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

NASA Astrophysics Data System (ADS)

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

2018-07-01

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

Molten core retention assembly

DOEpatents

Lampe, Robert F.

1976-06-22

Molten fuel produced in a core overheating accident is caught by a molten core retention assembly consisting of a horizontal baffle plate having a plurality of openings therein, heat exchange tubes having flow holes near the top thereof mounted in the openings, and a cylindrical, imperforate baffle attached to the plate and surrounding the tubes. The baffle assembly is supported from the core support plate of the reactor by a plurality of hanger rods which are welded to radial beams passing under the baffle plate and intermittently welded thereto. Preferably the upper end of the cylindrical baffle terminates in an outwardly facing lip to which are welded a plurality of bearings having slots therein adapted to accept the hanger rods.

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

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

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

Nuclear reactor alignment plate configuration

DOEpatents

Altman, David A; Forsyth, David R; Smith, Richard E; Singleton, Norman R

2014-01-28

An alignment plate that is attached to a core barrel of a pressurized water reactor and fits within slots within a top plate of a lower core shroud and upper core plate to maintain lateral alignment of the reactor internals. The alignment plate is connected to the core barrel through two vertically-spaced dowel pins that extend from the outside surface of the core barrel through a reinforcement pad and into corresponding holes in the alignment plate. Additionally, threaded fasteners are inserted around the perimeter of the reinforcement pad and into the alignment plate to further secure the alignment plate to the core barrel. A fillet weld also is deposited around the perimeter of the reinforcement pad. To accomodate thermal growth between the alignment plate and the core barrel, a gap is left above, below and at both sides of one of the dowel pins in the alignment plate holes through with the dowel pins pass.

Pore-water extraction from unsaturated tuff by triaxial and one-dimensional compression methods, Nevada Test Site, Nevada

USGS Publications Warehouse

Mower, Timothy E.; Higgins, Jerry D.; Yang, In C.; Peters, Charles A.

1994-01-01

Study of the hydrologic system at Yucca Mountain, Nevada, requires the extraction of pore-water samples from welded and nonwelded, unsaturated tuffs. Two compression methods (triaxial compression and one-dimensional compression) were examined to develop a repeatable extraction technique and to investigate the effects of the extraction method on the original pore-fluid composition. A commercially available triaxial cell was modified to collect pore water expelled from tuff cores. The triaxial cell applied a maximum axial stress of 193 MPa and a maximum confining stress of 68 MPa. Results obtained from triaxial compression testing indicated that pore-water samples could be obtained from nonwelded tuff cores that had initial moisture contents as small as 13 percent (by weight of dry soil). Injection of nitrogen gas while the test core was held at the maximum axial stress caused expulsion of additional pore water and reduced the required initial moisture content from 13 to 11 percent. Experimental calculations, together with experience gained from testing moderately welded tuff cores, indicated that the triaxial cell used in this study could not apply adequate axial or confining stress to expel pore water from cores of densely welded tuffs. This concern led to the design, fabrication, and testing of a one-dimensional compression cell. The one-dimensional compression cell used in this study was constructed from hardened 4340-alloy and nickel-alloy steels and could apply a maximum axial stress of 552 MPa. The major components of the device include a corpus ring and sample sleeve to confine the sample, a piston and base platen to apply axial load, and drainage plates to transmit expelled water from the test core out of the cell. One-dimensional compression extracted pore water from nonwelded tuff cores that had initial moisture contents as small as 7.6 percent; pore water was expelled from densely welded tuff cores that had initial moisture contents as small as 7.7 percent. Injection of nitrogen gas at the maximum axial stress did not produce additional pore water from nonwelded tuff cores, but was critical to recovery of pore water from densely welded tuff cores. Gas injection reduced the required initial moisture content in welded tuff cores from 7.7 to 6.5 percent. Based on the mechanical ability of a pore-water extraction method to remove water from welded and nonwelded tuff cores, one-dimensional compression is a more effective extraction method than triaxial compression. However, because the effects that one-dimensional compression has on pore-water chemistry are not completely understood, additional testing will be needed to verify that this method is suitable for pore-water extraction from Yucca Mountain tuffs.

Effect of pressure and shielding gas on the microstructure of hyperbaric metal cored GMAW welds down to 111 bar

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

Jorge, J.C.F.; Santos, V.R. dos; Santos, J.F. dos

1995-12-31

The microstructural evolution of hyperbaric C-Mn weld metals was studied by means of bead-on-plate welds deposit with GMAW process using a commercial metal cored wire. The welding was carried out in the flat position in the range of 51 bar to 111 bar with He+ CO{sub 2} as shielding gas, which CO{sub 2} content varied from 0.1% to 0.8 %. The microstructures were quantitatively analyzed by optical microscopy to evaluate the amount of constituents according to the IIW/IIS terminology. The results showed that all weld metals presented great amounts of acicular ferrite and a stronger influence of pressure on microstructuremore » compared to the influence of the shielding gas.« less

Boiling-Water Reactor internals aging degradation study. Phase 1

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

Luk, K.H.

1993-09-01

This report documents the results of an aging assessment study for boiling water reactor (BWR) internals. Major stressors for BWR internals are related to unsteady hydrodynamic forces generated by the primary coolant flow in the reactor vessel. Welding and cold-working, dissolved oxygen and impurities in the coolant, applied loads and exposures to fast neutron fluxes are other important stressors. Based on results of a component failure information survey, stress corrosion cracking (SCC) and fatigue are identified as the two major aging-related degradation mechanisms for BWR internals. Significant reported failures include SCC in jet-pump holddown beams, in-core neutron flux monitor drymore » tubes and core spray spargers. Fatigue failures were detected in feedwater spargers. The implementation of a plant Hydrogen Water Chemistry (HWC) program is considered as a promising method for controlling SCC problems in BWR. More operating data are needed to evaluate its effectiveness for internal components. Long-term fast neutron irradiation effects and high-cycle fatigue in a corrosive environment are uncertainty factors in the aging assessment process. BWR internals are examined by visual inspections and the method is access limited. The presence of a large water gap and an absence of ex-core neutron flux monitors may handicap the use of advanced inspection methods, such as neutron noise vibration measurements, for BWR.« less

Reduction in welding fume and metal exposure of stainless steel welders: an example from the WELDOX study.

PubMed

Lehnert, Martin; Weiss, Tobias; Pesch, Beate; Lotz, Anne; Zilch-Schöneweis, Sandra; Heinze, Evelyn; Van Gelder, Rainer; Hahn, Jens-Uwe; Brüning, Thomas

2014-07-01

In a plant where flux-cored arc welding was applied to stainless steel, we investigated changes in airborne and internal metal exposure following improvements of exhaust ventilation and respiratory protection. Twelve welders were examined at a time in 2008 and in 2011 after improving health protection. Seven welders were enrolled in both surveys. Exposure measurement was performed by personal sampling of respirable welding fume inside the welding helmets during one work shift. Urine and blood samples were taken after the shift. Chromium (Cr), nickel (Ni), and manganese (Mn) were determined in air and biological samples. The geometric mean of respirable particles could be reduced from 4.1 mg/m(3) in 2008-0.5 mg/m(3) in 2011. Exposure to airborne metal compounds was also strongly reduced (Mn: 399 vs. 6.8 μg/m(3); Cr: 187 vs. 6.3 μg/m(3); Ni: 76 vs. 2.8 μg/m(3)), with the most striking reduction inside helmets with purified air supply. Area sampling revealed several concentrations above established or proposed exposure limits. Urinary metal concentrations were also reduced, but to a lesser extent (Cr: 14.8 vs. 4.5 μg/L; Ni: 7.9 vs. 3.1 μg/L). Although biologically regulated, the mean Mn concentration in blood declined from 12.8 to 8.9 μg/L. This intervention study demonstrated a distinct reduction in the exposure of welders using improved exhaust ventilation and welding helmets with purified air supply in the daily routine. Data from area sampling and biomonitoring indicated that the area background level may add considerably to the internal exposure.

Superplastic Forming/Adhesive Bonding of Aluminum (SPF/AB) Multi-Sheet Structures

NASA Technical Reports Server (NTRS)

Wagner, John A. (Technical Monitor); Will, Jeff D.; Cotton, James D.

2003-01-01

A significant fraction of airframe structure consists of stiffened panels that are costly and difficult to fabricate. This program explored a potentially lower-cost processing route for producing such panels. The alternative process sought to apply concurrent superplastic forming and adhesive bonding of aluminum alloy sheets. Processing conditions were chosen to balance adequate superplasticity of the alloy with thermal stability of the adhesive. As a first objective, an air-quenchable, superplastic aluminum-lithium alloy and a low-volatile content, low-viscosity adhesive with compatible forming/curing cycles were identified. A four-sheet forming pack was assembled which consisted of a welded two-sheet core separated from the face sheets by a layer of adhesive. Despite some preliminary success, of over 30 forming trials none was completely successful. The main problem was inadequate superplasticity in the heat-affected zones of the rib welds, which generally fractured prior to completion of the forming cycle. The welds are a necessary component in producing internal ribs by the 'four-sheet' process. Other challenges, such as surface preparation and adhesive bonding, were adequately solved. But without the larger issue of tearing at the weld locations, complex panel fabrication by SPF/AB does not appear viable.

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

ERIC Educational Resources Information Center

Knapp, John; Harper, Eddie

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

Agricultural Mechanics Unit for Plant Science Core Curriculum. Volume 15, Number 4. Instructor's Guide.

ERIC Educational Resources Information Center

Linhardt, Richard E.; Hunter, Bill

This instructor's guide is intended for use in teaching the agricultural mechanics unit of a plant science core curriculum. Covered in the individual units of the guide are the following topics: arc welding (following safety procedures, controlling distortion, selecting and caring for electrodes, identifying the material to be welded, and welding…

Development of a wear-resistant flux cored wire of Fe-C-Si-Mn-Cr-Ni-Mo-V system for deposit welding of mining equipment parts

NASA Astrophysics Data System (ADS)

Osetkovsky, I. V.; Kozyrev, N. A.; Kryukov, R. E.; Usoltsev, A. A.; Gusev, A. I.

2017-09-01

The effect of introduction of cobalt in the charge of the flux cored wire of Fe-C-Si-Mn-Cr-Ni-Mo-V system operating under abrasive and abrasive-shock loads is studied. In the laboratory conditions samples of flux cored wires were made, deposition was performed, the effect of cobalt on the hardness and the degree of wear was evaluated, metallographic studies were carried out. The influence of cobalt introduced into the charge of the flux cored wire of Fe-C-Si-Mn-Cr-Ni-Mo-V system on the structure, nature of nonmetallic inclusions, hardness and wear resistance of the weld metal was studied. In the laboratory conditions samples flux cored wire were made using appropriate powdered materials. As a carbon-fluorine-containing material dust from gas cleaning units of aluminum production was used. In the course of the study the chemical composition of the weld metal was determined, metallographic analysis was performed, mechanical properties were determined. As a result of the metallographic analysis the size of the former austenite grain, martensite dispersion in the structure of the weld metal, the level of contamination with its nonmetallic inclusions were established.

Fabrication of cooled radial turbine rotor

NASA Technical Reports Server (NTRS)

Hammer, A. N.; Aigret, G. G.; Psichogios, T. P.; Rodgers, C.

1986-01-01

A design and fabrication program was conducted to evaluate a unique concept for constructing a cooled, high temperature radial turbine rotor. This concept, called split blade fabrication was developed as an alternative to internal ceramic coring. In this technique, the internal cooling cavity is created without flow dividers or any other detail by a solid (and therefore stronger) ceramic plate which can be more firmly anchored within the casting shell mold than can conventional detailed ceramic cores. Casting is conducted in the conventional manner, except that the finished product, instead of having finished internal cooling passages, is now a split blade. The internal details of the blade are created separately together with a carrier sheet. The inserts are superalloy. Both are produced by essentially the same software such that they are a net fit. The carrier assemblies are loaded into the split blade and the edges sealed by welding. The entire wheel is Hot Isostatic Pressed (HIPed), braze bonding the internal details to the inside of the blades. During this program, two wheels were successfully produced by the split blade fabrication technique.

The structure and properties of the modified nitrogenated high-chromium steel for welding the parts of oil and gas equipment

NASA Astrophysics Data System (ADS)

Sokolov, G. N.; Artem'ev, A. A.; Dubcov, Yu. N.; Eremin, E. N.; Litvinenko-Ar'kov, V. B.

2017-08-01

The influence of nitrogen and titanium carbonitride particles on the structure and properties of high-chromium steel, deposited by flux cored wire, has been studied. It has been shown that the quality formation of the weld metal and pore absence in it are achieved with nitrogen concentration in wire filler no more than 0.32 mass%. It has been found that in adding titanium carbonitride particles from 0.2 to 0.6 mass% to wire filler the effect of weld Fe-C-Cr-Mo-Ni-N system metal modification is implemented and its operational properties increase. The developed flux cored wire has been recommended for oil and gas equipment welding.

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

PubMed

Taube, Fabian

2013-01-01

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

Size-separated particle fractions of stainless steel welding fume particles - A multi-analytical characterization focusing on surface oxide speciation and release of hexavalent chromium.

PubMed

Mei, N; Belleville, L; Cha, Y; Olofsson, U; Odnevall Wallinder, I; Persson, K-A; Hedberg, Y S

2018-01-15

Welding fume of stainless steels is potentially health hazardous. The aim of this study was to investigate the manganese (Mn) and chromium (Cr) speciation of welding fume particles and their extent of metal release relevant for an inhalation scenario, as a function of particle size, welding method (manual metal arc welding, metal arc welding using an active shielding gas), different electrodes (solid wires and flux-cored wires) and shielding gases, and base alloy (austenitic AISI 304L and duplex stainless steel LDX2101). Metal release investigations were performed in phosphate buffered saline (PBS), pH 7.3, 37°, 24h. The particles were characterized by means of microscopic, spectroscopic, and electroanalytical methods. Cr was predominantly released from particles of the welding fume when exposed in PBS [3-96% of the total amount of Cr, of which up to 70% as Cr(VI)], followed by Mn, nickel, and iron. Duplex stainless steel welded with a flux-cored wire generated a welding fume that released most Cr(VI). Nano-sized particles released a significantly higher amount of nickel compared with micron-sized particle fractions. The welding fume did not contain any solitary known chromate compounds, but multi-elemental highly oxidized oxide(s) (iron, Cr, and Mn, possibly bismuth and silicon). Copyright © 2017 The Authors. Published by Elsevier B.V. All rights reserved.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

In Process Measurement of Hydrogen in Welding

DTIC Science & Technology

1986-09-01

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

High-power CW and long-pulse lasers in the green wavelength regime for copper welding

NASA Astrophysics Data System (ADS)

Pricking, Sebastian; Huber, Rudolf; Klausmann, Konrad; Kaiser, Elke; Stolzenburg, Christian; Killi, Alexander

2016-03-01

We report on industrial high-power lasers in the green wavelength regime. By means of a thin disk oscillator and a resonator-internal nonlinear crystal for second harmonic generation we are able to extract up to 8 kW pulse power in the few-millisecond range at a wavelength of 515 nm with a duty cycle of 10%. Careful shaping and stabilization of the polarization and spectral properties leads to a high optical-to-optical efficiency larger than 55%. The beam parameter product is designed and measured to be below 5 mm·mrad which allows the transport by a fiber with a 100 μm core diameter. The fiber and beam guidance optics are adapted to the green wavelength, enabling low transmission losses and stable operation. Application tests show that this laser is perfectly suited for copper welding due to the superior absorption of the green wavelength compared to IR, which allows us to produce weld spots with an unprecedented reproducibility in diameter and welding depth. With an optimized set of parameters we could achieve a splatter-free welding process of copper, which is crucial for welding electronic components. Furthermore, the surface condition does not influence the welding process when the green wavelength is used, which allows to skip any expensive preprocessing steps like tin-coating. With minor changes we could operate the laser in cw mode and achieved up to 1.7 kW of cw power at 515 nm with a beam parameter product of 2.5 mm·mrad. These parameters make the laser perfectly suitable for additional applications such as selective laser melting of copper.

Mississippi Curriculum Framework for Welding (Program CIP: 48.0508--Welder/Welding Technologist). Secondary Programs.

ERIC Educational Resources Information Center

Mississippi Research and Curriculum Unit for Vocational and Technical Education, State College.

This document, which reflects Mississippi's statutory requirement that instructional programs be based on core curricula and performance-based assessment, contains outlines of the instructional units required in local instructional management plans and daily lesson plans for welding I and II. Presented first are a program description and course…

Identification of internal defects of hardfacing coatings in regeneration of machine parts

NASA Astrophysics Data System (ADS)

Józwik, Jerzy; Dziedzic, Krzysztof; Pashechko, Mykhalo; Łukasiewicz, Andrzej

2017-10-01

The quality control of hardfacing is one of the areas where non-destructive testing is applied. To detect defects and inconsistencies in the industrial practice one uses the same methods as in the testing of welded joints. Computed Tomography is a type of X-ray spectroscopy. It is used as a diagnostic method that allows to obtain layered images of examined hardfacing. The paper presents the use of Computed Tomography for the evaluation of defects of hardfacing parts and errors. Padding welds were produced using GMA consumable electrode welding with CO2 active gas. The padding material used were cored wires FILTUB DUR 16, and ones produced from a Fe-Mn-C-Si-Cr-Mo-Ti-W alloy. The layers were padded on to different surfaces: C45, 165CrV12, 42CrMo4, S235JR steel. Typical defects occurring in the pads and the influence of the type of wire on the concentration of defects were characterized. The resulting pads were characterized by occurring inconsistencies taking the form of pores, intrusions and fractures.

Status of Fuel Development and Manufacturing for Space Nuclear Reactors at BWX Technologies

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

Carmack, W.J.; Husser, D.L.; Mohr, T.C.

2004-02-04

New advanced nuclear space propulsion systems will soon seek a high temperature, stable fuel form. BWX Technologies Inc (BWXT) has a long history of fuel manufacturing. UO2, UCO, and UCx have been fabricated at BWXT for various US and international programs. Recent efforts at BWXT have focused on establishing the manufacturing techniques and analysis capabilities needed to provide a high quality, high power, compact nuclear reactor for use in space nuclear powered missions. To support the production of a space nuclear reactor, uranium nitride has recently been manufactured by BWXT. In addition, analytical chemistry and analysis techniques have been developedmore » to provide verification and qualification of the uranium nitride production process. The fabrication of a space nuclear reactor will require the ability to place an unclad fuel form into a clad structure for assembly into a reactor core configuration. To this end, BWX Technologies has reestablished its capability for machining, GTA welding, and EB welding of refractory metals. Specifically, BWX Technologies has demonstrated GTA welding of niobium flat plate and EB welding of niobium and Nb-1Zr tubing. In performing these demonstration activities, BWX Technologies has established the necessary infrastructure to manufacture UO2, UCx, or UNx fuel, components, and complete reactor assemblies in support of space nuclear programs.« less

Geohydrologic data from test hole USW UZ-7, Yucca Mountain area, Nye County, Nevada

USGS Publications Warehouse

Kume, Jack; Hammermeister, D.P.

1990-01-01

This report contains a description of the methods used in drilling and coring of the test-hole USW UZ-7, a description of the methods used in collecting, handling, and testing of test-hole samples; Lithologic information from the test hole; and water-content, water-potential, bulk-density, grain-density, porosity, and tritium data for the test hole. Test-hole USW UZ-7 was drilled and cored to a total depth of 62.94 m. The drilling was done using air as a drilling fluid to minimize disturbance to the water content of cores, drill-bit cuttings, and borehole wall-rock. Beginning at the land surface, the unsaturated-zone rock that was penetrated consisted of alluvium; welded and partially to nonwelded ash-flow tuff; bedded and reworked ash-fall tuff; nonwelded ash-flow tuff; and welded ash-flow tuff. Values of gravimetric water content and water potential of alluvium were intermediate between the extreme values in welded and nonwelded units of tuff. Gravimetric water content was largest in bedded and nonwelded ash-fall tuffs and was smallest in welded ash-flow tuff. Values of water potential were more negative in densely welded ash-flow tuffs and were less negative in bedded and nonwelded ash-fall tuffs. Bulk density was largest in densely welded ash-flow tuffs and smallest in nonwelded and bedded ash-fall tuffs. Grain density was uniform but was slightly larger in nonwelded and bedded ash-fall tuffs than in welded ash-flow tuffs. Porosity trends were opposite to bulk-density trends. Tritium content in alluvium was smallest near the alluvium-bedrock contact, markedly increased in the middle of the deposit, and decreased in the near-surface zone of the deposit. (Author 's abstract)

One-step femtosecond laser welding and internal machining of three glass substrates

NASA Astrophysics Data System (ADS)

Tan, Hua; Duan, Ji'an

2017-05-01

In this paper, it demonstrated one-step femtosecond laser welding and internal machining of three fused silica substrates in the optical- and non-optical-contact regimes by focusing 1030-nm laser pulses at the middle of the second substrate. Focusing laser pulses within the second glass in optical-contact and non-optical-contact samples induces permanent internal structural modification, leading to the three glass substrates bonding together simultaneously. The bonding mechanism is based on the internal modification of glass, and this mechanism is different from that of ordinary glass welding at the interface. Welding-spot size is affected by not only the gap distance (ablation effect) and heat transmission, but also by gravity through examining the sizes of the welding spots on the four contact welding surfaces. The maximum bonding strength of the lower interface (56.2 MPa) in the optical-contact regime is more than double that (27.6 MPa) in the non-optical-contact regime.

SIMS depth profiling of working environment nanoparticles

NASA Astrophysics Data System (ADS)

Konarski, P.; Iwanejko, I.; Mierzejewska, A.

2003-01-01

Morphology of working environment nanoparticles was analyzed using sample rotation technique in secondary ion mass spectrometry (SIMS). The particles were collected with nine-stage vacuum impactor during gas tungsten arc welding (GTAW) process of stainless steel and shielded metal arc welding (SMAW) of mild steel. Ion erosion of 300-400 nm diameter nanoparticles attached to indium substrate was performed with 2 keV, 100 μm diameter, Ar + ion beam at 45° ion incidence and 1 rpm sample rotation. The results show that both types of particles have core-shell morphology. A layer of fluorine, chlorine and carbon containing compounds covers stainless steel welding fume particles. The cores of these particles are enriched in iron, manganese and chromium. Outer shell of mild steel welding fume particles is enriched in carbon, potassium, chlorine and fluorine, while the deeper layers of these nanoparticles are richer in main steel components.

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

Klimenov, V. A., E-mail: klimenov@tpu.ru; National Research Tomsk Polytechnic University, 30 Lenin Av., Tomsk, 634050; Kurgan, K. A., E-mail: kirill-k2.777@mail.ru

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.

Use of eddy current mixes to solve a weld examination application

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

Ward, R.C.; LaBoissonniere, A.

1995-12-31

The augmentation of typical nondestructive (i.e., ultrasound) weld inspection techniques by the use of eddy current tools may significantly enhance the quality and reliability of weld inspections. One recent example is the development of an eddy current technique for use in the examination of BWR core shroud welds, where multi-frequency mixes are used to eliminate signals coming from the weld material so that the examination of the heat affected zone is enhanced. An analysis tool most commonly associated with ultrasound examinations, the C-Scan based on gated information, may be implemented with eddy current data to enhance analysis.

Weld defect identification in friction stir welding using power spectral density

NASA Astrophysics Data System (ADS)

Das, Bipul; Pal, Sukhomay; Bag, Swarup

2018-04-01

Power spectral density estimates are powerful in extraction of useful information retained in signal. In the current research work classical periodogram and Welch periodogram algorithms are used for the estimation of power spectral density for vertical force signal and transverse force signal acquired during friction stir welding process. The estimated spectral densities reveal notable insight in identification of defects in friction stir welded samples. It was observed that higher spectral density against each process signals is a key indication in identifying the presence of possible internal defects in the welded samples. The developed methodology can offer preliminary information regarding presence of internal defects in friction stir welded samples can be best accepted as first level of safeguard in monitoring the friction stir welding process.

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

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

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

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

75 FR 76025 - Stainless Steel Butt-Weld Pipe Fittings From Japan, Korea, and Taiwan

Federal Register 2010, 2011, 2012, 2013, 2014

2010-12-07

... INTERNATIONAL TRADE COMMISSION [Investigation Nos. 731-TA-376 and 563-564 (Third Review)] Stainless Steel Butt-Weld Pipe Fittings From Japan, Korea, and Taiwan AGENCY: United States International... steel butt-weld pipe fittings from Japan, Korea, and Taiwan would be likely to lead to continuation or...

The Yucca Mountain Project prototype air-coring test, U12g tunnel, Nevada test site

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

Ray, J.M.; Newsom, J.C.

1994-12-01

The Prototype Air-Coring Test was conducted at the Nevada Test Site (NTS) G-Tunnel facility to evaluate standard coring techniques, modified slightly for air circulation, for use in testing at a prospective nuclear waste repository at Yucca Mountain, Nevada. Air-coring technology allows sampling of subsurface lithology with minimal perturbation to ambient characteristic such as that required for exploratory holes near aquifers, environmental applications, and site characterization work. Two horizontal holes were cored, one 50 ft long and the other 150 ft long, in densely welded fractured tuff to simulate the difficult drilling conditions anticipated at Yucca Mountain. Drilling data from sevenmore » holes on three other prototype tests in nonwelded tuff were also collected for comparison. The test was used to establish preliminary standards of performance for drilling and dust collection equipment and to assess procedural efficiencies. The Longyear-38 drill achieved 97% recovery for HQ-size core (-2.5 in.), and the Atlas Copco dust collector (DCT-90) captured 1500 lb of fugitive dust in a mine environment with only minor modifications. Average hole production rates were 6-8 ft per 6-h shift in welded tuff and almost 20 ft per shift on deeper holes in nonwelded tuff. Lexan liners were successfully used to encapsulate core samples during the coring process and protect core properties effectively. The Prototype Air-Coring Test demonstrated that horizontal air coring in fractured welded tuff (to at least 150 ft) can be safely accomplished by proper selection, integration, and minor modification of standard drilling equipment, using appropriate procedures and engineering controls. The test also indicated that rig logistics, equipment, and methods need improvement before attempting a large-scale dry drilling program at Yucca Mountain.« less

A reliability analysis framework with Monte Carlo simulation for weld structure of crane's beam

NASA Astrophysics Data System (ADS)

Wang, Kefei; Xu, Hongwei; Qu, Fuzheng; Wang, Xin; Shi, Yanjun

2018-04-01

The reliability of the crane product in engineering is the core competitiveness of the product. This paper used Monte Carlo method analyzed the reliability of the weld metal structure of the bridge crane whose limit state function is mathematical expression. Then we obtained the minimum reliable welding feet height value for the welds between cover plate and web plate on main beam in different coefficients of variation. This paper provides a new idea and reference for the growth of the inherent reliability of crane.

Structural, mechanical and corrosion studies of Cr-rich inclusions in 152 cladding of dissimilar metal weld joint

NASA Astrophysics Data System (ADS)

Li, Yifeng; Wang, Jianqiu; Han, En-Hou; Yang, Chengdong

2018-01-01

Cr-rich inclusions were discovered in 152 cladding at the inner wall of domestic dissimilar metal weld joint, and their morphologies, microstructures, mechanical properties and corrosion behaviors were systematically characterized by SEM, TEM, nanoindentation and FIB. The results indicate that the Cr-rich inclusions originate from large-size Cr particles in 152 welding electrode flux, and they are 50-150 μm in size in most cases, and there is a continuous transition zone of 2-5 μm in width between the Cr inclusion core and 152 cladding matrix, and the transition zone consists of Ni & Fe-rich dendritic austenite and Cr23C6 and Cr matrix. The transition zone has the highest nanoindentation hardness (7.66 GPa), which is much harder than the inclusion core (5.14 GPa) and 152 cladding (3.71 GPa). In-situ microscopic tensile tests show that cracks initialize preferentially in transition zone, and then propagate into the inclusion core, and creep further into 152 cladding after penetrating the core area. The inclusion core and its transition zone both share similar oxide film structure with nickel-base 152 cladding matrix in simulated primary water, while those two parts present better general corrosion resistance than 152 cladding matrix due to higher Cr concentration.

Development of explosive welding procedures to fabricate channeled nozzle structures

NASA Technical Reports Server (NTRS)

Pattee, H. E.; Linse, V. D.

1976-01-01

Research was conducted to demonstrate the feasibility of fabricating a large contoured structure with complex internal channeling by explosive welding procedures. Structures or nozzles of this nature for wind tunnel applications were designed. Such nozzles vary widely in their complexity. However, in their simplest form, they consist of a grooved base section to which a cover sheet is attached to form a series of internal cooling passages. The cover sheet attachment can be accomplished in various ways: fusion welding, brazing, and diffusion welding. The cover sheet has also been electroformed in place. Of these fabrication methods, brazing has proved most successful in producing nozzles with complex contoured surfaces and a multiplicity of internal channels.

Optimization of cladding parameters for resisting corrosion on low carbon steels using simulated annealing algorithm

NASA Astrophysics Data System (ADS)

Balan, A. V.; Shivasankaran, N.; Magibalan, S.

2018-04-01

Low carbon steels used in chemical industries are frequently affected by corrosion. Cladding is a surfacing process used for depositing a thick layer of filler metal in a highly corrosive materials to achieve corrosion resistance. Flux cored arc welding (FCAW) is preferred in cladding process due to its augmented efficiency and higher deposition rate. In this cladding process, the effect of corrosion can be minimized by controlling the output responses such as minimizing dilution, penetration and maximizing bead width, reinforcement and ferrite number. This paper deals with the multi-objective optimization of flux cored arc welding responses by controlling the process parameters such as wire feed rate, welding speed, Nozzle to plate distance, welding gun angle for super duplex stainless steel material using simulated annealing technique. Regression equation has been developed and validated using ANOVA technique. The multi-objective optimization of weld bead parameters was carried out using simulated annealing to obtain optimum bead geometry for reducing corrosion. The potentiodynamic polarization test reveals the balanced formation of fine particles of ferrite and autenite content with desensitized nature of the microstructure in the optimized clad bead.

75 FR 70908 - Circular Welded Austenitic Stainless Pressure Pipe From the People's Republic of China: Extension...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-11-19

... DEPARTMENT OF COMMERCE International Trade Administration [A-570-930] Circular Welded Austenitic... Results of the Antidumping Duty Administrative Review AGENCY: Import Administration, International Trade... Farlander and Patrick O'Connor, AD/CVD Operations, Import Administration, International Trade Administration...

Contrasting styles of welding observed in the proximal Askja 1875 eruption deposits II: Local welding

NASA Astrophysics Data System (ADS)

Carey, R. J.; Houghton, B. F.; Thordarson, T.

2008-03-01

As an alternative to classical welding models of fall deposits due to the progressive accumulation of hot tephra which then weld, we describe here welded deposits on the northern 1875 caldera rim of Askja volcano that have welded due to the influence of hot, discrete spatter bombs impacting into and supplying heat to a halo of surrounding tephra. This style of welding we term 'local welding' in contrast to 'regional welding' which is described elsewhere [Carey, R.J., Houghton, B.F., Thordarson, T., 2008. Contrasting styles of welding observed in the proximal Askja 1875 eruption deposits I: Regional welding. J. Volcanol. Geotherm. Res. 171, 1-19. doi:10.1016/j.jvolgeores.2007.11.020]. Locally welded deposits are associated with the rhyolitic Plinian phase of the 1875 eruption of Askja volcano. Two distinct welding units (W1 and W2) are interbedded with Plinian fall on the northern caldera rim, and grade outwards to weakly dispersed non-welded fall. Spatter bombs are found in both welding units but vary in their characteristic sizes and internal features. In the W1 unit simple bombs with homogeneous internal characteristics up to ˜ 60 cm in diameter are found. In the W2 unit, large discrete spatter bombs with complex internal features range up to 9 m in diameter. We describe here two case studies showing the effects of a) single small spatter bombs; b) multiple small spatter bombs and c) large discrete spatter bombs varying in size. Vertical and lateral profiles through welding zones reveal that the primary controls on local welding are the availability of supplied or added heat and the loading capacity of the spatter bomb. Local welding grades are much higher than that of regional welding, as the combined effects of heat, compaction and insulation can provide suitable conditions which lead to dense welding and, proximal to the spatter bomb, rheomorphic flowage. If heating and loading exceed the critical requirement for welding, porosity loss via matrix welding and vesicle collapse occurs to a point where further strain must be accommodated as shearing and ductile flowage. The spatter bombs are found only within the weakly dispersed welding units and are the final erupted products of each fountaining phase. Their low viscosities are evident by their deformation on impact and fluidal forms, and hold some important clues to eruption dynamics in the shallow conduit and vent regions.

Ceramic backup ring prevents undesirable weld-metal buildup

NASA Technical Reports Server (NTRS)

Leonard, G. E.

1971-01-01

Removable ceramic backup material butted against weld zone back prevents weld metal buildup at that site. Method is successful with manual tungsten-inert gas /TIG/ welding of 316 corrosion resistant steel /CRES/ pieces with 0.76 cm throat diameter and 1.57 cm pipe internal diameter.

Arc Welding Dictionary 2. Project HIRE.

ERIC Educational Resources Information Center

Gardner, David C.; And Others

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

Microstructure, Pitting Corrosion Resistance and Impact Toughness of Duplex Stainless Steel Underwater Dry Hyperbaric Flux-Cored Arc Welds

PubMed Central

Hu, Yu; Shen, Xiao-Qin; Wang, Zhong-Min

2017-01-01

Duplex stainless steel multi-pass welds were made at 0.15 MPa, 0.45 MPa, and 0.75 MPa pressure, simulating underwater dry hyperbaric welding by the flux-cored arc welding (FCAW) method, with welds of normal pressure as a benchmark. The purpose of this work was to estimate the effect of ambient pressure on the microstructure, pitting corrosion resistance and impact toughness of the weld metal. The microstructure measurement revealed that the ferrite content in the weld metal made at 0.45 MPa is the lowest, followed by that of 0.75 MPa and 0.15 MPa. The analysis of potentiodynamic polarization tests at 30 °C and 50 °C demonstrated that the pitting corrosion resistance depends on the phases of the lower pitting resistance equivalent numbers (PREN), secondary austenite and ferrite. The weld metal made at 0.45 MPa had the best resistance to pitting corrosion at 30 °C and 50 °C with the highest PRENs of secondary austenite and ferrite. The weld metal made at 0.15 MPa displayed the lowest pitting corrosion resistance at 30 °C with the lowest PREN of secondary austenite, while the weld metal made at 0.75 MPa was the most seriously eroded after being tested at 50 °C for the lowest PREN of ferrite, with large cluster pits seen in ferrite at 50 °C. The impact tests displayed a typical ductile-brittle transition because of the body-centered cubic (BCC) structure of the ferrite when the test temperature was lowered. All the weld metals met the required value of 34 J at −40 °C according to the ASTM A923. The highest ferrite content corresponded to the worst impact toughness, but the highest toughness value did not correspond to the greatest austenite content. With the decreasing of the test temperature, the drop value of absorbed energy was correlated to the ferrite content. Additionally, in this work, the weld metal made at 0.45 MPa had the best combined properties of pitting resistance and impact toughness. PMID:29258262

Microstructure, Pitting Corrosion Resistance and Impact Toughness of Duplex Stainless Steel Underwater Dry Hyperbaric Flux-Cored Arc Welds.

PubMed

Hu, Yu; Shi, Yong-Hua; Shen, Xiao-Qin; Wang, Zhong-Min

2017-12-18

Duplex stainless steel multi-pass welds were made at 0.15 MPa, 0.45 MPa, and 0.75 MPa pressure, simulating underwater dry hyperbaric welding by the flux-cored arc welding (FCAW) method, with welds of normal pressure as a benchmark. The purpose of this work was to estimate the effect of ambient pressure on the microstructure, pitting corrosion resistance and impact toughness of the weld metal. The microstructure measurement revealed that the ferrite content in the weld metal made at 0.45 MPa is the lowest, followed by that of 0.75 MPa and 0.15 MPa. The analysis of potentiodynamic polarization tests at 30 °C and 50 °C demonstrated that the pitting corrosion resistance depends on the phases of the lower pitting resistance equivalent numbers (PREN), secondary austenite and ferrite. The weld metal made at 0.45 MPa had the best resistance to pitting corrosion at 30 °C and 50 °C with the highest PRENs of secondary austenite and ferrite. The weld metal made at 0.15 MPa displayed the lowest pitting corrosion resistance at 30 °C with the lowest PREN of secondary austenite, while the weld metal made at 0.75 MPa was the most seriously eroded after being tested at 50 °C for the lowest PREN of ferrite, with large cluster pits seen in ferrite at 50 °C. The impact tests displayed a typical ductile-brittle transition because of the body-centered cubic (BCC) structure of the ferrite when the test temperature was lowered. All the weld metals met the required value of 34 J at -40 °C according to the ASTM A923. The highest ferrite content corresponded to the worst impact toughness, but the highest toughness value did not correspond to the greatest austenite content. With the decreasing of the test temperature, the drop value of absorbed energy was correlated to the ferrite content. Additionally, in this work, the weld metal made at 0.45 MPa had the best combined properties of pitting resistance and impact toughness.

76 FR 4633 - Carbon Steel Butt-Weld Pipe Fittings From the People's Republic of China: Notice of Court...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-01-26

... DEPARTMENT OF COMMERCE International Trade Administration [A-570-814] Carbon Steel Butt-Weld Pipe..., International Trade Administration, Department of Commerce. SUMMARY: On January 6, 2011, the United States Court of International Trade (``CIT'') sustained the Department of Commerce's (``the Department'') results...

Effects of welding heat and travel speed on the impact property and microstructure of FC welds

NASA Astrophysics Data System (ADS)

Lee, Jeong Soo; Jeong, Sang Hoon; Lim, Dong Yong; Yun, Jin Oh; Kim, Myung Hyun

2010-10-01

This paper is concerned with the effects of welding heat (current x voltage = W) and travel speed (v) on the impact property and microstructure of FC (flux cored) welds. Two sets of plate were welded under different welding conditions such as higher W, v and lower W, v, while maintaining identical heat input. We evaluated the effects of each factor by Charpy impact test and observation of the microstructure, and then compared these data with the results of the numerical temperature analysis. The size of the re-heated zone was increased as the v value decreased, and the results of numerical analysis also revealed the same tendency. Cooling rate of welds (both of as-welded and re-heated zones) decreased as the W value increased. Despite identical heat input conditions, the use of lower W and v made the microstructure finer and increased the volume fraction of AF, thereby leading to a substantial improvement of the impact property.

75 FR 62366 - Circular Welded Carbon Steel Pipes and Tubes From Taiwan: Final Results of Antidumping Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-10-08

... DEPARTMENT OF COMMERCE International Trade Administration [A-583-008] Circular Welded Carbon Steel... antidumping duty order on circular welded carbon steel pipes and tubes from Taiwan. See Preliminary Results of Antidumping Duty Administrative Review: Circular Welded Carbon Steel [[Page 62367

Heat exchanger tube mounts

DOEpatents

Wolowodiuk, W.; Anelli, J.; Dawson, B.E.

1974-01-01

A heat exchanger in which tubes are secured to a tube sheet by internal bore welding is described. The tubes may be moved into place in preparation for welding with comparatively little trouble. A number of segmented tube support plates are provided which allow a considerable portion of each of the tubes to be moved laterally after the end thereof has been positioned in preparation for internal bore welding to the tube sheet. (auth)

49 CFR 195.106 - Internal design pressure.

Code of Federal Regulations, 2013 CFR

2013-10-01

... temperature higher than 900 °F (482 °C) for any period of time or over 600 °F (316 °C) for more than 1 hour... 1.00 Electric resistance welded 1.00 Furnace lap welded 0.80 Furnace butt welded 0.60 ASTM A106... 1.00 API 5L Seamless 1.00 Electric resistance welded 1.00 Electric flash welded 1.00 Submerged arc...

77 FR 5240 - Light-Walled Welded Rectangular Carbon Steel Tubing From Taiwan: Continuation of Antidumping Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-02-02

... DEPARTMENT OF COMMERCE International Trade Administration [A-583-803] Light-Walled Welded... revocation of the antidumping duty order on light-walled welded rectangular carbon steel tubing from Taiwan..., and the ITC instituted, the sunset review of the antidumping duty order \\1\\ on light-walled welded...

77 FR 24459 - Stainless Steel Butt-Weld Pipe Fittings From Italy: Final Results of Antidumping Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-04-24

... CR, of wrought austenitic stainless steel fittings of seamless and welded construction covered by the... DEPARTMENT OF COMMERCE International Trade Administration [A-475-828] Stainless Steel Butt-Weld... administrative review of the antidumping duty order on stainless steel butt-weld pipe fittings (SSBW pipe...

75 FR 63439 - Certain Welded Carbon Steel Standard Pipes and Tubes From India: Extension of the Final Results...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-10-15

... DEPARTMENT OF COMMERCE International Trade Administration [A-533-502] Certain Welded Carbon Steel... or (202) 482-1690, respectively. SUPPLEMENTARY INFORMATION: Background On June 14, 2010, the... antidumping duty order on certain welded carbon steel standard pipes and tubes from India. See Certain Welded...

Critical Initial Flaw Size Analysis

NASA Technical Reports Server (NTRS)

Dawicke, David S.; Raju, Ivatury S.; Cheston, Derrick J.

2008-01-01

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The USS consists of several "tuna can" segments that are approximately 216 inches in diameter, 115 inches tall, and 0.5 inches thick. A 6 inch wide by 1 inch thick flange is welded to the skin and is used to fasten adjacent tuna cans. A schematic of a "tuna can" and the location of the flange-to-skin weld are shown in Figure 1. Gussets (shown in yellow in Figure 1) are welded to the skin and flange every 10 degrees around the circumference of the "tuna can". The flange-to-skin weld is a flux core butt weld with a fillet weld on the inside surface, as illustrated in Figure 2. The welding process may create loss of fusion defects in the weld that could develop into fatigue cracks and jeopardize the structural integrity of the Ares I-X vehicle. The CIFS analysis was conducted to determine the largest crack in the weld region that will not grow to failure within 4 lifetimes, as specified by NASA standard 5001 & 5019 [1].

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

NASA Astrophysics Data System (ADS)

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

2010-07-01

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

73rd American Welding Society annual meeting

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

Not Available

1992-01-01

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

75 FR 69626 - Certain Welded Carbon Steel Standard Pipes and Tubes From India: Final Results of Antidumping...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-11-15

... DEPARTMENT OF COMMERCE International Trade Administration [A-533-502] Certain Welded Carbon Steel... order on certain welded carbon steel standard pipes and tubes from India. The period of review is May 1... carbon steel standard pipes and tubes from India. See Certain Welded Carbon Steel Standard Pipes and...

Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes.

PubMed

Sivapirakasam, S P; Mohan, Sreejith; Santhosh Kumar, M C; Thomas Paul, Ashley; Surianarayanan, M

2017-04-01

Background Cr(VI) is a suspected human carcinogen formed as a by-product of stainless steel welding. Nano-alumina and nano-titania coating of electrodes reduced the welding fume levels. Objective To investigate the effect of nano-coating of welding electrodes on Cr(VI) formation rate (Cr(VI) FR) from a shielded metal arc welding process. Methods The core welding wires were coated with nano-alumina and nano-titania using the sol-gel dip coating technique. Bead-on plate welds were deposited on SS 316 LN plates kept inside a fume test chamber. Cr(VI) analysis was done using an atomic absorption spectrometer (AAS). Results A reduction of 40% and 76%, respectively, in the Cr(VI) FR was observed from nano-alumina and nano-titania coated electrodes. Increase in the fume level decreased the Cr(VI) FR. Discussion Increase in fume levels blocked the UV radiation responsible for the formation of ozone thereby preventing the formation of Cr(VI).

Development of a Constitutive Model Predicting the Point of Short-Circuit Within Lithium-Ion Battery Cells

DTIC Science & Technology

2012-06-01

polyolefin layer, typically polypropylene or polyethylene. The separator keeps the anodic and cathodic layers from touching. An internal short-circuit is...be seen that there are both spot welds and laser welds are used in the construction of the individual cylindrical cell. When constructing larger...manufacturing, to include resistance welding, laser welding, ultrasonic welding, and mechanical joining are detailed in Shawn Lee, S., et al(2010) (9

Brittle crack arrestability of thick steel plate welds in large structure

NASA Astrophysics Data System (ADS)

An, Gyu Baek; Park, Joon Sik

2011-10-01

Recently, there has been such a critical issue in shipbuilding industry that much larger and stronger ships are required to develop oil and gas in the Arctic region. Attention has been paid to obtaining high strength, good toughness at low temperature, and good weldability. An experimental study was performed to evaluate the brittle crack arrest toughness value (Kca) and brittle crack arrest method of welded joints using EH40 grade steel with a thickness of 80 mm. The test specimens were made by both flux cored arc welding (FCAW) and combined welding (EGW+FCAW) processes. Temperature gradient ESSO test was performed to measure the Kca of the base metal. Also, a constant temperature (-10 °C) ESSO test was performed to establish a brittle crack arrest method using high toughness welding consumable with real structural specimens. The research aims in this study were to investigate the effect of joint design and welding consumable for the crack arrestability of thick steel plates using EH40 grade shipbuilding steel of straight block joint weld line with two kinds of welding processes.

Application of the Mathar Method to Identify Internal Stress Variation in Steel as a Welding Process Result

NASA Astrophysics Data System (ADS)

Kowalski, Dariusz

2017-06-01

The paper deals with the method to identify internal stresses in two-dimensional steel members. Steel members were investigated in the delivery stage and after assembly, by means of electric-arc welding. In order to perform the member assessment two methods to identify the stress variation were applied. The first is a non-destructive measurement method employing local external magnetic field and to detecting the induced voltage, including Barkhausen noise The analysis of the latter allows to assess internal stresses in a surface layer of the material. The second method, essential in the paper, is a semi-trepanation Mathar method of tensometric strain variation measurement in the course of a controlled void-making in the material. Variation of internal stress distribution in the material led to the choice of welding technology to join. The assembly process altered the actual stresses and made up new stresses, triggering post-welding stresses as a response for the excessive stress variation.

Profiling mild steel welding processes to reduce fume emissions and costs in the workplace.

PubMed

Keane, Michael J; Siert, Arlen; Chen, Bean T; Stone, Samuel G

2014-05-01

To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMAW) and flux-cored arc-welding (FCAW) processes were also profiled. The fumes were collected quantitatively in an American Welding Society-type fume chamber and weighed, recovered, homogenized, and analyzed by inductively coupled atomic emission spectroscopy for total metals. The processes included GMAW with short circuit, globular transfer, axial spray, pulsed spray, Surface Tension Transfer™, Regulated Metal Deposition™, and Cold Metal Transfer™ (CMT) modes. Flux-cored welding was gas shielded, and SMAW was a single rod type. Results indicate a wide range of fume emission factors for the process variations studied. Fume emission rates per gram of electrode consumed were highest for SMAW (~13 mg fume g(-1) electrode) and lowest for GMAW processes such as pulsed spray (~1.5mg g(-1)) and CMT (~1mg g(-1)). Manganese emission rates per gram of electrode consumed ranged from 0.45 mg g(-1) (SMAW) to 0.08 mg g(-1) (CMT). Nickel emission rates were generally low and ranged from ~0.09 (GMAW short circuit) to 0.004 mg g(-1) (CMT). Iron emission rates ranged from 3.7 (spray-mode GMAW) to 0.49 mg g(-1) (CMT). The processes studied have significantly different costs, and cost factors are presented based on a case study to allow comparisons between processes in specific cost categories. Costs per linear meter of weld were $31.07 (SMAW), $12.37 (GMAW short circuit), and $10.89 (FCAW). Although no single process is the best for minimizing fume emissions and costs while satisfying the weld requirements, there are several processes that can minimize emissions. This study provides information to aid in those choices. Suggestions for overcoming barriers to utilizing new and less hazardous welding processes are also discussed.

Profiling Mild Steel Welding Processes to Reduce Fume Emissions and Costs in the Workplace

PubMed Central

Keane, Michael J.; Siert, Arlen; Chen, Bean T.; Stone, Samuel G.

2015-01-01

To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMAW) and flux-cored arc-welding (FCAW) processes were also profiled. The fumes were collected quantitatively in an American Welding Society-type fume chamber and weighed, recovered, homogenized, and analyzed by inductively coupled atomic emission spectroscopy for total metals. The processes included GMAW with short circuit, globular transfer, axial spray, pulsed spray, Surface Tension Transfer™, Regulated Metal Deposition™, and Cold Metal Transfer™ (CMT) modes. Flux-cored welding was gas shielded, and SMAW was a single rod type. Results indicate a wide range of fume emission factors for the process variations studied. Fume emission rates per gram of electrode consumed were highest for SMAW (~13 mg fume g−1 electrode) and lowest for GMAW processes such as pulsed spray (~1.5 mg g−1) and CMT (~1 mg g−1). Manganese emission rates per gram of electrode consumed ranged from 0.45 mg g−1 (SMAW) to 0.08 mg g−1 (CMT). Nickel emission rates were generally low and ranged from ~0.09 (GMAW short circuit) to 0.004 mg g−1 (CMT). Iron emission rates ranged from 3.7 (spray-mode GMAW) to 0.49 mg g−1 (CMT). The processes studied have significantly different costs, and cost factors are presented based on a case study to allow comparisons between processes in specific cost categories. Costs per linear meter of weld were $31.07 (SMAW), $12.37 (GMAW short circuit), and $10.89 (FCAW). Although no single process is the best for minimizing fume emissions and costs while satisfying the weld requirements, there are several processes that can minimize emissions. This study provides information to aid in those choices. Suggestions for overcoming barriers to utilizing new and less hazardous welding processes are also discussed. PMID:24515891

Friction Stir Welding of Thick Section Aluminum for Military Vehicle Applications

DTIC Science & Technology

2012-12-01

Friction Stir Welding of Thick Section Aluminum for Military Vehicle Applications by Brian Thompson, Kevin Doherty, Craig Niese, Mike Eff...International Symposium on Friction Stir Welding (9ISFSW), Huntsville, AL, 15–17 May 2012. Approved for public release...Aberdeen Proving Ground, MD 21005-5069 ARL-RP-417 December 2012 Friction Stir Welding of Thick Section Aluminum for Military

Hybrid Welding of 45 mm High Strength Steel Sections

NASA Astrophysics Data System (ADS)

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

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

78 FR 70069 - Circular Welded Carbon-Quality Steel Pipe From China

Federal Register 2010, 2011, 2012, 2013, 2014

2013-11-22

... INTERNATIONAL TRADE COMMISSION [Investigation Nos. 701-TA-447 and 731-TA-1116 (Review)] Circular Welded Carbon-Quality Steel Pipe From China Determination On the basis of the record \\1\\ developed in the subject five-year reviews, the United States International Trade Commission (Commission) determines...

77 FR 65712 - Circular Welded Carbon-Quality Steel Pipe From Vietnam; Termination of Investigation

Federal Register 2010, 2011, 2012, 2013, 2014

2012-10-30

... INTERNATIONAL TRADE COMMISSION [Investigation No. 701-TA-485 (Final)] Circular Welded Carbon-Quality Steel Pipe From Vietnam; Termination of Investigation AGENCY: United States International Trade... carbon-quality steel pipe from Vietnam (investigation No. 701-TA-485 (Final)) is terminated. DATES...

Continuous internal channels formed in aluminum fusion welds

NASA Technical Reports Server (NTRS)

Gault, J.; Sabo, W.

1967-01-01

Process produces continuous internal channel systems on a repeatable basis in 2014-T6 aluminum. Standard machining forms the initial channel, which is filled with tungsten carbide powder. TIG machine fusion welding completes formation of the channel. Chem-mill techniques enlarge it to the desired size.

Thermomechanically coupled conduction mode laser welding simulations using smoothed particle hydrodynamics

NASA Astrophysics Data System (ADS)

Hu, Haoyue; Eberhard, Peter

2017-10-01

Process simulations of conduction mode laser welding are performed using the meshless Lagrangian smoothed particle hydrodynamics (SPH) method. The solid phase is modeled based on the governing equations in thermoelasticity. For the liquid phase, surface tension effects are taken into account to simulate the melt flow in the weld pool, including the Marangoni force caused by a temperature-dependent surface tension gradient. A non-isothermal solid-liquid phase transition with the release or absorption of additional energy known as the latent heat of fusion is considered. The major heat transfer through conduction is modeled, whereas heat convection and radiation are neglected. The energy input from the laser beam is modeled as a Gaussian heat source acting on the initial material surface. The developed model is implemented in Pasimodo. Numerical results obtained with the model are presented for laser spot welding and seam welding of aluminum and iron. The change of process parameters like welding speed and laser power, and their effects on weld dimensions are investigated. Furthermore, simulations may be useful to obtain the threshold for deep penetration welding and to assess the overall welding quality. A scalability and performance analysis of the implemented SPH algorithm in Pasimodo is run in a shared memory environment. The analysis reveals the potential of large welding simulations on multi-core machines.

77 FR 18266 - Stainless Steel Butt-Weld Pipe Fittings From Italy, Malaysia, and the Philippines; Revised...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-03-27

... INTERNATIONAL TRADE COMMISSION [Investigation Nos. 731-TA-865-867 (Second Review)] Stainless Steel Butt-Weld Pipe Fittings From Italy, Malaysia, and the Philippines; Revised Schedule for the Subject Reviews AGENCY: United States International Trade Commission. ACTION: Notice. DATES: Effective Date: March...

76 FR 64312 - Light-Walled Welded Rectangular Carbon Steel Tubing From Taiwan: Final Results of the Expedited...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-10-18

... DEPARTMENT OF COMMERCE International Trade Administration [A-583-803] Light-Walled Welded... Duty Order AGENCY: Import Administration, International Trade Administration, Department of Commerce. SUMMARY: On July 1, 2011, the Department of Commerce (the Department) initiated the third sunset review of...

Fatigue properties of dissimilar metal laser welded lap joints

NASA Astrophysics Data System (ADS)

Dinsley, Christopher Paul

This work involves laser welding austenitic and duplex stainless steel to zinc-coated mild steel, more specifically 1.2mm V1437, which is a Volvo Truck Coiporation rephosphorised mild steel. The work investigates both tensile and lap shear properties of similar and dissimilar metal laser welded butt and lap joints, with the majority of the investigation concentrating on the fatigue properties of dissimilar metal laser welded lap joints. The problems encountered when laser welding zinc-coated steel are addressed and overcome with regard to dissimilar metal lap joints with stainless steel. The result being the production of a set of guidelines for laser welding stainless steel to zinc-coated mild steel. The stages of laser welded lap joint fatigue life are defined and the factors affecting dissimilar metal laser welded lap joint fatigue properties are analysed and determined; the findings suggesting that dissimilar metal lap joint fatigue properties are primarily controlled by the local stress at the internal lap face and the early crack growth rate of the material at the internal lap face. The lap joint rotation, in turn, is controlled by sheet thickness, weld width and interfacial gap. Laser welded lap joint fatigue properties are found to be independent of base material properties, allowing dissimilar metal lap joints to be produced without fatigue failure occurring preferentially in the weaker parent material, irrespective of large base material property differences. The effects of Marangoni flow on the compositions of the laser weld beads are experimentally characterised. The results providing definite proof of the stirring mechanism within the weld pool through the use of speeds maps for chromium and nickel. Keywords: Laser welding, dissimilar metal, Zinc-coated mild steel, Austenitic stainless steel, Duplex stainless steel, Fatigue, Lap joint rotation, Automotive.

Profiling stainless steel welding processes to reduce fume emissions, hexavalent chromium emissions and operating costs in the workplace

PubMed Central

Keane, Michael; Siert, Arlen; Stone, Samuel; Chen, Bean T.

2016-01-01

Nine gas metal arc welding (GMAW) processes for stainless steel were assessed for fume generation rates, fume generation rates per g of electrode consumed, and emission rates for hexavalent chromium (Cr6+). Elemental manganese, nickel, chromium, iron emissions per unit length of weld and labor plus consumables costs were similarly measured. Flux-cored arc welding and shielded metal arc (SMAW) processes were also studied. The objective was to identify the best welding processes for reducing workplace exposures, and estimate costs for all processes. Using a conical chamber, fumes were collected, weighed, recovered and analyzed by inductively-coupled atomic emission spectroscopy for metals, and by ion chromatography for Cr6+. GMAW processes used were Surface Tension Transfer™, Regulated Metal Deposition™, Cold Metal Transfer™, short-circuit, axial spray, and pulsed spray modes. Flux-cored welding used gas shielding; SMAW used E308 rods. Costs were estimated as dollars per m length of a ¼ in (6.3 mm) thick horizontal butt weld; equipment costs were estimated as ratios of new equipment costs to a 250 ampere capacity SMAW welding machine. Results indicate a broad range of fume emission factors for the processes studied. Fume emission rates per g of electrode were lowest for GMAW processes such as pulsed-spray mode (0.2 mg/g), and highest for SMAW (8 mg fume/g electrode). Emission rates of Cr6+ ranged from 50 to 7800 μg/min, and Cr6+ generation rates per g electrode ranged from 1 to 270μg/g. Elemental Cr generation rates spanned 13 to 330μg/g. Manganese emission rates ranged from 50 to 300μg/g. Nickel emission rates ranged from 4 to140 μg/g. Labor and consumables costs ranged from $3.15 (GMAW pulsed spray) to $7.40 (SMAW) per meter of finished weld, and were measured or estimated for all 11 processes tested. Equipment costs for some processes may be as much as 5 times the cost of a typical SMAW welding machine. The results show that all of the GMAW processes in this study can substantially reduce fume, Cr6+, manganese and costs relative to SMAW, the most commonly used welding process, and several have exceptional capabilities for reducing emissions. PMID:26267301

Profiling stainless steel welding processes to reduce fume emissions, hexavalent chromium emissions and operating costs in the workplace.

PubMed

Keane, Michael; Siert, Arlen; Stone, Samuel; Chen, Bean T

2016-01-01

Nine gas metal arc welding (GMAW) processes for stainless steel were assessed for fume generation rates, fume generation rates per g of electrode consumed, and emission rates for hexavalent chromium (Cr(6+)). Elemental manganese, nickel, chromium, iron emissions per unit length of weld, and labor plus consumables costs were similarly measured. Flux-cored arc welding and shielded metal arc (SMAW) processes were also studied. The objective was to identify the best welding processes for reducing workplace exposures, and estimate costs for all processes. Using a conical chamber, fumes were collected, weighed, recovered, and analyzed by inductively coupled atomic emission spectroscopy for metals, and by ion chromatography for Cr(6+). GMAW processes used were Surface Tension Transfer, Regulated Metal Deposition, Cold Metal Transfer, short-circuit, axial spray, and pulsed spray modes. Flux-cored welding used gas shielding; SMAW used E308 rods. Costs were estimated as dollars per m length of a ¼ in (6.3 mm) thick horizontal butt weld; equipment costs were estimated as ratios of new equipment costs to a 250 ampere capacity SMAW welding machine. Results indicate a broad range of fume emission factors for the processes studied. Fume emission rates per g of electrode were lowest for GMAW processes such as pulsed-spray mode (0.2 mg/g), and highest for SMAW (8 mg fume/g electrode). Emission rates of Cr(6+) ranged from 50-7800 µg/min, and Cr(6+) generation rates per g electrode ranged from 1-270 µg/g. Elemental Cr generation rates spanned 13-330 µg/g. Manganese emission rates ranged from 50-300 µg/g. Nickel emission rates ranged from 4-140 µg/g. Labor and consumables costs ranged from $3.15 (GMAW pulsed spray) to $7.40 (SMAW) per meter of finished weld, and were measured or estimated for all 11 processes tested. Equipment costs for some processes may be as much as five times the cost of a typical SMAW welding machine. The results show that all of the GMAW processes in this study can substantially reduce fume, Cr(6+), manganese and costs relative to SMAW, the most commonly used welding process, and several have exceptional capabilities for reducing emissions.

78 FR 31574 - Welded Stainless Steel Pressure Pipe From Malaysia, Thailand, and Vietnam; Institution of...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-05-24

... INTERNATIONAL TRADE COMMISSION [Investigation Nos. 731-TA-1210-1212 (Preliminary)] Welded Stainless Steel Pressure Pipe From Malaysia, Thailand, and Vietnam; Institution of Antidumping Duty..., by reason of imports from Malaysia, Thailand, and Vietnam of welded stainless steel pressure pipe...

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

NASA Astrophysics Data System (ADS)

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

2011-01-01

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

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

NASA Astrophysics Data System (ADS)

Durocher, J.; Richards, N. L.

2011-10-01

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

Experimental assessment of the influence of welding process parameters on Lamb wave transmission across ultrasonically welded thermoplastic composite joints

NASA Astrophysics Data System (ADS)

Ochôa, Pedro; Fernandez Villegas, Irene; Groves, Roger M.; Benedictus, Rinze

2018-01-01

One of the advantages of thermoplastic composites relative to their thermoset counterparts is the possibility of assembling components through welding. Ultrasonic welding in particular is very promising for industrialization. However, uncertainty in the fatigue and fracture behaviour of composites is still an obstacle to the full utilisation of these materials. Health monitoring is then of vital importance, and Lamb wave techniques have been widely recognised as some of the most promising approaches for that end. This paper presents the first experimental study about the influence of welding travel on the transmission of Lamb waves across ultrasonically welded thermoplastic composite joints in single-lap configuration. The main aim of this research is to start to understand how guided waves interact with the internal structure of ultrasonic welds, so that benign, manufacturing-related structural features can be distinguished from damaging ones in signal interpretation. The power transmission coefficient and the correlation coefficient proved to be suitable for analysing the wave propagation phenomena, allowing quantitative identification of small variations of weld-line thickness and intermolecular diffusion at the weld interface. The conclusions are used to develop a tentative damage detection criterion which can later on assist the design of a Lamb wave based structural health monitoring system for thermoplastic composite structures. The Lamb wave test results are backed up by phased-array inspections, which also provide some extra insight on the internal structure of ultrasonic welds.

Tool simplifies machining of pipe ends for precision welding

NASA Technical Reports Server (NTRS)

Matus, S. T.

1969-01-01

Single tool prepares a pipe end for precision welding by simultaneously performing internal machining, end facing, and bevel cutting to specification standards. The machining operation requires only one milling adjustment, can be performed quickly, and produces the high quality pipe-end configurations required to ensure precision-welded joints.

76 FR 9608 - Certain Welded Large Diameter Line Pipe From Mexico

Federal Register 2010, 2011, 2012, 2013, 2014

2011-02-18

... Large Diameter Line Pipe From Mexico AGENCY: United States International Trade Commission. ACTION... duty order on certain welded large diameter line pipe from Mexico. For further information concerning... welded large diameter line pipe from Mexico would not be likely to lead to continuation or recurrence of...

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

PubMed

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

2014-12-01

Welding fumes contain various toxic metals including chromium (Cr), nickel (Ni) and manganese (Mn). An assessment of the risk to health of local and systemic exposure to welding fumes requires the assessment of both external and internal doses. The aims of this study were to test the relevance in small and medium sized enterprises of a biomonitoring strategy based on urine spot-samples, to characterize the factors influencing the internal doses of metals in gas metal arc welders and to recommend effective risk management measures. 137 welders were recruited and urinary levels of metals were measured by ICP-MS on post-shift samples collected at the end of the working week. Cr, Ni and Mn mean concentrations (respectively 0.43, 1.69 and 0.27 μg/g creatinine) were well below occupational health guidance values, but still higher than background levels observed in the general population, confirming the absorption of metals generated in welding fumes. Both welding parameters (nature of base metal, welding technique) and working conditions (confinement, welding and grinding durations, mechanical ventilation and welding experience) were predictive of occupational exposure. Our results confirm the interest of biomonitoring for assessing health risks and recommending risk management measures for welders. Copyright © 2014. Published by Elsevier Ireland Ltd.

76 FR 78887 - Circular Welded Carbon Quality Steel Pipe From the People's Republic of China: Rescission of...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-12-20

... DEPARTMENT OF COMMERCE International Trade Administration [C-570-911] Circular Welded Carbon Quality Steel Pipe From the People's Republic of China: Rescission of Countervailing Duty Administrative Review AGENCY: Import Administration, International Trade Administration, Department of Commerce. DATES: Effective Date: December 20, 2011. FOR...

75 FR 71672 - Circular Welded Carbon Quality Steel Pipe From the People's Republic of China: Rescission of...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-11-24

... DEPARTMENT OF COMMERCE International Trade Administration [C-570-911] Circular Welded Carbon Quality Steel Pipe From the People's Republic of China: Rescission of Countervailing Duty Administrative Review AGENCY: Import Administration, International Trade Administration, Department of Commerce. DATES: Effective Date: November 24, 2010. FOR...

77 FR 19623 - Certain Welded Carbon Steel Standard Pipe from Turkey: Preliminary Results of Countervailing Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-04-02

... International Financial Statistics, a publication of the International Monetary Fund (IMF). For Euro-denominated... The Social Security Institution of the GOT administers the incentive for the Employer's Share in... certain welded carbon steel standard pipe from Turkey for the period January 1, 2010, through December 31...

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.

Impact of different welding techniques on biological effect markers in exhaled breath condensate of 58 mild steel welders.

PubMed

Hoffmeyer, Frank; Raulf-Heimsoth, Monika; Lehnert, Martin; Kendzia, Benjamin; Bernard, Sabine; Berresheim, Hans; Düser, Maria; Henry, Jana; Weiss, Tobias; Koch, Holger M; Pesch, Beate; Brüning, Thomas

2012-01-01

Total mass and composition of welding fumes are predominantly dependent on the welding technique and welding wire applied. The objective of this study was to investigate the impact of welding techniques on biological effect markers in exhaled breath condensate (EBC) of 58 healthy welders. The welding techniques applied were gas metal arc welding with solid wire (GMAW) (n=29) or flux cored wire (FCAW) (n=29). Welding fume particles were collected with personal samplers in the breathing zone inside the helmets. Levels of leukotriene B(4) (LTB(4)), prostaglandin E(2) (PGE(2)), and 8-isoprostane (8-iso-PGF(2α)) were measured with immunoassay kits and the EBC pH was measured after deaeration. Significantly higher 8-iso-PGF(2α) concentrations and a less acid pH were detected in EBC of welders using the FCAW than in EBC of welders using the GMAW technique. The lowest LTB(4) concentrations were measured in nonsmoking welders applying a solid wire. No significant influences were found in EBC concentrations of PGE(2) based upon smoking status or type of welding technique. This study suggests an enhanced irritative effect in the lower airways of mild steel welders due to the application of FCAW compared to GMAW, most likely associated with a higher emission of welding fumes.

10-kW-class YAG laser application for heavy components

NASA Astrophysics Data System (ADS)

Ishide, Takashi; Tsubota, S.; Nayama, Michisuke; Shimokusu, Yoshiaki; Nagashima, Tadashi; Okimura, K.

2000-02-01

The authors have put the YAG laser of the kW class to practical use for repair welding of nuclear power plant steam generator heat exchanger tubes, all-position welding of pipings, etc. This paper describes following developed methods and systems of high power YAG laser processing. First, we apply the 6 kW to 10 kW YAG lasers for welding and cutting in heavy components. The beam guide systems we have used are optical fibers which core diameter is 0.6 mm to 0.8 mm and its length is 200 m as standard one. Using these system, we can get the 1 pass penetration of 15 mm to 20 mm and multi pass welding for more thick plates. Cutting of 100 mm thickness plate data also described for dismantling of nuclear power plants. In these systems we carried out the in-process monitoring by using CCD camera image processing and monitoring fiber which placed coaxial to the YAG optical lens system. In- process monitoring by the monitoring fiber, we measured the light intensity from welding area. Further, we have developed new hybrid welding with the TIG electrode at the center of lens for high power. The hybrid welding with TIG-YAG system aims lightening of welding groove allowances and welding of high quality. Through these techniques we have applied 7 kW class YAG laser for welding in the components of nuclear power plants.

Monitoring of chromium and nickel in biological fluids of stainless steel welders using the flux-cored-wire (FCW) welding method.

PubMed

Stridsklev, Inger Cecilie; Schaller, Karl-Heinz; Langård, Sverre

2004-11-01

This study was undertaken to investigate the exposure to chromium (Cr) and nickel (Ni) in flux-cored wire (FCW) welders welding on stainless steel (SS). Seven FCW welders were monitored for 3 days to 1 workweek, measuring Cr and Ni in air, blood, and urine. The welders were questioned about exposure to Cr and Ni during their whole working careers, with emphasis on the week of monitoring, about the use of personal protective equipment and their smoking habits. The air concentrations were mean 200 microg/m(3) (range 2.4-2,744) for total Cr, 11.3 microg/m(3) (<0.2-151.3) for Cr(VI), and 50.4 microg/m(3) (<2.0-416.7) for Ni during the workdays for the five welders who were monitored with air measurements. The levels of Cr and Ni in biological fluids varied between different workplaces. For Cr in whole blood, plasma, and erythrocytes, the mean levels after work were 1.25 (<0.4-8.3) and 1.68 (<0.2-8.0) and 0.9 (<0.4-7.2) microg/l, respectively. For Ni most of the measurements in whole blood and plasma were below the detection limits, the mean levels after work being 0.84 (<0.8-3.3) and 0.57 microg/l (<0.4-1.7), respectively. Mean levels for Cr and Ni in the urine after work were 3.96 (0.34-40.7) and 2.50 (0.56-5.0) microg/g creatinine, respectively. Correlations between the Cr(VI) levels measured in air and the levels of total Cr in the measured biological fluids were found. The results seem to support the view that monitoring of Cr in the urine may be versatile for indirect monitoring of the Cr(VI) air level in FCW welders. The results seem to suggest that external and internal exposure to Cr and Ni in FCW welders welding SS is low in general.

77 FR 42697 - Stainless Steel Butt-Weld Pipe Fittings From Italy, Malaysia, and the Philippines: Continuation...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-07-20

...] Stainless Steel Butt-Weld Pipe Fittings From Italy, Malaysia, and the Philippines: Continuation of.... International Trade Commission that revocation of the antidumping duty orders on stainless steel butt-weld pipe... from Italy, Malaysia, and the Philippines.\\2\\ \\1\\ See Antidumping Duty Orders: Stainless Steel Butt...

77 FR 39735 - Stainless Steel Butt-Weld Pipe Fittings From Italy, Malaysia, and the Philippines

Federal Register 2010, 2011, 2012, 2013, 2014

2012-07-05

... revocation of the antidumping duty orders on stainless steel butt-weld pipe fittings From Italy, Malaysia... INTERNATIONAL TRADE COMMISSION [Investigation Nos. 731-TA-865-867 (Second Review)] Stainless Steel Butt-Weld Pipe Fittings From Italy, Malaysia, and the Philippines Determination On the basis of the...

76 FR 67146 - Stainless Steel Butt-Weld Pipe Fittings From Italy; Extension of Time Limit for Preliminary...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-10-31

... DEPARTMENT OF COMMERCE International Trade Administration [A-475-828] Stainless Steel Butt-Weld... antidumping duty order on stainless steel butt-weld pipe fittings from Italy in the Federal Register. See... preliminary results of this review within the original time frame because it needs to obtain additional...

Improving cylinder-type LiFePO4 battery performance via control of internal resistance

NASA Astrophysics Data System (ADS)

Purwanto, Agus; Jumari, Arif; Nizam, Muhammad; Widiyandari, Hendri; Sudaryanto; Deswita; Azmin Mohamad, Ahmad

2018-04-01

Strategies for controlling the internal resistance to improve battery performance were systematically investigated. Electrode densification of LiFePO4 cathodes significantly reduced the internal resistance of the prepared batteries. Densification by reduction to 31.25% of initial thickness resulted in optimal electrochemical performance of the prepared LiFePO4 batteries. The addition of KS 6 graphite material improved the conductivity of the cathodes, which was indicated by a lowering of the internal resistance. The internal resistance was decreased from 73 to 54 when the KS6/AB ratio was varied from 3 to 1. Another factor in controlling the internal resistance was the location of a welded aluminum tab in the cathode. The welding of an aluminum tab in a small gap in the cathode significantly reduced the internal resistance. Thus, three main factors can be performed during fabrication to reduce the internal resistance of a LiFePO4 battery: cathode densification, KS-6 graphite addition, and the arrangement of an aluminum tab welded to the cathode. By optimizing these factors, high-performance LFP batteries were produced.

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

NASA Astrophysics Data System (ADS)

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

2010-11-01

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

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

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

Ghosh, D.

1995-02-01

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

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

NASA Astrophysics Data System (ADS)

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

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

Moving, Moving, Moving- A Giant Rocket Fuel Tank

NASA Image and Video Library

2016-10-07

Technicians moved a giant fuel tank from the Vertical Assembly Center where the tank recently completed friction stir welding to an adjacent work area at NASA's Michoud Assembly Facility in New Orleans. More than 1.7 miles of welds have been completed for core stage hardware at Michoud. This liquid hydrogen fuel tank is the largest piece of the core stage that will provide the fuel for the first flight of NASA's new rocket, the Space Launch System, with the Orion spacecraft in 2018. The tank is more than 130 feet long, and together with the liquid oxygen tank holds 733,000 gallons of propellant to feed the vehicle's four RS-25 engines to produce a total of 2 million pounds of thrust. SLS will have the power and capacity to carry humans to Mars. For more information on the core stage: http://www.nasa.gov/exploration/syste... Video Credit: NASA/MAF/Eric Bordelon

Method and device for frictional welding

DOEpatents

Peacock, H.B.

1991-01-01

A method for friction welding that produces a seal having essentially no gas porosity, comprises two rotationally symmetric, generally cylindrical members, spaced apart and coaxially aligned, that are rotated with respect to each other and brought together under high pressure. One member is preferably a generally cylindrical cannister that stores uranium within its hollow walls. The other member is preferably a generally cylindrical, hollow weld ring. An annular channel formed in the weld ring functions as an internal flash trap and is uniquely designed so that substantially all of the welding flash generated from the friction welding is directed into the channel`s recessed bottom. Also, the channel design limits distortion of the two members during the friction welding, process, further contributing to the complete seal that is obtained.

Method and device for frictional welding

DOEpatents

Peacock, Harold B.

1992-01-01

A method for friction welding that produces a seal having essentially no gas porosity, comprises two rotationally symmetric, generally cylindrical members, spaced apart and coaxially aligned, that are rotated with respect to each other and brought together under high pressure. One member is preferably a generally cylindrical cannister that stores uranium within its hollow walls. The other member is preferably a generally cylindrical, hollow weld ring. An annular channel formed in the weld ring functions as an internal flash trap and is uniquely designed so that substantially all of the welding flash generated from the friction welding is directed into the channel's recessed bottom. Also, the channel design limits distortion of the two members during the friction welding process, further contributing to the complete seal that is obtained.

Investigation of dissimilar metal welds by energy-resolved neutron imaging.

PubMed

Tremsin, Anton S; Ganguly, Supriyo; Meco, Sonia M; Pardal, Goncalo R; Shinohara, Takenao; Feller, W Bruce

2016-08-01

A nondestructive study of the internal structure and compositional gradient of dissimilar metal-alloy welds through energy-resolved neutron imaging is described in this paper. The ability of neutrons to penetrate thick metal objects (up to several cm) provides a unique possibility to examine samples which are opaque to other conventional techniques. The presence of Bragg edges in the measured neutron transmission spectra can be used to characterize the internal residual strain within the samples and some microstructural features, e.g. texture within the grains, while neutron resonance absorption provides the possibility to map the degree of uniformity in mixing of the participating alloys and intermetallic formation within the welds. In addition, voids and other defects can be revealed by the variation of neutron attenuation across the samples. This paper demonstrates the potential of neutron energy-resolved imaging to measure all these characteristics simultaneously in a single experiment with sub-mm spatial resolution. Two dissimilar alloy welds are used in this study: Al autogenously laser welded to steel, and Ti gas metal arc welded (GMAW) to stainless steel using Cu as a filler alloy. The cold metal transfer variant of the GMAW process was used in joining the Ti to the stainless steel in order to minimize the heat input. The distributions of the lattice parameter and texture variation in these welds as well as the presence of voids and defects in the melt region are mapped across the welds. The depth of the thermal front in the Al-steel weld is clearly resolved and could be used to optimize the welding process. A highly textured structure is revealed in the Ti to stainless steel joint where copper was used as a filler wire. The limited diffusion of Ti into the weld region is also verified by the resonance absorption.

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

DTIC Science & Technology

2003-01-01

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

INTERNAL REPAIR OF PIPELINES

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

Robin Gordon; Bill Bruce; Ian Harris

2004-04-12

The two broad categories of deposited weld metal repair and fiber-reinforced composite liner repair technologies were reviewed for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Preliminary test programs were developed for both deposited weld metal repair and for fiber-reinforced composite liner repair. Evaluation trials have been conducted using a modified fiber-reinforced composite liner provided by RolaTube and pipe sections without liners. All pipe section specimens failed in areas of simulated damage. Pipe sections containing fiber-reinforcedmore » composite liners failed at pressures marginally greater than the pipe sections without liners. The next step is to evaluate a liner material with a modulus of elasticity approximately 95% of the modulus of elasticity for steel. Preliminary welding parameters were developed for deposited weld metal repair in preparation of the receipt of Pacific Gas & Electric's internal pipeline welding repair system (that was designed specifically for 559 mm (22 in.) diameter pipe) and the receipt of 559 mm (22 in.) pipe sections from Panhandle Eastern. The next steps are to transfer welding parameters to the PG&E system and to pressure test repaired pipe sections to failure. A survey of pipeline operators was conducted to better understand the needs and performance requirements of the natural gas transmission industry regarding internal repair. Completed surveys contained the following principal conclusions: (1) Use of internal weld repair is most attractive for river crossings, under other bodies of water, in difficult soil conditions, under highways, under congested intersections, and under railway crossings. (2) Internal pipe repair offers a strong potential advantage to the high cost of horizontal direct drilling (HDD) when a new bore must be created to solve a leak or other problem. (3) Typical travel distances can be divided into three distinct groups: up to 305 m (1,000 ft.); between 305 m and 610 m (1,000 ft. and 2,000 ft.); and beyond 914 m (3,000 ft.). All three groups require pig-based systems. A despooled umbilical system would suffice for the first two groups which represents 81% of survey respondents. The third group would require an onboard self-contained power unit for propulsion and welding/liner repair energy needs. (4) Pipe diameter sizes range from 50.8 mm (2 in.) through 1,219.2 mm (48 in.). The most common size range for 80% to 90% of operators surveyed is 508 mm to 762 mm (20 in. to 30 in.), with 95% using 558.8 mm (22 in.) pipe. An evaluation of potential repair methods clearly indicates that the project should continue to focus on the development of a repair process involving the use of GMAW welding and on the development of a repair process involving the use of fiber-reinforced composite liners.« less

75 FR 1335 - Circular Welded Carbon Steel Pipes and Tubes from Taiwan; Extension of Time Limit for Preliminary...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-01-11

... DEPARTMENT OF COMMERCE International Trade Administration [A-583-008] Circular Welded Carbon Steel... review of the antidumping duty order on circular welded carbon steel pipes and tubes from Taiwan.\\1\\ On... review within the original time frame because we require additional time to obtain information from the...

77 FR 2511 - Certain Welded Carbon Steel Pipe and Tube From Turkey: Extension of Time Limit for Preliminary...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-01-18

... DEPARTMENT OF COMMERCE International Trade Administration [A-489-501] Certain Welded Carbon Steel Pipe and Tube From Turkey: Extension of Time Limit for Preliminary Results of Antidumping Duty... certain welded carbon steel pipe and tube from Turkey covering the period May 1, 2010, through April 30...

76 FR 3083 - Certain Welded Carbon Steel Pipe and Tube From Turkey: Extension of Time Limit for Preliminary...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-01-19

... DEPARTMENT OF COMMERCE International Trade Administration [A-489-501] Certain Welded Carbon Steel Pipe and Tube From Turkey: Extension of Time Limit for Preliminary Results of Antidumping Duty... welded carbon steel pipe and tube from Turkey covering the period May 1, 2009, through April 30, 2010...

75 FR 3896 - Certain Welded Carbon Steel Pipe and Tube from Turkey: Extension of Time Limit for Preliminary...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-01-25

... DEPARTMENT OF COMMERCE International Trade Administration [A-489-501] Certain Welded Carbon Steel Pipe and Tube from Turkey: Extension of Time Limit for Preliminary Results of Antidumping Duty... antidumping duty order on certain welded carbon steel pipe and tube from Turkey covering the period May 1...

Microstructure Evolution and Selective Corrosion Resistance in Underwater Multi-pass 2101 Duplex Stainless Steel Welding Joints

NASA Astrophysics Data System (ADS)

Hu, Yu; Shi, Yonghua; Shen, Xiaoqin; Wang, Zhongmin

2018-05-01

A recently developed promising material, 2101 lean duplex stainless steel, represents an alternative to 304 austenite stainless steel. In this work, multi-pass 2101 weld joints were fabricated using the flux-cored arc welding method in a hyperbaric chamber. The pressure varied from 0 to 0.75 MPa. The evolution of the welding process and microstructure was investigated. γ 2 formation in the reheated zones of the WM and HAZ was not uniform. The closer the reheated zone is to the subsequent heat source, the greater the γ 2 formation in the reheated zone. Sufficient primary austenite transformation inhibited Cr2N precipitation and the subsequent intragranular γ 2 formation in the reheated weld passes of the 0.45 MPa weld metal. The localized corrosion resistance of each zone of the 0.45 MPa DSS joint was measured using non-destructive double-loop electrochemical potentiokinetic reactivation tests. The localized corrosion was induced by γ 2 and Cr2N. The root region of the 0.45 MPa weld metal underwent two subsequent welding thermal cycles, which induced increased γ 2 formation and lower resistance to corrosion because of the decreased pitting resistance value of γ 2. The correlation between microstructure evolution and the distribution of selective corrosion was determined.

Evaluating the Properties of Dissimilar Metal Welding Between Inconel 625 and 316L Stainless Steel by Applying Different Welding Methods and Consumables

NASA Astrophysics Data System (ADS)

Kourdani, Ahmad; Derakhshandeh-Haghighi, Reza

2018-04-01

The current work was carried out to characterize welding of Inconel 625 superalloy and 316L stainless steel. In the present study, shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW) with two types of filler metals (ERNiCrMo-3 and ERSS316L) and an electrode (ENiCrMo-3) were utilized. This paper describes the selection of the proper welding method and welding consumables in dissimilar metal joining. During solidification of ERNiCrMo-3 filler metal, Nb and Mo leave dendritic cores and are rejected to inter-dendritic regions. However, ERSS316L filler metal has small amounts of elements with a high tendency for segregation. So, occurrence of constitutional super-cooling for changing the solidification mode from cellular to dendritic or equiaxed is less probable. Using GTAW with lower heat input results in higher cooling rate and finer microstructure and less Nb segregation. The interface between weld metal and base metal and also unmixed zones was evaluated by scanning electron microscopy and energy dispersive X-ray (EDX) analysis. Microhardness measurements, tensile test, and Charpy impact test were performed to see the effect of these parameters on mechanical properties of the joints.

Influences of Cr/Ni equivalent ratios of filler wires on pitting corrosion and ductility-dip cracking of AISI 316L weld metals

NASA Astrophysics Data System (ADS)

Kim, Y. H.; Kim, D. G.; Sung, J. H.; Kim, I. S.; Ko, D. E.; Kang, N. H.; Hong, H. U.; Park, J. H.; Lee, H. W.

2011-02-01

To study the pitting corrosion of AISI 316L weld metals according to the chromium/nickel equivalent ratio (Creq/Nieq ratio), three filler wires were newly designed for the flux-cored arc welding process. The weld metal with delta-ferrite at less than 3 vol.%, was observed for ductility-dip cracking (DDC) in the reheated region after multi-pass welding. The tensile strength and yield strength increased with increasing Creq/Nieq ratio. The result of anodic polarization tests in a 0.1 M NaCl solution at the room temperature (25) for 45 min, revealed that the base metal and weld metals have a similar corrosion potential of -0.34 VSCE. The weld metal with the highest content of Cr had the highest pitting potential (0.39 VSCE) and the passivation range (0.64 VSCE) was higher than the base metal (0.21 VSCE and 0.46 VSCE, respectively). Adding 0.001 M Na2S to the 0.1M NaCl solution, the corrosion occurred more severely by H2S. The corrosion potentials of the base metal and three weld metals decreased to -1.0 VSCE. DDC caused the decrease of the pitting potential by inducing a locally intense corrosion attack around the crack openings.

A Comparative Study of Welded ODS Cladding materials for AFCI/GNEP Applications

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

Indrajit Charit; Megan Frary; Darryl Butt

2011-03-31

This research project involved working on the pressure resistance welding of oxide dispersion strengthened (ODS) alloys which will have a large role to play in advanced nuclear reactors. The project also demonstrated the research collaboration between four universities and one nation laboratory (Idaho National Laboratory) with participation from an industry for developing for ODS alloys. These alloys contain a high number density of very fine oxide particles that can impart high temperature strength and radiation damage resistance suitable for in-core applications in advanced reactors. The conventional fusion welding techniques tend to produce porosity-laden microstructure in the weld region and leadmore » to the agglomeration and non-uniform distribution of the neededoxide particles. That is why two solid state welding methods - pressure resistance welding (PRW) and friction stir welding (FSW) - were chosen to be evaluated in this project. The proposal is expected to support the development of Advanced Burner Reactors (ABR) under the GNEP program (now incorporated in Fuel Cycle R&D program). The outcomes of the concluded research include training of graduate and undergraduate students and get them interested in nuclear related research.« less

Exposure to Inhalable, Respirable, and Ultrafine Particles in Welding Fume

PubMed Central

Pesch, Beate

2012-01-01

This investigation aims to explore determinants of exposure to particle size-specific welding fume. Area sampling of ultrafine particles (UFP) was performed at 33 worksites in parallel with the collection of respirable particles. Personal sampling of respirable and inhalable particles was carried out in the breathing zone of 241 welders. Median mass concentrations were 2.48 mg m−3 for inhalable and 1.29 mg m−3 for respirable particles when excluding 26 users of powered air-purifying respirators (PAPRs). Mass concentrations were highest when flux-cored arc welding (FCAW) with gas was applied (median of inhalable particles: 11.6 mg m−3). Measurements of particles were frequently below the limit of detection (LOD), especially inside PAPRs or during tungsten inert gas welding (TIG). However, TIG generated a high number of small particles, including UFP. We imputed measurements

Exposure to inhalable, respirable, and ultrafine particles in welding fume.

PubMed

Lehnert, Martin; Pesch, Beate; Lotz, Anne; Pelzer, Johannes; Kendzia, Benjamin; Gawrych, Katarzyna; Heinze, Evelyn; Van Gelder, Rainer; Punkenburg, Ewald; Weiss, Tobias; Mattenklott, Markus; Hahn, Jens-Uwe; Möhlmann, Carsten; Berges, Markus; Hartwig, Andrea; Brüning, Thomas

2012-07-01

This investigation aims to explore determinants of exposure to particle size-specific welding fume. Area sampling of ultrafine particles (UFP) was performed at 33 worksites in parallel with the collection of respirable particles. Personal sampling of respirable and inhalable particles was carried out in the breathing zone of 241 welders. Median mass concentrations were 2.48 mg m(-3) for inhalable and 1.29 mg m(-3) for respirable particles when excluding 26 users of powered air-purifying respirators (PAPRs). Mass concentrations were highest when flux-cored arc welding (FCAW) with gas was applied (median of inhalable particles: 11.6 mg m(-3)). Measurements of particles were frequently below the limit of detection (LOD), especially inside PAPRs or during tungsten inert gas welding (TIG). However, TIG generated a high number of small particles, including UFP. We imputed measurements

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

NASA Astrophysics Data System (ADS)

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

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

Novel low-cost vision-sensing technology with controllable of exposal time for welding

NASA Astrophysics Data System (ADS)

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

2005-02-01

In the process of robot Welding, position of welding seam and welding pool shape is detected by CCD camera for quality control and seam tracking in real-time. It is difficult to always get a clear welding image in some welding methods, such as TIG welding. A novel idea that the exposal time of CCD camera is automatically controlled by arc voltage or arc luminance is proposed to get clear welding image. A set of special device and circuits are added to a common industrial CCD camera in order to flexibly control the CCD to start or close exposal by control of the internal clearing signal of the accumulated charge. Two special vision sensors according to the idea are developed. Their exposal grabbing can be triggered respectively by the arc voltage and the variety of the arc luminance. Two prototypes have been designed and manufactured. Experiments show that they can stably grab clear welding images at appointed moment, which is a basic for the feedback control of automatic welding.

Friction Welding For Cladding Applications: Processing, Microstructure and Mechanical Properties of Inertia Friction Welds of Stainless Steel to Low Carbon Steel and Evaluation of Wrought and Welded Austenitic Stainless Steels for Cladding Applications in Acidchloride Service

NASA Astrophysics Data System (ADS)

Switzner, Nathan

Friction welding, a solid-state joining method, is presented as a novel alternative process step for lining mild steel pipe and forged components internally with a corrosion resistant (CR) metal alloy for petrochemical applications. Currently, fusion welding is commonly used for stainless steel overlay cladding, but this method is costly, time-consuming, and can lead to disbonding in service due to a hard martensite layer that forms at the interface due to partial mixing at the interface between the stainless steel CR metal and the mild steel base. Firstly, the process parameter space was explored for inertia friction butt welding using AISI type 304L stainless steel and AISI 1018 steel to determine the microstructure and mechanical properties effects. A conceptual model for heat flux density versus radial location at the faying surface was developed with consideration for non-uniform pressure distribution due to frictional forces. An existing 1 D analytical model for longitudinal transient temperature distribution was modified for the dissimilar metals case and to account for material lost to the flash. Microstructural results from the experimental dissimilar friction welds of 304L stainless steel to 1018 steel were used to discuss model validity. Secondly, the microstructure and mechanical property implications were considered for replacing the current fusion weld cladding processes with friction welding. The nominal friction weld exhibited a smaller heat softened zone in the 1018 steel than the fusion cladding. As determined by longitudinal tensile tests across the bond line, the nominal friction weld had higher strength, but lower apparent ductility, than the fusion welds due to the geometric requirements for neck formation adjacent to a rigid interface. Martensite was identified at the dissimilar friction weld interface, but the thickness was smaller than that of the fusion welds, and the morphology was discontinuous due to formation by a mechanism of solid-state mixing. Thirdly, the corrosion resistance of multiple austenitic stainless steels (types 304, 316, and 309) processed in varying ways was compared for acid chloride environments using advanced electrochemical techniques. Physical simulation of fusion claddings and friction weld claddings (wrought stainless steels) was used for sample preparation to determine compositional and microstructural effects. Pitting resistance correlated firstly with Cr content, with N and Mo additions providing additional benefits. The high ferrite fraction of as-welded samples reduced their corrosion resistance. Wrought type 309L outperformed as-welded type 309L in dissolved mass loss and reverse corrosion rate from the potentiodynamic scan in 1.0 N HCl/3.5% NaCl solution. Electrochemical impedance results indicated that wrought 309L and 316L developed a corrosion resistant passive film more rapidly than other alloys in 0.1 N HCl/3.5% NaCl, and also performed well in long term (160-day) corrosion testing in the same environment. Fourthly, to prove the concept of internal CR lining by friction welding, a conical work piece of 304L stainless steel was friction welded internally to 1018 steel.

Method and device for frictional welding

DOEpatents

Peacock, H.B.

1992-10-13

A method is described for friction welding that produces a seal having essentially no gas porosity, comprises two rotationally symmetric, generally cylindrical members, spaced apart and coaxially aligned, that are rotated with respect to each other and brought together under high pressure. One member is preferably a generally cylindrical canister that stores uranium within its hollow walls. The other member is preferably a generally cylindrical, hollow weld ring. An annular channel formed in the weld ring functions as an internal flash trap and is uniquely designed so that substantially all of the welding flash generated from the friction welding is directed into the channel's recessed bottom. Also, the channel design limits distortion of the two members during the friction welding process, further contributing to the complete seal that is obtained. 5 figs.

Robotic and automatic welding development at the Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

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

1988-01-01

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

77 FR 48965 - Certain Carbon Steel Butt-Weld Pipe Fittings From the People's Republic of China: Notice of Court...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-08-15

... DEPARTMENT OF COMMERCE International Trade Administration [A-570-814] Certain Carbon Steel Butt... scope of the Order \\1\\ as excluding carbon steel butt-weld pipe fittings from the People's Republic of... Carbon Steel Butt-Weld Pipe Fittings From the People's Republic of China, 57 FR 29702 (July 6, 1992...

78 FR 12784 - Welded Large Diameter Line Pipe From Japan; Scheduling of a Full Five-Year Review Concerning the...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-02-25

... Diameter Line Pipe From Japan; Scheduling of a Full Five-Year Review Concerning the Antidumping Duty Order on Welded Large Diameter Line Pipe From Japan AGENCY: United States International Trade Commission... revocation of the antidumping duty order on welded large diameter line pipe from Japan would be likely to...

Effect of Cr Contents and Heat Treating on Reverted Austenite in Maraging Steel Weldments

NASA Astrophysics Data System (ADS)

Kim, S. W.; Lee, H. W.

2018-05-01

By conducting flux cored arc welding (FCAW) on maraging steels with Cr contents of 1.4 and 5.2 wt%, this study observed the effects of Cr content and heat treating on reverted austenite formation in welded maraging steel. Aging treatment was carried out at the temperatures of 450, 480 and 530 °C for 3 h in each condition. As the aging temperature increased, reverted austenite was formed along the interdendritic and intercellular grain boundaries, and the proportion of reverted austenite increased with increasing Cr addition. The aging process led to the segregation of Ti and Mo along the interdendritic and intercellular grain boundaries. Some of the welded specimens were subjected to solution heat treatment at 820 and 1250 °C for 1 h after welding, resulting in a decrease in reverted austenite fraction.

Effect of Cr Contents and Heat Treating on Reverted Austenite in Maraging Steel Weldments

NASA Astrophysics Data System (ADS)

Kim, S. W.; Lee, H. W.

2018-03-01

By conducting flux cored arc welding (FCAW) on maraging steels with Cr contents of 1.4 and 5.2 wt%, this study observed the effects of Cr content and heat treating on reverted austenite formation in welded maraging steel. Aging treatment was carried out at the temperatures of 450, 480 and 530 °C for 3 h in each condition. As the aging temperature increased, reverted austenite was formed along the interdendritic and intercellular grain boundaries, and the proportion of reverted austenite increased with increasing Cr addition. The aging process led to the segregation of Ti and Mo along the interdendritic and intercellular grain boundaries. Some of the welded specimens were subjected to solution heat treatment at 820 and 1250 °C for 1 h after welding, resulting in a decrease in reverted austenite fraction.

LC and ferromagnetic resonance in soft/hard magnetic microwires

NASA Astrophysics Data System (ADS)

Tian, Bin; Vazquez, Manuel

2015-12-01

The magnetic behavior of soft/hard biphase microwires is introduced here. The microwires consist of a Co59.1Fe14.8Si10.2B15.9 soft magnetic nucleus and a Co90Ni10 hard outer shell separated by an intermediate insulating Pyrex glass microtube. By comparing the resistance spectrums of welding the ends of metallic core (CC) or welding the metallic core and outer shell (CS) to the connector, it is found that one of the two peaks in the resistance spectrum is because the LC resonance depends on the inductor and capacitors in which one is the capacitor between the metallic core and outer shell, and the other is between the outer shell and connector. Correspondingly, another peak is for the ferromagnetic resonance of metallic core. After changing the capacitance of the capacitors, the frequency of LC resonance moves to high frequency band, and furthermore, the peak of LC resonance in the resistance spectrum disappeared. These magnetostatically coupled biphase systems are thought to be of large potential interest as sensing elements in sensor devices.

In-Situ Welding Carbon Nanotubes into a Porous Solid with Super-High Compressive Strength and Fatigue Resistance

PubMed Central

Lin, Zhiqiang; Gui, Xuchun; Gan, Qiming; Chen, Wenjun; Cheng, Xiaoping; Liu, Ming; Zhu, Yuan; Yang, Yanbing; Cao, Anyuan; Tang, Zikang

2015-01-01

Carbon nanotube (CNT) and graphene-based sponges and aerogels have an isotropic porous structure and their mechanical strength and stability are relatively lower. Here, we present a junction-welding approach to fabricate porous CNT solids in which all CNTs are coated and welded in situ by an amorphous carbon layer, forming an integral three-dimensional scaffold with fixed joints. The resulting CNT solids are robust, yet still highly porous and compressible, with compressive strengths up to 72 MPa, flexural strengths up to 33 MPa, and fatigue resistance (recovery after 100,000 large-strain compression cycles at high frequency). Significant enhancement of mechanical properties is attributed to the welding-induced interconnection and reinforcement of structural units, and synergistic effects stemming from the core-shell microstructures consisting of a flexible CNT framework and a rigid amorphous carbon shell. Our results provide a simple and effective method to manufacture high-strength porous materials by nanoscale welding. PMID:26067176

In-Situ Welding Carbon Nanotubes into a Porous Solid with Super-High Compressive Strength and Fatigue Resistance.

PubMed

Lin, Zhiqiang; Gui, Xuchun; Gan, Qiming; Chen, Wenjun; Cheng, Xiaoping; Liu, Ming; Zhu, Yuan; Yang, Yanbing; Cao, Anyuan; Tang, Zikang

2015-06-11

Carbon nanotube (CNT) and graphene-based sponges and aerogels have an isotropic porous structure and their mechanical strength and stability are relatively lower. Here, we present a junction-welding approach to fabricate porous CNT solids in which all CNTs are coated and welded in situ by an amorphous carbon layer, forming an integral three-dimensional scaffold with fixed joints. The resulting CNT solids are robust, yet still highly porous and compressible, with compressive strengths up to 72 MPa, flexural strengths up to 33 MPa, and fatigue resistance (recovery after 100,000 large-strain compression cycles at high frequency). Significant enhancement of mechanical properties is attributed to the welding-induced interconnection and reinforcement of structural units, and synergistic effects stemming from the core-shell microstructures consisting of a flexible CNT framework and a rigid amorphous carbon shell. Our results provide a simple and effective method to manufacture high-strength porous materials by nanoscale welding.

In-Situ Welding Carbon Nanotubes into a Porous Solid with Super-High Compressive Strength and Fatigue Resistance

NASA Astrophysics Data System (ADS)

Lin, Zhiqiang; Gui, Xuchun; Gan, Qiming; Chen, Wenjun; Cheng, Xiaoping; Liu, Ming; Zhu, Yuan; Yang, Yanbing; Cao, Anyuan; Tang, Zikang

2015-06-01

Carbon nanotube (CNT) and graphene-based sponges and aerogels have an isotropic porous structure and their mechanical strength and stability are relatively lower. Here, we present a junction-welding approach to fabricate porous CNT solids in which all CNTs are coated and welded in situ by an amorphous carbon layer, forming an integral three-dimensional scaffold with fixed joints. The resulting CNT solids are robust, yet still highly porous and compressible, with compressive strengths up to 72 MPa, flexural strengths up to 33 MPa, and fatigue resistance (recovery after 100,000 large-strain compression cycles at high frequency). Significant enhancement of mechanical properties is attributed to the welding-induced interconnection and reinforcement of structural units, and synergistic effects stemming from the core-shell microstructures consisting of a flexible CNT framework and a rigid amorphous carbon shell. Our results provide a simple and effective method to manufacture high-strength porous materials by nanoscale welding.

Evaluation of Training Samples Manually Welded With the Universal Handtool in a Space Simulation Chamber

NASA Technical Reports Server (NTRS)

Russell, C. K.; Malone, T. W.; Cato, S. N.

2004-01-01

The international space welding experiment was designed to evaluate the universal handtool (UHT) functions as a welding, brazing, coating, and cutting tool for in-space operations. The UHT is an electron beam welding system developed by the Paton Welding Institute (PWI), Kiev, Ukraine, and operated a 8 kV with up to 1 kW of power. In preparation for conducting the space welding experiment, cosmonauts were trained to properly operate the UHT and correctly process samples. This Technical Memorandum presents the results of the destructive and nondestructive evaluation of the training samples made in Russia in 1998. It was concluded that acceptable welds can be made with the UHT despite the constraints imposed by a space suit. The lap joint fillet weld configuration was more suitable than the butt joint configuration for operators with limited welding experience. The tube braze joint configuration designed by the PWI was easily brazed in a repeatable manner.

HEAT INPUT AND POST WELD HEAT TREATMENT EFFECTS ON REDUCED-ACTIVATION FERRITIC/MARTENSITIC STEEL FRICTION STIR WELDS

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

Tang, Wei; Chen, Gaoqiang; Chen, Jian

Reduced-activation ferritic/martensitic (RAFM) steels are an important class of structural materials for fusion reactor internals developed in recent years because of their improved irradiation resistance. However, they can suffer from welding induced property degradations. In this paper, a solid phase joining technology friction stir welding (FSW) was adopted to join a RAFM steel Eurofer 97 and different FSW parameters/heat input were chosen to produce welds. FSW response parameters, joint microstructures and microhardness were investigated to reveal relationships among welding heat input, weld structure characterization and mechanical properties. In general, FSW heat input results in high hardness inside the stir zonemore » mostly due to a martensitic transformation. It is possible to produce friction stir welds similar to but not with exactly the same base metal hardness when using low power input because of other hardening mechanisms. Further, post weld heat treatment (PWHT) is a very effective way to reduce FSW stir zone hardness values.« less

Transient calcite fracture fillings in a welded tuff, Snowshoe Mountain, Colorado

USGS Publications Warehouse

Hoch, A.R.; Reddy, M.M.; Heymans, M.J.

2000-01-01

The core from two boreholes (13.1 and 19.2 m depth) drilled 500 m apart in the fractured, welded tuff near the summit of the Snowshoe Mountain, Colorado (47??30'N, 106??55'W) had unique petrographic and hydrodynamic properties. Borehole SM-4 had highly variable annual water levels, in contrast to SM-1a, whose water level remained near the land surface. Core samples from both boreholes (n = 10 and 11) were examined petrographically in thin sections impregnated with epoxy containing rhodamine to mark the pore system features, and were analyzed for matrix porosity and permeability. Core from the borehole sampling the vadose zone was characterized by open fractures with enhanced porosity around phenocrysts due to chemical weathering. Fractures within the borehole sampling the phreatic zone were mineralized with calcite and had porosity characteristics similar to Unweathered and unfractured rock. At the top of the phreatic zone petrography indicates that calcite is dissolving, thereby changing the hydrogeochemical character of the rock (i.e. permeability, porosity, reactive surface area, and mineralogy). Radiocarbon ages and C and O stable isotopes indicate that calcite mineralization occurred about 30 to 40 ka ago and that there was more than one mineralization event. Results of this study also provide some relationships between primary porosity development from 3 types of fracture in a welded tuff. (C) 2000 Elsevier Science Ltd.

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

NASA Technical Reports Server (NTRS)

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

1984-01-01

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

Fabrication of Aluminum Tubes Filled with Aluminum Alloy Foam by Friction Welding.

PubMed

Hangai, Yoshihiko; Nakano, Yukiko; Koyama, Shinji; Kuwazuru, Osamu; Kitahara, Soichiro; Yoshikawa, Nobuhiro

2015-10-23

Aluminum foam is usually used as the core of composite materials by combining it with dense materials, such as in Al foam core sandwich panels and Al-foam-filled tubes, owing to its low tensile and bending strengths. In this study, all-Al foam-filled tubes consisting of ADC12 Al-Si-Cu die-cast aluminum alloy foam and a dense A1050 commercially pure Al tube with metal bonding were fabricated by friction welding. First, it was found that the ADC12 precursor was firmly bonded throughout the inner wall of the A1050 tube without a gap between the precursor and the tube by friction welding. No deformation of the tube or foaming of the precursor was observed during the friction welding. Next, it was shown that by heat treatment of an ADC12-precursor-bonded A1050 tube, gases generated by the decomposition of the blowing agent expand the softened ADC12 to produce the ADC12 foam interior of the dense A1050 tube. A holding time during the foaming process of approximately t H = 8.5 min with a holding temperature of 948 K was found to be suitable for obtaining a sound ADC12-foam-filled A1050 tube with sufficient foaming, almost uniform pore structures over the entire specimen, and no deformation or reduction in the thickness of the tube.

Fabrication of Aluminum Tubes Filled with Aluminum Alloy Foam by Friction Welding

PubMed Central

Hangai, Yoshihiko; Nakano, Yukiko; Koyama, Shinji; Kuwazuru, Osamu; Kitahara, Soichiro; Yoshikawa, Nobuhiro

2015-01-01

Aluminum foam is usually used as the core of composite materials by combining it with dense materials, such as in Al foam core sandwich panels and Al-foam-filled tubes, owing to its low tensile and bending strengths. In this study, all-Al foam-filled tubes consisting of ADC12 Al-Si-Cu die-cast aluminum alloy foam and a dense A1050 commercially pure Al tube with metal bonding were fabricated by friction welding. First, it was found that the ADC12 precursor was firmly bonded throughout the inner wall of the A1050 tube without a gap between the precursor and the tube by friction welding. No deformation of the tube or foaming of the precursor was observed during the friction welding. Next, it was shown that by heat treatment of an ADC12-precursor-bonded A1050 tube, gases generated by the decomposition of the blowing agent expand the softened ADC12 to produce the ADC12 foam interior of the dense A1050 tube. A holding time during the foaming process of approximately tH = 8.5 min with a holding temperature of 948 K was found to be suitable for obtaining a sound ADC12-foam-filled A1050 tube with sufficient foaming, almost uniform pore structures over the entire specimen, and no deformation and minimum reduction in the thickness of the tube. PMID:28793629

Study on influence of three kinds of stress on crack propagation in butt welds of spiral coil waterwall for ultra supercritical boiler

NASA Astrophysics Data System (ADS)

Yan, Zhenrong; Si, Jun

2017-09-01

The spiral coil waterwall is the main pressure parts and the core functional components of Ultra Supercritical Boiler. In the process of operation, the spiral coil waterwall is under the combined action of welding residual stress, installation defects stress and working fluid stress, Cracks and crack propagation are easy to occur in butt welds with defects. In view of the early cracks in the butt welds of more T23 water cooled walls, in this paper, the influence of various stresses on the crack propagation in the butt welds of spiral coil waterwall was studied by numerical simulation. Firstly, the welding process of T23 water cooled wall tube was simulated, and the welding residual stress field was obtained. Then,on the basis, put the working medium load on the spiral coil waterwall, the supercoated stress distribution of the welding residual stress and the stress of the working medium is obtained. Considering the bending moment formed by stagger joint which is the most common installation defects, the stress field distribution of butt welds in T23 water-cooled wall tubes was obtained by applying bending moment on the basis of the stress field of the welding residual stress and the working medium stress. The results show that, the welding residual stress is small, the effect of T23 heat treatment after welding to improve the weld quality is not obvious; The working medium load plays a great role in the hoop stress of the water cooled wall tube, and promotes the cracks in the butt welds; The axial stress on the water cooled wall tube produced by the installation defect stress is obvious, the stagger joint, and other installation defects are the main reason of crack propagation of spiral coil waterwall. It is recommended that the control the bending moment resulting from the stagger joint not exceed 756.5 NM.

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

PubMed

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

2006-04-01

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

Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture

NASA Astrophysics Data System (ADS)

Hehr, Adam; Wenning, Justin; Terrani, Kurt; Babu, Sudarsanam Suresh; Norfolk, Mark

2017-03-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact with the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. It is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.

Five-axis ultrasonic additive manufacturing for nuclear component manufacture

DOE PAGES

Hehr, Adam; Wenning, Justin; Terrani, Kurt A.; ...

2016-01-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact withmore » the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. Lastly, it is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.« less

Investigation of dissimilar metal welds by energy-resolved neutron imaging

DOE PAGES

Tremsin, Anton S.; Ganguly, Supriyo; Meco, Sonia M.; ...

2016-06-09

A nondestructive study of the internal structure and compositional gradient of dissimilar metal-alloy welds through energy-resolved neutron imaging is described in this paper. The ability of neutrons to penetrate thick metal objects (up to several cm) provides a unique possibility to examine samples which are opaque to other conventional techniques. The presence of Bragg edges in the measured neutron transmission spectra can be used to characterize the internal residual strain within the samples and some microstructural features, e.g. texture within the grains, while neutron resonance absorption provides the possibility to map the degree of uniformity in mixing of the participatingmore » alloys and intermetallic formation within the welds. In addition, voids and other defects can be revealed by the variation of neutron attenuation across the samples. This paper demonstrates the potential of neutron energy-resolved imaging to measure all these characteristics simultaneously in a single experiment with sub-mm spatial resolution. Two dissimilar alloy welds are used in this study: Al autogenously laser welded to steel, and Ti gas metal arc welded (GMAW) to stainless steel using Cu as a filler alloy. The cold metal transfer variant of the GMAW process was used in joining the Ti to the stainless steel in order to minimize the heat input. The distributions of the lattice parameter and texture variation in these welds as well as the presence of voids and defects in the melt region are mapped across the welds. The depth of the thermal front in the Al–steel weld is clearly resolved and could be used to optimize the welding process. As a result, a highly textured structure is revealed in the Ti to stainless steel joint where copper was used as a filler wire. The limited diffusion of Ti into the weld region is also verified by the resonance absorption.« less

Investigation of dissimilar metal welds by energy-resolved neutron imaging

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

Tremsin, Anton S.; Ganguly, Supriyo; Meco, Sonia M.

A nondestructive study of the internal structure and compositional gradient of dissimilar metal-alloy welds through energy-resolved neutron imaging is described in this paper. The ability of neutrons to penetrate thick metal objects (up to several cm) provides a unique possibility to examine samples which are opaque to other conventional techniques. The presence of Bragg edges in the measured neutron transmission spectra can be used to characterize the internal residual strain within the samples and some microstructural features, e.g. texture within the grains, while neutron resonance absorption provides the possibility to map the degree of uniformity in mixing of the participatingmore » alloys and intermetallic formation within the welds. In addition, voids and other defects can be revealed by the variation of neutron attenuation across the samples. This paper demonstrates the potential of neutron energy-resolved imaging to measure all these characteristics simultaneously in a single experiment with sub-mm spatial resolution. Two dissimilar alloy welds are used in this study: Al autogenously laser welded to steel, and Ti gas metal arc welded (GMAW) to stainless steel using Cu as a filler alloy. The cold metal transfer variant of the GMAW process was used in joining the Ti to the stainless steel in order to minimize the heat input. The distributions of the lattice parameter and texture variation in these welds as well as the presence of voids and defects in the melt region are mapped across the welds. The depth of the thermal front in the Al–steel weld is clearly resolved and could be used to optimize the welding process. As a result, a highly textured structure is revealed in the Ti to stainless steel joint where copper was used as a filler wire. The limited diffusion of Ti into the weld region is also verified by the resonance absorption.« less

Investigation of dissimilar metal welds by energy-resolved neutron imaging

PubMed Central

Tremsin, Anton S.; Ganguly, Supriyo; Meco, Sonia M.; Pardal, Goncalo R.; Shinohara, Takenao; Feller, W. Bruce

2016-01-01

A nondestructive study of the internal structure and compositional gradient of dissimilar metal-alloy welds through energy-resolved neutron imaging is described in this paper. The ability of neutrons to penetrate thick metal objects (up to several cm) provides a unique possibility to examine samples which are opaque to other conventional techniques. The presence of Bragg edges in the measured neutron transmission spectra can be used to characterize the internal residual strain within the samples and some microstructural features, e.g. texture within the grains, while neutron resonance absorption provides the possibility to map the degree of uniformity in mixing of the participating alloys and intermetallic formation within the welds. In addition, voids and other defects can be revealed by the variation of neutron attenuation across the samples. This paper demonstrates the potential of neutron energy-resolved imaging to measure all these characteristics simultaneously in a single experiment with sub-mm spatial resolution. Two dissimilar alloy welds are used in this study: Al autogenously laser welded to steel, and Ti gas metal arc welded (GMAW) to stainless steel using Cu as a filler alloy. The cold metal transfer variant of the GMAW process was used in joining the Ti to the stainless steel in order to minimize the heat input. The distributions of the lattice parameter and texture variation in these welds as well as the presence of voids and defects in the melt region are mapped across the welds. The depth of the thermal front in the Al–steel weld is clearly resolved and could be used to optimize the welding process. A highly textured structure is revealed in the Ti to stainless steel joint where copper was used as a filler wire. The limited diffusion of Ti into the weld region is also verified by the resonance absorption. PMID:27504075

Welding with the thin disc laser: new processing and application potentials

NASA Astrophysics Data System (ADS)

Hügel, H.; Ruβ, A.; Weberpals, J.; Dausinger, F.

2005-09-01

Thin disc lasers represent a new class of welding lasers in that they combine the beneficial characteristics of CO2- and Nd:YAG-lasers. Their good focusability--values of M2 around 20 are typical for devices in the multi kW power range--can be utilized in several ways to improve the welding performance: compared to lamp-pumped Nd:YAG-lasers, the laser power required at the threshold to the deep penetration regime can be reduced, the welding depth can be increased and far higher values of traverse speed are applicable at prescribed welding depths. Alternatively, the high beam quality allows the use of focusing optics with large focal lengths, hence enabling the realization of "remote welding" concepts. At the same time, a wavelength of 1.03 μm (Yb:YAG) provides, in comparison to CO2-lasers, a high absorptivity at metallic workpieces and a low sensitivity against plasma production; both effects contribute to the efficiency, stability and achievable quality of the welding process. Further, beam delivery via flexible glass fibers with core diameters of 100 μm to 150 μm is possible. With these features and an overall (plug) efficiency of more than 20 %, this laser offers a large potential for many applications.

Microstructural analysis of laser weld fusion zone in Haynes 282 superalloy

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

Osoba, L.O.; Ding, R.G.; Ojo, O.A., E-mail: ojo@cc.umanitoba.ca

Analytical electron microscopy and spectroscopy analyses of the fusion zone (FZ) microstructure in autogenous laser beam welded Haynes 282 (HY 282) superalloy were performed. The micro-segregation patterns observed in the FZ indicate that Co, Cr and Al exhibited a nearly uniform distribution between the dendrite core and interdendritic regions while Ti and Mo were rejected into the interdendritic liquid during the weld solidification. Transmission electron diffraction analysis and energy dispersive X-ray microanalysis revealed the second phase particles formed along the FZ interdendritic region to be Ti-Mo rich MC-type carbide particles. Weld FZ solidification cracking, which is sometimes associated with themore » formation of {gamma}-{gamma}' eutectic in {gamma}' precipitation strengthened nickel-base superalloys, was not observed in the HY 282 superalloy. Modified primary solidification path due to carbon addition in the newly developed superalloy is used to explain preclusion of weld FZ solidification cracking in the material. - Highlights: Black-Right-Pointing-Pointer A newly developed superalloy was welded by CO{sub 2} laser beam joining technique. Black-Right-Pointing-Pointer Electron microscopy characterization of the weld microstructure was performed. Black-Right-Pointing-Pointer Identified interdendritic microconstituents consist of MC-type carbides. Black-Right-Pointing-Pointer Modification of primary solidification path is used to explain cracking resistance.« less

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

PubMed

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

2012-09-01

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

Electrofriction method of manufacturing squirrel cage rotors

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

Hsu, John S.

2005-04-12

A method of making a squirrel cage rotor of copper material for use in AC or DC motors, includes forming a core with longitudinal slots, inserting bars of conductive material in the slots, with ends extending out of opposite ends of the core, and joining the end rings to the bars, wherein the conductive material of either the end rings or the bars is copper. Various methods of joining the end rings to the bars are disclosed including electrofriction welding, current pulse welding and brazing, transient liquid phase joining and casting. Pressure is also applied to the end rings tomore » improve contact and reduce areas of small or uneven contact between the bar ends and the end rings. Rotors made with such methods are also disclosed.« less

The relationship between corrosion protection and hydrogen embrittlement properties of HAZ in flux cored are welding

NASA Astrophysics Data System (ADS)

Kim, Seong-Jong; Moon, Kyung-Man

2002-07-01

The cathodic protection method is being widely used in marine structural steel. However, a high tensile steel such as RE 36 steel used for marine structural steel is easily susceptible to hydrogen embrittlement due to overprotection as well as the preferential corrosion of the heat affected zone (HAZ). In this paper, corrosion resistance and mechanical properties were investigated from the electrochemical view and mechanical view in as-wedded and post-weld heat treated specimens. Fracture surface was analyzed by SEM. The corrosion resistance in post-weld heat treated at 550°C was superior to that at other post-weld heat treatment (PWHT) temperature. On the other hand, elongation was decreased with a shift to the low potential direction which may cause hydrogen embrittlement. And a quasi-cleavage (Q.C) fracture mode was also observed significantly with a potential increase to the active direction.

Demonstration of a Large-Scale Tank Assembly via Circumferential Friction Stir Welds

NASA Technical Reports Server (NTRS)

Jones, Clyde S.; Adams, Glynn; Colligan, Kevin

2000-01-01

A collaborative effort between NASA/Marshall Space Flight Center and the Michoud Unit of Lockheed Martin Space Systems Company was undertaken to demonstrate assembly of a large-scale aluminum tank using circumferential friction stir welds. The hardware used to complete this demonstration was fabricated as a study of near-net- shape technologies. The tooling used to complete this demonstration was originally designed for assembly of a tank using fusion weld processes. This presentation describes the modifications and additions that were made to the existing fusion welding tools required to accommodate circumferential friction stir welding, as well as the process used to assemble the tank. The tooling modifications include design, fabrication and installation of several components. The most significant components include a friction stir weld unit with adjustable pin length capabilities, a continuous internal anvil for 'open' circumferential welds, a continuous closeout anvil, clamping systems, an external reaction system and the control system required to conduct the friction stir welds and integrate the operation of the tool. The demonstration was intended as a development task. The experience gained during each circumferential weld was applied to improve subsequent welds. Both constant and tapered thickness 14-foot diameter circumferential welds were successfully demonstrated.

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

NASA Technical Reports Server (NTRS)

Jemian, W. A.

1985-01-01

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

The Effect of Ultrasonic Peening on Service Life of the Butt-Welded High-Temperature Steel Pipes

NASA Astrophysics Data System (ADS)

Daavari, Morteza; Vanini, Seyed Ali Sadough

2015-09-01

Residual stresses introduced by manufacturing processes such as casting, forming, machining, and welding have harmful effects on the mechanical behavior of the structures. In addition to the residual stresses, weld toe stress concentration can play a determining effect. There are several methods to improve the mechanical properties such as fatigue behavior of the welded structures. In this paper, the effects of ultrasonic peening on the fatigue life of the high-temperature seamless steel pipes, used in the petrochemical environment, have been investigated. These welded pipes are fatigued due to thermal and mechanical loads caused by the cycle of cooling, heating, and internal pressure fluctuations. Residual stress measurements, weld geometry estimation, electrochemical evaluations, and metallography investigations were done as supplementary examinations. Results showed that application of ultrasonic impact treatment has led to increased fatigue life, fatigue strength, and corrosion resistance of A106-B welded steel pipes in petrochemical corrosive environment.

Control of occupational exposure to hexavalent chromium and ozone in tubular wire arc-welding processes by replacement of potassium by lithium or by addition of zinc.

PubMed

Dennis, John H; French, Michael J; Hewitt, Peter J; Mortazavi, Seyed B; Redding, Christopher A J

2002-01-01

Hexavalent chromium [Cr(VI)] and ozone are produced in many arc-welding processes. Cr(VI) is formed when welding with chromium-containing alloys and is a suspected carcinogen. Ozone is formed by the action of ultraviolet light from the arc on oxygen and can cause severe irritation to the eyes and mucous membranes. Previous work has demonstrated that reduction of sodium and potassium in manual metal arc-welding electrodes leads to substantial reductions in Cr(VI) concentrations in the fume as well as a reduction in the fume formation rate. In this paper replacement of potassium by lithium in a tubular wire welding electrode (self-shielding flux-cored) is shown to give reductions in Cr(VI) concentrations and fume formation rates. Previous work has also demonstrated that use of a tubular wire (metal cored) containing 1% zinc can, under certain conditions, result in a reduction in Cr(VI) formation rate and in ozone concentration near the arc but with a rise in the total fume formation rate. The effects of different shield gases and different levels of zinc are examined. An experimental chromium-containing tubular wire with 1% zinc was used with the following shield gases: argon, Argoshield 5, Argoshield 20, Helishield 101, Ar + 2% CO2, Ar + 5% CO2, Ar + 1% O2 and Ar + 2% O2. The wire gave > 98% reduction in Cr(VI) formation rate compared to the control wire provided the shield gas contained no oxygen. When the shield gas did contain oxygen, 1% zinc enhanced Cr(VI) formation rate, resulting in more than double the rates measured when welding with the control wire. Experiments with zinc concentrations, from 0.018 to 0.9% using Helishield 101, gave results indicating that there is an optimum zinc concentration from the point of view of Cr(VI) reduction. Implications of the use of lithium or zinc on the overall exposure risk are discussed.

Heat-affected zone and phase composition of 0.09 C-2 Mn-1 Si-Fe steel depending on welding technique

NASA Astrophysics Data System (ADS)

Popova, Natalya; Ozhiganov, Eugeniy; Nikonenko, Elena; Ababkov, Nikolay; Smirnov, Aleksander; Koneva, Nina

2017-11-01

The paper presents the transmission electron microscopy (TEM) investigations of the structure and phase composition of the heat-affected zone (HAZ) in welded joint modified by four types of welding, namely: electrode welding and electropercussive welding both with and without the introduction of artificial flaws. Artificial flows are aluminum pieces. TEM investigations are carried out within HAZ between the deposited and base metal at 1 mm distance to the latter. The type 0.09C-2Mn-1Si-Fe steel is used as weld material. It is shown that the welding process has an effect on the material morphology, phase composition, faulted structure and its parameters. Long-range stresses are divided into plastic and elastic components. It is demonstrated that the type of welding does not change the structural quality of welded joint represented by perlite and ferrite as contrasted with their volume fraction. According to observations, any type of welding with the introduction of artificial flaws results in the destruction of perlite. Polarization of the dislocation structure occurs. The amplitude of mean internal stresses does not practically depend on the welding type. It is shown that the introduction of artificial flaws both during electrode and electropercussive welding reduce the quantitative parameters of the faulted structure.

Detection and assessment of flaws in friction stir welded metallic plates

NASA Astrophysics Data System (ADS)

Fakih, Mohammad Ali; Mustapha, Samir; Tarraf, Jaafar; Ayoub, Georges; Hamade, Ramsey

2017-04-01

Investigated is the ability of ultrasonic guided waves to detect flaws and assess the quality of friction stir welds (FSW). AZ31B magnesium plates were friction stir welded. While process parameters of spindle speed and tool feed were fixed, shoulder penetration depth was varied resulting in welds of varying quality. Ultrasonic waves were excited at different frequencies using piezoelectric wafers and the fundamental symmetric (S0) mode was selected to detect the flaws resulting from the welding process. The front of the first transmitted wave signal was used to capture the S0 mode. A damage index (DI) measure was defined based on the amplitude attenuation after wave interaction with the welded zone. Computed Tomography (CT) scanning was employed as a nondestructive testing (NDT) technique to assess the actual weld quality. Derived DI values were plotted against CT-derived flaw volume resulting in a perfectly linear fit. The proposed approach showed high sensitivity of the S0 mode to internal flaws within the weld. As such, this methodology bears great potential as a future predictive method for the evaluation of FSW weld quality.

77 FR 2318 - Certain Circular Welded Pipe and Tube From Brazil, India, Korea, Mexico, Taiwan, Thailand, and...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-01-17

..., Taiwan, Thailand, and Turkey; Scheduling of Full Five-Year Reviews AGENCY: United States International... Turkey, the antidumping duty orders on welded carbon steel pipe and tube from India, Thailand, and Turkey...

Material processing: AI-MSG modification

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

Woolsey, C.C.; Carnazzola, A.

1973-12-18

This specification establishes fabrication processing requirements such as cleaning, welding, brazing, and post-weld heat treating for the modification of the Atomics International (AI) Modular Steam Generator (MSG) for use in the Large Leak Test Rig (LLTR) for the study of sodium-water reactions.

ISWE: A Case Study of Technology Utilization

NASA Technical Reports Server (NTRS)

Benfield, M. P.; Mitchell, D. P.; Vanhooser, M. T.; Landrum, D. B.

1998-01-01

The International Space Welding Experiment is a joint project between the E.O. Paton Welding Institute of Kiev, Ukraine and the George C. Marshall Space Flight Center in Huntsville, Alabama. When an international partner is involved in a project, differences in design and testing philosophy can become a factor in the development of the hardware. This report addresses selected issues that arose during the ISWE hardware development as well as the solutions the ISWE team made.

Initiation and growth kinetics of solidification cracking during welding of steel

PubMed Central

Aucott, L.; Huang, D.; Dong, H. B.; Wen, S. W.; Marsden, J. A.; Rack, A.; Cocks, A. C. F.

2017-01-01

Solidification cracking is a key phenomenon associated with defect formation during welding. To elucidate the failure mechanisms, solidification cracking during arc welding of steel are investigated in situ with high-speed, high-energy synchrotron X-ray radiography. Damage initiates at relatively low true strain of about 3.1% in the form of micro-cavities at the weld subsurface where peak volumetric strain and triaxiality are localised. The initial micro-cavities, with sizes from 10 × 10−6 m to 27 × 10−6 m, are mostly formed in isolation as revealed by synchrotron X-ray micro-tomography. The growth of micro-cavities is driven by increasing strain induced to the solidifying steel. Cavities grow through coalescence of micro-cavities to form micro-cracks first and then through the propagation of micro-cracks. Cracks propagate from the core of the weld towards the free surface along the solidifying grain boundaries at a speed of 2–3 × 10−3 m s−1. PMID:28074852

Selecting Processes to Minimize Hexavalent Chromium from Stainless Steel Welding

PubMed Central

KEANE, M.; SIERT, A.; STONE, S.; CHEN, B.; SLAVEN, J.; CUMPSTON, A.; ANTONINI, J.

2015-01-01

Eight welding processes/shielding gas combinations were assessed for generation of hexavalent chromium (Cr6+) in stainless steel welding fumes. The processes examined were gas metal arc welding (GMAW) (axial spray, short circuit, and pulsed spray modes), flux cored arc welding (FCAW), and shielded metal arc welding (SMAW). The Cr6+ fractions were measured in the fumes; fume generation rates, Cr6+ generation rates, and Cr6+ generation rates per unit mass of welding wire were determined. A limited controlled comparison study was done in a welding shop including SMAW, FCAW, and three GMAW methods. The processes studied were compared for costs, including relative labor costs. Results indicate the Cr6+ in the fume varied widely, from a low of 2800 to a high of 34,000 ppm. Generation rates of Cr6+ ranged from 69 to 7800 μg/min, and Cr6+ generation rates per unit of wire ranged from 1 to 270 μg/g. The results of field study were similar to the findings in the laboratory. The Cr6+ (ppm) in the fume did not necessarily correlate with the Cr6+ generation rate. Physical properties were similar for the processes, with mass median aerodynamic diameters ranging from 250 to 336 nm, while the FCAW and SMAW fumes were larger (360 and 670 nm, respectively). Conclusion: The pulsed axial spray method was the best choice of the processes studied based on minimal fume generation, minimal Cr6+ generation, and cost per weld. This method is usable in any position, has a high metal deposition rate, and is relatively simple to learn and use. PMID:26690276

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

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

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

1998-12-31

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

WELDING PROCESS

DOEpatents

Zambrow, J.; Hausner, H.

1957-09-24

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

Re-weldability tests of irradiated 316L(N) stainless steel using laser welding technique

NASA Astrophysics Data System (ADS)

Yamada, Hirokazu; Kawamura, Hiroshi; Tsuchiya, Kunihiko; Kalinin, George; Kohno, Wataru; Morishima, Yasuo

2002-12-01

SS316L(N)-IG is the candidate material for the in-vessel and ex-vessel components of fusion reactors such as ITER (International Thermonuclear Experimental Reactor). This paper describes a study on re-weldability of un-irradiated and/or irradiated SS316L(N)-IG and the effect of helium generation on the mechanical properties of the weld joint. The laser welding process is used for re-welding of the water cooling branch pipeline repairs. It is clarified that re-welding of SS316L(N)-IG irradiated up to about 0.2 dpa (3.3 appm He) can be carried out without a serious deterioration of tensile properties due to helium accumulation. Therefore, repair of the ITER blanket cooling pipes can be performed by the laser welding process.

Effect of Backing Plate Thermal Property on Friction Stir Welding of 25-mm-Thick AA6061

NASA Astrophysics Data System (ADS)

Upadhyay, Piyush; Reynolds, Anthony

2014-04-01

By using backing plates made out of materials with widely varying thermal diffusivity this work seeks to elucidate the effects of the root side thermal boundary condition on weld process variables and resulting joint properties. Welds were made in 25.4-mm-thick AA6061 using ceramic, titanium, steel, and aluminum as backing plate (BP) material. Welds were also made using a "composite backing plate" consisting of longitudinal narrow strip of low diffusivity material at the center and two side plates of high diffusivity aluminum. Stir zone temperature during the welding was measured using two thermocouples spot welded at the core of the probe: one at the midplane height and another near the tip of the probe corresponding to the root of the weld. Steady state midplane probe temperatures for all the BPs used were found to be very similar. Near root peak temperature, however, varied significantly among weld made with different BPs all other things being equal. Whereas the near root and midplane temperature were the same in the case of ceramic backing plate, the root peak temperature was 318 K (45 °C) less than the midplane temperature in the case of aluminum BP. The trends of nugget hardness and grain size in through thickness direction were in agreement with the measured probe temperatures. Hardness and tensile test results show that the use of composite BP results in stronger joint compared to monolithic steel BP.

The research of PSD location method in micro laser welding fields

NASA Astrophysics Data System (ADS)

Zhang, Qiue; Zhang, Rong; Dong, Hua

2010-11-01

In the field of micro laser welding, besides the special requirement in the parameter of lasers, the locating in welding points accurately is very important. The article adopt position sensitive detector (PSD) as hard core, combine optic system, electric circuits and PC and software processing, confirm the location of welding points. The signal detection circuits adopt the special integrate circuit H-2476 to process weak signal. It is an integrated circuit for high-speed, high-sensitivity optical range finding, which has stronger noiseproof feature, combine digital filter arithmetic, carry out repair the any non-ideal factors, increasing the measure precision. The amplifier adopt programmable amplifier LTC6915. The system adapt two dimension stepping motor drive the workbench, computer and corresponding software processing, make sure the location of spot weld. According to different workpieces to design the clamps. The system on-line detect PSD 's output signal in the moving processing. At the workbench moves in the X direction, the filaments offset is detected dynamic. Analyze the X axes moving sampling signal direction could be estimate the Y axes moving direction, and regulate the Y axes moving values. The workbench driver adopt A3979, it is a stepping motor driver with insert transducer and operate easily. It adapts the requirement of location in micro laser welding fields, real-time control to adjust by computer. It can be content up 20 μm's laser micro welding requirement on the whole. Using laser powder cladding technology achieve inter-penetration welding of high quality and reliability.

Quality of Metal Deposited Flux Cored Wire With the System Fe-C-Si-Mn-Cr-Mo-Ni-V-Co

NASA Astrophysics Data System (ADS)

Gusev, Aleksander I.; Kozyrev, Nikolay A.; Osetkovskiy, Ivan V.; Kryukov, Roman E.; Kozyreva, Olga A.

2017-10-01

Studied the effect of the introduction of vanadium and cobalt into the charge powder fused wire system Fe-C-Si-Mn-Cr-Ni-Mo-V, used in cladding assemblies and equipment parts and mechanisms operating under abrasive and abrasive shock loads. the cored wires samples were manufactured in the laboratory conditions and using appropriate powder materials and as a carbonfluoride contained material were used the dust from gas purification of aluminum production, with the following components composition, %: Al2O3 = 21-46.23; F = 18-27; Na2O = 8-15; K2O = 0.4-6; CaO = 0.7-2.3; Si2O = 0.5-2.48; Fe2O3 = 2.1-3.27; C = 12.5-30.2; MnO = 0.07-0.9; MgO = 0.06-0.9; S = 0.09-0.19; P = 0.1-0.18. Surfacing was produced on the St3 metal plates in 6 layers under the AN-26C flux by welding truck ASAW-1250. Cutting and preparation of samples for research had been implemented. The chemical composition and the hydrogen content of the weld metal were determined by modern methods. The hardness and abrasion rate of weld metal had been measured. Conducted metallographic studies of weld metal: estimated microstructure, grain size, contamination of oxide non-metallic inclusions. Metallographic studies showed that the microstructure of the surfaced layer by cored wire system Fe-C-Si-Mn-Cr-Mo-Ni-V-Co is uniform, thin dendrite branches are observed. The microstructure consists of martensite, which is formed inside the borders of the former austenite grain retained austenite present in small amounts in the form of separate islands, and thin layers of δ-ferrite, which is located on the borders of the former austenite grains. Carried out an assessment the effect of the chemical composition of the deposited metal on the hardness and wear and hydrogen content. In consequence of multivariate correlation analysis, it was determined dependence to the hardness of the deposited layer and the wear resistance of the mass fraction of the elements included in the flux-cored wires of the system Fe-C-Si-Mn-Cr-Mo-Ni-V-Co. The calculated value of the average approximation error suggests that the dependence is adequate and can be used to determine the resulting indicators. These dependencies can be used to predict the hardness of the deposited layer and its wear resistance while changing the chemical composition of the weld metal.

Methods for pore water extraction from unsaturated zone tuff, Yucca Mountain, Nevada

USGS Publications Warehouse

Scofield, K.M.

2006-01-01

Assessing the performance of the proposed high-level radioactive waste repository at Yucca Mountain, Nevada, requires an understanding of the chemistry of the water that moves through the host rock. The uniaxial compression method used to extract pore water from samples of tuffaceous borehole core was successful only for nonwelded tuff. An ultracentrifugation method was adopted to extract pore water from samples of the densely welded tuff of the proposed repository horizon. Tests were performed using both methods to determine the efficiency of pore water extraction and the potential effects on pore water chemistry. Test results indicate that uniaxial compression is most efficient for extracting pore water from nonwelded tuff, while ultracentrifugation is more successful in extracting pore water from densely welded tuff. Pore water splits collected from a single nonwelded tuff core during uniaxial compression tests have shown changes in pore water chemistry with increasing pressure for calcium, chloride, sulfate, and nitrate. Pore water samples collected from the intermediate pressure ranges should prevent the influence of re-dissolved, evaporative salts and the addition of ion-deficient water from clays and zeolites. Chemistry of pore water splits from welded and nonwelded tuffs using ultracentrifugation indicates that there is no substantial fractionation of solutes.

The Infrastructure of an Integrated Virtual Reality Environment for International Space Welding Experiment

NASA Technical Reports Server (NTRS)

Wang, Peter Hor-Ching

1996-01-01

This study is a continuation of the summer research of 1995 NASA/ASEE Summer Faculty Fellowship Program. This effort is to provide the infrastructure of an integrated Virtual Reality (VR) environment for the International Space Welding Experiment (ISWE) Analytical Tool and Trainer and the Microgravity Science Glovebox (MSG) Analytical Tool study. Due to the unavailability of the MSG CAD files and the 3D-CAD converter, little was done to the MSG study. However, the infrastructure of the integrated VR environment for ISWE is capable of performing the MSG study when the CAD files become available. Two primary goals are established for this research. First, the essential peripheral devices for an integrated VR environment will be studied and developed for the ISWE and MSG studies. Secondly, the training of the flight crew (astronaut) in general orientation, procedures, and location, orientation, and sequencing of the welding samples and tools are built into the VR system for studying the welding process and training the astronaut.

Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

Internal wire guide for GTAW welding

NASA Technical Reports Server (NTRS)

Morgan, Gene E. (Inventor); Dyer, Gerald E. (Inventor)

1989-01-01

A welding torch for gas tungsten arc welding apparatus has a filler metal wire guide positioned within the torch, and within the shielding gas nozzle. The wire guide is adjacent to the tungsten electrode and has a ceramic liner through which the wire is fed. This reduces the size of the torch and eliminates the outside clearance problems that exit with external wire guides. Additionally, since the wire is always within the shielding gas, oxidizing of the wire is eliminated.

Recommendations and Requirements for Welding and Inspection of Titanium Piping for U.S. Navy Surface Ship Applications

DTIC Science & Technology

1999-09-01

The same general relationship is true for mixtures of argon and helium.) Argon is also more readily available and less costly than helium... true square-edge to assure proper inert gas shielding during welding. Perpendicularity of the edges should be maintained within 5 degrees. All clamps...toes. A horoscope is not required for internal inspection of inaccessible backside pipe welds. The acceptance criteria for color inspection and

Automatic Welding System

NASA Astrophysics Data System (ADS)

1982-01-01

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

Analysis of rail welding methods for mine rail access with the use of modern technologies

NASA Astrophysics Data System (ADS)

Usoltsev, A. A.; Shevchenko, R. A.; Kozyrev, N. A.; Kriukov, R. E.; Shishkin, P. E.

2017-09-01

Welded joint zones are weak sections of the railway track for all traffic cases (in the case of high-speed traffic and heavy traffic). In the paper advantages and disadvantages of the basic ways of rails welding, which are widely used today, are considered: electrocontact and aluminothermic. Carefully selected mode of differentially thermally strengthened rails string will allow the process of correction after heat treatment to be minimized and internal residual compressive stresses to be kept. Particular attention should be paid to the method of rails welding, in which after rails welding during their cooling it is offered to perform quasi-isothermal exposure in the temperature range of fine structure formation by passing pulses of alternating electric current through the welded joint maintaining this temperature until the end of the transformation. The use of quasi-isothermal exposure at a temperature of 600 - 650 °C makes it possible to obtain a finely dispersed structure of the welded seam of rails without additional heat treatment.

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

NASA Technical Reports Server (NTRS)

Querin, Joseph A.; Schneider, Judy A.

2008-01-01

In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

46 CFR 35.01-25 - Sacrificial anode installations-TB/ALL.

Code of Federal Regulations, 2011 CFR

2011-10-01

... attachments. (3) Each anode shall have at least two welded or bolted connections to the supporting structure.... (5) The recommended construction of the anode should utilize a mild steel core with necessary...

46 CFR 35.01-25 - Sacrificial anode installations-TB/ALL.

Code of Federal Regulations, 2010 CFR

2010-10-01

... attachments. (3) Each anode shall have at least two welded or bolted connections to the supporting structure.... (5) The recommended construction of the anode should utilize a mild steel core with necessary...

Alining Large Cylinders for Welding

NASA Technical Reports Server (NTRS)

Ehl, J. H.

1985-01-01

Special tooling alines and holds internally-stiffened large-diameter cylindrical parts for welding. Alinement brackets attached to strengthening fins on insides of cylindrical tank sections. Jackscrews on brackets raised or lowered to eliminate mismatches between adjacent sections. Tooling substantially reduces costs while allowing more precise control and improved quality.

Thermodynamic, Transport and Chemical Properties of Reference JP-8

DTIC Science & Technology

2006-06-01

external diameter, 0.18 cm internal diameter) that are sealed on one end with a stainless steel plug welded by a clean tungsten-inert-gas ( TIG ) 15...tubing with an internal diameter of 0.02 cm, also TIG welded to the cell. Each cell and valve is capable of withstanding a pressure in excess of 105... process . Each cell is connected to a high-pressure high-temperature valve at the other end with a short length of 0.16 cm diameter 316 stainless steel

Development and Application of Laser Peening System for PWR Power Plants

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

Masaki Yoda; Itaru Chida; Satoshi Okada

2006-07-01

Laser peening is a process to improve residual stress from tensile to compressive in surface layer of materials by irradiating high-power laser pulses on the material in water. Toshiba has developed a laser peening system composed of Q-switched Nd:YAG laser oscillators, laser delivery equipment and underwater remote handling equipment. We have applied the system for Japanese operating BWR power plants as a preventive maintenance measure for stress corrosion cracking (SCC) on reactor internals like core shrouds or control rod drive (CRD) penetrations since 1999. As for PWRs, alloy 600 or 182 can be susceptible to primary water stress corrosion crackingmore » (PWSCC), and some cracks or leakages caused by the PWSCC have been discovered on penetrations of reactor vessel heads (RVHs), reactor bottom-mounted instrumentation (BMI) nozzles, and others. Taking measures to meet the unconformity of the RVH penetrations, RVHs themselves have been replaced in many PWRs. On the other hand, it's too time-consuming and expensive to replace BMI nozzles, therefore, any other convenient and less expensive measures are required instead of the replacement. In Toshiba, we carried out various tests for laser-peened nickel base alloys and confirmed the effectiveness of laser peening as a preventive maintenance measure for PWSCC. We have developed a laser peening system for PWRs as well after the one for BWRs, and applied it for BMI nozzles, core deluge line nozzles and primary water inlet nozzles of Ikata Unit 1 and 2 of Shikoku Electric Power Company since 2004, which are Japanese operating PWR power plants. In this system, laser oscillators and control devices were packed into two containers placed on the operating floor inside the reactor containment vessel. Laser pulses were delivered through twin optical fibers and irradiated on two portions in parallel to reduce operation time. For BMI nozzles, we developed a tiny irradiation head for small tubes and we peened the inner surface around J-groove welds after laser ultrasonic testing (LUT) as the remote inspection, and we peened the outer surface and the weld for Ikata Unit 2 supplementary. For core deluge line nozzles and primary water inlet nozzles, we peened the inner surface of the dissimilar metal welding, which is of nickel base alloy, joining a safe end and a low alloy metal nozzle. In this paper, the development and the actual application of the laser peening system for PWR power plants will be described. (authors)« less

Friction Pull Plug Welding in Aluminum Alloys

NASA Technical Reports Server (NTRS)

Brooke, Shane A.; Bradford, Vann

2012-01-01

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

Effects of pulmonary exposure to chemically-distinct welding fumes on neuroendocrine markers of toxicity.

PubMed

Krajnak, K; Sriram, K; Johnson, C; Roberts, J R; Mercer, R; Miller, G R; Wirth, O; Antonini, J M

2017-01-01

Exposure to welding fumes may result in disorders of the pulmonary, cardiovascular, and reproductive systems. Welders are also at a greater risk of developing symptoms similar to those seen in individuals with idiopathic Parkinson's disease. In welders, there are studies that suggest that alterations in circulating prolactin concentrations may be indicative of injury to the dopamine (DA) neurons in the substantia nigra. The goal of these studies was to use an established model of welding particulate exposure to mimic the effects of welding fume inhalation on reproductive functions. Since previous investigators suggested that changes in circulating prolactin may be an early marker of DA neuron injury, movement disorders, and reproductive dysfunction, prolactin, hypothalamic tyrosine hydroxylase (TH) levels (a marker of DA synthesis), and other measures of hypothalamic-pituitary-gonadal (HPG) function were measured after repetitive instillation of welding fume particulates generated by flux core arc-hard surfacing (FCA-HS), manual metal arc-hard surfacing (MMA-HS) or gas metal arc-mild steel (GMA-MS) welding, or manganese chloride (MnCl 2 ). Exposure to welding fume particulate resulted in the accumulation of various metals in the pituitary and testes of rats, along with changes in hypothalamic TH and serum prolactin levels. Exposure to particulates with high concentrations of soluble manganese (Mn) appeared to exert the greatest influence on TH activity levels and serum prolactin concentrations. Thus, circulating prolactin levels may serve as a biomarker for welding fume/Mn-induced neurotoxicity. Other reproductive measures were collected, and these data were consistent with epidemiological findings that prolactin and testosterone may serve as biomarkers of welding particulate induced DA neuron and reproductive dysfunction.

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 possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.

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

PubMed

Flynn, Michael R; Susi, Pam

2012-08-01

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

Generation rate of carbon monoxide from CO2 arc welding.

PubMed

Ojima, Jun

2013-01-01

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

Simple method for forming thin-wall pressure vessels

NASA Technical Reports Server (NTRS)

Erickson, A. L.; Guist, L. R.

1972-01-01

Application of internal hydrostatic pressure to seam-welded circular cylindrical tanks having corner-welded, flat, circular ends forms large thin-walled high quality tanks. Form limits expansion of cylindrical portion of final tank while hemispherical ends develop freely; no external form or restraint is required to fabricate spherical tanks.

75 FR 68327 - Certain Welded Carbon Steel Standard Pipes and Tubes From India: Rescission of Antidumping Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-11-05

... Lloyds Metals & Engineers Ltd. and Lloyds Steel Industries Ltd.) (collectively, Lloyds) and Ushdev... and all affiliates, Lloyds Metals & Engineers Ltd., and Lloyds Steel Industries Ltd. Because we... DEPARTMENT OF COMMERCE International Trade Administration [A-533-502] Certain Welded Carbon Steel...

Small Gas Engine Repair.

ERIC Educational Resources Information Center

Connecticut State Dept. of Education, Hartford. Div. of Vocational-Technical Schools.

Instructional materials are provided for a small gas engine course. A list of objectives appears first, followed by a list of internal parts and skills/competencies related to those parts for engine work, ignition and electrical systems, fuel system, crankcase lubrication system, arc welding skills, and gas welding skills. Outlines are provided…

Experimental research on the dynamic behaviors of the keyhole and molten pool in laser deep-penetration welding

NASA Astrophysics Data System (ADS)

Zhang, Yi; Lin, Qida; Yin, Xuni; Li, Simeng; Deng, Jiquan

2018-04-01

Both the morphology and temperature are two important characteristics of the keyhole and the molten pool in laser deep-penetration welding. The modified ‘sandwich’ method was adopted to overcome the difficulty in obtaining inner information about the keyhole and the molten pool. Based on this method, experimental platforms were built for observing the variations in the surface morphology, the longitudinal keyhole profile and the internal temperature. The experimental results of three dynamic behaviors exbibit as follows. The key factor, which makes the pool width go into a quasi-steady state, lies in the balance between the vortex and the sideways flows around the keyhole. Experimental observation shows that the keyhole goes through three stages in laser welding: the rapid drilling stage, the slow drilling stage and the quasi-steady state. The time for achieving a relative fixed keyhole depth is close to the formation time of the maximum pool width. The internal temperatures inside the keyhole and the molten pool first experience a rapid increase, then a decrease and finally go into a quasi-steady state. Compared to that in the unstable stage, the liquid–metal uphill formed in the stable stage of laser welding has less influence on the internal temperature.

INTERNAL REPAIR OF PIPELINES

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

Robin Gordon; Bill Bruce; Nancy Porter

2003-05-01

The two broad categories of deposited weld metal repair and fiber-reinforced composite repair technologies were reviewed for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Preliminary test programs were developed for both deposited weld metal repairs and for fiber-reinforced composite repair. To date, all of the experimental work pertaining to the evaluation of potential repair methods has focused on fiber-reinforced composite repairs. Hydrostatic testing was also conducted on four pipeline sections with simulated corrosion damage: twomore » with composite liners and two without.« less

PROCEEDINGS OF THE FIFTH INTERNATIONAL CONFERENCE ON NONDESTRUCTIVE TESTING, [HELD AT MONTREAL, CANADA, MAY 21--26, 1967].

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

None

1969-07-01

The Fifth International Conference on Nondestructive Testing was held in Montreal, Canada, for the purpose of promoting international collaboration in all matters related to the development and use of nondestructive test methods. A total of 82 papers were selected for presentation. Session titles included: evaluation of material quality; ultrasonics - identification and measurements; thermal methods; testing of welds; visual aids in nondestructive testing; measurements of stress and elastic properties; magnetic and eddy-current methods; surface methods and neutron radiography; standardization - general; ultrasonics at elevated temperatures; applications; x-ray techniques; radiography; ultrasonic standardization; training and qualification; and, correlation of weld defects.

Fume generation and content of total chromium and hexavalent chromium in flux-cored arc welding.

PubMed

Yoon, Chung Sik; Paik, Nam Won; Kim, Jeong Han

2003-11-01

This study was performed to investigate the fume generation rates (FGRs) and the concentrations of total chromium and hexavalent chromium when stainless steel was welded using flux-cored arc welding (FCAW) with CO2 gas. FGRs and concentrations of total chromium and hexavalent chromium were quantified using a method recommended by the American Welding Society, inductively coupled plasma-atomic emission spectroscopy (NIOSH Method 7300) and ion chromatography (modified NIOSH Method 7604), respectively. The amount of total fume generated was significantly related to the level of input power. The ranges of FGR were 189-344, 389-698 and 682-1157 mg/min at low, optimal and high input power, respectively. It was found that the FGRs increased with input power by an exponent of 1.19, and increased with current by an exponent of 1.75. The ranges of total chromium fume generation rate (FGRCr) were 3.83-8.27, 12.75-37.25 and 38.79-76.46 mg/min at low, optimal and high input power, respectively. The ranges of hexavalent chromium fume generation rate (FGRCr6+) were 0.46-2.89, 0.76-6.28 and 1.70-11.21 mg/min at low, optimal and high input power, respectively. Thus, hexavalent chromium, which is known to be a carcinogen, generated 1.9 (1.0-2.7) times and 3.7 (2.4-5.0) times as the input power increased from low to optimal and low to high, respectively. As a function of input power, the concentration of total chromium in the fume increased from 1.57-2.65 to 5.45-8.13% while the concentration of hexavalent chromium ranged from 0.15 to 1.08%. The soluble fraction of hexavalent chromium produced by FCAW was approximately 80-90% of total hexavalent chromium. The concentration of total chromium and the solubility of hexavalent chromium were similar to those reported from other studies of shielded metal arc welding fumes, and the concentration of hexavalent chromium was similar to that obtained for metal inert gas-welding fumes.

Diffusion-Welded Microchannel Heat Exchanger for Industrial Processes

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

Piyush Sabharwall; Denis E. Clark; Michael V. Glazoff

The goal of next generation reactors is to increase energy ef?ciency in the production of electricity and provide high-temperature heat for industrial processes. The ef?cient transfer of energy for industrial applications depends on the ability to incorporate effective heat exchangers between the nuclear heat transport system and the industrial process. The need for ef?ciency, compactness, and safety challenge the boundaries of existing heat exchanger technology. Various studies have been performed in attempts to update the secondary heat exchanger that is downstream of the primary heat exchanger, mostly because its performance is strongly tied to the ability to employ more ef?cientmore » industrial processes. Modern compact heat exchangers can provide high compactness, a measure of the ratio of surface area-to-volume of a heat exchange. The microchannel heat exchanger studied here is a plate-type, robust heat exchanger that combines compactness, low pressure drop, high effectiveness, and the ability to operate with a very large pressure differential between hot and cold sides. The plates are etched and thereafter joined by diffusion welding, resulting in extremely strong all-metal heat exchanger cores. After bonding, any number of core blocks can be welded together to provide the required ?ow capacity. This study explores the microchannel heat exchanger and draws conclusions about diffusion welding/bonding for joining heat exchanger plates, with both experimental and computational modeling, along with existing challenges and gaps. Also, presented is a thermal design method for determining overall design speci?cations for a microchannel printed circuit heat exchanger for both supercritical (24 MPa) and subcritical (17 MPa) Rankine power cycles.« less

Effects of Welding Parameters on Mechanical Properties in Electron Beam Welded CuCrZr Alloy Plates

NASA Astrophysics Data System (ADS)

Jaypuria, Sanjib; Doshi, Nirav; Pratihar, Dilip Kumar

2018-03-01

CuCrZr alloys are attractive structural materials for plasma-facing components (PFC) and heat sink element in the International Thermonuclear Experimental Reactor (ITER) fusion reactors. This material has gained so much attention because of its high thermal conductivity and fracture toughness, high resistance to radiation damage and stability at elevated temperatures. The objective of this work is to study the effects of electron beam welding parameters on the mechanical strength of the butt welded CuCrZr joint. Taguchi method is used as the design of experiments to optimize the input parameters, such as accelerating voltage, beam current, welding speed, oscillation amplitude and frequency. The joint strength and ductility are the desired responses, which are measured through ultimate tensile strength and percent elongation, respectively. Accelerating voltage and welding speed are found to have significant influence on the strength. A combination of low amplitude and high-frequency oscillation is suggested for the higher joint strength and ductility. There is a close agreement between Taguchi predicted results and experimental ones. Fractographic analysis of joint and weld zone analysis are carried out to study the failure behaviour and microstructural variation in the weld zone, respectively.

Friction Pull Plug Welding in Aluminum Alloys

NASA Technical Reports Server (NTRS)

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

2011-01-01

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

Assembly of 5.5-Meter Diameter Developmental Barrel Segments for the Ares I Upper Stage

NASA Technical Reports Server (NTRS)

Carter, Robert W.

2011-01-01

Full scale assembly welding of Ares I Upper Stage 5.5-Meter diameter cryogenic tank barrel segments has been performed at the Marshall Space Flight Center (MSFC). One full-scale developmental article produced under the Ares 1 Upper Stage project is the Manufacturing Demonstration Article (MDA) Barrel. This presentation will focus on the welded assembly of this barrel section, and associated lessons learned. Among the MDA articles planned on the Ares 1 Program, the Barrel was the first to be completed, primarily because the process of manufacture from piece parts (barrel panels) utilized the most mature friction stir process planned for use on the Ares US program: Conventional fixed pin Friction Stir Welding (FSW). This process is in use on other space launch systems, including the Shuttle s External Tank, the Delta IV common booster core, the Delta II, and the Atlas V rockets. The goals for the MDA Barrel development were several fold: 1) to prove out Marshall Space Flight Center s new Vertical Weld Tool for use in manufacture of cylindrical barrel sections, 2) to serve as a first run for weld qualification to a new weld specification, and 3) to provide a full size cylindrical section for downstream use in precision cleaning and Spray-on Foam Insulation development. The progression leading into the welding of the full size barrel included sub scale panel welding, subscale cylinder welding, a full length confidence weld, and finally, the 3 seamed MDA barrel processing. Lessons learned on this MDA program have been carried forward into the production tooling for the Ares 1 US Program, and in the use of the MSFC VWT in processing other large scale hardware, including two 8.4 meter diameter Shuttle External Tank barrel sections that are currently being used in structural analysis to validate shell buckling models.

Restoration of Worn Movable Bridge Props with Use of Bronze Claddings.

PubMed

Viňáš, Ján; Vrabeľ, Marek; Greš, Miroslav; Brezina, Jakub; Sabadka, Dušan; Fedorko, Gabriel; Molnár, Vieroslav

2018-03-21

This article examined the possibility of using CuSn6P claddings in sliding bearing renovation of movable pontoon bridge props. The bronze layer was welded on cylinders of the high-strength steel S355J0WP EN 10155-93, in an inert atmosphere using an automated welding method (gas tungsten arc welding). Pulsed arc welding was used to minimize the effects of heat on the cladding area, while also accounting for the differences in the physical properties of the joined metals. The sliding bearing was created in two layers. The quality of the cladding layer was evaluated by nondestructive and/or destructive tests. The quality of the surface was assessed by visual inspection (visual testing) in accordance with the EN ISO 17637 standard. The quality of the claddings was evaluated by metallographic analysis, performed using light microscopy. The microhardness values of a few weld areas were determined by Vickers tests, performed according to the EN ISO 9015-2 standard. The analyses confirmed that the welding parameters and filler material used resulted in high-quality weld joints with no internal (subsurface) or metallurgical defects.

Restoration of Worn Movable Bridge Props with Use of Bronze Claddings

PubMed Central

Viňáš, Ján; Vrabeľ, Marek; Greš, Miroslav; Brezina, Jakub; Sabadka, Dušan; Fedorko, Gabriel

2018-01-01

This article examined the possibility of using CuSn6P claddings in sliding bearing renovation of movable pontoon bridge props. The bronze layer was welded on cylinders of the high-strength steel S355J0WP EN 10155-93, in an inert atmosphere using an automated welding method (gas tungsten arc welding). Pulsed arc welding was used to minimize the effects of heat on the cladding area, while also accounting for the differences in the physical properties of the joined metals. The sliding bearing was created in two layers. The quality of the cladding layer was evaluated by nondestructive and/or destructive tests. The quality of the surface was assessed by visual inspection (visual testing) in accordance with the EN ISO 17637 standard. The quality of the claddings was evaluated by metallographic analysis, performed using light microscopy. The microhardness values of a few weld areas were determined by Vickers tests, performed according to the EN ISO 9015–2 standard. The analyses confirmed that the welding parameters and filler material used resulted in high-quality weld joints with no internal (subsurface) or metallurgical defects. PMID:29561762

Internal Stress Distribution Measurement of TIG Welded SUS304 Samples Using Neutron Diffraction Technique

NASA Astrophysics Data System (ADS)

Muslih, M. Refai; Sumirat, I.; Sairun; Purwanta

2008-03-01

The distribution of residual stress of SUS304 samples that were undergone TIG welding process with four different electric currents has been measured. The welding has been done in the middle part of the samples that was previously grooved by milling machine. Before they were welded the samples were annealed at 650 degree Celsius for one hour. The annealing process was done to eliminate residual stress generated by grooving process so that the residual stress within the samples was merely produced from welding process. The calculation of distribution of residual stress was carried out by measuring the strains within crystal planes of Fe(220) SUS304. Strain, Young modulus, and Poisson ratio of Fe(220) SUS304 were measured using DN1-M neutron diffractometer. Young modulus and Poisson ratio of Fe(220) SUS304 sample were measured in-situ. The result of calculations showed that distribution of residual stress of SUS304 in the vicinity of welded area is influenced both by treatments given at the samples-making process and by the electric current used during welding process.

76 FR 71938 - Circular Welded Carbon Steel Pipes and Tubes From Thailand: Extension of Time Limit for...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-11-21

... DEPARTMENT OF COMMERCE International Trade Administration [A-549-502] Circular Welded Carbon Steel Pipes and Tubes From Thailand: Extension of Time Limit for Preliminary Results of Antidumping Duty... and tubes from Thailand for the period March 1, 2010, through February 28, 2011. See Initiation of...

76 FR 4373 - In the Matter of Certain Composite Wear Components and Welding Products Containing Same; Notice...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-01-25

... INTERNATIONAL TRADE COMMISSION [Investigation No. 337-TA-644] In the Matter of Certain Composite Wear Components and Welding Products Containing Same; Notice of Commission Determination to Temporarily Rescind Its Limited Exclusion Order and Cease and Desist Order Entered on November 24, 2009 Pending...

76 FR 3612 - Circular Welded Carbon Steel Pipes and Tubes From Taiwan; Extension of Time Limit for Preliminary...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-01-20

... DEPARTMENT OF COMMERCE International Trade Administration [A-583-008] Circular Welded Carbon Steel... Steel Pipes and Tubes From Taiwan: Notice of Partial Rescission of Antidumping Duty Administrative... complete the preliminary results of this review within the original time frame because we require...

76 FR 57020 - Circular Welded Carbon Steel Pipes and Tubes From Taiwan: Notice of Partial Rescission of...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-09-15

...) Tension Steel Industries Co. Ltd. Partial Rescission The applicable regulation, 19 CFR 351.213(d)(1....); and (6) Tension Steel Industries Co. Ltd. This review will continue with respect to Yieh Phui... DEPARTMENT OF COMMERCE International Trade Administration [A-583-008] Circular Welded Carbon Steel...

Effect of temporal pulse shaping on the reduction of laser weld defects in a Pd-Ag-Sn dental alloy.

PubMed

Bertrand, C; Poulon-Quintin, A

2011-03-01

To describe the influence of pulse shaping on the behavior of a palladium-based dental alloy during laser welding and to show how its choice is effective to promote good weld quality. Single spots, weld beads and welds with 80% overlapping were performed on Pd-Ag-Sn cast plates. A pulsed Nd:Yag laser was used with a specific welding procedure using all the possibilities for pulse-shaping: (1) the square pulse shape as the default setting, (2) a rising edge slope for gradual heating, (3) a falling edge slope to slow the cooling and (4) a combination of a rising and falling edges called bridge shape. The optimization of the pulse shape is supposed to enhance weldability and produce defect-free welds (cracks, pores…) Vickers microhardness measurements were made on cross sections of the welds. A correlation between laser welding parameters and microstructure evolution was found. Hot cracking and internal porosities were systematically detected when using rapid cooling. The presence of these types of defects was significantly reduced with the slow cooling of the molten pool. The best weld quality was obtained with the use of the bridge shape. The use of a slow cooling ramp is the only way to significantly reduce the presence of typical defects within the welds for this Pd-based alloy studied. Copyright © 2010 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Incidence of rhinitis and asthma related to welding in Northern Europe.

PubMed

Storaas, Torgeir; Zock, Jan-Paul; Morano, Ana Espinosa; Holm, Mathias; Bjørnsson, Eythor; Forsberg, Bertil; Gislason, Thorarinn; Janson, Christer; Norback, Dan; Omenaas, Ernst; Schlünssen, Vivi; Torén, Kjell; Svanes, Cecilie

2015-11-01

Welding-related asthma is well recognised but less is known about rhinitis in relation to welding. The aim here, was to study associations between welding, rhinitis and asthma in a general population sample, and factors influencing selection into and out of a welding occupation.Adult-onset asthma and non-infectious rhinitis were investigated in the international multicentre population-based Respiratory Health in Northern Europe (RHINE) study, including 16,191 responders aged 26-54 years. Ever welding (n=2181), welding >25% of working time (n=747), and welding in stainless steel >6 months (n=173) were assessed by questionnaire. Subjects with rhinitis or asthma onset when aged <18 years were excluded. Incidence rates for asthma and rhinitis were calculated from year of disease onset, and start and end of welding job. Cox's proportional hazard models adjusting for age, sex, parental education and study centre, and Kaplan-Meier curves were used.Rhinitis incidence was higher among welders (hazard ratio (HR) 1.4, 95% CI 1.3-1.6), consistent in men and women, and across centres (pheterogeneity=0.4). In men, asthma incidence was higher among welders (HR 1.4, 95% CI 1.04-1.97). Quitting welding was indicated higher after adult-onset rhinitis (HR 1.1, 95% CI 1.0-1.3). Adult-onset rhinitis and asthma was higher among welders, consistent across population samples from Northern Europe. No pre-employment selection was found, whereas selection out of welding jobs was suggested. Copyright ©ERS 2015.

High performance computation of residual stress and distortion in laser welded 301L stainless sheets

DOE PAGES

Huang, Hui; Tsutsumi, Seiichiro; Wang, Jiandong; ...

2017-07-11

Transient thermo-mechanical simulation of stainless plate laser welding process was performed by a highly efficient and accurate approach-hybrid iterative substructure and adaptive mesh method. Especially, residual stress prediction was enhanced by considering various heat effects in the numerical model. The influence of laser welding heat input on residual stress and welding distortion of stainless thin sheets were investigated by experiment and simulation. X-ray diffraction (XRD) and contour method were used to measure the surficial and internal residual stress respectively. Effect of strain hardening, annealing and melting on residual stress prediction was clarified through a parametric study. It was shown thatmore » these heat effects must be taken into account for accurate prediction of residual stresses in laser welded stainless sheets. Reasonable agreement among residual stresses by numerical method, XRD and contour method was obtained. Buckling type welding distortion was also well reproduced by the developed thermo-mechanical FEM.« less

High performance computation of residual stress and distortion in laser welded 301L stainless sheets

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

Huang, Hui; Tsutsumi, Seiichiro; Wang, Jiandong

Transient thermo-mechanical simulation of stainless plate laser welding process was performed by a highly efficient and accurate approach-hybrid iterative substructure and adaptive mesh method. Especially, residual stress prediction was enhanced by considering various heat effects in the numerical model. The influence of laser welding heat input on residual stress and welding distortion of stainless thin sheets were investigated by experiment and simulation. X-ray diffraction (XRD) and contour method were used to measure the surficial and internal residual stress respectively. Effect of strain hardening, annealing and melting on residual stress prediction was clarified through a parametric study. It was shown thatmore » these heat effects must be taken into account for accurate prediction of residual stresses in laser welded stainless sheets. Reasonable agreement among residual stresses by numerical method, XRD and contour method was obtained. Buckling type welding distortion was also well reproduced by the developed thermo-mechanical FEM.« less

Study on a New Combination Method and High Efficiency Outer Rotor Type Permanent Magnet Motors

NASA Astrophysics Data System (ADS)

Enomoto, Yuji; Kitamura, Masashi; Motegi, Yasuaki; Andoh, Takashi; Ochiai, Makoto; Abukawa, Toshimi

The segment stator core, high space factor coil, and high efficiency magnet are indispensable technologies in the development of compact and a high efficiency motors. But adoption of the segment stator core and high space factor coil has not progressed in the field of outer rotor type motors, for the reason that the inner components cannot be laser welded together. Therefore, we have examined a segment stator core combination technology for the purposes of getting a large increase in efficiency and realizing miniaturization. We have also developed a characteristic estimation method which provides the most suitable performance for segment stator core motors.

Video Intertank for the Core Stage for the first SLS Flight

NASA Image and Video Library

2017-06-29

This video shows the Space Launch System interank, which recently completed assembly at NASA's Michoud Assembly Facility in New Orleans. This tank was bolted together with more than 7,000 bolts. It is the only part of the SLS core stage assembly with bolts rather than by welding. The rocket's interank is located between the core stage liquid oxygen and liquid hydrogen fuel tanks. It has to be strong because the two SLS solid rocket boosters attache to the sides of it. This flight article will be connected to four other parts to form the core stage for the first integrated flight of SLS and Orion.

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

NASA Technical Reports Server (NTRS)

Choquet, Claude

2011-01-01

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

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.

A Field Study on the Respiratory Deposition of the Nano-Sized Fraction of Mild and Stainless Steel Welding Fume Metals.

PubMed

Cena, L G; Chisholm, W P; Keane, M J; Chen, B T

2015-01-01

A field study was conducted to estimate the amount of Cr, Mn, and Ni deposited in the respiratory system of 44 welders in two facilities. Each worker wore a nanoparticle respiratory deposition (NRD) sampler during gas metal arc welding (GMAW) of mild and stainless steel and flux-cored arc welding (FCAW) of mild steel. Several welders also wore side-by-side NRD samplers and closed-face filter cassettes for total particulate samples. The NRD sampler estimates the aerosol's nano-fraction deposited in the respiratory system. Mn concentrations for both welding processes ranged 2.8-199 μg/m3; Ni concentrations ranged 10-51 μg/m3; and Cr concentrations ranged 40-105 μg/m3. Cr(VI) concentrations ranged between 0.5-1.3 μg/m3. For the FCAW process the largest concentrations were reported for welders working in pairs. As a consequence this often resulted in workers being exposed to their own welding fumes and to those generated from the welding partner. Overall no correlation was found between air velocity and exposure (R2 = 0.002). The estimated percentage of the nano-fraction of Mn deposited in a mild-steel-welder's respiratory system ranged between 10 and 56%. For stainless steel welding, the NRD samplers collected 59% of the total Mn, 90% of the total Cr, and 64% of the total Ni. These results indicate that most of the Cr and more than half of the Ni and Mn in the fumes were in the fraction smaller than 300 nm.

Measuring Weld Profiles By Computer Tomography

NASA Technical Reports Server (NTRS)

Pascua, Antonio G.; Roy, Jagatjit

1990-01-01

Noncontacting, nondestructive computer tomography system determines internal and external contours of welded objects. System makes it unnecessary to take metallurgical sections (destructive technique) or to take silicone impressions of hidden surfaces (technique that contaminates) to inspect them. Measurements of contours via tomography performed 10 times as fast as measurements via impression molds, and tomography does not contaminate inspected parts.

Advanced radiator concepts utilizing honeycomb panel heat pipes

NASA Technical Reports Server (NTRS)

Fleischman, G. L.; Peck, S. J.; Tanzer, H. J.

1987-01-01

The feasibility of fabricating and processing moderate temperature range vapor chamber type heat pipes in a low mass honeycomb panel configuration for highly efficient radiator fins for potential use on the space station was investigated. A variety of honeycomb panel facesheet and core-ribbon wick concepts were evaluated within constraints dictated by existing manufacturing technology and equipment. Concepts evaluated include type of material, material and panel thickness, wick type and manufacturability, liquid and vapor communication among honeycomb cells, and liquid flow return from condenser to evaporator facesheet areas. A thin-wall all-welded stainless steel design with methanol as the working fluid was the initial prototype unit. It was found that an aluminum panel could not be fabricated in the same manner as a stainless steel panel due to diffusion bonding and resistance welding considerations. Therefore, a formed and welded design was developed. The prototype consists of ten panels welded together into a large panel 122 by 24 by 0.15 in., with a heat rejection capability of 1000 watts and a fin efficiency of essentially 1.0.

Final Report: A Transport Phenomena Based Approach to Probe Evolution of Weld Macro and Microstructures and A Smart Bi-directional Model of Fusion Welding

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

Dr. Tarasankar DebRoy

In recent years, applications of numerical heat transfer and fluid flow models of fusion welding have resulted in improved understanding of both the welding processes and welded materials. They have been used to accurately calculate thermal cycles and fusion zone geometry in many cases. Here we report the following three major advancements from this project. First, we show how microstructures, grain size distribution and topology of welds of several important engineering alloys can be computed starting from better understanding of the fusion welding process through numerical heat transfer and fluid flow calculations. Second, we provide a conclusive proof that themore » reliability of numerical heat transfer and fluid flow calculations can be significantly improved by optimizing several uncertain model parameters. Third, we demonstrate how the numerical heat transfer and fluid flow models can be combined with a suitable global optimization program such as a genetic algorithm for the tailoring of weld attributes such as attaining a specified weld geometry or a weld thermal cycle. The results of the project have been published in many papers and a listing of these are included together with a list of the graduate thesis that resulted from this project. The work supported by the DOE award has resulted in several important national and international awards. A listing of these awards and the status of the graduate students are also presented in this report.« less

Strategies for risk assessment and control in welding: challenges for developing countries.

PubMed

Hewitt, P J

2001-06-01

Metal arc welding ranges from primitive (manual) to increasingly complex automated welding processes. Welding occupies 1% of the labour force in some industrialised countries and increasing knowledge of health risks, necessitating improved assessment strategies and controls have been identified by the International Institute of Welding (IIW), ILO, WHO and other authoritative bodies. Challenges for developing countries need to be addressed. For small scale production and repair work, predominantly by manual metal arc on mild steel, the focus in developing economies has correctly been on control of obvious physical and acute health affects. Development introduces more sophisticated processes and hazards. Work pieces of stainless steel and consumables with chromium, nickel and manganese constituents are used with increasingly complex semi-manual or automated systems involving variety of fluxes or gasses. Uncritical adoption of new welding technologies by developing countries potentiates future health problems. Control should be integral at the design stage, otherwise substantive detriments and later costs can ensue. Developing countries need particular guidance on selection of the optimised welding consumables and processes to minimise such detriments. The role of the IIW and the MFRU are described. Applications of occupational hygiene principals of prevention and control of welding fume at source by process modification are presented.

Earth boring apparatus with multiple welds

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

Bolton, J.B.; Crews, S.T.

1981-06-16

A box tool joint member of generally tubular configuration is adapted for securement by welding to one end of a steel tube to form a drill pipe. The box tool joint member comprises a body having a cylindrical outer periphery, an internally threaded socket at one end of the body, and a weld neck of smaller outer diameter than the body adjacent to the other end of the body. A tapered transition piece connecting the neck with the adjacent end of the body provides an elevator shoulder. A correlative pin tool joint member is welded to the opposite end ofmore » the tube to complete the drill pipe. The box tool joint member has an annular band of hard facing over the outer periphery of the transition piece and extending down over the adjacent part of the weld neck and up around the adjacent part of the body. The hard facing is corrosion resistant and has a smooth finished surface. Underneath the hard facing and extending beyond both ends of the hard facing is an annular butter layer of non-hardenable steel. The tool joint member is hardened and tempered after the butter layer is welded into a body groove and before the hard facing is welded on .The butter layer is grooved before the hard facing is welded on.« less

Dose-dependent progression of parkinsonism in manganese-exposed welders

PubMed Central

Searles Nielsen, Susan; Criswell, Susan R.; Sheppard, Lianne; Seixas, Noah; Warden, Mark N.; Checkoway, Harvey

2017-01-01

Objective: To determine whether the parkinsonian phenotype prevalent in welders is progressive, and whether progression is related to degree of exposure to manganese (Mn)-containing welding fume. Methods: This was a trade union–based longitudinal cohort study of 886 American welding-exposed workers with 1,492 examinations by a movement disorders specialist, including 398 workers with 606 follow-up examinations up to 9.9 years after baseline. We performed linear mixed model regression with cumulative Mn exposure as the independent variable and annual change in Unified Parkinson Disease Rating Scale motor subsection part 3 (UPDRS3) as the primary outcome, and subcategories of the UPDRS3 as secondary outcomes. The primary exposure metric was cumulative Mn exposure in mg Mn/m3-year estimated from detailed work histories. Results: Progression of parkinsonism increased with cumulative Mn exposure. Specifically, we observed an annual change in UPDRS3 of 0.24 (95% confidence interval 0.10–0.38) for each mg Mn/m3-year of exposure. Exposure was most strongly associated with progression of upper limb bradykinesia, upper and lower limb rigidity, and impairment of speech and facial expression. The association between welding exposure and progression appeared particularly marked in welders who did flux core arc welding in a confined space or workers whose baseline examination was within 5 years of first welding exposure. Conclusions: Exposure to Mn-containing welding fume may cause a dose-dependent progression of parkinsonism, especially upper limb bradykinesia, limb rigidity, and impairment of speech and facial expression. PMID:28031394

Effect of Nickel Contents on the Microstructure and Mechanical Properties for Low-Carbon Bainitic Weld Metals

NASA Astrophysics Data System (ADS)

Mao, Gaojun; Cao, Rui; Yang, Jun; Jiang, Yong; Wang, Shuai; Guo, Xili; Yuan, Junjun; Zhang, Xiaobo; Chen, Jianhong

2017-05-01

Multi-pass weld metals were deposited on Q345 base steel using metal powder-flux-cored wire with various Ni contents to investigate the effects of the Ni content on the weld microstructure and property. The types of the microstructures were identified by optical microscope, scanning electron microscope, transmission electron microscope, and micro-hardness tests. As a focusing point, the lath bainite and lath martensite were distinguished by their compositions, morphologies, and hardness. In particular, a number of black plane facets appearing between lath bainite or lath martensite packets were characterized by laser scanning confocal microscope. The results indicated that with the increase in Ni contents in the range of 0, 2, 4, and 6%, the microstructures in the weld-deposited metal were changed from the domination of the granular bainite to the majority of the lath bainite and/or the lath martensite and the micro-hardness of the weld-deposited metal increased. Meanwhile, the average width of columnar grain displays a decreasing trend and prior austenite grain size decreases while increases with higher Ni content above 4%. Yield strength and ultimate tensile strength decrease, while the reduction in fracture area increases with the decreasing Ni mass fraction and the increasing test temperature, respectively. And poor yield strength in Ni6 specimen can be attributed to elements segregation caused by weld defect. Finally, micro-hardness distribution in correspondence with specimens presents as a style of cloud-map.

International Workshop on Gamma Aluminide Alloy Technology. Section Four

DTIC Science & Technology

1997-04-18

a «—■ i— Q. O C (N i < 00 i H B £ 32 £ M U XI c o L. 4-» 5 Autogenous keyhole plasma weld in Ti-48Al-2Mn-2Nb casting, xlO...34: -, Sl Overview of joining gamma alloys P Threadgill J Lee, W A Baeslack and T J Kelly: Weld fusion zone phenomena in Ti (45-48)A1-Nb-Cr y...titanium aluminides, submitted to Welding Journal. a c 9 "" o « JL ° V GO I ■ CO ’ V ** K _ L

Development of the Corporal: The Embryo of the Army Missile Program, Volume II: Supporting Data. Documents 1 through 31

DTIC Science & Technology

1961-04-01

heads, were used. Flights E-4 through E-6 utilized forged cylinders of SAE 4140 , machined to 0.25- inch wall thickness with machined skirts. The heads...cylindrical portion of the air tank in E-1 was welded of SAE 4130 steel plates 0.50 inch thick. The heads were 0.375 inch thick, whereas the internal...Edward S. Forman, and Weld Arnold. The early phases of the research were financed by a fund of $1,000 from Mr. Weld Arnold. "The first activities of

75 FR 13729 - Circular Welded Non-Alloy Steel Pipe from the Republic of Korea: Extension of Time Limit for the...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-03-23

... Steel Pipe from the Republic of Korea: Extension of Time Limit for the Final Results and Rescission in Part of the Antidumping Duty Administrative Review AGENCY: Import Administration, International Trade... Welded Non-Alloy Steel Pipe from the Republic of Korea: Preliminary Results and Rescission in Part of the...

Microstructural analysis of the 2195 aluminum-lithium alloy welds

NASA Technical Reports Server (NTRS)

Talia, George E.

1993-01-01

The principal objective of this research was to explain a tendency of 2195 Al-Li alloy to crack at elevated temperature during welding. Therefore, a study was made on the effect of welding and thermal treatment on the microstructure of Al-Li Alloy 2195. The critical roles of precipitates, boundaries, phases, and other features of the microstructure were inferred from the crack propagation paths and the morphology of fracture surface of the alloy with different microstructures. Particular emphasis was placed on the microstructures generated by the welding process and the mechanisms of crack propagation in such structures. Variation of the welding parameters and thermal treatments were used to alter the micro/macro structures, and they were characterized by optical and scanning electron microscopy. A theoretical model is proposed to explain changes in the microstructure of welded material. This model proposes a chemical reaction in which gases from the air (i.e., nitrogen) release hydrogen inside the alloy. Such a reaction could generate large internal stresses capable to induce porosity and crack-like delamination in the material.

Rheology of welding: experimental constraints

NASA Astrophysics Data System (ADS)

Quane, S. L.; Russell, J. K.; Kennedy, L. A.

2003-04-01

The rheological behavior of pyroclastic deposits during welding is incompletely understood and is based on a surprisingly small number of experimental studies. Previous pioneering experimental studies were done on small (1 cm thick) samples of ash/crystal mixtures under constant load. They established minimum welding temperatures between 600 and 700^oC under loads of 0.7 MPa (˜40 m of ignimbrite) to 3.6 MPa (˜250 m depth of ignimbrite). However, these data are neither sufficiently comprehensive nor coherent enough to fully describe the rheology of pyroclastic mixtures. In addition, previous studies did not examine the microstructural and geometric changes associated with welding compaction. Our goal is to provide accurate and comprehensive constitutive relationships between material properties, temperature, load and strain rate for pyroclastic material undergoing welding. Here we present results from a newly designed experimental apparatus. The experimental apparatus consists of a LoadTrac II fully automated uniaxial compression load frame manufactured by Geocomp Corporation. The load frame has a built in displacement transducer and can run both constant strain rate (10-6 to 0.25 cm/s) and constant load (up to 1150 kg) tests to a maximum displacement of 7.5 cm. The sample assembly comprises 5 cm diameter cylindrical upper and lower pistons (insulating ceramic with steel conductive ends) housed in a copper jacket. Samples are 5 cm diameter cores and can vary in length from 1 to 15 cm depending on experimental needs. A fiber insulated tube furnace capable of reaching temperatures ≈1000^oC surrounds the sample assembly. Temperature is measured using a thermocouple located inside the sample through the bottom piston; the furnace controller is capable of maintaining temperature fluctuations to <5^oC. Deformation experiments are performed on pre-fabricated cylinders of soda-lime glass beads and rhyolitic volcanic ash, as well as, cores of pumiceous rhyodacite. Experimental runs use strain rates of 10-4 and 10-5 cm/s and loads of ˜0 to 4.5 MPa. Experiments are run at temperatures between 400 and 850^oC corresponding to below and above the calorimetric glass transition temperatures of the respective materials. Data deriving from constant load and constant strain rate experiments are being used to constrain rheological models for welding of pyroclastic material.

Laser balloon angioplasty: effect of tissue temperature on weld strength of human postmortem intima-media separations.

PubMed

Jenkins, R D; Sinclair, I N; Anand, R; Kalil, A G; Schoen, F J; Spears, J R

1988-01-01

Dehiscence of portions of atheromatous plaques fractured during percutaneous transluminal coronary angioplasty may contribute to both abrupt reclosure and gradual restenosis. Laser balloon angioplasty has been shown to be effective in welding human plaque-arterial wall separations in vitro by heating tissues with a Nd:YAG laser during balloon inflation. To define the potentially useful therapeutic range of tissue temperature required to achieve thermal welds, 220 1-cm diameter discs of human postmortem atheromatous aortic tissue, the intimal plaque of which had been separated from the media, were exposed to 3-25 watts of Nd:YAG laser radiation delivered over a 12-mm2 nominal spot size for 20 seconds via a 400-micron core optical fiber. As measured with a thermistor, adventitial temperature reflected the temperature at the plaque-media junction to within 10 degrees C. The degree of tissue temperature elevation was related to delivered energy, while effective tissue penetration increased to maximum depth of 3 mm at the highest power density. Strength of tissue welds was defined as the force required to shear opposing layers of welded segments. Adventitial tissue temperatures below 80 degrees C were not associated with appreciable welds, while equilibrium temperatures between 95 degrees C and 140 degrees C were consistently associated with effective mean weld strengths, which increased linearly from 25 to 110 g, respectively. Temperatures greater than 150 degrees C were associated with rapid tissue dehydration and charring. These data suggest that the therapeutic range of tissue temperature that provides effective thermal fusion of intima-media separations is broad and that the depth and degree of thermal coagulation can be controlled by manipulation of laser energy delivery.

A Field Study on the Respiratory Deposition of the Nano-Sized Fraction of Mild and Stainless Steel Welding Fume Metals

PubMed Central

Cena, L. G.; Chisholm, W. P.; Keane, M. J.; Chen, B. T.

2016-01-01

A field study was conducted to estimate the amount of Cr, Mn, and Ni deposited in the respiratory system of 44 welders in two facilities. Each worker wore a nanoparticle respiratory deposition (NRD) sampler during gas metal arc welding (GMAW) of mild and stainless steel and flux-cored arc welding (FCAW) of mild steel. Several welders also wore side-by-side NRD samplers and closed-face filter cassettes for total particulate samples. The NRD sampler estimates the aerosol's nano-fraction deposited in the respiratory system. Mn concentrations for both welding processes ranged 2.8–199 μg/m3; Ni concentrations ranged 10–51 μg/m3; and Cr concentrations ranged 40–105 μg/m3. Cr(VI) concentrations ranged between 0.5–1.3 μg/m3. For the FCAW process the largest concentrations were reported for welders working in pairs. As a consequence this often resulted in workers being exposed to their own welding fumes and to those generated from the welding partner. Overall no correlation was found between air velocity and exposure (R2 = 0.002). The estimated percentage of the nano-fraction of Mn deposited in a mild-steel-welder's respiratory system ranged between 10 and 56%. For stainless steel welding, the NRD samplers collected 59% of the total Mn, 90% of the total Cr, and 64% of the total Ni. These results indicate that most of the Cr and more than half of the Ni and Mn in the fumes were in the fraction smaller than 300 nm. PMID:25985454

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.

Automated generation of weld path trajectories.

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

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

2003-06-01

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

Experimental exposure of healthy subjects with emissions from a gas metal arc welding process--part II: biomonitoring of chromium and nickel.

PubMed

Gube, Monika; Brand, Peter; Schettgen, Thomas; Bertram, Jens; Gerards, Kerstin; Reisgen, Uwe; Kraus, Thomas

2013-01-01

The objective of this study was to investigate whether there is a relationship between the external exposure dose of chromium and nickel caused by a metal active gas welding process with a solid high-alloyed steel welding wire and inner exposure of subjects. In order to perform welding fume exposure under controlled and standardized conditions, the investigations were conducted in the "Aachen Workplace Simulation Laboratory". To perform biological monitoring of chromium and nickel, blood and urine samples of 12 healthy male non-smokers who never worked as welders were collected before and after a 6-h exposure to ambient air (0 mg/m(3)) and to welding fumes of a metal active gas welding process once with a concentration of the welding fume of 1 mg/m(3) and once with a concentration of 2.5 mg/m(3). Although the internal exposure to chromium and nickel in this study was comparatively low, the subjects showed significantly increased concentrations of these metals in urine after exposure to welding fume compared to the values at baseline. Moreover, the observed increase was significantly dose dependent for both of the substances. For the biological monitoring of chromium and nickel in urine of subjects exposed to welding fumes, a dependency on exposure dose was seen under standardized conditions after a single exposure over a period of 6 h. Thus, this study contributes to a better understanding of the relationship between ambient and biological exposures from welding fumes and provides a good basis for evaluating future biological threshold values for these metals in welding occupation.

A Decade of Friction Stir Welding R and D at NASA's Marshall Space Flight Center and a Glance into the Future

NASA Technical Reports Server (NTRS)

Ding, Jeff; Carter, Bob; Lawless, Kirby; Nunes, Arthur; Russell, Carolyn; Suites, Michael; Schneider, Judy

2006-01-01

Welding at NASA's Marshall Space Flight Center (MSFC), Huntsville, Alabama, has taken a new direction through the last 10 years. Fusion welding processes, namely variable polarity plasma arc (VPPA) and tungsten inert gas (TIG) were once the corner stone of welding development in the Space Flight Center's welding laboratories, located in the part of MSFC know as National Center for Advanced Manufacturing (NCM). Developed specifically to support the Shuttle Program's External Tank and later International Space Station manufacturing programs, was viewed as the paragon of welding processes for joining aluminum alloys. Much has changed since 1994, however, when NASA's Jeff Ding brought the FSW process to the NASA agency. Although, at that time, FSW was little more than a "lab curiosity", NASA researchers started investigating where the FSW process would best fit NASA manufacturing programs. A laboratory FSW system was procured and the first welds were made in fall of 1995. The small initial investment NASA made into the first FSW system has certainly paid off for the NASA agency in terms of cost savings, hardware quality and notoriety. FSW is now a part of Shuttle External Tank (ET) production and the preferred weld process for the manufacturing of components for the new Crew Launch Vehicle (CLV) and Heavy Lift Launch Vehicle (HLLV) that will take this country back to the moon. It is one of the solid state welding processes being considered for on-orbit space welding and repair, and is of considerable interest for Department of Defense @OD) manufacturing programs. MSFC involvement in these and other programs makes NASA a driving force in this country's development of FSW and other solid state welding technologies. Now, a decade later, almost the entire on-going welding R&D at MSFC now focuses on FSW and other more advanced solid state welding processes.

Parametric representation of weld fillets using shell finite elements—a proposal based on minimum stiffness and inertia errors

NASA Astrophysics Data System (ADS)

Echer, L.; Marczak, R. J.

2018-02-01

The objective of the present work is to introduce a methodology capable of modelling welded components for structural stress analysis. The modelling technique was based on the recommendations of the International Institute of Welding; however, some geometrical features of the weld fillet were used as design parameters in an optimization problem. Namely, the weld leg length and thickness of the shell elements representing the weld fillet were optimized in such a way that the first natural frequencies were not changed significantly when compared to a reference result. Sequential linear programming was performed for T-joint structures corresponding to two different structural details: with and without full penetration weld fillets. Both structural details were tested in scenarios of various plate thicknesses and depths. Once the optimal parameters were found, a modelling procedure was proposed for T-shaped components. Furthermore, the proposed modelling technique was extended for overlapped welded joints. The results obtained were compared to well-established methodologies presented in standards and in the literature. The comparisons included results for natural frequencies, total mass and structural stress. By these comparisons, it was observed that some established practices produce significant errors in the overall stiffness and inertia. The methodology proposed herein does not share this issue and can be easily extended to other types of structure.

76 FR 8345 - Certain Carbon Steel Butt-Weld Pipe Fittings From Brazil, Japan, Taiwan, Thailand, and the People...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-02-14

... DEPARTMENT OF COMMERCE International Trade Administration [A-351-602, A-588-602, A-583-605, A-549-807, A-570-814] Certain Carbon Steel Butt-Weld Pipe Fittings From Brazil, Japan, Taiwan, Thailand, and the People's Republic of China: Final Results of the Expedited Sunset Reviews of the Antidumping Duty Orders Correction In notice document 2011...

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

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

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

2014-02-18

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

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

NASA Astrophysics Data System (ADS)

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

2014-02-01

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

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

NASA Astrophysics Data System (ADS)

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

2016-01-01

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

Analysis of Proportional Integral and Optimized Proportional Integral Controllers for Resistance Spot Welding System (RSWS) - A Performance Perspective

NASA Astrophysics Data System (ADS)

Rama Subbanna, S.; Suryakalavathi, M., Dr.

2017-08-01

This paper is an attempt to accomplish a performance analysis of the different control techniques on spikes reduction method applied on the medium frequency transformer based DC spot welding system. Spike reduction is an important factor to be considered while spot welding systems are concerned. During normal RSWS operation welding transformer’s magnetic core can become saturated due to the unbalanced resistances of both transformer secondary windings and different characteristics of output rectifier diodes, which causes current spikes and over-current protection switch-off of the entire system. The current control technique is a piecewise linear control technique that is inspired from the DC-DC converter control algorithms to register a novel spike reduction method in the MFDC spot welding applications. Two controllers that were used for the spike reduction portion of the overall applications involve the traditional PI controller and Optimized PI controller. Care is taken such that the current control technique would maintain a reduced spikes in the primary current of the transformer while it reduces the Total Harmonic Distortion. The performance parameter that is involved in the spikes reduction technique is the THD, Percentage of current spike reduction for both techniques. Matlab/SimulinkTM based simulation is carried out for the MFDC RSWS with KW and results are tabulated for the PI and Optimized PI controllers and a tradeoff analysis is carried out.

Solidification and solidification cracking in nitrogen-strengthened austenitic stainless steels

NASA Astrophysics Data System (ADS)

Ritter, Ann M.; Savage, Warren F.

1986-04-01

The solidification behavior of three heats of nitrogen-strengthened austenitic stainless steel was examined and was correlated with solidification mode predictions and with hot cracking resistance. The heat of NITRONIC* 50 solidified by the austenitic-ferrite mode, and the NITRONIC 50W and NITRONIC 50W - Nb heats solidified by the ferritic-austenitic mode. This behavior was in good agreement with predictions based on Espy’s formulas for Cr and Ni equivalents. Both the NITRONIC 50W and NITRONIC 50W + Nb welds contained primary delta-ferrite, with the latter weld and the NITRONIC 50 weld also containing some eutectic ferrite. Solute profiles in austenite near the eutectic ferrite showed decreasing Fe and increasing Cr, Ni, Mn, and Mo relative to austenite in the dendrite cores. Numerous Nb-rich precipitates were found on the eutectic ferrite/austenite interfaces and within the eutectic ferrite. The precipitates were mainly Nb(C, N), with some Z-phase, a Nb-rich nitride, also detected. One instance of the transformation of eutectic ferrite to sigma-phase was observed to have occurred during cooling of the NITRONIC 50 weld. Hot cracking was seen in the NITRONIC 50 and NITRONIC 50W + Nb welds and resulted from the formation of a niobium carbonitride eutectic in the interdendritic regions. In the absence of Nb, the NITRONIC 50W heat formed no observable eutectic constituents and did not hot crack. The presence of hot cracks in the NITRONIC 50W + Nb weld indicates that solidification by the ferritic-austenitic mode did not counteract the effects of small Nb additions.

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

NASA Astrophysics Data System (ADS)

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

2005-01-01

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

Laser welding in penetrating keratoplasty and cataract surgery of pediatric patients: early results

NASA Astrophysics Data System (ADS)

Rossi, Francesca; Pini, Roberto; Menabuoni, Luca; Malandrini, Alex; Canovetti, Annalisa; Lenzetti, Ivo; Capozzi, Paolo; Valente, Paola; Buzzonetti, Luca

2013-03-01

Diode laser welding of ocular tissues is a procedure that enables minimally invasive closure of a corneal wound. This procedure is based on a photothermal effect: a water solution of Indocyanine Green (ICG) is inserted in the surgical wound, in order to stain the corneal tissue walls. The stained tissue is then irradiated with a low power infrared diode laser, delivering laser light through a 300-μm core diameter optical fiber. This procedure enables an immediate closure of the wounds: it is thus possible to reduce or to substitute the use of surgical threads. This is of particular interest in children, because the immediate closure improves refractive outcome and anti-amblyopic effect; moreover this procedure avoids several general anaesthesia for suture management. In this work, we present the first use of diode laser welding procedure in paediatric patients. 5 selected patients underwent cataract surgery (Group 1), while 4 underwent fs-laserassisted penetrating keratoplasty (Group 2). In Group 1 the conventional surgery procedure was performed, while no stitches were used for the closure of the surgical wounds: these were laser welded and immediately closed. In Group 2 the donor button was sutured upon the recipient by 8 single stitches, instead of 16 single stitches or a running suture. The laser welding procedure was performed in order to join the donor tissue to the recipient bed. Objective observations in the follow up study evidenced a perfect adhesion of the laser welded tissues, no collateral effects and an optimal restoration of the treated tissues.

Effect of Post-weld Heat Treatment on the Mechanical Properties of Supermartensitic Stainless Steel Deposit

NASA Astrophysics Data System (ADS)

Zappa, Sebastián; Svoboda, Hernán; Surian, Estela

2017-02-01

Supermartensitic stainless steels have good weldability and adequate tensile property, toughness and corrosion resistance. They have been developed as an alternative technology, mainly for oil and gas industries. The final properties of a supermartensitic stainless steel deposit depend on its chemical composition and microstructure: martensite, tempered martensite, ferrite, retained austenite and carbides and/or nitrides. In these steels, the post-weld heat treatments (PWHTs) are usually double tempering ones, to ensure both complete tempering of martensite and high austenite content, to increase toughness and decrease hardness. The aim of this work was to study the effect of post-weld heat treatments (solution treatment with single and double tempering) on the mechanical properties of a supermartensitic stainless steel deposit. An all-weld metal test coupon was welded according to standard ANSI/AWS A5.22-95 using a GMAW supermartensitic stainless steel metal cored wire, under gas shielding. PWHTs were carried out varying the temperature of the first tempering treatment with and without a second tempering one, after solution treatment. All-weld metal chemical composition analysis, metallurgical characterization, hardness and tensile property measurements and Charpy-V tests were carried out. There are several factors which can be affected by the PWHTs, among them austenite content is a significant one. Different austenite contents (0-42%) were found. Microhardness, tensile property and toughness were affected with up to 15% of austenite content, by martensite tempering and carbide precipitation. The second tempering treatment seemed not to have had an important effect on the mechanical properties measured in this work.

Friction Stir Welding and Processing

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

Hovanski, Yuri; Carsley, John; Clarke, Kester D.

2015-05-01

With nearly twenty years of international research and collaboration in friction stir welding (FSW) and processing industrial applications have spread into nearly every feasible market. Currently applications exist in aerospace, railway, automotive, personal computers, technology, marine, cutlery, construction, as well as several other markets. Implementation of FSW has demonstrated diverse opportunities ranging from enabling new materials to reducing the production costs of current welding technologies by enabling condensed packaging solutions for traditional fabrication and assembly. TMS has sponsored focused instruction and communication in this technology area for more than fifteen years, with leadership from the Shaping and Forming Committee, whichmore » organizes a biannual symposium each odd year at the annual meeting. A focused publication produced from each of these symposia now comprises eight volumes detailing the primary research and development activities in this area over the last two decades. The articles assembled herein focus on both recent developments and technology reviews of several key markets from international experts in this area.« less

The detection of flaws in austenitic welds using the decomposition of the time-reversal operator

NASA Astrophysics Data System (ADS)

Cunningham, Laura J.; Mulholland, Anthony J.; Tant, Katherine M. M.; Gachagan, Anthony; Harvey, Gerry; Bird, Colin

2016-04-01

The non-destructive testing of austenitic welds using ultrasound plays an important role in the assessment of the structural integrity of safety critical structures. The internal microstructure of these welds is highly scattering and can lead to the obscuration of defects when investigated by traditional imaging algorithms. This paper proposes an alternative objective method for the detection of flaws embedded in austenitic welds based on the singular value decomposition of the time-frequency domain response matrices. The distribution of the singular values is examined in the cases where a flaw exists and where there is no flaw present. A lower threshold on the singular values, specific to austenitic welds, is derived which, when exceeded, indicates the presence of a flaw. The detection criterion is successfully implemented on both synthetic and experimental data. The datasets arising from welds containing a flaw are further interrogated using the decomposition of the time-reversal operator (DORT) method and the total focusing method (TFM), and it is shown that images constructed via the DORT algorithm typically exhibit a higher signal-to-noise ratio than those constructed by the TFM algorithm.

Microstructural Influence on Mechanical Properties in Plasma Microwelding of Ti6Al4V Alloy

NASA Astrophysics Data System (ADS)

Baruah, M.; Bag, S.

2016-11-01

The complexity of joining Ti6Al4V alloy enhances with reduction in sheet thickness. The present work puts emphasis on microplasma arc welding (MPAW) of 500-μm-thick Ti6Al4V alloy in butt joint configuration. Using controlled and regulated arc current, the MPAW process is specifically designed to use in joining of thin sheet components over a wide range of process parameters. The weld quality is assessed by carefully controlling the process parameters and by reducing the formation of oxides. The combined effect of welding speed and current on the weld joint properties is evaluated for joining of Ti6Al4V alloy. The macro- and microstructural characterizations of the weldment by optical microscopy as well as the analysis of mechanical properties by microtensile and microhardness test have been performed. The weld joint quality is affected by specifically designed fixture that controls the oxidation of the joint and introduces high cooling rate. Hence, the solidified microstructure of welded specimen influences the mechanical properties of the joint. The butt joint of titanium alloy by MPAW at optimal process parameters is of very high quality, without any internal defects and with minimum residual distortion.

The detection of flaws in austenitic welds using the decomposition of the time-reversal operator

PubMed Central

Cunningham, Laura J.; Mulholland, Anthony J.; Gachagan, Anthony; Harvey, Gerry; Bird, Colin

2016-01-01

The non-destructive testing of austenitic welds using ultrasound plays an important role in the assessment of the structural integrity of safety critical structures. The internal microstructure of these welds is highly scattering and can lead to the obscuration of defects when investigated by traditional imaging algorithms. This paper proposes an alternative objective method for the detection of flaws embedded in austenitic welds based on the singular value decomposition of the time-frequency domain response matrices. The distribution of the singular values is examined in the cases where a flaw exists and where there is no flaw present. A lower threshold on the singular values, specific to austenitic welds, is derived which, when exceeded, indicates the presence of a flaw. The detection criterion is successfully implemented on both synthetic and experimental data. The datasets arising from welds containing a flaw are further interrogated using the decomposition of the time-reversal operator (DORT) method and the total focusing method (TFM), and it is shown that images constructed via the DORT algorithm typically exhibit a higher signal-to-noise ratio than those constructed by the TFM algorithm. PMID:27274683

Shrink-Fit Solderable Inserts Seal Hermetically

NASA Technical Reports Server (NTRS)

Croucher, William C.

1992-01-01

Shrink-fit stainless-steel insert in aluminum equipment housing allows electrical connectors to be replaced by soldering, without degrading hermeticity of housing or connector. Welding could destroy electrostatic-sensitive components and harm housing and internal cables. Steel insert avoids problems because connector soldered directly to it rather than welded to housing. Seals between flange and housing, and between connector and flange resistant to leaks, even after mechanical overloading and thermal shocking.

Conceptual waste packaging options for deep borehole disposal

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

Su, Jiann -Cherng; Hardin, Ernest L.

This report presents four concepts for packaging of radioactive waste for disposal in deep boreholes. Two of these are reference-size packages (11 inch outer diameter) and two are smaller (5 inch) for disposal of Cs/Sr capsules. All four have an assumed length of approximately 18.5 feet, which allows the internal length of the waste volume to be 16.4 feet. However, package length and volume can be scaled by changing the length of the middle, tubular section. The materials proposed for use are low-alloy steels, commonly used in the oil-and-gas industry. Threaded connections between packages, and internal threads used to sealmore » the waste cavity, are common oilfield types. Two types of fill ports are proposed: flask-type and internal-flush. All four package design concepts would withstand hydrostatic pressure of 9,600 psi, with factor safety 2.0. The combined loading condition includes axial tension and compression from the weight of a string or stack of packages in the disposal borehole, either during lower and emplacement of a string, or after stacking of multiple packages emplaced singly. Combined loading also includes bending that may occur during emplacement, particularly for a string of packages threaded together. Flask-type packages would be fabricated and heat-treated, if necessary, before loading waste. The fill port would be narrower than the waste cavity inner diameter, so the flask type is suitable for directly loading bulk granular waste, or loading slim waste canisters (e.g., containing Cs/Sr capsules) that fit through the port. The fill port would be sealed with a tapered, threaded plug, with a welded cover plate (welded after loading). Threaded connections between packages and between packages and a drill string, would be standard drill pipe threads. The internal flush packaging concepts would use semi-flush oilfield tubing, which is internally flush but has a slight external upset at the joints. This type of tubing can be obtained with premium, low-profile threaded connections at each end. The internal-flush design would be suitable for loading waste that arrives from the originating site in weld-sealed, cylindrical canisters. Internal, tapered plugs with sealing filet welds would seal the tubing at each end. The taper would be precisely machined onto both the tubing and the plug, producing a metal-metal sealing surface that is compressed as the package is subjected to hydrostatic pressure. The lower plug would be welded in place before loading, while the upper plug would be placed and welded after loading. Conceptual Waste Packaging Options for Deep Borehole Disposal July 30, 2015 iv Threaded connections between packages would allow emplacement singly or in strings screwed together at the disposal site. For emplacement on a drill string the drill pipe would be connected directly into the top package of a string (using an adapter sub to mate with premium semi-flush tubing threads). Alternatively, for wireline emplacement the same package designs could be emplaced singly using a sub with wireline latch, on the upper end. Threaded connections on the bottom of the lowermost package would allow attachment of a crush box, instrumentation, etc.« less

EVALUATION OF DATA OBTAINED ON "MANUFACTURING PROCESS" DEVELOPMENT BUNDLES PD 1 THROUGH 5 PRIOR TO MACHINING OPERATIONS

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

Frankhouser, W.L.; Eyler, J.H.

1956-07-24

Five reference fuel rod bundles were welded and evaluated dimensionally. Dimensional data are presented for the as-welded condition and for the annealed bundle with spacer strips removed (prior to the final machining operations). The welding sequence developed for Core Manufacturing should provide A'' boundles in respect to rod spacing measurements. It will probably not be possible to meet the same requirements for water channel averages, because the design tolerances are not consistent with some factors inherent to the production process. A method to improve this situation is presented. The data presented were evaluated in a fashion similar to that whichmore » would be used in the proposed scheme. Rods tended to bow resulting in a slightly barrel-shaped'' boundle. It is believed this condition can be overcome by providing special bundle peripheral clamps during annealing. Rod distortion should also be reduced by a redesign and relocation of strip spacers. The new design is proposed. (auth)« less

USSR Report, International Affairs

DTIC Science & Technology

1987-04-28

such processes as thermal processing, welding, assembly, painting, application of paint and lacquer coatings and other operations in various branches...the rubric "International Panorama ": "The Responsibility of the Shipper According to the Laws of Bulgaria, East Germany and Czechoslovakia"] [Text

PARENT Quick Blind Round-Robin Test Report

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

Braatz, Brett G.; Heasler, Patrick G.; Meyer, Ryan M.

The U.S. Nuclear Regulatory Commission has established the Program to Assess the Reliability of Emerging Nondestructive Techniques (PARENT) whose goal is to investigate the effectiveness of current and novel nondestructive examination procedures and techniques to find flaws in nickel-alloy welds and base materials. This is to be done by conducting a series of open and blind international round-robin tests on a set of piping components that include large-bore dissimilar metal welds, small-bore dissimilar metal welds, and bottom-mounted instrumentation penetration welds. The blind testing is being conducted in two segments, one is called Quick-Blind and the other is called Blind. Themore » Quick-Blind testing and destructive analysis of the test blocks has been completed. This report describes the four Quick-Blind test blocks used, summarizes their destructive analysis, gives an overview of the nondestructive evaluation (NDE) techniques applied, provides an analysis inspection data, and presents the conclusions drawn.« less

Study of metal transfer in CO2 laser+GMAW-P hybrid welding using argon-helium mixtures

NASA Astrophysics Data System (ADS)

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

2014-03-01

The metal transfer in CO2 Laser+GMAW-P hybrid welding by using argon-helium mixtures was investigated and the effect of the laser on the mental transfer is discussed. A 650 nm laser, in conjunction with the shadow graph technique, is used to observe the metal transfer process. In order to analyze the heat input to the droplet and the droplet internal current line distribution. An optical emission spectroscopy system was employed to estimate default parameter and optimized plasma temperature, electron number densities distribution. The results indicate that the CO2 plasma plume have a significant impact to the electrode melting, droplet formation, detachment, impingement onto the workpiece and weld morphology. Since the current distribution direction flow changes to the keyhole, to obtain a metal transfer mode of one droplet per pulse, the welding parameters should be adjusted to a higher pulse time (TP) and a lower voltage.

Mississippi Curriculum Framework for Metal Trades (Program CIP: 48.0590--Metal Trades). Secondary Programs.

ERIC Educational Resources Information Center

Mississippi Research and Curriculum Unit for Vocational and Technical Education, State College.

This document, which reflects Mississippi's statutory requirement that instructional programs be based on core curricula and performance-based assessment, contains outlines of the instructional units required in local instructional management plans and daily lesson plans for metal trades I, IIA (advanced welding), and IIB (advanced machine shop).…

Tribological characterization of the drill pipe tool joints reconditioned by using welding technologies

NASA Astrophysics Data System (ADS)

Caltaru, M.; Badicioiu, M.; Ripeanu, R. G.; Dinita, A.; Minescu, M.; Laudacescu, E.

2018-01-01

Drill pipe is a seamless steel pipe with upset ends fitted with special threaded ends that are known as tool joints. During drilling operations, the wall thickness of the drill pipe and the outside diameter of the tool joints will be gradually reduced due to wear. The present research work investigate the possibility of reconditioning the drill pipe tool joints by hardbanding with a new metal-cored coppered flux cored wire, Cr-Mo alloyed, using the gas metal active welding process, taking into considerations two different hardbanding technologies, consisting in: hardbanding drill pipe tool joints after removing the old hardbanding material and surface reconstruction with a compensation material (case A), and hardbanding tool joint drill pipe, without removing the old hardbanding material (case B). The present paper brings forward the experimental researches regarding the tribological characterization of the reconditioned drill pipe tool joint by performing macroscopic analyses, metallographic analyses, Vickers hardness measurement, chemical composition measurement and wear tests conducted on ball on disk friction couples, in order to certify the quality of the hardbanding obtained by different technological approaches, to validate the optimum technology.

Investigation of Friction Stir Welding of Al Metal Matrix Composite Materials

NASA Technical Reports Server (NTRS)

Diwan, Ravinder M.

2003-01-01

The innovative process of Friction Stir Welding (FSW) has generated tremendous interest since its inception about a decade or so ago since the first patent in 1991 by TWI of Cambridge, England. This interest has been seen in many recent international conferences and publications on the subject and relevant published literature. Still the process needs both intensive basic study of deformation mechanisms during this FSW process and analysis and feasibility study to evaluate production methods that will yield high quality strong welds from the stirring action of the appropriate pin tool into the weld plate materials. Development of production processes is a complex task that involves effects of material thickness, materials weldability, pin tool design, pin height, and pin shoulder diameter and related control conditions. The frictional heating with rotational speeds of the pin tool as it plunges into the material and the ensuing plastic flow arising during the traverse of the welding faying surfaces provide the known special advantages of the FSW process in the area of this new advanced joining technology.

Fabrication method for cores of structural sandwich materials including star shaped core cells

DOEpatents

Christensen, Richard M.

1997-01-01

A method for fabricating structural sandwich materials having a core pattern which utilizes star and non-star shaped cells. The sheets of material are bonded together or a single folded sheet is used, and bonded or welded at specific locations, into a flat configuration, and are then mechanically pulled or expanded normal to the plane of the sheets which expand to form the cells. This method can be utilized to fabricate other geometric cell arrangements than the star/non-star shaped cells. Four sheets of material (either a pair of bonded sheets or a single folded sheet) are bonded so as to define an area therebetween, which forms the star shaped cell when expanded.

Geoengineering characterization of welded tuffs from laboratory and field investigations

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

Zimmerman, R.M.; Nimick, F.B.; Board, M.P.

1984-12-31

Welded tuff beneath Yucca Mountain adjacent to the Nevada Test Site (NTS) is being considered for development as a high-level radioactive waste repository by the Nevada Nuclear Waste Storage Investigations (NNWSI) Project. Because access into Yucca Mountain has been limited to borehole explorations, early geoengineering materials characterizations have been derived from laboratory tests on cores from Yucca Mountain and from laboratory and field tests on welded tuffs located in G-Tunnel on the NTS. G-Tunnel contains welded tuffs that have similar properties and stress states to those at Yucca Mountain and has been the location for in situ rock mechanics testing.more » The purpose of this paper is to summarize the geoengineering material property data obtained to date and to compare appropriate laboratory and field data from G-Tunnel to findings from Yucca Mountain. Geomechanical and thermal data are provided and are augmented by limited geological and hydrological data. A comparison of results of laboratory measurements on tuffs from Yucca Mountain and G-Tunnel indicates good agreement between the bulk densities, saturations, moduli of elasticity, Poisson`s ratios, and P-wave velocities. The G-Tunnel tuff has slightly lower thermal conductivity, tensile strength, compressive strength and slightly higher matrix permeability than does the welded tuff near the proposed repository horizon at Yucca Mountain. From a laboratory-to-field scaling perspective, the modulus of deformation shows the most sensitivity to field conditions because of the presence of the joints found in the field. 14 references, 1 table.« less

Geoengineering characterization of welded tuffs from laboratory and field investigations

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

Zimmerman, R.M.; Nimick, F.B.; Board, M.P.

1984-12-31

Welded tuff beneath Yucca Mountain adjacent to the Nevada Test Site (NTS) is being considered for development as a high-level radioactive waste repository by the Nevada Nuclear Waste Storage Investigations (NNWSI) Project. Because access into Yucca Mountain has been limited to borehole explorations, early geoengineering materials characterizations have been derived from laboratory tests on cores from Yucca Mountain and from laboratory and field tests on welded tuffs located in G-Tunnel on the NTS. G-Tunnel contains welded tuffs that have similar properties and stress states to those at Yucca Mountain and has been the location for in situ rock mechanics testing.more » The purpose of this paper is to summarize the geoengineering material property data obtained to date and to compare appropriate laboratory and field data from G-Tunnel to findings from Yucca Mountain. Geomechanical and thermal data are provided and are augmented by limited geological and hydrological data. A comparison of results of laboratory measurements on tuffs from Yucca Mountain and G-Tunnel indicates good agreement between the bulk densities, saturations, moduli of elasticity, Poisson`s ratios, and P-wave velocities. The G-Tunnel tuff has slightly lower thermal conductivity, tensile strength, compressive strength and slightly higher matrix permeability than does the welded tuff near the proposed repository horizon at Yucca Mountain. From a laboratory-to-field scaling perspective, the modulus of deformation shows the most sensitivity to field conditions because of the presence of joints found in the field. 14 refs., 1 tab.« less

Detection and assessment of flaws in friction stir welded joints using ultrasonic guided waves: experimental and finite element analysis

NASA Astrophysics Data System (ADS)

Fakih, Mohammad Ali; Mustapha, Samir; Tarraf, Jaafar; Ayoub, Georges; Hamade, Ramsey

2018-02-01

Ultrasonic guided waves (GWs), e.g. Lamb waves, have been proven effective in the detection of defects such as corrosion, cracking, delamination, and debonding in both composite and metallic structures. They are a significant tool employed in structural health monitoring. In this study, the ability of ultrasonic GWs to assess the quality of friction stir welding (FSW) was investigated. Four friction stir welded AZ31B magnesium plates processed with different welding parameters and a non-welded plate were used. The fundamental symmetric (S0) Lamb wave mode was excited using piezoelectric wafers (PZTs). Further, the S0 mode was separated using the "Improved complete ensemble empirical mode decomposition with adaptive noise (Improved CEEMDAN)" technique. A damage index (DI) was defined based on the variation in the amplitude of the captured wave signals in order to detect the presence and asses the severity of damage resulting from the welding process. As well, computed tomography (CT) scanning was used as a non-destructive testing (NDT) technique to assess the actual weld quality and validate predictions based on the GW approach. The findings were further confirmed using finite element analysis (FEA). To model the actual damage profile in the welds, "Mimics" software was used for the 3D reconstruction of the CT scans. The built 3D models were later used for evaluation of damage volume and for FEA. The damage volumes were correlated to the damage indices computed from both experimental and numerical data. The proposed approach showed high sensitivity of the S0 mode to internal flaws within the friction stir welded joints. This methodology has great potential as a future classification method of FSW quality.

Manganese speciation of laboratory-generated welding fumes

PubMed Central

Andrews, Ronnee N.; Keane, Michael; Hanley, Kevin W.; Feng, H. Amy; Ashley, Kevin

2015-01-01

The objective of this laboratory study was to identify and measure manganese (Mn) fractions in chamber-generated welding fumes (WF) and to evaluate and compare the results from a sequential extraction procedure for Mn fractions with that of an acid digestion procedure for measurement of total, elemental Mn. To prepare Mn-containing particulate matter from representative welding processes, a welding system was operated in short circuit gas metal arc welding (GMAW) mode using both stainless steel (SS) and mild carbon steel (MCS) and also with flux cored arc welding (FCAW) and shielded metal arc welding (SMAW) using MCS. Generated WF samples were collected onto polycarbonate filters before homogenization, weighing and storage in scintillation vials. The extraction procedure consisted of four sequential steps to measure various Mn fractions based upon selective solubility: (1) soluble Mn dissolved in 0.01 M ammonium acetate; (2) Mn (0,II) dissolved in 25 % (v/v) acetic acid; (3) Mn (III,IV) dissolved in 0.5% (w/v) hydroxylamine hydrochloride in 25% (v/v) acetic acid; and (4) insoluble Mn extracted with concentrated hydrochloric and nitric acids. After sample treatment, the four fractions were analyzed for Mn by inductively coupled plasma-atomic emission spectroscopy (ICP-AES). WF from GMAW and FCAW showed similar distributions of Mn species, with the largest concentrations of Mn detected in the Mn (0,II) and insoluble Mn fractions. On the other hand, the majority of the Mn content of SMAW fume was detected as Mn (III,IV). Although the concentration of Mn measured from summation of the four sequential steps was statistically significantly different from that measured from the hot block dissolution method for total Mn, the difference is small enough to be of no practical importance for industrial hygiene air samples, and either method may be used for Mn measurement. The sequential extraction method provides valuable information about the oxidation state of Mn in samples and allows for comparison to results from previous work and from total Mn dissolution methods. PMID:26345630

Manganese speciation of laboratory-generated welding fumes.

PubMed

Andrews, Ronnee N; Keane, Michael; Hanley, Kevin W; Feng, H Amy; Ashley, Kevin

The objective of this laboratory study was to identify and measure manganese (Mn) fractions in chamber-generated welding fumes (WF) and to evaluate and compare the results from a sequential extraction procedure for Mn fractions with that of an acid digestion procedure for measurement of total, elemental Mn. To prepare Mn-containing particulate matter from representative welding processes, a welding system was operated in short circuit gas metal arc welding (GMAW) mode using both stainless steel (SS) and mild carbon steel (MCS) and also with flux cored arc welding (FCAW) and shielded metal arc welding (SMAW) using MCS. Generated WF samples were collected onto polycarbonate filters before homogenization, weighing and storage in scintillation vials. The extraction procedure consisted of four sequential steps to measure various Mn fractions based upon selective solubility: (1) soluble Mn dissolved in 0.01 M ammonium acetate; (2) Mn (0,II) dissolved in 25 % (v/v) acetic acid; (3) Mn (III,IV) dissolved in 0.5% (w/v) hydroxylamine hydrochloride in 25% (v/v) acetic acid; and (4) insoluble Mn extracted with concentrated hydrochloric and nitric acids. After sample treatment, the four fractions were analyzed for Mn by inductively coupled plasma-atomic emission spectroscopy (ICP-AES). WF from GMAW and FCAW showed similar distributions of Mn species, with the largest concentrations of Mn detected in the Mn (0,II) and insoluble Mn fractions. On the other hand, the majority of the Mn content of SMAW fume was detected as Mn (III,IV). Although the concentration of Mn measured from summation of the four sequential steps was statistically significantly different from that measured from the hot block dissolution method for total Mn, the difference is small enough to be of no practical importance for industrial hygiene air samples, and either method may be used for Mn measurement. The sequential extraction method provides valuable information about the oxidation state of Mn in samples and allows for comparison to results from previous work and from total Mn dissolution methods.

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

Wang, Yiyu; Kannan, Rangasayee; Li, Leijun, E-mail

Non-equilibrium microstructure of the heat-affected zone (HAZ) in the as-welded modified 9Cr–1Mo–V–Nb pipe steel (P91) weldment deposited by gas tungsten arc welding (GTAW) and flux core arc welding (FCAW) has been characterized by field-emission scanning electron microscope (FESEM) and electron backscatter diffraction (EBSD). The heterogeneous structures in the sub-layers of the as-welded HAZ are attributable to phase transformations caused by the welding thermal cycles and the local structure variations in the as-received base metal. Coarse-grained heat-affected zone (CGHAZ) has a prior austenite grain (PAG) size of 20 μm. Fine uniformly-distributed precipitates and a higher fraction of MX carbonitrides are observedmore » in the CGHAZ. Fine-grained heat-affected zone (FGHAZ) consists of the finest grains (1.22 μm measured by EBSD, 5 μm PAG size), coarse undissolved M{sub 23}C{sub 6} carbides within the PAG boundaries and fine nucleated M{sub 23}C{sub 6} particles within the martensite laths. Inter-critical heat-affected zone (ICHAZ) consists of partially austenitized grains and over-tempered martensite laths. EBSD kernel average misorientation (KAM) map in the FGHAZ close to the ICHAZ illustrates the greatest local strain variations with a moderate normalized KAM value of 0.92°. The majority (88.1%) of the matrix grains in the CGHAZ are classified as deformed grains by EBSD grain average misorientation (GAM) evaluation. The FGHAZ close to the ICHAZ has the most recrystallized grains with an area fraction of 14.4%. The highest density variation of precipitates within grains in the FGHAZ originates from the inhomogeneous chemistry in the base metal. - Highlights: •A comprehensive characterization of the as-welded HAZ of P91 weldment is conducted. •Structural features in the each layer of the HAZ are quantified by EBSD. •Structural heterogenities in HAZ are due to welding cycle and base metal structure. •FGHAZ contains the finest grain structure and largest precipitate density variation.« less

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 to the ferrite, the pitting corrosion occurred at the ferrite and austenite interface or within the austenite.

Development and trial manufacturing of 1/2-scale partial mock-up of blanket box structure for fusion experimental reactor

NASA Astrophysics Data System (ADS)

Hashimoto, Toshiyuki; Takatsu, Hideyuki; Sato, Satoshi

1994-07-01

Conceptual design of breeding blanket has been discussed during the CDA (Conceptual Design Activities) of ITER (International Thermonuclear Experimental Reactor). Structural concept of breeding blanket is based on box structure integrated with first wall and shield, which consists of three coolant manifolds for first wall, breeding and shield regions. The first wall must have cooling channels to remove surface heat flux and nuclear heating. The box structure includes plates to form the manifolds and stiffening ribs to withstand enormous electromagnetic load, coolant pressure and blanket internal (purge gas) pressure. A 1/2-scale partial model of the blanket box structure for the outboard side module near midplane is manufactured to estimate the fabrication technology, i.e. diffusion bonding by HIP (Hot Isostatic Pressing) and EBW (Electron Beam Welding) procedure. Fabrication accuracy is a key issue to manufacture first wall panel because bending deformation during HIP may not be small for a large size structure. Data on bending deformation during HIP was obtained by preliminary manufacturing of HIP elements. For the shield structure, it is necessary to reduce the welding strain and residual stress of the weldment to establish the fabrication procedure. Optimal shape of the parts forming the manifolds, welding locations and welding sequence have been investigated. In addition, preliminary EBW tests have been performed in order to select the EBW conditions, and fundamental data on built-up shield have been obtained. Especially, welding deformation by joining the first wall panel to the shield has been measured, and total deformation to build-up shield by EBW has been found to be smaller than 2 mm. Consequently, the feasibility of fabrication technologies has been successfully demonstrated for a 1m-scaled box structure including the first wall with cooling channels by means of HIP, EBW and TIG (Tungsten Inert Gas arc)-welding.

International Symposium on Interfacial Joining and Surface Technology (IJST2013)

NASA Astrophysics Data System (ADS)

Takahashi, Yasuo

2014-08-01

Interfacial joining (bonding) is a widely accepted welding process and one of the environmentally benign technologies used in industrial production. As the bonding temperature is lower than the melting point of the parent materials, melting of the latter is kept to a minimum. The process can be based on diffusion bonding, pressure welding, friction welding, ultrasonic bonding, or brazing-soldering, all of which offer many advantages over fusion welding. In addition, surface technologies such as surface modification, spraying, coating, plating, and thin-film formation are necessary for advanced manufacturing, fabrication, and electronics packaging. Together, interfacial joining and surface technology (IJST) will continue to be used in various industrial fields because IJST is a very significant form of environmentally conscious materials processing. The international symposium of IJST 2013 was held at Icho Kaikan, Osaka University, Japan from 27-29 November, 2013. A total of 138 participants came from around the world to attend 56 oral presentations and 36 posters presented at the symposium, and to discuss the latest research and developments on interfacial joining and surface technologies. This symposium was also held to commemorate the 30th anniversary of the Technical Commission on Interfacial Joining of the Japan Welding Society. On behalf of the chair of the symposium, it is my great pleasure to present this volume of IOP Conference Series: Materials Science and Engineering (MSE). Among the presentations, 43 papers are published here, and I believe all of the papers have provided the welding community with much useful information. I would like to thank the authors for their enthusiastic and excellent contributions. Finally, I would like to thank all members of the committees, secretariats, participants, and everyone who contributed to this symposium through their support and invaluable effort for the success of IJST 2013. Yasuo Takahashi Chair of IJST 2013 Details of the committees are available in the PDF

Human biomonitoring of aluminium after a single, controlled manual metal arc inert gas welding process of an aluminium-containing worksheet in nonwelders.

PubMed

Bertram, Jens; Brand, Peter; Hartmann, Laura; Schettgen, Thomas; Kossack, Veronika; Lenz, Klaus; Purrio, Ellwyn; Reisgen, Uwe; Kraus, Thomas

2015-10-01

Several existing field studies evaluate aluminium welding works but no thoroughly controlled exposure scenario for welding fume has been described yet. This study provides information about the uptake and elimination of aluminium from welding fumes under controlled conditions. In the Aachen Workplace Simulation Laboratory, we are able to generate welding fumes of a defined particle mass concentration. We exposed 12, until then occupationally unexposed participants with aluminium-containing welding fumes of a metal inert gas (MIG) welding process of a total dust mass concentration of 2.5 mg/m(3) for 6 h. Room air filter samples were collected, and the aluminium concentration in air derived. Urine and plasma samples were collected directly before and after the 6-h lasting exposure, as well as after 1 and 7 days. Human biomonitoring methods were used to determine the aluminium content of the samples with high-resolution continuum source atomic absorption spectrometry. Urinary aluminium concentrations showed significant changes after exposure compared to preexposure levels (mean t(1) (0 h) 13.5 µg/L; mean t(2) (6 h) 23.5 µg/L). Plasma results showed the same pattern but pre-post comparison did not reach significance. We were able to detect a significant increase of the internal aluminium burden of a single MIG aluminium welding process in urine, while plasma failed significance. Biphasic elimination kinetic can be observed. The German BAT of 60 µg/g creatinine was not exceeded, and urinary aluminium returned nearly to baseline concentrations after 7 days.

Risk of ischemic heart disease following occupational exposure to welding fumes: a systematic review with meta-analysis.

PubMed

Mocevic, Emina; Kristiansen, Pernille; Bonde, Jens Peter

2015-04-01

Air pollution has been linked to an increased risk of ischemic heart disease (IHD), but less is known about occupational exposure to welding fumes and the risk of IHD. The objective of this paper was to review the epidemiological evidence on causal links between welding fume exposure and risk of IHD and to investigate whether the risk of IHD depends on specific welding characteristics. A systematic search in Medline 1979-2013 and EMBASE 1974-2013 identified 18 epidemiological studies with at least one risk estimate of IHD morbidity or mortality among workers exposed to welding fumes. Following an assessment of completeness of reporting, confounding, and bias, each risk estimate was characterized as more or less reliable. Pooled risk estimates were computed across studies by random effect meta-analyses. The weighted relative risk (RR) for IHD following exposure to welding fumes was 1.09 [95 % confidence interval (CI) 1.00, 1.19]. We calculated a RR of 1.39 (95 % CI 0.96, 2.02) among studies using an internal reference group and 1.08 (95 % CI 0.99, 1.18) for studies using an external reference group. An increased risk was observed for acute myocardial infarction RR = 1.69 (95 % CI 1.18, 2.42) and other IHDs RR = 1.06 (95 % CI 0.98, 1.14). There was too limited evidence to evaluate the risk of IHD related to specific welding characteristics. Several studies indicate that welding is associated with a moderately increased risk of IHD; however, bias and confounding cannot be ruled out with reasonable confidence.

Precision Joining Center

NASA Astrophysics Data System (ADS)

Powell, J. W.; Westphal, D. A.

1991-08-01

A workshop to obtain input from industry on the establishment of the Precision Joining Center (PJC) was held on July 10-12, 1991. The PJC is a center for training Joining Technologists in advanced joining techniques and concepts in order to promote the competitiveness of U.S. industry. The center will be established as part of the DOE Defense Programs Technology Commercialization Initiative, and operated by EG&G Rocky Flats in cooperation with the American Welding Society and the Colorado School of Mines Center for Welding and Joining Research. The overall objectives of the workshop were to validate the need for a Joining Technologists to fill the gap between the welding operator and the welding engineer, and to assure that the PJC will train individuals to satisfy that need. The consensus of the workshop participants was that the Joining Technologist is a necessary position in industry, and is currently used, with some variation, by many companies. It was agreed that the PJC core curriculum, as presented, would produce a Joining Technologist of value to industries that use precision joining techniques. The advantage of the PJC would be to train the Joining Technologist much more quickly and more completely. The proposed emphasis of the PJC curriculum on equipment intensive and hands-on training was judged to be essential.

Neuropsychological sequelae of exposure to welding fumes in a group of occupationally exposed men.

PubMed

Bowler, Rosemarie M; Gysens, Sabine; Diamond, Emily; Booty, Andrew; Hartney, Christopher; Roels, Harry A

2003-10-01

This study compares the neuropsychological function, emotional status, visual function, and illness prevalence of 76 former and current chemical industry welders primarily involved in steel welding, and exposed to welding fumes for an average of 24.9 years with that of 42 unexposed, non-welder controls. Health and occupational history questionnaires were administered, as were the neuropsychological tests included in the World Health Organization Neurobehavioral Core Test Battery, Luria Motor Test, and selected tests from the WAIS-III, and WMS-III. Emotional status tests included the BSI, POMS, BAI, and BDI, and vision tests included the Snellen near visual acuity, Lanthony d-15 color vision, Vistech Contrast Sensitivity, and Schirmer strips. While welders and controls performed similarly on tests of verbal skills, verbal retention, and auditory span, welders performed worse than controls on tests of verbal learning, working memory, cognitive flexibility, visuomotor processing speed, and motor efficiency. Welders had poorer color vision and emotional status, and increased prevalence of illnesses and psychiatric symptoms. The increased symptoms in welders were related to decreased scores on tasks measuring verbal learning, visuomotor abilities, visuospatial abilities, and information processing, and motor efficiency. Within the group of welders, the number of hours welding was negatively related to scores on verbal learning, auditory span, working memory, cognitive flexibility, and motor efficiency.

Acoustic Emission Weld Monitoring in the 2195 Aluminum-Lithium Alloy

NASA Technical Reports Server (NTRS)

Walker, James L.

2005-01-01

Due to its low density, the 2195 aluminum-lithium alloy was developed as a replacement for alloy 2219 in the Space Shuttle External Tank (ET). The external tank is the single largest component of the space shuttle system. It is 154 feet long and 27.6 feet in diameter, and serves as the structural backbone for the shuttle during launch, absorbing most of the 7 million plus pounds of thrust produced. The almost 4% decrease in density between the two materials provides an extra 7500 pounds of payload capacity necessary to put the International Space Station components into orbit. The ET is an all-welded structure; hence, the requirement is for up to five rewelds without hot cracking. Unfortunately, hot cracking during re-welding or repair operations was occurring and had to be dealt with before the new super lightweight tank could be used. Weld metal porosity formation was also of concern because it leads to hot cracking during weld repairs. Accordingly, acoustic emission (AE) nondestructive testing was employed to monitor the formation of porosity and hot cracks in order to select the best filler metal and optimize the weld schedule. The purpose of this work is to determine the feasibility of detecting hot cracking in welded aluminum-lithium (Al-Li) structures through the analysis of acoustic emission data. By acoustically characterizing the effects of reheating during a repair operation, the potential for hidden flaws coalescing and becoming "unstable" as the panel is repaired could be reduced. Identification of regions where microcrack growth is likely to occur and the location of active flaw growth in the repair weld will provide the welder with direct feedback as to the current weld quality enabling adjustments to the repair process be made in the field. An acoustic emission analysis of the source mechanisms present during welding has been conducted with the goals of locating regions in the weld line that are susceptible to damage from a repair operation, identifying the formation of critically sized flaws and providing accept/reject criteria for the quality of a weld as it is performed.

Bottom head to shell junction assembly for a boiling water nuclear reactor

DOEpatents

Fife, Alex Blair; Ballas, Gary J.

1998-01-01

A bottom head to shell junction assembly which, in one embodiment, includes an annular forging having an integrally formed pump deck and shroud support is described. In the one embodiment, the annular forging also includes a top, cylindrical shaped end configured to be welded to one end of the pressure vessel cylindrical shell and a bottom, conical shaped end configured to be welded to the disk shaped bottom head. Reactor internal pump nozzles also are integrally formed in the annular forging. The nozzles do not include any internal or external projections. Stubs are formed in each nozzle opening to facilitate welding a pump housing to the forging. Also, an upper portion of each nozzle opening is configured to receive a portion of a diffuser coupled to a pump shaft which extends through the nozzle opening. Diffuser openings are formed in the integral pump deck to provide additional support for the pump impellers. The diffuser opening is sized so that a pump impeller can extend at least partially therethrough. The pump impeller is connected to the pump shaft which extends through the nozzle opening.

Bottom head to shell junction assembly for a boiling water nuclear reactor

DOEpatents

Fife, A.B.; Ballas, G.J.

1998-02-24

A bottom head to shell junction assembly which, in one embodiment, includes an annular forging having an integrally formed pump deck and shroud support is described. In the one embodiment, the annular forging also includes a top, cylindrical shaped end configured to be welded to one end of the pressure vessel cylindrical shell and a bottom, conical shaped end configured to be welded to the disk shaped bottom head. Reactor internal pump nozzles also are integrally formed in the annular forging. The nozzles do not include any internal or external projections. Stubs are formed in each nozzle opening to facilitate welding a pump housing to the forging. Also, an upper portion of each nozzle opening is configured to receive a portion of a diffuser coupled to a pump shaft which extends through the nozzle opening. Diffuser openings are formed in the integral pump deck to provide additional support for the pump impellers. The diffuser opening is sized so that a pump impeller can extend at least partially therethrough. The pump impeller is connected to the pump shaft which extends through the nozzle opening. 5 figs.

Development of a chromium-free consumable for joining stainless steels

NASA Astrophysics Data System (ADS)

Sowards, Jeffrey William

Government regulations in the United States (OSHA Standards: 1910; 1915; 1917; 1918; 1926) and abroad are decreasing allowable exposure levels of hexavalent chromium to welding related personnel. The latest OSHA ruling in 2006 reduced the permissible exposure limit of airborne hexavalent chromium from 52 to 5 mug m-3. Achieving the new level may not be practical from an engineering controls standpoint during the fabrication of tightly enclosed stainless steel components such as the inside of ship hulls and boiler vessels. One method of addressing this problem is to implement a chromium-free welding consumable that provides equivalent mechanical performance and corrosion characteristics to current stainless steel welding consumables. This project was aimed at developing such a consumable and evaluating its suitability for replacement of current stainless steel consumables such as E308L-16. A new shielded metal arc welding (SMAW) consumable based on the Ni-Cu-Ru system was developed for austenitic stainless steel welding. The focus of this work was evaluating the mechanical properties, weldability, and fume formation characteristics of the various iterations of consumables developed. Welds deposited on Type 304 stainless steel were evaluated with weldability tests including: mechanical testing, hot ductility testing, Strain-to-fracture testing, Transverse Varestraint testing, and button melting. Mechanical properties of weld deposits of each consumable were found to exceed minimum values of Type 304 stainless steel based on tensile testing. Guide bend testing showed that weld deposits met minimum weld ductility requirements for stainless steel consumables, such as E308-16. Hot ductility testing revealed a narrow crack susceptible region (33 to 54°C) indicating a low susceptibility to weld metal liquation cracking. GTA welds exhibited superior ductility when compared to SMA welds. This was attributed to a lack of slag inclusions in the weld deposit, which are effective weld strengtheners. Varestraint testing revealed that weld deposits have a higher solidification cracking susceptibility than stainless steel consumables used to join Type 304. Higher cracking susceptibility was attributed to austenitic solidification of the weld metal resulting in increased weld segregation and stabilization of a TiC eutectic reaction at the end of solidification. No solidification cracks were observed in actual weld deposits. Evaluation of weld microsegregation patterns showed higher dilutions of Type 304 increased segregation of Ti, promoting a TiC eutectic reaction at the end of solidification. Thermodynamic modeling techniques were used to describe the solidification the Ni-Cu weld deposits as a function of dilution with Type 304. Solidification cracking susceptibility was shown to increase with dilution during evaluation with the Cast Pin Tear Test indicating high dilution welds should be avoided to minimize solidification cracking during welding. The Strain-to-fracture test was used to examine DDC cracking susceptibility, and revealed that this alloy has a higher susceptibility to solid-state weld cracking than austenitic stainless alloys such as 304. Threshold strain levels necessary to initiate cracking in the weld deposits were in the range of 2 to 3%. These values are comparable to other Ni-base alloys with a moderate to high susceptibility to DDC. Fume generation rates (FGR) of the new consumable were measured and bulk fume phases were analyzed with X-ray diffraction. FGR values were found to be similar to current SMAW and flux cored arc welding consumables. No chromium bearing compounds were observed during X-ray diffraction measurements, and the bulk fume consisted primarily of halides and metallic-oxides. Fume generated by the new consumable was subjected to colorimetric testing showing hexavalent Cr content (0.02 wt-%) was reduced by two orders of magnitude compared to E308-16 (2.6 wt-%). The source of this hexavalent chromium was from evaporation of the base metal due to the welding heat source. The consumable developed in this study, having a nominal composition of Ni-7.5Cu-1Ru-0.5Al-0.5Ti-0.02C, met virtually all the design criteria that were initially established. Work performed by the Fontana Corrosion Center showed that the weld deposits met corrosion design criteria to prevent localized attack of the weld metal. Work performed in this study showed that mechanical properties were comparable to stainless steel consumables, and weld cracking susceptibility was comparable to Ni-base welding consumables. The consumable was also found to have good operability characteristics. (Abstract shortened by UMI.)

Absorbed Dose Determination Using Experimental and Analytical Predictions of X-Ray Spectra

NASA Technical Reports Server (NTRS)

Edwards, D. L.; Carruth, Ralph (Technical Monitor)

2001-01-01

Electron beam welding in a vacuum is a technology that NASA is investigating as a joining technique for manufacture of space structures. This investigation characterizes the x-ray environment due to operation of an in-vacuum electron beam welding tool and provides recommendations for adequate shielding for astronauts performing the in-vacuum electron beam welding. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the U.S. Space Shuttle. This series of experiments was named the international space welding experiment (ISWE). The hardware associated with the ISWE was leased to NASA by the Paton Welding Institute (PWI) in Ukraine for ground-based welding experiments in preparation for flight. Two ground tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests used thermoluminescence dosimeters (TLD's) shielded with material currently used by astronauts during extravehicular activities to measure the radiation dose. The TLD's were exposed to x-ray radiation generated by operation of the ISWE in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x rays of energy less than 10 keV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was completely verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by ISWE electron beam impact with metal. These x-ray spectra were normalized to an equivalent ISWE exposure, then used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the ISWE in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in agreement with the measured TLD values.

Prediction and Measurement of X-Ray Spectral and Intensity Distributions from Low Energy Electron Impact Sources

NASA Technical Reports Server (NTRS)

Edwards, David L.

1999-01-01

In-vacuum electron beam welding is a technology that NASA considered as a joining technique for manufacture of space structures. The interaction of energetic electrons with metal produces x-rays. The radiation exposure to astronauts performing the in-vacuum electron beam welding must be characterized and minimized to insure safe operating conditions. This investigation characterized the x-ray environment due to operation of an in-vacuum electron beam welding tool. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the United States Space Shuttle. This series of experiments was named the International Space Welding Experiment (ISWE). The hardware associated with the ISWE was leased to NASA, by the Paton Welding Institute (PWI) in Ukraine, for ground based welding experiments in preparation for flight. Two tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests consisted of Thermoluminescence Dosimeters (TLD's) shielded with material currently used by astronauts during Extra Vehicular Activities (EVA) and exposed to x-ray radiation generated by operation of an in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x-rays of energy less than 10 KeV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by electron impact with metal. These x-ray spectra were used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in good agreement with the TLD values.

LCD OF AIR INTAKE MANIFOLDS PHASE 2: FORD F250 AIR INTAKE MANIFOLD

EPA Science Inventory

The life cycle design methodology was applied to the design analysis of three alternatives for the lower plehum of the air intake manifold for us with a 5.4L F-250 truck engine: a sand cast aluminum, a lost core molded nylon composite, and a vibration welded nylon composite. The ...

Core Stage Forward Skirt Umbilical Installation onto Mobile Laun

NASA Image and Video Library

2017-05-25

A construction worker welds a metal part during installation of the Core Stage Forward Skirt Umbilical on the mobile launcher tower at NASA's Kennedy Space Center in Florida. The mobile launcher tower will be equipped with a number of lines, called umbilicals that will connect to the Space Launch System (SLS) rocket and Orion spacecraft for Exploration Mission-1 (EM-1). The CSFSU will be located at about the 180-foot level on the tower, above the liquid oxygen tank. The CSFSU is an umbilical that will swing into position to provide connections to the core stage forward skirt of the SLS rocket, and then swing away before launch. Its main purpose is to provide conditioned air/GN2 to the SLS core stage forward skirt cavity. The Ground Systems Development and Operations Program is overseeing installation of the umbilicals.

Occupational heat strain in a hot underground metal mine.

PubMed

Lutz, Eric A; Reed, Rustin J; Turner, Dylan; Littau, Sally R

2014-04-01

In a hot underground metal mine, this study evaluated the relationship between job task, physical body type, work shift, and heat strain. Thirty-one miners were evaluated during 98 shifts while performing deep shaft-sinking tasks. Continuous core body temperature, heart rate, pre- and postshift urine specific gravity (USG), and body mass index were measured. Cutting and welding tasks were associated with significantly (P < 0.05) increased core body temperature, maximum heart rate, and increased postshift urine specific gravity. Miners in the obese level II and III body mass index categories, as well as those working night shift, had lower core body temperatures (P < 0.05). This study confirms that job task, body type, and shift are risk factors for heat strain.

Fabrication method for cores of structural sandwich materials including star shaped core cells

DOEpatents

Christensen, R.M.

1997-07-15

A method for fabricating structural sandwich materials having a core pattern which utilizes star and non-star shaped cells is disclosed. The sheets of material are bonded together or a single folded sheet is used, and bonded or welded at specific locations, into a flat configuration, and are then mechanically pulled or expanded normal to the plane of the sheets which expand to form the cells. This method can be utilized to fabricate other geometric cell arrangements than the star/non-star shaped cells. Four sheets of material (either a pair of bonded sheets or a single folded sheet) are bonded so as to define an area therebetween, which forms the star shaped cell when expanded. 3 figs.

Continuous fields of land cover for the conterminous United States using Landsat data: First results from the Web-Enabled Landsat Data (WELD) project

USGS Publications Warehouse

Hansen, M.C.; Egorov, Alexey; Roy, David P.; Potapov, P.; Ju, J.; Turubanova, S.; Kommareddy, I.; Loveland, Thomas R.

2011-01-01

Vegetation Continuous Field (VCF) layers of 30 m percent tree cover, bare ground, other vegetation and probability of water were derived for the conterminous United States (CONUS) using Landsat 7 Enhanced Thematic Mapper Plus (ETM+) data sets from the Web-Enabled Landsat Data (WELD) project. Turnkey approaches to land cover characterization were enabled due to the systematic WELD Landsat processing, including conversion of digital numbers to calibrated top of atmosphere reflectance and brightness temperature, cloud masking, reprojection into a continental map projection and temporal compositing. Annual, seasonal and monthly WELD composites for 2008 were used as spectral inputs to a bagged regression and classification tree procedure using a large training data set derived from very high spatial resolution imagery and available ancillary data. The results illustrate the ability to perform Landsat land cover characterizations at continental scales that are internally consistent while retaining local spatial and thematic detail.

Real-time control for manufacturing space shuttle main engines: Work in progress

NASA Technical Reports Server (NTRS)

Ruokangas, Corinne C.

1988-01-01

During the manufacture of space-based assemblies such as Space Shuttle Main Engines, flexibility is required due to the high-cost and low-volume nature of the end products. Various systems have been developed pursuing the goal of adaptive, flexible manufacturing for several space applications, including an Advanced Robotic Welding System for the manufacture of complex components of the Space Shuttle Main Engines. The Advanced Robotic Welding System (AROWS) is an on-going joint effort, funded by NASA, between NASA/Marshall Space Flight Center, and two divisions of Rockwell International: Rocketdyne and the Science Center. AROWS includes two levels of flexible control of both motion and process parameters: Off-line programming using both geometric and weld-process data bases, and real-time control incorporating multiple sensors during weld execution. Both control systems were implemented using conventional hardware and software architectures. The feasibility of enhancing the real-time control system using the problem-solving architecture of Schemer is investigated and described.

A Simplified Model for the Effect of Weld-Induced Residual Stresses on the Axial Ultimate Strength of Stiffened Plates

NASA Astrophysics Data System (ADS)

Chen, Bai-Qiao; Guedes Soares, C.

2018-03-01

The present work investigates the compressive axial ultimate strength of fillet-welded steel-plated ship structures subjected to uniaxial compression, in which the residual stresses in the welded plates are calculated by a thermo-elasto-plastic finite element analysis that is used to fit an idealized model of residual stress distribution. The numerical results of ultimate strength based on the simplified model of residual stress show good agreement with those of various methods including the International Association of Classification Societies (IACS) Common Structural Rules (CSR), leading to the conclusion that the simplified model can be effectively used to represent the distribution of residual stresses in steel-plated structures in a wide range of engineering applications. It is concluded that the widths of the tension zones in the welded plates have a quasi-linear behavior with respect to the plate slenderness. The effect of residual stress on the axial strength of the stiffened plate is analyzed and discussed.

Investigation on microstructure and properties of narrow-gap laser welding on reduced activation ferritic/martensitic steel CLF-1 with a thickness of 35 mm

NASA Astrophysics Data System (ADS)

Wu, Shikai; Zhang, Jianchao; Yang, Jiaoxi; Lu, Junxia; Liao, Hongbin; Wang, Xiaoyu

2018-05-01

Reduced activation ferritic martensitic (RAFM) steel is chosen as a structural material for test blanket modules (TBMs) to be constructed in International Thermonuclear Experimental Reactor (ITER) and China Fusion Engineering Test Reactor (CFETR). Chinese specific RAFM steel named with CLF-1 has been developed for CFETR. In this paper, a narrow-gap groove laser multi-pass welding of CLF-1 steel with thickness of 35 mm is conduced by YLS-15000 fiber laser. Further, the microstructures of different regions in the weld joint were characterized, and tensile impact and micro-hardness tests were carried out for evaluating the mecharical properties. The results show that the butt weld joint of CLF-1 steel with a thickness of 35 mm was well-formed using the optimal narrow-gap laser filler wire welding and no obvious defects was found such as incomplete fusion cracks and pores. The microstructures of backing layer is dominated by lath martensites and the Heat-Affected Zone (HAZ) was mainly filled with two-phase hybrid structures of secondary-tempering sorbites and martensites. The filler layer is similar to the backing layer in microstructures. In tensile tests, the tensile samples from different parts of the joint all fractured at base metal (BM). The micro-hardness of weld metal (WM) was found to be higher than that of BM and the Heat-Affected Zone (HAZ) exhibited no obvious softening. After post weld heat treatment (PWHT), it can be observed that the fusion zone of the autogenous welding bead and the upper filling beads mainly consist of lath martensites which caused the lower impact absorbing energy. The HAZ mainly included two-phase hybrid structures of secondary-tempering sorbites and martensites and exhibited favorable impact toughness.

Pulmonary fibrosis and exposure to steel welding fume.

PubMed

Cosgrove, M P

2015-12-01

Arc welders who have been exposed to high concentrations of steel welding fume for prolonged periods of time may develop pulmonary fibrosis but the nature of the fibrotic changes has been debated over the last 80 years without any clear international consensus. To characterize the nature of the pulmonary fibrosis that develops in response to steel welding fume exposure and to provide a working hypothesis that would explain the findings of the existing research, to provide a platform for future research and to inform future occupational and clinical management of welders with pulmonary effects from welding fume. Review of the world literature on pulmonary fibrosis and welding of steel in all languages using PubMed, with further secondary search of references in the articles found in the primary search. Google and Reference Manager were used as further confirmatory search tools. Only case series and case reports were found but these provided consistent evidence that the consequence of exposure to steel welding fume at high levels for a prolonged period of time is a type of pulmonary fibrosis similar to, and possibly the same as, respiratory bronchiolitis which eventually develops into desquamative interstitial pneumonia with ongoing exposure. Steel welding fume may cause an occupational respiratory bronchiolitis which may develop into de squamative interstitial pneumonia with ongoing exposure. This concept may explain the difficulties in interpreting the wider literature on welding fume and lung function at lower exposures and may also explain the increased risk of lung cancer in welders. © The Author 2015. Published by Oxford University Press on behalf of the Society of Occupational Medicine. All rights reserved. For Permissions, please email: journals.permissions@oup.com.

Stochastic Model of Fracture Frequency Heterogeneity in a Welded Tuff EGS reservoir, Snake River Plain, Idaho, USA

NASA Astrophysics Data System (ADS)

Moody, A.; Fairley, J. P., Jr.

2014-12-01

In light of recent advancements in reservoir enhancement and injection tests at active geothermal fields, there is interest in investigating the geothermal potential of widespread subsurface welded tuffs related to caldera collapse on the Snake River Plain (SRP). Before considering stimulation strategies, simulating heat extraction from the reservoir under in-situ fracture geometries will give a first-order estimation of extractable heat. With only limited deep boreholes drilled on the SRP, few analyses of the bulk hydrologic properties of the tuffs exist. Acknowledging the importance of the spatial heterogeneity of fractures to the permeability and injectivity of reservoirs hosted in impermeable volcanic units, we present fracture distributions from ICDP hole 5036-2A drilled as a part of Project HOTSPOT. The core documents more than 1200 m of largely homogeneous densely welded tuff hosting an isothermal warm-water reservoir at ~60˚ C. Multiple realizations of a hypothetical reservoir are created using sequential indicator algorithms that honor the observed vertical fracture frequency statistics. Results help form criteria for producing geothermal energy from the SRP.

Friction Stir Welding at MSFC: Kinematics

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.

2001-01-01

In 1991 The Welding Institute of the United Kingdom patented the Friction Stir Welding (FSW) process. In FSW a rotating pin-tool is inserted into a weld seam and literally stirs the faying surfaces together as it moves up the seam. By April 2000 the American Welding Society International Welding and Fabricating Exposition featured several exhibits of commercial FSW processes and the 81st Annual Convention devoted a technical session to the process. The FSW process is of interest to Marshall Space Flight Center (MSFC) as a means of avoiding hot-cracking problems presented by the 2195 aluminum-lithium alloy, which is the primary constituent of the Lightweight Space Shuttle External Tank. The process has been under development at MSFC for External Tank applications since the early 1990's. Early development of the FSW process proceeded by cut-and-try empirical methods. A substantial and complex body of data resulted. A theoretical model was wanted to deal with the complexity and reduce the data to concepts serviceable for process diagnostics, optimization, parameter selection, etc. A first step in understanding the FSW process is to determine the kinematics, i.e., the flow field in the metal in the vicinity of the pin-tool. Given the kinematics, the dynamics, i.e., the forces, can be targeted. Given a completed model of the FSW process, attempts at rational design of tools and selection of process parameters can be made.

The use of supercomputer modelling of high-temperature failure in pipe weldments to optimize weld and heat affected zone materials property selection

NASA Astrophysics Data System (ADS)

Wang, Z. P.; Hayhurst, D. R.

1994-07-01

The creep deformation and damage evolution in a pipe weldment has been modeled by using the finite-element continuum damage mechanics (CDM) method. The finite-element CDM computer program DAMAGE XX has been adapted to run with increased speed on a Cray XMP/416 supercomputer. Run times are sufficiently short (20 min) to permit many parametric studies to be carried out on vessel lifetimes for different weld and heat affected zone (HAZ) materials. Finite-element mesh sensitivity was studied first in order to select a mesh capable of correctly predicting experimentally observed results using at least possible computer time. A study was then made of the effect on the lifetime of a butt welded vessel of each of the commomly measured material parameters for the weld and HAZ materials. Forty different ferritic steel welded vessels were analyzed for a constant internal pressure of 45.5 MPa at a temperature of 565 C; each vessel having the same parent pipe material but different weld and HAZ materials. A lifetime improvement has been demonstrated of 30% over that obtained for the initial materials property data. A methodology for weldment design has been established which uses supercomputer-based CDM analysis techniques; it is quick to use, provides accurate results, and is a viable design tool.

Comparison of pressure drop and filtration efficiency of particulate respirators using welding fumes and sodium chloride.

PubMed

Cho, Hyun-Woo; Yoon, Chung-Sik; Lee, Jin-Ho; Lee, Seung-Joo; Viner, Andrew; Johnson, Erik W

2011-07-01

Respirators are used to help reduce exposure to a variety of contaminants in workplaces. Test aerosols used for certification of particulate respirators (PRs) include sodium chloride (NaCl), dioctyl phthalate, and paraffin oil. These aerosols are generally assumed to be worst case surrogates for aerosols found in the workplace. No data have been published to date on the performance of PRs with welding fumes, a hazardous aerosol that exists in real workplace settings. The aim of this study was to compare the performance of respirators and filters against a NaCl aerosol and a welding fume aerosol and determine whether or not a correlation between the two could be made. Fifteen commercial PRs and filters (seven filtering facepiece, two replaceable single-type filters, and six replaceable dual-type filters) were chosen for investigation. Four of the filtering facepiece respirators, one of the single-type filters, and all of the dual-type filters contained carbon to help reduce exposure to ozone and other vapors generated during the welding process. For the NaCl test, a modified National Institute for Occupational Safety and Health protocol was adopted for use with the TSI Model 8130 automated filter tester. For the welding fume test, welding fumes from mild steel flux-cored arcs were generated and measured with a SIBATA filter tester (AP-634A, Japan) and a manometer in the upstream and downstream sections of the test chamber. Size distributions of the two aerosols were measured using a scanning mobility particle sizer. Penetration and pressure drop were measured over a period of aerosol loading onto the respirator or filter. Photos and scanning electron microscope images of clean and exposed respirators were taken. The count median diameter (CMD) and mass median diameter (MMD) for the NaCl aerosol were smaller than the welding fumes (CMD: 74 versus 216 nm; MMD: 198 versus 528 nm, respectively). Initial penetration and peak penetration were higher with the NaCl aerosol. However, pressure drop increased much more rapidly in the welding fume test than the NaCl aerosol test. The data and images clearly show differences in performance trends between respirator models. Therefore, general correlations between NaCl and weld fume data could not be made. These findings suggest that respirators certified with a surrogate test aerosol such as NaCl are appropriate for filtering welding fume (based on penetration). However, some respirators may have a more rapid increase in pressure drop from the welding fume accumulating on the filter. Therefore, welders will need to choose which models are easier to breathe through for the duration of their use and replace respirators or filters according to the user instructions and local regulations.

Study of the properties of flux cored wire of Fe-C-Si-Mn-Cr-Mo-Ni-V-Co system for the strengthening of nodes and parts of equipment used in the mineral mining

NASA Astrophysics Data System (ADS)

Gusev, A. I.; Kozyrev, N. A.; Usoltsev, A. A.; Kryukov, R. E.; Osetkovsky, I. V.

2017-09-01

The effect of the introduction of vanadium and cobalt into the charge of the powder surfacing wire of Fe-C-Si-Mn-Cr-Mo-Ni system is studied. In the laboratory conditions, the samples of flux cored wires were produced. The surfacing made by the prepared wire was produced under the flux AN-26C, on the plates of steel St3 in 6 layers with the help of ASAW-1250 welding tractor. Reduction of carbon content in the deposited layer to 0.19-0.2% with simultaneous change in the content of chromium, nickel, molybdenum and other elements present in it contributes to the enlargement of the martensite needles and the increase in the size of the former austenite grain. The obtained dependences of hardness of the deposited layer and its wear resistance on the mass fraction of elements, included in the composition of powder wires of the proposed system, can be used to predict the hardness of the welded layer and its wear resistance under different operating conditions for mining equipment and coal mining equipment.

Biological effect markers in exhaled breath condensate and biomonitoring in welders: impact of smoking and protection equipment.

PubMed

Gube, Monika; Ebel, Joachim; Brand, Peter; Göen, Thomas; Holzinger, Karl; Reisgen, Uwe; Kraus, Thomas

2010-10-01

The objective of this study was to investigate the effect of welding as well as the impact of smoking and protection measures on biological effect markers in exhaled breath condensate. Additionally, biomonitoring of chromium, aluminium and nickel in urine was performed to quantify internal exposure. Exhaled breath condensate (EBC) and urine samples of 45 male welders and 24 male non-exposed control subjects were collected on Friday pre-shift and after 8 h of work post-shift. In EBC, biological effect markers such as malondialdehyde, nitrite, nitrate, 3-nitrotyrosine, tyrosine, hydroxyproline, proline, H(2)O(2) and pH-value were measured while aluminium, nickel, and chromium were measured in the urine samples. Although internal exposure to aluminium, nickel and chromium in this study was low, welders showed significantly increased concentrations of all these parameters at baseline compared to non-exposed controls. Moreover, welders had higher nitrate concentrations in EBC at baseline and after shift. Nitrate concentration was considerably lower after shift if personal protection equipment was used. H(2)O(2) was increased only when subjects smoked during shift. It has been shown that welding-associated long-term and short-term health effects could be detected in a population of welders. The results also showed that using personal protection equipment is of high importance and H(2)O(2) may be an effect marker associated with smoking rather than with welding fumes, while nitrate in EBC seems to be sensitive to welding fume exposure.

METHOD OF MAKING AND PLATE CONNECTION

DOEpatents

Patriarca, P.; Shubert, C.E.; Slaughter, G.M.

1963-02-26

This invention relates to a method of joining, by welding or brazing, a tube to a plate, particularly where the tube and the plate are of different thickness or have different thermal conductivities and are subject to high temperatures. In this method the tube is inserted in the core of a plate containing an annular groove in its back face concentric with the bore and in communication with the bore. One end of the tube is welded substantially flush with the front end of the plate. Brazing alloy is placed in the groove on the back face of the plate and heat is applied to the plate and tube to melt the brazing alloy to permit the alloy to flow into the bore and bond the tube to the plate. (AEC)

Laser welding of chitosan-GNRs films for the closure of a capsulorhexis

NASA Astrophysics Data System (ADS)

Rossi, Francesca; Matteini, Paolo; Ratto, Fulvio; Menabuoni, Luca; Lenzetti, Ivo; Pini, Roberto

2011-03-01

In this work we present the first attempt to close the anterior lens capsule bag by the use of chitosan patches, where Gold Nanorods (GNRs) are embedded. GNRs exhibit intense localized plasmon resonances at optical frequencies in the near infrared (NIR): upon excitation with a NIR laser, a strong photothermal effect is produced, which can be exploited to develop minimally invasive therapies. Here we use the chitosan-GNRs films as a novel NIR sensitive nanocomposite for the photothermal conversion of NIR laser light during surgical interventions of tissue welding. Chitosan is an attractive biomaterial due to its biodegradability, biocompatibility, antimicrobial and wound healing-promoting activity. Colloidal GNRs were embedded in chitosan based, highly stabilized, flexible and easy-to-handle films, which were stored in water until the time of surgery. In these preliminary tests, a capsulorhexis was performed in freshly enucleated porcine eyes. The lens was aspired, then the patch was put onto the capsule bag and welded: a diode laser (810 nm) was used to deliver single spots (200 μm core diameter optical fiber) of local capsule/patch adhesion. Then the bag was refilled with silicon oil. The result is an immediate closure of the capsular tissue, with high mechanical strength. The laser welded chitosan- GNRs films are an innovative and highly stable solution to be exploited for the treatment of capsular breaks and for the implementation of a lens refilling procedure.

Innovative Tools Advance Revolutionary Weld Technique

NASA Technical Reports Server (NTRS)

2009-01-01

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Absorbed dose determination using experimental and analytical predictions of x-ray spectra

NASA Astrophysics Data System (ADS)

Edwards, David Lee

1999-10-01

Electron beam welding in a vacuum is a technology that NASA is investigating as a joining technique for manufacture of space structures. The interaction of energetic electrons with metal produces x-rays. This investigation characterizes the x-ray environment due to operation of an in-vacuum electron beam welding tool and provides recommendations for adequate radiation shielding for astronauts performing the in-vacuum electron beam welding. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the United States Space Shuttle. This series of experiments was named the International Space Welding Experiment (ISWE). The hardware associated with the ISWE was leased to NASA, by the Paton Welding Institute (PWI) in Ukraine, for ground based welding experiments in preparation for flight. Two ground tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests used Thermoluminescence Dosimeters (TLD's) shielded with material currently used by astronauts during Extra Vehicular Activities (EVA) to measure the radiation dose. The TLD's were exposed to x- ray radiation generated by operation of the ISWE in- vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x-rays of energy less than 10 keV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was completely verified. Therefore alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by ISWE electron beam impact with metal. These x-ray spectra were normalized to an equivalent ISWE exposure then used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the ISWE in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in good agreement with the measured TLD values.

Human biomonitoring of chromium and nickel from an experimental exposure to manual metal arc welding fumes of low and high alloyed steel.

PubMed

Bertram, Jens; Brand, Peter; Schettgen, Thomas; Lenz, Klaus; Purrio, Ellwyn; Reisgen, Uwe; Kraus, Thomas

2015-05-01

The uptake and elimination of metals from welding fumes is currently not fully understood. In the Aachen Workplace Simulation Laboratory (AWSL) it is possible to investigate the impact of welding fumes on human subjects under controlled exposure conditions. In this study, the uptake and elimination of chromium or chromium (VI) respectively as well as nickel was studied in subjects after exposure to the emissions of a manual metal arc welding process using low or high alloyed steel. In this present study 12 healthy male non-smokers, who never worked as welders before, were exposed for 6h to welding fumes of a manual metal arc welding process. In a three-fold crossover study design, subjects were exposed in randomized order to either clean air, emissions from welding low alloyed steel, and emissions from welding high alloyed steel. Particle mass concentration of the exposure aerosol was 2.5mg m(-3). The content of chromium and nickel in the air was determined by analysing air filter samples on a high emission scenario. Urine analysis for chromium and nickel was performed before and after exposure using methods of human biomonitoring. There were significantly elevated chromium levels after exposure to welding fumes from high alloyed steel compared to urinary chromium levels before exposure to high alloyed welding fumes, as well as compared to the other exposure scenarios. The mean values increased from 0.27 µg l(-1) to 18.62 µg l(-1). The results were in good agreement with already existing correlations between external and internal exposure (German exposure equivalent for carcinogenic working materials EKA). The variability of urinary chromium levels was high. For urinary nickel no significant changes could be detected at all. Six-hour exposure to 2.5mg m(-3) high alloyed manual metal arc welding fumes lead to elevated urinary chromium levels far higher (7.11-34.16 µg l(-1)) than the German biological exposure reference value (BAR) of 0.6 µg l(-1) directly after exposure. On the other hand mean urinary nickel concentrations slightly increased, but did not exceed background levels due to lower bioavailability. We could underline with our single exposure experiment that a welding work related chromium exposure can be measured immediately after the work shift, while the same is not possible for nickel exposure due to lower nickel bioavailability. The data provide useful information for real occupational welding work places. © The Author 2014. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.

Nondestructive Evaluation Methods for the Ares I Common Bulkhead

NASA Technical Reports Server (NTRS)

Walker, James

2010-01-01

A large scale bonding demonstration test article was fabricated to prove out manufacturing techniques for the current design of the NASA Ares I Upper Stage common bulkhead. The common bulkhead serves as the single interface between the liquid hydrogen and liquid oxygen portions of the Upper Stage propellant tank. The bulkhead consists of spin-formed aluminum domes friction stir welded to Y-rings and bonded to a perforated phenolic honeycomb core. Nondestructive evaluation methods are being developed for assessing core integrity and the core-to-dome bond line of the common bulkhead. Detection of manufacturing defects such as delaminations between the core and face sheets as well as service life defects such as crushed or sheared core resulting from impact loading are all of interest. The focus of this work will be on the application of thermographic, shearographic, and phased array ultrasonic methods to the bonding demonstration article as well as various smaller test panels featuring design specific defect types and geometric features.

Proceedings of the International Electronic Circuit Packaging Symposium (3rd) on Advances in Electronic Circuit Packaging Held at Boulder, Colorado on 15-17 August 1962. Volume 3,

DTIC Science & Technology

1963-01-01

the connector pin, which was then sol - dered at various levels of wire build up. It is proposed, with a slight modification of the connector terminal...sacrificial anode for galvanic protection of other metals. Aluminum Aluminum and its alloys show promise for applications in long-life oceano - graphic...section of a dumet weld lead. Calculations and actual heat measurements on the effects of welding and sol - dering within 0.060 in. of the component

Digital Radiography Using Digital Detector Arrays Fulfills Critical Applications for Offshore Pipelines

NASA Astrophysics Data System (ADS)

Moreira, EdsonVasques; Barbosa Rabello, JoséMaurício; Pereira, MarcelodosSantos; Lopes, RicardoTadeu; Zscherpel, Uwe

2010-12-01

Digital radiography in the inspection of welded pipes to be installed under deep water offshore gas and oil pipelines, like a presalt in Brazil, in the paper has been investigated. The aim is to use digital radiography for nondestructive testing of welds as it is already in use in the medical, aerospace, security, automotive, and petrochemical sectors. Among the current options, the DDA (Digital Detector Array) is considered as one of the best solutions to replace industrial films, as well as to increase the sensitivity to reduce the inspection cycle time. This paper shows the results of this new technique, comparing it to radiography with industrial films systems. In this paper, 20 test specimens of longitudinal welded pipe joints, specially prepared with artificial defects like cracks, lack of fusion, lack of penetration, and porosities and slag inclusions with varying dimensions and in 06 different base metal wall thicknesses, were tested and a comparison of the techniques was made. These experiments verified the purposed rules for parameter definitions and selections to control the required digital radiographic image quality as described in the draft international standard ISO/DIS 10893-7. This draft is first standard establishing the parameters for digital radiography on weld seam of welded steel pipes for pressure purposes to be used on gas and oil pipelines.

An improved method of crafting a multi-electrode spiral cuff for the selective.

PubMed

Rozman, Janez; Pečlin, Polona; Ribarič, Samo; Godec, Matjaž; Burja, Jaka

2018-01-17

This article reviews an improved methodology and technology for crafting a multi-electrode spiral cuff for the selective activation of nerve fibres in particular superficial regions of a peripheral nerve. The analysis, structural and mechanical properties of the spot welds used for the interconnections between the stimulating electrodes and stainless-steel lead wires are presented. The cuff consisted of 33 platinum electrodes embedded within a self-curling 17-mm-long silicone spiral sheet with a nominal internal diameter of 2.5 mm. The weld was analyzed using scanning electron microscopy and nanohardness tests, while the interconnection was investigated using destructive load tests. The functionality of the cuff was tested in an isolated porcine vagus nerve. The results of the scanning electron microscopy show good alloying and none of the typical welding defects that occur between the wire and the platinum foil. The results of the destructive load tests show that the breaking loads were between 3.22 and 5 N. The results of the nanohardness testing show that the hardness of the weld was different for the particular sites on the weld sample. Finally, the results of the functional testing show that for different stimulation intensities both the compound action potential deflection and the shape are modulated.

LPT. EBOR (TAN646) interior, installing reactor in STF pool ("vault"). ...

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

LPT. EBOR (TAN-646) interior, installing reactor in STF pool ("vault"). Pressure vessel shows core barrel and outlet nozzle (next to man below) to inner duct weld, which is prepared and in position for stress relieving. Camera facing southeast. Photographer: Comiskey. Date: January 20, 1965. INEEL negative no. 65-239 - Idaho National Engineering Laboratory, Test Area North, Scoville, Butte County, ID

Friction Stir Welding of Line-Pipe Steels

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

Sanderson, Samuel; Mahoney, Murray; Feng, Zhili

Friction stir welding (FSW) offers both economic and technical advantages over conventional fusion welding practices for welding line-pipe. For offshore line-pipe construction, the economic savings has been shown to be considerable, approaching a calculated 25%. Offshore pipe is relatively small diameter but heavy wall compared to onshore pipe. One concern is the ability to achieve consistent full weld penetration in an on-site offshore FSW operation, e.g., on a lay-barge. In addition, depending on the size and morphology of the unwelded zone, lack of penetration at the weld root can be difficult if not impossible to detect by conventional NDE methods.more » Thus, an approach to assure consistent full penetration via process control is required for offshore line-pipe construction using FSW. For offshore construction, an internal structural mandrel can be used offering the opportunity to use a sacrificial anvil FSW approach. With this approach, a small volume of sacrificial material can be inserted into the structural anvil. The FSW tool penetrates into the sacrificial anvil, beyond the inner diameter of the pipe wall, thus assuring full penetration. The sacrificial material is subsequently removed from the pipe inner wall. In the work presented herein, FSW studies were completed on both 6 mm and 12 mm wall thickness line-pipe. Lastly, post-FSW evaluations including radiography, root-bend tests, and metallography demonstrated the merits of the sacrificial anvil approach to achieve consistent full penetration.« less

Transformation characteristics of TiNi/TiNi alloys synthesized by explosive welding

NASA Astrophysics Data System (ADS)

Li, Juntao; Zheng, Yanjun; Cui, Lishan

2007-10-01

Effects of severe deformation and heat treatment on the transformation behaviors of explosively welded duplex TiNi/TiNi shape memory alloys (SMAs) were investigated by the differential scanning calorimeter (DSC). The explosively welded duplex TiNi/TiNi plate of 0.7 mm in thickness was cold-rolled at room temperature to the extent of 60% reduction in thickness and then annealed at different temperatures (573-973 K) for different time (15 min-10 h). Low temperature (623-723 K) heat treatment led to amorphous crystallization. At higher temperature (873 K), the re-crystallization took place in the specimens. Analysis showed that the change of internal stresses is just the root cause of the change of transformation temperature. The relationships between the transformation behaviors and the heat treatment were discussed in the present report.

The effects of weld-repair and hot isostatic pressing on the fracture properties of Ti-5Al-2.5Sn ELI castings

NASA Technical Reports Server (NTRS)

Misra, M. S.; Lemeshewsky, S.; Bolstad, D.

1982-01-01

The Ti-5Al-2.5Sn extremely low interstitial alloy employed in the large castings which form the critical attachment fittings of the Space Shuttle External Tank was selected because of its high fracture resistance at cryogenic temperatures. Casting was selected over alternative fabrication methods because of its lower cost and adaptability to design changes, although it was found necessary to weld-repair surface and subsurface casting defects in order to reduce the scrap rate and maintain the inherent cost advantage of the castings. Hot Isostatic Pressing was experimentally found to heal the surface and internal defects of the castings, but did not improve tensile or fracture properties and was therefore rejected as a production technique. Production castings are instead weld-repaired, without any mechanical property degradation.

Influence of nanomodification additives on the properties of multilayer composite coating obtained in laser surfacing

NASA Astrophysics Data System (ADS)

Cherepanov, A. N.; Orishich, A. M.; Ovcharenko, V. E.; Malikov, A. G.; Drozdov, V. O.; Pshenichnikov, A. P.

2017-10-01

The paper presents the results of numerical and experimental studies of the process of obtaining a permanent joint of two plates of heterogeneous metals that cannot be welded in the usual way: alloy Grade 4 and steel AISI 321 using a laser beam and an intermediate composite insert. The composite insert was obtained by explosion welding of four thin plates of titanium (Grade 4), niobium, copper, and steel (AISI 321). The insert was placed between the welded plates of titanium and steel, and the steel plate was welded with the steel part of the insert, and the titanium plate was welded with the titanium part of the insert. The plates were welded using a CO2 laser. The connection of metals with the help of explosion is carried out without their melting, so the formation of the brittle intermetallics does not occur in most cases. This ensures the greatest strength of the joints as compared to the joints obtained by other welding methods. To analyze the distribution of thermal fields in the composite insert and welded plates, a numerical study was conducted of the laser welding of steel and titanium plates with the corresponding parts of the insert. The purpose of the study was to determine the rational parameters of welding (laser beam power, speed of its movement, size and position of the focal spot), at which there was no complete melting of the steel and titanium parts of the insert during through penetration of the welded plates. The experimental part of the work is devoted to analysis of formation of the internal boundaries and microstructure of the composite insert and the strength of the permanent joint. It is shown that as a result of the explosion welding, weld seams of different wavelike configuration are formed. The most pronounced wavelike boundary is observed in the steel-copper connection, since these materials have a face-centered cubic lattice and are easily subjected to plastic deformation. At the contact boundaries of the plates, transition diffusion zones with different widths (from 5 to 40 μm) and element concentrations are formed. The hardness in the boundary diffusion zones is higher than in the connected metals, which is due to the diffusion interaction of the materials adjacent to each other. It has been established that the tensile strength of the composite insert is comparable to the maximum strength of Grade 4 alloy (456-511 MPa), and the failure in most cases occurred over the least durable component of the composite material, which is the copper plate, whose strength was significantly increased by cold hardening during explosion welding and diffusion of elements of the contacting plates.

Development of a field method for measuring manganese in welding fume.

PubMed

Dale Marcy, A; Drake, Pamela L

2007-11-01

Workers who perform routine welding tasks are potentially exposed to fume that may contain manganese. Manganese may cause respiratory problems and is implicated in causing the occurrence of Parkinson-like symptoms. In this study, a field colorimetric method for extracting and measuring manganese in welding fume was developed. The method uses ultrasonic extraction with an acidic hydrogen peroxide solution to extract welding fume collected on polyvinyl chloride filters. Commercially available pre-packaged reagents are used to produce a colored solution, created by a reaction of manganese(ii) with 1-(2-pyridylazo)-2-naphthol. Absorbance measurements are then made using a portable spectrophotometer. The method detection limit and limit of quantification (LOQ) were 5.2 microg filter(-1) and 17 microg filter(-1), respectively, with a dynamic range up to 400 microg filter(-1). When the results are above the LOQ for the colorimetric method, the manganese masses are equivalent to those measured by the International Organization for Standardization Method 15202-2, which employs a strong acid digestion and analysis using inductively coupled plasma-optical emission spectrometry.

76 FR 66899 - Certain Circular Welded Non-Alloy Steel Pipe From Brazil, Mexico, the Republic of Korea, and...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-10-28

... DEPARTMENT OF COMMERCE International Trade Administration [A-351-809, A-201-805, A-580-809, A-583..., International Trade Administration, Department of Commerce. SUMMARY: On August 1, 2011 the Department of Commerce (Department) initiated the third five-year (sunset) reviews of the antidumping duty orders on...

Space Launch System Launch Vehicle Stage Adapter Hardware Completes Manufacturing

NASA Image and Video Library

2017-08-28

The Launch Vehicle Stage Adapter for the first flight of the Space Launch System, NASA’s new deeps space rocket, recently completed manufacturing at NASA’s Marshal Space Flight Center in Huntsville, Alabama. The LVSA, the largest piece of the rocket welded together in Marshall’s Huntsville manufacturing area, will connect two major sections of SLS – the 27.6-foot diameter core stage and the 16.4-foot interim cryogenic propulsion stage – for the first integrated flight of SLS and the Orion spacecraft. Teledyne Brown Engineering of Huntsville, the prime contractor for the adapter, has completed manufacturing, and engineers are preparing to apply thermal insulation. It will be the largest piece of hardware that Marshall. The LVSA was moved from the NASA welding area to NASA’s Center for Advanced Manufacturing where the thermal protection system will be applied.

Microstructure development and texture evolution of aluminum multi-port extrusion tube during the porthole die extrusion

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

Fan, X.H.

Aluminum multi-port extrusion tube is processed by the porthole die extrusion and the internal tube walls are welded through the solid state metallurgical bonding. In order to observe the development of grains and their orientations under severe plastic deformation and solid state welding, the extrusion butt together with the die is quenched immediately after extrusion to preserve the grain structure in the processing. The forming histories of selected material points are obtained by analyzing the optical microscopy graph. The evolution of the microstructure along the forming path is characterized by electro backscattered diffraction. It is found that geometrical dynamic recrystallizationmore » happens in the process. Grains are elongated, scattered at the transition zone and shear intensive zone, and then pinched off when they are pushed out from the die orifice. The shear-type orientations are predominant at the surface layer on the longitudinal section of the tube web and have penetrated into the intermediate layer. The rolling-type orientations are formed at the central layer. Texture gradient through the thickness of the tube web is observed. And cube orientated grains are found at the seam weld region. - Highlights: •Microstructure of extrusion butt is preserved after the micro scale porthole die extrusion. •Grain morphology history along forming path is investigated. •Texture evolutions on three material flows are present. •Texture gradient exists on the longitudinal section of the internal wall of profile. •Rolling-type and cube textures are found at the solid state welding region.« less

Laser-activated protein solder for peripheral nerve repair

NASA Astrophysics Data System (ADS)

Trickett, Rodney I.; Lauto, Antonio; Dawes, Judith M.; Owen, Earl R.

1995-05-01

A 100 micrometers core optical fiber-coupled 75 mW diode laser operating at a wavelength of 800 nm has been used in conjunction with a protein solder to stripe weld severed rat tibial nerves, reducing the long operating time required for microsurgical nerve repair. Welding is produced by selective laser denaturation of the albumin based solder which contains the dye indocyanine green. Operating time for laser soldering was 10 +/- 5 min. (n equals 20) compared to 23 +/- 9 min. (n equals 10) for microsuturing. The laser solder technique resulted in patent welds with a tensile strength of 15 +/- 5 g, while microsutured nerves had a tensile strength of 40 +/- 10 g. Histopathology of the laser soldered nerves, conducted immediately after surgery, displayed solder adhesion to the outer membrane with minimal damage to the inner axons of the nerves. An in vivo study is under way comparing laser solder repaired tibial nerves to conventional microsuture repair. At the time of submission 15 laser soldered nerves and 7 sutured nerves were characterized at 3 months and showed successful regeneration with compound muscle action potentials of 27 +/- 8 mV and 29 +/- 8 mW respectively. A faster, less damaging and long lasting laser based anastomotic technique is presented.

Microwave Induced Welding of Carbon Nanotube-Thermoplastic Interfaces for Enhanced Mechanical Strength of 3D Printed Parts

NASA Astrophysics Data System (ADS)

Sweeney, Charles; Lackey, Blake; Saed, Mohammad; Green, Micah

Three-dimensional (3D) printed parts produced by fused-filament fabrication of a thermoplastic polymer have become increasingly popular at both the commercial and consumer level. The mechanical integrity of these rapid-prototyped parts however, is severely limited by the interfillament bond strength between adjacent extruded layers. In this report we propose for the first time a method for welding thermoplastic interfaces of 3D printed parts using the extreme heating response of carbon nanotubes (CNTs) to microwave energy. To achieve this, we developed a coaxial printer filament with a pure polylactide (PLA) core and a CNT composite sheath. This produces parts with a thin electrically percolating network of CNTs at the interfaces between adjacent extruded layers. These interfaces are then welded together upon microwave irradiation at 2.45GHz. Our patent-pending method has been shown to increase the tensile toughness by 1000% and tensile strength by 35%. We investigated the dielectric properties of the PLA/CNT composites at microwave frequencies and performed in-situ microwave thermometry using a forward-looking infrared (FLIR) camera to characterize the heating response of the PLA/CNT composites upon microwave irradiation.

30 CFR 18.98 - Enclosures, joints, and fastenings; pressure testing.

Code of Federal Regulations, 2013 CFR

2013-07-01

... consistent with unyielding components during a pressure-time history as derived from a series of oscillograms...; pressure testing. (a) Cast or welded enclosures shall be designed to withstand a minimum internal pressure...

30 CFR 18.98 - Enclosures, joints, and fastenings; pressure testing.

Code of Federal Regulations, 2012 CFR

2012-07-01

... consistent with unyielding components during a pressure-time history as derived from a series of oscillograms...; pressure testing. (a) Cast or welded enclosures shall be designed to withstand a minimum internal pressure...

30 CFR 18.98 - Enclosures, joints, and fastenings; pressure testing.

Code of Federal Regulations, 2014 CFR

2014-07-01

... consistent with unyielding components during a pressure-time history as derived from a series of oscillograms...; pressure testing. (a) Cast or welded enclosures shall be designed to withstand a minimum internal pressure...

30 CFR 18.98 - Enclosures, joints, and fastenings; pressure testing.

Code of Federal Regulations, 2010 CFR

2010-07-01

... consistent with unyielding components during a pressure-time history as derived from a series of oscillograms...; pressure testing. (a) Cast or welded enclosures shall be designed to withstand a minimum internal pressure...

30 CFR 18.98 - Enclosures, joints, and fastenings; pressure testing.

Code of Federal Regulations, 2011 CFR

2011-07-01

... consistent with unyielding components during a pressure-time history as derived from a series of oscillograms...; pressure testing. (a) Cast or welded enclosures shall be designed to withstand a minimum internal pressure...

High Strength Steel Welding Research

DTIC Science & Technology

2005-05-27

E.S.K. Menon, and M.G. Hall, "Sympathetic Nucleation: An Overview," Materials Science and Engineering B, Solid State Materials for Advanced Technology ...GTAW of Titanium Using Flux-cored Wire with Magnesium Fluoride Kook-soo Bang’, Greg Chirieleison 2, and Stephen Liu 2 1 Division of Advanced Materials...O CHAPTER I O INTRODUCTION * The application of advanced high strength low alloy (HSLA) steels has been * limited by the availability of suitable

Slow fatigue testing of titanium grade 29 in air and seawater

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

Atteraas, L.; Hersvik, G.; Solbakken, H.

1999-07-01

ASTM Grade 29 titanium has been fatigue tested in air and seawater at 110 C at a low frequency. The possible influence of seawater is completely masked by the fact that all the specimens of welded titanium, and most of the parent metal samples, had internal fracture initiations. Compared to the parent metal, the welded pipe specimens (5G orbital TIG) had a significantly lower fatigue life at the relatively high cyclic stress levels employed ({sigma}{sub max} = 0.85 {sigma}{sub y}). This is attributed to the presence of pores. Fractographic studies of failed weld metal specimens indicate that the fracture initiationmore » takes place in the material immediately surrounding a pore, with an abrupt crack formation, marking the beginning of the crack growth phase. The duration of the crack initiation phase shows large variations, whereas the growth phase duration varies little.« less

Effective dose in the manufacturing process of rutile covered welding electrodes.

PubMed

Herranz, M; Rozas, S; Pérez, C; Idoeta, R; Núñez-Lagos, R; Legarda, F

2013-03-01

Shielded metal arc welding using covered electrodes is the most common welding process. Sometimes the covering contains naturally occurring radioactive materials (NORMs). In Spain the most used electrodes are those covered with rutile mixed with other materials. Rutile contains some detectable natural radionuclides, so it can be considered a NORM. This paper mainly focuses on the use of MCNP (Monte Carlo N-Particle Transport Code) as a predictive tool to obtain doses in a factory which produces this type of electrode and assess the radiological impact in a specific facility after estimating the internal dose.To do this, in the facility, areas of highest radiation and positions of workers were identified, radioactive content of rutile and rutile covered electrodes was measured, and, considering a worst possible scenario, external dose at working points has been calculated using MCNP. This procedure has been validated comparing the results obtained with those from a pressurised ionisation chamber and TLD dosimeters. The internal dose has been calculated using DCAL (dose and risk calculation). The doses range between 8.8 and 394 μSv yr(-1), always lower than the effective dose limit for the public, 1 mSv yr(-1). The highest dose corresponds to the mixing area.

49 CFR 179.200-16 - Gauging devices, top loading and unloading devices, venting and air inlet devices.

Code of Federal Regulations, 2010 CFR

2010-10-01

... be made of cast, forged, or fabricated metal. Each sump or siphon bowl must be of good welding... must have walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are not greater than the circumferential stress which would exist under the same internal...

49 CFR 179.200-16 - Gauging devices, top loading and unloading devices, venting and air inlet devices.

Code of Federal Regulations, 2013 CFR

2013-10-01

... be made of cast, forged, or fabricated metal. Each sump or siphon bowl must be of good welding... must have walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are not greater than the circumferential stress which would exist under the same internal...

49 CFR 179.200-16 - Gauging devices, top loading and unloading devices, venting and air inlet devices.

Code of Federal Regulations, 2014 CFR

2014-10-01

... be made of cast, forged, or fabricated metal. Each sump or siphon bowl must be of good welding... must have walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are not greater than the circumferential stress which would exist under the same internal...

49 CFR 179.100-13 - Venting, loading and unloading valves, measuring and sampling devices.

Code of Federal Regulations, 2013 CFR

2013-10-01

... metal. Each sump or siphon bowl must be of good welding quality in conjunction with the metal of the... walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are no greater than the circumferential stress that would exist under the same internal pressure...

49 CFR 179.100-13 - Venting, loading and unloading valves, measuring and sampling devices.

Code of Federal Regulations, 2012 CFR

2012-10-01

... metal. Each sump or siphon bowl must be of good welding quality in conjunction with the metal of the... walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are no greater than the circumferential stress that would exist under the same internal pressure...

49 CFR 179.100-13 - Venting, loading and unloading valves, measuring and sampling devices.

Code of Federal Regulations, 2014 CFR

2014-10-01

... metal. Each sump or siphon bowl must be of good welding quality in conjunction with the metal of the... walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are no greater than the circumferential stress that would exist under the same internal pressure...

49 CFR 179.200-16 - Gauging devices, top loading and unloading devices, venting and air inlet devices.

Code of Federal Regulations, 2012 CFR

2012-10-01

... be made of cast, forged, or fabricated metal. Each sump or siphon bowl must be of good welding... must have walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are not greater than the circumferential stress which would exist under the same internal...

49 CFR 179.100-13 - Venting, loading and unloading valves, measuring and sampling devices.

Code of Federal Regulations, 2011 CFR

2011-10-01

... metal. Each sump or siphon bowl must be of good welding quality in conjunction with the metal of the... walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are no greater than the circumferential stress that would exist under the same internal pressure...

49 CFR 179.200-16 - Gauging devices, top loading and unloading devices, venting and air inlet devices.

Code of Federal Regulations, 2011 CFR

2011-10-01

... be made of cast, forged, or fabricated metal. Each sump or siphon bowl must be of good welding... must have walls of such thickness and be so reinforced that the stresses in the walls caused by a given internal pressure are not greater than the circumferential stress which would exist under the same internal...

Primary welding and crystallisation textures preserved in the intra-caldera ignimbrites of the Permian Ora Formation, northern Italy: implications for deposit thermal state and cooling history

NASA Astrophysics Data System (ADS)

Willcock, M. A. W.; Cas, R. A. F.

2014-06-01

Exceptional exposure through a Permian intra-caldera ignimbrite fill within the 42 × 40 km Ora caldera (>1,290 km3 erupted volume) provides an opportunity to study welding textures in a thick intra-caldera ignimbrite succession. The ignimbrite succession records primary dense welding, a simple cooling unit structure, common crystallisation zones, and remarkably preserves fresh to slightly hydrated glass in local vitrophyre zones. Evidence for primary syn- and post-emplacement welding consists of (a) viscously deformed and sintered juvenile glass and relict shard textures; (b) complete deposit welding; (c) subtle internal welding intensity variations; (d) vitrophyre preserved locally at the base of the ignimbrite succession; (e) persistent fiamme juvenile clast shapes throughout the succession at the macroscopic and microscopic scales, defining a moderate to well-developed eutaxitic texture; (f) common undulating juvenile clast (pumice) margins and feathery terminations; (g) a general loss of deposit porosity; and (h) perlitic fracturing. A low collapsing or fountaining explosive eruption column model is proposed to have facilitated the ubiquitous welding of the deposit, which in turn helped preserve original textures. The ignimbrite succession preserves no evidence of a time break through the sequence and columnar joints cross-gradational ignimbrite lithofacies boundaries, so the ignimbrite is interpreted to represent a simple cooling unit. Aspect ratio and anisotropy of magnetic susceptibility (AMS) analyses through stratigraphic sections within the thick intra-caldera succession and at the caldera margin reveal variable welding compaction and strain profiles. Significantly, these data show that welding degree/intensity may vary in an apparently simple cooling unit because of variations in eruption process recorded in differing lithofacies. These data imply complex eruption, emplacement, and cooling processes. Three main crystallisation textural zones are identified in the ignimbrite succession: localised vitrophyre zones, widespread microcrystalline to sparsely spherulitic pseudomorphed vitriclastic textural zones, and thick granophyric zones. These zones record a typical spectrum from rapid to prolonged cooling. The non-uniform crystallisation patterns reflect variations in deposit thickness, the relative position of deposits within the larger ignimbrite succession, the type of substrate material, and the degree of confinement in the intra-caldera setting. We support previous work suggesting that traditional welding classifications (e.g. Smith, US Geological Survey Professional Paper 354-F 1960b) are most appropriate for use within altered and/or ancient ignimbrite successions.

Microstructural Evolution and Creep-Rupture Behavior of A-USC Alloy Fusion Welds

NASA Astrophysics Data System (ADS)

Bechetti, Daniel H.; DuPont, John N.; Siefert, John A.; Shingledecker, John P.

2016-09-01

Characterization of the microstructural evolution of fusion welds in alloys slated for use in advanced ultrasupercritical (A-USC) boilers during creep has been performed. Creep-rupture specimens involving INCONEL® 740, NIMONIC® 263 (INCONEL and NIMONIC are registered trademarks of Special Metals Corporation), and Haynes® 282® (Haynes and 282 are registered trademarks of Haynes International) have been analyzed via light optical microscopy, scanning electron microscopy, X-ray diffraction, and thermodynamic and kinetic modeling. Focus has been given to the microstructures that develop along the grain boundaries in these alloys during creep at temperatures relevant to the A-USC process cycle, and particular attention has been paid to any evidence of the formation of local γ'-denuded or γ'-free zones. This work has been performed in an effort to understand the microstructural changes that lead to a weld strength reduction factor (WSRF) in these alloys as compared to solution annealed and aged alloy 740 base metal. γ' precipitate-free zones have been identified in alloy 740 base metal, solution annealed alloy 740 weld metal, and alloy 263 weld metal after creep. Their development during long-term thermal exposure is correlated with the stabilization of phases that are rich in γ'-forming elements ( e.g., η and G) and is suppressed by precipitation of phases that do not contain the γ' formers ( e.g., M23C6 and μ). The location of failure and creep performance in terms of rupture life and WSRF for each welded joint is presented and discussed.

Quality Enhancement of Ultrasonic TOFD Signals from Carbon Steel Weld Pad with Notches.

PubMed

Manjula, K; Vijayarekha, K; Venkatraman, B

2018-03-01

Welding is an integral part of component fabrication in industry. Even though the science and art of welding are more than 100 years old, defects continue to occur during welding. Codes of practice require that the welds be tested and evaluated. Conventionally ultrasonic testing has been widely applied in industry for the detection and evaluation of the flaws/defects in the weldments. With advances in sensor and signal analysis technologies, the last two decades have seen extensive developments in the field of ultrasonic testing. We have advanced techniques such as Time of Flight Diffraction (TOFD) which has better probability of detection for linear defects. A major irritant during the application of TOFD, especially for the testing of carbon steel weldments, is the presence of noise. A variety of approaches has been used internationally for the suppression of such noise and each has its own merits and demerits. This paper focuses on a method of enhancing the TOFD A-scan signals in carbon steel weldments by suppressing the noise from them using the discrete wavelet transform (DWT). The analysis clearly indicates that the DWT gives better signal-to-noise ratio improvement using higher-order wavelet filters with 4-level DWT decomposition. However the computational cost of this signal enhancement depends on the wavelet filter chosen along with the chosen level of DWT decomposition. Copyright © 2017 Elsevier B.V. All rights reserved.

Case-control study of lung cancer in civilian employees at the Portsmouth Naval Shipyard, Kittery, Maine.

PubMed

Rinsky, R A; Melius, J M; Hornung, R W; Zumwalde, R D; Waxweiler, R J; Landrigan, P J; Bierbaum, P J; Murray, W E

1988-01-01

Case-control analysis of deaths due to lung cancer (International Classification of Diseases, Eighth Revision, code 162) among persons who worked at the Portsmouth Naval Shipyard, Kittery, Maine, between 1952 and 1977 found elevated odds ratios for exposures to ionizing radiation, asbestos, and welding byproducts. The radiation-related excess was statistically significant in persons with cumulative lifetime exposures of 1.0-4.999 rem. When asbestos and welding histories were combined into a single risk factor, odds ratios for the combined exposure were significantly elevated for two of three duration-of-exposure categories examined. Further analysis of data on radiation exposure, controlling for exposures to asbestos and welding, found reductions in initial estimates of radiation risk at all levels of radiation exposure. This reduction suggests that radiation workers were more heavily exposed to asbestos and/or welding fumes than were other workers and that those exposures confounded the observed association between radiation and lung cancer. Analysis of mortality by time since first exposure to radiation revealed no pattern of progressive increase as latency increased. By contrast, odds ratios for asbestos/welding increased with latency. Data on cigarette smoking and socioeconomic status were not available. The results of this study do not preclude a possible association between radiation exposure at the Portsmouth Naval Shipyard and excess mortality from lung cancer. However, they provide no evidence in support of such a relation.

Optical sensing in laser machining

NASA Astrophysics Data System (ADS)

Smurov, Igor; Doubenskaia, Maria

2009-05-01

Optical monitoring of temperature evolution and temperature distribution in laser machining provides important information to optimise and to control technological process under study. The multi-wavelength pyrometer is used to measure brightness temperature under the pulsed action of Nd:YAG laser on stainless steel substrates. Specially developed "notch" filters (10-6 transparency at 1.06 μm wavelength) are applied to avoid the influence of laser radiation on temperature measurements. The true temperature is restored based on the method of multi-colour pyrometry. Temperature monitoring of the thin-walled gilded kovar boxes is applied to detect deviation of the welding seam from its optimum position. The pyrometers are used to control CO2-laser welding of steel and Ti plates: misalignment of the welded plates, variation of the welding geometry, internal defects, deviation of the laser beam trajectory from the junction, etc. The temperature profiles along and across the welding axis are measured by the 2D pyrometer. When using multi-component powder blends in laser cladding, for example metal matrix composite with ceramic reinforcement, one needs to control temperature of the melt to avoid thermal decomposition of certain compounds (as WC) and to assure melting of the base metal (as Co). Infra-red camera FLIR Phoenix RDAS provides detailed information on distribution of brightness temperature in laser cladding zone. CCD-camera based diagnostic system is used to measure particles-in-flight velocity and size distribution.

A path to in-space welding and to other in-space metal processing technologies using Space Shuttle small payloads

NASA Technical Reports Server (NTRS)

Tamir, David

1992-01-01

As we venture into space, it becomes necessary to assemble, expand, and repair space-based structures for our housing, research, and manufacturing. The zero gravity-vacuum of space challenges us to employ construction options which are commonplace on Earth. Rockwell International (RI) has begun to undertake the challenge of space-based construction via numerous options, of which one is welding. As of today, RI divisions have developed appropriate resources and technologies to bring space-based welding within our grasp. Further work, specifically in the area of developing space experiments to test RI technology, is required. RI Space Welding Project's achievements to date, from research and development (R&E) efforts in the areas of microgravity, vacuum, intra- / extra- vehicular activity and spinoff technologies, are reviewed. Special emphasis is given to results for G-169's (Get Away Special) microgravity flights aboard a NASA KC-135. Based on these achievements, a path to actual development of a space welding system is proposed with options to explore spinoff in-space metal processing technologies. This path is constructed by following a series of milestone experiments, of which several are to utilize NASA's Shuttle Small Payload Programs. Conceptual designs of the proposed shuttle payload experiments are discussed with application of lessons learned from G-169's design, development, integration, testing, safety approval process, and KC-135 flights.

Development of Optimized Welding Solutions for X100 Linepipe Steel

DOT National Transportation Integrated Search

2011-09-01

This investigation is part of a major consolidated program of research sponsored by the US Department of Transportation (DOT) Pipeline Hazardous Materials Safety Administration (PHMSA) and the Pipeline Research Council International (PRCI) to advance...

Development of welded metal bellows having minimum effective diameter change

NASA Technical Reports Server (NTRS)

Henschel, J. K.; Stevens, J. B.; Harvey, A. C.; Howland, J. S.; Rhee, S. S.

1972-01-01

A program of analysis, design, and fabrication was conducted to develop welded metal bellows having a minimum change in effective diameter for cryogenic turbomachinery face seal applications. Linear analysis of the principle types of bellows provided identification of concepts capable of meeting basic operation requirements. For the 6-inch (.152 m) mean diameter, 1.5-inch free length bellows studied, nonlinear analysis showed that opposed and nested toroidal bellows plates stiffened by means of alternating stiffener rings were capable of maintaining constant effective diameter within 0.3% and 0.1% respectively under the operating conditions of interest. Changes in effective diameter were due principally to bellows axial deflection with pressure differential having a lesser influence. Fabrication problems associated with joining the thin bellows plates to the relatively heavy stiffener rings were encountered and precluded assembly and testing of a bellows core. Fabrication problems are summarized and recommended fabrication methods for future effort are presented.

Demonstration of pharmaceutical tablet coating process by injection molding technology.

PubMed

Puri, Vibha; Brancazio, David; Harinath, Eranda; Martinez, Alexander R; Desai, Parind M; Jensen, Keith D; Chun, Jung-Hoon; Braatz, Richard D; Myerson, Allan S; Trout, Bernhardt L

2018-01-15

We demonstrate the coating of tablets using an injection molding (IM) process that has advantage of being solvent free and can provide precision coat features. The selected core tablets comprising 10% w/w griseofulvin were prepared by an integrated hot melt extrusion-injection molding (HME-IM) process. Coating trials were conducted on a vertical injection mold machine. Polyethylene glycol and polyethylene oxide based hot melt extruded coat compositions were used. Tablet coating process feasibility was successfully demonstrated using different coating mold designs (with both overlapping and non-overlapping coatings at the weld) and coat thicknesses of 150 and 300 μm. The resultant coated tablets had acceptable appearance, seal at the weld, and immediate drug release profile (with an acceptable lag time). Since IM is a continuous process, this study opens opportunities to develop HME-IM continuous processes for transforming powder to coated tablets. Copyright © 2017 Elsevier B.V. All rights reserved.

Statistical modeling to determine sources of variability in exposures to welding fumes.

PubMed

Liu, Sa; Hammond, S Katharine; Rappaport, Stephen M

2011-04-01

Exposures to total particulate matter (TP) and manganese (Mn) received by workers during welding and allied hot processes were analyzed to assess the sources and magnitudes of variability. Compilation of data from several countries identified 2065 TP and 697 Mn measurements for analysis. Linear mixed models were used to determine fixed effects due to different countries, industries and trades, process characteristics, and the sampling regimen, and to estimate components of variance within workers (both intraday and interday), between workers (within worksites), and across worksites. The fixed effects explained 55 and 49% of variation in TP and Mn exposures, respectively. The country, industry/trade, type of ventilation, and type of work/welding process were the major factors affecting exposures to both agents. Measurements in the USA were generally higher than those in other countries. Exposure to TP was 67% higher in enclosed spaces and 43% lower with local exhaust ventilation (LEV), was higher among boilermakers and was higher when either a mild-steel base metal or a flux cored consumable was used. Exposure to Mn was 750% higher in enclosed spaces and 67% lower when LEV was present. Air concentrations of Mn were significantly affected by the welding consumables but not by the base metal. Resistance welding produced significantly lower TP and Mn exposures compared to other welding processes. Interestingly, exposures to TP had not changed over the 40 years of observation, while those of Mn showed (non-significant) reductions of 3.6% year(-1). After controlling for fixed effects, variance components between worksites and between-individual workers within a worksite were reduced by 89 and 57% for TP and 75 and 63% for Mn, respectively. The within-worker variation (sum of intraday and interday variance components) of Mn exposure was three times higher than that of TP exposure. The estimated probabilities of exceeding occupational exposure limits were very high (generally much >10%) for both agents. Welding exposures to TP and Mn vary considerably across the world and across occupational groups. Exposures to both contaminants have been and continue to be unacceptably high in most sectors of industry. Because exposures to the two agents have different sources and characteristics, separate control strategies should be considered to reduce welders' exposures to TP and Mn.

Fabrication of a prototype dipole for the SSC Low Energy Booster

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

Spencer, C.M.

1993-12-01

The Low Energy Booster of the Superconducting Super Collider (SSC) will be a synchrotron containing 96 dipoles operating between 0.13 T and 1.35 T at 10 Hz. Each dipole`s 1.865 m-long core is made from {approximately}2900 steel laminations (lams), each 52 {times} 66 cm and 0.635 mm thick. A need to minimize power supply costs and stringent field specifications led to a straight core with very tight mechanical tolerances of the order of 0.05 mm. To satisfy these tolerances, we decided to stack the core in a vertical position; i.e., with the laminations laid horizontally. We designed and built anmore » unusual vertical stacking fixture that pivots into a horizontal position after all the laminations have been stacked and compressed and four support angles welded onto the laminations. The stacking fixture, our experience using it, and conclusions as to the merits of stacking such a long core vertically will be described. The methods of insulating and potting the pancake coils and their installation into the unsplittable core is also described.« less

Percussive arc welding apparatus

DOEpatents

Hollar, Jr., Donald L.

2002-01-01

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

The association of occupational metals exposure and oxidative damage, telomere shortening in fitness equipments manufacturing workers

PubMed Central

KO, Jiunn-Liang; CHENG, Yu-Jung; LIU, Guan-Cen; HSIN, I-Lun; CHEN, Hsiu-Ling

2017-01-01

The welding is the major working process in fitness equipment manufacturing industry, and International Agency for Research on Cancer has classified welding fumes as possibly carcinogenic to humans (Group 2B). The present study aimed to evaluate associations between the occupational exposure of metals and oxidative damage and telomere length shortening in workers involved in the manufacture of fitness equipment. The blood metal concentrations were monitored and malondialdehyde (MDA), alkaline Comet assay was determined as oxidative damage in 117 workers from two representative fitness equipment manufacturing plants. MDA levels varied according to workers’ roles at the manufacturing plants, and showed a trend as cutting>painting>welding>administration workers. Welders had marginally shorter average telomere lengths than the administrative workers (p=0.058). Cr and Mn levels were significantly greater in welders than they were in administrative workers. There were significantly positive correlations between MDA and Cr and Mn levels, the major components of welding fume. However, the association would be eliminated if co-metals exposure were considered simultaneously. In future, telomere length and MDA might be potential biomarkers for predicting cardiovascular disease in co-metals exposed workers. PMID:28420806

77 FR 19219 - Circular Welded Carbon-Quality Steel Pipe From the United Arab Emirates: Preliminary Negative...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-03-30

...: Joshua Morris or Dustin Ross, AD/CVD Operations, Office 1, Import Administration, International Trade... Countervailing Duty Order: Oil Country Tubular Goods from Canada, 51 FR 21783 (June 16, 1986) (describing subject...

[Measurement and analysis of hand-transmitted vibration of vibration tools in workplace for automobile casting and assembly].

PubMed

Xie, X S; Qi, C; Du, X Y; Shi, W W; Zhang, M

2016-02-20

To investigate the features of hand-transmitted vibration of common vibration tools in the workplace for automobile casting and assembly. From September to October, 2014, measurement and spectral analysis were performed for 16 typical hand tools(including percussion drill, pneumatic wrench, grinding machine, internal grinder, and arc welding machine) in 6 workplaces for automobile casting and assembly according to ISO 5349-1-2001 Mechanical vibration-Measurement and evaluation of human exposure to hand-transmitted vibration-part 1: General requirements and ISO 5349-2-2001 Mechanical vibration-Measurement and evaluation of human exposure to hand-transmitted vibration-Part 2: Practical guidance for measurement in the workplace. The vibration acceleration waveforms of shearing machine, arc welding machine, and pneumatic wrench were mainly impact wave and random wave, while those of internal grinder, angle grinder, percussion drill, and grinding machine were mainly long-and short-period waves. The daily exposure duration to vibration of electric wrench, pneumatic wrench, shearing machine, percussion drill, and internal grinder was about 150 minutes, while that of plasma cutting machine, angle grinder, grinding machine, bench grinder, and arc welding machine was about 400 minutes. The range of vibration total value(ahv) was as follows: pneumatic wrench 0.30~11.04 m/s(2), grinding wheel 1.61~8.97 m/s(2), internal grinder 1.46~8.70 m/s(2), percussion drill 11.10~14.50 m/s(2), and arc welding machine 0.21~2.18 m/s(2). The workers engaged in cleaning had the longest daily exposure duration to vibration, and the effective value of 8-hour energy-equivalent frequency-weighted acceleration for them[A(8)] was 8.03 m/s(2), while this value for workers engaged in assembly was 4.78 m/s(2). The frequency spectrogram with an 1/3-time frequency interval showed that grinding machine, angle grinder, and percussion drill had a high vibration acceleration, and the vibration limit curve was recommended for those with a frequency higher than 400 min/d. The workers who are engaged in cleaning, grinding, and a few positions of assembly and use grinding machine, angle grinder, internal grinder, and percussion drill are exposed to vibrations with a high vibration acceleration and at a high position of the frequency spectrum. The hand-transmitted vibration in the positions of cutting, polishing, and cleaning in automobile casting has great harm, and the harm caused by pneumatic wrench in automobile assembly should be taken seriously.

Metallography of Battery Resistance Spot Welds

NASA Technical Reports Server (NTRS)

Martinez, J. E.; Johannes, L. B.; Gonzalez, D.; Yayathi, S.; Figuered, J. M.; Darcy, E. C.; Bilc, Z. M.

2015-01-01

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Welding of Vanadium, Tantalum, 304L and 21-6-9 Stainless Steels, and Titanium Alloys at Lawrence Livermore National Laboratory using a Fiber Delivered 2.2 kW Diode Pumped CW Nd:YAG Laser

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

Palmer, T; Elmer, J; Pong, R

This report summarizes the results of a series of laser welds made between 2003 and 2005 at Lawrence Livermore National Laboratory (LLNL). The results are a compilation of several, previously unpublished, internal LLNL reports covering the laser welding of vanadium, tantalum, 304L stainless steel, 21-6-9 (Nitronic 40) steel, and Ti-6Al-4V. All the welds were made using a Rofin Sinar DY-022 diode pumped continuous wave Nd:YAG laser. Welds are made at sharp focus on each material at various power levels and travel speeds in order to provide a baseline characterization of the performance of the laser welder. These power levels aremore » based on measurements of the output power of the laser system, as measured by a power meter placed at the end of the optics train. Based on these measurements, it appears that the system displays a loss of approximately 10% as the beam passes through the fiber optic cable and laser optics. Since the beam is delivered to the fixed laser optics through a fiber optic cable, the effects of fiber diameter are also briefly investigated. Because the system utilizes 1:1 focusing optics, the laser spot size at sharp focus generally corresponds to the diameter of the fiber with which the laser is delivered. Differences in the resulting weld penetration in the different materials system are prevalent, with the welds produced on the Nitronic 40 material displaying the highest depths (> 5 mm) and minimal porosity. A Primes focusing diagnostic has also been installed on this laser system and used to characterize the size and power density distribution of the beams as a function of both power and focus position. Further work is planned in which this focusing diagnostic will be used to better understand the effects of changes in beam properties on the resulting weld dimensions in these and other materials systems.« less

Advantages and challenges of dissimilar materials in automotive lightweight construction

NASA Astrophysics Data System (ADS)

Weberpals, Jan-Philipp; Schmidt, Philipp A.; Böhm, Daniel; Müller, Steffen

2015-03-01

The core of future automotive lightweight materials is the joining technology of various material mixes. The type of joining will be essential, particularly in electrified propulsion systems, especially as an improved electrical energy transmission leads to a higher total efficiency of the vehicle. The most evident parts to start the optimization process are the traction battery, the electrical performance modules and the engines. Consequently aluminum plays a very central role for lightweight construction applications. However, the physical-technical requirements of components often require the combination with other materials. Thus the joining of mixed material connections is an essential key technology for many of the current developments, for example in the areas E-Mobility, solar energy and lightweight construction. Due to these advantages mixed material joints are already established in the automotive industry and laser beam remote welding is now a focus technology for mixed material connections. The secret of the laser welding process with mixed materials lies within the different areas of the melting phase diagram depending on the mixing ratio and the cooling down rate. According to that areas with unwanted, prim, intermetallic phases arise in the fusion zone. Therefore, laser welding of mixed material connections can currently only be used with additional filler in the automotive industry.

Development of Mini-Compact Tension Test Method for Determining Fracture Toughness Master Curves for Reactor Pressure Vessel Steels

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

Sokolov, Mikhail A.

Small specimens are playing the key role in evaluating properties of irradiated materials. The use of small specimens provides several advantages. Typically, only a small volume of material can be irradiated in a reactor at desirable conditions in terms of temperature, neutron flux, and neutron dose. A small volume of irradiated material may also allow for easier handling of specimens. Smaller specimens reduce the amount of radioactive material, minimizing personnel exposures and waste disposal. However, use of small specimens imposes a variety of challenges as well. These challenges are associated with proper accounting for size effects and transferability of smallmore » specimen data to the real structures of interest. Any fracture toughness specimen that can be made out of the broken halves of standard Charpy specimens may have exceptional utility for evaluation of reactor pressure vessels (RPVs) since it would allow one to determine and monitor directly actual fracture toughness instead of requiring indirect predictions using correlations established with impact data. The Charpy V-notch specimen is the most commonly used specimen geometry in surveillance programs. Validation of the mini compact tension specimen (mini-CT) geometry has been performed on previously well characterized Midland beltline Linde 80 (WF-70) weld in the unirradiated condition. It was shown that the fracture toughness transition temperature, To, measured by these Mini-CT specimens is almost the same as To value that was derived from various larger fracture toughness specimens. Moreover, an International collaborative program has been established to extend the assessment and validation efforts to irradiated Linde 80 weld metal. The program is underway and involves the Oak Ridge National Laboratory (ORNL), Central Research Institute for Electrical Power Industry (CRIEPI), and Electric Power Research Institute (EPRI). The irradiated Mini-CT specimens from broken halves of previously tested Charpy specimens of Midland beltline weld have been machined and just arrived to ORNL as part of this international collaboration. The ORNL will initiate tests of the irradiated Linde 80 weld in FY2017 and results of this international program will be reported in FY2018.« less

Crack growth rates and fracture toughness of irradiated austenitic stainless steels in BWR environments.

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

Chopra, O. K.; Shack, W. J.

2008-01-21

In light water reactors, austenitic stainless steels (SSs) are used extensively as structural alloys in reactor core internal components because of their high strength, ductility, and fracture toughness. However, exposure to high levels of neutron irradiation for extended periods degrades the fracture properties of these steels by changing the material microstructure (e.g., radiation hardening) and microchemistry (e.g., radiation-induced segregation). Experimental data are presented on the fracture toughness and crack growth rates (CGRs) of wrought and cast austenitic SSs, including weld heat-affected-zone materials, that were irradiated to fluence levels as high as {approx} 2x 10{sup 21} n/cm{sup 2} (E > 1more » MeV) ({approx} 3 dpa) in a light water reactor at 288-300 C. The results are compared with the data available in the literature. The effects of material composition, irradiation dose, and water chemistry on CGRs under cyclic and stress corrosion cracking conditions were determined. A superposition model was used to represent the cyclic CGRs of austenitic SSs. The effects of neutron irradiation on the fracture toughness of these steels, as well as the effects of material and irradiation conditions and test temperature, have been evaluated. A fracture toughness trend curve that bounds the existing data has been defined. The synergistic effects of thermal and radiation embrittlement of cast austenitic SS internal components have also been evaluated.« less

Levels and predictors of airborne and internal exposure to chromium and nickel among welders--results of the WELDOX study.

PubMed

Weiss, Tobias; Pesch, Beate; Lotz, Anne; Gutwinski, Eleonore; Van Gelder, Rainer; Punkenburg, Ewald; Kendzia, Benjamin; Gawrych, Katarzyna; Lehnert, Martin; Heinze, Evelyn; Hartwig, Andrea; Käfferlein, Heiko U; Hahn, Jens-Uwe; Brüning, Thomas

2013-03-01

The objective of this analysis was to investigate levels and determinants of exposure to airborne and urinary chromium (Cr, CrU) and nickel (Ni, NiU) among 241 welders. Respirable and inhalable welding fume was collected during a shift, and the metal content was determined using inductively coupled plasma mass spectrometry. In post-shift urine, CrU and NiU were measured by means of graphite furnace atom absorption spectrometry, with resulting concentrations varying across a wide range. Due to a large fraction below the limits of quantitation we applied multiple imputations to the log-transformed exposure variables for the analysis of the data. Respirable Cr and Ni were about half of the concentrations of inhalable Cr and Ni, respectively. CrU and NiU were determined with medians of 1.2 μg/L (interquartile range <1.00; 3.61) and 2.9 μg/L (interquartile range <1.50; 5.97). Furthermore, Cr and Ni correlated in respirable welding fume (r=0.79, 95% CI 0.74-0.85) and urine (r=0.55, 95% CI 0.44-0.65). Regression models identified exposure-modulating variables in form of multiplicative factors and revealed slightly better model fits for Cr (R(2) respirable Cr 48%, CrU 55%) than for Ni (R(2) respirable Ni 42%, NiU 38%). The air concentrations were mainly predicted by the metal content in electrodes or base material in addition to the welding technique. Respirable Cr and Ni were good predictors for CrU and NiU, respectively. Exposure was higher when welding was performed in confined spaces or with inefficient ventilation, and lower in urine when respirators were used. In conclusion, statistical modelling allowed the evaluation of determinants of internal and external exposure to Cr and Ni in welders. Welding parameters were stronger predictors than workplace conditions. Airborne exposure was lowest inside respirators with supply of purified air. Copyright © 2012 Elsevier GmbH. All rights reserved.

Experimental Design for Evaluation of Co-extruded Refractory Metal/Nickel Base Superalloy Joints

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

ME Petrichek

2005-12-16

Prior to the restructuring of the Prometheus Program, the NRPCT was tasked with delivering a nuclear space reactor. Potential NRPCT nuclear space reactor designs for the Prometheus Project required dissimilar materials to be in contact with each other while operating at extreme temperatures under irradiation. As a result of the high reactor core temperatures, refractory metals were the primary candidates for many of the reactor structural and cladding components. They included the tantalum-base alloys ASTAR-811C and Ta-10W, the niobium-base alloy FS-85, and the molybdenum base alloys Moly 41-47.5 Rhenium. The refractory metals were to be joined to candidate nickel basemore » alloys such as Haynes 230, Alloy 617, or Nimonic PE 16 either within the core if the nickel-base alloys were ultimately selected to form the outer core barrel, or at a location exterior to the core if the nickel-base alloys were limited to components exterior to the core. To support the need for dissimilar metal joints in the Prometheus Project, a co-extrusion experiment was proposed. There are several potential methods for the formation of dissimilar metal joints, including explosive bonding, friction stir welding, plasma spray, inertia welding, HIP, and co-extrusion. Most of these joining methods are not viable options because they result in the immediate formation of brittle intermetallics. Upon cooling, intermetallics form in the weld fusion zone between the joined metals. Because brittle intermetallics do not form during the initial bonding process associated with HIP, co-extrusion, and explosive bonding, these three joining procedures are preferred for forming dissimilar metal joints. In reference to a Westinghouse Astronuclear Laboratory report done under a NASA sponsored program, joints that were fabricated between similar materials via explosive bonding had strengths that were directly affected by the width of the diffusion barrier. It was determined that the diffusion zone should not exceed a critical thickness (0.0005 in.). A diffusion barrier that exceeded this thickness would likely fail. The joint fabrication method must therefore mechanically bond the two materials causing little or no interdiffusion upon formation. Co-extrusion fits this description since it forms a mechanical joint between two materials by using heat and pressure. The two materials to be extruded are first assembled and sealed within a co-extrusion billet which is subsequently heated and then extruded through a die. For a production application, once the joint is formed, it is dejacketed to remove the outer canister. The remaining piece consists of two materials bonded together with a thin diffusion barrier. Therefore, the long-term stability of the joint is determined primarily by the kinetics of interdiffusion reaction between the two materials. An experimental design for co-extrusion of refractory metals and nickel-based superalloys was developed to evaluate this joining process and determine the long-term stability of the joints.« less

Lithostratigraphy and shear-wave velocity in the crystallized Topopah Spring Tuff, Yucca Mountain, Nevada

USGS Publications Warehouse

Buesch, D.C.; Stokoe, K.H.; Won, K.C.; Seong, Y.J.; Jung, J.L.; Schuhen, M.D.

2006-01-01

Evaluation of the potential future response to seismic events of the proposed spent nuclear fuel and high-level radioactive waste repository at Yucca Mountain, Nevada, is in part based on the seismic properties of the host rock, the 12.8-million-year-old Topopah Spring Tuff. Because of the processes that formed the tuff, the densely welded and crystallized part has three lithophysal and three nonlithophysal zones, and each zone has characteristic variations in lithostratigraphic features and structures of the rocks. Lithostratigraphic features include lithophysal cavities; rims on lithophysae and some fractures; spots (which are similar to rims but without an associated cavity or aperture); amounts of porosity resulting from welding, crystallization, and vapor-phase corrosion and mineralization; and fractures. Seismic properties, including shear-wave velocity (Vs), have been measured on 38 pieces of core, and there is a good "first order" correlation with the lithostratigraphic zones; for example, samples from nonlithophysal zones have larger Vs values compared to samples from lithophysal zones. Some samples have Vs values that are outside the typical range for the lithostratigraphic zone; however, these samples typically have one or more fractures, "large" lithophysal cavities, or "missing pieces" relative to the sample size. Shear-wave velocity data measured in the tunnels have similar relations to lithophysal and nonlithophysal rocks; however, tunnel-based values are typically smaller than those measured in core resulting from increased lithophysae and fracturing effects. Variations in seismic properties such as Vs data from small-scale samples (typical and "flawed" core) to larger scale transects in the tunnels provide a basis for merging our understanding of the distributions of lithostratigraphic features (and zones) with a method to scale seismic properties.

Steam generator for liquid metal fast breeder reactor

DOEpatents

Gillett, James E.; Garner, Daniel C.; Wineman, Arthur L.; Robey, Robert M.

1985-01-01

Improvements in the design of internal components of J-shaped steam generators for liquid metal fast breeder reactors. Complex design improvements have been made to the internals of J-shaped steam generators which improvements are intended to reduce tube vibration, tube jamming, flow problems in the upper portion of the steam generator, manufacturing complexities in tube spacer attachments, thermal stripping potentials and difficulties in the weld fabrication of certain components.

Behaviour of the iron vapour core in the arc of a controlled short-arc GMAW process with different shielding gases

NASA Astrophysics Data System (ADS)

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

2012-02-01

The controlled metal transfer process (CMT) is a variation of the gas metal arc welding (GMAW) process which periodically varies wire feeding speed. Using a short-arc burning phase to melt the wire tip before the short circuit, heat input to the workpiece is reduced. Using a steel wire and a steel workpiece, iron vapour is produced in the arc, its maximum concentration lying centrally. The interaction of metal vapour and welding gas considerably impacts the arc profile and, consequently, the heat transfer to the weldpool. Optical emission spectroscopy has been applied to determine the radial profiles of the plasma temperature and iron vapour concentration, as well as their temporal behaviour in the arc period for different mixtures of Ar, O2 and CO2 as shielding gases. Both the absolute iron vapour density and the temporal expansion of the iron core differ considerably for the gases Ar + 8%O2, Ar + 18% CO2 and 100% CO2 respectively. Pronounced minimum in the radial temperature profile is found in the arc centre in gas mixtures with high Ar content under the presence of metal vapour. This minimum disappears in pure CO2 gas. Consequently, the temperature and electrical and thermal conductivity in the arc when CO2 is used as a shielding gas are considerably lower.

Evaluation of Internal Brushing on Pinch Weld Quality

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

Korinko, P

2005-12-01

Post machining operations such as borescope inspection can cause linear indications down the length of the bore of fill stems. Often these indications are removed or obscured using rotary wire brushing. This study evaluated the effect this mechanical operation may have on pinch weld quality when relatively cold welds were made. A total of four stems with two levels of brushing of both Type 304L and 21-6-9 stainless steels were tested. In addition, two each of the Type 304L stems were Nitradd cleaned and the other two were aqueously cleaned; all four 21-6-9 stems were aqueously cleaned. All of themore » brushed stem areas exhibited more surface anomalies based on borescope evaluation. On average, the bond rating was a higher value (worse) for the brushed areas than the unadulterated areas for both Type 304L and 21-6-9 stems. The test method used may have biased the results towards a lesser quality bond for the brushed areas so additional testing is recommended.« less

Welding of Pyroclastic Deposits: Questions Arising from Experiments (Invited)

NASA Astrophysics Data System (ADS)

Russell, K.; Quane, S.; Robert, G.; Andrews, G. D.; Kennedy, B. M.

2009-12-01

Ultimately, all natural magmas vesiculate near the Earth’s surface to produce bubble-rich melts, that commonly foam to the point of fragmentation producing pyroclastic deposits. Vesiculation processes increase porosity and create permeability thereby increasing the efficacy of fluid escape and suppressing explosivity. Conversely, processes that destroy porosity and permeability, including bubble collapse, compaction, and welding, inhibit the escape of fluids and can produce overpressures leading to explosive behavior. Compaction and welding processes are pervasive in volcanic deposits and pertinent to: i) formation of spatter-fed clastogenic lava flows, ii) sintering of fragmental material in volcanic conduits, and to iii) welding of pyroclastic flow and fall deposits. The rate at which porous pyroclastic deposits compact and sinter (i.e., welding; cf. Grunder and Russell, 2005) governs the efficacy with which porosity (and ultimately permeability) is lost (Sparks et al., 1999). Ultimately, rates of welding reflect the aggregate rheological properties of the deposit. Here, we present an ensemble of experimental results used to investigate the rheology of hot, porous, pyroclastic materials during compaction. We have used a GEOCOMP Loadtrac II device modified to perform constant displacement rate or constant load deformation experiments on large (7 x 4.5 cm) unconfined cores of pumice, lava, or sintered ash. The experiments are at temperatures (T ~ 800-900°C), load stresses (< 150 MPa), and strain rates (10-6 to -2 s-1) consistent with the emplacement of pyroclastic flows. The effects of fluid pressure have also been studied experimentally by using a steel cell and piston system that permits high-T deformation experiments at controlled PH2O (Robert et al. 2008). Our experiments simulate compaction of natural pyroclastic deposits and provide the data to parameterize a relationship between the effective viscosity of the hot, porous deposit of ash (η), the viscosity of the melt fragments (ηo) and porosity (Φ) of the deposit (Quane et al. 2009): log η = log ηo - 2.5Φ/(1-Φ). This relationship is used to model compaction and welding of processes in ignimbrites and in volcanic conduits as a function of load, temperature and porosity. Our analysis shows that compaction operates very rapidly at high-T such that welding in ignimbrites is fully decoupled from cooling history and may even rival the depositional timescales of pyroclastic density currents. Experiments performed at PH2O values of ~1-3 MPa recover lower values of effective viscosity (109.2 - 9.4 Pa s), despite being run at substantially lower temperature (640-665°C). The presence of the H2O fluid expands the window of viscous (vs. brittle) deformation and prevents the strain hardening that normally accompanies porosity reduction allowing for the continuous accumulation of strain. These results apply to welding of rheomorphic ignimbrites and the compaction, annealing and eventual sealing of volcanic conduits.

Community College Presidents' Core Internal Metaphors

ERIC Educational Resources Information Center

DeBraak, LaRonna S.

2011-01-01

This study identified the core internal metaphors of 8 community college presidents, 4 females and 4 males. The participants of this study resided in both rural and metropolitan communities. Core internal metaphors were adopted due to a strong association to a primary conceptual metaphor, which the participants had internalized as a result of…

Statistical Analysis of Stress Signals from Bridge Monitoring by FBG System.

PubMed

Ye, Xiao-Wei; Su, You-Hua; Xi, Pei-Sen

2018-02-07

In this paper, a fiber Bragg grating (FBG)-based stress monitoring system instrumented on an orthotropic steel deck arch bridge is demonstrated. The FBG sensors are installed at two types of critical fatigue-prone welded joints to measure the strain and temperature signals. A total of 64 FBG sensors are deployed around the rib-to-deck and rib-to-diagram areas at the mid-span and quarter-span of the investigated orthotropic steel bridge. The local stress behaviors caused by the highway loading and temperature effect during the construction and operation periods are presented with the aid of a wavelet multi-resolution analysis approach. In addition, the multi-modal characteristic of the rainflow counted stress spectrum is modeled by the method of finite mixture distribution together with a genetic algorithm (GA)-based parameter estimation approach. The optimal probability distribution of the stress spectrum is determined by use of Bayesian information criterion (BIC). Furthermore, the hot spot stress of the welded joint is calculated by an extrapolation method recommended in the specification of International Institute of Welding (IIW). The stochastic characteristic of stress concentration factor (SCF) of the concerned welded joint is addressed. The proposed FBG-based stress monitoring system and probabilistic stress evaluation methods can provide an effective tool for structural monitoring and condition assessment of orthotropic steel bridges.

Exposures to quartz, diesel, dust, and welding fumes during heavy and highway construction.

PubMed

Woskie, Susan R; Kalil, Andrew; Bello, Dhimiter; Virji, M Abbas

2002-01-01

Personal samples for exposure to dust, diesel exhaust, quartz, and welding fume were collected on heavy and highway construction workers. The respirable, thoracic, and inhalable fractions of dust and quartz exposures were estimated from 260 personal impactor samples. Respirable quartz exposures exceeded the National Institute for Occupational Safety and Health (NIOSH) recommended exposure limit (REL) in 7-31% of cases for the trades sampled. More than 50% of the samples in the installation of drop ceilings and wall tiles and concrete finish operations exceeded the NIOSH REL for quartz. Thoracic exposures to quartz and dust exceeded respirable exposures by a factor of 4.5 and 2.8, respectively. Inhalable exposures to quartz and dust exceeded respirable exposures by a factor of 25.6 and 9.3, respectively. These findings are important due to the identification of quartz as a carcinogen by the National Toxicology Program and the International Agency for Research on Cancer. Fourteen percent of the personal samples for EC (n = 261), collected as a marker for diesel exhaust, exceeded the American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit value (TLV) for diesel exhaust. Seventeen of the 22 (77%) samples taken during a partially enclosed welding operation reached or exceeded the ACGIH TLV of 5 mg/m3 for welding fume.

Construction and Instrumentation of Full-Scale Geogrid Reinforced Pavement Test Sections

DTIC Science & Technology

2008-04-01

dataloggers (described below), which have internal thermistors that provide a refer- ence temperature. The dataloggers were programmed to record tempera...stainless steel plates welded together around the periphery and enclosing a fluid connected to a pressure trans- ducer through a high-pressure

Nuclear reactor internals alignment configuration

DOEpatents

Gilmore, Charles B [Greensburg, PA; Singleton, Norman R [Murrysville, PA

2009-11-10

An alignment system that employs jacking block assemblies and alignment posts around the periphery of the top plate of a nuclear reactor lower internals core shroud to align an upper core plate with the lower internals and the core shroud with the core barrel. The distal ends of the alignment posts are chamfered and are closely received within notches machined in the upper core plate at spaced locations around the outer circumference of the upper core plate. The jacking block assemblies are used to center the core shroud in the core barrel and the alignment posts assure the proper orientation of the upper core plate. The alignment posts may alternately be formed in the upper core plate and the notches may be formed in top plate.

In Situ SEM Observations of Fracture Behavior of Laser Welded-Brazed Al/Steel Dissimilar Joint

NASA Astrophysics Data System (ADS)

Xia, Hongbo; Tan, Caiwang; Li, Liqun; Ma, Ninshu

2018-03-01

Laser welding-brazing of 6061-T6 aluminum alloy to DP590 dual-phase steel with Al-Si12 flux-cored filler wire was performed. The microstructure at the brazing interface was characterized. Fracture behavior was observed and analyzed by in situ scanning electron microscope. The microstructure of the brazing interface showed that inhomogeneous intermetallic compounds formed along the thickness direction, which had a great influence on the crack initiation and propagation. In the top region, the reaction layer at the interface consisted of scattered needle-like Fe(Al,Si)3 and serration-shaped Fe1.8Al7.2Si. In the middle region, the compound at the interface was only serration-shaped Fe1.8Al7.2Si. In the bottom region, the interface was composed of lamellar-shaped Fe1.8Al7.2Si. The cracks were first detected in the bottom region and propagated from bottom to top along the interface. At the bottom region, the crack initiated and propagated along the Fe1.8Al7.2Si/weld seam interface during the in situ tensile test. When the crack propagated into the middle region, a deflection of crack propagation appeared. The crack first propagated along the steel/Fe1.8Al7.2Si interface and then moved along the weld seam until the failure of the joint. The tensile strength of the joint was 146.5 MPa. Some micro-cracks were detected at Fe(Al,Si)3 and the interface between the steel substrate and Fe(Al,Si)3 in the top region while the interface was still connected.

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

NASA Astrophysics Data System (ADS)

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

2011-06-01

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

The APL-UW Multiport Acoustic Projector System

DTIC Science & Technology

2009-12-01

delivered are shown in Figs. 18 and 19 . Concern regarding heat build-up in the device led APL-UW to provide two thermistors to Coiltron during the...winding process to be inserted deep inside the windings, near the core, for monitoring during operation. Leads from these thermistors can be seen in...using a chain bridle attached to the bolt eyes fixed into the top of the main tube. A tentative plan was devised to lift from a hard point welded onto

Fiber laser platform for highest flexibility and reliability in industrial femtosecond micromachining: TruMicro Series 2000

NASA Astrophysics Data System (ADS)

Jansen, Florian; Kanal, Florian; Kahmann, Max; Tan, Chuong; Diekamp, Holger; Scelle, Raphael; Budnicki, Aleksander; Sutter, Dirk

2018-02-01

In this work we present an ultrafast laser system distinguished by its industry-ready reliability and its outstanding flexibility that allows for real-time process-inherent parameter. The robust system design and linear amplifier architecture make the all-fiber series TruMicro 2000 ideally suited for passive coupling to hollow-core delivery fibers. In addition to details on the laser system itself, various application examples are shown, including welding of different glasses and ablation of silicon carbide and silicon.

Launch Vehicle Stage Adapter Move

NASA Image and Video Library

2017-08-24

A NASA KAMAG transporter moves the Space Launch System’s launch vehicle stage adapter (LVSA) to an area where spray-on foam insulation will be applied. The LVSA recently completed manufacturing on a 30 foot welding tool at NASA’s Marshall Space Flight Center in Huntsville, Al. The LVSA will be coated with insulation that will protect it during it’s trip to space. The LVSA provides structural support and connects the core stage and the interim cryogenic propulsion stage during the first integrated flight of SLS and Orion.

Dual wire welding torch and method

DOEpatents

Diez, Fernando Martinez; Stump, Kevin S.; Ludewig, Howard W.; Kilty, Alan L.; Robinson, Matthew M.; Egland, Keith M.

2009-04-28

A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

75 FR 4584 - Wire Decking From China

Federal Register 2010, 2011, 2012, 2013, 2014

2010-01-28

... INTERNATIONAL TRADE COMMISSION [Investigation Nos. 701-TA-466 and 731-TA-1162 (Final)] Wire... subsidized and less-than-fair-value imports from China of wire decking, provided for in subheadings 9403.90... subject merchandise as ``welded-wire rack decking, which is also known as, among other things, ``pallet...

Protected, high-temperature connecting cable

NASA Technical Reports Server (NTRS)

Engdahl, R. E.

1967-01-01

Ceramic insulated, swaged stainless steel, sheathed, protective atmosphere cable admits electrical leads into an 1800 deg F air-environment test chamber. The cable has some bending capability and provides for nine niobium alloy conductors. An argon purge during the TIG weld closure protects internal wires from oxidation and embrittlement.

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

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Cantrell, Mark; Carter, Robert

2003-01-01

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

Formation of Oxides in the Interior of Friction Stir Welds

NASA Technical Reports Server (NTRS)

Schneider, Judy; Chen, Po; Nunes, Arthur C., Jr.

2016-01-01

In friction stir welding (FSWing) the actual solid state joining takes place between the faying surfaces which form the weld seam. Thus the seam trace is often investigated for clues when the strength of the weld is reduced. Aluminum and its alloys are known to form a native, protective oxide on the surface. If these native surface oxides are not sufficiently broken up during the FSW process, they are reported to remain in the FSW interior and weaken the bond strength. This type of weld defect has been referred to as a lazy "S", lazy "Z", joint line defect, kissing bond, or residual oxide defect. Usually these defects are mitigated by modification of the process parameters, such as increased tool rotation rate, which causes a finer breakup of the native oxide particles. This study proposes that there may be an alternative mechanism for formation of oxides found within the weld nugget. As the oxidation rate increases at elevated temperatures above 400ºC, it may be possible for enhanced oxidation to occur on the interior surfaces during the FSW process from entrained air entering the seam gap. Normally, FSWs of aluminum alloys are made without a purge gas and it is unknown how process parameters and initial fit up could affect a potential air path into the interior during the processing. In addition, variations in FSW parameters, such as the tool rotation, are known to have a strong influence on the FSW temperature which may affect the oxidation rate if internal surfaces are exposed to entrained air. A series of FSWs were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. As the thickness of the panels increased, there was an increased tendency for a gap to form in advance of the weld tool. If sufficient air is able to enter the workpiece gap prior to consolidation, the weld temperature can increase the oxidation rate on the interior surfaces. These oxidation rates would also be accelerated in areas of localized liquation. Metallographs from the weld panels showed indications of liquation at the grain boundaries. In FSWs of thicker panels, these regions of liquation were found to be heavily oxidized. The quality of the FSWs was evaluated from tensile testing at room temperature. As the panel thickness increased, a slight decrease in tensile strength was observed which was attributed to the presence of oxides. No oxide formation was observed in the thinner workpieces, although there were indications of localized liquation at the grain boundaries. Results from this study will assist in a better understand of the mechanisms of oxide formation in FSW interiors and provide methodology for minimizing their occurrence.

The Evolution of Friction Stir Welding Theory at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Nunes, Arthur C.

2012-01-01

From 1995 to the present the friction stir welding (FSW) process has been under study at Marshall Space Flight Center (MSFC). This is an account of the progressive emergence of a set of conceptual tools beginning with the discovery of the shear surface, wiping metal transfer, and the invention of a kinematic model and making possible a treatment of both metallurgical structure formation and process dynamics in friction stir welding from a unified point of view. It is generally observed that the bulk of the deformation of weld metal around the FSW pin takes place in a very narrow, almost discontinuous zone with high deformation rates characteristic of metal cutting. By 1999 it was realized that this zone could be treated as a shear surface like that in simple metal cutting models. At the shear surface the seam is drawn out and compressed and pressure and flow conditions determine whether or not a sound weld is produced. The discovery of the shear surface was followed by the synthesis of a simple 3- flow kinematic model of the FSW process. Relative to the tool the flow components are: (1) an approaching translational flow at weld speed V, (2) a rotating cylindrical plug flow with the angular velocity of the tool , and (3) a relatively slow ring vortex flow (like a smoke ring) encircling the tool and driven by shoulder scrolls and pin threads. The rotating plug flow picks up an element of weld metal, rotates it around with the tool, and deposits it behind the tool ( wiping metal transfer ); it forms plan section loops in tracers cut through by the tool. Radially inward flow from the ring vortex component retains metal longer in the rotating plug and outward flow expels metal earlier; this interaction forms the looping weld seam trace and the tongue and groove bimetallic weld contour. The radial components of the translational and ring vortex flows introduce parent metal intrusions into the small grained nugget material close to the tool shoulder; if this feature is pronounced, nugget collapse may result. Certain weld features, in particular internal banding seen in transverse section as onion rings and associated surface ridges called tool marks , have long implied an oscillation flow component, but have only recently been attributed in the literature to tool eccentricity. Rotating plug shape, typically a hollow cylinder flared at the end where it sticks to the shoulder, varies as pressure distribution on the tool determines where sticking occurs. Simplified power input estimates balanced against heat loss estimates give reasonable temperature estimates, explain why the power requirement changes hardly at all over a wide range of RPM s, and yield isotherms that seem to fall along boundaries of parameter windows of operation.

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

NASA Astrophysics Data System (ADS)

Pu, Juan; Yu, Shengfu; Li, Yuanyuan

2017-07-01

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

Assessment of cold welding properties of the internal conical interface of two commercially available implant systems.

PubMed

Norton, M R

1999-02-01

The cone-screw abutment has been shown to diminish micromovement by reducing the burden of component loosening and fracture. However, anecdotal concern for cold welding of cone-screw joints in implant design has been identified as a potential source for lack of retrievability. This comparative study evaluated the loosening torque, as a percentage of tightening torque, for the ITI Straumann and Astra Tech (3.5 and 4.0 mm diameters) implant systems, which use an 8-degree and 11-degree internal cone, respectively. Implants and abutments from each system were mounted in a torque device, and a range of tightening torques was applied. Loosening torques were then measured, and the influence of conus angle, interfacial surface area, saliva contamination, and time delay to loosening were all assessed. The loosening torque only exceeded tightening torque at the highest levels, just before component failure, when plastic deformation was expected. For all clinically relevant levels of torque, both in a dry environment and with components bathed in artificial saliva at 37 degrees C, loosening torque was always seen to be 80% to 90% of tightening torque, demonstrating that cold welding does not occur. There was a high correlation between loosening and tightening torque for all systems tested, but no statistical difference when comparing wet versus dry or comparing individual data for each system. It can be concluded that for clinically relevant levels of tightening torque, no problems are anticipated with respect to retrievability.

National Launch System Space Transportation Main Engine

NASA Technical Reports Server (NTRS)

Hoodless, Ralph M., Jr.; Monk, Jan C.; Cikanek, Harry A., III

1991-01-01

The present liquid-oxygen/liquid-hydrogen engine is described as meeting the specific requirements of the National Launch System (NLS) Program including cost-effectiveness and robustness. An overview of the NLS and its objectives is given which indicates that the program aims to develop a flexible launch system to meet security, civil, and commercial needs. The Space Transportation Main Engine (STME) provides core and boost propulsion for the 1.5-stage vehicle and core propulsion for the solid booster vehicle. The design incorporates step-throttling, order-of-magnitude reductions in welds, and configuration targets designed to optimize robustness. The STME is designed to provide adaptable and dependable propulsion while minimizing recurring costs and is designed to meet the needs of NLS and other typical space-transportation programs currently being planned.

Lifting clamp positively grips structural shapes

NASA Technical Reports Server (NTRS)

Reinhardt, E. C.

1966-01-01

Welded steel clamps securely grip structural shapes of various sizes for crane operations. The clamp has adjustable clamping jaws and screw-operated internal v-jaws and provides greater safety than hoisting slings presently used. The structural member can be rotated in any manner, angle, or direction without being released by the clamp.

Underwater laser weld bowing distortion behavior and mechanism of thin 304 stainless steel plates

NASA Astrophysics Data System (ADS)

Huang, ZunYue; Luo, Zhen; Ao, Sansan; Cai, YangChuan

2018-10-01

Underwater laser weld bowing distortion behavior and mechanism of thin 304 stainless steel plates are studied in the paper. The influence of underwater laser welding parameters (such as laser power, welding speed, defocusing distance and gas flow rate) on weld bowing distortion was investigated through central composite rotatable design and an orthogonal test. A quadratic response model was established to evaluate the underwater laser weld bowing distortion by central composite rotatable design and the order of the impacts of the welding parameters on weld bowing distortion was studied by an orthogonal test. The weld bowing distortion after welding was determined by the digital image correlation technique. The weld bowing distortion of in-air laser welding and underwater laser welding were compared and it revealed that the shape of the in-air and underwater laser welded specimens are the same, but the weld bowing distortion amount of in-air welding is larger than that of underwater welding. Weld bowing distortion mechanism was studied by the digital image correlation technique, and it was demonstrated that weld bowing distortion is associated with the welding plate temperature gradient during laser welding. The wider weld width also resulted in larger weld bowing distortion.

Gas-cooled nuclear reactor

DOEpatents

Peinado, Charles O.; Koutz, Stanley L.

1985-01-01

A gas-cooled nuclear reactor includes a central core located in the lower portion of a prestressed concrete reactor vessel. Primary coolant gas flows upward through the core and into four overlying heat-exchangers wherein stream is generated. During normal operation, the return flow of coolant is between the core and the vessel sidewall to a pair of motor-driven circulators located at about the bottom of the concrete pressure vessel. The circulators repressurize the gas coolant and return it back to the core through passageways in the underlying core structure. If during emergency conditions the primary circulators are no longer functioning, the decay heat is effectively removed from the core by means of natural convection circulation. The hot gas rising through the core exits the top of the shroud of the heat-exchangers and flows radially outward to the sidewall of the concrete pressure vessel. A metal liner covers the entire inside concrete surfaces of the concrete pressure vessel, and cooling tubes are welded to the exterior or concrete side of the metal liner. The gas coolant is in direct contact with the interior surface of the metal liner and transfers its heat through the metal liner to the liquid coolant flowing through the cooling tubes. The cooler gas is more dense and creates a downward convection flow in the region between the core and the sidewall until it reaches the bottom of the concrete pressure vessel when it flows radially inward and up into the core for another pass. Water is forced to flow through the cooling tubes to absorb heat from the core at a sufficient rate to remove enough of the decay heat created in the core to prevent overheating of the core or the vessel.

A process model for the heat-affected zone microstructure evolution in duplex stainless steel weldments: Part I. the model

NASA Astrophysics Data System (ADS)

Hemmer, H.; Grong, Ø.

1999-11-01

The present investigation is concerned with modeling of the microstructure evolution in duplex stainless steels under thermal conditions applicable to welding. The important reactions that have been modeled are the dissolution of austenite during heating, subsequent grain growth in the delta ferrite regime, and finally, the decomposition of the delta ferrite to austenite during cooling. As a starting point, a differential formulation of the underlying diffusion problem is presented, based on the internal-state variable approach. These solutions are later manipulated and expressed in terms of the Scheil integral in the cases where the evolution equation is separable or can be made separable by a simple change of variables. The models have then been applied to describe the heat-affected zone microstructure evolution during both thick-plate and thin-plate welding of three commercial duplex stainless steel grades: 2205, 2304, and 2507. The results may conveniently be presented in the form of novel process diagrams, which display contours of constant delta ferrite grain size along with information about dissolution and reprecipitation of austenite for different combinations of weld input energy and peak temperature. These diagrams are well suited for quantitative readings and illustrate, in a condensed manner, the competition between the different variables that lead to structural changes during welding of duplex stainless steels.

Statistical Analysis of Stress Signals from Bridge Monitoring by FBG System

PubMed Central

Ye, Xiao-Wei; Xi, Pei-Sen

2018-01-01

In this paper, a fiber Bragg grating (FBG)-based stress monitoring system instrumented on an orthotropic steel deck arch bridge is demonstrated. The FBG sensors are installed at two types of critical fatigue-prone welded joints to measure the strain and temperature signals. A total of 64 FBG sensors are deployed around the rib-to-deck and rib-to-diagram areas at the mid-span and quarter-span of the investigated orthotropic steel bridge. The local stress behaviors caused by the highway loading and temperature effect during the construction and operation periods are presented with the aid of a wavelet multi-resolution analysis approach. In addition, the multi-modal characteristic of the rainflow counted stress spectrum is modeled by the method of finite mixture distribution together with a genetic algorithm (GA)-based parameter estimation approach. The optimal probability distribution of the stress spectrum is determined by use of Bayesian information criterion (BIC). Furthermore, the hot spot stress of the welded joint is calculated by an extrapolation method recommended in the specification of International Institute of Welding (IIW). The stochastic characteristic of stress concentration factor (SCF) of the concerned welded joint is addressed. The proposed FBG-based stress monitoring system and probabilistic stress evaluation methods can provide an effective tool for structural monitoring and condition assessment of orthotropic steel bridges. PMID:29414850

A Metallurgical Evaluation of the Powder-Bed Laser Additive Manufactured 4140 Steel Material

NASA Astrophysics Data System (ADS)

Wang, Wesley; Kelly, Shawn

2016-03-01

Using laser powder bed fusion (PBF-L) additive manufacturing (AM) process for steel or iron powder has been attempted for decades. This work used a medium carbon steel (AISI 4140) powder to explore the feasibility of AM. The high carbon equivalent of 4140 steel (CEIIW ≈ 0.83) has a strong tendency toward cold cracking. As such, the process parameters must be carefully controlled to ensure the AM build quality. Through an orthogonally designed experimental matrix, a laser-welding procedure was successfully developed to produce 4140 steel AM builds with no welding defects. In addition, the microstructure and micro-cleanliness of the as-welded PBF-L AM builds were also examined. The results showed an ultra-fine martensite lath structure and an ultra-clean internal quality with minimal oxide inclusion distribution. After optimizing the PBF-L AM process parameters, including the laser power and scan speed, the as-welded AM builds yielded an average tensile strength higher than 1482 MPa and an average 33 J Charpy V-notch impact toughness at -18°C. The surface quality, tensile strength, and Charpy V-notch impact toughness of AM builds were comparable to the wrought 4140 steel. The excellent mechanical properties of 4140 steel builds created by the PBF-L AM AM process make industrial production more feasible, which shows great potential for application in the aerospace, automobile, and machinery industries.

Overview of the program to assess the reliability of emerging nondestructive techniques open testing and study of flaw type effect on NDE response

NASA Astrophysics Data System (ADS)

Meyer, Ryan M.; Komura, Ichiro; Kim, Kyung-cho; Zetterwall, Tommy; Cumblidge, Stephen E.; Prokofiev, Iouri

2016-02-01

In February 2012, the U.S. Nuclear Regulatory Commission (NRC) executed agreements with VTT Technical Research Centre of Finland, Nuclear Regulatory Authority of Japan (NRA, former JNES), Korea Institute of Nuclear Safety (KINS), Swedish Radiation Safety Authority (SSM), and Swiss Federal Nuclear Safety Inspectorate (ENSI) to establish the Program to Assess the Reliability of Emerging Nondestructive Techniques (PARENT). The goal of PARENT is to investigate the effectiveness of current emerging and perspective novel nondestructive examination procedures and techniques to find flaws in nickel-alloy welds and base materials. This is done by conducting a series of open and blind international round-robin tests on a set of large-bore dissimilar metal welds (LBDMW), small-bore dissimilar metal welds (SBDMW), and bottom-mounted instrumentation (BMI) penetration weld test blocks. The purpose of blind testing is to study the reliability of more established techniques and included only qualified teams and procedures. The purpose of open testing is aimed at a more basic capability assessment of emerging and novel technologies. The range of techniques applied in open testing varied with respect to maturity and performance uncertainty and were applied to a variety of simulated flaws. This paper will include a brief overview of the PARENT blind and open testing techniques and test blocks and present some of the blind testing results.

Comparison of Two Methods for Determination of Strontium Isotopes in Pore Water at Yucca Mountain, Nevada

NASA Astrophysics Data System (ADS)

Marshall, B. D.; Futa, K.; Scofield, K. M.

2002-12-01

The proposed radioactive waste repository at Yucca Mountain, Nevada would be constructed in the high-silica rhyolite member of the Topopah Spring Tuff, an ash-flow tuff within the ~500-m-thick unsaturated zone. Dry-drilled rock cores from this unit have been packaged to preserve their water content. Two methods have been used to extract the strontium contained in the pore water for isotopic measurements. In the first method, samples of dried core were crushed, and the 0.25 to 2.4 mm size fractions were leached with ultra-pure water for about 1 hour to dissolve the salts left behind by the evaporated pore water. Concentrations of strontium in the pore water were calculated from determinations of porosity and saturation on adjacent core and the measured strontium concentration in the leachate. In the second method, pore water was extracted from sealed core using an ultracentrifuge, minimizing evaporation of water from the core at all steps in the process. The centrifugation of 150 to 200 g of welded tuff at 15,000 rpm for 6 hours typically results in the recovery of as much as 3 ml of pore water for analysis. Strontium isotope compositions were determined by thermal ionization mass spectrometry; 87Sr /86Sr ratios have a reproducibility of 0.00005. The ranges of 87Sr/86Sr ratios determined by the two methods are identical: 0.71215 to 0.71267 in the leachates (n = 35) and 0.71214 to 0.71266 in the extracted pore waters (n = 21). However, the calculated strontium concentrations in the leachates average 300 μg/L, whereas those in the extracted pore water average 1440 μg/L, indicating that a substantial portion of the pore-water salts remain in the crushed rock after leaching. The strontium data determined on extracted pore water shows that the leaching of pore-water salts results in accurate 87Sr/86Sr, but that a substantial correction to the strontium concentration is required due to the inefficiency of the leaching procedure and the small pore sizes in the welded tuffs. The strontium isotope data obtained on leachates can be used to constrain models of water-rock interaction and estimates of travel times in the unsaturated zone.

Design, Development and Testing of Inconel Alloy IN718 Spherical Gas Bottle for Oxygen Storage

NASA Astrophysics Data System (ADS)

Chenna Krishna, S.; Agilan, M.; Sudarshan Rao, G.; Singh, Satish Kumar; Narayana Murty, S. V. S.; Venkata Narayana, Ganji; Beena, A. P.; Rajesh, L.; Jha, Abhay K.; Pant, Bhanu

2017-11-01

This paper describes the details of design, manufacture and testing of 200 mm diameter spherical gas bottle of Inconel 718 (IN718) with nominal wall thickness of 2.3 mm. Gas bottle was designed for the specified internal pressure loading with a thickness of 2.9 mm at the circumferential weld which was brought down to 2.3 mm at the membrane locations. Hemispherical forgings produced through closed-die hammer forging were machined and electron beam welded to produce a spherical gas bottle. Duly welded gas bottle was subjected to standard aging treatment to achieve the required tensile strength. Aged gas bottle was inspected for dimensions and other stringent quality requirements using various nondestructive testing techniques. After inspection, gas bottle was subjected to pressure test for maximum expected operating pressure and proof pressure of 25 and 37.5 MPa, respectively. Strain gauges were bonded at different locations on the gas bottle to monitor the strains during the pressure test and correlated with the predicted values. The predicted strain matched well with the experimental strain confirming the design and structural integrity.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Study of Gravity Effects on Titanium Laser Welding in the Vertical Position

PubMed Central

Yuan, Zhang; Pu, Haitao; Li, Haigang; Cheng, Hao; Du, Dong; Shan, Jiguo

2017-01-01

To obtain satisfactory welds in positional laser beam welding, it is necessary to know how process parameters will influence the quality of welds in different welding positions. In this study, the titanium alloy Ti6Al4V sheets were laser welded in two vertical welding positions (vertical up and vertical down), and the appearance, porosity, strength, and ductility of the laser joints were evaluated. Results show that undercuts of the vertical up welds were greater than that of vertical down welds, while the porosity contents were much higher in vertical down welds than that in vertical up welds. When welding with a higher heat input, the vertical up welding position resulted in poor weld profiles (undercuts and burn-through holes), whereas the vertical down welding position led to excessive porosity contents in welds. Both severe undercut and excessive porosity were detrimental to the tensile properties of the welds. Weld appearance was improved and porosity contents were reduced by using a lower heat input, achieving better weld quality. Therefore, it is suggested that process parameter settings with relatively high laser powers and welding speeds, which can result in lower heat inputs, are used when laser welding the Ti6Al4V titanium alloys vertically. PMID:28885573

Study of Gravity Effects on Titanium Laser Welding in the Vertical Position.

PubMed

Chang, Baohua; Yuan, Zhang; Pu, Haitao; Li, Haigang; Cheng, Hao; Du, Dong; Shan, Jiguo

2017-09-08

To obtain satisfactory welds in positional laser beam welding, it is necessary to know how process parameters will influence the quality of welds in different welding positions. In this study, the titanium alloy Ti6Al4V sheets were laser welded in two vertical welding positions (vertical up and vertical down), and the appearance, porosity, strength, and ductility of the laser joints were evaluated. Results show that undercuts of the vertical up welds were greater than that of vertical down welds, while the porosity contents were much higher in vertical down welds than that in vertical up welds. When welding with a higher heat input, the vertical up welding position resulted in poor weld profiles (undercuts and burn-through holes), whereas the vertical down welding position led to excessive porosity contents in welds. Both severe undercut and excessive porosity were detrimental to the tensile properties of the welds. Weld appearance was improved and porosity contents were reduced by using a lower heat input, achieving better weld quality. Therefore, it is suggested that process parameter settings with relatively high laser powers and welding speeds, which can result in lower heat inputs, are used when laser welding the Ti6Al4V titanium alloys vertically.

Effects of laser-weld joint opening size on fatigue strength of Ti-6Al-4V structures with several diameters.

PubMed

Nuñez-Pantoja, J M C; Vaz, L G; Nóbilo, M A A; Henriques, G E P; Mesquita, M F

2011-03-01

This study was conducted to evaluate the fatigue strength of Ti-6Al-4V laser-welded joints with several diameters and joint openings. Sixty dumbbell rods were machined in Ti-6Al-4V alloy with central diameters of 1·5, 2·0 and 3·5 mm. The specimens were sectioned and then welded using two joint openings (0·0 and 0·6 mm). The combination of variables created six groups, which when added to the intact groups made a total of nine groups (n = 10). Laser welding was executed as follows: 360 V per 8 ms (1·5 and 2·0 mm) and 380 V per 9 ms (3·5 mm) with focus and frequency regulated to zero. The joints were finished, polished and submitted to radiographic examination to be analysed visually for the presence of porosity. The specimens were then subjected to a mechanical cyclic test, and the number of cycles until failure was recorded. The fracture surface was examined with a scanning electron microscope (SEM). The Kruskal-Wallis test and Dunn test (α = 0·05) indicated that the number of cycles required for fracture was lower for all specimens with joint openings of 0·6 mm, and for 3·5-mm-diameter specimens with joint openings of 0·0 mm. The Spearman correlation coefficient (α = 0·05) indicated that there was a negative correlation between the number of cycles and the presence of porosity. So, laser welding of Ti-6Al-4V structures with a thin diameter provides the best conditions for the juxtaposition of parts. Radiographic examination allows for the detection of internal voids in titanium joints. © 2010 Blackwell Publishing Ltd.

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

PubMed

Chai, Guo-Ming; Zhu, Yi-Feng

2010-04-01

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

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.

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

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

Hovanski, Yuri; Carsley, John; Carlson, Blair

2014-01-15

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

An International Round-Robin Test of NDE Reliability for PWSCC

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

Schuster, George J.; Cumblidge, Stephen E.; Doctor, Steven R.

2007-12-01

In this paper we describe the round robin tests that have been designed and are being conducted in the international program. Participants in the PINC have offered more than 30 test blocks for use in round-robin tests of NDE effectiveness. The test blocks have more than 130 flaws in nickel-base weld metal that are intended to simulate PWSCC in a variety of component geometries. NDE techniques representative of current in-service inspections are being applied, along with emerging NDE approaches.

Manufacturing development for the SAFE 100 kW core

NASA Astrophysics Data System (ADS)

Carter, Robert; Roman, Jose; Salvail, Pat

2002-01-01

In stark contrast to what is sometimes considered the norm in traditional manufacturing processes, engineers at the Marshall Space Flight Center (MSFC) arc in the practice of altering the standard in an effort to realize other potential methods in core manufacturing. While remaining within the bounds of the materials database, we are researching into core manufacturing techniques that may have been overlooked in the past due to funding and/or time constraints. To augment proven core fabrication capabilities we are pursuing plating processes as another possible method for core build-up and assembly. Although brazing and a proprietary HIP cycle are used for module assembly (proven track record for stability and endurance), it is prudent to pursue secondary or backup methods of module and core assembly. For this reason heat tube manufacture and module assembly by means of plating is being investigated. Potentially, the plating processes will give engineers the ability to manufacture replacement modules for any module that might fail to perform nominally, and to assemble/disassemble a complete core in much less time than would be required for the conventional Braze-HIP process. Another area of improvement in core manufacturing capabilities is the installation of a sodium and lithium liquid metal heat pipe fill machine. This, along with the ability to Electron Beam Weld heat pipe seals and wet-in the pipes in the necessary vacuum atmosphere, will eliminate the need to ship potentially hazardous components outside for processing. In addition to developing core manufacturing techniques, the SAFE manufacturing team has been evaluating the thermal heat transfer characteristics, and manufacturability of several heat exchanger design concepts. .

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

NASA Astrophysics Data System (ADS)

Kim, Taewon; Suga, Yasuo; Koike, Takashi

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

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

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

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

1979-01-01

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

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.

78 FR 54864 - Light-Walled Rectangular Pipe and Tube From Mexico: Preliminary Results and Partial Rescission of...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-09-06

... DEPARTMENT OF COMMERCE International Trade Administration [A-201-836] Light-Walled Rectangular... the antidumping duty order on light-walled rectangular pipe and tube (LWR pipe and tube) from Mexico... The merchandise subject to the order is certain welded carbon- quality light-walled steel pipe and...

77 FR 19192 - Circular Welded Carbon-Quality Steel Pipe From India: Preliminary Affirmative Countervailing Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-03-30

.... See Memorandum to Susan H. Kuhbach, Director, Office 1 from David Layton, International Trade Analyst... Provision of Hot-Rolled Steel by the Steel Authority of India (``SAIL'') for Less Than Adequate Remuneration... the questions regarding land received at less than adequate remuneration, Zenith prevented us from...

76 FR 37320 - Certain Welded Stainless Steel Pipes From the Republic of Korea: Notice of Court Decision Not in...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-06-27

... Steel Pipes From the Republic of Korea: Notice of Court Decision Not in Harmony With Final Results of Administrative Review and Amended Final Results AGENCY: Import Administration, International Trade Administration...) sustained the Department of Commerce's (the Department's) results of redetermination as applied to...

76 FR 33210 - Preliminary Results of Antidumping Duty Administrative Review: Circular Welded Carbon Steel Pipes...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-06-08

... DEPARTMENT OF COMMERCE International Trade Administration [A-583-008] Preliminary Results of... Enterprise Co., Ltd. (Yieh Phui) have been made below normal value (NV). If these preliminary results are adopted in our final results, we will instruct U.S. Customs and Border Protection (CBP) to assess...

Friction Stir Welding of Magnesium Alloy Type AZ 31

NASA Astrophysics Data System (ADS)

Kupec, Tomáš; Behúlová, Mária; Turňa, Milan; Sahul, Miroslav

The paper deals with welding of Mg alloy of the type AZ 31 by Friction Stir Welding technology (FSW). The FSW technology is at present predominantly used for welding light metals and alloys, as aluminium, magnesium and their alloys. Experimental part consists of performing the simulation and fabrication of welded joints on a new-installed welding equipment available at the Welding Research Institute — Industrial Institute of SR Bratislava. Welding tools made of tool steel type H 13 were used for welding experiments. Geometry of welding tools was designed on the base of literature knowledge. Suitable welding parameters and conditions were determined using numerical simulation. Main emphasis was laid upon the tool revolutions, welding speed and tool bevel angle. The effect of welding parameters on the quality of welded joints was assessed. Assessment of welded joints was carried out by radiography, light microscopy, hardness measurement and EDX microanalysis. Static tensile test was employed for mechanical testing.

Creep Deformation, Rupture Analysis, Heat Treatment and Residual Stress Measurement of Monolithic and Welded Grade 91 Steel for Power Plant Components

NASA Astrophysics Data System (ADS)

Shrestha, Triratna

Modified 9Cr-1 Mo (Grade 91) steel is currently considered as a candidate material for reactor pressure vessels (RPVs) and reactor internals for the Very High Temperature Reactor (VHTR), and in fossil-fuel fired power plants at higher temperatures and stresses. The tensile creep behavior of Grade 91 steel was studied in the temperature range of 600°C to 750°C and stresses between 35 MPa and 350 MPa. Heat treatment of Grade 91 steel was studied by normalizing and tempering the steel at various temperatures and times. Moreover, Thermo-Ca1c(TM) calculation was used to predict the precipitate stability and their evolution, and construct carbon isopleths of Grade 91 steel. Residual stress distribution across gas tungsten arc welds (GTAW) in Grade 91 steel was measured by the time-of-flight neutron diffraction using the Spectrometer for Materials Research at Temperature and Stress (SMARTS) diffractometer at Lujan Neutron Scattering Center, Los Alamos National Laboratory, Los Alamos, NM, USA. Analysis of creep results yielded stress exponents of ˜9-11 in the higher stress regime and ˜1 in the lower stress regime. The creep behavior of Grade 91 steel was described by the modified Bird-Mukherjee-Dorn relation. The rate-controlling creep deformation mechanism in the high stress regime was identified as the edge dislocation climb with a stress exponent of n = 5. On the other hand, the deformation mechanism in the Newtonian viscous creep regime (n = 1) was identified as the Nabarro-Herring creep. Creep rupture data were analyzed in terms of Monkman-Grant relation and Larson-Miller parameter. Creep damage tolerance factor and stress exponent were used to identify the cause of creep damage. The fracture surface morphology of the ruptured specimens was studied by scanning electron microscopy to elucidate the failure mechanisms. Fracture mechanism map for Grade 91 steel was developed based on the available material parameters and experimental observations. The microstructural evolution of heat treated steel was correlated with the differential scanning calorimetric study. The combination of microstructural studies with optical microscopy, scanning and transmission electron microscopy, microhardness profiles, and calorimetric plots helped in the understanding of the evolution of microstructure and precipitates in Grade 91 steel. The residual stresses were determined at the mid-thickness of the plate, 4.35 mm and 2.35 mm below the surface of the as-welded and post-weld heat treated plate. The residual stresses of the as-welded plate were compared with the post-weld heat treated plate. The post-weld heat treatment significantly reduced the residual stress in the base metal, heat affected zone, and the weld zone. Vickers microhardness profiles of the as-welded, and post-weld heat treated specimens were also determined and correlated with the observed residual stress profile and microstructure.

Contribution to applications of EBW in instrument techniques

NASA Astrophysics Data System (ADS)

Hrabovsky, Miroslav

1999-07-01

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

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

NASA Technical Reports Server (NTRS)

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

2000-01-01

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

Fundamentals and advances in the development of remote welding fabrication systems

NASA Technical Reports Server (NTRS)

Agapakis, J. E.; Masubuchi, K.; Von Alt, C.

1986-01-01

Operational and man-machine issues for welding underwater, in outer space, and at other remote sites are investigated, and recent process developments are described. Probable remote welding missions are classified, and the essential characteristics of fundamental remote welding tasks are analyzed. Various possible operational modes for remote welding fabrication are identified, and appropriate roles for humans and machines are suggested. Human operator performance in remote welding fabrication tasks is discussed, and recent advances in the development of remote welding systems are described, including packaged welding systems, stud welding systems, remotely operated welding systems, and vision-aided remote robotic welding and autonomous welding systems.

Physical and hydraulic properties of volcanic rocks from Yucca Mountain, Nevada

USGS Publications Warehouse

Flint, Lorraine E.

2003-01-01

A database of physical and hydraulic properties was developed for rocks in the unsaturated zone at Yucca Mountain, Nevada, a site under consideration as a geologic repository for high-level radioactive waste. The 5320 core samples were collected from 23 shallow (<100 m) and 10 deep (500-1000 m) vertical boreholes. Hydrogeologic units have been characterized in the unsaturated zone [Flint, 1998] that represent rocks with ranges of welding, lithophysae, and high and low temperature alteration (as a result of the depositional, cooling, and alterational history of the lithostratigraphic layers). Lithostratigraphy, the hydrogeologic unit, and the corresponding properties are described. In addition, the physical properties of bulk density, porosity, and particle density; the hydraulic properties of saturated hydraulic conductivity and moisture retention characteristics; and the field water content were measured and compiled for each core sample.

TEST STAND 4697 CONSTRUCTION

NASA Image and Video Library

2016-01-06

A CRANE MOVES THE FIRST STEEL TIER TO BE BOLTED INTO PLACE ON JAN. 6, FOR WELDING OF A SECOND NEW STRUCTURAL TEST STAND AT NASA'S MARSHALL SPACE FLIGHT CENTER IN HUNTSVILLE, ALABAMA -- CRITICAL TO DEVELOPMENT OF NASA'S SPACE LAUNCH SYSTEM. WHEN COMPLETED THIS SUMMER, THE 85-FOOT-TALL TEST STAND 4697 WILL USE HYDRAULIC CYLINDERS TO SUBJECT THE LIQUID OXYGEN TANK AND HARDWARE OF THE MASSIVE SLS CORE STAGE TO THE SAME LOADS AND STRESSES IT WILL ENDURE DURING A LAUNCH. THE STAND IS RISING IN MARSHALL'S WEST TEST AREA, WHERE WORK IS ALSO UNDERWAY ON THE 215-FOOT-TALL TOWERS OF TEST STAND 4693, WHICH WILL CONDUCT SIMILAR STRUCTURAL TESTS ON THE SLS CORE STAGE'S LIQUID HYDROGEN TANK. SLS, THE MOST POWERFUL ROCKET EVER BUILT, WILL CARRY ASTRONAUTS IN NASA'S ORION SPACECRAFT ON DEEP SPACE MISSIONS, INCLUDING THE JOURNEY TO MARS.

Advanced Welding Concepts

NASA Technical Reports Server (NTRS)

Ding, Robert J.

2010-01-01

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

Soldadura (Welding). Spanish Translations for Welding.

ERIC Educational Resources Information Center

Hohhertz, Durwin

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

Numerical and experimental determination of weld pool shape during high-power diode laser welding

NASA Astrophysics Data System (ADS)

Klimpel, Andrzej; Lisiecki, Aleksander; Szymanski, Andrzej; Hoult, Anthony P.

2003-10-01

In this paper, results of investigations on the shape of weld pool during High Power Diode Laser (HPDL) welding are presented. The results of tests showed that the shape of weld pool and mechanism of laser welding with a rectangular pattern of 808 nm laser radiation differs distinctly from previous laser welding mechanisms. For all power densities the conduction mode welds were observed and weld pool geometry depends significantly on the welding parameters.

Mapping the rehabilitation interventions of a community stroke team to the extended International Classification of Functioning, Disability and Health Core Set for Stroke.

PubMed

Evans, Melissa; Hocking, Clare; Kersten, Paula

2017-12-01

This study aim was to evaluate whether the Extended International Classification of Functioning, Disability and Health Core Set for Stroke captured the interventions of a community stroke rehabilitation team situated in a large city in New Zealand. It was proposed that the results would identify the contribution of each discipline, and the gaps and differences in service provision to Māori and non-Māori. Applying the Extended International Classification of Functioning, Disability and Health Core Set for Stroke in this way would also inform whether this core set should be adopted in New Zealand. Interventions were retrospectively extracted from 18 medical records and linked to the International Classification of Functioning, Disability and Health and the Extended International Classification of Functioning, Disability and Health Core Set for Stroke. The frequencies of linked interventions and the health discipline providing the intervention were calculated. Analysis revealed that 98.8% of interventions provided by the rehabilitation team could be linked to the Extended International Classification of Functioning, Disability and Health Core Set for Stroke, with more interventions for body function and structure than for activities and participation; no interventions for emotional concerns; and limited interventions for community, social and civic life. Results support previous recommendations for additions to the EICSS. The results support the use of the Extended International Classification of Functioning, Disability and Health Core Set for Stroke in New Zealand and demonstrates its use as a quality assurance tool that can evaluate the scope and practice of a rehabilitation service. Implications for Rehabilitation The Extended International Classification of Functioning Disability and Health Core Set for Stroke appears to represent the stroke interventions of a community stroke rehabilitation team in New Zealand. As a result, researchers and clinicians may have increased confidence to use this core set in research and clinical practice. The Extended International Classification of Functioning Disability and Health Core Set for Stroke can be used as a quality assurance tool to establish whether a community stroke rehabilitation team is meeting the functional needs of its stroke population.

A Brief Introduction to the Theory of Friction Stir Welding

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.

2008-01-01

Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and is already an important welding process for the aerospace industry, where welds of optimal quality are demanded. The structure of welds determines weld properties. The structure of friction stir welds is determined by the flow field in the weld metal in the vicinity of the weld tool. A simple kinematic model of the FSW flow field developed at Marshall Space Flight Center, which enables the basic features of FSW microstructure to be understood and related to weld process parameters and tool design, is explained.

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

NASA Astrophysics Data System (ADS)

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

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

INTERNAL REPAIR OF PIPELINES

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

Bill Bruce; Nancy Porter; George Ritter

2005-07-20

The two broad categories of fiber-reinforced composite liner repair and deposited weld metal repair technologies were reviewed and evaluated for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Principal conclusions from a survey of natural gas transmission industry pipeline operators can be summarized in terms of the following performance requirements for internal repair: (1) Use of internal repair is most attractive for river crossings, under other bodies of water, in difficult soil conditions, under highways, undermore » congested intersections, and under railway crossings. (2) Internal pipe repair offers a strong potential advantage to the high cost of horizontal direct drilling when a new bore must be created to solve a leak or other problem. (3) Typical travel distances can be divided into three distinct groups: up to 305 m (1,000 ft.); between 305 m and 610 m (1,000 ft. and 2,000 ft.); and beyond 914 m (3,000 ft.). All three groups require pig-based systems. A despooled umbilical system would suffice for the first two groups which represents 81% of survey respondents. The third group would require an onboard self-contained power unit for propulsion and welding/liner repair energy needs. (4) The most common size range for 80% to 90% of operators surveyed is 508 mm (20 in.) to 762 mm (30 in.), with 95% using 558.8 mm (22 in.) pipe. Evaluation trials were conducted on pipe sections with simulated corrosion damage repaired with glass fiber-reinforced composite liners, carbon fiber-reinforced composite liners, and weld deposition. Additional un-repaired pipe sections were evaluated in the virgin condition and with simulated damage. Hydrostatic failure pressures for pipe sections repaired with glass fiber-reinforced composite liner were only marginally greater than that of pipe sections without liners, indicating that this type of liner is only marginally effective at restoring the pressure containing capabilities of pipelines. Failure pressures for larger diameter pipe repaired with a semi-circular patch of carbon fiber-reinforced composite lines were also marginally greater than that of a pipe section with un-repaired simulated damage without a liner. These results indicate that fiber reinforced composite liners have the potential to increase the burst pressure of pipe sections with external damage Carbon fiber based liners are viewed as more promising than glass fiber based liners because of the potential for more closely matching the mechanical properties of steel. Pipe repaired with weld deposition failed at pressures lower than that of un-repaired pipe in both the virgin and damaged conditions, indicating that this repair technology is less effective at restoring the pressure containing capability of pipe than a carbon fiber-reinforced liner repair. Physical testing indicates that carbon fiber-reinforced liner repair is the most promising technology evaluated to-date. In lieu of a field installation on an abandoned pipeline, a preliminary nondestructive testing protocol is being developed to determine the success or failure of the fiber-reinforced liner pipeline repairs. Optimization and validation activities for carbon-fiber repair methods are ongoing.« less

INTERNAL REPAIR OF PIPELINES

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

Robin Gordon; Bill Bruce; Ian Harris

2004-12-31

The two broad categories of fiber-reinforced composite liner repair and deposited weld metal repair technologies were reviewed and evaluated for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Principal conclusions from a survey of natural gas transmission industry pipeline operators can be summarized in terms of the following performance requirements for internal repair: (1) Use of internal repair is most attractive for river crossings, under other bodies of water, in difficult soil conditions, under highways, undermore » congested intersections, and under railway crossings. (2) Internal pipe repair offers a strong potential advantage to the high cost of horizontal direct drilling when a new bore must be created to solve a leak or other problem. (3) Typical travel distances can be divided into three distinct groups: up to 305 m (1,000 ft.); between 305 m and 610 m (1,000 ft. and 2,000 ft.); and beyond 914 m (3,000 ft.). All three groups require pig-based systems. A despooled umbilical system would suffice for the first two groups which represents 81% of survey respondents. The third group would require an onboard self-contained power unit for propulsion and welding/liner repair energy needs. (4) The most common size range for 80% to 90% of operators surveyed is 508 mm (20 in.) to 762 mm (30 in.), with 95% using 558.8 mm (22 in.) pipe. Evaluation trials were conducted on pipe sections with simulated corrosion damage repaired with glass fiber-reinforced composite liners, carbon fiber-reinforced composite liners, and weld deposition. Additional un-repaired pipe sections were evaluated in the virgin condition and with simulated damage. Hydrostatic failure pressures for pipe sections repaired with glass fiber-reinforced composite liner were only marginally greater than that of pipe sections without liners, indicating that this type of liner is only marginally effective at restoring the pressure containing capabilities of pipelines. Failure pressures for larger diameter pipe repaired with a semi-circular patch of carbon fiber-reinforced composite lines were also marginally greater than that of a pipe section with un-repaired simulated damage without a liner. These results indicate that fiber reinforced composite liners have the potential to increase the burst pressure of pipe sections with external damage Carbon fiber based liners are viewed as more promising than glass fiber based liners because of the potential for more closely matching the mechanical properties of steel. Pipe repaired with weld deposition failed at pressures lower than that of un-repaired pipe in both the virgin and damaged conditions, indicating that this repair technology is less effective at restoring the pressure containing capability of pipe than a carbon fiber-reinforced liner repair. Physical testing indicates that carbon fiber-reinforced liner repair is the most promising technology evaluated to-date. The first round of optimization and validation activities for carbon-fiber repairs are complete. Development of a comprehensive test plan for this process is recommended for use in the field trial portion of this program.« less

INTERNAL REPAIR OF PIPELINES

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

Robin Gordon; Bill Bruce; Ian Harris

2004-08-17

The two broad categories of fiber-reinforced composite liner repair and deposited weld metal repair technologies were reviewed and evaluated for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Principal conclusions from a survey of natural gas transmission industry pipeline operators can be summarized in terms of the following performance requirements for internal repair: (1) Use of internal repair is most attractive for river crossings, under other bodies of water, in difficult soil conditions, under highways, undermore » congested intersections, and under railway. (2) Internal pipe repair offers a strong potential advantage to the high cost of horizontal direct drilling when a new bore must be created to solve a leak or other problem. (3) Typical travel distances can be divided into three distinct groups: up to 305 m (1,000 ft.); between 305 m and 610 m (1,000 ft. and 2,000 ft.); and beyond 914 m (3,000 ft.). All three groups require pig-based systems. A despooled umbilical system would suffice for the first two groups which represents 81% of survey respondents. The third group would require an onboard self-contained power unit for propulsion and welding/liner repair energy needs. (4) The most common size range for 80% to 90% of operators surveyed is 508 mm (20 in.) to 762 mm (30 in.), with 95% using 558.8 mm (22 in.) pipe. Evaluation trials were conducted on pipe sections with simulated corrosion damage repaired with glass fiber-reinforced composite liners, carbon fiber-reinforced composite liners, and weld deposition. Additional un-repaired pipe sections were evaluated in the virgin condition and with simulated damage. Hydrostatic failure pressures for pipe sections repaired with glass fiber-reinforced composite liner were only marginally greater than that of pipe sections without liners, indicating that this type of liner is only marginally effective at restoring the pressure containing capabilities of pipelines. Failure pressures for larger diameter pipe repaired with a semi-circular patch of carbon fiber-reinforced composite lines were also marginally greater than that of a pipe section with un-repaired simulated damage without a liner. These results indicate that fiber reinforced composite liners have the potential to increase the burst pressure of pipe sections with external damage Carbon fiber based liners are viewed as more promising than glass fiber based liners because of the potential for more closely matching the mechanical properties of steel. Pipe repaired with weld deposition failed at pressures lower than that of un-repaired pipe in both the virgin and damaged conditions, indicating that this repair technology is less effective at restoring the pressure containing capability of pipe than a carbon fiber-reinforced liner repair. Physical testing indicates that carbon fiber-reinforced liner repair is the most promising technology evaluated to-date. Development of a comprehensive test plan for this process is recommended for use in the field trial portion of this program.« less

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 49 Transportation 3 2013-10-01 2013-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 3 2011-10-01 2011-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 49 Transportation 3 2012-10-01 2012-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 49 Transportation 3 2014-10-01 2014-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

Primary Water Stress Corrosion Cracks in Nickel Alloy Dissimilar Metal Welds: Detection and Sizing Using Established and Emerging Nondestructive Examination Techniques

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

Braatz, Brett G.; Cumblidge, Stephen E.; Doctor, Steven R.

2012-12-31

The U.S. Nuclear Regulatory Commission has established the Program to Assess the Reliability of Emerging Nondestructive Techniques (PARENT) as a follow-on to the international cooperative Program for the Inspection of Nickel Alloy Components (PINC). The goal of PINC was to evaluate the capabilities of various nondestructive evaluation (NDE) techniques to detect and characterize surface-breaking primary water stress corrosion cracks in dissimilar-metal welds (DMW) in bottom-mounted instrumentation (BMI) penetrations and small-bore (≈400-mm diameter) piping components. A series of international blind round-robin tests were conducted by commercial and university inspection teams. Results from these tests showed that a combination of conventional andmore » phased-array ultrasound techniques provided the highest performance for flaw detection and depth sizing in dissimilar metal piping welds. The effective detection of flaws in BMIs by eddy current and ultrasound shows that it may be possible to reliably inspect these components in the field. The goal of PARENT is to continue the work begun in PINC and apply the lessons learned to a series of open and blind international round-robin tests that will be conducted on a new set of piping components including large-bore (≈900-mm diameter) DMWs, small-bore DMWs, and BMIs. Open round-robin testing will engage universities and industry worldwide to investigate the reliability of emerging NDE techniques to detect and accurately size flaws having a wide range of lengths, depths, orientations, and locations. Blind round-robin testing will invite testing organizations worldwide, whose inspectors and procedures are certified by the standards for the nuclear industry in their respective countries, to investigate the ability of established NDE techniques to detect and size flaws whose characteristics range from easy to very difficult to detect and size. This paper presents highlights of PINC and reports on the plans and progress for PARENT round-robin tests.« less

Research and application of self - propagating welding technology

NASA Astrophysics Data System (ADS)

Ma, Yunhe; Li, Zhizun; Wang, Jianjiang; Sun, Liming

2018-04-01

Self-propagating welding is an important application area of self-propagating high-temperature synthesis technology (SHS technology), suitable for special environment and special materials welding. This paper briefly introduces the principle of self - propagating welding and its technical characteristics, and briefly summarizes the current research and application of SHS welding around three aspects of thin film welding, welding of refractory welding and emergency welding of battlefield.

Electromagnetic interference from welding and motors on implantable cardioverter-defibrillators as tested in the electrically hostile work site.

PubMed

Fetter, J G; Benditt, D G; Stanton, M S

1996-08-01

This study was designed to determine the susceptibility of an implanted cardioverter-defibrillator to electromagnetic interference in an electrically hostile work site environment, with the ultimate goal of allowing the patient to return to work. Normal operation of an implanted cardioverter-defibrillator depends on reliable sensing of the heart's electrical activity. Consequently, there is concern that external electromagnetic interference from external sources in the work place, especially welding equipment or motor-generator systems, may be sensed and produce inappropriate shocks or abnormal reed switch operation, temporarily suspending detection of ventricular tachycardia or ventricular fibrillation. The effects of electromagnetic interference on the operation of one type of implantable cardioverter-defibrillator (Medtronic models 7217 and 7219) was measured by using internal event counter monitoring in 10 patients operating arc welders at up to 900 A or working near 200-hp motors and 1 patient close to a locomotive starter drawing up to 400 A. The electromagnetic interference produced two sources of potential interference on the sensing circuit or reed switch operation, respectively: 1) electrical fields with measured frequencies up to 50 MHz produced by the high currents during welding electrode activation, and 2) magnetic fields produced by the current in the welding electrode and cable. The defibrillator sensitivity was programmed to the highest (most sensitive) value: 0.15 mV (model 7219) or 0.3 mV (model 7217). The ventricular tachycardia and ventricular fibrillation therapies were temporarily turned off but the detection circuits left on. None of the implanted defibrillators tested were affected by oversensing of the electric field as verified by telemetry from the detection circuits. The magnetic field from 225-A welding current produced a flux density of 1.2 G; this density was not adequate to close the reed switch, which requires approximately 10 G. Our testing at the work site revealed no electrical interference with this type of defibrillator. Patients were allowed to return to work. The following precautions should be observed by the patient: 1) maintain a minimal distance of 2 ft (61 cm) from the welding arc and cables or large motors, 2) do not exceed tested currents with the welding equipment, 3) wear insulated gloves while operating electrical equipment, 4) verify that electrical equipment is properly grounded, and 5) stop welding and leave the work area immediately if a therapy is delivered or a feeling of lightheadedness is experienced.

Laser Beam Welding of Nitride Steel Components

NASA Astrophysics Data System (ADS)

Gu, Hongping; Yin, Guobin; Shulkin, Boris

Laser beam welding is a joining technique that has many advantages over conventional GMAW welding, such as low heat input, short cycle time as well as good cosmetic welds. Laser beam welding has been widely used for welding powertrain components in automotive industry. When welding nitride steel components, however, laser beam welding faces a great challenge. The difficulty lies in the fact that the nitride layer in the joint releases the nitrogen into the weld pool, resulting in a porous weld. This research presents an industrial ready solution to prevent the nitrogen from forming gas bubbles in the weld.

Creep rupture testing of alloy 617 and A508/533 base metals and weldments.

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

Natesan, K.; Li, M.; Soppet, W.K.

2012-01-17

The NGNP, which is an advanced HTGR concept with emphasis on both electricity and hydrogen production, involves helium as the coolant and a closed-cycle gas turbine for power generation with a core outlet/gas turbine inlet temperature of 750-1000 C. Alloy 617 is a prime candidate for VHTR structural components such as reactor internals, piping, and heat exchangers in view of its resistance to oxidation and elevated temperature strength. However, lack of adequate data on the performance of the alloy in welded condition prompted to initiate a creep test program at Argonne National Laboratory. In addition, Testing has been initiated tomore » evaluate the creep rupture properties of the pressure vessel steel A508/533 in air and in helium environments. The program, which began in December 2009, was certified for quality assurance NQA-1 requirements during January and February 2010. Specimens were designed and fabricated during March and the tests were initiated in April 2010. During the past year, several creep tests were conducted in air on Alloy 617 base metal and weldment specimens at temperatures of 750, 850, and 950 C. Idaho National Laboratory, using gas tungsten arc welding method with Alloy 617 weld wire, fabricated the weldment specimens. Eight tests were conducted on Alloy 617 base metal specimens and nine were on Alloy 617 weldments. The creep rupture times for the base alloy and weldment tests were up to {approx}3900 and {approx}4500 h, respectively. The results showed that the creep rupture lives of weld specimens are much longer than those for the base alloy, when tested under identical test conditions. The test results also showed that the creep strain at fracture is in the range of 7-18% for weldment samples and were much lower than those for the base alloy, under similar test conditions. In general, the weldment specimens showed more of a flat or constant creep rate region than the base metal specimens. The base alloy and the weldment exhibited tertiary creep after 50-60% of the rupture life, irrespective of test temperature in the range of 750-950 C. The results showed that the stress dependence of the creep rate followed a power law for both base alloy and weldments. The data also showed that the stress exponent for creep is the same and one can infer that the same mechanism is operative in both base metal and weldments in the temperature range of the current study. SEM fractography analysis indicated that both base metal and weldment showed combined fracture modes consisting of dimple rupture and intergranular cracking. Intergranular cracking was more evident in the weldment specimens, which is consistent with the observation of lower creep ductility in the weldment than in the base metal.« less

Friction plug welding

NASA Technical Reports Server (NTRS)

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

2001-01-01

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

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach

PubMed Central

Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

2016-01-01

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design. PMID:28773800

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach.

PubMed

Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

2016-08-09

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design.

Method and apparatus for assessing weld quality

DOEpatents

Smartt, Herschel B.; Kenney, Kevin L.; Johnson, John A.; Carlson, Nancy M.; Clark, Denis E.; Taylor, Paul L.; Reutzel, Edward W.

2001-01-01

Apparatus for determining a quality of a weld produced by a welding device according to the present invention includes a sensor operatively associated with the welding device. The sensor is responsive to at least one welding process parameter during a welding process and produces a welding process parameter signal that relates to the at least one welding process parameter. A computer connected to the sensor is responsive to the welding process parameter signal produced by the sensor. A user interface operatively associated with the computer allows a user to select a desired welding process. The computer processes the welding process parameter signal produced by the sensor in accordance with one of a constant voltage algorithm, a short duration weld algorithm or a pulsed current analysis module depending on the desired welding process selected by the user. The computer produces output data indicative of the quality of the weld.

Parametric study in weld mismatch of longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. L.; Brunair, R. M.

1991-01-01

Welded joints are an essential part of pressure vessels such as the Space Shuttle Main Engine (SSME) Turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet x rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered. Using the finite element method and mathematical formulations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thickness on both sides of the joint. From the study, the finite element results and theoretical solutions are presented.

Study of weld offset in longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. S.; Brunair, R. M.

1992-01-01

Welded joints are an essential part of rocket engine structures such as the Space Shuttle Main Engine (SSME) turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet X-rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered in this report. Using the FEM and beamlike plate approximations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thicknesses on both sides of the joint. Following the study, some conclusions are derived for the weld offsets.

Weld analysis and control system

NASA Technical Reports Server (NTRS)

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

1994-01-01

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

B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Russell, Carolyn

2000-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2012-07-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

An Approach to Maximize Weld Penetration During TIG Welding of P91 Steel Plates by Utilizing Image Processing and Taguchi Orthogonal Array

NASA Astrophysics Data System (ADS)

Singh, Akhilesh Kumar; Debnath, Tapas; Dey, Vidyut; Rai, Ram Naresh

2017-10-01

P-91 is modified 9Cr-1Mo steel. Fabricated structures and components of P-91 has a lot of application in power and chemical industry owing to its excellent properties like high temperature stress corrosion resistance, less susceptibility to thermal fatigue at high operating temperatures. The weld quality and surface finish of fabricated structure of P91 is very good when welded by Tungsten Inert Gas welding (TIG). However, the process has its limitation regarding weld penetration. The success of a welding process lies in fabricating with such a combination of parameters that gives maximum weld penetration and minimum weld width. To carry out an investigation on the effect of the autogenous TIG welding parameters on weld penetration and weld width, bead-on-plate welds were carried on P91 plates of thickness 6 mm in accordance to a Taguchi L9 design. Welding current, welding speed and gas flow rate were the three control variables in the investigation. After autogenous (TIG) welding, the dimension of the weld width, weld penetration and weld area were successfully measured by an image analysis technique developed for the study. The maximum error for the measured dimensions of the weld width, penetration and area with the developed image analysis technique was only 2 % compared to the measurements of Leica-Q-Win-V3 software installed in optical microscope. The measurements with the developed software, unlike the measurements under a microscope, required least human intervention. An Analysis of Variance (ANOVA) confirms the significance of the selected parameters. Thereafter, Taguchi's method was successfully used to trade-off between maximum penetration and minimum weld width while keeping the weld area at a minimum.

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.

A highly efficient and compact long pulse Nd:YAG rod laser with 540 J of pulse energy for welding application.

PubMed

Choubey, Ambar; Vishwakarma, S C; Misra, Pushkar; Jain, R K; Agrawal, D K; Arya, R; Upadhyaya, B N; Oak, S M

2013-07-01

We have developed an efficient and high average power flash lamp pumped long pulse Nd:YAG laser capable of generating 1 kW of average output power with maximum 540 J of single pulse energy and 20 kW of peak power. The laser pulse duration can be varied from 1 to 40 ms and repetition rate from 1 to 100 Hz. A compact and robust laser pump chamber and resonator was designed to achieve this high average and peak power. It was found that this laser system provides highest single pulse energy as compared to other long pulsed Nd:YAG laser systems of similar rating. A slope efficiency of 5.4% has been achieved, which is on higher side for typical lamp pumped solid-state lasers. This system will be highly useful in laser welding of materials such as aluminium and titanium. We have achieved 4 mm deep penetration welding of these metals under optimized conditions of output power, pulse energy, and pulse duration. The laser resonator was optimized to provide stable operation from single shot to 100 Hz of repetition rate. The beam quality factor was measured to be M(2) ~ 91 and pulse-to-pulse stability of ±3% for the multimode operation. The laser beam was efficiently coupled through an optical fiber of 600 μm core diameter and 0.22 numerical aperture with power transmission of 90%.

Laser-activated protein bands for peripheral nerve repair

NASA Astrophysics Data System (ADS)

Lauto, Antonio; Trickett, Rodney I.; Malik, Richard; Dawes, Judith M.; Owen, Earl R.

1996-01-01

A 100 micrometer core optical fiber-coupled 75 mW diode laser operating at a wavelength of 800 nm has been used in conjunction with a protein solder to stripe weld severed rat tibial nerves, reducing the long operating time required for microsurgical nerve repair. Welding is produced by selective laser denaturation of the protein based solder which contains the dye indocyanine green. Operating time for laser soldering was 10 plus or minus 5 min. (n equals 24) compared to 23 plus or minus 9 min (n equals 13) for microsuturing. The laser solder technique resulted in patent welds with a tensile strength of 15 plus or minus 5 g, while microsutured nerves had a tensile strength of 40 plus or minus 10 g. Histopathology of the laser soldered nerves, conducted immediately after surgery, displayed solder adhesion to the outer membrane with minimal damage to the inner axons of the nerves. An in vivo study, with a total of fifty-seven adult male wistar rats, compared laser solder repaired tibial nerves to conventional microsuture repair. Twenty-four laser soldered nerves and thirteen sutured nerves were characterized at three months and showed successful regeneration with average compound muscle action potentials (CMAP) of 2.4 plus or minus 0.7 mV and 2.7 plus or minus 0.8 mV respectively. Histopathology of the in vivo study, confirmed the comparable regeneration of axons in laser and suture operated nerves. A faster, less damaging and long lasting laser based anastomotic technique is presented.

Spot-Welding Gun Is Easy To Use

NASA Technical Reports Server (NTRS)

Morgan, Gene E.; Nguyen, Francis H.

1991-01-01

Electrical-resistance spot-welding gun designed to produce more welds per unit time by decreasing technician's effort and fatigue. Vacuum cups on frame secure welding gun to workpiece while compressed air drives welding tip against workpiece to make spot resistance weld. When weld completed, vacuum in frame cups released so frame and gun moved to position of next spot weld.

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

NASA Technical Reports Server (NTRS)

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

2012-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Effect of welding position on porosity formation in aluminum alloy welds

NASA Technical Reports Server (NTRS)

Haryung, J.; Wroth, R. S.

1967-01-01

Program investigates the effects of varied welding positions on weld qualities. Progressive changes in bead geometry occur as the weld plane angle is varied from upslope to downslope. The gravitational effect on the weld puddle varies greatly with welding position.

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

NASA Astrophysics Data System (ADS)

Ishide, Takashi; Tsubota, Shuho; Watanabe, Masao

2003-03-01

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

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.

Research on the microstructure and properties of laser-MIG hybrid welded joint of Invar alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Zhang, Dan; Wei, Yanhong; Wang, Yuhua

2017-12-01

In order to solve the problem of large deformation, low production efficiency and high tendency of hot cracking in welding 19.05 mm thick plates of Fe36Ni Invar alloy, laser-MIG hybrid multi-layer welding technique (LMHMW) has been developed. To investigate the influence of different welding parameters on the joint properties, optical microscope observation, SEM, EDS and microhardness measurement were conducted. Experimental results illustrated that different matching of welding parameters significantly affected the depth-to-width ratio, formation of defects and HAZ width. Besides, weld zone were consisted of two regions according to the different grain shape. The region near center of weld seam (region 1) was columnar dendrite induced by laser, while the region far away from weld seam center (region 2) was cellular dendrite which was mainly caused by MIG arc. The peak value of microhardness appeared at the center of weld seam since the grains in region 1 were relatively fine, and the lowest hardness value was obtained in HAZ. In addition, results showed that the sheets can be welded at optimum process parameters, with few defects such as, surface oxidation, porosity, cracks and lack of penetration in the welding seam: laser power of backing weld P = 5500 W, welding current I = 240 A, welding speed v = 1 m/min. laser power of filling weld P = 2000 W, welding current I = 220 A, welding speed v = 0.35 m/min. laser power of cosmetic weld P = 2000 W, welding current I = 300 A, welding speed v = 0.35 m/min.

Damage Tolerance Assessment of Friction Pull Plug Welds

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

Friction stir welding is a solid state welding process developed and patented by The Welding Institute in Cambridge, England. Friction stir welding has been implemented in the aerospace industry in the fabrication of longitudinal welds in pressurized cryogenic propellant tanks. As the industry looks to implement friction stir welding in circumferential welds in pressurized cryogenic propellant tanks, techniques to close out the termination hole associated with retracting the pin tool are being evaluated. Friction pull plug welding is under development as a one means of closing out the termination hole. A friction pull plug weld placed in a friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite, plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size in the test or service environments. Test data relating residual strength capability to flaw size in two aluminum alloy friction plug weld configurations is presented.

Automated Welding System

NASA Technical Reports Server (NTRS)

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

1993-01-01

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

Influence of Welding Process and Post Weld Heat Treatment on Microstructure and Pitting Corrosion Behavior of Dissimilar Aluminium Alloy Welds

NASA Astrophysics Data System (ADS)

Venkata Ramana, V. S. N.; Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

Welding of dissimilar Aluminum alloy welds is becoming important in aerospace, shipbuilding and defence applications. In the present work, an attempt has been made to weld dissimilar aluminium alloys using conventional gas tungsten arc welding (GTAW) and friction stir welding (FSW) processes. An attempt was also made to study the effect of post weld heat treatment (T4 condition) on microstructure and pitting corrosion behaviour of these welds. Results of the present investigation established the differences in microstructures of the base metals in T4 condition and in annealed conditions. It is evident that the thickness of the PMZ is relatively more on AA2014 side than that of AA6061 side. In FS welds, lamellar like shear bands are well noticed on the top of the stir zone. The concentration profile of dissimilar friction stir weld in T4 condition revealed that no diffusion has taken place at the interface. Poor Hardness is observed in all regions of FS welds compared to that of GTA welds. Pitting corrosion resistance of the dissimilar FS welds in all regions was improved by post weld heat treatment.

Influence of Oxides on Microstructures and Mechanical Properties of High-Strength Steel Weld Joint

NASA Astrophysics Data System (ADS)

Cai, Yangchuan; Luo, Zhen; Huang, Zunyue; Zeng, Yida

2016-11-01

A comprehensive investigation was conducted into the effect of oxides on penetrations, microstructures and mechanical properties of BS700MC super steel weld bead. Boron oxide changed the penetration of weld bead by changing the Marangoni convection in the weld pool and contracting the welding arc. Chromium oxide only changed the Marangoni convection in the weld pool to increase the penetration of super steel. Thus, the super steel weld bead has higher penetration coated with flux boron oxide than that coated with chromium oxide. In other words, the activating flux TIG (A-TIG) welding with flux boron oxide has less welding heat input than the A-TIG welding with flux chromium oxide. As a result, on the one hand, there existed more fine and homogeneous acicular ferrites in the microstructure of welding heat-affected zone when the super steel was welded by A-TIG with flux boron oxide. Thus, the weld beads have higher value of low-temperature impact toughness. On the other hand, the softening degree of welding heat-affected zone, welded by A-TIG with flux boron oxide, will be decreased for the minimum value of welding heat input.

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

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

Automatic orbital GTAW welding: Highest quality welds for tomorrow's high-performance systems

NASA Technical Reports Server (NTRS)

Henon, B. K.

1985-01-01

Automatic orbital gas tungsten arc welding (GTAW) or TIG welding is certain to play an increasingly prominent role in tomorrow's technology. The welds are of the highest quality and the repeatability of automatic weldings is vastly superior to that of manual welding. Since less heat is applied to the weld during automatic welding than manual welding, there is less change in the metallurgical properties of the parent material. The possibility of accurate control and the cleanliness of the automatic GTAW welding process make it highly suitable to the welding of the more exotic and expensive materials which are now widely used in the aerospace and hydrospace industries. Titanium, stainless steel, Inconel, and Incoloy, as well as, aluminum can all be welded to the highest quality specifications automatically. Automatic orbital GTAW equipment is available for the fusion butt welding of tube-to-tube, as well as, tube to autobuttweld fittings. The same equipment can also be used for the fusion butt welding of up to 6 inch pipe with a wall thickness of up to 0.154 inches.

Method for enhanced control of welding processes

DOEpatents

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

2000-01-01

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

Assessment of Stress Corrosion Cracking Resistance of Activated Tungsten Inert Gas-Welded Duplex Stainless Steel Joints

NASA Astrophysics Data System (ADS)

Alwin, B.; Lakshminarayanan, A. K.; Vasudevan, M.; Vasantharaja, P.

2017-12-01

The stress corrosion cracking behavior of duplex stainless steel (DSS) weld joint largely depends on the ferrite-austenite phase microstructure balance. This phase balance is decided by the welding process used, heat input, welding conditions and the weld metal chemistry. In this investigation, the influence of activated tungsten inert gas (ATIG) and tungsten inert gas (TIG) welding processes on the stress corrosion cracking (SCC) resistance of DSS joints was evaluated and compared. Boiling magnesium chloride (45 wt.%) environment maintained at 155 °C was used. The microstructure and ferrite content of different weld zones are correlated with the outcome of sustained load, SCC test. Irrespective of the welding processes used, SCC resistance of weld joints was inferior to that of the base metal. However, ATIG weld joint exhibited superior resistance to SCC than the TIG weld joint. The crack initiation and final failure were in the weld metal for the ATIG weld joint; they were in the heat-affected zone for the TIG weld joint.

Weld pool oscillation during GTA welding of mild steel

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

Xiao, Y.H.; Ouden, G. den

1993-08-01

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

Comparison between hybrid laser-MIG welding and MIG welding for the invar36 alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Li, Yubo; Ou, Wenmin; Yu, Fengyi; Chen, Jie; Wei, Yanhong

2016-11-01

The invar36 alloy is suitable to produce mold of composite materials structure because it has similar thermal expansion coefficient with composite materials. In the present paper, the MIG welding and laser-MIG hybrid welding methods are compared to get the more appropriate method to overcome the poor weldability of invar36 alloy. According to the analysis of the experimental and simulated results, it has been proved that the Gauss and cone combined heat source model can characterize the laser-MIG hybrid welding heat source well. The total welding time of MIG welding is 8 times that of hybrid laser-MIG welding. The welding material consumption of MIG welding is about 4 times that of hybrid laser-MIG welding. The stress and deformation simulation indicate that the peak value of deformation during MIG welding is 3 times larger than that of hybrid laser-MIG welding.

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.

An in-mold packaging process for plastic fluidic devices.

PubMed

Yoo, Y E; Lee, K H; Je, T J; Choi, D S; Kim, S K

2011-01-01

Micro or nanofluidic devices have many channel shapes to deliver chemical solutions, body fluids or any fluids. The channels in these devices should be covered to prevent the fluids from overflowing or leaking. A typical method to fabricate an enclosed channel is to bond or weld a cover plate to a channel plate. This solid-to-solid bonding process, however, takes a considerable amount of time for mass production. In this study, a new process for molding a cover layer that can enclose open micro or nanochannels without solid-to-solid bonding is proposed and its feasibility is estimated. First, based on the design of a model microchannel, a brass microchannel master core was machined and a plastic microchannel platform was injection-molded. Using this molded platform, a series of experiments was performed for four process or mold design parameters. Some feasible conditions were successfully found to enclosed channels without filling the microchannels for the injection molding of a cover layer over the plastic microchannel platform. In addition, the bond strength and seal performance were estimated in a comparison with those done by conventional bonding or welding processes.

Heat flux instrumentation for Hyflite thermal protection system

NASA Technical Reports Server (NTRS)

Diller, T. E.

1994-01-01

Using Thermal Protection Tile core samples supplied by NASA, the surface characteristics of the FRCI, TUFI, and RCG coatings were evaluated. Based on these results, appropriate methods of surface preparation were determined and tested for the required sputtering processes. Sample sensors were fabricated on the RCG coating and adhesion was acceptable. Based on these encouraging results, complete Heat Flux Microsensors were fabricated on the RCG coating. The issue of lead attachment was addressed with the annnealing and welding methods developed at NASA Lewis. Parallel gap welding appears to be the best method of lead attachment with prior heat treatment of the sputtered pads. Sample Heat Flux Microsensors were submitted for testing in the NASA Ames arc jet facility. Details of the project are contained in two attached reports. One additional item of interest is contained in the attached AIAA paper, which gives details of the transient response of a Heat Flux Microsensors in a shock tube facility at Virginia Tech. The response of the heat flux sensor was measured to be faster than 10 micro-s.

Internal core tightener

DOEpatents

Brynsvold, Glen V.; Snyder, Jr., Harold J.

1976-06-22

An internal core tightener which is a linear actuated (vertical actuation motion) expanding device utilizing a minimum of moving parts to perform the lateral tightening function. The key features are: (1) large contact areas to transmit loads during reactor operation; (2) actuation cam surfaces loaded only during clamping and unclamping operation; (3) separation of the parts and internal operation involved in the holding function from those involved in the actuation function; and (4) preloaded pads with compliant travel at each face of the hexagonal assembly at the two clamping planes to accommodate thermal expansion and irradiation induced swelling. The latter feature enables use of a "fixed" outer core boundary, and thus eliminates the uncertainty in gross core dimensions, and potential for rapid core reactivity changes as a result of core dimensional change.

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

NASA Astrophysics Data System (ADS)

Hu, Min

2018-02-01

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

Computerized adaptive control weld skate with CCTV weld guidance project

NASA Technical Reports Server (NTRS)

Wall, W. A.

1976-01-01

This report summarizes progress of the automatic computerized weld skate development portion of the Computerized Weld Skate with Closed Circuit Television (CCTV) Arc Guidance Project. The main goal of the project is to develop an automatic welding skate demonstration model equipped with CCTV weld guidance. The three main goals of the overall project are to: (1) develop a demonstration model computerized weld skate system, (2) develop a demonstration model automatic CCTV guidance system, and (3) integrate the two systems into a demonstration model of computerized weld skate with CCTV weld guidance for welding contoured parts.

46 CFR 56.50-60 - Systems containing oil.

Code of Federal Regulations, 2014 CFR

2014-10-01

... °F must be of seamless steel. (See § 56.50-65 of this part.) (k) Oil piping drains, strainers and... is of steel construction, all welded, and not concealed. (d) Piping subject to internal head pressure... installed on the outside of the oil tanks must be made of steel, ductile cast iron ASTM A 395 (incorporated...

46 CFR 56.50-60 - Systems containing oil.

Code of Federal Regulations, 2012 CFR

2012-10-01

... °F must be of seamless steel. (See § 56.50-65 of this part.) (k) Oil piping drains, strainers and... is of steel construction, all welded, and not concealed. (d) Piping subject to internal head pressure... installed on the outside of the oil tanks must be made of steel, ductile cast iron ASTM A 395 (incorporated...

46 CFR 56.50-60 - Systems containing oil.

Code of Federal Regulations, 2011 CFR

2011-10-01

... °F must be of seamless steel. (See § 56.50-65 of this part.) (k) Oil piping drains, strainers and... is of steel construction, all welded, and not concealed. (d) Piping subject to internal head pressure... installed on the outside of the oil tanks must be made of steel, ductile cast iron ASTM A 395 (incorporated...

46 CFR 56.50-60 - Systems containing oil.

Code of Federal Regulations, 2010 CFR

2010-10-01

... °F must be of seamless steel. (See § 56.50-65 of this part.) (k) Oil piping drains, strainers and... is of steel construction, all welded, and not concealed. (d) Piping subject to internal head pressure... installed on the outside of the oil tanks must be made of steel, ductile cast iron ASTM A 395 (incorporated...

46 CFR 56.50-60 - Systems containing oil.

Code of Federal Regulations, 2013 CFR

2013-10-01

... °F must be of seamless steel. (See § 56.50-65 of this part.) (k) Oil piping drains, strainers and... is of steel construction, all welded, and not concealed. (d) Piping subject to internal head pressure... installed on the outside of the oil tanks must be made of steel, ductile cast iron ASTM A 395 (incorporated...

49 CFR 195.205 - Repair, alteration and reconstruction of aboveground breakout tanks that have been in service.

Code of Federal Regulations, 2010 CFR

2010-10-01

..., examination, and material requirements of those respective standards. (3) For high pressure tanks built to API... service must be capable of withstanding the internal pressure produced by the hazardous liquid to be... approximately atmospheric pressure constructed of carbon and low alloy steel, welded or riveted, and non...

Syllabus in Trade Welding.

ERIC Educational Resources Information Center

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

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

Filler wire for aluminum alloys and method of welding

NASA Technical Reports Server (NTRS)

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

2003-01-01

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

Modeling of plasma and thermo-fluid transport in hybrid welding

NASA Astrophysics Data System (ADS)

Ribic, Brandon D.

Hybrid welding combines a laser beam and electrical arc in order to join metals within a single pass at welding speeds on the order of 1 m min -1. Neither autonomous laser nor arc welding can achieve the weld geometry obtained from hybrid welding for the same process parameters. Depending upon the process parameters, hybrid weld depth and width can each be on the order of 5 mm. The ability to produce a wide weld bead increases gap tolerance for square joints which can reduce machining costs and joint fitting difficulty. The weld geometry and fast welding speed of hybrid welding make it a good choice for application in ship, pipeline, and aerospace welding. Heat transfer and fluid flow influence weld metal mixing, cooling rates, and weld bead geometry. Cooling rate affects weld microstructure and subsequent weld mechanical properties. Fluid flow and heat transfer in the liquid weld pool are affected by laser and arc energy absorption. The laser and arc generate plasmas which can influence arc and laser energy absorption. Metal vapors introduced from the keyhole, a vapor filled cavity formed near the laser focal point, influence arc plasma light emission and energy absorption. However, hybrid welding plasma properties near the opening of the keyhole are not known nor is the influence of arc power and heat source separation understood. A sound understanding of these processes is important to consistently achieving sound weldments. By varying process parameters during welding, it is possible to better understand their influence on temperature profiles, weld metal mixing, cooling rates, and plasma properties. The current literature has shown that important process parameters for hybrid welding include: arc power, laser power, and heat source separation distance. However, their influence on weld temperatures, fluid flow, cooling rates, and plasma properties are not well understood. Modeling has shown to be a successful means of better understanding the influence of processes parameters on heat transfer, fluid flow, and plasma characteristics for arc and laser welding. However, numerical modeling of laser/GTA hybrid welding is just beginning. Arc and laser welding plasmas have been previously analyzed successfully using optical emission spectroscopy in order to better understand arc and laser plasma properties as a function of plasma radius. Variation of hybrid welding plasma properties with radial distance is not known. Since plasma properties can affect arc and laser energy absorption and weld integrity, a better understanding of the change in hybrid welding plasma properties as a function of plasma radius is important and necessary. Material composition influences welding plasma properties, arc and laser energy absorption, heat transfer, and fluid flow. The presence of surface active elements such as oxygen and sulfur can affect weld pool fluid flow and bead geometry depending upon the significance of heat transfer by convection. Easily vaporized and ionized alloying elements can influence arc plasma characteristics and arc energy absorption. The effects of surface active elements on heat transfer and fluid flow are well understood in the case of arc and conduction mode laser welding. However, the influence of surface active elements on heat transfer and fluid flow during keyhole mode laser welding and laser/arc hybrid welding are not well known. Modeling has been used to successfully analyze the influence of surface active elements during arc and conduction mode laser welding in the past and offers promise in the case of laser/arc hybrid welding. A critical review of the literature revealed several important areas for further research and unanswered questions. (1) The understanding of heat transfer and fluid flow during hybrid welding is still beginning and further research is necessary. (2) Why hybrid welding weld bead width is greater than that of laser or arc welding is not well understood. (3) The influence of arc power and heat source separation distance on cooling rates during hybrid welding are not known. (4) Convection during hybrid welding is not well understood despite its importance to weld integrity. (5) The influence of surface active elements on weld geometry, weld pool temperatures, and fluid flow during high power density laser and laser/arc hybrid welding are not known. (6) Although the arc power and heat source separation distance have been experimentally shown to influence arc stability and plasma light emission during hybrid welding, the influence of these parameters on plasma properties is unknown. (7) The electrical conductivity of hybrid welding plasmas is not known, despite its importance to arc stability and weld integrity. In this study, heat transfer and fluid flow are analyzed for laser, gas tungsten arc (GTA), and laser/GTA hybrid welding using an experimentally validated three dimensional phenomenological model. By evaluating arc and laser welding using similar process parameters, a better understanding of the hybrid welding process is expected. The role of arc power and heat source separation distance on weld depth, weld pool centerline cooling rates, and fluid flow profiles during CO2 laser/GTA hybrid welding of 321 stainless steel are analyzed. Laser power is varied for a constant heat source separation distance to evaluate its influence on weld temperatures, weld geometry, and fluid flow during Nd:YAG laser/GTA hybrid welding of A131 structural steel. The influence of oxygen and sulfur on keyhole and weld bead geometry, weld temperatures, and fluid flow are analyzed for high power density Yb doped fiber laser welding of (0.16 %C, 1.46 %Mn) mild steel. Optical emission spectroscopy was performed on GTA, Nd:YAG laser, and Nd:YAG laser/GTA hybrid welding plasmas for welding of 304L stainless steel. Emission spectroscopy provides a means of determining plasma temperatures and species densities using deconvoluted measured spectral intensities, which can then be used to calculate plasma electrical conductivity. In this study, hybrid welding plasma temperatures, species densities, and electrical conductivities were determined using various heat source separation distances and arc currents using an analytical method coupled calculated plasma compositions. As a result of these studies heat transfer by convection was determined to be dominant during hybrid welding of steels. The primary driving forces affecting hybrid welding fluid flow are the surface tension gradient and electromagnetic force. Fiber laser weld depth showed a negligible change when increasing the (0.16 %C, 1.46 %Mn) mild steel sulfur concentration from 0.006 wt% to 0.15 wt%. Increasing the dissolved oxygen content in weld pool from 0.0038 wt% to 0.0257 wt% increased the experimental weld depth from 9.3 mm to 10.8 mm. Calculated partial pressure of carbon monoxide increased from 0.1 atm to 0.75 atm with the 0.0219 wt% increase in dissolved oxygen in the weld metal and may explain the increase in weld depth. Nd:YAG laser/GTA hybrid welding plasma temperatures were calculated to be approximately between 7927 K and 9357 K. Increasing the Nd:YAG laser/GTA hybrid welding heat source separation distance from 4 mm to 6 mm reduced plasma temperatures between 500 K and 900 K. Hybrid welding plasma total electron densities and electrical conductivities were on the order of 1 x 1022 m-3 and 3000 S m-1, respectively.

Programmable Positioner For Spot Welding

NASA Technical Reports Server (NTRS)

Roden, William A.

1989-01-01

Welding station mechanized by installing preset indexing system and gear drive. Mechanism includes a low-cost, versatile, single-axis motion control and motor drive to provide fully-automatic weld sequencing and spot-to-spot spacing. Welding station relieves operator of some difficult, tedious tasks and increases both productivity and quality of welds. Results in welds of higher quality and greater accuracy, fewer weld defects, and faster welding operation.

Welding polarity effects on weld spatters and bead geometry of hyperbaric dry GMAW

NASA Astrophysics Data System (ADS)

Xue, Long; Wu, Jinming; Huang, Junfen; Huang, Jiqiang; Zou, Yong; Liu, Jian

2016-03-01

Welding polarity has influence on welding stability to some extent, but the specific relationship between welding polarity and weld quality has not been found, especially under the hyperbaric environment. Based on a hyperbaric dry welding experiment system, gas metal arc welding(GMAW) experiments with direct current electrode positive(DCEP) and direct current electrode negative(DCEN) operations are carried out under the ambient pressures of 0.1 MPa, 0.4 MPa, 0.7 MPa and 1.0 MPa to find the influence rule of different welding polarities on welding spatters and weld bead geometry. The effects of welding polarities on the weld bead geometry such as the reinforcement, the weld width and the penetration are discussed. The experimental results show that the welding spatters gradually grow in quantity and size for GMAW with DCEP, while GMAW with DCEN can produce fewer spatters comparatively with the increase of the ambient pressure. Compared with DCEP, the welding current and arc voltage waveforms for DCEN is more stable and the distribution of welding current probability density for DCEN is more concentrated under the hyperbaric environment. When the ambient pressure is increased from 0.1 MPa to 1.0 MPa, the effects of welding polarities on the reinforcement, the weld width and the penetration are as follows: an increase of 0.8 mm for the weld reinforcement is produced by GMAW with DCEN and 1.3 mm by GMAW with DCEP, a decrease of 7.2 mm for the weld width is produced by DCEN and 6.1 mm by DCEP; and an increase of 3.9 mm for the penetration is produced by DCEN and 1.9 mm by DCEP. The proposed research indicates that the desirable stability in the welding procedure can be achieved by GMAW with DCEN operation under the hyperbaric environment.

Strengthening core public health capacity based on the implementation of the International Health Regulations (IHR) (2005): Chinese lessons

PubMed Central

Liu, Bin; Sun, Yan; Dong, Qian; Zhang, Zongjiu; Zhang, Liang

2015-01-01

As an international legal instrument, the International Health Regulations (IHR) is internationally binding in 196 countries, especially in all the member states of the World Health Organization (WHO). The IHR aims to prevent, protect against, control, and respond to the international spread of disease and aims to cut out unnecessary interruptions to traffic and trade. To meet IHR requirements, countries need to improve capacity construction by developing, strengthening, and maintaining core response capacities for public health risk and Public Health Emergency of International Concern (PHEIC). In addition, all the related core capacity requirements should be met before June 15, 2012. If not, then the deadline can be extended until 2016 upon request by countries. China has promoted the implementation of the IHR comprehensively, continuingly strengthening the core public health capacity and advancing in core public health emergency capacity building, points of entry capacity building, as well as risk prevention and control of biological events (infectious diseases, zoonotic diseases, and food safety), radiological, nuclear, and chemical events, and other catastrophic events. With significant progress in core capacity building, China has dealt with many public health emergencies successfully, ensuring that its core public health capacity has met the IHR requirements, which was reported to WHO in June 2014. This article describes the steps, measures, and related experiences in the implementation of IHR in China. PMID:26029897

Effect of Different Chromium Additions on the Microstructure and Mechanical Properties of Multipass Weld Joint of Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Kang, Dong Hoon; Lee, Hae Woo

2012-12-01

The correlation between the mechanical properties and ferrite volume fraction (approximately 40, 50, and 60 Ferrite Number [FN]) in duplex stainless steel weld metals were investigated by changing the Cr content in filler wires with a flux-cored arc-welding (FCAW) process. The interpass temperature was thoroughly maintained under a maximum of 423 K (150 °C), and the heat input was also sustained at a level under 15 KJ/cm in order to minimize defects. The microstructure examination demonstrated that the δ-ferrite volume fraction in the deposited metals increased as the Cr/Ni equivalent ratio increased, and consequently, chromium nitride (Cr2N) precipitation was prone to occur in the ferrite domains due to low solubility of nitrogen in this phase. Thus, more dislocations are pinned by the precipitates, thereby lowering the mobility of the dislocations. Not only can this lead to the strength improvement, but also it can accentuate embrittlement of the weld metal at subzero temperature. Additionally, the solid-solution strengthening by an increase of Cr and Mo content in austenite phase depending on the reduction of austenite proportion also made an impact on the increase of the tensile and yield strength. On the other hand, the impact test (at 293 K, 223 K, and 173 K [20 °C, -50 °C, and -100 °C]) showed that the specimen containing about 40 to 50 FN had the best result. The absorbed energy of about 40 to 50 J sufficiently satisfied the requirements for industrial applications at 223 K (-50 °C), while the ductile-to-brittle transition behavior exhibited in weldment containing 60 FN. As the test temperature decreased under 223 K (-50 °C), a narrow and deep dimple was transformed into a wide and shallow dimple, and a significant portion of the fracture surface was occupied by a flat cleavage facet with river patterns.

Airborne exposure to inhalable hexavalent chromium in welders and other occupations: Estimates from the German MEGA database.

PubMed

Pesch, Beate; Kendzia, Benjamin; Hauptmann, Kristin; Van Gelder, Rainer; Stamm, Roger; Hahn, Jens-Uwe; Zschiesche, Wolfgang; Behrens, Thomas; Weiss, Tobias; Siemiatycki, Jack; Lavoué, Jerome; Jöckel, Karl-Heinz; Brüning, Thomas

2015-07-01

This study aimed to estimate occupational exposure to inhalable hexavalent chromium (Cr(VI)) using the exposure database MEGA. The database has been compiling Cr(VI) concentrations and ancillary data about measurements at German workplaces. We analysed 3659 personal measurements of inhalable Cr(VI) collected between 1994 and 2009. Cr(VI) was determined spectrophotometrically at 540 nm after reaction with diphenylcarbazide. We assigned the measurements to pre-defined at-risk occupations using the information provided about the workplaces. Two-thirds of the measurements were below the limit of quantification (LOQ) and multiply imputed according to the distribution above LOQ. The 75th percentile value was 5.2 μg/m(3) and the 95th percentile was 57.2 μg/m(3). We predicted the geometric mean for 2h sampling in the year 2000, and the time trend of Cr(VI) exposure in these settings with and without adjustment for the duration of measurements. The largest dataset was available for welding (N = 1898), which could be further detailed according to technique. The geometric means were above 5 μg/m(3) in the following situations: spray painting, shielded metal arc welding, and flux-cored arc welding if applied to stainless steel. The geometric means were between 1 μg/m(3) and 5 μg/m(3) for gas metal arc welding of stainless steel, cutting, hard-chromium plating, metal spraying and in the chemical chromium industry. The exposure profiles described here are useful for epidemiologic and industrial health purposes. Exposure to Cr(VI) varies not only between occupations, but also within occupations as shown for welders. In epidemiologic studies, it would be desirable to collect exposure-specific information in addition to the job title. Copyright © 2015 Elsevier GmbH. All rights reserved.

Friction Stir Welding

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.

2008-01-01

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

Evaluating the SCC resistance of underwater welds in sodium tetrathionate

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

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

1997-12-01

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

Production of ozone and reactive oxygen species after welding.

PubMed

Liu, H H; Wu, Y C; Chen, H L

2007-11-01

Many toxic substances including heavy metals, ozone, carbon monoxide, carbon dioxide, and nitrogen oxides are generated during welding. Ozone (O(3)) is a strong oxidant that generates reactive oxygen species (ROS) in tissue, and ambient ROS exposure associated with particles has been determined to cause DNA damage. Ozone is produced within 30 seconds during welding. However, the length of time that O(3) remains in the air after welding is completed (post-welding) is unknown. The current study aimed to assess the distributions of ambient ROS and O(3) before the start of welding (pre-welding), during welding, and after welding. The highest O(3) levels, equal to 195 parts per billion (ppb), appeared during welding. Ozone levels gradually decreased to 60 ppb 10 minutes after the welding was completed. The highest ROS level was found in samples taken during welding, followed by samples taken after the welding was completed. The lowest ROS level was found in samples taken before the welding had started. Ozone and ROS levels were poorly correlated, but a similar trend was found for O(3) and ROS levels in particles (microM/mg). Although particles were not generated after welding, ROS and O(3) still persisted for more than 10 minutes. Meanwhile, because O(3) continues after welding, how long the occupational protective system should be used depends on the welding materials and the methods used. In addition, the relationship between metal fumes and ROS generation during the welding process should be further investigated.

Automatic welding systems for large ship hulls

NASA Astrophysics Data System (ADS)

Arregi, B.; Granados, S.; Hascoet, JY.; Hamilton, K.; Alonso, M.; Ares, E.

2012-04-01

Welding processes represents about 40% of the total production time in shipbuilding. Although most of the indoor welding work is automated, outdoor operations still require the involvement of numerous operators. To automate hull welding operations is a priority in large shipyards. The objective of the present work is to develop a comprehensive welding system capable of working with several welding layers in an automated way. There are several difficulties for the seam tracking automation of the welding process. The proposed solution is the development of a welding machine capable of moving autonomously along the welding seam, controlling both the position of the torch and the welding parameters to adjust the thickness of the weld bead to the actual gap between the hull plates.

Effect of friction stir welding parameters on defect formation

NASA Astrophysics Data System (ADS)

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

2015-10-01

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

Non-destructive Magnetic Evaluation of Laser Weld Quality in Hot Rolled Coils

NASA Astrophysics Data System (ADS)

Mohapatra, J. N.; Chakradhar, I.; Rao, K. R. C.; Rao, V. V. L.; Kaza, Marutiram

2015-06-01

Weld quality evaluation was conducted on laser welded thin sectsions (2 mm) of hot-rolled (HR) low-carbon steel coils during cold rolling process. The analysis revealed that the poor welds consisting of the weld defects like incomplete fusion, cluster of porosity, and large difference in hardness between the weld zone and base metal were responsible for the weld failures. Experiments were conducted by varying the welding parameters; laser power and welding speed to optimize the parameters for minimizing the weld defects. The optimized weld process parameters have helped elimination of weld defects and the results are verified with microscopy and microhardness measurements. As destructive evaluation techniques are time consuming and not always permitted in industrial applications, attempts have been made in the present investigation for the utilization of suitable non-destructive techniques for the evaluation of weld quality. Non-destructive magnetic techniques of magnetic hysteresis loop and magnetic Barkhausen emissions were used in the present investigation to establish possible correlations of magnetic properties across the weld seam with the mechanical property (microhardness) for evaluation of weld quality. It is inferred that the magnetic properties of coercivity and inverse of root mean square voltage can be effectively utilized to determine weld quality in HR steel coils.

Tool For Friction Stir Tack Welding of Aluminum Alloys

NASA Technical Reports Server (NTRS)

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

2003-01-01

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

Correlation analysis of the variation of weld seam and tensile strength in laser welding of galvanized steel

NASA Astrophysics Data System (ADS)

Sinha, Amit Kumar; Kim, Duck Young; Ceglarek, Darek

2013-10-01

Many advantages of laser welding technology such as high speed and non-contact welding make the use of the technology more attractive in the automotive industry. Many studies have been conducted to search the optimal welding condition experimentally that ensure the joining quality of laser welding that relies both on welding system configuration and welding parameter specification. Both non-destructive and destructive techniques, for example, ultrasonic inspection and tensile test are widely used in practice for estimating the joining quality. Non-destructive techniques are attractive as a rapid quality testing method despite relatively low accuracy. In this paper, we examine the relationship between the variation of weld seam and tensile shear strength in the laser welding of galvanized steel in a lap joint configuration in order to investigate the potential of the variation of weld seam as a joining quality estimator. From the experimental analysis, we identify a trend in between maximum tensile shear strength and the variation of weld seam that clearly supports the fact that laser welded parts having larger variation in the weld seam usually have lower tensile strength. The discovered relationship leads us to conclude that the variation of weld seam can be used as an indirect non-destructive testing method for estimating the tensile strength of the welded parts.

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.

Recent Developments and Research Progress on Friction Stir Welding of Titanium Alloys: An Overview

NASA Astrophysics Data System (ADS)

Karna, Sivaji; Cheepu, Muralimohan; Venkateswarulu, D.; Srikanth, V.

2018-03-01

Titanium and its alloys are joined by various welding processes. However, Fusion welding of titanium alloys resulted solidification problems like porosity, segregation and columnar grains. The problems occurred in conventional welding processes can be resolved using a solid state welding i.e. friction stir welding. Aluminium and Magnesium alloys were welded by friction stir welding. However alloys used for high temperature applications such as titanium alloys and steels are arduous to weld using friction stir welding process because of tool limitations. Present paper summarises the studies on joining of Titanium alloys using friction stir welding with different tool materials. Selection of tool material and effect of welding conditions on mechanical and microstructure properties of weldments were also reported. Major advantage with friction stir welding is, we can control the welding temperature above or below β-transus temperature by optimizing the process parameters. Stir zone in below beta transus condition consists of bi-modal microstructure and microstructure in above β-transus condition has large prior β- grains and α/β laths present in the grain. Welding experiments conducted below β- transus condition has better mechanical properties than welding at above β-transus condition. Hardness and tensile properties of weldments are correlated with the stir zone microstructure.

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.

Welding characteristics of 27, 40 and 67 kHz ultrasonic plastic welding systems using fundamental- and higher-resonance frequencies.

PubMed

Tsujino, Jiromaru; Hongoh, Misugi; Yoshikuni, Masafumi; Hashii, Hidekazu; Ueoka, Tetsugi

2004-04-01

The welding characteristics of 27, 40 and 67 kHz ultrasonic plastic welding systems that are driven at only the fundamental-resonance frequency vibration were compared, and also those of the welding systems that were driven at the fundamental and several higher resonance frequencies simultaneously were studied. At high frequency, welding characteristics can be improved due to the larger vibration loss of plastic materials. For welding of rather thin or small specimens, as the fundamental frequency of these welding systems is higher and the numbers of driven higher frequencies are driven simultaneously, larger welded area and weld strength were obtained.

Intelligent Modeling Combining Adaptive Neuro Fuzzy Inference System and Genetic Algorithm for Optimizing Welding Process Parameters

NASA Astrophysics Data System (ADS)

Gowtham, K. N.; Vasudevan, M.; Maduraimuthu, V.; Jayakumar, T.

2011-04-01

Modified 9Cr-1Mo ferritic steel is used as a structural material for steam generator components of power plants. Generally, tungsten inert gas (TIG) welding is preferred for welding of these steels in which the depth of penetration achievable during autogenous welding is limited. Therefore, activated flux TIG (A-TIG) welding, a novel welding technique, has been developed in-house to increase the depth of penetration. In modified 9Cr-1Mo steel joints produced by the A-TIG welding process, weld bead width, depth of penetration, and heat-affected zone (HAZ) width play an important role in determining the mechanical properties as well as the performance of the weld joints during service. To obtain the desired weld bead geometry and HAZ width, it becomes important to set the welding process parameters. In this work, adaptative neuro fuzzy inference system is used to develop independent models correlating the welding process parameters like current, voltage, and torch speed with weld bead shape parameters like depth of penetration, bead width, and HAZ width. Then a genetic algorithm is employed to determine the optimum A-TIG welding process parameters to obtain the desired weld bead shape parameters and HAZ width.

Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

NASA Astrophysics Data System (ADS)

Vasantharaja, P.; Vasudevan, M.

2012-02-01

Low Activation Ferritic-Martensitic steels (LAFM) are chosen as the candidate material for structural components in fusion reactors. The structural components are generally fabricated by welding processes. Activated Tungsten Inert Gas (A-TIG) welding is an emerging process for welding of thicker components. In the present work, attempt was made to develop A-TIG welding technology for LAFM steel plates of 10 mm thick. Activated flux was developed for LAFM steel by carrying out various bead-on-plate TIG welds without flux and with flux. The optimum flux was identified as one which gave maximum depth of penetration at minimum heat input values. With the optimized flux composition, LAFM steel plate of 10 mm thickness was welded in square butt weld joint configuration using double side welding technique. Optical and Scanning Electron Microscopy was used for characterizing the microstructures. Microhardness measurements were made across the weld cross section for as welded and post weld heat treated samples. Tensile and impact toughness properties were determined. The mechanical properties values obtained in A-TIG weld joint were comparable to that obtained in weld joints of LAFM steel made by Electron beam welding process.

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

NASA Astrophysics Data System (ADS)

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

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

Superplastic Forming of Duplex Stainless Steel for Aerospace Part

NASA Astrophysics Data System (ADS)

Lee, Ho-Sung; Yoon, Jong-Hoon; Yoo, Joon-Tae; Yi, Young-Moo

2011-08-01

In this study, the high temperature forming behavior of duplex stainless steel has been characterized and the outer shell of a combustion chamber was fabricated with pressure difference of hot gas. It consists of two parts which are the outer skin made of stainless steel to sustain the internal pressure and the inner shell made of copper alloy for regenerative cooling channels. Two outer skins partitioned to half with respect to the symmetric axis was prepared by hot gas forming process with a maximum pressure of 7 MPa following to FEM analysis. For inner layer, copper alloy was machined for cooling channels and then placed in the gas pressure welding fixture. It is shown that the optimum condition of gas pressure welding is 7 MPa at 890 °C, for one hour. EDX analysis and scanning electron microscope micrograph confirm the atomic diffusion process is observed at the interface and copper atoms diffuse into steel, while iron and chrome atoms diffuse into copper. The result shows that the manufacturing method with superplastic forming and gas pressure welding of steel and copper alloy has been successful for near net shape manufacturing of scaled combustion chamber of launch vehicle.

Method of fabricating a flow device

DOEpatents

Hale, Robert L.

1978-01-01

This invention is a novel method for fabricating leak-tight tubular articles which have an interior flow channel whose contour must conform very closely with design specifications but which are composed of metal which tends to warp if welded. The method comprises designing two longitudinal half-sections of the article, the half-sections being contoured internally to cooperatively form the desired flow passageway. Each half-section is designed with a pair of opposed side flanges extending between the end flanges and integral therewith. The half-sections are positioned with their various flanges in confronting relation and with elongated metal gaskets extending between the confronting flanges for the length of the array. The gaskets are a deformable metal which is fusion-weldable to the end flanges. The mating side flanges are joined mechanically to deform the gaskets and provide a longitudinally sealed assembly. The portions of the end flanges contiguous with the ends of the gaskets then are welded to provide localized end welds which incorporate ends of the gaskets, thus transversely sealing the assembly. This method of fabrication provides leak-tight articles having the desired precisely contoured flow channels, whereas various conventional methods have been found unsatisfactory.

Survey of welding processes.

DOT National Transportation Integrated Search

2003-07-01

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

Effect of Shielding Gas on the Properties of AW 5083 Aluminum Alloy Laser Weld Joints

NASA Astrophysics Data System (ADS)

Vyskoč, Maroš; Sahul, Miroslav; Sahul, Martin

2018-04-01

The paper deals with the evaluation of the shielding gas influence on the properties of AW 5083 aluminum alloy weld joints produced with disk laser. Butt weld joints were produced under different shielding gas types, namely Ar, He, Ar + 5 vol.% He, Ar + 30 vol.% He and without shielding weld pool. Light and electron microscopy, computed tomography, microhardness measurements and tensile testing were used for evaluation of weld joint properties. He-shielded weld joints were the narrowest ones. On the other hand, Ar-shielded weld joints exhibited largest weld width. The choice of shielding gas had significant influence on the porosity level of welds. The lowest porosity was observed in weld joint produced in Ar with the addition of 5 vol.% He shielding atmosphere (only 0.03%), while the highest level of porosity was detected in weld joint produced in pure He (0.24%). Except unshielded aluminum alloy weld joint, the lowest tensile strength was recorded in He-shielded weld joints. On the contrary, the highest average microhardness was measured in He-shielded weld joints.