. N.; Mali, V. I.; Bataev, I. A.; Bataev, A. A.; Esikov, M. A.; Smirnov, A. I.; Skorokhod, K. A.

    2013-01-01

    The structure and microhardness of Cu-Ta joints produced by explosive welding were studied. It was found that, during explosive welding, an intermediate layer 20⋯40 μm thick with a finely dispersed heterophase structure, formed between the welded copper and tantalum plates. The structure of the layer was studied by scanning and transmission electron microscopy. Microvolumes with tantalum particles distributed in a copper matrix and microvolumes of copper particles in a tantalum matrix were detected. The tantalum particles in copper have a size of 5⋯500 nm, with a predominance of 5⋯50 nm particles. A mechanism for the formation of the finely dispersed heterophase structure in explosive welding is proposed. The microhardness of interlayers with the heterophase structure reaches 280 HV, which far exceeds the microhardness of copper (~130 HV) and tantalum (~160 HV). Many twins of deformation origin were found in the structure of the copper plate. The effect of heating temperature in the range from 100 to 900°C on the microhardness of copper, tantalum, and the Cu-Ta welded joint was studied. Upon heating to 900°C, the microhardness of the intermediate layer decreases from 280 to 150 HV. The reduction in the strength properties of the weld material is mainly due to structural transformations in copper. PMID:24453818

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

    SciTech Connect

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

    2015-05-15

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-05-01

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

  15. A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of Welded Joints in Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Tikader, Sujoy; Biswas, Pankaj; Puri, Asit Baran

    2016-06-01

    Friction stir welding (FSW) has been the most attracting solid state welding process as it serves numerous advantages like good mechanical, metallurgical properties etc. Non weldable aluminium alloys like 5XXX, 7XXX series can be simply joined by this process. In this present study a mathematical model has been developed and experiments were successfully performed to evaluate mechanical properties of FSW on similar aluminium alloys i.e. AA1100 for different process parameters and mainly two kind of tool geometry (straight cylindrical and conical or cylindrical tapered shaped pin with flat shoulder). Tensile strength and micro hardness for different process parameters are reported of the welded plate sample. It was noticed that in FSW of similar alloy with tool made of SS-310 tool steel, friction is the major contributor for the heat generation. It was seen that tool geometry, tool rotational speed, plunging force by the tool and traverse speed have significant effect on tensile strength and hardness of friction stir welded joints.

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

  17. Investigation on Mechanical Properties of 9%Cr/CrMoV Dissimilar Steels Welded Joint

    NASA Astrophysics Data System (ADS)

    Liu, Xia; Lu, Fenggui; Yang, Renjie; Wang, Peng; Xu, Xiaojin; Huo, Xin

    2015-04-01

    Advanced 9%Cr steel with good heat resistance and CrMoV with good toughness were chosen as candidate materials to fabricate combined rotor for steam turbine operating at over 620 °C. But the great difference in base metals properties presents a challenge in achieving sound defect-free joint with optimal properties in dissimilar welded rotor. In this paper, appropriate selection of filler metal, welding parameters, and post-weld heat treatment was combined to successfully weld 1100-mm-diameter 9%Cr/CrMoV dissimilar experimental rotor through ultra-narrow gap submerge arc welding. Some properties such as hardness, low-cycle fatigue (LCF), and high-cycle fatigue (HCF) combined with microstructural characterization qualify the integrity of the weld. Microstructural analysis indicated the presence of high-temperature tempered martensite as the phase responsible for the improved properties obtained in the weld. The Coffin-Manson parameters were obtained by fitting the data in LCF test, while the conditional fatigue strength was derived from the HCF test based on S-N curve. Analysis of hardness profile showed that the lowest value occurred at heat-affected zone adjacent to base metal which represents the appropriate location of fracture for the samples after LCF and HCF tests.

  18. Fatigue Life Improvement for Cruciform Welded Joint by Mechanical Surface Treatment using Hammer Peening and UNSM

    NASA Astrophysics Data System (ADS)

    Han, Seung-Ho; Han, Jeong-Woo; Nam, Yong-Yun; Cho, In-Ho

    For the improvement of fatigue strength of welded structures, mechanical post treatments have been applied in various industrial fields and have in most cases been founded to give substantial increases in their fatigue lives. These methods, generally, consist of the modification of weld toe geometry and the introduction of compressive residual stresses. In mechanical surface treatments, e.g. PHP (pneumatic hammer peening) and UNSM (ultrasonic nano-crystal surface modification), the weld profile is modified due to remove or reduce minute crack-like flaws, and compressive residual stresses are also induced. In this study, a pneumatic hammer peening procedure and a UNSM device were introduced, and a quantitative measure of fatigue strength improvement was performed. The fatigue strength at 2 × 106 cycles of hammer-peened and UNSM treated on a non-load carrying cruciform welded joint shows 220 and 260MPa, respectively, which are more than two times higher than that of as-welded specimen. Especially, the surface layer in the vicinity weld toe treated by the UNSM provides nano-crystal structure created by an ultrasonic cold forging and introduces very high welding residual stress in compression.

  19. A Combined Experimental/Computational Analysis of the Butt-Friction-Stir-Welded AA2139-T8 Joints

    NASA Astrophysics Data System (ADS)

    Grujicic, M.; Snipes, J. S.; Ramaswami, S.; Yen, C.-F.

    2016-07-01

    Combined experimental and computational investigations are carried out of the mechanical properties of materials residing in different weld zones of friction stir-welded (FSW) joints of thick plates of AA2139-T8. The experimental portion of the work comprised (a) identification of the weld zones within the FSW joints, through the use of optical-microscopy characterization of a transverse section; (b) validation of the weld zones identified in (a) via the generation of a micro-hardness field over the same transverse section; (c) extracting and subsequently testing miniature tensile specimens from different weld zones; and (d) extracting and testing a larger-size tensile specimen spanning transversely the FSW weld. The computational portion of the work comprised (i) validation of the mechanical properties, as determined experimentally using the miniature tensile specimens, of the material residing within different zones of the FSW joint; and (ii) clarification of the benefits yielded by the knowledge of the local material properties within the FSW joint. These benefits arise from the fact that (a) joint mechanical properties are generally inferior to those of the base metal; (b) the width of the weld in thick metallic-armor is often comparable to the armor thickness, and therefore may represent a significant portion of the armor exposed-surface area; and (c) modeling of the weld-material structural response under loading requires the availability of high-fidelity/validated material constitutive models, and the development of such models requires knowledge of the local weld-material mechanical properties.

  20. A Vision-Aided 3D Path Teaching Method before Narrow Butt Joint Welding

    PubMed Central

    Zeng, Jinle; Chang, Baohua; Du, Dong; Peng, Guodong; Chang, Shuhe; Hong, Yuxiang; Wang, Li; Shan, Jiguo

    2017-01-01

    For better welding quality, accurate path teaching for actuators must be achieved before welding. Due to machining errors, assembly errors, deformations, etc., the actual groove position may be different from the predetermined path. Therefore, it is significant to recognize the actual groove position using machine vision methods and perform an accurate path teaching process. However, during the teaching process of a narrow butt joint, the existing machine vision methods may fail because of poor adaptability, low resolution, and lack of 3D information. This paper proposes a 3D path teaching method for narrow butt joint welding. This method obtains two kinds of visual information nearly at the same time, namely 2D pixel coordinates of the groove in uniform lighting condition and 3D point cloud data of the workpiece surface in cross-line laser lighting condition. The 3D position and pose between the welding torch and groove can be calculated after information fusion. The image resolution can reach 12.5 μm. Experiments are carried out at an actuator speed of 2300 mm/min and groove width of less than 0.1 mm. The results show that this method is suitable for groove recognition before narrow butt joint welding and can be applied in path teaching fields of 3D complex components. PMID:28492481

  1. A study on the control of melting ratio to increase mechanical properties of laser welded joints between AISI 440C and AISI 430F

    NASA Astrophysics Data System (ADS)

    Romoli, L.; Rashed, C. A. A.; Lovicu, G.; Ishak, R.

    2015-05-01

    Laser beam welding of dissimilar AISI 440C and AISI 430F stainless steels was investigated in a circular constrained configuration. The beam incidence angle and the offset of the focusing position respect to the contact point between the two materials were used as main control parameters to vary the melting ratio inside the seam. The objective of the study is twofold: to avoid surface microcracks related to the high percentage of carbon of the martensitic steel and to enhance the shear strength of the weld by making it less brittle. To reach this scope the effects of incidence angle and offset on weld bead geometry and melting ratio were studied by means of metallographic analyses, microstructure and microhardness characterization. As last step, the weld mechanical strength was tested by tensile-shear stress test on the whole seam. Experiments demonstrated that varying incidence angle and offsetting the focal position is a reliable method to modify the melting ratio and maintaining the expected resistance length at the material interface, as well. It was found that increasing the percentage of ferritic steel into the joint has beneficial effects on the weld quality and on the shear resistance. The critical carbon content determining the mechanical properties in the fusion zone can be calculated by taking into account the melting ratio.

  2. A study on an efficient prediction of welding deformation for T-joint laser welding of sandwich panel PART I : Proposal of a heat source model

    NASA Astrophysics Data System (ADS)

    Kim, Jae Woong; Jang, Beom Seon; Kim, Yong Tai; Chun, Kwang San

    2013-09-01

    The use of I-Core sandwich panel has increased in cruise ship deck structure since it can provide similar bending strength with conventional stiffened plate while keeping lighter weight and lower web height. However, due to its thin plate thickness, i.e. about 4~6 mm at most, it is assembled by high power CO2 laser welding to minimize the welding deformation. This research proposes a volumetric heat source model for T-joint of the I-Core sandwich panel and a method to use shell element model for a thermal elasto-plastic analysis to predict welding deformation. This paper, Part I, focuses on the heat source model. A circular cone type heat source model is newly suggested in heat transfer analysis to realize similar melting zone with that observed in experiment. An additional suggestion is made to consider negative defocus, which is commonly applied in T-joint laser welding since it can provide deeper penetration than zero defocus. The proposed heat source is also verified through 3D thermal elasto-plastic analysis to compare welding deformation with experimental results. A parametric study for different welding speeds, defocus values, and welding powers is performed to investigate the effect on the melting zone and welding deformation. In Part II, focuses on the proposed method to employ shell element model to predict welding deformation in thermal elasto-plastic analysis instead of solid element model.

  3. Analysis of factors responsible for the accelerated creep rupture of 12% Cr martensitic steel weld joints

    NASA Astrophysics Data System (ADS)

    Kudryavtsev, A. S.; Okhapkin, K. A.; Mikhailov, M. S.; Skutin, V. S.; Zubova, G. E.; Fedotov, B. V.

    2016-06-01

    In the process of the investigation of the heat resistance of a 0.07C-12Cr-Ni-Mo-V-Nb steel of the martensitic-ferritic class, a reduction was revealed in the long-term strength of its welded joints to below the level of the strength of the base metal. To establish the causes for the accelerated failure of the welded joints, an imitation of the thermal cycles was carried out that produce the structure of the heataffected zone using a dilatometer. In the samples with the structure that corresponds to that of the heataffected zone, a local zone of softening was revealed. The investigations of the metal structure using transmission electron microscopy have shown that the reduction in the creep rupture strength was caused by structural changes under the conditions of the thermal cycle of welding upon the staying of the steel in the temperature range between the Ac 1 and Ac 3 points.

  4. Structural Performance Evaluation of Composite-To-Steel Weld Bonded Joint

    SciTech Connect

    Shah, Bhavesh; Frame, Barbara J; Dove, Caroline; Fuchs, Hannes

    2010-01-01

    The Automotive Composites Consortium (ACC), a collaboration of Chrysler, Ford, General Motors, and the US Department of Energy is conducting a focal project to demonstrate the use of composite materials in high volume structural applications such as an underbody capable of carrying crash loads. One of the critical challenges is to attach the composite part to the steel structure in a high-volume automotive manufacturing environment and meet the complex requirements for crash. Weld-bonding, a combination of adhesive bonding and spot welding, was selected as the primary joining method. A novel concept of bonding doubler steel strips to composite enabled the spot welding to the steel structure, ensuring the compability with the OEM assembly processes. The structural performance of the joint, including durability, was assessed via analytical and physical testing under quasi-static loading at various temperatures. This paper discusses the results of the experiments designed to generate key modeling parameters for Finite Element Analysis of the joint.

  5. High-power Laser Welding of Thick Steel-aluminum Dissimilar Joints

    NASA Astrophysics Data System (ADS)

    Lahdo, Rabi; Springer, André; Pfeifer, Ronny; Kaierle, Stefan; Overmeyer, Ludger

    According to the Intergovernmental Panel on Climate Change (IPCC), a worldwide reduction of CO2-emissions is indispensable to avoid global warming. Besides the automotive sector, lightweight construction is also of high interest for the maritime industry in order to minimize CO2-emissions. Using aluminum, the weight of ships can be reduced, ensuring lower fuel consumption. Therefore, hybrid joints of steel and aluminum are of great interest to the maritime industry. In order to provide an efficient lap joining process, high-power laser welding of thick steel plates (S355, t = 5 mm) and aluminum plates (EN AW-6082, t = 8 mm) is investigated. As the weld seam quality greatly depends on the amount of intermetallic phases within the joint, optimized process parameters and control are crucial. Using high-power laser welding, a tensile strength of 10 kN was achieved. Based on metallographic analysis, hardness tests, and tensile tests the potential of this joining method is presented.

  6. Corrosion resistance of GTAW and EBW welded joints of DIN W. Nr. 1.4462 (UNS S31803): Effect of post-weld-heat-treatment

    SciTech Connect

    Brandi, S.D.; Padilha, A.F.; Wolynec, S.

    1996-12-01

    The duplex stainless steels present better corrosion behavior than the conventional stainless steels. This is due to their chemical composition (Cr, Ni, Mo, N) and a balanced microstructure (50% ferrite). It might be an increase on the volumetric fraction of ferrite, depending on the cooling rate after welding. In the same way the chemical composition can be altered by a loss of the alloying elements during welding, such as N. Both phenomena will decrease the corrosion resistance of the weldment. Autogenous GTAW and EBW were used to join the plates. Several corrosion tests were used to evaluate the behavior of the joints in as-welded (AW) and post-welded-heat-treated (PWHT) conditions. The results were analyzed and correlated to the microstructure of the welded joints. The main conclusion of this work is that corrosion resistance of both joint processes (EBW and GTAW) in as-welded condition is inadequate. PWHT (post-weld-heat-treatment) dissolved the chromium-rich precipitates, restored the equilibrium amount of austenite in the joints and recovered their corrosion resistance.

  7. Microstructure and Properties of TIG/FSW Welded Joints of a New Al-Zn-Mg-Sc-Zr Alloy

    NASA Astrophysics Data System (ADS)

    Lei, Xuefeng; Deng, Ying; Peng, Yongyi; Yin, Zhimin; Xu, Guofu

    2013-09-01

    A new Al-Zn-Mg-Sc-Zr alloy with low Sc content was welded by tungsten inert gas (TIG) and friction stir welding (FSW) techniques. The microstructure and properties of those two welded joints were investigated by property tests and microstructural observations. The results show that the new Al-Zn-Mg-Sc-Zr alloy has desirable welding property. The ultimate tensile strength and welding coefficient of the TIG joint reach 405 MPa and 76.7%, respectively, and in FSW joint those property values reach 490 MPa and 92.6%, respectively. The studied base metal has a deformed fibrous subgrains structure, many nano-scaled Al3(Sc,Zr) particles, and very fine aging precipitates. In the TIG joint, the fusion zone consists of coarsened dendritic grains and the heat-affected zone (HAZ) has fibrous micro-scaled subgrains. The FSW welded joint is characterized by a weld nugget zone, thermo-mechanically affected zone (TMAZ), and HAZ. Due to plastic deformation around the rotating pin and anti-recrystallized effectiveness of Al3(Sc,Zr) particles, the weld nugget zone has a very fine subgrain structure. The TMAZ experiences some dissolution of aging precipitates. Coarsening of aging precipitates was observed in the HAZ. The better mechanical properties of the FSW joint are derived from a fine subgrain structure and homogeneous chemical compositions.

  8. Effects of laser power density on static and dynamic mechanical properties of dissimilar stainless steel welded joints

    NASA Astrophysics Data System (ADS)

    Wei, Yan-Peng; Li, Mao-Hui; Yu, Gang; Wu, Xian-Qian; Huang, Chen-Guang; Duan, Zhu-Ping

    2012-10-01

    The mechanical properties of laser welded joints under impact loadings such as explosion and car crash etc. are critical for the engineering designs. The hardness, static and dynamic mechanical properties of AISI304 and AISI316 L dissimilar stainless steel welded joints by CO2 laser were experimentally studied. The dynamic strain-stress curves at the strain rate around 103 s-1 were obtained by the split Hopkinson tensile bar (SHTB). The static mechanical properties of the welded joints have little changes with the laser power density and all fracture occurs at 316 L side. However, the strain rate sensitivity has a strong dependence on laser power density. The value of strain rate factor decreases with the increase of laser power density. The welded joint which may be applied for the impact loading can be obtained by reducing the laser power density in the case of welding quality assurance.

  9. T-joints of Ti alloys with hybrid laser-MIG welding: macro-graphic and micro-hardness analyses

    NASA Astrophysics Data System (ADS)

    Spina, R.; Sorgente, D.; Palumbo, G.; Scintilla, L. D.; Brandizzi, M.; Satriano, A. A.; Tricarico, L.

    2012-03-01

    Titanium alloys are characterized by high mechanical properties and elevated corrosion resistance. The combination of laser welding with MIG/GMAW has proven to improve beneficial effects of both processes (keyhole, gap-bridging ability) while limiting their drawbacks (high thermal gradient, low mechanical resistance) In this paper, the hybrid Laser-GMAW welding of Ti-6Al-4V 3-mm thick sheets is investigated using a specific designed trailing shield. The joint geometry was the double fillet welded T-joint. Bead morphologies, microstructures and mechanical properties (micro-hardness) of welds were evaluated and compared to those achieved for the base metals.

  10. Mechanism of accelerated corrosion in Zircaloy-4 laser and electron-beam welds

    SciTech Connect

    McDonald, S.G.; Sabol, G.P.

    1982-01-01

    The corrosion resistance of a series of Zircaloy-4 laser, electron-beam (EB), and tungsten inert gas (TIG) welds was evaluated in high-temperature water and steam. Corrosion exposures carried out in 633 K water revealed that all welds had excellent corrosion resistance at this temperature. However, corrosion exposures carried out in 673 K steam indicated that the laser and EB welds were susceptible to accelerated corrosion, whereas the TIG welds were not. It is believed that alloy depletion and the resultant loss of high-temperature corrosion resistance can be eliminated or minimized by performing welding operations at a power density such that the metal surface is heated above the melting point, but below the boiling point. 23 refs.

  11. Fractured welds stir not debate

    SciTech Connect

    Rosenbaum, D.B.; Stocker, L.J.P.

    1996-05-06

    This article reviews the growing discussion regarding the failures of welded joints in a number of beam-to-column connections. In the Northridge Earthquake of 1994, there were a large number of such failures, and weld material E70T-4 was the common element in each failure. This weld material is utilized with FCAW, a semiautomatic welding process that allows a higher deposition rate. The manufacturer of the weld material argues that many of the welds were improperly performed, while others argue that the fracture toughness of the weld material is very low. With a minor defect, this would lead to brittle fracture under the cyclic loading that would occur during a seismic event. Use of the manual SMAW process using weld material E7018 is recommended.

  12. Joints, fissures, and voids in rhyolite welded ash-flow tuff at Teton damsite, Idaho

    USGS Publications Warehouse

    Prostka, Harold J.

    1977-01-01

    Several kinds of joints, fissures, and voids are present in densely welded rhyolite ash-flow tuff at Teton damsite. Older fissures and voids probably were formed in the ash-flow sheet during secondary flowage, which probably was caused by differential compaction or settling over irregular topography. The younger, more abundant fissures are mostly steep cooling joints that probably have been opened farther by horizontal tectonic extension and gravitational creep, perhaps aided by lateral stress relief.

  13. Friction stir spot welded joints of 409L stainless steels fabricated by a convex shoulder tool

    NASA Astrophysics Data System (ADS)

    Hossain, Md. Abu Mowazzem; Hasan, Md. Tariqul; Hong, Sung-Tae; Miles, Michael; Cho, Hoon-Hwe; Han, Heung Nam

    2013-11-01

    Spot joints of ferritic 409L stainless steel are successfully fabricated by friction stir spot welding (FSSW) using a convex shoulder tool. The welding process, microstructure and failure of the FSSW joint are investigated experimentally. During the FSSW process, the Z-force history shows significant variations depending on the contact phenomena between the tool and the joined sheets, while the Z-torque history shows a rather steady increase without pronounced changes in the trend until the initiation of dwelling. Electron back-scatter diffraction suggests that both continuous dynamic recrystallization and recovery occurred in the stir zone during the FSSW process. Observation of the FSSW joint that failed under the given lap shear load shows that the cracks, which are the result of the interfaces between the upper and lower sheets, propagated into the weld along the interfacial surfaces, after which a necking/shear failure occurred. Finally, the rupture of the joint, which was initiated by the necking/shear failure, propagated along the circumference of the weld.

  14. Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint

    NASA Astrophysics Data System (ADS)

    Das, H.; Kumar, A.; Rajkumar, K. V.; Saravanan, T.; Jayakumar, T.; Pal, Tapan Kumar

    2015-11-01

    Dissimilar lap joints of aluminum sheet (AA 6061) of 2 mm thickness and zinc-coated steel sheet of 1 mm thickness were produced by friction stir welding with different combinations of rotational speed and travel speed. Ultrasonic C- and B-scanning, and radiography have been used in a complementary manner for detection of volumetric (cavity and flash) and planar (de bond) defects as the defects are in micron level. Advanced ultrasonic C-scanning did not provide any idea about the defects, whereas B-scanning cross-sectional image showed an exclusive overview of the micron-level defects. A digital x-ray radiography methodology is proposed for quality assessment of the dissimilar welds which provide three-fold increase in signal-to-noise ratio with improved defect detection sensitivity. The present study clearly shows that the weld tool rotational speed and travel speed have a decisive role on the quality of the joints obtained by the friction stir welding process. The suitability of the proposed NDE techniques to evaluate the joint integrity of dissimilar FSW joints is thus established.

  15. New Equipment for Testing the Fatigue Strength of Riveted and Welded Joints

    NASA Technical Reports Server (NTRS)

    Muller, W

    1940-01-01

    The mechanical and electrical construction of a new experimental instrument for fatigue testing riveted and welded joints is described. This experimental device has the advantage of being able to stress, even with comparatively low magnetic exciter force, structural components in alternate bending by resonance vibrations up to incipient fatigue failure.

  16. Ultrasonic examination of welded joints of great thickness in mechanical equipment under pressure

    NASA Technical Reports Server (NTRS)

    Emil, N.

    1974-01-01

    The requirements involved in choosing ultrasonic devices, the factors that affect testing, and recommended calibration methods are discussed. The ultrasonic testing method is the only method that up to now permits detection of defects in welded joints of great thickness. The results are conditioned by the performances of the devices employed as well as by the degree of instruction of the personnel.

  17. Parallel-gap welding for joints between copper conductors and Kovar

    NASA Technical Reports Server (NTRS)

    Mc Daniel, G. E.

    1971-01-01

    Welding technique produces more reliable joints than soldering. Investigation used different sizes of copper conductors and component lead ribbons, corrosion protection platings, and melting points of metals being joined. Optimum combination is gold-plated component lead ribbons and solder-plated copper conductors.

  18. TORE SUPRA experience of copper chromium zirconium electron beam welding

    NASA Astrophysics Data System (ADS)

    Durocher, A.; Lipa, M.; Chappuis, Ph.; Schlosser, J.; Huber, T.; Schedler, B.

    2002-12-01

    The specification of TORE SUPRA to perform quasi steady state plasma operation has induced several R&D studies on the actively cooled structures of the plasma facing components and the associated assembling processes of the materials. Various industrial copper alloys have been characterized and tested to select the most optimized grade for EB welding. Welding samples of representative geometry were also analysed.

  19. Preliminary assessment of the fracture behavior of weld material in full-thickness clad beams

    SciTech Connect

    Keeney, J.A.; Bass, B.R.; McAfee, W.J.; Iskander, S.K.

    1994-10-01

    This report describes a testing program that utilizes full-thickness clad beam specimens to quantify fracture toughness for shallow cracks in material for which metallurgical conditions are prototypic of those found in reactor pressure vessels (RPVs). The beam specimens are fabricated from a section of an RPV wall (removed from a canceled nuclear plant) that includes weld, plate, and clad material. Metallurgical factors potentially influencing fracture toughness for shallow cracks in the beam specimens include material gradients due to welding and cladding applications, as well as material inhomogeneities in welded regions due to reheating in multiple weld passes. A summary of the testing program includes a description of the specimen geometry, material properties, the testing procedure, and the experimental results form three specimens. The yield strength of the weld material was determined to be 36% higher than the yield strength of the base material. An irradiation-induced increase in yield strength of the weld material could result in a yield stress that exceeds the upper limit where code curves are valid. The high yield strength for prototypic weld material may have implications for RPV structural integrity assessments. Analyses of the test data are discussed, including comparisons of measured displacements with finite-element analysis results, applications of toughness estimation techniques, and interpretations of constraint conditions implied by stress-based constraint methodologies. Metallurgical conditions in the region of the cladding heat-affected zone are proposed as a possible explanation for the lower-bound fracture toughness measured with one of the shallow-crack clad beam specimens. Fracture toughness data from the three clad beam specimens are compared with other shallow- and deep-crack uniaxial beam and cruciform data generated previously from A 533 Grade B plate material.

  20. X-ray opaque additive for inspection of weld joints

    NASA Technical Reports Server (NTRS)

    Brown, R. L.; Cook, J. L.

    1974-01-01

    Thin coating of copper applied to each faying surface of aluminum-alloy improve X ray detection of welding defects. Copper may be applied by spraying, coating, or deposition. Its thickness of faying surfaces must be uniform in range. Coating must be free from spalling and blistering and must contain no porosity.

  1. Effect of Stress Relief Annealing on Microstructure & Mechanical Properties of Welded Joints Between Low Alloy Carbon Steel and Stainless Steel

    NASA Astrophysics Data System (ADS)

    Nivas, R.; Das, G.; Das, S. K.; Mahato, B.; Kumar, S.; Sivaprasad, K.; Singh, P. K.; Ghosh, M.

    2017-01-01

    Two types of welded joints were prepared using low alloy carbon steel and austenitic stainless steel as base materials. In one variety, buttering material and weld metal were Inconel 82. In another type, buttering material and weld metal were Inconel 182. In case of Inconel 82, method of welding was GTAW. For Inconel 182, welding was done by SMAW technique. For one set of each joints after buttering, stress relief annealing was done at 923 K (650 °C) for 90 minutes before further joining with weld metal. Microstructural investigation and sub-size in situ tensile testing in scanning electron microscope were carried out for buttered-welded and buttered-stress relieved-welded specimens. Adjacent to fusion boundary, heat-affected zone of low alloy steel consisted of ferrite-pearlite phase combination. Immediately after fusion boundary in low alloy steel side, there was increase in matrix grain size. Same trend was observed in the region of austenitic stainless steel that was close to fusion boundary between weld metal-stainless steel. Close to interface between low alloy steel-buttering material, the region contained martensite, Type-I boundary and Type-II boundary. Peak hardness was obtained close to fusion boundary between low alloy steel and buttering material. In this respect, a minimum hardness was observed within buttering material. The peak hardness was shifted toward buttering material after stress relief annealing. During tensile testing no deformation occurred within low alloy steel and failure was completely through buttering material. Crack initiated near fusion boundary between low alloy steel-buttering material for welded specimens and the same shifted away from fusion boundary for stress relieved annealed specimens. This observation was at par with the characteristics of microhardness profile. In as welded condition, joints fabricated with Inconel 82 exhibited superior bond strength than the weld produced with Inconel 182. Stress relief annealing

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

    SciTech Connect

    Liu Fei; Zhang Zhaodong; Liu Liming

    2012-07-15

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

  3. Robotic gas metal arc welding of small diameter saddle type joints using multi-stripe structured light

    NASA Astrophysics Data System (ADS)

    Bonser, Gary R.; Parker, Graham A.

    1999-11-01

    Single-stripe structured light sensors are widely used in conjunction with arc welding robots for seam-tracking purposes. The interaction of the projected light with the weld joint and component surfaces produces characteristic line shapes with feature points that can be recognized at high speed by an underlying vision system. Unfortunately they are suitable only for the major classes of weld joint typically encountered within industry--long, straight, or gently curving fillet or butt joints. We present a multistripe structured light sensor that detects and measures the position of the saddle type weld joint formed by two small (< 50-mm)-diameter intersecting tubes. The underlying image processing algorithms detect the weld feature points from each stripe along with four calibration points to generate the entire weld path in the robot workcell base coordinate system before welding commences. The system is validated within an existing welding application; detecting 93% of the weld feature points within +/- 0.4 mm when used on 30-mm-diam tubes.

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

    NASA Astrophysics Data System (ADS)

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

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

  5. Fine-tuned Remote Laser Welding of Aluminum to Copper with Local Beam Oscillation

    NASA Astrophysics Data System (ADS)

    Fetzer, Florian; Jarwitz, Michael; Stritt, Peter; Weber, Rudolf; Graf, Thomas

    Local beam oscillation in remote laser welding of aluminum to copper was investigated. Sheets of 1 mm thickness were welded in overlap configuration with aluminum as top material. The laser beam was scanned in a sinusoidal mode perpendicular to the direction of feed and the influence of the oscillation parameters frequency and amplitude on the weld geometry was investigated. Scanning frequencies up to 1 kHz and oscillation amplitudes in the range from 0.25 mm to 1 mm were examined. Throughout the experiments the laser power and the feed rate were kept constant. A decrease of welding depth with amplitude and frequency is found. The scanning amplitude had a strong influence and allowed coarse setting of the welding depth into the lower material, while the frequency allowed fine tuning in the order of 10% of the obtained depth. The oscillation parameters were found to act differently on the aluminum sheet compared to copper sheet regarding the amount of fused material. It is possible to influence the geometry of the fused zones separately for both sheets. Therefore the average composition in the weld can be set with high precision via the oscillation parameters. A setting of the generated intermetallics in the weld zone is possible without adjustment of laser power and feed rate.

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

    NASA Astrophysics Data System (ADS)

    Yang, Shanglu

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

  7. A comparative evaluation of low-cycle fatigue behavior of type 316LN base metal, 316 weld metal, and 316LN/316 weld joint

    NASA Astrophysics Data System (ADS)

    Valsan, M.; Sundararaman, D.; Rao, K. Bhanu Sankara; Mannan, S. L.

    1995-05-01

    A comparative evaluation of the low-cycle fatigue (LCF) behavior of type 316LN base metal, 316 weld metal, and 316LN/316 weld joints was carried out at 773 and 873 K. Total strain-controlled LCF tests were conducted at a constant strain rate of 3 × 10-3 s-1 with strain amplitudes in the range ±0.20 to ±1.0 pct. Weld pads with single V and double V configuration were prepared by the shielded metal-arc welding (SMAW) process using 316 electrodes for weld-metal and weld-joint specimens. Optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM) of the untested and tested samples were carried out to elucidate the deformation and the fracture behavior. The cyclic stress response of the base metal shows a very rapid hardening to a maximum stress followed by a saturated stress response. Weld metal undergoes a relatively short initial hardening followed by a gradual softening regime. Weld joints exhibit an initial hardening and a subsequent softening regime at all strain amplitudes, except at low strain amplitudes where a saturation regime is noticed. The initial hardening observed in base metal has been attributed to interaction between dislocations and solute atoms/complexes and cyclic saturation to saturation in the number density of slip bands. From TEM, the cyclic softening in weld metal was ascribed to the annihilation of dislocations during LCF. Type 316LN base metal exhibits better fatigue resistance than weld metal at 773 K, whereas the reverse holds true at 873 K. The weld joint shows the lowest life at both temperatures. The better fatigue resistance of weld metal is related to the brittle transformed delta ferrite structure and the high density of dislocations at the interface, which inhibits the growth rate of cracks by deflecting the crack path. The lower fatigue endurance of the weld joint was ascribed to the shortening of the crack initiation phase caused by surface intergranular crack initiation and to the poor

  8. The relationship between the super plasticity of laser welding joint of titanium alloy and hydrogen treatment

    NASA Astrophysics Data System (ADS)

    Cao, Zean; Cheng, Donghai; Jiang, Xunyan; Hu, Dean; Chen, Yiping

    2017-06-01

    The superplastic deformation uniformity of laser welded joint of TC4 titanium alloy is improved by hydrogen treatment. The non-uniform deformation coefficient K was introduced to quantification ally characterize the non-uniform deformation. The results show when the content of hydrogen exceeds 0.29%, the super plasticity of the titanium alloy welded plate decreases with the increase of the hydrogen content. The decrease of the shrinkage of the base material is larger than that of the weld section with the increase of hydrogen content. The K can be used to describe the non-uniform deformation of the weld and the base material during the superplastic deformation of laser welded joint of the TC4. The K value increases with increaseing hydrogen content, increaseing deformation temperature and decreaseing strain rate. The K value reaches the maximum of 0.84 with hydrogen content of 1.299%, deformation temperature of 920 °C, strain rate of 10-4S-1.

  9. Transferring Electron Beam Welding Parameters Between DIfferent Machines and Facilities Using Advanced Diagnostics

    SciTech Connect

    Elmer, J W; Palmer, T A; Terrill, P; Knicklas, K D; Mustaleski, T M; Burgardt, P

    2004-06-17

    Transferring electron beam (EB) welding parameters between different welders can be a costly and time consuming process requiring the completion of expensive weld parameter studies. In order to modernize and streamline this process, the LLNL Beam Profiler diagnostic tool, which has been developed and tested at Lawrence Livermore National Laboratory (LLNL) to measure the size, shape, and power density distribution of electron beams, is currently being used to characterize the performance of EB machines at several U.S. Department of Energy facilities. The characterization of these machines involves performing defocus studies on each welder to measure the properties of 1 kW beams made at constant current, voltage, and work distance settings. Using these carefully characterized beams, autogenous welds on 304L stainless steel were then made at LLNL and replicated on the other machines. A key finding from these studies was that the widespread use of work distance values measured from the surface of the part being welded to the top of the EB vacuum chamber are suitable only for machines with a similar upper column design. Otherwise, the focus-lens to part distance must be determined and controlled. A simple method for determining the focus-lens to part distance with the LLNL Beam Profiler diagnostic tool is presented. The ability to transfer EB welds between machines represents a major accomplishment in the development and more widespread use of this diagnostic tool. This work also serves as a basis for the continuing development of procedures and equipment for characterizing electron beams and as a precursor to the development of a modern weld transfer procedure.

  10. Joint properties of cast Fe-Pt magnetic alloy laser welded to gold alloys.

    PubMed

    Watanabe, Ikuya; Nguyen, Khoi; Benson, P Andrew; Tanaka, Yasuhiro

    2006-01-01

    This study investigated the joint properties of a cast Fe-Pt magnetic alloy (Fe-36 at % Pt) laser welded to three gold alloys. The gold alloys used were ADA Type II and Type IV gold alloys, and an Ag-based (Ag-Au) gold alloy. Cast plates (0.5 x 3.0 x 10 mm) were prepared for each alloy. After the cast Fe-Pt plates were heat treated, they were butted against each of the three alloys and then laser welded with Nd:YAG laser at 200 V. Homogeneously welded specimens were also prepared for each alloy. Tensile testing was conducted at a crosshead speed of 1 mm/min. Failure load (N) and elongation (%) were recorded. After tensile testing, the fractured surfaces were examined with the use of SEM. The failure-load values of the group of alloys welded homogeneously were ranked in the order of: Ag-Au alloy > Type IV alloy > Type II alloy > Fe-Pt alloy. The Type IV alloy welded to Fe-Pt alloy had the highest failure-load value among the three alloys tested. The elongation results tended to follow a similar pattern. The results of this study indicated that Type IV gold alloy is a suitable alloy for metal frameworks to which cast Fe-Pt magnetic alloy is laser welded.

  11. Development of temper-bead technique applied to dissimilar welded joints of nuclear pressure vessels

    SciTech Connect

    Higuchi, Makoto; Umemoto, Tadahiro; Matsusita, Akitake; Shiraiwa, Takanori

    1996-06-01

    When nuclear pressure vessels made of low-alloy steel (P-3 Group 3) need repair or modification, technical standards for welding of electrical structures should be applied, and then postweld heat treatment (PWHT) should be done. However, cases in which PWHT is impractical are theoretically possible due to a variety of restrictions. To deal with such a problem, there is a regulation for repair weld technique, without PWHT, in accordance with ASME B and PV Code. This method is called temper-bead technique, which gives the weldments sufficient toughness by tempering the hardened zone of the heat-affected zone on the first layer of the base metal using the heat of the following weld beads. Because there is no regulation in Japan covering this method, a procedure is required to perform it under a special license, after a verification test has been passed. An attempt has been made to develop a method, on the supposition that the temper-bead technique is adopted for replacement of what is called dissimilar welded joints, so that a nickel base alloy is buildup welded at the tip of the nozzle of the low-alloy steel pressure vessel, and a stainless steel pipe is butt welded.

  12. Integrity assessment of the ferritic / austenitic dissimilar weld joint between intermediate heat exchanger and steam generator in fast reactor

    SciTech Connect

    Jayakumar, T.; Laha, K.; Chandravathi, K. S.; Parameswaran, P.; Goyal, S.; Kumar, J. G.; Mathew, M. D.

    2012-07-01

    Integrity of the modified 9Cr-1Mo / alloy 800 dissimilar joint welded with Inconel 182 electrodes has been assessed under creep condition based on the detailed analysis of microstructure and stress distribution across the joint by finite element analysis. A hardness peak at the ferritic / austenitic weld interface and a hardness trough at the inter-critical heat affected zone (HAZ) in ferritic base metal developed. Un-tempered martensite was found at the ferritic / austenitic weld interface to impart high hardness in it; whereas annealing of martensitic structure of modified 9Cr-1Mo steel by inter-critical heating during welding thermal cycle resulted in hardness tough in the inter-critical HAZ. Creep tests were carried out on the joint and ferritic steel base metal at 823 K over a stress range of 160-320 MPa. The joint possessed lower creep rupture strength than its ferritic steel base metal. Failure of the joint at relatively lower stresses occurred at the ferritic / austenitic weld interface; whereas it occurred at inter-critical region of HAZ at moderate stresses. Cavity nucleation associated with the weld interface particles led to premature failure of the joint. Finite element analysis of stress distribution across the weld joint considering the micro-mechanical strength inhomogeneity across it revealed higher von-Mises and principal stresses at the weld interface. These stresses induced preferential creep cavitation at the weld interface. Role of precipitate in enhancing creep cavitation at the weld interface has been elucidated based on the FE analysis of stress distribution across it. (authors)

  13. Effect of Zinc Coatings on Joint Properties and Interfacial Reactions in Aluminum to Steel Ultrasonic Spot Welding

    NASA Astrophysics Data System (ADS)

    Haddadi, F.; Strong, D.; Prangnell, P. B.

    2012-03-01

    Dissimilar joining of aluminum to steel sheet in multimaterial automotive structures is an important potential application of ultrasonic spot welding (USW). Here, the weldability of different zinc-coated steels with aluminum is discussed, using a 2.5-kW USW welder. Results show that soft hot-dipped zinc (DX56-Z)-coated steel results in better weld performance than hard (galv-annealed) zinc coatings (DX53-ZF). For Al to hard galv-annealed-coated steel welds, lap shear strengths reached a maximum of ~80% of the strength of an Al-Al joint after a 1.0 s welding time. In comparison, welds between Al6111-T4 and hot dipped soft zinc-coated steel took longer to achieve the same maximum strength, but nearly matched the Al-Al joint properties. The reasons for these different behaviors are discussed in terms of the interfacial reactions between the weld members.

  14. Estimate of the allowable dimensions of diagnosed defects in category III and IV welded pipeline joints{sup 1}

    SciTech Connect

    Grin', E. A.; Bochkarev, V. I.

    2013-01-15

    An approach for estimating the permissible dimensions of technological defects in butt welded joints in category III and IV pipelines is described. The allowable size of a welding defect is determined from the condition of compliance with the specifications on strength for a reference cross section (damaged joint) of the pipeline taking into account its weakening by a given defect.With regard to the fairly widespread discovery of technological defects in butt welded joints during diagnostics of auxiliary pipelines for thermal electric power plants, the proposed approach can be used in practice by repair and consulting organizations.

  15. Numerical Simulation of Tension Properties for Al-Cu Alloy Friction Stir-Welded Joints with GTN Damage Model

    NASA Astrophysics Data System (ADS)

    Sun, Guo-Qin; Sun, Feng-Yang; Cao, Fang-Li; Chen, Shu-Jun; Barkey, Mark E.

    2015-11-01

    The numerical simulation of tensile fracture behavior on Al-Cu alloy friction stir-welded joint was performed with the Gurson-Tvergaard-Needleman (GTN) damage model. The parameters of the GTN model were studied in each region of the friction stir-welded joint by means of inverse identification. Based on the obtained parameters, the finite element model of the welded joint was built to predict the fracture behavior and tension properties. Good agreement can be found between the numerical and experimental results in the location of the tensile fracture and the mechanical properties.

  16. Influence of structure on static cracking resistance and fracture of welded joints of pipe steels of strength class K60

    NASA Astrophysics Data System (ADS)

    Tereshchenko, N. A.; Tabatchikova, T. I.; Yakovleva, I. L.; Makovetskii, A. N.; Shander, S. V.

    2017-07-01

    The static cracking resistance of a number of welded joints made from pipe steels of K60 strength class has been determined. It has been established that the deformation parameter CTOD varies significantly at identical parameters of weldability of steels. The character of fracture has been investigated and the zone of local brittleness of welded joints has been studied. It has been shown that the ability of a metal to resist cracking is determined by the austenite grain size and by the bainite morphology in the region of overheating in the heat-affected zone of a welded joint.

  17. Effect of laser beam offset on microstructure and mechanical properties of pulsed laser welded BTi-6431S/TA15 dissimilar titanium alloys

    NASA Astrophysics Data System (ADS)

    Zhang, Hao; Hu, Shengsun; Shen, Junqi; Li, Dalong; Bu, Xianzheng

    2015-11-01

    Laser beam welding was used to weld dissimilar joints in BTi-6431S/TA15 titanium alloys. The effect of laser beam offset on microstructural characterizations and mechanical properties of the joints were investigated. Microstructural evolution of the joints was characterized by optical microscopy (OM) and X-ray diffraction (XRD). Tensile testing was conducted at room temperature and at 550 °C. The results demonstrated that with the exception of some porosity, a good quality joint could be achieved. Martensite α' and acicular α structures were present in the fusion zone (FZ). The amount of martensite α' present with the -0.2 mm beam offset was less than that with the 0.2 mm beam offset. Acicular α and martensite α' transformations occurred in the high temperature heat-affected zone (HT-HAZ) of both the BTi-6431S and TA15 alloys. In the low-temperature heat-affected zone (LT-HAZ), the BTi-6431S and TA15 alloy microstructures exhibited a mixture of secondary α, primary α, and prior β phases. The microhardness values in the FZ followed the order: -0.2 mm> 0 mm> 0.2 mm. Tensile testing at room temperature and at 550 °C resulted in fracture of the TA15 alloy base metal. The fracture morphology exhibited a ductile dimple feature.

  18. Thermal and mechanical properties of e-beam irradiated butt-fusion joint in high-density polyethylene pipes

    NASA Astrophysics Data System (ADS)

    Vijayan, Vipin; Pokharel, Pashupati; Kang, Min Kwan; Choi, Sunwoong

    2016-05-01

    The effects of electron beam irradiation on the thermal and mechanical properties of a butt-fusion joint in high density polyethylene (HDPE) pipes were investigated. Differential scanning calorimetry, X-ray diffraction, and Fourier transform infra-red spectroscopy of welded samples revealed the changes of crystallinity due to the cross linking effect of electron beam irradiation. The suppression of the degree of crystallinity with increasing the irradiation dose from 0 kGy to 500 kGy indicated that the e-beam radiation induced cross-links among the polymer chains at the weld zone. The cross-link junction at the joint of HDPE pipe prevented chain folding and reorganization leading to the formation of imperfect crystallites with smaller size and also less in content. Tensile test of the welded samples with different dose of e-beam irradiation showed the increased values of the yield stress and Young's modulus as a function of irradiation dose. On the other hand, the elongation at break diminished clearly with increasing the irradiation doses.

  19. Numerical and experimental study of the weld joints formation in welding foam materials

    SciTech Connect

    Bezginov, Roman O. E-mail: rakrekt@mail.ru; Krektuleva, Raisa A. E-mail: rakrekt@mail.ru; Mishin, Mikhail A. E-mail: rakrekt@mail.ru; Cherepanov, Oleg I. Cherepanov, Roman O.

    2014-11-14

    A numerical analysis of fusion welding of steel- and aluminum-based foam materials is carried out. The schemes of the structured and stochastic pore distribution are considered. The research results were used to conduct the experiments which confirmed the reliability of the numerical calculations.

  20. Low Cycle and Thermo-Mechanical Fatigue of Friction Welded Dissimilar Superalloys Joint

    NASA Astrophysics Data System (ADS)

    Sakaguchi, Motoki; Sano, Atsushi; Tran, Tra Hung; Okazaki, Masakazu; Sekihara, Masaru

    The high temperature strengths of the dissimilar friction welded superalloys joint between the cast polycrystalline Mar-M247 and the forged IN718 alloys have been investigated under low cycle and thermo-mechanical fatigue loadings, in comparison with those of the base metals. The experiments showed that the lives of the dissimilar joints were significantly influenced by the test conditions and loading modes. Not only the lives themselves but also the failure positions and mechanisms were sensitive to the loading mode. The fracture behaviors depending on the loading modes and test conditions were discussed, based on the macroscopic elastic follow-up mechanism and the microstructural inhomogeneity in the friction weld joint.

  1. Experimental and numerical evaluation of the fatigue behaviour in a welded joint

    NASA Astrophysics Data System (ADS)

    Almaguer, P.; Estrada, R.

    2014-07-01

    Welded joints are an important part in structures. For this reason, it is always necessary to know the behaviour of them under cyclic loads. In this paper a S - N curve of a butt welded joint of the AISI 1015 steel and Cuban manufacturing E6013 electrode is showed. Fatigue tests were made in an universal testing machine MTS810. The stress ratio used in the test was 0,1. Flaws in the fatigue specimens were characterized by means of optical and scanning electron microscopy. SolidWorks 2013 software was used to modeling the specimens geometry, while to simulate the fatigue behaviour Simulation was used. The joint fatigue limit is 178 MPa, and a cut point at 2 039 093 cycles. Some points of the simulations are inside of the 95% confidence band.

  2. On the Critical Technological Issues of Friction Stir Welding T-Joints of Dissimilar Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Astarita, A.; Squillace, A.; Scala, A.; Prisco, A.

    2012-08-01

    In this article, friction stir welded T-joints of innovative dissimilar aluminum alloys have been produced and tested with the aim to investigate the feasibility of using this joining technique, in this configuration, in the aerospace field with the final aim to save weight. The introduction of both this new welding technique and innovative alloys, such as AA 2198 and AA 6056, could allow making lighter and stronger structures. Some experiments, carried out previously, have shown that the fixturing device, the tool geometry, and the tilt angle play a significant role in the joint soundness. A wide experimental characterization has been carried out on FSW T-joints of AA 6056 T4 extrudes to AA 2198 T3 rolled plates. The results attained allow to put in evidence some critical issues on the investigated configuration and can be considered as a further acquired knowledge in the understanding and the design of friction stir processes.

  3. Geometry and Material Constraint Effects on Creep Crack Growth Behavior in Welded Joints

    NASA Astrophysics Data System (ADS)

    Li, Y.; Wang, G. Z.; Xuan, F. Z.; Tu, S. T.

    2017-02-01

    In this work, the geometry and material constraint effects on creep crack growth (CCG) and behavior in welded joints were investigated. The CCG paths and rates of two kinds of specimen geometry (C(T) and M(T)) with initial cracks located at soft HAZ (heat-affected zone with lower creep strength) and different material mismatches were simulated. The effect of constraint on creep crack initiation (CCI) time was discussed. The results show that there exists interaction between geometry and material constraints in terms of their effects on CCG rate and CCI time of welded joints. Under the condition of low geometry constraint, the effect of material constraint on CCG rate and CCI time becomes more obvious. Higher material constraint can promote CCG due to the formation of higher stress triaxiality around crack tip. Higher geometry constraint can increase CCG rate and reduce CCI time of welded joints. Both geometry and material constraints should be considered in creep life assessment and design for high-temperature welded components.

  4. Study on fatigue crack propagation characteristics around welded joint interface in complexed conditions

    NASA Astrophysics Data System (ADS)

    Ota, Akihiko; Suzuki, Naoyuki; Maeda, Yoshio; Mawari, Toshio; Matsuoka, Saburo; Nishijima, Satoshi

    1993-01-01

    Marine structures are often constructed by welding, and they are subject to repeated loading such as waves and mechanical vibrations which can create fatigue cracks and consequently break the structures. Fatigue crack propagation properties of welded joints are studied under random loading in the air, synthetic sea water, and compressive cycling. It was found that the most crucial factor that controls fatigue crack propagation was high tensile residual stress fields of welded joints. This stress constantly kept the cracks open, simplifying fatigue crack propagation, and therefore, the rate of crack propagation could be assessed with high accuracy. In the transverse matching welded joints with cracks in the center, crack closure did not occur due to the tensile residual stress constantly induced at the crack ends in the center of the test samples. Fatigue crack propagation was accelerated both in artificial sea water and in compressive cycling compared to that in the air, and the fatigue lowest values were about half. Serious crack closures occurred in compressive cycling in which dry hours exceeded 45 minutes, and the fatigue crack propagation rate deteriorated remarkably. Mean fatigue crack propagation rate under the random loading is estimated precisely using equivalent stress intensity factor limit.

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

    NASA Astrophysics Data System (ADS)

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

    2012-05-01

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

  6. Mechanical characteristics and microstructure of weld joint of high-temperature martensitic steel containing 9% Cr

    NASA Astrophysics Data System (ADS)

    Shakhova, Ya. E.; Belyakov, A. N.; Kaibyshev, R. O.

    2016-04-01

    The structure and mechanical characteristics of a weld joint of 10Kh9K3V2MFBR steel (0.097 C, 0.17.Si, 0.54 Mn, 8.75 Cr, 0.21 Ni, 0.51 Mo, 0.07 Nb, 0.23 V, 0.004 N, 0.003 B, 1.6 W, 0.15 Cu, and Fe for balance, wt %) have been studied; the joint was produced by hand welding in an argon atmosphere using 03Kh20N45M7G6B welding wire (0.3 C, 20 Cr, 45 Ni, 7 Mo, 6 Mn, and 1 Nb, wt %). The weld joint is divided into the zone of the base metal, a thermal effect zone, which consists of zones that contain fine and coarse original austenitic grains, and the zone of seam metal. It has been shown that the weld joint of 10Kh9K3V2MFBR steel possesses high strength characteristics at the room temperature under static loading and a satisfactorily impact toughness, which has the minimum value of 30 J/cm2 in the zone of the seam metal and does not depend on the temperature. With a decrease in the temperature from the room temperature to 253 K, a ductile-brittle transition occurs in the thermal effect zone. Creep tests carried out at the temperature of 923 K have shown that the long-term strength of the weld seam is lower than that of the base material in the entire stress range being tested. At stresses of 140 MPa or higher, the acceleration of creep in the weld seam is observed, while at low stresses of about 120 MPa, the rates of creep in the weld seam and in the base metal remain similar until the transition to the stage of accelerated fracture occurs. The difference in the values of the long-term strength is due to premature fracture, which occurs in the thermal effect zone with the finegrained structure.

  7. Analysing the strength of friction stir spot welded joints of aluminium alloy by fuzzy logic

    NASA Astrophysics Data System (ADS)

    Vaira Vignesh, R.; Padmanaban, R.; Arivarasu, M.; Karthick, K. P.; Abirama Sundar, A.; Gokulachandran, J.

    2016-09-01

    Friction stir spot welding (FSSW) is a recent joining technique developed for spot welding of thin metal sheets. This process currently finds application in automotive, aerospace, marine and sheet metal industry. In this work, the effect of FSSW process parameters namely tool rotation speed, shoulder diameter and dwell time on Tensile shear failure load (TSFL) is investigated. Box-Behnken design is selected for conducting experiments. Fuzzy based soft computing is used to develop a model for TSFL of AA6061 joints fabricated by FSSW. The interaction of the process parameters on TSFL is also presented.

  8. Numerical investigation on friction welding of alumina / AA 6063 T6 joints

    NASA Astrophysics Data System (ADS)

    Hynes, N. Rajesh Jesudoss; Velu, P. Shenbaga; Tharmaraj, R.; Kumar, R.

    2016-05-01

    Friction welding is the most suitable candidate for joining the dissimilar materials such as AA 6063 T6 alloy/Alumina for critical situations in high temperature and high corrosion resistance applications. In the present work, the numerical simulation was carried out to understand the mechanism of joining of AA 6063 T6 alloy/ Alumina rod by friction welding process. The developed thermo mechanical model is a highly nonlinear due to the interaction between the temperature fields and time dependent of the material properties. The developed numerical tool could be used to predict the temperature distribution, stress, strain and deformation of the dissimilar joints.

  9. Interfacial and Mechanical Behavior of AA5456 Filling Friction-Stir-Welded Lap Joints Using Similar and Dissimilar Pins

    NASA Astrophysics Data System (ADS)

    Behmand, Saleh Alaei; Mirsalehi, Seyyed Ehsan; Omidvar, Hamid; Safarkhanian, Mohammad Ali

    2016-10-01

    In this article, filling friction stir welding (FFSW) of the remaining exit holes of AA5456 alloy friction-stir-welded lap joints was studied. For this purpose, the influences of different rotating speeds, holding times, and pin materials, AA5456 and AA2024, on the metallurgical structure and joint strength were investigated. The observations showed that defect-free lap joints are successfully obtainable by this method using similar and dissimilar consumable pins. The results indicated that the higher rotating speed and holding time adversely affect the weld performance. The best result was achieved for 30 seconds holding time, 500 rpm rotating speed, and AA2024 consumable pin. In this condition, a lap shear strength of 10 pct higher than that of the nonfilled joint, equivalent to about 94 pct of the original defect-free FSW joint, was obtained, whereas the GTAW filled joint showed only approximately 87 pct of the continuous FSW joint strength.

  10. Effect of Welding Speed on Mechanical Properties and the Strain-Hardening Behavior of Friction Stir Welded 7075 Aluminum Alloy Joints

    NASA Astrophysics Data System (ADS)

    Xu, Weifeng; Li, Zhaoxi; Sun, Xiaohong

    2017-03-01

    The effect of welding speed on the microstructural evolution, mechanical properties and strain-hardening behavior of friction stir welded (FSWed) high-strength AA7075-T651 was investigated. Large intermetallic particles and grains, whose sizes increased at lower welding speeds, were present in the heat-affected zone. FSWed joints fabricated at the higher welding speed or lower strain rates exhibited higher strength, joint efficiency and ductility than those fabricated at lower welding speeds or higher strain rates. A maximum joint efficiency of 97.5% and an elongation to failure of 15.9% were obtained using a welding speed of 400 mm/min at a strain rate of 10-5 s-1. The hardening capacity, strain-hardening exponent and strain-hardening rate of the FSWed joints were significantly higher than those of the base material, but materials exhibited stage III and stage IV hardening characteristics. The results morphology of the fracture surfaces is consistent with the above results.

  11. Effect of Welding Speed on Mechanical Properties and the Strain-Hardening Behavior of Friction Stir Welded 7075 Aluminum Alloy Joints

    NASA Astrophysics Data System (ADS)

    Xu, Weifeng; Li, Zhaoxi; Sun, Xiaohong

    2017-04-01

    The effect of welding speed on the microstructural evolution, mechanical properties and strain-hardening behavior of friction stir welded (FSWed) high-strength AA7075-T651 was investigated. Large intermetallic particles and grains, whose sizes increased at lower welding speeds, were present in the heat-affected zone. FSWed joints fabricated at the higher welding speed or lower strain rates exhibited higher strength, joint efficiency and ductility than those fabricated at lower welding speeds or higher strain rates. A maximum joint efficiency of 97.5% and an elongation to failure of 15.9% were obtained using a welding speed of 400 mm/min at a strain rate of 10-5 s-1. The hardening capacity, strain-hardening exponent and strain-hardening rate of the FSWed joints were significantly higher than those of the base material, but materials exhibited stage III and stage IV hardening characteristics. The results morphology of the fracture surfaces is consistent with the above results.

  12. Nickel nanowires mesh fabricated by ion beam irradiation-induced nanoscale welding for transparent conducting electrodes

    NASA Astrophysics Data System (ADS)

    Honey, S.; Ahmad, I.; Madhuku, M.; Naseem, S.; Maaza, M.; Kennedy, J. V.

    2017-07-01

    In this report, random nickel nanowires (Ni-NWs) meshes are fabricated by ions beam irradiation-induced nanoscale welding of NWs on intersecting positions. Ni-NWs are exposed to beam of 50 KeV Argon (Ar+) ions at various fluencies in the range ~1015 ions cm-2 to 1016 ions cm-2 at room temperature. Ni-NWs are welded due to accumulation of Ar+ ions beam irradiation-induced sputtered atoms on crossing positions. Ar+ ions irradiated Ni-NWs meshes are optically transparent and optical transparency is enhanced with increase in beam fluence of Ar+ ions. Ar+ ions beam irradiation-induced welded and optically transparent mesh is then exposed to 2.75 MeV hydrogen (H+) ions at fluencies 1  ×  1015 ions cm-2, 3  ×  1015 ions cm-2 and 1  ×  1016 ions cm-2 at room temperature. MeV H+ ions irradiation-induced local heat cause melting and fusion of NWs on intersecting points and eventually lead to reduce contact resistance between Ni-NWs. Electrical conductivity is enhanced with increase in beam fluence of H+ ions. These welded highly transparent and electrically conductive Ni-NWs meshes can be employed as transparent conducting electrodes in optoelectronic devices.

  13. Characterization the microstructure of pulsed Nd:YAG welding method in low frequencies; correlation with tensile and fracture behavior in laser-welded nitinol joints

    NASA Astrophysics Data System (ADS)

    Shojaei Zoeram, Ali; Rahmani, Aida; Asghar Akbari Mousavi, Seyed Ali

    2017-05-01

    The precise controllability of heat input in pulsed Nd:YAG welding method provided by two additional parameters, frequency and pulse duration, has made this method very promising for welding of alloys sensitive to heat input. The poor weldability of Ti-rich nitinol as a result of the formation of Ti2Ni IMC has deprived us of the unique properties of this alloy. In this study, to intensify solidification rate during welding of Ti-rich nitinol, pulsed Nd:YAG laser beam in low frequency was employed in addition to the employment of a copper substrate. Specific microstructure produced in this condition was characterized and the effects of this microstructure on tensile and fracture behavior of samples welded by two different procedures, full penetration and double-sided method with halved penetration depth for each side were investigated. The investigations revealed although the combination of low frequencies, the use of a high thermal conductor substrate and double-sided method eliminated intergranular fracture and increased tensile strength, the particular microstructure, built in the pulsed welding method in low frequencies, results to the formation of the longitudinal cracks during the first stages of tensile test at weld centerline. This degrades tensile strength of welded samples compared to base metal. The results showed samples welded in double-sided method performed much better than samples welded in full penetration mode.

  14. Site-Dependent Tension Properties of Inertia Friction-Welded Joints Made From Dissimilar Ni-based Superalloys

    NASA Astrophysics Data System (ADS)

    Senkov, O. N.; Mahaffey, D. W.; Semiatin, S. L.; Woodward, C.

    2015-03-01

    Microstructure, tensile properties, and fracture behavior of the inertia friction weld joints of dissimilar superalloys, cast Mar-M247 and wrought LSHR, were studied to assess the weld quality. Tensile tests were conducted at 23 and 704 °C on the samples containing different areas of the weld interface of the same welded material. The stress-strain curves were registered at different axial distances from the weld interface. In all tested samples, plastic deformation was localized on Mar-M247 side, outside the heat-affected zone (HAZ), and the resistance to plastic deformation of Mar-M247 increased with a decrease in the distance from the weld interface inside HAZ. Only elastic deformation occurred on the LSHR side. Fracture occurred on the Mar-M247 side, outside HAZ, or at the weld interface. In the latter case, welding defects in the form of clusters of nanometer-sized oxide and carbide particles were observed at the fracture surfaces. These results revealed that the IFW process is capable of producing the weld joints between Mar-M247 and LSHR with the fracture strength higher than that of Mar-M247. However, optimization of the IFW processing parameters is required to minimize clustering of oxide/carbide particles at the weld interface in this alloy pair.

  15. 7. DETAIL, NOTCHED ROUGH HEWN JOINTS AND BEAMS PLUS WINDOW ...

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

    7. DETAIL, NOTCHED ROUGH HEWN JOINTS AND BEAMS PLUS WINDOW UNDER 1ST FLOOR PORCH, SOUTH ELEVATION, LOOKING NORTH-NORTHWEST. - Fort Leavenworth, Building No. 17, 20-22 Sumner Place, Leavenworth, Leavenworth County, KS

  16. 29. View of paired concreteencased columns at joint between beams ...

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

    29. View of paired concrete-encased columns at joint between beams contrasted against wider single columns. Looking east. - Stillwell Avenue Station, Intersection of Stillwell & Surf Avenues, Brooklyn, Kings County, NY

  17. Effect of welding parameters on high-power diode laser welding on thin sheet

    NASA Astrophysics Data System (ADS)

    Salminen, Antti; Jansson, Anssi; Kujanpaa, Veli

    2003-06-01

    High power diode laser (HPDL) is the newest laser tool for industrial manufacturing. The most promising areas of application of HPDL are thin sheet welding and hardening. The HPDL has several advantages and disadvantages compared to lasers CO2 and Nd:YAG lasers currently used for welding. There is quite a few industrial applications in which diode laser is the most suitable laser. A typical industrial installation consists of a HPDL, an industrial robot, work piece manipulation and safety enclosures. The HPDL welding process is at this moment conduction limited and has therefore different parameters than the keyhole welding. In this study the basic HPDL welding parameters and the effect of the parameters on the welding process, weld quality and efficiency are examined. Joint types tested are butt joint and fillet lap joint. The parameters tested are beam intensity, welding speed, spot size, beam impingement angle. The materials tested are common carbon steel and stainless steel. By the experiments carried out it can be seen that all of these parameters have an effect on the weld quality and the absorption of the laser power during welding. The higher the beam intensity is the shorter also the throughput time is. However, in case of fillet joint the maximum welding speed and best visual out look are achieved with totally different set of parameters. Based on these experiments it can, however, be seen that reliable welding parameters can be established for the welding of various industrial products. The beam quality of the diode laser is not optimum for high speed keyhole welding but it is a flexible tool to be used for different joint types.

  18. Reasons for crack nucleation in welded joints of main gas-pipelines after a long-term operation

    NASA Astrophysics Data System (ADS)

    Maruschak, P. O.; Bishchak, R. T.; Shlapak, L. S.; Panin, S. V.

    2017-02-01

    A crack of operational origin in the welded joint of the main gas pipeline is analyzed. The reasons for its nucleation and impact on technological microdefects that were formed earlier during the welding are found. Micromechanisms and stages of nucleation and propagation of the crack are investigated.

  19. Welding.

    ERIC Educational Resources Information Center

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

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

  20. Welding.

    ERIC Educational Resources Information Center

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

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

  1. Hybrid joints manufactured by ultrasound enhanced friction stir welding (USE-FSW) - corrosion properties

    NASA Astrophysics Data System (ADS)

    Benfer, S.; Fürbeth, W.; Thomä, M.; Wagner, G.; Straß, B.; Wolter, B.

    2017-03-01

    To realize lightweight structures of material combinations like aluminum/magnesium and aluminum/steel an Ultrasound Enhanced Friction Stir Welding (USE-FSW) process was used. This process has a beneficial influence on the resulting microstructure (elimination of the brittle intermetallic phase Al3Mg2 as coherent layer) and the mechanical properties (increased tensile strength) of Al/Mg-joints and was now also applied for Al/steel-hybrid joints. Besides the mechanical properties the corrosion properties of the hybrid joints may play a significant role concerning the later use of the hybrid materials. Therefore, the corrosion properties of various hybrid joints have been investigated by different methods. With the Scanning Kelvin Probe (SKP) Volta potential differences between the base alloys and the welded area were investigated in air. The two-dimensional color-plots illustrate not only the Volta potential differences between the different phases but also their oxidation properties in air during the measurement time. Electrochemical measurements (open circuit potential and potentiodynamic polarization) have been carried out for the investigation of the corrosion properties of the FSW and USE-FSW hybrid joints in 0.5 molar NaCl solution. A three electrode setup within a mini-cell was used to enable measurements on different areas of the joints. This allows to observe the corrosion activity of the base alloys and the nugget phase separately. Differences between Al/steel-hybrid joints processed with and without ultrasound enhancement are discussed and compared with Al/Mg-hybrids.

  2. Acoustic emissions during deformation of intact and jointed welded tuff

    NASA Astrophysics Data System (ADS)

    Holcomb, D. J.; Teufel, L. W.

    1982-07-01

    Monitoring of acoustic emissions (AE) has been widely used as a means of detecting failure in intact rock. For intact rock the technique is simple, because an increasing rate of AE is usually a sign of impending failure. However, most large rock masses contain numerous joints and the behavior of the joints controls the properties of the rock mass In particular, the failure mode often becomes stable or unstable slip (stick-slip) on a joint at stresses well below those required for failure of the intact rock. As an aid to understanding and monitoring the behavior of jointed rock masses, we have done a series of experiments on intact and artificially jointed samples of Grouse Canyon tuff. The tuff was selected because it is under consideration as a disposal medium for nuclear wastes. The samples were instrumented to measure axial and transverse displacements and AE rates.

  3. Numerical simulation of full-penetration laser beam welding of thick aluminium plates with inductive support

    NASA Astrophysics Data System (ADS)

    Bachmann, Marcel; Avilov, Vjaceslav; Gumenyuk, Andrey; Rethmeier, Michael

    2012-01-01

    A three-dimensional laminar steady-state numerical model was developed to investigate the influence of an alternating current (ac) magnetic field during high-power full-penetration laser welding on the weld pool dynamics and weld cross section of a 20 mm thick aluminium plate in flat position. Three-dimensional heat transfer, fluid dynamics including phase transition and electromagnetic field partial differential equations were solved iteratively with the commercial finite element software COMSOL Multiphysics using temperature-dependent material properties up to evaporation temperature. Thermocapillary convection at the weld pool surfaces, natural convection and latent heat of solid-liquid phase transition were taken into account in this model. Solidification was modelled by the Carman-Kozeny equation for porous media morphology. The ac magnet was mounted on the root side of the weld specimen. The magnetic field was aligned perpendicular to the welding direction. The flow pattern in the melt and thus also the temperature distribution were significantly changed by the application of oscillating magnetic fields. It was shown that the application of an ac magnetic field to laser beam welding allows for a prevention of the gravity drop-out. The simulation results are in good qualitative agreement with the experimental observations.

  4. Prediction of Tensile Strength of Friction Stir Weld Joints with Adaptive Neuro-Fuzzy Inference System (ANFIS) and Neural Network

    NASA Technical Reports Server (NTRS)

    Dewan, Mohammad W.; Huggett, Daniel J.; Liao, T. Warren; Wahab, Muhammad A.; Okeil, Ayman M.

    2015-01-01

    Friction-stir-welding (FSW) is a solid-state joining process where joint properties are dependent on welding process parameters. In the current study three critical process parameters including spindle speed (??), plunge force (????), and welding speed (??) are considered key factors in the determination of ultimate tensile strength (UTS) of welded aluminum alloy joints. A total of 73 weld schedules were welded and tensile properties were subsequently obtained experimentally. It is observed that all three process parameters have direct influence on UTS of the welded joints. Utilizing experimental data, an optimized adaptive neuro-fuzzy inference system (ANFIS) model has been developed to predict UTS of FSW joints. A total of 1200 models were developed by varying the number of membership functions (MFs), type of MFs, and combination of four input variables (??,??,????,??????) utilizing a MATLAB platform. Note EFI denotes an empirical force index derived from the three process parameters. For comparison, optimized artificial neural network (ANN) models were also developed to predict UTS from FSW process parameters. By comparing ANFIS and ANN predicted results, it was found that optimized ANFIS models provide better results than ANN. This newly developed best ANFIS model could be utilized for prediction of UTS of FSW joints.

  5. On the microstructure-polarization behavior correlation of a 9Cr-1Mo steel weld joint

    NASA Astrophysics Data System (ADS)

    George, G.; Shaikh, H.; Parvathavarthini, N.; George, R. P.; Khatak, H. S.

    2001-08-01

    The use of 9Cr-1Mo ferritic steel necessitates its fabrication by the process of welding. The heat-affected zone (HAZ) of 9Cr-1Mo ferritic steel is a combination of many microstructures. In the present study, the corrosion properties of the base metal, weld metal, and the various regions of the HAZ are assessed with respect to their microstructures. The various microstructures in the HAZ were simulated by heat treatment of the normalized and tempered base metal at 1463, 1200, and 1138 K for 5 min followed by oil quenching. The microstructure of the base metal in the normalized and tempered condition revealed martensite laths with M23C6 carbides at lath boundaries, and uniform dispersion of fine, acicular M2C. The weld metal showed predominantly martensitic structure with dispersion of carbides. Simulation of the microstructures of the HAZ by heat treatment resulted in the following microstructures: coarse-grained martensite of 75 µm size at 1463 K, fine-grained martensite at 1200 K, and martensite + proeutectoid α-ferrite at 1138 K. In all cases, carbide precipitation was observed in the martensitic matrix. Microhardness measurements of HAZ-simulated base metal showed increasing hardness with increasing heat treatment temperature. The hardness values obtained corresponded very well with the regions of the actual HAZ in the weld joint. Electrochemical polarization studies were carried out on the base metal, weld metal, weldment (base metal + weld metal + HAZ), and the simulated HAZ structures in 0.5 M sulfuric acid solution. Critical current densities ( i crit1 and i crit2), passive current densities ( i pass and i sec-pass), and transpassive potential ( E tp) were the parameters considered for evaluating the corrosion resistance. The HAZ structures simulated at 1463 and 1200 K, corresponding to coarse- and fine-grained martensitic regions of an actual HAZ, had corrosion properties as good as the normalized and tempered base metal. Of the various simulated HAZ

  6. Optimization of Laser Keyhole Welding Strategies of Dissimilar Metals by FEM Simulation

    NASA Astrophysics Data System (ADS)

    Garcia Navas, Virginia; Leunda, Josu; Lambarri, Jon; Sanz, Carmen

    2015-07-01

    Laser keyhole welding of dissimilar metals has been simulated to study the effect of welding strategies (laser beam displacements and tilts) and combination of metals to be welded on final quality of the joints. Molten pool geometry and welding penetration have been studied but special attention has been paid to final joint material properties, such as microstructure/phases and hardness, and especially to the residual stress state because it greatly conditions the service life of laser-welded components. For a fixed strategy (laser beam perpendicular to the joint) austenitic to carbon steel laser welding leads to residual stresses at the joint area very similar to those obtained in austenitic to martensitic steel welding, but welding of steel to Inconel 718 results in steeper residual stress gradients and higher area at the joint with detrimental tensile stresses. Therefore, when the difference in thermo-mechanical properties of the metals to be welded is higher, the stress state generated is more detrimental for the service life of the component, and consequently more relevant is the optimization of welding strategy. In laser keyhole welding of austenitic to martensitic stainless steel and austenitic to carbon steel, the optimum welding strategy is displacing the laser beam 1 mm toward the austenitic steel. In the case of austenitic steel to Inconel welding, the optimum welding strategy consists in setting the heat source tilted 45 deg and moved 2 mm toward the austenitic steel.

  7. Influence of microstructure and elemental partitioning on pitting corrosion resistance of duplex stainless steel welding joints

    NASA Astrophysics Data System (ADS)

    Zhang, Zhiqiang; Jing, Hongyang; Xu, Lianyong; Han, Yongdian; Zhao, Lei; Zhang, Jianli

    2017-02-01

    The influences of microstructure and elemental partitioning on pitting corrosion resistance of duplex stainless steel joints welded by gas tungsten arc welding (GTAW) and flux-cored arc welding (FCAW) with different shielding gas compositions were studied by optical microscopy, electron backscatter diffraction, scanning electron microscopy, transmission electron microscopy, energy dispersive spectroscopy, electron probe microanalysis, and potentiostatic and potentiodynamic polarization methods The adding 2% N2 in shielding gas facilitated primary austenite formation in GTAW weld metal (WM) and suppressed Cr2N precipitation in GTAW weld root. In the HAZ, the banded microstructure disappeared while the coarse ferrite grains maintained same orientation as the banded ferrite in the BM. In the WM, the ferrite had one single orientation throughout a grain, whereas several families of austenite appeared. The austenite both in BM and WM enriched in Ni and nitro`gen, while Cr and Mo were concentrated in the ferrite and thus no element showed clear dendritic distribution in the WM (ER2209 and E2209T1). In addition, the secondary austenite had higher Ni content but lower Cr and Mo content than the primary austenite. The N2-supplemented shielding gas promoted nitrogen solid-solution in the primary and secondary austenite. Furthermore, the secondary austenite had relatively lower pitting resistance equivalent number (PREN) than the ferrite and primary austenite, thereby resulting in its preferential corrosion. The Cr2N precipitation led to relatively poor resistance to pitting corrosion in three HAZs and pure Ar shielding GTAW weld root. The N2-supplemented shielding gas improved pitting corrosion resistance of GTAW joint by increasing PREN of secondary austenite and suppressing Cr2N precipitation. In addition, the FCAW WM had much poorer resistance to pitting corrosion than the GTAW WM due to many O-Ti-Si-Mn inclusions. In the BM, since the austenite with lower PREN compared

  8. An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.; Nunes, Arthur C., Jr.

    1998-01-01

    The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface

  9. An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.; Nunes, Arthur C., Jr.

    1998-01-01

    The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface

  10. Sensitization of Laser-beam Welded Martensitic Stainless Steels

    NASA Astrophysics Data System (ADS)

    Dahmen, Martin; Rajendran, Kousika Dhasanur; Lindner, Stefan

    Ferritic and martensitic stainless steels are an attractive alternative in vehicle production due to their inherent corrosion resistance. By the opportunity of press hardening, their strength can be increased to up to 2000 MPa, making them competitors for unalloyed ultra-high strength steels. Welding, nevertheless, requires special care, especially when it comes to joining of high strength heat treated materials. With an adopted in-line heat treatment of the welds in as-rolled as well as press hardened condition, materials with sufficient fatigue strength and acceptable structural behavior can be produced. Because of microstructural transformations in the base material such as grain coarsening and forced carbide precipitation, the corrosion resistance of the weld zone may be locally impaired. Typically the material in the heat-affected zone becomes sensitive to intergranular cracking in the form of knife-edge corrosion besides the fusion line. The current study comprises of two text scenarios. By an alternating climate test, general response in a corroding environment is screened. In order to understand the corrosion mechanisms and to localize the sensitive zones, sensitisation tests were undertaken. Furthermore, the applicability of a standard test according to ASTM 763-83 was examined. It was found that the alternative climate test does not reveal any corrosion effects. Testing by the oxalic acid test revealed clearly the effect of welding, weld heat treatment and state of thermal processing. Also application of the standard which originally suited for testing ferritic stainless steels could have been justified.

  11. Stud Reinforcement in Beam-Column Joints under Seismic Loads

    NASA Astrophysics Data System (ADS)

    Ibrahim, Hatem Hassan Ali

    Current codes recommend large amounts of shear reinforcement for reinforced concrete beam-column joints causing significant congestion. This research aims at investigating experimentally and numerically the efficiency of using studs with a head at each end in lieu of conventional closed hoops in reinforced concrete beam-column joints. The proposed reinforcement reduces congestion and ensures easier assembly of the reinforcing cage, saving labour cost and enhancing performance of the joint. Based on this research, a recommended arrangement and detailing of headed studs and their design for exterior beam-column joint are presented. The experimental investigation consisted of testing ten full-scale beam-column joint specimens under quasi-static cyclic loading. The specimens represented an exterior beam-column joint subassembly isolated at the points of contra-flexure from a typical multi-storey, multi-bay reinforced concrete frame. A test setup was developed to simulate the lateral inter-storey drift. The test parameters included: the type, arrangement and amount of shear reinforcement, the load history and rate of loading, and the amount of reinforcement for out-of-plane confinement of the joint. Envelopes of the hysteretic behaviour of the specimens and the joint deformation under shear stress are presented. The stiffness degradation, the strain levels in the joint reinforcement, the contribution of joint, beam, and column to the inter-storey drift, and the energy dissipation were compared. All the test specimens reinforced with headed studs in the joint achieved considerable enhancement in their behaviour under cyclic loads and exhibited a performance close to that of a joint reinforced with closed hoops and cross ties according to the code. All the specimens with adequate out-of-plane confinement had an equivalent behaviour compared with the code-based specimen and achieved a desirable mode of failure. Use of double-headed studs proved to be a viable option for

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

    PubMed Central

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

    2015-01-01

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

  13. Effects of Mo, Ti and B on Microstructure and Mechanical Properties of Underwater Wet Welding Joints

    NASA Astrophysics Data System (ADS)

    Liu, Duo; Guo, Ning; Xu, Changsheng; Li, Hongliang; Yang, Ke; Feng, Jicai

    2017-05-01

    Alloy components are designed and transferred into weld metal via electrode covering to address the deterioration of the microstructure and mechanical properties of underwater wet welds. Emphasis is placed on studying the effects that the Mo, Ti and B contents have on the microstructure, tensile strength and low-temperature toughness of the underwater wet welding joint. The as-welded metal obtained at a water depth of 3 m is analyzed. The results indicate that the addition of Mo depresses the formation of coarse pro-eutectoid ferrite. However, a higher Mo content (0.609 wt.%) results in the formation of lath-like bainite and martensite, which are harmful to the plasticity and toughness of the weld. Acicular ferrite nucleation increases with the combined addition of Ti and B. The deposited metal with the optimum alloy components ratio achieves good plasticity and toughness while maintaining its tensile strength of 592 MPa, with the impact toughness at 0 °C and elongation reaching 53.34 J and 16.2%, respectively.

  14. Effects of Mo, Ti and B on Microstructure and Mechanical Properties of Underwater Wet Welding Joints

    NASA Astrophysics Data System (ADS)

    Liu, Duo; Guo, Ning; Xu, Changsheng; Li, Hongliang; Yang, Ke; Feng, Jicai

    2017-03-01

    Alloy components are designed and transferred into weld metal via electrode covering to address the deterioration of the microstructure and mechanical properties of underwater wet welds. Emphasis is placed on studying the effects that the Mo, Ti and B contents have on the microstructure, tensile strength and low-temperature toughness of the underwater wet welding joint. The as-welded metal obtained at a water depth of 3 m is analyzed. The results indicate that the addition of Mo depresses the formation of coarse pro-eutectoid ferrite. However, a higher Mo content (0.609 wt.%) results in the formation of lath-like bainite and martensite, which are harmful to the plasticity and toughness of the weld. Acicular ferrite nucleation increases with the combined addition of Ti and B. The deposited metal with the optimum alloy components ratio achieves good plasticity and toughness while maintaining its tensile strength of 592 MPa, with the impact toughness at 0 °C and elongation reaching 53.34 J and 16.2%, respectively.

  15. Uniaxial Tensile and Simple Shear Behavior of Resistance Spot-Welded Dual-Phase Steel Joints

    NASA Astrophysics Data System (ADS)

    Tao, Hong; Tong, Wei; Hector, Louis G.; Zavattieri, Pablo D.

    2008-08-01

    Small test coupons were machined from single spot welds in a dual-phase steel (DP600) to investigate deformation and failure of weld joints in both tension and shear. Quasi-static ( ifmmodeexpandafterdotelseexpandafter\\.fi{\\upvarepsilon } ˜ 10^{{ - 4}} 1/{text{s}} ) testing was conducted in a miniature tensile stage with a custom image acquisition system. Strain accumulation in each weld was analyzed where fracture occurred, which was typically outside the fusion zone. A few shear test coupons that failed in the fusion zone were found to have the same spheroidal defects noted in previous work, and thus, severely limited weld strength and ductility. A novel strain mapping method based upon digital image correlation was employed to generate two-dimensional deformation maps, from which local stress-strain curves to failure were computed. As an important first step toward incorporation of material models into weld simulations, a preliminary finite element analysis of a tension test successfully reproduced the experimental results with material models for the base, heat-affected, and fusion zone materials generated from prior work.

  16. The porosity formation mechanism in the laser-MIG hybrid welded joint of Invar alloy

    NASA Astrophysics Data System (ADS)

    Zhan, Xiaohong; Gao, Qiyu; Gu, Cheng; Sun, Weihua; Chen, Jicheng; Wei, Yanhong

    2017-10-01

    The porosity formation mechanism in the laser-metal inter gas (MIG) multi-layer hybrid welded (HW) joint of 19.05 mm thick Invar alloy is investigated. The microstructure characteristics and energy dispersive spectroscopy (EDS) are analyzed. The phase identification was conducted by the X-ray diffractometer (XRD). Experimental results show that the generation of porosity is caused by the relatively low laser power in the root pass and low current in the cover pass. It is also indicated that the microstructures of the welded joints are mainly observed to be columnar crystal and equiaxial crystal, which are closely related to the porosity formation. The EDS results show that oxygen content is significantly high in the inner wall of the porosity. The XRD results indicate that the BM and the WB of laser-MIG HW all are composed of Fe0.64Ni0.36 and γ-(Fe,Ni). When the weld pool is cooled quickly, [NiO] [FeO] and [MnO] are formed that react on C to generate CO/CO2 gases. The porosity of laser-MIG HW for Invar alloy is oxygen pore. The root source of metallurgy porosity formation is that the dissolved gases are hard to escape sufficiently and thus exist in the weld pool. Furthermore, 99.99% pure Argon is recommended as protective gas in the laser-MIG HW of Invar alloy.

  17. Evaluation of near-surface stress distributions in dissimilar welded joint by scanning acoustic microscopy.

    PubMed

    Kwak, Dong Ryul; Yoshida, Sanichiro; Sasaki, Tomohiro; Todd, Judith A; Park, Ik Keun

    2016-04-01

    This paper presents the results from a set of experiments designed to ultrasonically measure the near surface stresses distributed within a dissimilar metal welded plate. A scanning acoustic microscope (SAM), with a tone-burst ultrasonic wave frequency of 200 MHz, was used for the measurement of near surface stresses in the dissimilar welded plate between 304 stainless steel and low carbon steel. For quantitative data acquisition such as leaky surface acoustic wave (leaky SAW) velocity measurement, a point focus acoustic lens of frequency 200 MHz was used and the leaky SAW velocities within the specimen were precisely measured. The distributions of the surface acoustic wave velocities change according to the near-surface stresses within the joint. A three dimensional (3D) finite element simulation was carried out to predict numerically the stress distributions and compare with the experimental results. The experiment and FE simulation results for the dissimilar welded plate showed good agreement. This research demonstrates that a combination of FE simulation and ultrasonic stress measurements using SAW velocity distributions appear promising for determining welding residual stresses in dissimilar material joints.

  18. Characteristics of AZ31 Mg alloy joint using automatic TIG welding

    NASA Astrophysics Data System (ADS)

    Liu, Hong-tao; Zhou, Ji-xue; Zhao, Dong-qing; Liu, Yun-teng; Wu, Jian-hua; Yang, Yuan-sheng; Ma, Bai-chang; Zhuang, Hai-hua

    2017-01-01

    The automatic tungsten-inert gas welding (ATIGW) of AZ31 Mg alloys was performed using a six-axis robot. The evolution of the microstructure and texture of the AZ31 auto-welded joints was studied by optical microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy, and electron backscatter diffraction. The ATIGW process resulted in coarse recrystallized grains in the heat affected zone (HAZ) and epitaxial growth of columnar grains in the fusion zone (FZ). Substantial changes of texture between the base material (BM) and the FZ were detected. The {0002} basal plane in the BM was largely parallel to the sheet rolling plane, whereas the c-axis of the crystal lattice in the FZ inclined approximately 25° with respect to the welding direction. The maximum pole density increased from 9.45 in the BM to 12.9 in the FZ. The microhardness distribution, tensile properties, and fracture features of the AZ31 auto-welded joints were also investigated.

  19. Experimental Research on Fatigue Failure for 2219-T6 Aluminum Alloy Friction Stir-Welded Joints

    NASA Astrophysics Data System (ADS)

    Sun, Guo-Qin; Niu, Jiang-Pei; Chen, Ya-Jing; Sun, Feng-Yang; Shang, De-Guang; Chen, Shu-Jun

    2017-08-01

    The fatigue experiment was executed for the 2219-T6 aluminum alloy friction stir-welded joints at the rotation speed of 800 r/min and the welding velocity of 150 mm/min. Most fatigue failures occurred in the weld nugget zone (WNZ), the thermo-mechanical affected zone and the nearby areas. The experimental results demonstrated that the sudden hardness gradient increases sites corresponding to the fatigue failure locations. The high-angle grain boundaries with the highest concentration were scattered within the WNZ. The microcracks initiated at the intersection of the soft grains. More than one crack initiation site was observed within the WNZ and the thermo-mechanical affected zone, when the fracture occurred in these areas. The rough surface of the welding area should be one of the main reasons for the fatigue failure occurrence. The fatigue crack growth rate in the WNZ at the first stage was fastest in comparison with the fatigue crack growth rate in the other areas of the joint.

  20. Effect of Peculiarities of Heat Transfer, Diffusion and Phase Transformation on Joint Formation During Welding of Dissimilar Materials by High Power Fiber Laser

    NASA Astrophysics Data System (ADS)

    Turichin, Gleb; Klimova, Olga; Valdaytseva, Ekaterina

    The article describes mathematical models of diffusion and thermal processes for welding of dissimilar materials and kinetic model of diffusion-controlled deposition and growth of intermetallic inclusions in the weld. Developed models were combined and implemented in the model of weld joint formation for dissimilar materials. To verify a model the microstructure analysis of weld joints and elemental analysis in the diffusion zone by SEM has been made for welding of systems Fe-Cu, Al-Ti, Fe-Al. The good agreement between calculated and experimental data has been obtained. Examples of developed technologies of welding of dissimilar materials using high-power fiber lasers were discussed also.

  1. Simulation of Local Material Properties during Laser Beam Welding of Aluminum-Titanium Compounds

    NASA Astrophysics Data System (ADS)

    Barr, Annika; Hunkel, Martin; von Hehl, Axel

    Combinations of aluminum and titanium by firmly bonding via laser beam welding enable the production of customized hybrid designs with enhanced properties. A novel approach of coupling process, microstructure and mechanical simulation, considering the development of weld geometry and local material conditions, is intended to deliver a fast and reliable method for evaluating the quasi-static strength of laser beam welded hybrid compounds. For microstructure and mechanical simulations a comprehensive data set of material specific mechanical properties is required to reach simulation results. This includes hot tensile tests, tensile tests concerning the heat affected zone (by means of micro flat specimens) and metallographic examinations to determine the microstructure and hardness. The data set was implemented into a simulation model in order to validate the simulation results including microstructure evolution and resulting local mechanical properties. These results provide the basis for refining and advancing the coupled simulation model.

  2. Study on fundamental processes of laser welded metals observed with intense x-ray beams

    NASA Astrophysics Data System (ADS)

    Muramatsu, T.; Daido, H.; Shobu, T.; Takase, K.; Tsukimori, K.; Kureta, M.; Segawa, M.; Nishimura, A.; Suzuki, Y.; Kawachi, T.

    With use of photon techniques including visible light, soft and hard x-rays, precise fundamental laser welding processes in the repair and maintenance of nuclear plant engineering were reviewed mechanistically. We make discussions centered on the usefulness of an intense soft x-ray beams for evaluations of spatial residual strain distribution and welded metal convection behavior including the surface morphology. Numerical results obtained with a general purpose three-dimensional code SPLICE for the simulation of the welding and solidifying phenomena. Then it is concluded that the x-ray beam would be useful as one of the powerful tools for understanding the mechanisms of various complex phenomena with higher accuracy and higher resolution.

  3. Effect of adding powder on joint properties of laser penetration welding for dual phase steel and aluminum alloy

    NASA Astrophysics Data System (ADS)

    Zhou, D. W.; Liu, J. S.; Lu, Y. Z.; Xu, S. H.

    2017-09-01

    The experiments of laser penetration welding for dual phase steel and aluminum alloy were carried out, and the effect of adding Mn or Si powder on mechanical properties and microstructure of the weld was investigated. Some defects, such as spatter, inclusion, cracks and softening in heat affected zone (HAZ), can be avoided in welding joints, and the increased penetration depth is obtained by adding Mn or Si powder. The average tensile-shear strength of Si-added joint is 3.84% higher than that of Mn-added joint, and the strength of both joints exceeds that of no-added joint. In the case of adding Mn powder, small amount of liquid Al is mixed into steel molten pool, and the Al content increases in both sides of the weld, which leads to the increased weld width in aluminum molten pool. Thus, transverse area increases in jointing steel to aluminum, which is significant for the improved tensile-shear strength of joints. As far as adding Si powder is concerned, it is not the case, the enhancement of the joint properties benefits from improvement of metallurgical reaction.

  4. Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

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

    2017-01-01

    AA2014 aluminum alloy (Al-Cu alloy) has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW) parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE), analysis of variance (ANOVA), response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5°.

  5. Evaluation of fatigue properties of 316FR stainless steel welded joints at elevated temperature

    SciTech Connect

    Kaguchi, Hitoshi; Koto, Hiroyuki; Fujioka, Terutaka; Taguchi, Kosei; Sukekawa, Masayuki

    1996-12-01

    316FR is an improved version of type 316 stainless steel for elevated temperature use with lower carbon content than conventional type 316 stainless steel. Fatigue properties of GTAW joints of 316FR stainless steel have been investigated. Heat affected zone (HAZ) of 316FR becomes harder than base metal. A method based on the stress-strain relationship of three elements, which are base metal, HAZ and weld portions, has been proposed and applied to the evaluations of fatigue tests. The tri-metal analysis model gives good agreements between experimental results and predicted fatigue lives of the 316FR welded joints. This material is to be used in the DFBR reactor in Japan.

  6. Electron-microscopic examination of the transition zone of aluminum-tantalum bimetallic joints (explosion welding)

    NASA Astrophysics Data System (ADS)

    Volkova, A. Yu.; Greenberg, B. A.; Ivanov, M. A.; Elkina, O. A.; Inozemtsev, A. V.; Plotnikov, A. V.; Patselov, A. M.; Kozhevnikov, V. E.

    2014-04-01

    A study of the structure of an aluminum-tantalum joint and a comparison of this structure with the structures of iron-silver and copper-tantalum joints have revealed the following processes of the interpenetration of the materials that occur during explosion welding: the formation of protrusions, the injection of particles of one material into the other, and the formation of zones of local melting. Regardless of the mutual solubility of the metals being welded, two types of fragmentation occur, i.e., (1) a granulating fragmentation (GF), which includes the formation, explosion-governed (EG) dispersion, and partial consolidation of particles, and (2) the fragmentation that is usually observed during severe plastic deformation. It is important that this traditional fragmentation is not accompanied by the formation and EG dispersion of particles. This feature allows one to easily distinguish these types of fragmentation (traditional and GF fragmentation).

  7. Influence of the Strength Mismatch of a Narrow Gap Welded Joint of SA508 on the Plastic η Factor

    NASA Astrophysics Data System (ADS)

    Koo, J. M.; Huh, Y.; Seok, C. S.

    2012-11-01

    In this article, the influence of the strength mismatch of a narrow gap welded joint of SA508 on the η factor was evaluated. The η factor is the principal parameter that determines the plastic portion of the J-integral. The specimens for tensile and hardness tests were collected from piping with narrow gap welding and the stress-strain curve and hardness were obtained from those. From these results, the Ramberg-Osgood (R-O) constant was obtained. Also, the finite element analysis was performed with variations in the strength mismatch and the weld width. The η factor equation considering the strength mismatch and the weld width of a narrow gap welded joint was suggested.

  8. Acoustic emissions during deformation of intact and jointed welded tuff

    SciTech Connect

    Holcomb, D.J.; Teufel, L.W.

    1982-07-01

    Monitoring of acoustic emissions (AE) has been widely used as a means of detecting failure in intact rock. For intact rock the technique is simple, because an increasing rate of AE is usually a sign of impending failure. However, most large rock masses contain numerous joints and the behavior of the joints controls the properties of the rock mass. In particular, the failure mode often becomes stable or unstable slip (stick-slip) on a joint at stresses well below those required for failure of the intact rock. As an aid to understanding and monitoring the behavior of jointed rock masses, we have done a series of experiments on intact and artificially jointed samples of Grouse Canyon tuff. The tuff was selected because it is under consideration as a disposal medium for nuclear wastes. The samples were instrumented to measure axial and transverse displacements and AE rates. Testing was done in a servo-controlled machine at axial displacement rates of 5 x 10{sup -5} cm/sec, and confining pressures ranging from 10 to 40 MPa. For the jointed samples four modes of slip were identified. First, stable sliding accompanied by a steady rate of AE. Second, stick-slip with a sharp drop in load, large displacements but no premonitory AE or slip. Third, stick-slip, as in mode 2, but with premonitory AE and slip. Fourth, slow stick-slip where the load dropped and the displacements increased but the process was slow and culminated in stable sliding. Mode 4 exhibited premonitory AE and slip and after the event, a steady rate of AE during sliding. There seemed to be no way to predict which mode would occur at a given point in the test. In all cases where stable or unstable slip occurred there was a corresponding occurrence of AE. This indicates that slip is related to damage to the joint surfaces and adjacent material. Monitoring AE would be a useful method of detecting slip.

  9. Type IV Creep Damage Behavior in Gr.91 Steel Welded Joints

    NASA Astrophysics Data System (ADS)

    Hongo, Hiromichi; Tabuchi, Masaaki; Watanabe, Takashi

    2012-04-01

    Modified 9Cr-1Mo steel (ASME Grade 91 steel) is used as a key structural material for boiler components in ultra-supercritical (USC) thermal power plants at approximately 873 K (600 °C). The creep strength of welded joints of this steel decreases as a result of Type IV creep cracking that forms in the heat-affected zone (HAZ) under long-term use at high temperatures. The current article aims to elucidate the damage processes and microstructural degradations that take place in the HAZ of these welded joints. Long-term creep tests for base metal, simulated HAZ, and welded joints were conducted at 823 K, 873 K, and 923 K (550 °C, 600 °C, and 650 °C). Furthermore, creep tests of thick welded joint specimens were interrupted at several time steps at 873 K (600 °C) and 90 MPa, after which the distribution and evolution of creep damage inside the plates were measured quantitatively. It was found that creep voids are initiated in the early stages (0.2 of life) of creep rupture life, which coalesce to form a crack at a later stage (0.8 of life). In a fine-grained HAZ, creep damage is concentrated chiefly in an area approximately 20 pct below the surface of the plate. The experimental creep damage distributions coincide closely with the computed results obtained by damage mechanics analysis using the creep properties of a simulated fine-grained HAZ. Both the concentration of creep strain and the high multiaxial stress conditions in the fine-grained HAZ influence the distribution of Type IV creep damage.

  10. Microstructure, Hardness, and Residual Stress Distributions in T-Joint Weld of HSLA S500MC Steel

    NASA Astrophysics Data System (ADS)

    Frih, Intissar; Montay, Guillaume; Adragna, Pierre-Antoine

    2017-03-01

    This paper investigates the characterization of the microstructure, hardness, and residual stress distributions of MIG-welded high-strength low-alloy S500MC steel. The T-joint weld for 10-mm-thick plates was joined using a two passes MIG welding technology. The contour method was performed to measure longitudinal welding residual stress. The obtained results highlighted a good correlation between the metallurgical phase constituents and hardness distribution within the weld zones. In fact, the presence of bainite and smaller ferrite grain size in the weld-fusion zone might be the reason for the highest hardness measured in this region. A similar trend of the residual stress and hardness distributions was also obtained.

  11. Microstructure, Hardness, and Residual Stress Distributions in T-Joint Weld of HSLA S500MC Steel

    NASA Astrophysics Data System (ADS)

    Frih, Intissar; Montay, Guillaume; Adragna, Pierre-Antoine

    2017-01-01

    This paper investigates the characterization of the microstructure, hardness, and residual stress distributions of MIG-welded high-strength low-alloy S500MC steel. The T-joint weld for 10-mm-thick plates was joined using a two passes MIG welding technology. The contour method was performed to measure longitudinal welding residual stress. The obtained results highlighted a good correlation between the metallurgical phase constituents and hardness distribution within the weld zones. In fact, the presence of bainite and smaller ferrite grain size in the weld-fusion zone might be the reason for the highest hardness measured in this region. A similar trend of the residual stress and hardness distributions was also obtained.

  12. Fatigue limits of titanium-bar joints made with the laser and the electric resistance welding techniques: microstructural characterization and hardness properties.

    PubMed

    Degidi, Marco; Nardi, Diego; Morri, Alessandro; Sighinolfi, Gianluca; Tebbel, Florian; Marchetti, Claudio

    2017-09-01

    Fatigue behavior of the titanium bars is of utmost importance for the safe and reliable operation of dental implants and prosthetic constructions based on these implants. To date, however, only few data are available on the fatigue strength of dental prostheses made with electric resistance welding and laser welding techniques. This in-vitro study highlighted that although the joints made with the laser welding approach are credited of a superior tensile strength, joints made with electric resistance welding exhibited double the minimum fatigue strength with respect to the joints made with laser welding (120 vs 60 N).

  13. Space processing applications of ion beam technology. [surface finishing, welding, milling and film deposition

    NASA Technical Reports Server (NTRS)

    Grodzka, P. G.

    1977-01-01

    Ion thruster engines for spacecraft propulsion can serve as ion beam sources for potential space processing applications. The advantages of space vacuum environments and the possible gravity effects on thruster ion beam materials operations such as thin film growth, ion milling, and surface texturing were investigated. The direct gravity effect on sputter deposition and vapor deposition processes are discussed as well as techniques for cold and warm welding.

  14. Electron Beam Welding of IN792 DS: Effects of Pass Speed and PWHT on Microstructure and Hardness

    PubMed Central

    Angella, Giuliano; Montanari, Roberto; Richetta, Maria; Varone, Alessandra

    2017-01-01

    Electron Beam (EB) welding has been used to realize seams on 2 mm-thick plates of directionally solidified (DS) IN792 superalloy. The first part of this work evidenced the importance of pre-heating the workpiece to avoid the formation of long cracks in the seam. The comparison of different pre-heating temperatures (PHT) and pass speeds (v) allowed the identification of optimal process parameters, namely PHT = 300 °C and v = 2.5 m/min. The microstructural features of the melted zone (MZ); the heat affected zone (HAZ), and base material (BM) were investigated by optical microscopy (OM), scanning electron microscopy (SEM), energy dispersion spectroscopy (EDS), electron back-scattered diffraction (EBSD), X-ray diffraction (XRD), and micro-hardness tests. In the as-welded condition; the structure of directionally oriented grains was completely lost in MZ. The γ’ phase in MZ consisted of small (20–40 nm) round shaped particles and its total amount depended on both PHT and welding pass speed, whereas in HAZ, it was the same BM. Even if the amount of γ’ phase in MZ was lower than that of the as-received material, the nanometric size of the particles induced an increase in hardness. EDS examinations did not show relevant composition changes in the γ’ and γ phases. Post-welding heat treatments (PWHT) at 700 and 750 °C for two hours were performed on the best samples. After PWHTs, the amount of the ordered phase increased, and the effect was more pronounced at 750 °C, while the size of γ’ particles in MZ remained almost the same. The hardness profiles measured across the joints showed an upward shift, but peak-valley height was a little lower, indicating more homogeneous features in the different zones. PMID:28872620

  15. Assessment of Electron Beam Welding in Shipyard Construction,

    DTIC Science & Technology

    1985-12-01

    would be detrimentally dangerous so monitoring the weld seam with 100% UT should be considered. A large immersion ultrasonic monitoring area directly...Vacuum Puinhn Set Pzra ing time partial vacin 2 3 3 4 6 8 8 ,2 x 10 mbar (mnm) Pumping tize, high vacnmz 7 Tl 4 mbar (mi) 3 7 5 7 9 12 17i Alpha

  16. Differences between Laser and Arc Welding of HSS Steels

    NASA Astrophysics Data System (ADS)

    Němeček, Stanislav; Mužík, Tomáš; Míšek, Michal

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

  17. Potential for EMU Fabric Damage by Electron Beam and Molten Metal During Space Welding for the International Space Welding Experiment

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.

    1998-01-01

    As a consequence of preparations concerning the International Space Welding Experiment (ISWE), studies were performed to better understand the effect of molten metal contact and electron beam impingement with various fabrics for space suit applications. The question arose as to what would occur if the electron beam from the Ukrainian Universal Hand Tool (UHT) designed for welding in space were to impinge upon a piece of Nextel AF-62 ceramic cloth designed to withstand temperatures up to 1427 C. The expectation was that the electron beam would lay down a static charge pattern with no damage to the ceramic fabric. The electron beam is capable of spraying the fabric with enough negative charge to repel further electrons from the fabric before significant heating occurs. The static charge pattern would deflect any further charge accumulation except for a small initial amount of leakage to the grounded surface of the welder. However, when studies were made of the effect of the electron beam on the insulating ceramic fabric it was surprisingly found that the electron beam did indeed burn through the ceramic fabric. It was also found that the shorter electron beam standoff distances had longer burnthrough times than did some greater electron beam standoff distances. A possible explanation for the longer burnthrough times for the small electron beam standoff distance would be outgassing of the fabric which caused the electron beam hand-tool to cycle on and off to provide some protection for the cathodes. The electron beam hand tool was observed to cycle off at the short standoff distance of two inches likely due to vapors being outgassed. During the electron beam welding process there is an electron leakage, or current leakage, flow from the fabric. A static charge pattern is initially laid down by the electron beam current flow. The static charge makes up the current leakage flow which initially slightly heats up the fabric. The initially laid down surface charge leaks a

  18. The effect of CO2 laser beam welded AISI 316L austenitic stainless steel on the viability of fibroblast cells, in vitro.

    PubMed

    Köse, Ceyhun; Kaçar, Ramazan; Zorba, Aslı Pınar; Bağırova, Melahat; Allahverdiyev, Adil M

    2016-03-01

    It has been determined by the literature research that there is no clinical study on the in vivo and in vitro interaction of the cells with the laser beam welded joints of AISI 316L biomaterial. It is used as a prosthesis and implant material and that has adequate mechanical properties and corrosion resistance characteristics. Therefore, the interaction of the CO2 laser beam welded samples and samples of the base metal of AISI 316L austenitic stainless steel with L929 fibroblast cells as an element of connective tissue under in vitro conditions has been studied. To study the effect of the base metal and the laser welded test specimens on the viability of the fibroblast cells that act as an element of connective tissues in the body, they were kept in DMEMF-12 medium for 7, 14, 28 days and 18 months. The viability study was experimentally studied using the MTT method for 7, 14, 28 days. In addition, the direct interaction of the fibroblast cells seeded on 6 different plates with the samples was examined with an inverted microscope. The MTT cell viability experiment was repeated on the cells that were in contact with the samples. The statistical relationship was analyzed using a Tukey test for the variance with the GraphPad statistics software. The data regarding metallic ion release were identified with the ICP-MS method after the laser welded and main material samples were kept in cell culture medium for 18 months. The cell viability of the laser welded sample has been detected to be higher than that of the base metal and the control based on 7th day data. However, the laser welded sample's viability of the fibroblast cells has diminished by time during the test period of 14 and 28 days and base metal shows better viability when compared to the laser welded samples. On the other hand, the base metal and the laser welded sample show better cell viability effect when compared to the control group. According to the ICP-MS results of the main material and laser welded

  19. Reduced Pressure Electron Beam Welding Evaluation Activities on a Ni-Cr-Mo Alloy for Nuclear Waste Packages

    SciTech Connect

    Wong, F; Punshon, C; Dorsch, T; Fielding, P; Richard, D; Yang, N; Hill, M; DeWald, A; Rebak, R; Day, S; Wong, L; Torres, S; McGregor, M; Hackel, L; Chen, H-L; Rankin, J

    2003-09-11

    The current waste package design for the proposed repository at Yucca Mountain Nevada, USA, employs gas tungsten arc welding (GTAW) in fabricating the waste packages. While GTAW is widely used in industry for many applications, it requires multiple weld passes. By comparison, single-pass welding methods inherently use lower heat input than multi-pass welding methods which results in lower levels of weld distortion and also narrower regions of residual stresses at the weld TWI Ltd. has developed a Reduced Pressure Electron Beam (RPEB) welding process which allows EB welding in a reduced pressure environment ({le} 1 mbar). As it is a single-pass welding technique, use of RPEB welding could (1) achieve a comparable or better materials performance and (2) lead to potential cost savings in the waste package manufacturing as compared to GTAW. Results will be presented on the initial evaluation of the RPEB welding on a Ni-Cr-Mo alloy (a candidate alloy for the Yucca Mountain waste packages) in the areas of (a) design and manufacturing simplifications, (b) material performance and (c) weld reliability.

  20. An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.

    1996-01-01

    In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several

  1. The Microstructure and Gamma Prime Distributions in Inertia Friction Welded Joint of P/M Superalloy FGH96

    NASA Astrophysics Data System (ADS)

    Zhang, Chi; Shen, Wenfei; Zhang, Liwen; Xia, Yingnan; Li, Ruiqin

    2017-03-01

    A gamma prime (γ') precipitation ( 35% in volume)-hardened powder metallurgy (P/M) superalloy FGH96 was welded using inertia friction welding (IFW). The microstructure and γ' distributions in the joints in two conditions, hot isostatic pressed state and solution-treated and aged state, were characterized. The recrystallization of grains, the dissolution and re-precipitation of γ' in the joints were discussed in terms of the temperature evolutions which were calculated by finite element model analysis. Regardless of the initial states, fully recrystallized fine grain structure formed at welded zone. Meanwhile, very fine γ' precipitations were re-precipitated at the welded zone. These recrystallized grain structure and fine re-precipitated γ' resulted in increasing hardness of IFW joint while making the hardness dependent on the microstructure and γ' precipitation.

  2. Physical Nature of the Processes in Structure Forming, Phase and Chemical Composition of pipe Permanent Joints when MMA Welding

    NASA Astrophysics Data System (ADS)

    Il'yaschenko, D. P.; Chinakhov, D. A.; Danilov, V. I.; Sadykov, I. D.

    2016-04-01

    The paper outlines peculiarities of structure formation, phase and chemical composition in regard to heat content in molten electrode metal beads when pipe steel (steel 09G2S) welding using power sources with various energy characteristics. Mathematical calculations indicate an inverter power source provides minor heat content into the bead of electrode metal when welding. Experimental research has pointed at 4-9 % increase in impact strength of joints produced using an inverter power source in comparison with samples produced applying a diode rectifier. The following factors can possibly give rise to the increasing impact strength: difference in microstructures of weld joints, up to 50% shortening ferritic plates in metal of weld joint, change in dimensions of ferritic grains in the heat-affected zone by as much as 17.5 %, and decrease in the extent of heat-affected zone by 50%.

  3. Microstructures and Mechanical Properties of Laser Welding Joint of a CLAM Steel with Revised Chemical Compositions

    NASA Astrophysics Data System (ADS)

    Chen, Shuhai; Huang, Jihua; Lu, Qi; Zhao, Xingke

    2016-05-01

    To suppress the tendency to form delta ferrite in weld metal (WM) of China low activation martensitic (CLAM) steel joint, a CLAM steel with revised chemical compositions was designed. Laser welding of the CLAM steel was investigated. The microstructures of the WM and heat-affected zone were analyzed. The impact toughness of the WM was evaluated by a Charpy impact test method with three V notches. The influence of temper temperature on mechanical properties was analyzed. It was found that the delta ferrite was eliminated almost completely in laser WM of CLAM steel with revised chemical compositions which has lower tendency to form delta ferrite than original chemical compositions. The joint has higher tensile strength than the parent metal. With increasing the heat input, the impact toughness of the joint is approximatively equal with that of parent metal first and then decreases obviously. Temper treatment could effectively improve mechanical property of the joint. When the temper temperature exceeds 600 °C, the impact toughness of the joint is higher than that of the parent metal.

  4. Improvement in Fatigue Performance of Aluminium Alloy Welded Joints by Laser Shock Peening in a Dynamic Strain Aging Temperature Regime

    PubMed Central

    Su, Chun; Zhou, Jianzhong; Meng, Xiankai; Huang, Shu

    2016-01-01

    As a new treatment process after welding, the process parameters of laser shock peening (LSP) in dynamic strain aging (DSA) temperature regimes can be precisely controlled, and the process is a non-contact one. The effects of LSP at elevated temperatures on the distribution of the surface residual stress of AA6061-T6 welded joints were investigated by using X-ray diffraction technology with the sin2ϕ method and Abaqus software. The fatigue life of the welded joints was estimated by performing tensile fatigue tests. The microstructural evolution in surface and fatigue fractures of the welded joints was presented by means of surface integrity and fracture surface testing. In the DSA temperature regime of AA6061-T6 welded joints, the residual compressive stress was distributed more stably than that of LSP at room temperature. The thermal corrosion resistance and fatigue properties of the welded joints were also improved. The experimental results and numerical analysis were in mutual agreement. PMID:28773920

  5. Improvement in Fatigue Performance of Aluminium Alloy Welded Joints by Laser Shock Peening in a Dynamic Strain Aging Temperature Regime.

    PubMed

    Su, Chun; Zhou, Jianzhong; Meng, Xiankai; Huang, Shu

    2016-09-26

    As a new treatment process after welding, the process parameters of laser shock peening (LSP) in dynamic strain aging (DSA) temperature regimes can be precisely controlled, and the process is a non-contact one. The effects of LSP at elevated temperatures on the distribution of the surface residual stress of AA6061-T6 welded joints were investigated by using X-ray diffraction technology with the sin²ϕ method and Abaqus software. The fatigue life of the welded joints was estimated by performing tensile fatigue tests. The microstructural evolution in surface and fatigue fractures of the welded joints was presented by means of surface integrity and fracture surface testing. In the DSA temperature regime of AA6061-T6 welded joints, the residual compressive stress was distributed more stably than that of LSP at room temperature. The thermal corrosion resistance and fatigue properties of the welded joints were also improved. The experimental results and numerical analysis were in mutual agreement.

  6. Metallurgical Effects of Shunting Current on Resistance Spot-Welded Joints of AA2219 Sheets

    NASA Astrophysics Data System (ADS)

    Jafari Vardanjani, M.; Araee, A.; Senkara, J.; Jakubowski, J.; Godek, J.

    2016-08-01

    Shunting effect is the loss of electrical current via the secondary circuit provided due to the existence of previous nugget in a series of welding spots. This phenomenon influences on metallurgical aspects of resistance spot-welded (RSW) joints in terms of quality and performance. In this paper RSW joints of AA2219 sheets with 1 mm thickness are investigated metallurgically for shunted and single spots. An electro-thermal finite element analysis is performed on the RSW process of shunted spot and temperature distribution and variation are obtained. These predictions are then compared with experimental micrographs. Three values of 5 mm, 20 mm, and infinite (i.e., single spot) are assumed for welding distance. Numerical and experimental results are matching each other in terms of nugget and HAZ geometry as increasing distance raised nugget size and symmetry of HAZ. In addition, important effect of shunting current on nugget thickness, microstructure, and Copper segregation on HAZ grain boundaries were discovered. A quantitative analysis is also performed about the influence of welding distance on important properties including ratio of nugget thickness and diameter ( r t), ratio of HAZ area on shunted and free side of nugget ( r HA), and ratio of equivalent segregated and total amount of Copper, measured in sample ( r Cu) on HAZ. Increasing distance from 5 mm to infinite, indicated a gain of 111.04, -45.55, and -75.15% in r t, r HA, and r Cu, respectively, while obtained ratios for 20 mm welding distance was suitable compared to single spot.

  7. Robotic Vision for Welding

    NASA Technical Reports Server (NTRS)

    Richardson, R. W.

    1986-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-09-01

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

  9. A comparative evaluation of low-cycle fatigue behavior of type 316LN base metal, 316 weld metal, and 316LN/316 weld joint

    SciTech Connect

    Valsan, M.; Sundararaman, D.; Sankara Rao, K.B.; Mannan, S.L.

    1995-05-01

    A comparative evaluation of the low-cycle fatigue (LCF) behavior of type 316LN base metal, carried out at 773 and 873 K. Total strain-controlled LCF tests were conducted at a constant strain rate of 3 {times} 10{sup {minus}3} s{sup {minus}1} with strain amplitudes in the range {+-}0.20 to {+-}1.0 pct. Weld pads with single V and double V configuration were prepared by the shielded metal-arc welding (SMAW) process using 316 electrodes for weld-metal and weld-joint specimens. Optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM) of the untested and tested samples were carried out to elucidate the deformation and the fracture behavior. The cyclic stress response of the base metal shows a very rapid hardening to a maximum stress followed by a saturated stress response. Weld metal undergoes a relatively short initial hardening followed by a gradual softening regime. Weld joints exhibit an initial hardening and a subsequent softening regime at all strain amplitudes, except at low strain amplitudes where a saturation regime is noticed. The initial hardening observed in base metal has been attributed to interaction between dislocations and solute atoms/complexes and cyclic saturation to saturation in the number density of slip bands. The 18-8 group of austenitic stainless steels, such as AISI type 316, 304, and their modified grades, finds applications as structural material for various components of the liquid-metal-cooled fast breeder reactor (LMFBR).

  10. Fusion welding studies using laser on Ti-SS dissimilar combination

    NASA Astrophysics Data System (ADS)

    Shanmugarajan, B.; Padmanabham, G.

    2012-11-01

    Laser welding investigations were carried out on dissimilar Ti-SS combination. The study is aimed to improve the weld strength and ductility by minimizing harmful intermetallics and taking advantage of high cooling rates in laser welding. Results of continuous wave 3.5 kW CO2 laser welding of totally dissimilar combination of Titanium and stainless steel (304) have been discussed. Bead on plate welding experiments were conducted to identify the laser welding parameters using depth of penetration as criteria. The welding of dissimilar combination has been attempted both autogenously and with interlayers such as Vanadium (V) and Tantalum (Ta) in the form of laser cladding as well as strip. Autogenous welds were carried out by varying the laser power, welding speed and position of the laser beam with respect to the joint centre. The resultant welds are characterized by macrostructure analysis, SEM/EDAX and XRD and as welded tensile test in UTM. The autogenous welds have exhibited extensive cracking even when welded at high speeds or by manipulating the beam position with respect to the joint. Similarly Vandaium as interlayer could not achieve crack free joint. A joint with 40 MPa strength could be made with Ta as interlayer. Results and analysis of these variants of laser welded joints are reported and discussed.

  11. Strengthening of defected beam-column joints using CFRP.

    PubMed

    Mahmoud, Mohamed H; Afefy, Hamdy M; Kassem, Nesreen M; Fawzy, Tarek M

    2014-01-01

    This paper presents an experimental study for the structural performance of reinforced concrete (RC) exterior beam-column joints rehabilitated using carbon-fiber-reinforced polymer (CFRP). The present experimental program consists of testing 10 half-scale specimens divided into three groups covering three possible defects in addition to an adequately detailed control specimen. The considered defects include the absence of the transverse reinforcement within the joint core, insufficient bond length for the beam main reinforcement and inadequate spliced implanted column on the joint. Three different strengthening schemes were used to rehabilitate the defected beam-column joints including externally bonded CFRP strips and sheets in addition to near surface mounted (NSM) CFRP strips. The failure criteria including ultimate capacity, mode of failure, initial stiffness, ductility and the developed ultimate strain in the reinforcing steel and CFRP were considered and compared for each group for the control and the CFRP-strengthened specimens. The test results showed that the proposed CFRP strengthening configurations represented the best choice for strengthening the first two defects from the viewpoint of the studied failure criteria. On the other hand, the results of the third group showed that strengthening the joint using NSM strip technique enabled the specimen to outperform the structural performance of the control specimen while strengthening the joints using externally bonded CFRP strips and sheets failed to restore the strengthened joints capacity.

  12. Microstructural characterisation of friction stir welding joints of mild steel to Ni-based alloy 625

    SciTech Connect

    Rodriguez, J.; Ramirez, A.J.

    2015-12-15

    In this study, 6-mm-thick mild steel and Ni-based alloy 625 plates were friction stir welded using a tool rotational speed of 300 rpm and a travel speed of 100 mm·min{sup −1}. A microstructural characterisation of the dissimilar butt joint was performed using optical microscopy, scanning and transmission electron microscopy, and energy dispersive X-ray spectroscopy (XEDS). Six different weld zones were found. In the steel, the heat-affected zone (HAZ) was divided into three zones and was composed of ferrite, pearlite colonies with different morphologies, degenerated regions of pearlite and allotriomorphic and Widmanstätten ferrite. The stir zone (SZ) of the steel showed a coarse microstructure consisting of allotriomorphic and Widmanstätten ferrite, degenerate pearlite and MA constituents. In the Ni-based alloy 625, the thermo-mechanically affected zone (TMAZ) showed deformed grains and redistribution of precipitates. In the SZ, the high deformation and temperature produced a recrystallised microstructure, as well as fracture and redistribution of MC precipitates. The M{sub 23}C{sub 6} precipitates, present in the base material, were also redistributed in the stir zone of the Ni-based alloy. TMAZ in the steel and HAZ in the Ni-based alloy could not be identified. The main restorative mechanisms were discontinuous dynamic recrystallisation in the steel, and discontinuous and continuous dynamic recrystallisation in the Ni-based alloy. The interface region between the steel and the Ni-based alloy showed a fcc microstructure with NbC carbides and an average length of 2.0 μm. - Highlights: • Comprehensive microstructural characterisation of dissimilar joints of mild steel to Ni-based alloy • Friction stir welding of joints of mild steel to Ni-based alloy 625 produces sound welds. • The interface region showed deformed and recrystallised fcc grains with NbC carbides and a length of 2.0 μm.

  13. Fatigue Crack Growth Behavior of a New Type of 10% Cr Martensitic Steel Welded Joints with Ni-Based Weld Metal

    NASA Astrophysics Data System (ADS)

    Zhang, Qunbing; Zhang, Jianxun

    2017-06-01

    In the present work, the fatigue crack growth (FCG) behavior of a new type of 10% Cr martensitic steel welded joints with Ni-based weld metal was comparatively studied for different regions including base metal (BM), heat-affected zone (HAZ) and weld metal (WM). FCG results indicated that the tempered lath martensite BM has a higher fatigue crack growth resistance than the tempered granular martensite HAZ that without a typical lath structure. In comparison, the austenitic WM has the highest fatigue crack growth threshold. Meanwhile, due to the microstructural and chemical compositional differences between BM and WM, a clear interface existed in the welded joints. At the region of the interface, the microstructures were physically connected and an element transition layer was formed. Although the starter notch was positioned at the region of interface, the fatigue crack gradually deviated from the interface and ultimately propagated along the inter-critically heat-affected zone. The difference in microstructure is considered as the primary factor that resulted in the different fatigue crack growth behaviors of the welded joints. In addition, the continuous microstructure connection and composition transition at the interface contributed to the good fatigue resistance at this region.

  14. Fatigue Crack Growth Behavior of a New Type of 10% Cr Martensitic Steel Welded Joints with Ni-Based Weld Metal

    NASA Astrophysics Data System (ADS)

    Zhang, Qunbing; Zhang, Jianxun

    2017-08-01

    In the present work, the fatigue crack growth (FCG) behavior of a new type of 10% Cr martensitic steel welded joints with Ni-based weld metal was comparatively studied for different regions including base metal (BM), heat-affected zone (HAZ) and weld metal (WM). FCG results indicated that the tempered lath martensite BM has a higher fatigue crack growth resistance than the tempered granular martensite HAZ that without a typical lath structure. In comparison, the austenitic WM has the highest fatigue crack growth threshold. Meanwhile, due to the microstructural and chemical compositional differences between BM and WM, a clear interface existed in the welded joints. At the region of the interface, the microstructures were physically connected and an element transition layer was formed. Although the starter notch was positioned at the region of interface, the fatigue crack gradually deviated from the interface and ultimately propagated along the inter-critically heat-affected zone. The difference in microstructure is considered as the primary factor that resulted in the different fatigue crack growth behaviors of the welded joints. In addition, the continuous microstructure connection and composition transition at the interface contributed to the good fatigue resistance at this region.

  15. Electrochemical impedance spectroscopy study on the corrosion of the weld zone of 3Cr steel welded joints in CO2 environments

    NASA Astrophysics Data System (ADS)

    Xu, Li-ning; Zhu, Jin-yang; Lu, Min-xu; Zhang, Lei; Chang, Wei

    2015-05-01

    The welded joints of 3Cr pipeline steel were fabricated with commercial welding wire using the gas tungsten arc welding (GTAW) technique. Potentiodynamic polarization curves, linear polarization resistance (LPR), electrochemical impedance spectroscopy (EIS), scanning electron microscopy (SEM), and energy-dispersive spectrometry (EDS) were used to investigate the corrosion resistance and the growth of a corrosion film on the weld zone (WZ). The changes in electrochemical characteristics of the film were obtained through fitting of the EIS data. The results showed that the average corrosion rate of the WZ in CO2 environments first increased, then fluctuated, and finally decreased gradually. The formation of the film on the WZ was divided into three stages: dynamic adsorption, incomplete-coverage layer formation, and integral layer formation.

  16. Investigations for the improvement of space shuttle main engine electron beam welding equipment

    NASA Technical Reports Server (NTRS)

    Smock, R. A.; Taylor, R. A.; Wall, W. A., Jr.

    1977-01-01

    Progress made in the testing, evaluation, and correction of MSFC's 7.5 kW electron beam welder in support of space shuttle main engine component welding is summarized. The objective of this project was to locate and correct the deficiencies in the welder. Some 17 areas were deficient in the 7.5 kW ERI welding system and the associated corrective action was taken to improve its operational performance. An overall improvement of 20 times the original reliability was obtained at full rated capacity after the modifications were made.

  17. Active solute effects on surface ripples in electron-beam welding solidification

    NASA Astrophysics Data System (ADS)

    Wei, P. S.; Chen, Y. H.; Ku, J. S.; Ho, C. Y.

    2003-08-01

    Surface rippling on workpieces containing surface-active solutes after solidification, during electron-beam welding or melting, is experimentally and analytically investigated. Most alloys contain one or more surface-active solutes such as O, S, Se, and Te. This leads to surface-tension coefficients being positive at low temperatures. In this work, the accelerating voltage and welding currents of the electron-beam welder used are 50 kV and 10 and 15 mA, respectively, with welding speeds of 20, 30, and 40 mm/s, while the workpieces are different steels containing sulfur of 0.0035, 0.008, and 0.014 wt pct and oxygen of 0.002 wt pct. The average amplitudes of ripples are measured for different beam powers, welding speeds, and sulfur contents. Extending a previous work studying rippling on alloys having negative surface-tension coefficients, the present work predicts average amplitudes of ripples by accounting for heat transfer and fluid flow induced by a positive temperature-dependent surface-tension gradient in the molten pool near the solidification front. It is found for the first time that dimensionless average amplitudes are increased by increasing the product of the Prandtl and Marangoni numbers, the product of the adsorption coefficient and the active solute content, and the elasticity number. The predicted results show good agreement with experimental data.

  18. Creep Deformation and Rupture Behavior of Single- and Dual-Pass 316LN Stainless-Steel-Activated TIG Weld Joints

    NASA Astrophysics Data System (ADS)

    Vijayanand, V. D.; Vasudevan, M.; Ganesan, V.; Parameswaran, P.; Laha, K.; Bhaduri, A. K.

    2016-06-01

    Creep deformation and rupture behavior of single-pass and dual-pass 316LN stainless steel (SS) weld joints fabricated by an autogenous activated tungsten inert gas welding process have been assessed by performing metallography, hardness, and conventional and impression creep tests. The fusion zone of the single-pass joint consisted of columnar zones adjacent to base metals with a central equiaxed zone, which have been modified extensively by the thermal cycle of the second pass in the dual-pass joint. The equiaxed zone in the single-pass joint, as well as in the second pass of the dual-pass joint, displayed the lowest hardness in the joints. In the dual-pass joint, the equiaxed zone of the first pass had hardness comparable to the columnar zone. The hardness variations in the joints influenced the creep deformation. The equiaxed and columnar zone in the first pass of the dual-pass joint was more creep resistant than that of the second pass. Both joints possessed lower creep rupture life than the base metal. However, the creep rupture life of the dual-pass joint was about twofolds more than that of the single-pass joint. Creep failure in the single-pass joint occurred in the central equiaxed fusion zone, whereas creep cavitation that originated in the second pass was blocked at the weld pass interface. The additional interface and strength variation between two passes in the dual-pass joint provides more restraint to creep deformation and crack propagation in the fusion zone, resulting in an increase in the creep rupture life of the dual-pass joint over the single-pass joint. Furthermore, the differences in content, morphology, and distribution of delta ferrite in the fusion zone of the joints favors more creep cavitation resistance in the dual-pass joint over the single-pass joint with the enhancement of creep rupture life.

  19. Development of a nozzle for underwater laser beam welds

    SciTech Connect

    Habenicht, I.; Santos, J.F. dos; Szelagowski, P.; Franz, T.

    1996-12-01

    The present study describes the work carried out to develop a nozzle for the welding or treatment of surfaces of components underwater. Two different types of nozzles have been investigated: contactless and sealed. With the former a dry working zone could only be achieved at very high gas flow and at a maximum extension of 2--3mm. The nozzles based on the labyrinth sealing concept were capable of producing and maintaining a dry working zone with acceptable gas flow and an extension range of 4mm. In the development of this nozzle the following factors have been considered: number of rubber layers, included angle of the sealing, quantity, position and diameter of the gas outlets and the extension range. The underwater nozzle developed in the course of this work has been successfully tested in a simulated patch welding repair of a stainless steel pipe at 3m water depth.

  20. Character of melting and evaporation in laser beam welding of two aluminum alloys

    SciTech Connect

    Xijing, W.; Katayama, S.; Matsunawa, A.

    1997-02-01

    The phenomenon of evaporation within the keyhole during laser beam welding of aluminum Alloys A5052 and A5083 was investigated under different welding conditions. The character of the molten pool was compared and analyzed. It was found that the evaporation of the main alloying element for these alloys, magnesium, greatly influenced the reaction force induced between the metal vapor and thermal plasma, which in turn affected the degree of penetration. The results of these experiments also confirmed that increasing shielding gas flow rate, within a limit, and a light increase in the entrance angle of the laser beam improved meltability and increased penetration depth. Surface preparation was also observed to improve beam absorption and increase penetration.

  1. Numerical Simulation and Experimental Validation of MIG Welding of T-Joints of Thin Aluminum Plates for Top Class Vehicles

    NASA Astrophysics Data System (ADS)

    Bonazzi, Enrico; Colombini, Elena; Panari, Davide; Vergnano, Alberto; Leali, Francesco; Veronesi, Paolo

    2017-01-01

    The integration of experiments with numerical simulations can efficiently support a quick evaluation of the welded joint. In this work, the MIG welding operation on aluminum T-joint thin plate has been studied by the integration of both simulation and experiments. The aim of the paper is to enlarge the global database, to promote the use of thin aluminum sheets in automotive body industries and to provide new data. Since the welding of aluminum thin plates is difficult to control due to high speed of the heat source and high heat flows during heating and cooling, a simulation model could be considered an effective design tool to predict the real phenomena. This integrated approach enables new evaluation possibilities on MIG-welded thin aluminum T-joints, as correspondence between the extension of the microstructural zones and the simulation parameters, material hardness, transient 3D temperature distribution on the surface and inside the material, stresses, strains, and deformations. The results of the mechanical simulations are comparable with the experimental measurements along the welding path, especially considering the variability of the process. The results could well predict the welding-induced distortion, which together with local heating during welding must be anticipated and subsequently minimized and counterbalance.

  2. Reactor cooling water expansion joint bellows: The role of the seam weld in fatigue crack development

    SciTech Connect

    West, S.L.; Nelson, D.Z.; Louthan, M.R. Jr.

    1992-12-01

    The secondary cooling water system pressure boundary of Savannah River Site reactors includes expansion joints utilizing a thin-wall bellows. While successfully used for over thirty years, an occasional replacement has been required because of the development of small, circumferential fatigue cracks in a bellows convolute. One such crack was recently shown to have initiated from a weld heat-affected zone liquation microcrack. The crack, initially open to the outer surface of the rolled and seam welded cylindrical bellows section, was closed when cold forming of the convolutes placed the outer surface in residual compression. However, the bellows was placed in tension when installed, and the tensile stresses reopened the microcrack. This five to eight grain diameter microcrack was extended by ductile fatigue processes. Initial extension was by relatively rapid propagation through the large-grained weld metal, followed by slower extension through the fine-grained base metal. A significant through-wall crack was not developed until the crack extended into the base metal on both sides of the weld. Leakage of cooling water was subsequently detected and the bellows removed and a replacement installed.

  3. The prediction of residual stress and its influence on the mechanical properties of weld joint

    NASA Astrophysics Data System (ADS)

    Ni, J.; Wahab, M. A.

    2017-05-01

    A three-dimensional metallo-thermo-mechanical analysis of bead on plate welding is performed in this work. This coupled model enables to capture the microstructural development and temperature history at local region. As a result, the residual stress is evaluated based on the temperature-dependent mechanical properties computed by the mixture of individual phase. Isotropic hardening is assumed in the finite element (FE) analysis. At the same time, the distribution of residual stress is also predicted by treating the mechanical properties as integral values of sheet metal. The two simulated fields of stress and strain after welding are analysed and compared. Moreover, as it is known that welding changes the mechanical properties of the original material, especially in fusion zone (FZ) and heat affected zone (HAZ), the stress and strain data at interested areas (HAZ and FZ) are subtracted for comparison. The predicted stress and strain fields are imported to subsequent simulation of standard tensile test. The stress-strain curves are compared with the one of base material. It is found that residual stress has significant influence on the structural performance of weld joints.

  4. Dynamic analysis for planar beam with clearance joint

    NASA Astrophysics Data System (ADS)

    Yao, XiaoGuang; Guo, XiaoSong; Feng, YongBao; Yu, ChuanQiang; Ma, Changlin

    2015-03-01

    An analytical model was presented in this study to describe the dynamic characteristics of a planar rotation beam with clearance joint. The spherical contact model was introduced to calculate the collision forces for the planar revolute joint. Unlike previous research, to acquire an accurate and convergent solution, the second-order coupling term of the beam axial deformation is taken into account. Then, the flexible beam was divided into discrete elements via the finite element method. The dynamic equations of the model were deduced via the Hamilton's principle. Further, the dynamic responses were obtained and analyzed in the non-inertial and inertial coordinates. To prove the validity of the presented methodology, a virtual prototype model with identical conditions was created in ADAMS. A numerical example was simultaneously calculated by the two different approaches. Comparison of the results shows that the two approaches match quite well. Finally, some valuable conclusions describing the inner-joint collision process are extracted and summarized.

  5. Welding development for V-Cr-Ti alloys

    SciTech Connect

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

    1994-09-01

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

  6. Effects of aging treatment and heat input on the microstructures and mechanical properties of TIG-welded 6061-T6 alloy joints

    NASA Astrophysics Data System (ADS)

    Peng, Dong; Shen, Jun; Tang, Qin; Wu, Cui-ping; Zhou, Yan-bing

    2013-03-01

    Aging treatment and various heat input conditions were adopted to investigate the microstructural evolution and mechanical properties of TIG welded 6061-T6 alloy joints by microstructural observations, microhardness tests, and tensile tests. With an increase in heat input, the width of the heat-affected zone (HAZ) increases and grains in the fusion zone (FZ) coarsen. Moreover, the hardness of the HAZ decreases, whereas that of the FZ decreases initially and then increases with an increase in heat input. Low heat input results in the low ultimate tensile strength of the welded joints due to the presence of partial penetrations and pores in the welded joints. After a simple artificial aging treatment at 175°C for 8 h, the microstructure of the welded joints changes slightly. The mechanical properties of the welded joints enhance significantly after the aging process as few precipitates distribute in the welded seam.

  7. Detection of micro gap weld joint by using magneto-optical imaging and Kalman filtering compensated with RBF neural network

    NASA Astrophysics Data System (ADS)

    Gao, Xiangdong; Chen, Yuquan; You, Deyong; Xiao, Zhenlin; Chen, Xiaohui

    2017-02-01

    An approach for seam tracking of micro gap weld whose width is less than 0.1 mm based on magneto optical (MO) imaging technique during butt-joint laser welding of steel plates is investigated. Kalman filtering(KF) technology with radial basis function(RBF) neural network for weld detection by an MO sensor was applied to track the weld center position. Because the laser welding system process noises and the MO sensor measurement noises were colored noises, the estimation accuracy of traditional KF for seam tracking was degraded by the system model with extreme nonlinearities and could not be solved by the linear state-space model. Also, the statistics characteristics of noises could not be accurately obtained in actual welding. Thus, a RBF neural network was applied to the KF technique to compensate for the weld tracking errors. The neural network can restrain divergence filter and improve the system robustness. In comparison of traditional KF algorithm, the RBF with KF was not only more effectively in improving the weld tracking accuracy but also reduced noise disturbance. Experimental results showed that magneto optical imaging technique could be applied to detect micro gap weld accurately, which provides a novel approach for micro gap seam tracking.

  8. Heat and fluid flow in complex joints during gas metal arc welding—Part I: Numerical model of fillet welding

    NASA Astrophysics Data System (ADS)

    Zhang, W.; Kim, C.-H.; DebRoy, T.

    2004-05-01

    Gas metal arc (GMA) fillet welding is one of the most important processes for metal joining because of its high productivity and amiability to automation. This welding process is characterized by the complicated V-shaped joint geometry, a deformable weld pool surface, and the additions of hot metal droplets. In the present work, a three-dimensional numerical heat transfer and fluid flow model was developed to examine the temperature profiles, velocity fields, weld pool shape and size, and the nature of the solidified weld bead geometry during GMA fillet welding. The model solved the equations of conservation of mass, momentum, and energy using a boundary fitted curvilinear coordinate system. Apart from the direct transport of heat from the welding arc, additional heat from the metal droplets was modeled considering a volumetric heat source. The deformation of the weld pool surface was calculated by minimizing the total surface energy. Part I of this article is focused on the details of the numerical model such as coordinate transformation and calculation of volumetric heat source and free surface profile. An application of the model to GMA fillet welding of mild steel is described in an accompanying article (W. Zhang, C.-H. Kim and T. DebRoy, J. Appl Phys. 95, 5220 (2004)).

  9. Joint properties of cast Fe-Pt magnetic alloy laser-welded to Co-Cr alloy.

    PubMed

    Baba, Naoki; Watanabe, Ikuya; Tanaka, Yasuhiro; Hisatsune, Kunihiro; Atsuta, Mitsuru

    2005-12-01

    This study investigated the joint properties of Fe-Pt alloy laser-welded to Co-Cr alloy. Cast plates (0.5 x 3.0 x 10 mm) were prepared with Fe-Pt and Co-Cr alloys. Fe-Pt plates were butted against Co-Cr plates and laser-welded using Nd:YAG laser. Control and homogeneously welded specimens were also prepared. Laser welding was performed with and without argon shielding. Tensile testing was conducted, and both fracture force (Ff: N) and elongation (El: %) were recorded. There were no differences in the Ff value between the specimens with and without argon shielding for the welded Fe-Pt/Co-Cr. Lower Ff value of the welded specimen was obtained in the order of Fe-Pt alloy < Fe-Pt/Co-Cr < Co-Cr alloy. The results indicated that Fe-Pt welded to Co-Cr had Ff values between the values of homogeneously welded Fe-Pt and Co-Cr alloys. Argon shielding, on the other hand, had no effect on the weld strength between Fe-Pt and Co-Cr alloys.

  10. Microstructure and Phase Composition of a Low-Power YAG Laser-MAG Welded Stainless Steel Joint

    NASA Astrophysics Data System (ADS)

    Huang, R. S.; Kang, L.; Ma, X.

    2008-12-01

    This article presents multipass hybrid welding of austenitic stainless steel (ASS) structure by using the low-power Nd:YAG laser-metal active gas (MAG) arc hybrid welding method. The purpose of this work is to investigate and qualify the effects of multipass hybrid welding of ASS structure on the microstructure, phase composition, weld postheat influence, and weld bead (WB) precipitated phase. The results demonstrated that sound welded joints without any solidification and shrinkage defects could be obtained after welding. The top and the bottom portions of the workpieces were joined completely. At room temperature, the microstructures of different regions in WB were different and the WB microstructures were composed of columnar γ-austenite and δ-ferrite phases. The fraction of δ-ferrite decreased from 20% to 10%, and its morphology changed orderly from lath, skeleton, vermicular to reticular with an increase in the number of welding cycles. Because of the influence of postweld heat, the weld metal phase chemistry at 3 mm distance from the top of the WB surface underwent a notable modification that corresponded to an evolution of the partition coefficients toward the parent metal values. This indicated corrosion resistance of the microstructure is equivalent to that of the parent metal.

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

    SciTech Connect

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

    2014-10-15

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

  12. Modern fiber laser beam welding of the newly-designed precipitation-strengthened nickel-base superalloys

    NASA Astrophysics Data System (ADS)

    Naffakh Moosavy, Homam; Aboutalebi, Mohammad-Reza; Seyedein, Seyed Hossein; Goodarzi, Massoud; Khodabakhshi, Meisam; Mapelli, Carlo; Barella, Silvia

    2014-04-01

    In the present research, the modern fiber laser beam welding of newly-designed precipitation-strengthened nickel-base superalloys using various welding parameters in constant heat input has been investigated. Five nickel-base superalloys with various Ti and Nb contents were designed and produced by Vacuum Induction Melting furnace. The fiber laser beam welding operations were performed in constant heat input (100 J mm-2) and different welding powers (400 and 1000 W) and velocities (40 and 100 mm s-1) using 6-axis anthropomorphic robot. The macro- and micro-structural features, weld defects, chemical composition and mechanical property of 3.2 mm weldments were assessed utilizing optical and scanning electron microscopes equipped with EDS analysis and microhardness tester. The results showed that welding with higher powers can create higher penetration-to-width ratios. The porosity formation was increased when the welding powers and velocities were increased. None of the welds displayed hot solidification and liquation cracks in 400 and 1000 W welding powers, but liquation phenomenon was observed in all the heat-affected zones. With increasing the Nb content of the superalloys the liquation length was increased. The changing of the welding power and velocity did not alter the hardness property of the welds. The hardness of welds decreased when the Ti content declined in the composition of superalloys. Finally, the 400 and 1000 W fiber laser powers with velocity of 40 and 100 m ms-1 have been offered for hot crack-free welding of the thin sheet of newly-designed precipitation-strengthened nickel-base superalloys.

  13. EFFECT OF TOOL FEATURE ON THE JOINT STRENGTH OF DISSIMILAR FRICTION STIR LAP WELDS

    SciTech Connect

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

    2011-04-25

    Several variations of friction stir tools were used to investigate the effects on the joint strengths of dissimilar friction stir lap welds. In the present lap weld configuration the top sheet was a 2.32 mm thick Mg (AZ 31) alloy. The bottom sheet consisted of two different steels, a (i) 0.8 mm thick electro-galvanized (EG) mild steel, or a (ii) 1.5 mm thick hot dip galvanized (HDG) high strength low alloy (HSLA) steel. Initially the tool shape was modified to accommodate the material, at which point the tool geometry was fixed. With a fixed tool geometry an additional feature was added to the pin bottom on one of the tools by incorporating a short hard insert, which would act as a stronger bottom sheet cutter. The effects of such modification on the unguided lap shear strength, and associated microstructural changes are discussed in this study.

  14. Investigation of Interfacial Layer for Ultrasonic Spot Welded Aluminum to Copper Joints.

    PubMed

    Zhang, Zijiao; Wang, Kaifeng; Li, Jingjing; Yu, Qian; Cai, Wayne

    2017-10-02

    The bonding formation for ultrasonic welding of dissimilar metals has been shrouded in mystery because of the complex thermomechanical behavior at the bonding interface. We investigated the microstructure and phases at the bonding interface of ultrasonically welded aluminum to copper joints using transmission electron microscopy, and found a ~10 nm thick transition layer composed of amorphous phase and nanocrystallines, which was believed to form the bonding between these two metals in addition to mechanical interlocking observed at a larger scale. Interdiffusion of parent elements (i.e. Al and Cu) was noticed in the amorphous phase, which was mainly driven by plastic deformation in solid state introduced by ultrasonic vibration. High densities of dislocations and stacking faults were also observed in the parent metals close to the transition layer, confirming the effects of severe plastic deformation.

  15. The effect of electron beam welding on the creep rupture properties of a Nb-Zr-C alloy

    NASA Technical Reports Server (NTRS)

    Moore, T. J.; Titran, R. H.; Grobstein, T. L.

    1986-01-01

    Creep rupture tests of electron beam welded PWC-11 sheet were conducted at 1350 K. Full penetration, single pass welds were oriented transverse to the testing direction in 1 mm thick sheet. With this orientation, stress was imposed equally on the base metal, weld metal, and heat-affected zone. Tests were conducted in both the postweld annealed and aged conditions. Unwelded specimens with similar heat treatments were tested for comparative purposes. It was found that the weld region is stronger than the base metal for both the annealed and aged conditions and that the PWC-11 material is stronger in the annealed condition than in the aged condition.

  16. Diode laser welding of high yield steel

    NASA Astrophysics Data System (ADS)

    Lisiecki, Aleksander

    2013-01-01

    The following article describes results of investigations on influence of laser welding parameters on the weld shape, quality and mechanical properties of 2.5 mm thick butt joints of thermo-mechanically rolled, high yield strength steel for cold forming S420MC (according to EN 10149 - 3 and 060XLK according to ASTM) welded with high power diode laser HPDL ROFIN SINAR DL 020 with rectangular laser beam spot and 2.2 kW output power, and 808 nm wavelength. The investigations at the initial stage were focused on detailed analysis of influence of the basic laser welding parameters such as laser power and welding speed on the shape and quality of single bead produced during bead-on-plate welding. Then the optimal parameters were chosen for laser welding of 2.5 mm thick butt joints of the thermo-mechanically rolled, high yield strength steel sheets for cold forming S420MC. The test joints were prepared as single square groove and one-side laser welded without an additional material, at a flat position. Edges of steel sheets were melted in argon atmosphere by the laser beam focused on the top joint surface. The test welded joints were investigated by visual inspection, metallographic examinations, mechanical tests such as tensile tests and bending tests. It was found that the high power diode laser may be applied successfully for one-side welding of the S420MC steel butt joints. Additionally it was found that in the optimal range of laser welding parameters the high quality joint were produced.

  17. Influence of Heat Input on the Content of Delta Ferrite in the Structure of 304L Stainless Steel GTA Welded Joints

    NASA Astrophysics Data System (ADS)

    Sejč, Pavol; Kubíček, Rastislav

    2011-12-01

    Welding of austenitic stainless steel has its specific issues, even when the weldability is considered good. The main problems of austenitic stainless steel welding are connected with its metallurgical weldability. The amount of the components presented in the structure of stainless steel welded joint affect its properties, therefore the understanding of the behavior of stainless steel during its welding is important for successful processing and allows the fabricators the possibility to manage the resulting issues. This paper is focused on the influence of heat input on the structural changes in GTA welded joints of austenitic stainless steel designated: ASTM SA TP 304L.

  18. Impact of tool wear on joint strength in friction stir spot welding of DP 980 steel

    SciTech Connect

    Miles, Michael; Ridges, Chris; Hovanski, Yuri; Peterson, Jeremy; Santella, M. L.; Steel, Russel

    2011-09-14

    Friction stir spot welding has been shown to be a viable method of joining ultra high strength steel (UHSS), both in terms of joint strength and process cycle time. However, the cost of tooling must be reasonable in order for this method to be adopted as an industrial process. Recently a new tool alloy has been developed, using a blend of PCBN and tungsten rhenium (W-Re) in order to improve the toughness of the tool. Wear testing results are presented for two of these alloys: one with a composition of 60% PCBN and 40% W-Re, and one with 70% PCBN and 30% W-Re. The sheet material used for all wear testing was 1.4 mm DP 980. Lap shear testing was used to show the relationship between tool wear and joint strength. The Q70 tool provided the best combination of wear resistance and joint strength.

  19. Tensile and Fatigue Properties of Single and Multiple Dissimilar Welded Joints of DP980 and HSLA

    NASA Astrophysics Data System (ADS)

    Cui, Q. L.; Parkes, D.; Westerbaan, D.; Nayak, S. S.; Zhou, Y.; Saha, D. C.; Liu, D.; Goodwin, F.; Bhole, S.; Chen, D. L.

    2017-01-01

    The present study focused on single and multiple dissimilar joints between DP980 and high-strength low-alloy (HSLA) galvanized steels. The tensile properties of the dissimilar joint between the strong DP980 and the relatively soft HSLA reflected only the properties of HSLA with plastic deformation, and final fracture took place entirely in HSLA. The fatigue properties of the dissimilar joints were more intriguing, with the strong DP980 outperforming at high stress amplitude and the ductile HSLA outperforming at low stress amplitude. For different load amplitudes, fatigue failure occurred in different materials and at different locations. The fatigue strength of DP980 was more negatively impaired by weld defects than that of HSLA.

  20. Tensile and Fatigue Properties of Single and Multiple Dissimilar Welded Joints of DP980 and HSLA

    NASA Astrophysics Data System (ADS)

    Cui, Q. L.; Parkes, D.; Westerbaan, D.; Nayak, S. S.; Zhou, Y.; Saha, D. C.; Liu, D.; Goodwin, F.; Bhole, S.; Chen, D. L.

    2017-02-01

    The present study focused on single and multiple dissimilar joints between DP980 and high-strength low-alloy (HSLA) galvanized steels. The tensile properties of the dissimilar joint between the strong DP980 and the relatively soft HSLA reflected only the properties of HSLA with plastic deformation, and final fracture took place entirely in HSLA. The fatigue properties of the dissimilar joints were more intriguing, with the strong DP980 outperforming at high stress amplitude and the ductile HSLA outperforming at low stress amplitude. For different load amplitudes, fatigue failure occurred in different materials and at different locations. The fatigue strength of DP980 was more negatively impaired by weld defects than that of HSLA.