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Sample records for laser-tig hybrid welding

  1. Study on microstructure and mechanical properties of 304 stainless steel joints by TIG, laser and laser -TIG hybrid welding

    NASA Astrophysics Data System (ADS)

    Yan, Jun; Gao, Ming; Zeng, Xiaoyan

    2010-04-01

    This paper investigated the microstructure and mechanical properties of 304 stainless steel joints by tungsten inert gas (TIG) welding, laser welding and laser-TIG hybrid welding. The X-ray diffraction was used to analyze the phase composition, while the microscopy was conducted to study the microstructure characters of joints. Finally, tensile tests were performed and the fracture surfaces were analyzed. The results showed that the joint by laser welding had highest tensile strength and smallest dendrite size in all joints, while the joint by TIG welding had lowest tensile strength, biggest dendrite size. Furthermore, transition zone and heat affected zone can be observed in the joint of TIG welding. The fractograph observation showed that the TIG welding joint existed as cup-cone shaped fracture, while the laser welding and hybrid welding joints existed as pure-shear fracture. The laser welding and hybrid welding are suitable for welding 304 stainless steel owing to their high welding speed and excellent mechanical properties.

  2. Laser-TIG Welding of Titanium Alloys

    NASA Astrophysics Data System (ADS)

    Turichin, G.; Tsibulsky, I.; Somonov, V.; Kuznetsov, M.; Akhmetov, A.

    2016-08-01

    The article presents the results of investigation the technological opportunity of laser-TIG welding of titanium alloys. The experimental stand for implementation of process with the capability to feed a filler wire was made. The research of the nature of transfer the filler wire into the welding pool has been demonstrated. The influence of distance between the electrode and the surface of the welded plates on the stability of the arc was shown. The relationship between welding velocity, the position of focal plane of the laser beam and the stability of penetration of plates was determined.

  3. Microstructure characteristics and mechanical properties of laser-TIG hybrid welded dissimilar joints of Ti-22Al-27Nb and TA15

    NASA Astrophysics Data System (ADS)

    Zhang, Kezhao; Lei, Zhenglong; Chen, Yanbin; Liu, Ming; Liu, Yang

    2015-10-01

    Laser-TIG-hybrid-welding (TIG - tungsten inert gas) process was successfully applied to investigate the microstructure and tensile properties of Ti-22Al-27Nb/TA15 dissimilar joints. The HAZ of the arc zone in Ti-22Al-27Nb was characterized by three different regions: single B2, B2+α2 and B2+α2+O, while the single B2 phase region was absent in the HAZ of the laser zone. As for the HAZ in TA15 alloy, the microstructure mainly contained acicular α‧ martensites near the fusion line and partially remained the lamellar structure near the base metal. The fusion zone consisted of B2 phase due to the relatively high content of β phase stabilizing elements and fast cooling rate during the welding process. The tensile strength of the welds was higher than that of TA15 alloy because of the fully B2 microstructure in the fusion zone, and the fracture preferentially occurred on the base metal of TA15 alloy during the tensile tests at room temperature and 650 °C.

  4. The influence of laser pulse waveform on laser-TIG hybrid welding of AZ31B magnesium alloy

    NASA Astrophysics Data System (ADS)

    Song, Gang; Luo, Zhimin

    2011-01-01

    By dividing laser pulse duration into two parts, three kinds of laser waveforms are designed, including a high power density pulse (HPDP) laser in a short duration set at the beginning of the laser waveform. This paper aims to find out the laser pulse waveform and idiographic critical values of HPDP, which can affect the magnesium penetration in laser-tungsten inert gas (TIG) hybrid welding. Results show that when the laser pulse duration of HPDP is not more than 0.4 ms, the welding penetration values of lasers with HPDP are larger than otherwise. Also, the welding penetration values of laser with HPDP have increased by up to 26.1%. It has been found that with HPDP, the laser can form the keyhole more easily because the interaction between laser and the plate is changed, when the TIG arc preheats the plate. Besides, the laser with high power density and short duration strikes on the plates so heavily that the corresponding background power can penetrate into the bottom of the keyhole and maintain the keyhole open, which facilitates the final welding penetration.

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

    NASA Astrophysics Data System (ADS)

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

    2013-02-01

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

  6. Ultrasonic Welding of Hybrid Joints

    NASA Astrophysics Data System (ADS)

    Wagner, Guntram; Balle, Frank; Eifler, Dietmar

    2012-03-01

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

  7. Evolution of a Laser Hybrid Welding Map

    NASA Astrophysics Data System (ADS)

    Kaplan, Alexander F. H.; Frostevarg, Jan; Ilar, Torbjörn; Bang, Hee-Seon; Bang, Han-Sur

    Laser arc hybrid welding combines the advantages but also the complex physical mechanisms of gas metal arc welding and laser keyhole welding. From manifold mainly experimental but also theoretical research results a map with versatile functions was initiated for the first time. The purpose is to survey the overall context and to facilitate navigation to the various phenomena that are shown through case studies accompanied by theoretical explanations and guidelines for optimization. Though not complete, the map enables systematic and graphical navigation to relevant publications. Based on a fundamental structure of the map, which was decided early, it is inherently extendable in the future by adding existing and new knowledge, also from other research groups, enabling evolution. The fundament of the map structure comprises gouge thickness, joint type and metal grade, in coherence with product and weld designers' starting points. The next hierarchy level of the map offers options in the joint type as well as in hybrid welding techniques. The latter contains techniques like double-sided welding, pulse shaping management of the arc or laser, CMT arcs, tandem arcs, or remelting of undercuts. In addition to laser-arc hybrid welding, other hybrid laser techniques like multilayer hot-wire laser welding of narrow gaps or hybrid laser friction stir welding can be taken into account. At the other end of the hierarchy, the map offers via a database-like archive electronic navigation to research results like weld macrographs, high speed imaging or numerical simulation results of the welding process.

  8. Coaxial hybrid CO2-MIG welding system and its application in welding of aluminum alloys

    NASA Astrophysics Data System (ADS)

    Zhang, Xudong; Chen, Wuzhu; Shuang, Yuanqing; Wang, Kangjian

    2005-01-01

    Hybrid laser-arc welding is becoming one of the most significant laser welding technologies in industry due to its higher welding efficiency, higher tolerance to gaps between plates, and adjustment of composition and microstructure of the weld metal. Comparing with common off axis hybrid laser-arc welding, coaxially combined laser beam and arc can provide a symmetrical circular thermal source on the workpiece surface, which is convenient for 3-D welding. This paper introduces a coaxial hybrid CO2 laser-pulsed MIG welding system and conducts experiments of welding Al-Mg alloy plates under different welding conditions. The basic physical phenomena during welding are observed and the weld bead shape (penetration depth, weld width) are measured. The results show that hybrid laser-MIG can stabilize the arc, remarkably increase the total welding efficiency and improve the quality of weld bead formation. In addition, process and control techniques for hybrid laser-MIG welding are also proposed.

  9. LaserHybrid welding for industrial applications

    NASA Astrophysics Data System (ADS)

    Staufer, H.

    2007-05-01

    In view of the demands made by the end users in the field of application of vehicle construction for an ever-higher product quality and improved performance, continuous innovations are considered to be absolutely decisive for being successful. This especially applies to the welding technology, and therefore the goal is to develop new, better and more powerful welding processes. In joining technology the high welding speed on the one and the good gap bridging ability on the other hand play a significant part. However, both features cannot be achieved by conventional laser welding processes. Therefore, a hybrid process is being. It is no doubt that the laser beam welding and the MIG welding have been established in the welding technology for very long, and that both processes allow a wide field of application in the joining technology. New possibilities and synergetic effects, however, are based on the combination of both processes.

  10. 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.

  11. Hybrid Laser-Arc Welding Tanks Steels

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

  13. Optimization of parameters in hybrid welding of aluminum alloy

    NASA Astrophysics Data System (ADS)

    Jokinen, Tommi; Jernstroem, Petteri; Karhu, Miikka; Vanttaja, Ilkka; Kujanpaeae, Veli

    2003-03-01

    Numerous advantages of hybrid welding, in which laser beam and arc has combined, over autogenous laser welding has been reported. Especially in case of inaccurate joint preparation or fixturing of the plates to be welded because of the filler metal added to the process through MIG-welding. Also additional heat, coming from the arc to the process, enables higher welding speed and deeper penetration. Aluminum alloy (AlMg3) was used in the experiments. Welding was carried out by using the hybrid process (combination of Nd:YAG- and MIG-welding) in the flat position. The joint preparation was carried out as shear cut and different gap widths were used. Welding experiments were made systematically using a statistical experiment procedure called TAGUCHI-method. Parameters, for example alignment of point of arc and laser, varied in experiments. Also characteristic parameters of both welding methods were changed according to the experimental procedure. In this paper results of welding experiments are reported as well as parameters used. A phenomenona of the hybrid process with aluminum is discussed and also reasons for weld defects occurred are pointed out.

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

    NASA Astrophysics Data System (ADS)

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

    2015-03-01

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

  15. Hybrid Welding Possibilities of Thick Sections for Arctic Applications

    NASA Astrophysics Data System (ADS)

    Bunaziv, Ivan; Akselsen, Odd M.; Ren, Xiaobo; Salminen, Antti

    The arctic shelf contains about 20% of all undiscovered hydrocarbons on our planet, therefore oil and gas industry requires advanced steels to be used which withstand appropriate fracture toughness up to -60 °C and suitable welding technologies. High brightness laser with combination with arc source can be appropriate joining process even for very high strength advanced steels above 700 MPa for low temperature applications. Hybrid welding has improved each year becoming more standardized and reliable welding process. However, until now, its application was limited to shipbuilding and pipeline industry. Due to many reasonable advantages, hybrid welding, especially when it is combined with MIG/MAG, can be used in every possible industry. Inherent filler wire addition from the MIG/MAG source can improve fracture toughness at lower temperatures and increase overall productivity. This paper provides information about recent breakthrough in hybrid welding of thick section high-strength steels.

  16. 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.

  17. The effect of welding direction in CO2 LASER - MIG hybrid welding of mild steel plates

    NASA Astrophysics Data System (ADS)

    Abilash, M.; Senthil kumar, D.; Padmanabham, G.; Paniprabhakar; Padmanaban, R.; Thirumalini, S.

    2016-09-01

    In this paper, hybrid laser-arc welding process has been studied based on the relative position of the laser and the arc (i.e. laser-leading and arc-leading arrangement) and, the effects of welding parameters, such as the laser power, arc current, arc voltage and the welding speed on the weld bead were investigated. The study indicates that the welding direction has a significant effect on the weld bead and weld pool behaviour. The result shows that laserleading configuration shows better bead characteristics when compared to arc-leading configuration. This is because in the laser-leading case molten metal flow is inward, while in the arc-leading case the metal flow is outward leading to variation in solidification front resulting in lack of synergic effects of both processes.

  18. Hybrid laser welding techniques for enhanced welding efficiency

    SciTech Connect

    Beyer, E.; Poprawe, R.; Brenner, B.

    1996-12-31

    One of the remarkable characteristics of the laser beam welding process is its thin deep welding seam. This thin seam is produced as a result of the high welding speed and the low heat input, leading to a low distortion. However, the overall electrical efficiency of a CO{sub 2}-laser is in the range of 5-7% and the efficiency of a Nd:YAG-laser is only approximately 2-3%. There are several applications in which the thin laser seam and the high welding speed, in particular, have technical advantages, making the whole process economical. However, there are also a lot of possible applications, for which laser welding is too expensive at the moment or, in which the thin seam leads to a lot of unsolved metallurgical problems. To avoid these problems, a welding technique is presently being developed at the ILT and IWS which combines laser keyhole welding with Tungsten inert gas and metal inert gas welding and introduces an inductor for a preheating and a controlled heat flow. The paper is divided into two sections. The first section describes recent investigations carried out by the ILT into the laser arc combination and the second section describes the combination of the laser and induction techniques, presenting also an application presently being used in production in the car industry. This work has been completed by the Fraunhofer-Institut fur Werkstoffphysik und Schichttechnologie IWS in Dresden.

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

    NASA Astrophysics Data System (ADS)

    Mazar Atabaki, Mehdi

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

  20. Microstructure characteristics of laser MIG hybrid welded mild steel

    NASA Astrophysics Data System (ADS)

    Gao, Ming; Zeng, Xiaoyan; Yan, Jun; Hu, Qianwu

    2008-07-01

    To deepen the understanding of laser-arc hybrid welding, the weld shape and microstructure characteristics of laser-metal inert gas hybrid welded mild steel were analyzed. The results showed typical hybrid weld could be classified as two parts: the wide upper zone and the narrow nether zone, which were defined as arc zone and laser zone, respectively. In the hybrid weld, the microstructure, alloy element distribution and microhardness all have evident difference between laser zone and arc zone. The microstructure of arc zone consists of coarse columnar dendrite and fine acicular dendrite between the columnar dendrites, but that of laser zone is composed of fine equiaxed dendrite in weld center and columnar dendrite around the equiaxed dendrite. Compared to arc zone, laser zone has finer grain size, higher microhardness, smaller alloy element content in the fusion zone and narrower heat affected zone. The discussions demonstrated that the observed difference was caused by the difference of temperature gradient, crystallizing and the effects of arc pressure on the molten pool between laser zone and arc zone.

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

    NASA Astrophysics Data System (ADS)

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

    2006-01-01

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

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

    SciTech Connect

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

    2011-04-15

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

  3. The influence of shielding gas in hybrid LASER MIG welding

    NASA Astrophysics Data System (ADS)

    Tani, Giovanni; Campana, Giampaolo; Fortunato, Alessandro; Ascari, Alessandro

    2007-07-01

    Hybrid LASER-GMAW welding technique has been recently studied and developed in order to meet the needs of modern welding industries. The two sources involved in this process play, in fact, a complementary role: fast welding speed, deep bead penetration and high energy concentration can be achieved through the LASER beam, while gap bridgeability and cost-effectiveness are typical of the GMAW process. Particularly interesting, in this context, is the CO 2 LASER-MIG welding which differs from the Nd:YAG LASER-MIG technique for the high powers that can be exploited and for the good power/cost ratio of the process. This paper is a part of a wide study on the hybrid CO 2 LASER-MIG welding and investigates the influence of the shielding gas both on the stability of the process and on the dimensional characteristics of the weld bead. Two different parameters have been taken into consideration in order to develop this analysis: the shielding gas composition and the shielding gas flow. The experiment, performed on AISI 304 stainless steel plates, has been planned exploiting design of experiment techniques. The results have been analyzed through a statistical approach in order to determine the real influence of each parameter on the overall process.

  4. High Power Laser Hybrid Welding - Challenges and Perspectives

    NASA Astrophysics Data System (ADS)

    Nielsen, Steen Erik

    High power industrial lasers at power levels up to 100 kW is now available on the market. Therefore, welding of thicker materials has become of interest for the heavy metal industry e.g. shipyards and wind mill producers. Further, the power plant industry, producers of steel pipes, heavy machinery and steel producers are following this new technology with great interest. At Lindø Welding Technology (LWT), which is a subsidiary to FORCE Technology, a 32-kwatt disc laser is installed. At this laser facility, welding procedures related to thick section steel applications are developed. Material thicknesses between 40 and 100 mm are currently of interest. This paper describes some of the challenges that are related to the development of the high power hybrid laser welding process as well as to the perspectives for the technology as a production tool for the heavy metal industry.

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

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

  6. 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

  7. Laser-Hybrid welding, an innovative technology to join automotive body parts

    NASA Astrophysics Data System (ADS)

    Sieben, Manuel; Brunnecker, Frank

    The design of Tail lamps has been changed dramatically since cars built. At modern lamps, the lenses are absolutely transparent and allow a direct view onto the weld seam. Conventional welding technologies, such as vibration and hot plate welding cannot compete with this demand. Focused on this targeted application, LPKF Laser & Electronics AG has developed in cooperation with the Bavarian Laser Centre a unique Laser welding technology called hybrid welding.

  8. Hybrid Modeling of Elastic Wave Scattering in a Welded Cylinder

    NASA Astrophysics Data System (ADS)

    Mahmoud, A.; Shah, A. H.; Popplewell, N.

    2003-03-01

    In the present study, a 3D hybrid method, which couples the finite element region with guided elastic wave modes, is formulated to investigate the scattering by a non-axisymmetric crack in a welded steel pipe. The algorithm is implemented on a parallel computing platform. Implementation is facilitated by the dynamic memory allocation capabilities of Fortran 90™ and the parallel processing directives of OpenMp™. The algorithm is validated against available numerical results. The agreement with a previous 2D hybrid model is excellent. Novel results are presented for the scattering of the first longitudinal mode from different non-axisymmetric cracks. The trend of the new results is consistent with the previous findings for the axisymmetric case. The developed model has potential application in ultrasonic nondestructive evaluation of welded steel pipes.

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

    NASA Astrophysics Data System (ADS)

    Kutsuna, Muneharu; Chen, Liang

    2003-03-01

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

  10. Residual Stress and Fatigue Strength of Hybrid Laser-MIG-Welded A7N01P-T4

    NASA Astrophysics Data System (ADS)

    Wang, Qiuying; Chen, Hui; Qiu, Peixian; Zhu, Zongtao

    2016-09-01

    A7N01P-T4 aluminum alloy is widely used in some important welded components of high-speed trains. The hybrid laser-metal inert gas (MIG) welding process was studied to solve problems associated with the MIG welding process, such as low welding efficiency, high residual stress and deformation, and serious loss of strength. A high-speed camera, a voltage and current collection system, and NI DAQ were used to acquire arc profiles, welding voltage, and welding current simultaneously. Thermal cycle tests were carried out. Residual stresses induced by the welding process and fatigue strength of the joint were investigated. Large-size fatigue specimens were used in fatigue tests. The results show that the energy of the hybrid welding process is focused, and the power density of hybrid welding process is intense. The heat input per unit of the hybrid welding process is only half of that of the MIG welding process. Compared with the MIG welded joint, the overall residual stress level of the hybrid-welded joint is lower. The peak longitudinal stress of the hybrid-welded joint is reduced by 20 pct. The fatigue strength of hybrid joints is 14 pct higher than that of MIG-welded joints. Narrow weld and HAZ, weak softening behavior, and low residual stress level are the causes of the improvement of fatigue strength.

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

    NASA Astrophysics Data System (ADS)

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

    2014-04-01

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

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

    NASA Astrophysics Data System (ADS)

    Liu, Liming; Chen, Minghua

    2011-09-01

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

  13. Investigation of mixing and diffusion processes in hybrid spot laser-MIG keyhole welding

    NASA Astrophysics Data System (ADS)

    Zhou, J.; Tsai, H. L.

    2009-05-01

    In hybrid laser-MIG keyhole welding, anti-crack elements can be added into the weld pool through a filler metal in anticipation of compensating mass loss, preventing porosity formation and improving compositional and mechanical properties of the welds. Understanding the mixing and diffusion of the filler metal in the molten pool is vital to achieve these desired objectives. In this study, mathematical models and associated numerical techniques have been developed to investigate the mixing and diffusion processes in hybrid laser-MIG keyhole welding. The transient interactions between droplets and weld pool and dynamics of the melt flow are studied. The effects of key process parameters, such as droplet size (wire diameter), droplet generation frequency (wire feed speed) and droplet impinging speed, on mixing/diffusion are systematically investigated. It was found that compositional homogeneity of the weld pool is determined by the competition between the mixing rate and the solidification rate. A small-size filler droplet together with high generation frequency can increase the latitudinal diffusion of the filler metal into the weld pool, while the large-size droplet along with the low generation frequency helps to get more uniform longitudinal diffusion. Increasing the impinging velocity of the filler droplet can improve the latitudinal diffusion of the filler metal. However, a high impinging velocity can cause a lower diffusion zone in the upper part of the welds. This study provides a good foundation for optimizing the hybrid laser-MIG keyhole welding process to achieve quality welds with desired properties.

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-06-01

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

  16. Towards real time diagnostics of Hybrid Welding Laser/GMAW

    SciTech Connect

    McJunkin, T. R.; Kunerth, D. C.; Nichol, C. I.; Todorov, E.; Levesque, S.

    2014-02-18

    Methods are currently being developed towards a more robust system real time feedback in the high throughput process combining laser welding with gas metal arc welding. A combination of ultrasonic, eddy current, electronic monitoring, and visual techniques are being applied to the welding process. Initial simulation and bench top evaluation of proposed real time techniques on weld samples are presented along with the concepts to apply the techniques concurrently to the weld process. Consideration for the eventual code acceptance of the methods and system are also being researched as a component of this project. The goal is to detect defects or precursors to defects and correct when possible during the weld process.

  17. Towards Real Time Diagnostics of Hybrid Welding Laser/GMAW

    SciTech Connect

    Timothy Mcjunkin; Dennis C. Kunerth; Corrie Nichol; Evgueni Todorov; Steve Levesque; Feng Yu; Robert Danna Couch

    2013-07-01

    Methods are currently being developed towards a more robust system real time feedback in the high throughput process combining laser welding with gas metal arc welding. A combination of ultrasonic, eddy current, electronic monitoring, and visual techniques are being applied to the welding process. Initial simulation and bench top evaluation of proposed real time techniques on weld samples are presented along with the concepts to apply the techniques concurrently to the weld process. Consideration for the eventual code acceptance of the methods and system are also being researched as a component of this project. The goal is to detect defects or precursors to defects and correct when possible during the weld process.

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

    PubMed

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

    2013-04-01

    The plasma radiation of laser-double wire hybrid welding was collected by using fiber spectrometer, the coupling mechanism of arc with laser was studied through high-speed photography during welding process, and the temperature of hybrid plasma was calculated by using the method of Boltzmann plot. The results indicated that with laser hybrid, luminance was enhanced; radiation intensity became stronger; arc was attracted to the laser point; cross section contracted and arc was more stable. The laser power, welding current and arc-arc distance are important factors that have great influence on electron temperature. Increase in the laser power, amplification of welding current and reduction of arc-arc distance can all result in the rise of temperature. PMID:23841392

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

    SciTech Connect

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

    2015-01-01

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

  20. Welding.

    ERIC Educational Resources Information Center

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

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

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

    NASA Astrophysics Data System (ADS)

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

    2011-10-01

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

  2. Thick-section Laser and Hybrid Welding of Austenitic Stainless Steels

    NASA Astrophysics Data System (ADS)

    Kujanpää, Veli

    Austenitic stainless steels are generally known to have very good laser weldability, when ordinary grades of sheets are concerned. But it is not necessarily the case, if special grades of fully austenitic structures with e.g. high molybdenum, or thick-section are used. It is also known that hot cracking susceptibility is strictly controlled by composition and welding parameters. If solidification is primary ferritic, hot cracking resistance is dramatically increased. It is also well known that laser welding needs a careful control of weld edge preparation and air gap between the edges. The dependence on edge quality can be decreased by using filler metal, either cold wire, hot wire or hybrid laser-arc welding. An additional role is high molybdenum contents where micro segregation can cause low local contents in weld which can decrease the corrosion properties, if filler metal is not used. Another feature in laser welding is its incomplete mixing, especially in thick section applications. It causes inhomogeneity, which can make uneven microstructure, as well as uneven mechanical and corrosion properties In this presentation the features of laser welding of thick section austenitic stainless steels are highlighted. Thick section (up to 60 mm) can be made by multi-pass laser or laser hybrid welding. In addition to using filler metal, it requires careful joint figure planning, laser head planning, weld parameter planning, weld filler metal selection, non-destructive and destructive testing and metallography to guarantee high-quality welds in practice. In addition some tests with micro segregation is presented. Also some examples of incomplete mixing is presented.

  3. Modelling grain-scattered ultrasound in austenitic stainless-steel welds: A hybrid model

    SciTech Connect

    Nowers, O.; Duxbury, D. J.; Velichko, A.; Drinkwater, B. W.

    2015-03-31

    The ultrasonic inspection of austenitic stainless steel welds can be challenging due to their coarse grain structure, charaterised by preferentially oriented, elongated grains. The anisotropy of the weld is manifested as both a ‘steering’ of the beam and the back-scatter of energy due to the macroscopic granular structure of the weld. However, the influence of weld properties, such as mean grain size and orientation distribution, on the magnitude of scattered ultrasound is not well understood. A hybrid model has been developed to allow the study of grain-scatter effects in austenitic welds. An efficient 2D Finite Element (FE) method is used to calculate the complete scattering response from a single elliptical austenitic grain of arbitrary length and width as a function of the specific inspection frequency. A grain allocation model of the weld is presented to approximate the characteristic structures observed in austenitic welds and the complete scattering behaviour of each grain calculated. This model is incorporated into a semi-analytical framework for a single-element inspection of a typical weld in immersion. Experimental validation evidence is demonstrated indicating excellent qualitative agreement of SNR as a function of frequency and a minimum SNR difference of 2 dB at a centre frequency of 2.25 MHz. Additionally, an example Monte-Carlo study is presented detailing the variation of SNR as a function of the anisotropy distribution of the weld, and the application of confidence analysis to inform inspection development.

  4. Modelling grain-scattered ultrasound in austenitic stainless-steel welds: A hybrid model

    NASA Astrophysics Data System (ADS)

    Nowers, O.; Duxbury, D. J.; Velichko, A.; Drinkwater, B. W.

    2015-03-01

    The ultrasonic inspection of austenitic stainless steel welds can be challenging due to their coarse grain structure, charaterised by preferentially oriented, elongated grains. The anisotropy of the weld is manifested as both a `steering' of the beam and the back-scatter of energy due to the macroscopic granular structure of the weld. However, the influence of weld properties, such as mean grain size and orientation distribution, on the magnitude of scattered ultrasound is not well understood. A hybrid model has been developed to allow the study of grain-scatter effects in austenitic welds. An efficient 2D Finite Element (FE) method is used to calculate the complete scattering response from a single elliptical austenitic grain of arbitrary length and width as a function of the specific inspection frequency. A grain allocation model of the weld is presented to approximate the characteristic structures observed in austenitic welds and the complete scattering behaviour of each grain calculated. This model is incorporated into a semi-analytical framework for a single-element inspection of a typical weld in immersion. Experimental validation evidence is demonstrated indicating excellent qualitative agreement of SNR as a function of frequency and a minimum SNR difference of 2 dB at a centre frequency of 2.25 MHz. Additionally, an example Monte-Carlo study is presented detailing the variation of SNR as a function of the anisotropy distribution of the weld, and the application of confidence analysis to inform inspection development.

  5. GMA-laser Hybrid Welding of High-strength Fine-grain Structural Steel with an Inductive Preheating

    NASA Astrophysics Data System (ADS)

    Lahdo, Rabi; Seffer, Oliver; Springer, André; Kaierle, Stefan; Overmeyer, Ludger

    The industrial useof GMA-laser hybrid welding has increased in the last 10 years, due to the brilliant quality of the laser beam radiation, and higher laser output powers. GMA-laser hybrid welding processes operate in a common molten pool. The combination of the laser beam and the arc results in improved welding speed, penetration depth, heat affected zone and gap bridgeability. Single-layer, GMA-laser hybrid welding processes have been developed for high-strength fine-grain structural steels with a grade of S690QL and a thickness of 15 mm and 20 mm. In addition, the welding process is assisted by an integrated, inductive preheating process to improve the mechanical properties of the welding seam. By using the determined parameters regarding the energy per unit length, and the preheating temperature, welding seams with high quality can be achieved.

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

    NASA Astrophysics Data System (ADS)

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

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-04-01

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

  8. Effect of Preheating in Hybrid Friction Stir Welding of Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Yaduwanshi, D. K.; Bag, S.; Pal, S.

    2014-10-01

    The controlled energy input into the system by introducing an extra heat source to enhance the material flow along with reduction of the plunging force remains a potential area of considerate for the development of hybrid friction stir welding (FSW) process. Hence, the effect of preheating on the weld joint properties is evaluated using plasma-assisted friction stir welding (P-FSW) process for joining aluminum alloy. A comparative study of mechanical and macro-microstructural characterizations of weld joint by FSW and P-FSW has been performed. Transverse tensile strength of weld joint is approximately 95% of base metal produced by P-FSW and is 8% more than conventional FSW welds. The effect of preheating enhances material flow and dissolution of fine oxide particles by plasma arc results in increase of strength and marginal modification of deformation behavior. The preheating brings uniformly distributed hardness in weld zone and the magnitude is higher in the advancing side with overall increase in average hardness value. Grain sizes are much finer due to the pinning effect of Al2O3 particles that retarded grain growth following recrystallization during P-FSW and thus led to more pronounced reduction in grain size and relatively brittle fracture during tensile loading of welded joint. Overall, the influence of preheating acts quite homogeneously throughout the structure as compared to conventional FSW. However, the results reveal that the development of P-FSW is still in initial stage and needs to improve in various aspects.

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-07-01

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

  12. Control of surface defects on plasma-MIG hybrid welds in cryogenic aluminum alloys

    NASA Astrophysics Data System (ADS)

    Lee, Hee-Keun; Chun, Kwang-San; Park, Sang-Hyeon; Kang, Chung-Yun

    2015-07-01

    Lately, high production rate welding processes for Al alloys, which are used as LNG FPSO cargo containment system material, have been developed to overcome the limit of installation and high rework rates. In particular, plasma-metal inert gas (MIG) hybrid (PMH) welding can be used to obtain a higher deposition rate and lower porosity, while facilitating a cleaning effect by preheating and post heating the wire and the base metal. However, an asymmetric undercut and a black-colored deposit are created on the surface of PMH weld in Al alloys. For controlling the surface defect formation, the wire feeding speed and nozzle diameter in the PMH weld was investigated through arc phenomena with high-speed imaging and metallurgical analysis.

  13. Hybrid Laser-Arc Welding of 10-mm-Thick Cast Martensitic Stainless Steel CA6NM: As-Welded Microstructure and Mechanical Properties

    NASA Astrophysics Data System (ADS)

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

    2016-07-01

    Cast CA6NM martensitic stainless steel plates, 10 mm in thickness, were welded using hybrid laser-arc welding. The effect of different welding speeds on the as-welded joint integrity was characterized in terms of the weld bead geometry, defects, microstructure, hardness, ultimate tensile strength, and impact energy. Significant defects such as porosity, root humping, underfill, and excessive penetration were observed at a low welding speed (0.5 m/min). However, the underfill depth and excessive penetration in the joints manufactured at welding speeds above 0.75 m/min met the specifications of ISO 12932. Characterization of the as-welded microstructure revealed untempered martensite and residual delta ferrite dispersed at prior-austenite grain boundaries in the fusion zone. In addition, four different heat-affected zones in the weldments were differentiated through hardness mapping and inference from the Fe-Cr-Ni ternary phase diagram. The tensile fracture occurred in the base metal for all the samples and fractographic analysis showed that the crack path is within the martensite matrix, along primary delta ferrite-martensite interfaces and within the primary delta ferrite. Additionally, Charpy impact testing demonstrated slightly higher fracture energy values and deeper dimples on the fracture surface of the welds manufactured at higher welding speeds due to grain refinement and/or lower porosity.

  14. Welding.

    ERIC Educational Resources Information Center

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

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

  15. The Numerical and Experimental Investigation of the Multi-layer Laser-MIG Hybrid Welding for Fe36Ni Invar Alloy

    NASA Astrophysics Data System (ADS)

    Zhan, Xiaohong; Liu, Yun; Ou, Wenmin; Gu, Cheng; Wei, Yanhong

    2015-12-01

    Numerical and experimental investigations of multi-layer laser-MIG hybrid welding for Fe36Ni Invar alloy were presented in this paper. The multi-layer laser-MIG hybrid welding experiments with different parameters were conducted for the 19.5-mm-thick Invar plates. A finite element (FE) model was established to predict the temperature field, residual stress, and deformation distribution during and after welding. A plane-conical combined heat source model was used to simulate the laser-MIG hybrid welding process. Different numbers of welding layers were chosen to study the effect of welding layer on the temperature field, residual stress, and deformation distribution. It was found that the maximum residual stress of Invar plates after laser-MIG hybrid welding is 300 MPa and maximum deformation is 0.4 mm, so that laser-MIG hybrid welding can be used in actual manufacture of Invar moulds.

  16. Thermo-Mechanical Modeling of Laser-Mig Hybrid Welding (lmhw)

    NASA Astrophysics Data System (ADS)

    Kounde, Ludovic; Engel, Thierry; Bergheau, Jean-Michel; Boisselier, Didier

    2011-01-01

    Hybrid welding is a combination of two different technologies such as laser (Nd: YAG, CO2…) and electric arc welding (MIG, MAG / TIG …) developed to assemble thick metal sheets (over 3 mm) in order to reduce the required laser power. As a matter of fact, hybrid welding is a lso used in the welding of thin materials to benefit from process, deep penetration and gap limit. But the thermo-mechanical behaviour of thin parts assembled by LMHW technology for railway cars production is far from being controlled the modeling and simulation contribute to the assessment of the causes and effects of the thermo mechanical behaviour in the assembled parts. In order to reproduce the morphology of melted and heat-affected zones, two analytic functions were combined to model the heat source of LMHW. On one hand, we applied a so-called "diaboloïd" (DB) which is a modified hyperboloid, based on experimental parameters and the analysis of the macrographs of the welds. On the other hand, we used a so-called "double ellipsoïd" (DE) which takes the MIG only contribution including the bead into account. The comparison between experimental result and numerical result shows a good agreement.

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

    NASA Astrophysics Data System (ADS)

    Yang, Shanglu

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

  18. Synergistically enhanced stability of highly flexible silver nanowire/carbon nanotube hybrid transparent electrodes by plasmonic welding.

    PubMed

    Lee, Jongsoo; Woo, Ju Yeon; Kim, Ju Tae; Lee, Byung Yang; Han, Chang-Soo

    2014-07-23

    Here, we report highly transparent and flexible AgNW/SWCNT hybrid networks on PET substrates combined with plasmonic welding for securing ultrahigh stability in mechanical and electrical properties under severe bending. Plasmonic welding produces local heating and welding at the junction of AgNWs and leads strong adhesion between AgNW and SWCNT as well as between hybrid structure and substrate. The initial sheet resistance of plasmon treated AgNW/SWCNT hybrid film was 26 Ω sq(-1), with >90% optical transmittance over the wavelength range 400-2700 nm. Following 200 cycles of convex/concave bending with a bending radius of 5 mm, the sheet resistance changed from 26 to 29 Ω sq(-1). This hybrid structure combined with the plasmonic welding process provided excellent stability, low resistance, and high transparency, and is suitable for highly flexible electronics applications, including touch panels, solar cells, and OLEDs.

  19. Synergistically enhanced stability of highly flexible silver nanowire/carbon nanotube hybrid transparent electrodes by plasmonic welding.

    PubMed

    Lee, Jongsoo; Woo, Ju Yeon; Kim, Ju Tae; Lee, Byung Yang; Han, Chang-Soo

    2014-07-23

    Here, we report highly transparent and flexible AgNW/SWCNT hybrid networks on PET substrates combined with plasmonic welding for securing ultrahigh stability in mechanical and electrical properties under severe bending. Plasmonic welding produces local heating and welding at the junction of AgNWs and leads strong adhesion between AgNW and SWCNT as well as between hybrid structure and substrate. The initial sheet resistance of plasmon treated AgNW/SWCNT hybrid film was 26 Ω sq(-1), with >90% optical transmittance over the wavelength range 400-2700 nm. Following 200 cycles of convex/concave bending with a bending radius of 5 mm, the sheet resistance changed from 26 to 29 Ω sq(-1). This hybrid structure combined with the plasmonic welding process provided excellent stability, low resistance, and high transparency, and is suitable for highly flexible electronics applications, including touch panels, solar cells, and OLEDs. PMID:24972024

  20. T-joints of Ti alloys with hybrid laser-MIG welding: macro-graphic and micro-hardness analyses

    NASA Astrophysics Data System (ADS)

    Spina, R.; Sorgente, D.; Palumbo, G.; Scintilla, L. D.; Brandizzi, M.; Satriano, A. A.; Tricarico, L.

    2012-03-01

    Titanium alloys are characterized by high mechanical properties and elevated corrosion resistance. The combination of laser welding with MIG/GMAW has proven to improve beneficial effects of both processes (keyhole, gap-bridging ability) while limiting their drawbacks (high thermal gradient, low mechanical resistance) In this paper, the hybrid Laser-GMAW welding of Ti-6Al-4V 3-mm thick sheets is investigated using a specific designed trailing shield. The joint geometry was the double fillet welded T-joint. Bead morphologies, microstructures and mechanical properties (micro-hardness) of welds were evaluated and compared to those achieved for the base metals.

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

    SciTech Connect

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

    2014-02-18

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

  2. Hybrid laser-MIG welding of aluminum alloys: The influence of shielding gases

    NASA Astrophysics Data System (ADS)

    Campana, G.; Ascari, A.; Fortunato, A.; Tani, G.

    2009-03-01

    In this paper, laser-GMAW hybrid welding technologies of light metals are investigated by focusing particularly on shielding gas related problems such as distribution on the welding zone, mixtures and flow. In particular, a Computational Fluid Dynamics (CFD) software was used with the aim to investigate the effect on gas distribution and contamination of the adoption of an isolation chamber surrounding the welding zone. In particular, the turbulent flow model adopted was a standard k- ɛ one. A simple parallelepipedal geometry for the isolation chamber was adopted whose width and depth were fixed, while the height was set as a variable. A simulation activity was carried out in order to evaluate the relationship among chamber height, flow rates and inlet angle inclinations. The simulated welding environment was simplified without considering the presence and the effect of the laser induced plasma plume and of the electric arc. The main results concern the influence of isolation chamber height, gas flow rate and gas inlet inclination on the shielding gas contamination and distribution in a zone near the heat sources-material interaction zone. These results underline that there are particular values of the chosen variables which optimize the gas distribution around the welding zone allowing to achieve an even and reliable shielding effect.

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

    NASA Astrophysics Data System (ADS)

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

    2016-09-01

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

  4. Using infrared thermography in order to compare laser and hybrid (laser+MIG) welding processes

    NASA Astrophysics Data System (ADS)

    Matteï, Simone; Grevey, Dominique; Mathieu, Alexandre; Kirchner, Laetitia

    2009-09-01

    In order to deepen the understanding of the differences between laser and laser-arc hybrid welding, comparisons were undertaken using thermography. The experiments were carried out for a T assembly of aluminium alloy plates. Modelling, based on the finite element method approach, was realized using IR temperature measurements and seam geometry. For a value of the power supply, depicted as a surface source in the hybrid case, agreement was found between simulated and measured temperatures. The arc power supply efficiency value is similar to the usually used value.

  5. Effect of welding wires on microstructure and mechanical properties of 2A12 aluminum alloy in CO 2 laser-MIG hybrid welding

    NASA Astrophysics Data System (ADS)

    Yan, Jun; Zeng, Xiaoyan; Gao, Ming; Lai, Jian; Lin, Tianxiao

    2009-05-01

    This paper represented the effect of welding wires on microstructure and mechanical properties of 2A12 aluminum alloy in CO 2 laser-metal inter gas (MIG) hybrid welding. Plates of 2A12 aluminum alloy were welded by ER4043 and ER2319 welding wires, respectively. Full penetration joints without any defects were produced. The X-ray diffraction was used to analyze the phase composition, while the scanning electron microscopy (SEM) was conducted to study the microstructure, segregation behaviors of major alloying elements and the eutectics formed at dendrite boundaries in the joints. The results showed that silicon and copper were concentrated at the dendrite boundaries and α-Al + Si + Al 2Cu + Mg 2Si eutectic was formed if the ER4043 welding wire was used. However, only copper was concentrated at the dendrite boundaries and α-Al + θ eutectic was formed by ER2319 welding wire. Finally, the tensile tests were performed and the fracture surfaces were analyzed. The results showed that the joint efficiency by ER2319 and ER4043 welding wires reached up to 78% and 69%, respectively. Coarse dimples and voids had been observed in the fractographs. The joints showed a transgranular type failure.

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

    NASA Astrophysics Data System (ADS)

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

    2014-07-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

  8. Welding.

    ERIC Educational Resources Information Center

    Cowan, Earl; And Others

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

  9. Welding.

    ERIC Educational Resources Information Center

    Baldwin, Harold; Whitney, Gregory

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

  10. 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.

  11. Influence of laser on the droplet behavior in short-circuiting, globular, and spray modes of hybrid fiber laser-MIG welding

    NASA Astrophysics Data System (ADS)

    Cai, Chuang; Feng, Jiecai; Li, Liqun; Chen, Yanbin

    2016-09-01

    The effects of laser on the droplet behavior in short-circuiting, globular, and spray modes of hybrid fiber laser-MIG welding were studied. Transfer sequence of a droplet, welding current wave and morphology of plasma in the three modes of arc welding and hybrid welding were comparatively investigated. Compared with arc welding, the transfer frequency and landing location of droplet in the three modes of hybrid welding changed. In short-circuiting and globular modes, the droplet transfer was promoted by the laser, while the droplet transfer was hindered by the laser in spray mode. The magnitudes and directions of electromagnetic force and plasma drag force acting on the droplet were the keys to affect the droplet behavior. The magnitudes and directions of electromagnetic force and plasma drag force were converted due to the variation of the current distribution into the droplet, which were caused by the laser induced plasma with low ionization potential.

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

    NASA Technical Reports Server (NTRS)

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

    1997-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

  14. Effect of power distribution on the weld quality during hybrid laser welding of an Al-Mg alloy

    NASA Astrophysics Data System (ADS)

    Leo, P.; Renna, G.; Casalino, G.; Olabi, A. G.

    2015-10-01

    This paper treats of the analysis of the effect of arc and laser powers on the quality of the arc assisted fiber laser welding of an Al-Mg alloy in the butt configuration. Grain size, weld geometry defects, porosity, and magnesium loss were measured. Magnesium content of the fused zone decreased as the laser power increased while the porosity increased with laser power. Microhardness profiles and tensile properties were explained on the basis of the joint microstructure and defects and related to the power distribution. The porosity level and Mg content in the fused zone affected both tensile strength and ductility. The power distribution that stabilized the welding process and minimize the weld porosity was defined.

  15. Study of the effect of low-power pulse laser on arc plasma and magnesium alloy target in hybrid welding by spectral diagnosis technique

    NASA Astrophysics Data System (ADS)

    Liu, Liming; Hao, Xinfeng

    2008-10-01

    In order to study the effect of laser pulses on arc plasma and target metal in the hybrid welding process, the spectra of the plasmas in the welding process of magnesium alloys are analysed in this paper. The acquisition system of plasma spectra is set up and the spectral lines of welding plasma are acquired. Compared with tungsten-inert gas (TIG) welding, the intensities of the spectral lines of magnesium increase sharply while those of Ar decrease for strong evaporation and ionization of magnesium alloys in low-power laser/arc hybrid welding. The electron temperature and density are estimated by the Boltzmann plot method and the Stark broadening effect. The result shows that the electron temperature of arc plasma in the hybrid welding process is much lower than that in TIG welding, especially in the laser beam-affected zone. In contrast, the electron density of the plasma is enhanced. The influences of laser parameters on electron temperature are also studied. The changes in electron temperature and density indicate that the effect of laser pulse on the target metal is the dominant factor influencing the electron temperature and density in low-power laser/arc hybrid welding.

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-11-01

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

  18. 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.

  19. The numerical simulation of heat transfer during a hybrid laser-MIG welding using equivalent heat source approach

    NASA Astrophysics Data System (ADS)

    Bendaoud, Issam; Matteï, Simone; Cicala, Eugen; Tomashchuk, Iryna; Andrzejewski, Henri; Sallamand, Pierre; Mathieu, Alexandre; Bouchaud, Fréderic

    2014-03-01

    The present study is dedicated to the numerical simulation of an industrial case of hybrid laser-MIG welding of high thickness duplex steel UR2507Cu with Y-shaped chamfer geometry. It consists in simulation of heat transfer phenomena using heat equivalent source approach and implementing in finite element software COMSOL Multiphysics. A numerical exploratory designs method is used to identify the heat sources parameters in order to obtain a minimal required difference between the numerical results and the experiment which are the shape of the welded zone and the temperature evolution in different locations. The obtained results were found in good correspondence with experiment, both for melted zone shape and thermal history.

  20. Investigation of strength of a hybrid adhesive anchor system used in precast concrete welded repair applications subjected to tensile and eccentric shear loading

    NASA Astrophysics Data System (ADS)

    Eilers, Michael Glenn

    A common precast industry repair for missing or misplaced connection plates is the use of an adhesive anchor system to fasten repair plates to precast members. Typically, the repair plate will experience elevated temperatures during the welding of the loose erection plate to the repair plate. Limited testing and theoretical data are currently available to provide design guidelines on how the elevated temperatures induced by welding affect the behavior and capacity of the adhesive anchoring systems. This dissertation outlines bond tests, eccentric shear tests, and a temperature investigation performed using a hybrid adhesive system in precast concrete repair applications. In addition, limited bond strength testing data using a high strength two-part epoxy adhesive is also included. The overall aim of this work is to provide test data and guidance to the industry and design professionals when designing adhesive anchoring systems for repair applications exposed to welding.

  1. A Lossless hybrid wavelet-fractal compression for welding radiographic images.

    PubMed

    Mekhalfa, Faiza; Avanaki, Mohammad R N; Berkani, Daoud

    2016-01-01

    In this work a lossless wavelet-fractal image coder is proposed. The process starts by compressing and decompressing the original image using wavelet transformation and fractal coding algorithm. The decompressed image is removed from the original one to obtain a residual image which is coded by using Huffman algorithm. Simulation results show that with the proposed scheme, we achieve an infinite peak signal to noise ratio (PSNR) with higher compression ratio compared to typical lossless method. Moreover, the use of wavelet transform speeds up the fractal compression algorithm by reducing the size of the domain pool. The compression results of several welding radiographic images using the proposed scheme are evaluated quantitatively and compared with the results of Huffman coding algorithm.

  2. A Lossless hybrid wavelet-fractal compression for welding radiographic images.

    PubMed

    Mekhalfa, Faiza; Avanaki, Mohammad R N; Berkani, Daoud

    2016-01-01

    In this work a lossless wavelet-fractal image coder is proposed. The process starts by compressing and decompressing the original image using wavelet transformation and fractal coding algorithm. The decompressed image is removed from the original one to obtain a residual image which is coded by using Huffman algorithm. Simulation results show that with the proposed scheme, we achieve an infinite peak signal to noise ratio (PSNR) with higher compression ratio compared to typical lossless method. Moreover, the use of wavelet transform speeds up the fractal compression algorithm by reducing the size of the domain pool. The compression results of several welding radiographic images using the proposed scheme are evaluated quantitatively and compared with the results of Huffman coding algorithm. PMID:26890900

  3. Combined Laser Beam Welding and Brazing Process for Aluminium Titanium Hybrid Structures

    NASA Astrophysics Data System (ADS)

    Möller, F.; Grden, M.; Thomy, C.; Vollertsen, F.

    The current state of the art in light-weight construction is - for the case of aircraft structures - the use of either aluminium or titanium. Whereas aluminium is light-weight and less expensive, titanium offers superior corrosion properties at higher cost. In order to combine the advantages of both materials, a hybrid Ti-Al structure is proposed for e.g. seat-track application. In this paper, an overview of the results from this research work and the accompanying thermo-mechanical simulations will be reported and discussed. On the basis of the development of an appropriate system technology, the process development will be described, focusing on the main influencing parameters of the process on joint properties.

  4. The use of exploratory experimental designs combined with thermal numerical modelling to obtain a predictive tool for hybrid laser/MIG welding and coating processes

    NASA Astrophysics Data System (ADS)

    Bidi, Lyes; Mattei, Simone; Cicala, Eugen; Andrzejewski, Henri; Le Masson, Philippe; Schroeder, Jeanne

    2011-04-01

    While hybrid laser welding and coating processes involve a large number of physical phenomena, it is currently impossible to predict, for a given set of influencing factors, the shape of the molten zone and the history of temperature fields inside the parts. This remains true for complex processes, such as the hybrid laser/MIG welding process, which consists in combining a laser beam with a MIG torch. The gains obtained result essentially from the synergy of the associated processes: the stability of the process, the quality of the seam realized, and the productivity are increased. This article shows how, by means of a reduced number of experiments (8), it is possible to predict the shape of the molten zone and the temperature field inside parts, for a given window of influencing factors. This method consists in combining the method of exploratory experimental designs with a numerical modelling of the thermal phenomena that occurs during the process, by using the 'heat equivalent source" approach [1-4]. Two validations of this method have been carried out: the first for a set of parameters inside the experimental design, and the other for a set of parameters that lies outside the experimental design, but inside the domain investigated.

  5. Pursuing low joint resistivity in Cu-stabilized REBa2Cu3O δ coated conductor tapes by the ultrasonic weld-solder hybrid method

    NASA Astrophysics Data System (ADS)

    Shin, Hyung-Seop; Kim, Jong-min; Dedicatoria, Marlon J.

    2016-01-01

    Development of a coated conductor tape joint with good quality and low joint resistivity, R sj, in terms of transport and mechanical properties, was attempted by direct bonding at the interface of the Cu-Cu stabilizers in overlapped GdBCO CC tapes. In this study, we attempted to achieve a low R sj by introducing hybrid joining, soldering and ultrasonic welding (UW), and its mechanism was analyzed theoretically. Coated conductor tapes were experimentally joined using various methods of soldering, UW, and combinations of the two. As a result, a much lower R sj of about 57 nΩ · cm2 was obtained for RCE-DR-processed GdBCO CC tape joints using the hybrid joining method. The mechanical properties of the jointed CC tapes were also evaluated at room temperature and 77 K under self-field. Load-displacement curves of joined CC tapes followed the curve of the single CC tape. Critical current and joint resistance, R j, of hybrid-joined CC tape were retained after double bending at room temperature up to 20 mm bending diameter.

  6. Welding IV.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

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

  7. Welding Curriculum.

    ERIC Educational Resources Information Center

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

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

  8. 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.

  9. Welding Technician

    ERIC Educational Resources Information Center

    Smith, Ken

    2009-01-01

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

  10. Elements of arc welding

    SciTech Connect

    Not Available

    1993-07-01

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

  11. 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…

  12. WELDING TORCH

    DOEpatents

    Correy, T.B.

    1961-10-01

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

  13. Plasma arc welding weld imaging

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  14. Welding III.

    ERIC Educational Resources Information Center

    Allegheny County Community Coll., Pittsburgh, PA.

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

  15. Welding Curriculum.

    ERIC Educational Resources Information Center

    EASTCONN Regional Educational Services Center, North Windham, CT.

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

  16. WELDING METHOD

    DOEpatents

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

    1959-09-29

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

  17. 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…

  18. Automatic programming of arc welding robots

    NASA Astrophysics Data System (ADS)

    Padmanabhan, Srikanth

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

  19. Welding method combining laser welding and MIG welding

    SciTech Connect

    Hamasaki, M.

    1985-03-26

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

  20. Laser Assisted Plasma Arc Welding

    SciTech Connect

    FUERSCHBACH,PHILLIP W.

    1999-10-05

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

  1. Welding Curtains

    NASA Technical Reports Server (NTRS)

    1984-01-01

    Concept of transparent welding curtains made of heavy duty vinyl originated with David F. Wilson, President of Wilson Sales Company. In 1968, Wilson's curtains reduced glare of welding arc and blocked ultraviolet radiation. When later research uncovered blue light hazards, Wilson sought improvement of his products. He contracted Dr. Charles G. Miller and James B. Stephens, both of Jet Propulsion Laboratory (JPL), and they agreed to undertake development of a curtain capable of filtering out harmful irradiance, including ultraviolet and blue light and provide protection over a broad range of welding operation. Working on their own time, the JPL pair spent 3 years developing a patented formula that includes light filtering dyes and small particles of zinc oxide. The result was the Wilson Spectra Curtain.

  2. Narrow gap laser welding

    DOEpatents

    Milewski, J.O.; Sklar, E.

    1998-06-02

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

  3. Narrow gap laser welding

    DOEpatents

    Milewski, John O.; Sklar, Edward

    1998-01-01

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

  4. Electroslag and electrogas welding

    NASA Technical Reports Server (NTRS)

    Campbell, H. C.

    1972-01-01

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

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

    PubMed

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

    2016-07-01

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

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

    PubMed

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

    2016-07-01

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

  7. WELDING APPARATUS

    DOEpatents

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

    1963-04-23

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

  8. 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.

  9. Weld pool phenomena

    SciTech Connect

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

    1994-09-01

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

  10. Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur C., Jr.

    2008-01-01

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

  11. Introduction to Welding.

    ERIC Educational Resources Information Center

    Fortney, Clarence; Gregory, Mike

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

  12. Optical Welding Torch

    NASA Technical Reports Server (NTRS)

    Richardson, R. W.

    1987-01-01

    Gas/tungsten-arc welding torch supports electrode at center while enabling viewing of weld area along torch axis. Gas torch accommodates lens and optical fibers, all part of vision system for welding robot. Welding torch includes spoked structure in central bore of optical body. Structure supports welding electrode, carries electric current to it, and takes heat away from it. Spokes formed by drilling six holes 60 degrees apart around center line of torch.

  13. Advanced Welding Applications

    NASA Technical Reports Server (NTRS)

    Ding, Robert J.

    2010-01-01

    Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

  14. Television Monitoring System for Welding

    NASA Technical Reports Server (NTRS)

    Vallow, K.; Gordon, S.

    1986-01-01

    Welding process in visually inaccessible spots viewed and recorded. Television system enables monitoring of welding in visually inaccessible locations. System assists welding operations and provide video record, used for weld analysis and welder training.

  15. Laser weld jig

    SciTech Connect

    Haupt, D.L.; Van Blarigan, P.

    1982-11-09

    A system is provided for welding a workpiece along a predetermined weld line that may be of irregular shape, which includes the step of forming a lip on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members. Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig forming the lip, and with the jig constructed to detachably hold parts to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

  16. Laser weld jig

    SciTech Connect

    Van Blarigan, Peter; Haupt, David L.

    1982-01-01

    A system is provided for welding a workpiece (10, FIG. 1) along a predetermined weld line (12) that may be of irregular shape, which includes the step of forming a lip (32) on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members (34, 36). Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space (17) at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig (24) forming the lip, and with the jig constructed to detachably hold parts (22, 20) to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

  17. Welded solar cell interconnection

    NASA Technical Reports Server (NTRS)

    Stofel, E. J.; Browne, E. R.; Meese, R. A.; Vendura, G. J.

    1982-01-01

    The efficiency of the welding of solar-cell interconnects is compared with the efficiency of soldering such interconnects, and the cases in which welding may be superior are examined. Emphasis is placed on ultrasonic welding; attention is given to the solar-cell welding machine, the application of the welding process to different solar-cell configurations, producibility, and long-life performance of welded interconnects. Much of the present work has been directed toward providing increased confidence in the reliability of welding using conditions approximating those that would occur with large-scale array production. It is concluded that there is as yet insufficient data to determine which of three methods (soldering, parallel gap welding, and ultrasonic welding) provides the longest-duration solar panel life.

  18. Fusion welding process

    DOEpatents

    Thomas, Kenneth C.; Jones, Eric D.; McBride, Marvin A.

    1983-01-01

    A process for the fusion welding of nickel alloy steel members wherein a ferrite containing pellet is inserted into a cavity in one member and melted by a welding torch. The resulting weld nugget, a fusion of the nickel containing alloy from the members to be welded and the pellet, has a composition which is sufficiently low in nickel content such that ferrite phases occur within the weld nugget, resulting in improved weld properties. The steel alloys encompassed also include alloys containing carbon and manganese, considered nickel equivalents.

  19. Weld controller for automated nuclear service welding

    SciTech Connect

    Barfield, K.L.; Strubhar, P.M.; Green, D.I.

    1995-12-31

    B and W Nuclear Technologies (BWNT) uses many different types of weld heads for automated welding in the commercial nuclear service industry. Some weld heads are purchased as standard items, while others are custom designed and fabricated by BWNT requiring synchronized multiaxis motion control. BWNT recently completed a development program to build a common weld controller that interfaces to all types of weld heads used by BWNT. Their goal was to construct a system that had the flexibility to add different modules to increase the capability of the controller as different application needs become necessary. The benefits from having a common controller are listed. This presentation explains the weld controller system and the types of applications to which it has been applied.

  20. Welding in airplane construction

    NASA Technical Reports Server (NTRS)

    Rechtlich, A; Schrenk, M

    1928-01-01

    The present article attempts to explain the principles for the production of a perfect weld and to throw light on the unexplained problems. Moreover, it is intended to elucidate the possibilities of testing the strength and reliability of welded parts.

  1. Effects of Sealing Run Welding with Defocused Laser Beam on the Quality of T-joint Fillet Weld

    NASA Astrophysics Data System (ADS)

    Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

    Fillet weld is the predominant weld type used for connecting different elements e.g. in shipbuilding, offshore and bridge structures. One of prevalent research questions is the structural integrity of the welded joint. Post weld improvement techniques are being actively researched, as high stress areas like an incomplete penetration on the root side or fluctuations in penetration depth cannot be avoided. Development of laser and laser-arc hybrid welding processes have greatly contributed to increase of production capacity and reduction of heat-induced distortions by producing single pass full penetration welds in thin- and medium thickness structural steel parts. Present study addresses the issue of how to improve the quality of the fillet welds by welding the sealing run on the root side with defocused laser beam. Welds having incomplete or excessive penetration were produced with several beam angles and laser beam spot sizes on surface. As a conclusion, significant decrease or even complete elimination of the seam irregularities, which act as the failure starting points during service, is achieved.

  2. Infrared Thermography For Welding

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Lucky, Brian D.; Spiegel, Lyle B.; Hudyma, Russell M.

    1992-01-01

    Infrared imaging and image-data-processing system shows temperatures of joint during welding and provides data from which rates of heating and cooling determined. Information used to control welding parameters to ensure reliable joints, in materials which microstructures and associated metallurgical and mechanical properties depend strongly on rates of heating and cooling. Applicable to variety of processes, including tungsten/inert-gas welding; plasma, laser, and resistance welding; cutting; and brazing.

  3. Comparing Laser Welding Technologies with Friction Stir Welding for Production of Aluminum Tailor-Welded Blanks

    SciTech Connect

    Hovanski, Yuri; Carsley, John; Carlson, Blair; Hartfield-Wunsch, Susan; Pilli, Siva Prasad

    2014-01-15

    A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

  4. Portable Weld Tester.

    ERIC Educational Resources Information Center

    Eckert, Douglas

    This training manual, which was developed for employees of an automotive plant, is designed to teach trainees to operate a portable weld tester (Miyachi MM-315). In chapter 1, the weld tester's components are illustrated and described, and the procedure for charging its batteries is explained. Chapter 2 illustrates the weld tester's parts,…

  5. Variable polarity arc welding

    NASA Technical Reports Server (NTRS)

    Bayless, E. O., Jr.

    1991-01-01

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

  6. Coil Welding Aid

    NASA Technical Reports Server (NTRS)

    Wiesenbach, W. T.; Clark, M. C.

    1983-01-01

    Positioner holds coil inside cylinder during tack welding. Welding aid spaces turns of coil inside cylinder and applies contact pressure while coil is tack-welded to cylinder. Device facilitates fabrication of heat exchangers and other structures by eliminating hand-positioning and clamping of individual coil turns.

  7. Active weld control

    NASA Technical Reports Server (NTRS)

    Powell, Bradley W.; Burroughs, Ivan A.

    1994-01-01

    Through the two phases of this contract, sensors for welding applications and parameter extraction algorithms have been developed. These sensors form the foundation of a weld control system which can provide action weld control through the monitoring of the weld pool and keyhole in a VPPA welding process. Systems of this type offer the potential of quality enhancement and cost reduction (minimization of rework on faulty welds) for high-integrity welding applications. Sensors for preweld and postweld inspection, weld pool monitoring, keyhole/weld wire entry monitoring, and seam tracking were developed. Algorithms for signal extraction were also developed and analyzed to determine their application to an adaptive weld control system. The following sections discuss findings for each of the three sensors developed under this contract: (1) weld profiling sensor; (2) weld pool sensor; and (3) stereo seam tracker/keyhole imaging sensor. Hardened versions of these sensors were designed and built under this contract. A control system, described later, was developed on a multiprocessing/multitasking operating system for maximum power and flexibility. Documentation for sensor mechanical and electrical design is also included as appendices in this report.

  8. Welding Course Curriculum.

    ERIC Educational Resources Information Center

    Genits, Joseph C.

    This guide is intended for use in helping students gain a fundamental background on the major aspects of the welding trade. The course emphasis is on mastery of the manipulative skills necessary to develop successful welding techniques and on acquisition of an understanding of the specialized tools and equipment used in welding. The first part…

  9. Instructional Guidelines. Welding.

    ERIC Educational Resources Information Center

    Fordyce, H. L.; Doshier, Dale

    Using the standards of the American Welding Society and the American Society of Mechanical Engineers, this welding instructional guidelines manual presents a course of study in accordance with the current practices in industry. Intended for use in welding programs now practiced within the Federal Prison System, the phases of the program are…

  10. Laser assisted arc welding for aluminum alloys

    SciTech Connect

    Fuerschbach, P.W.

    2000-01-01

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

  11. Method for welding beryllium

    DOEpatents

    Dixon, Raymond D.; Smith, Frank M.; O'Leary, Richard F.

    1997-01-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon.

  12. A critical review of laser beam welding

    NASA Astrophysics Data System (ADS)

    Martukanitz, Richard P.

    2005-03-01

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

  13. Optically controlled welding system

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1988-01-01

    An optically controlled welding system wherein a welding torch having through-the-torch viewing capabilities is provided with an optical beam splitter to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder to make the welding torch responsive thereto. Other features include an actively cooled electrode holder which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm, and a weld pool contour detector comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom, being characteristic of a penetrated or unpenetrated condition of the weld pool.

  14. Optically controlled welding system

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1989-01-01

    An optically controlled welding system (10) wherein a welding torch (12) having through-the-torch viewing capabilities is provided with an optical beam splitter (56) to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder (15) to make the welding torch responsive thereto. Other features includes an actively cooled electrode holder (26) which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm (28) and a weld pool contour detector (14) comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom being characteristic of a penetrated or unpenetrated condition of the weld pool.

  15. Robotic Welding Of Injector Manifold

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Shelley, D. Mark

    1992-01-01

    Brief report presents history, up through October 1990, of continuing efforts to convert from manual to robotic gas/tungsten arc welding in fabrication of main injector inlet manifold of main engine of Space Shuttle. Includes photographs of welding machinery, welds, and weld preparations. Of interest to engineers considering establishment of robotic-welding facilities.

  16. VPPA weld model evaluation

    NASA Astrophysics Data System (ADS)

    McCutcheon, Kimble D.; Gordon, Stephen S.; Thompson, Paul A.

    1992-07-01

    NASA uses the Variable Polarity Plasma Arc Welding (VPPAW) process extensively for fabrication of Space Shuttle External Tanks. This welding process has been in use at NASA since the late 1970's but the physics of the process have never been satisfactorily modeled and understood. In an attempt to advance the level of understanding of VPPAW, Dr. Arthur C. Nunes, Jr., (NASA) has developed a mathematical model of the process. The work described in this report evaluated and used two versions (level-0 and level-1) of Dr. Nunes' model, and a model derived by the University of Alabama at Huntsville (UAH) from Dr. Nunes' level-1 model. Two series of VPPAW experiments were done, using over 400 different combinations of welding parameters. Observations were made of VPPAW process behavior as a function of specific welding parameter changes. Data from these weld experiments was used to evaluate and suggest improvements to Dr. Nunes' model. Experimental data and correlations with the model were used to develop a multi-variable control algorithm for use with a future VPPAW controller. This algorithm is designed to control weld widths (both on the crown and root of the weld) based upon the weld parameters, base metal properties, and real-time observation of the crown width. The algorithm exhibited accuracy comparable to that of the weld width measurements for both aluminum and mild steel welds.

  17. VPPA weld model evaluation

    NASA Technical Reports Server (NTRS)

    Mccutcheon, Kimble D.; Gordon, Stephen S.; Thompson, Paul A.

    1992-01-01

    NASA uses the Variable Polarity Plasma Arc Welding (VPPAW) process extensively for fabrication of Space Shuttle External Tanks. This welding process has been in use at NASA since the late 1970's but the physics of the process have never been satisfactorily modeled and understood. In an attempt to advance the level of understanding of VPPAW, Dr. Arthur C. Nunes, Jr., (NASA) has developed a mathematical model of the process. The work described in this report evaluated and used two versions (level-0 and level-1) of Dr. Nunes' model, and a model derived by the University of Alabama at Huntsville (UAH) from Dr. Nunes' level-1 model. Two series of VPPAW experiments were done, using over 400 different combinations of welding parameters. Observations were made of VPPAW process behavior as a function of specific welding parameter changes. Data from these weld experiments was used to evaluate and suggest improvements to Dr. Nunes' model. Experimental data and correlations with the model were used to develop a multi-variable control algorithm for use with a future VPPAW controller. This algorithm is designed to control weld widths (both on the crown and root of the weld) based upon the weld parameters, base metal properties, and real-time observation of the crown width. The algorithm exhibited accuracy comparable to that of the weld width measurements for both aluminum and mild steel welds.

  18. Welding arc plasma physics

    NASA Technical Reports Server (NTRS)

    Cain, Bruce L.

    1990-01-01

    The problems of weld quality control and weld process dependability continue to be relevant issues in modern metal welding technology. These become especially important for NASA missions which may require the assembly or repair of larger orbiting platforms using automatic welding techniques. To extend present welding technologies for such applications, NASA/MSFC's Materials and Processes Lab is developing physical models of the arc welding process with the goal of providing both a basis for improved design of weld control systems, and a better understanding of how arc welding variables influence final weld properties. The physics of the plasma arc discharge is reasonably well established in terms of transport processes occurring in the arc column itself, although recourse to sophisticated numerical treatments is normally required to obtain quantitative results. Unfortunately the rigor of these numerical computations often obscures the physics of the underlying model due to its inherent complexity. In contrast, this work has focused on a relatively simple physical model of the arc discharge to describe the gross features observed in welding arcs. Emphasis was placed of deriving analytic expressions for the voltage along the arc axis as a function of known or measurable arc parameters. The model retains the essential physics for a straight polarity, diffusion dominated free burning arc in argon, with major simplifications of collisionless sheaths and simple energy balances at the electrodes.

  19. Weld electrode cooling study

    NASA Astrophysics Data System (ADS)

    Masters, Robert C.; Simon, Daniel L.

    1999-03-01

    The U.S. auto/truck industry has been mandated by the Federal government to continuously improve their fleet average gas mileage, measured in miles per gallon. Several techniques are typically used to meet these mandates, one of which is to reduce the overall mass of cars and trucks. To help accomplish this goal, lighter weight sheet metal parts, with smaller weld flanges, have been designed and fabricated. This paper will examine the cooling characteristics of various water cooled weld electrodes and shanks used in resistance spot welding applications. The smaller weld flanges utilized in modern vehicle sheet metal fabrications have increased industry's interest in using one size of weld electrode (1/2 inch diameter) for certain spot welding operations. The welding community wants more data about the cooling characteristics of these 1/2 inch weld electrodes. To hep define the cooling characteristics, an infrared radiometer thermal vision system (TVS) was used to capture images (thermograms) of the heating and cooling cycles of several size combinations of weld electrodes under typical production conditions. Tests results will show why the open ended shanks are more suitable for cooling the weld electrode assembly then closed ended shanks.

  20. Welding and joining: A compilation

    NASA Technical Reports Server (NTRS)

    1975-01-01

    A compilation is presented of NASA-developed technology in welding and joining. Topics discussed include welding equipment, techniques in welding, general bonding, joining techniques, and clamps and holding fixtures.

  1. 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.

  2. Dual wire welding torch and method

    SciTech Connect

    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.

  3. Ultrasonic Stir Welding

    NASA Technical Reports Server (NTRS)

    Nabors, Sammy

    2015-01-01

    NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.

  4. Welding in Space Workshop

    NASA Technical Reports Server (NTRS)

    Workman, Gary L.

    1990-01-01

    The potential was discussed for welding in space, its advantages and disadvantages, and what type of programs can benefit from the capability. Review of the various presentations and comments made in the course of the workshop suggests several routes to obtaining a better understanding of how welding processes can be used in NASA's initiatives in space. They are as follows: (1) development of a document identifying well processes and equipment requirements applicable to space and lunar environments; (2) more demonstrations of welding particular hardware which are to be used in the above environments, especially for space repair operations; (3) increased awareness among contractors responsible for building space equipment as to the potential for welding operations in space and on other planetary bodies; and (4) continuation of space welding research projects is important to maintain awareness within NASA that welding in space is viable and beneficial.

  5. Manganese Content Control in Weld Metal During MAG Welding

    NASA Astrophysics Data System (ADS)

    Chinakhov, D. A.; Chinakhova, E. D.; Sapozhkov, A. S.

    2016-08-01

    The influence of the welding current and method of gas shielding in MAG welding on the content of manganese is considered in the paper. Results of study of the welded specimens of steels 45 when applying welding wire of different formulas and different types of gas shielding (traditional shielding and double-jet shielding) are given. It is found that in MAG welding the value of the welding current and the speed of the gas flow from the welding nozzle have a considerable impact on the chemical composition of the weld metal. The consumable electrode welding under double-jet gas shielding provides the directed gas-dynamics in the welding area and enables controlling the electrode metal transfer and the chemical composition of a weld.

  6. WELDED JACKETED URANIUM BODY

    DOEpatents

    Gurinsky, D.H.

    1958-08-26

    A fuel element is presented for a neutronic reactor and is comprised of a uranium body, a non-fissionable jacket surrounding sald body, thu jacket including a portion sealed by a weld, and an inclusion in said sealed jacket at said weld of a fiux having a low neutron capture cross-section. The flux is provided by combining chlorine gas and hydrogen in the intense heat of-the arc, in a "Heliarc" welding muthod, to form dry hydrochloric acid gas.

  7. IR Spot Weld Inspect

    2014-01-01

    In automotive industry, destructive inspection of spot welds is still the mandatory quality assurance method due to the lack of efficient non-destructive evaluation (NDE) tools. However, it is costly and time-consuming. Recently at ORNL, a new NDE prototype system for spot weld inspection using infrared (IR) thermography has been developed to address this problem. This software contains all the key functions that ensure the NDE system to work properly: system input/output control, image acquisition, datamore » analysis, weld quality database generation and weld quality prediction, etc.« less

  8. IR Spot Weld Inspect

    SciTech Connect

    Chen, Jian; Feng, Zhili

    2014-01-01

    In automotive industry, destructive inspection of spot welds is still the mandatory quality assurance method due to the lack of efficient non-destructive evaluation (NDE) tools. However, it is costly and time-consuming. Recently at ORNL, a new NDE prototype system for spot weld inspection using infrared (IR) thermography has been developed to address this problem. This software contains all the key functions that ensure the NDE system to work properly: system input/output control, image acquisition, data analysis, weld quality database generation and weld quality prediction, etc.

  9. Physics of Fusion Welding

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.

    1986-01-01

    Applicabilities and limitations of three techniques analyzed. NASA technical memorandum discusses physics of electron-beam, gas/ tungsten-arc, and laser-beam welding. From comparison of capabilities and limitations of each technique with regard to various welding conditions and materials, possible to develop criteria for selecting best welding technique in specific application. All three techniques classified as fusion welding; small volume of workpiece melted by intense heat source. Heat source moved along seam, leaving in wake solid metal that joins seam edges together.

  10. Electric arc welding gun

    DOEpatents

    Luttrell, Edward; Turner, Paul W.

    1978-01-01

    This invention relates to improved apparatus for arc welding an interior joint formed by intersecting tubular members. As an example, the invention is well suited for applications where many similar small-diameter vertical lines are to be welded to a long horizontal header. The improved apparatus includes an arc welding gun having a specially designed welding head which is not only very compact but also produces welds that are essentially free from rolled-over solidified metal. The welding head consists of the upper end of the barrel and a reversely extending electrode holder, or tip, which defines an acute angle with the barrel. As used in the above-mentioned example, the gun is positioned to extend upwardly through the vertical member and the joint to be welded, with its welding head disposed within the horizontal header. Depending on the design of the welding head, the barrel then is either rotated or revolved about the axis of the vertical member to cause the electrode to track the joint.

  11. Novel Optimization Methodology for Welding Process/Consumable Integration

    SciTech Connect

    Quintana, Marie A; DebRoy, Tarasankar; Vitek, John; Babu, Suresh

    2006-01-15

    Advanced materials are being developed to improve the energy efficiency of many industries of future including steel, mining, and chemical, as well as, US infrastructures including bridges, pipelines and buildings. Effective deployment of these materials is highly dependent upon the development of arc welding technology. Traditional welding technology development is slow and often involves expensive and time-consuming trial and error experimentation. The reason for this is the lack of useful predictive tools that enable welding technology development to keep pace with the deployment of new materials in various industrial sectors. Literature reviews showed two kinds of modeling activities. Academic and national laboratory efforts focus on developing integrated weld process models by employing the detailed scientific methodologies. However, these models are cumbersome and not easy to use. Therefore, these scientific models have limited application in real-world industrial conditions. On the other hand, industrial users have relied on simple predictive models based on analytical and empirical equations to drive their product development. The scopes of these simple models are limited. In this research, attempts were made to bridge this gap and provide the industry with a computational tool that combines the advantages of both approaches. This research resulted in the development of predictive tools which facilitate the development of optimized welding processes and consumables. The work demonstrated that it is possible to develop hybrid integrated models for relating the weld metal composition and process parameters to the performance of welds. In addition, these tools can be deployed for industrial users through user friendly graphical interface. In principle, the welding industry users can use these modular tools to guide their welding process parameter and consumable composition selection. It is hypothesized that by expanding these tools throughout welding industry

  12. A study of narrow gap laser welding for thick plates using the multi-layer and multi-pass method

    NASA Astrophysics Data System (ADS)

    Li, Ruoyang; Wang, Tianjiao; Wang, Chunming; Yan, Fei; Shao, Xinyu; Hu, Xiyuan; Li, Jianmin

    2014-12-01

    This paper details a new method that combines laser autogenous welding, laser wire filling welding and hybrid laser-GMAW welding to weld 30 mm thick plate using a multi-layer, multi-pass process. A “Y” shaped groove was used to create the joint. Research was also performed to optimize the groove size and the processing parameters. Laser autogenous welding is first used to create the backing weld. The lower, narrowest part of the groove is then welded using laser wire filling welding. Finally, the upper part of the groove is welded using laser-GMAW hybrid welding. Additionally, the wire feeding and droplet transfer behaviors are observed by high speed photography. The two main conclusions from this work are: the wire is often biased towards the side walls, resulting in a lack of fusion at the joint and the creation of other defects for larger groove sizes. Additionally, this results in the droplet transfer behavior becoming unstable, leading to a poor weld appearance for smaller groove sizes.

  13. Ultrasonic Spot and Torsion Welding of Aluminum to Titanium Alloys: Process, Properties and Interfacial Microstructure

    NASA Astrophysics Data System (ADS)

    Balle, Frank; Magin, Jens

    Hybrid lightweight structures shape the development of future vehicles in traffic engineering and the aerospace industry. For multi-material concepts made out of aluminum and titanium alloys, the ultrasonic welding technique is an alternative effective joining technology. The overlapped structures can be welded in the solid state, even without gas shielding. In this paper the conventional ultrasonic spot welding with longitudinal oscillation mode is compared to the recent ultrasonic torsion welding with a torsional mode at 20 kHz working frequency. For each technique the process parameters welding force, welding energy and oscillation amplitude were optimized for the hybrid joints using design of experiments. Relationships between the process parameters, mechanical properties and related welding zone should be understood. Central aspects of the research project are microscopic studies of the joining zone in cross section and extensive fracture surface analysis. Detailed electron microscopy and spectroscopy of the hybrid interface help to understand the interfacial formation during ultrasonic welding as well as to transfer the gained knowledge for further multi-metal joints.

  14. Improved diffusion welding and roll welding of titanium alloys

    NASA Technical Reports Server (NTRS)

    Holko, K. H.

    1973-01-01

    Auto-vacuum cleaning technique was applied to titanium parts prior to welding. This provides oxide-free welding surfaces. Diffusion welding can be accomplished in as little as five minutes of hot pressing. Roll welding can be accomplished with only ten percent deformation.

  15. Fine welding with lasers.

    PubMed

    MacLellan, D

    2008-01-01

    The need for micro joining metallic alloys for surgical instruments, implants and advanced medical devices is driving a rapid increase in the implementation of laser welding technology in research, development and volume production. This article discusses the advantages of this welding method and the types of lasers used in the process.

  16. Welding blades to rotors

    NASA Technical Reports Server (NTRS)

    Hoklo, K. H.; Moore, T. J. (Inventor)

    1973-01-01

    A process is described to form T-joints between dissimilar thickness parts by magnetic force upset welding. This type of resistance welding is used to join compressor and turbine parts which thereby reduces the weight and cost of jet engines.

  17. Advanced Welding Torch

    NASA Technical Reports Server (NTRS)

    1996-01-01

    In order to more easily join the huge sections of the Space Shuttle external tank, Marshall Space Flight Center initiated development of the existing concept of Variable Polarity Plasma Arc (VPPA) welding. VPPA welding employs a variable current waveform that allows the system to operate for preset time increments in either of two polarity modes for effective joining of light alloys.

  18. Removing Welding Fumes

    NASA Technical Reports Server (NTRS)

    Moore, Lloyd J.; Hall, Vandel L.

    1987-01-01

    Portable exhaust duct for machining and welding shops removes oil mist, dust, smoke, and fumes. Duct used with shop exhaust system, inlets of which placed at various convenient locations in shop floor. Flanged connector on underside of wheeled base links flexible tube to exhaust system under floor. Made especially for welding in room with low ceiling.

  19. Laser Welding in Space

    NASA Technical Reports Server (NTRS)

    Workman, Gary L.; Kaukler, William F.

    1989-01-01

    Solidification type welding process experiments in conditions of microgravity were performed. The role of convection in such phenomena was examined and convective effects in the small volumes obtained in the laser weld zone were observed. Heat transfer within the weld was affected by acceleration level as indicated by the resulting microstructure changes in low gravity. All experiments were performed such that both high and low gravity welds occurred along the same weld beam, allowing the effects of gravity alone to be examined. Results indicate that laser welding in a space environment is feasible and can be safely performed IVA or EVA. Development of the hardware to perform the experiment in a Hitchhiker-g platform is recomended as the next step. This experiment provides NASA with a capable technology for welding needs in space. The resources required to perform this experiment aboard a Shuttle Hitchhiker-pallet are assessed. Over the four year period 1991 to 1994, it is recommended that the task will require 13.6 manyears and $914,900. In addition to demonstrating the technology and ferreting out the problems encountered, it is suggested that NASA will also have a useful laser materials processing facility for working with both the scientific and the engineering aspects of materials processing in space. Several concepts are also included for long-term optimization of available solar power through solar pumping solid state lasers directly for welding power.

  20. NASA welding assessment program

    NASA Technical Reports Server (NTRS)

    Patterson, R. E.

    1985-01-01

    A program was conducted to demonstrate the cycle life capability of welded solar cell modules relative to a soldered solar cell module in a simulated low earth orbit thermal environment. A total of five 18-cell welded (parallel gap resistance welding) modules, three 18-cell soldered modules, and eighteen single cell samples were fabricated using 2 x 4 cm silicon solar cells from ASEC, fused silica cover glass from OCLI, silver plated Invar interconnectors, DC 93-500 adhesive, and Kapton-Kevlar-Kapton flexible substrate material. Zero degree pull strength ranged from 2.4 to 5.7 lbs for front welded contacts (40 samples), and 3.5 to 6.2 lbs for back welded contacts (40 samples). Solar cell cross sections show solid state welding on both front and rear contacts. The 18-cell welded modules have a specific power of 124 W/kg and an area power density of 142 W/sq m (both at 28 C). Three welded and one soldered module were thermal cycle tested in a thermal vacuum chamber simulating a low earth orbit thermal environment.

  1. Vocational Preparation Curriculum: Welding.

    ERIC Educational Resources Information Center

    Usoro, Hogan

    Designed to be a workable guide for instructors serving the occupational needs of various categories of disadvantaged and handicapped students, this welding curriculum contains fourteen units of self-paced and self-contained instructional materials. The instructional units cover the following topics: job opportunities in welding, safety rules in…

  2. DC arc weld starter

    DOEpatents

    Campiotti, Richard H.; Hopwood, James E.

    1990-01-01

    A system for starting an arc for welding uses three DC power supplies, a high voltage supply for initiating the arc, an intermediate voltage supply for sustaining the arc, and a low voltage welding supply directly connected across the gap after the high voltage supply is disconnected.

  3. Welding: Scope and Sequence.

    ERIC Educational Resources Information Center

    Nashville - Davidson County Metropolitan Public Schools, TN.

    Intended for use by all welding instructors in the Metropolitan Nashville Public Schools, this guide provides a sequential listing of course content and scope. A course description provides a brief overview of the content of the courses offered in the welding program. General course objectives are then listed. Outlines of the course content are…

  4. Alternating-Polarity Arc Welding

    NASA Technical Reports Server (NTRS)

    Schwinghamer, R. J.

    1987-01-01

    Brief reversing polarity of welding current greatly improves quality of welds. NASA technical memorandum recounts progress in art of variable-polarity plasma-arc (VPPA) welding, with emphasis on welding of aluminum-alloy tanks. VPPA welders offer important advantages over conventional single-polarity gas/tungsten arc welders.

  5. Argon Welding Inside A Workpiece

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.

    1988-01-01

    Canopies convert large hollow workpiece into inert-gas welding chamber. Large manifold serves welding chamber for attachment of liner parts in argon atmosphere. Every crevice, opening and passageway provided with argon-rich environment. Weld defects and oxidation dramatically reduced; also welding time reduced.

  6. Arc Reflector For Welding Ducts

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.

    1990-01-01

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

  7. Multihole Arc-Welding Orifice

    NASA Technical Reports Server (NTRS)

    Swaim, Benji D.

    1989-01-01

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

  8. Vacuum Gas Tungsten Arc Welding

    NASA Technical Reports Server (NTRS)

    Weeks, J. L.; Todd, D. T.; Wooten, J. R.

    1997-01-01

    A two-year program investigated vacuum gas tungsten arc welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. After a vacuum chamber and GTAW power supply were modified, several difficult-to-weld materials were studied and key parameters developed. Finally, Incoloy 903 weld overlays were produced without microfissures.

  9. Ultrasonic seam welding. Final report

    SciTech Connect

    Darner, G.S.

    1980-06-01

    Ultrasonic seam welding has been evaluated for making continuous seam welds on aluminum and copper-foil conductors. A seam welding system has been designed and fabricated, weldable material combinations have been identified, and the process parameters for welding materials applicable to flat cable production have been established.

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

    NASA Astrophysics Data System (ADS)

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

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

  11. Effect of adhesive on molten pool structure and penetration in laser weld bonding of magnesium alloy

    NASA Astrophysics Data System (ADS)

    Liu, L. M.; Ren, D. X.

    2010-09-01

    Laser weld bonding (LWB) is a new hybrid technique that combines adhesive bonding with laser seam welding together, and can achieve higher joint strength than adhesive bonding or laser welding individually. Some new physical phenomena have been observed in this welding method, and the phenomena are different from the normal laser welding process, such as a remarkable deeper penetration in LWB than that in laser welding direct (LWD). The adhesive-induced gas can influence the molten pool structure in front of the keyhole, so that less energy is required for laser keyhole through the upper sheet; thus, higher laser power density can interact with the lower sheet, leading to deeper penetration. Simulation comparison experiments are set to indirectly verify these conclusions above.

  12. 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.

  13. Method for welding beryllium

    DOEpatents

    Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

    1997-04-01

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. 9 figs.

  14. Welding Sensor System

    NASA Technical Reports Server (NTRS)

    1993-01-01

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

  15. Method for welding beryllium

    SciTech Connect

    Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

    1995-12-31

    A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. Beryllium parts made using this method can be used as structural components in aircraft, satellites and space applications.

  16. Grinding Parts For Automatic Welding

    NASA Technical Reports Server (NTRS)

    Burley, Richard K.; Hoult, William S.

    1989-01-01

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

  17. 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.

  18. Resistance seam welding

    SciTech Connect

    Hollar, D.L. Jr.

    1992-03-01

    Considerable insight and understanding were achieved in regard to the influence of all of the weld parameters on the seam weld processes at Allied-Signal Inc., Kansas City Division (KCD). Several mechanical improvements were made in the seam weld equipment. The electrode design was modified to include glass bead blasting of the periphery. This greatly improved the electrode performance consistency. Also, the new electrode design defined a refurbishing process that allowed the electrodes to be used up to three times. Originally, the electrodes were discarded after one use. A substantial cost savings resulted form this improvement. A O to 1500 ampere current transformer was inserted in the weld circuit to monitor weld current during the weld as an additional process control element. The transformer is also used to calibrate the weld power supply. A monocular microscope with a cross hair reticle was added to allow more precise electrode alignment. Other improvements included increased brush spring force and the addition of a 5 to 1 gear reduction on the electrode drive motor. 5 refs.

  19. Model of Layered Weld Formation Under Narrow Gap Pulse Welding

    NASA Astrophysics Data System (ADS)

    Krampit, A. G.

    2016-04-01

    The model parameters of narrow gap pulse welding can be divided into input, internal and output ones. The breadth of gap, that is, clearance breadth between upright edges is one of key parameters securing high quality of a weld joint. The paper presents theoretical outcomes for the model of layered weld formation under narrow gap pulse welding. Based on these studies is developed model of processes, which occur in the weld pool under pulse grove welding. It comprises the scheme of liquid metal motion in the weld pool, scheme of fusion with the side edge and in the bottom part, and the scheme of welding current impulse effect on the structure of a weld joint.

  20. Imaging The Leading Edge Of A Weld

    NASA Technical Reports Server (NTRS)

    Mcgee, William F.; Rybicki, Daniel J.

    1994-01-01

    Proposed optical system integrated into plasma arc welding torch provides image of leading edge of weld pool and welding-arc-initiation point. Welding torch aligned better with joint. System includes coherent bundle of optical fibers and transparent cup.

  1. Robotics for welding research

    SciTech Connect

    Braun, G.; Jones, J.

    1984-09-01

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

  2. APPARATUS FOR ARC WELDING

    DOEpatents

    Lingafelter, J.W.

    1960-04-01

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

  3. Thermal stir welding apparatus

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey (Inventor)

    2011-01-01

    A welding method and apparatus are provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

  4. Thermal stir welding process

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey (Inventor)

    2012-01-01

    A welding method is provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

  5. Measurement of workpiece temperature during welding for welding robot control

    NASA Astrophysics Data System (ADS)

    Illegrams, P. F. A.

    MIG/MAG welding robot seam tracking system based on a symetrically noncontact temperature measurement is presented. Using literature in formation on temperature distribution during welding, a model for the prediction of the behavior of a pyrometer twin is constructed. The temperature difference between the measuring points constitutes the signal for a position control of the twin holding welding torch. As temperature measurement is made impossible by radiation originating from the welding arc, this is done during intermittent welding in time intervals in which the welding arc is switched off.

  6. Laser weld jig. [Patent application

    DOEpatents

    Van Blarigan, P.; Haupt, D.L.

    1980-12-05

    A system is provided for welding a workpiece along a predetermined weld line that may be of irregular shape, which includes the step of forming a lip on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members. Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reusable jig forming the lip, and with the jig constructed to detachably hold parts to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

  7. Flow Dynamics in Arc Welding

    SciTech Connect

    Lowke, John J.; Tanaka, Manabu

    2008-02-21

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

  8. Flow Dynamics in Arc Welding

    NASA Astrophysics Data System (ADS)

    Lowke, John J.; Tanaka, Manabu

    2008-02-01

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

  9. Weld failure detection

    DOEpatents

    Pennell, William E.; Sutton, Jr., Harry G.

    1981-01-01

    Method and apparatus for detecting failure in a welded connection, particrly applicable to not readily accessible welds such as those joining components within the reactor vessel of a nuclear reactor system. A preselected tag gas is sealed within a chamber which extends through selected portions of the base metal and weld deposit. In the event of a failure, such as development of a crack extending from the chamber to an outer surface, the tag gas is released. The environment about the welded area is directed to an analyzer which, in the event of presence of the tag gas, evidences the failure. A trigger gas can be included with the tag gas to actuate the analyzer.

  10. Friction stir welding tool

    DOEpatents

    Tolle; Charles R. , Clark; Denis E. , Barnes; Timothy A.

    2008-04-15

    A friction stir welding tool is described and which includes a shank portion; a shoulder portion which is releasably engageable with the shank portion; and a pin which is releasably engageable with the shoulder portion.

  11. Concurrent ultrasonic weld evaluation system

    DOEpatents

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

    1987-01-01

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

  12. Concurrent ultrasonic weld evaluation system

    DOEpatents

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

    1985-09-04

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

  13. Concurrent ultrasonic weld evaluation system

    DOEpatents

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

    1987-12-15

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

  14. Friction Stir Weld Tools

    NASA Technical Reports Server (NTRS)

    Carter, Robert W. (Inventor); Payton, Lewis N. (Inventor)

    2007-01-01

    A friction stir weld tool sleeve is supported by an underlying support pin. The pin material is preferably selected for toughness and fracture characteristics. The pin sleeve preferably has a geometry which employs the use of an interrupted thread, a plurality of flutes and/or eccentric path to provide greater flow through. Paddles have been found to assist in imparting friction and directing plastic metal during the welding process.

  15. Friction stir weld tools

    NASA Technical Reports Server (NTRS)

    Carter, Robert W. (Inventor); Payton, Lewis N. (Inventor)

    2007-01-01

    A friction stir weld tool sleeve is supported by an underlying support pin. The pin material is preferably selected for toughness and fracture characteristics. The pin sleeve preferably has a geometry which employs the use of an interrupted thread, a plurality of flutes and/or eccentric path to provide greater flow through. Paddles have been found to assist in imparting friction and directing plastic metal during the welding process.

  16. Defocusing Techniques for Multi-pass Laser Welding of Austenitic Stainless Steel

    NASA Astrophysics Data System (ADS)

    Karhu, Miikka; Kujanpää, Veli

    This study introduces an experimental work carried out in multi-pass laser welding with cold filler wire and laser-arc hybrid welding of thick section austenitic stainless steel. As it has been demonstrated earlier, hybrid and cold wire welding with a keyhole-mode can offer very efficient way to produce multi-pass welds in narrow gap thick section joints. However, when multi-pass welding is applied to one pass per layer method without e.g. scanning or defocusing, the used groove width needs to be very narrow in order to ensure the proper melting of groove side walls and thus to avoid lack of fusion/cold-run defects. As a consequence of the narrow groove, particularly in thick section joints, the accessibility of an arc torch or a wire nozzle into the very bottom of a groove in root pass welding can be considerably restricted. In an alternative approach described in this paper, a power density of a laser beam spot was purposely dispersed by using a defocusing technique. In groove filling experiments, a power density of defocused laser beam was kept in the range, which led the welding process towards to conduction limited regime and thus enabled to achieve broader weld cross-sections. The object was to study the feasibility of defocusing as a way to fill and bridge wider groove geometries than what can be welded with focused keyhole-mode welding with filler addition. The paper covers the results of multi-pass welding of up to 60 mm thick joints with single side preparations.

  17. Automatic Welding System

    NASA Technical Reports Server (NTRS)

    1982-01-01

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

  18. Weld radiograph enigmas

    NASA Technical Reports Server (NTRS)

    Jemian, Wartan A.

    1986-01-01

    Weld radiograph enigmas are features observed on X-ray radiographs of welds. Some of these features resemble indications of weld defects, although their origin is different. Since they are not understood, they are a source of concern. There is a need to identify their causes and especially to measure their effect on weld mechanical properties. A method is proposed whereby the enigmas can be evaluated and rated, in relation to the full spectrum of weld radiograph indications. Thie method involves a signature and a magnitude that can be used as a quantitive parameter. The signature is generated as the diference between the microdensitometer trace across the radiograph and the computed film intensity derived from a thickness scan along the corresponding region of the sample. The magnitude is the measured difference in intensity between the peak and base line values of the signature. The procedure is demonstated by comparing traces across radiographs of a weld sample before and after the introduction of a hole and by a system based on a MacIntosh mouse used for surface profiling.

  19. Fluid Flow Phenomena during Welding

    SciTech Connect

    Zhang, Wei

    2011-01-01

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

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

    DOEpatents

    Correy, T.B.

    1962-12-11

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

  1. Pre-weld heat treatment improves welds in Rene 41

    NASA Technical Reports Server (NTRS)

    Prager, M.

    1968-01-01

    Cooling of Rene 41 prior to welding reduces the incidence of cracking during post-weld heat treatment. The microstructure formed during the slow cooling rate favors elevated temperature ductility. Some vestiges of this microstructure are apparently retained during welding and thus enhance strain-age crack resistance in air.

  2. Certification of a weld produced by friction stir welding

    SciTech Connect

    Obaditch, Chris; Grant, Glenn J

    2013-10-01

    Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

  3. Welding arc length control system

    NASA Technical Reports Server (NTRS)

    Iceland, William F. (Inventor)

    1993-01-01

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

  4. Remote welding equipment for TPX

    SciTech Connect

    Silke, G.W.; Junge, R.

    1995-12-31

    Remote welding equipment and techniques are necessary for maintenance of the Tokamak Physics Experiment (TPX) Plasma Facing Components (PFCs). The processes identified for this application includes inside diameter (i.d.) and outside diameter (o.d.) Gas Tungsten Arc (GTA) welding of titanium and stainless steel alloys. Welding equipment developed for this application includes some unique features due to the specialized environment of the TPX vessel. Remote features of this equipment must include the ability to acquire and align the parts being welded, perform all welding operations and visually inspect the weld area. Designs for weld heads require the integration of industry proven hardware with the special features include compact size, remote manipulation, remote clamping and alignment, remote vision, full inert gas coverage, arc voltage control, wire feed, programmable weld schedules and failure recovery.

  5. Robotic Welding and Inspection System

    SciTech Connect

    H. B. Smartt; D. P. Pace; E. D. Larsen; T. R. McJunkin; C. I. Nichol; D. E. Clark; K. L. Skinner; M. L. Clark; T. G. Kaser; C. R. Tolle

    2008-06-01

    This paper presents a robotic system for GTA welding of lids on cylindrical vessels. The system consists of an articulated robot arm, a rotating positioner, end effectors for welding, grinding, ultrasonic and eddy current inspection. Features include weld viewing cameras, modular software, and text-based procedural files for process and motion trajectories.

  6. Welding. Performance Objectives. Basic Course.

    ERIC Educational Resources Information Center

    Vincent, Kenneth

    Several intermediate performance objectives and corresponding criterion measures are listed for each of eight terminal objectives for a basic welding course. The materials were developed for a 36-week (2 hours daily) course developed to teach the fundamentals of welding shop work, to become familiar with the operation of the welding shop…

  7. Improved welding of Rene-41

    NASA Technical Reports Server (NTRS)

    Nunez, S.

    1970-01-01

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

  8. Welding. Performance Objectives. Intermediate Course.

    ERIC Educational Resources Information Center

    Vincent, Kenneth

    Several intermediate performance objectives and corresponding criterion measures are listed for each of nine terminal objectives for an intermediate welding course. The materials were developed for a 36-week (3 hours daily) course designed to prepare the student for employment in the field of welding. Electric welding and specialized (TIG & MIG)…

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

    DOEpatents

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

    2013-05-07

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

  10. Study of inertia welding: the sensitivity of weld configuration and strength to variations in welding parameters

    SciTech Connect

    Mote, M.W.

    1981-12-01

    An experiment is described which is designed to demonstrate the forgiveness of inertia welding, that is, the relative insensitivity of weld strength to variations in energy (rotational speed of parts) and axial force. Although easily observed variations in the welding parameters produced easily observed changes in weldment configuration and changes in dimension (upset), only extremes in parameters produced changes in weld strength. Consequently, process monitoring and product inspection would be sufficient for quality assurance in a production environment.

  11. Complex vibration ultrasonic welding systems with large area welding tips.

    PubMed

    Tsujino, Jiromaru; Sano, Tsutomu; Ogata, Hayato; Tanaka, Soichi; Harada, Yoshiki

    2002-05-01

    Vibration and welding characteristics of complex vibration ultrasonic welding systems of 27 and 40 kHz were studied. Complex vibration systems, which have elliptical to circular or rectangular to square locus, are effective for ultrasonic welding of various specimens including the same and different metal specimens, and for direct welding of semiconductor tips and packaging of various electronic devices without solder. The complex vibration systems consist of a one-dimensional longitudinal-torsional vibration converter with slitted part, a stepped horn and a longitudinal vibration transducer as a driving source. The complex vibration welding tips of 27 and 40 kHz have enough area of 6-8 mm square for various welding specimens. Aluminum plate specimens of 0.3-1.0 mm thickness were successfully joined with weld strengths almost equal to aluminum specimen strength, and independent to the specimen direction. Required vibration amplitude of 40 kHz is smaller than that of 27 kHz.

  12. Weld Nugget Temperature Control in Thermal Stir Welding

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey (Inventor)

    2014-01-01

    A control system for a thermal stir welding system is provided. The control system includes a sensor and a controller. The sensor is coupled to the welding system's containment plate assembly and generates signals indicative of temperature of a region adjacent and parallel to the welding system's stir rod. The controller is coupled to the sensor and generates at least one control signal using the sensor signals indicative of temperature. The controller is also coupled to the welding system such that at least one of rotational speed of the stir rod, heat supplied by the welding system's induction heater, and feed speed of the welding system's weld material feeder are controlled based on the control signal(s).

  13. Laser-welded Dissimilar Steel-aluminum Seams for Automotive Lightweight Construction

    NASA Astrophysics Data System (ADS)

    Schimek, M.; Springer, A.; Kaierle, S.; Kracht, D.; Wesling, V.

    By reducing vehicle weight, a significant increase in fuel efficiency and consequently a reduction in CO 2 emissions can be achieved. Currently a high interest in the production of hybrid weld seams between steel and aluminum exists. Previous methods as laser brazing are possible only by using fluxes and additional materials. Laser welding can be used to join steel and aluminum without the use of additives. With a low penetration depth increases in tensile strength can be achieved. Recent results from laser welded overlap seams show that there is no compromise in strength by decreasing penetration depth in the aluminum.

  14. Advanced Welding Torch

    NASA Technical Reports Server (NTRS)

    1996-01-01

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

  15. Extravehicular activity welding experiment

    NASA Technical Reports Server (NTRS)

    Watson, J. Kevin

    1989-01-01

    The In-Space Technology Experiments Program (INSTEP) provides an opportunity to explore the many critical questions which can only be answered by experimentation in space. The objective of the Extravehicular Activity Welding Experiment definition project was to define the requirements for a spaceflight experiment to evaluate the feasibility of performing manual welding tasks during EVA. Consideration was given to experiment design, work station design, welding hardware design, payload integration requirements, and human factors (including safety). The results of this effort are presented. Included are the specific objectives of the flight test, details of the tasks which will generate the required data, and a description of the equipment which will be needed to support the tasks. Work station requirements are addressed as are human factors, STS integration procedures and, most importantly, safety considerations. A preliminary estimate of the cost and the schedule for completion of the experiment through flight and postflight analysis are given.

  16. Pulsed welding plasma source

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

  17. Welding Molecular Crystals.

    PubMed

    Adolf, Cyril R R; Ferlay, Sylvie; Kyritsakas, Nathalie; Hosseini, Mir Wais

    2015-12-16

    Both for fundamental and applied sciences, the design of complex molecular systems in the crystalline phase with strict control of order and periodicity at both microscopic and macroscopic levels is of prime importance for development of new solid-state materials and devices. The design and fabrication of complex crystalline systems as networks of crystals displaying task-specific properties is a step toward smart materials. Here we report on isostructural and almost isometric molecular crystals of different colors, their use for fabrication of core-shell crystals, and their welding by 3D epitaxial growth into networks of crystals as single-crystalline entities. Welding of crystals by self-assembly processes into macroscopic networks of crystals is a powerful strategy for the design of hierarchically organized periodic complex architectures composed of different subdomains displaying targeted characteristics. Crystal welding may be regarded as a first step toward the design of new hierarchically organized complex crystalline systems.

  18. Better welds for launch vehicles

    NASA Technical Reports Server (NTRS)

    Schwinghamer, Robert J.

    1987-01-01

    The use and benefits of automated variable polarity plasma arc (VPPA) welding of Al joints are described. The entire welding system, including welding head manipulator, weld-wire feed, torch, and power supply are computer controlled. The importance of proper torch dynamics and the control of argon gas flow through the plasma orifice are discussed. The use of arc-voltage control, the improvements in system monitoring, and the reduction or elimination of electromagnetic interferences are examined. VPPA welding is applicable to joining Space Shuttle components, and an example of its use on an External Tank of the Shuttle is presented.

  19. Ternary gas plasma welding torch

    NASA Technical Reports Server (NTRS)

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

    1995-01-01

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

  20. 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.

  1. Unique Cryogenic Welded Structures

    NASA Astrophysics Data System (ADS)

    Yushchenko, K. A.; Monko, G. G.

    2004-06-01

    For the last few decades, the E. O. Paton Electric Welding Institute has been active in the field of cryogenic materials science. Integrated research on development of new grades of steels and alloys for cryogenic engineering was carried out in collaboration with the leading institutions of Russia, Ukraine, and Georgia. Commercially applied welding technologies and consumables were developed. They include large, spherical tanks for storage of liquefied gases (from oxygen to helium) under high pressures; space simulators with a capacity of 10 000 m3 and more; and load-carrying elements of superconducting fusion magnetic systems for the TOKAMAK, MGD, and ITER series.

  2. Unique Cryogenic Welded Structures

    SciTech Connect

    Yushchenko, K.A.; Monko, G.G.

    2004-06-28

    For the last few decades, the E. O. Paton Electric Welding Institute has been active in the field of cryogenic materials science. Integrated research on development of new grades of steels and alloys for cryogenic engineering was carried out in collaboration with the leading institutions of Russia, Ukraine, and Georgia. Commercially applied welding technologies and consumables were developed. They include large, spherical tanks for storage of liquefied gases (from oxygen to helium) under high pressures; space simulators with a capacity of 10 000 m3 and more; and load-carrying elements of superconducting fusion magnetic systems for the TOKAMAK, MGD, and ITER series.

  3. Pulsed Long Arc Welding

    NASA Astrophysics Data System (ADS)

    Krampit, N. Yu

    2016-04-01

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

  4. Weld penetration and defect control

    SciTech Connect

    Chin, B.A.

    1992-05-15

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

  5. 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...

  6. 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...

  7. 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...

  8. 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...

  9. 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...

  10. Infrared-Controlled Welding of Solar Cells

    NASA Technical Reports Server (NTRS)

    Paulson, R.; Finnell, S. E.; Decker, H. J.; Hodor, J. R.

    1982-01-01

    Proposed apparatus for welding large arrays of solar cells to flexible circuit substrates would sense infrared emission from welding spot. Emission would provide feedback for control of welding heat. Welding platform containing optical fibers moves upward through slots in movable holding fixture to contact solar cells. Fibers pick up infrared radiation from weld area.

  11. Monitoring Weld Penetration Optically From Within Torch

    NASA Technical Reports Server (NTRS)

    Smith, Matthew A.; Gilbert, Jeffrey L.; Linsacum, Deron L.; Gutlow, David A.

    1993-01-01

    Photodetector or optical fiber leading to photodetector mounted inside gas/tungsten arc welding torch to monitor arc light reflected from oscillating surface of weld pool. Proposed optical monitoring components preserve compact profile of welding torch, maintained in fixed aim at weld-pool position at end of welding torch, and protected against bumping external objects.

  12. Welding Development: Marshall Space Flight Center

    NASA Technical Reports Server (NTRS)

    Ding, Jeff

    2007-01-01

    This paper presents the basic understanding of the friction stir welding process. It covers process description, pin tool operation and materials, metal flow theory, mechanical properties, and materials welded using the process. It also discusses the thermal stir welding process and the differences between thermal stir and friction stir welding. MSFC weld tools used for development are also presented.

  13. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding...

  14. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding...

  15. Method for welding chromium molybdenum steels

    DOEpatents

    Sikka, Vinod K.

    1986-01-01

    Chromium-molybdenum steels exhibit a weakening after welding in an area adjacent to the weld. This invention is an improved method for welding to eliminate the weakness by subjecting normalized steel to a partial temper prior to welding and subsequently fully tempering the welded article for optimum strength and ductility.

  16. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding...

  17. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding...

  18. 49 CFR 192.225 - Welding procedures.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding...

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

    NASA Technical Reports Server (NTRS)

    Looney, Alan

    1991-01-01

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

  20. Deconvoluting the Friction Stir Weld Process for Optimizing Welds

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Nunes, Arthur C.

    2008-01-01

    In the friction stir welding process, the rotating surfaces of the pin and shoulder contact the weld metal and force a rotational flow within the weld metal. Heat, generated by the metal deformation as well as frictional slippage with the contact surface, softens the metal and makes it easier to deform. As in any thermo-mechanical processing of metal, the flow conditions are critical to the quality of the weld. For example, extrusion of metal from under the shoulder of an excessively hot weld may relax local pressure and result in wormhole defects. The trace of the weld joint in the wake of the weld may vary geometrically depending upon the flow streamlines around the tool with some geometry more vulnerable to loss of strength from joint contamination than others. The material flow path around the tool cannot be seen in real time during the weld. By using analytical "tools" based upon the principles of mathematics and physics, a weld model can be created to compute features that can be observed. By comparing the computed observations with actual data, the weld model can be validated or adjusted to get better agreement. Inputs to the model to predict weld structures and properties include: hot working properties ofthe metal, pin tool geometry, travel rate, rotation and plunge force. Since metals record their prior hot working history, the hot working conditions imparted during FSW can be quantified by interpreting the final microstructure. Variations in texture and grain size result from variations in the strain accommodated at a given strain rate and temperature. Microstructural data from a variety of FSWs has been correlated with prior marker studies to contribute to our understanding of the FSW process. Once this stage is reached, the weld modeling process can save significant development costs by reducing costly trial-and-error approaches to obtaining quality welds.

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

    NASA Astrophysics Data System (ADS)

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

    2015-11-01

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

  2. Switchbox for welding torches

    NASA Technical Reports Server (NTRS)

    Burley, R. K.

    1980-01-01

    Switchbox can be used to change from one welding torch setup to another without stopping production line. Simple flip of switch connects gas, water, and power to selected torch. In conventional systems, production must be stopped so that maintenance people can disconnect and reconnect another torch.

  3. Welding Supplementary Units.

    ERIC Educational Resources Information Center

    Johnson, Don; And Others

    This document contains supplemental materials for special needs high school students intended to facilitate their mainstreaming in regular welding classes. Teacher's materials precede the materials for students and include general notes for the instructor, suggestions, eight references, a class progress chart, a questionnaire on the usefulness of…

  4. Welding nozzle position manipulator

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L. (Inventor); Gutow, David A. (Inventor)

    1994-01-01

    The present invention is directed to a welding nozzle position manipulator. The manipulator consists of an angle support to which the remaining components of the device are attached either directly or indirectly. A pair of pivotal connections attach a weld nozzle holding link to the angle support and provide a two axis freedom of movement of the holding link with respect to the support angle. The manipulator is actuated by a pair of adjusting screws angularly mounted to the angle support. These screws contact a pair of tapered friction surfaces formed on the upper portion of the welding nozzle holding link. A spring positioned between the upper portions of the support angle and the holding link provides a constant bias engagement between the friction surfaces of the holding link and the adjustment screws, so as to firmly hold the link in position and to eliminate any free play in the adjustment mechanism. The angular relationships between the adjustment screws, the angle support and the tapered friction surfaces of the weld nozzle holding link provide a geometric arrangement which permits precision adjustment of the holding link with respect to the angle support and also provides a solid holding link mount which is resistant to movement from outside forces.

  5. Welding. Student Learning Guide.

    ERIC Educational Resources Information Center

    Palm Beach County Board of Public Instruction, West Palm Beach, FL.

    This student learning guide contains 30 modules for completing a course in welding. It is designed especially for use in secondary schools in Palm Beach County, Florida. Each module covers one task, and consists of a purpose, performance objective, enabling objectives, learning activities keyed to resources, information sheets, student self-check…

  6. State Skill Standards: Welding

    ERIC Educational Resources Information Center

    Pointer, Mike; Naylor, Randy; Warden, John; Senek, Gene; Shirley, Charles; Lefcourt, Lew; Munson, Justin; Johnson, Art

    2005-01-01

    The Department of Education has undertaken an ambitious effort to develop statewide occupational skill standards. The standards in this document are for welding programs and are designed to clearly state what the student should know and be able to do upon completion of an advanced high-school program. The writing team determined that any statewide…

  7. Welding. Competencies for Articulation.

    ERIC Educational Resources Information Center

    Southeast Community Coll., Lincoln, NE.

    Materials contained in this guide present competencies describing welding skills necessary for success in initial employment or applicable to advanced educational placement, and may be used by administrators, students, and secondary and postsecondary vocational teachers. The student outcomes section provides guidelines for planning of and…

  8. Elementary TIG Welding Skills.

    ERIC Educational Resources Information Center

    Pierson, John E., III

    The text was prepared to help deaf students develop the skills needed by an employed welder. It uses simplified language and illustrations to present concepts which should be reinforced by practical experience with welding skills. Each of the 12 lessons contains: (1) an information section with many illustrations which presents a concept or…

  9. Welding of Stainless Materials

    NASA Technical Reports Server (NTRS)

    Bull, H; Johnson, Lawrence

    1929-01-01

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

  10. Welding. Student Learning Guides.

    ERIC Educational Resources Information Center

    Ridge Vocational-Technical Center, Winter Haven, FL.

    These 23 learning guides are self-instructional packets for 23 tasks identified as essential for performance on an entry-level job in welding. Each guide is based on a terminal performance objective (task) and 1-4 enabling objectives. For each enabling objective, some or all of these materials may be presented: learning steps (outline of student…

  11. Galvanic corrosion of beryllium welds

    SciTech Connect

    Hill, M.A.; Butt, D.P.; Lillard, R.S.

    1997-12-01

    Beryllium is difficult to weld because it is highly susceptible to cracking. The most commonly used filler metal in beryllium welds is Al-12 wt.% Si. Beryllium has been successfully welded using Al-Si filler metal with more than 30 wt.% Al. This filler creates an aluminum-rich fusion zone with a low melting point that tends to backfill cracks. Drawbacks to adding a filler metal include a reduction in service temperature, a lowering of the tensile strength of the weld, and the possibility for galvanic corrosion to occur at the weld. To evaluate the degree of interaction between Be and Al-Si in an actual weld, sections from a mock beryllium weldment were exposed to 0.1 M Cl{sup {minus}} solution. Results indicate that the galvanic couple between Be and the Al-Si weld material results in the cathodic protection of the weld and of the anodic dissolution of the bulk Be material. While the cathodic protection of Al is generally inefficient, the high anodic dissolution rate of the bulk Be during pitting corrosion combined with the insulating properties of the Be oxide afford some protection of the Al-Si weld material. Although dissolution of the Be precipitate in the weld material does occur, no corrosion of the Al-Si matrix was observed.

  12. SHADOW: a new welding technique

    NASA Astrophysics Data System (ADS)

    Kramer, Thorsten; Olowinsky, Alexander M.; Durand, Friedrich

    2002-06-01

    The new welding technique 'SHADOW ' is introduced. SHADOW means the use of a single pulse to generate a quasi continuous weld of several millimeters in length. HET processing time is defined by the pulse duration of the pulsed laser. At present, a state-of-the-art laser is capable of a maximum pulse duration of 20 ms. The variation of the laser power depend on time is a vital capability of the pulsed laser to adapt the energy deposition into the workpiece. Laser beam welds of several watch components were successfully performed. Similar metals like crowns and axes made out of stainless steel have been welded using pulsed laser radiation. Applying a series of about 130 single pulses for the crown-axis combination the total energy accumulates to 19.5 J. The use of the SHADOW welding technique reduces the energy to 2.5 J. While welding dissimilar metals like stainless steel and bras, the SHADOW welding reduces drastically the contamination as well as the distortion. Laser beam welding of copper has a low process reliability due to the high reflection and the high thermal conductivity. SHADOW welds of 3.6 mm length were performed on 250 micrometers thick copper plates with very high reproducibility. As a result, a pilot plant for laser beam welding of copper plates has been set up. The work to be presented has partly been funded by the European Commission in a project under the contract BRPR-CT-0634.

  13. Welding, Bonding and Fastening, 1984

    NASA Technical Reports Server (NTRS)

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

    1985-01-01

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

  14. Small-scale explosive welding of aluminum

    NASA Technical Reports Server (NTRS)

    Bement, L. J.

    1972-01-01

    Welding technique uses very small quantities of explosive ribbon to accomplish small-scale lap-welding of aluminum plates. Technique can perform small controlled welding with no length limitations and requires minimal protective shielding.

  15. Lightweight, High-Current Welding Gun

    NASA Technical Reports Server (NTRS)

    Starck, Thomas F.; Brennan, Andrew D.

    1989-01-01

    Lighweight resistance-welding, hand-held gun supplies alternating or direct current over range of 600 to 4,000 A and applies forces from 40 to 60 lb during welding. Used to weld metal sheets in multilayered stacks.

  16. Torch kit for welding in difficult areas

    NASA Technical Reports Server (NTRS)

    Stein, J. A.

    1971-01-01

    Miniature tungsten inert gas welding torch, used with variously formed interchangeable soft copper tubing extensions, provides inexpensive, accurate welding capability for inaccessible joints. Kit effectively welds stainless steel tubing 0.089 cm thick. Other applications are cited.

  17. Tracking Motions Of Manually Controlled Welding Torches

    NASA Technical Reports Server (NTRS)

    Russell, Carolyn; Gangl, Ken

    1996-01-01

    Techniques for measuring motions of manually controlled welding torches undergoing development. Positions, orientations, and velocities determined in real time during manual arc welding. Makes possible to treat manual welding processes more systematically so manual welds made more predictable, especially in cases in which mechanical strengths and other properties of welded parts highly sensitive to heat inputs and thus to velocities and orientations of welding torches.

  18. Dynamics of space welding impact and corresponding safety welding study.

    PubMed

    Fragomeni, James M; Nunes, Arthur C

    2004-03-01

    This study was undertaken in order to be sure that no hazard would exist from impingement of hot molten metal particle detachments upon an astronauts space suit during any future electron beam welding exercises or experiments. The conditions under which molten metal detachments might occur in a space welding environment were analyzed. The safety issue is important during welding with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at low earth orbit. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were determined for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. A weld pool detachment parameter for specifying the conditions for metal weld pool detachment by impact was derived and correlated to the experimental results. The experimental results were for the most part consistent with the theoretical analysis and predictions.

  19. Industrial laser welding evaluation study

    NASA Technical Reports Server (NTRS)

    Hella, R.; Locke, E.; Ream, S.

    1974-01-01

    High power laser welding was evaluated for fabricating space vehicle boosters. This evaluation was made for 1/4 in. and 1/2 in. aluminum (2219) and 1/4 in. and 1/2 in. D6AC steel. The Avco HPL 10 kW industrial laser was used to perform the evaluation. The objective has been achieved through the completion of the following technical tasks: (1) parameter study to optimize welding and material parameters; (2) preparation of welded panels for MSFC evaluation; and (3) demonstration of the repeatability of laser welding equipment. In addition, the design concept for a laser welding system capable of welding large space vehicle boosters has been developed.

  20. Welding wire pressure sensor assembly

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  1. INERT GAS SHIELD FOR WELDING

    DOEpatents

    Jones, S.O.; Daly, F.V.

    1958-10-14

    S>An inert gas shield is presented for arc-welding materials such as zirconium that tend to oxidize rapidly in air. The device comprises a rectangular metal box into which the welding electrode is introduced through a rubber diaphragm to provide flexibility. The front of the box is provided with a wlndow having a small hole through which flller metal is introduced. The box is supplied with an inert gas to exclude the atmosphere, and with cooling water to promote the solidification of the weld while in tbe inert atmosphere. A separate water-cooled copper backing bar is provided underneath the joint to be welded to contain the melt-through at the root of the joint, shielding the root of the joint with its own supply of inert gas and cooling the deposited weld metal. This device facilitates the welding of large workpieces of zirconium frequently encountered in reactor construction.

  2. Fast, Nonspattering Inert-Gas Welding

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.

    1991-01-01

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

  3. Chrome alloy welding fume study.

    PubMed

    Vorpahl, K W; Jordan, P T; Mathews, E J

    1976-10-01

    Breathing zone samples obtained at a production arc welding operation employing approximately 90 welders demonstrated excessive exposure to chromium from the welding of high chromium alloy steel. Breathing zone samples were collected inside welding helmets. Methods considered for reducing employee exposure included local exhaust ventilation and the use of air-supplied helmets. Air-supplied helmets were chosen as best suited for the production scheme and suitable devices were subsequently developed that reduced breathing zone contaminant levels well below applicable standards.

  4. Jointed Holder For Welding Electrodes

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.

    1991-01-01

    Adjustable-angle holder enables use of standard straight electrode with custom-fabricated bent gas cup for welding in difficult-to-reach places. Electrode replaced easily, without removing cup, with aid of tool loosening miniature collet nut on holder. Consumes fewer electrodes for given amount of welding. Angle of holder continuously adjustable to fit angle of gas cup or geometry of part welded. Holder made double-jointed to accommodate gas cup having compound angles.

  5. Pulsed ultrasonic stir welding system

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey (Inventor)

    2013-01-01

    An ultrasonic stir welding system includes a welding head assembly having a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. During a welding operation, ultrasonic pulses are applied to the rod as it rotates about its longitudinal axis. The ultrasonic pulses are applied in such a way that they propagate parallel to the longitudinal axis of the rod.

  6. Steel Collet For Welding Electrodes

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Gutow, David A.; Burley, Richard K.; Fogul, Irving

    1992-01-01

    Improved steel collet holds electrode for tungsten inert-gas welding but allows quick and easy replacement. Also ensures reliable arc starting. Slip-on compression ring compresses tapered section of body of collet around inner end of welding electrode. Collet mounted in receptacle below stack of lenses and filters in coaxial-vision welding torch. Blind hole in collet protects outermost lens from damage by electrode.

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

  8. Pulsed ultrasonic stir welding method

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey (Inventor)

    2013-01-01

    A method of performing ultrasonic stir welding uses a welding head assembly to include a plate and a rod passing through the plate. The rod is rotatable about a longitudinal axis thereof. In the method, the rod is rotated about its longitudinal axis during a welding operation. During the welding operation, a series of on-off ultrasonic pulses are applied to the rod such that they propagate parallel to the rod's longitudinal axis. At least a pulse rate associated with the on-off ultrasonic pulses is controlled.

  9. Health hazards of welding fumes.

    PubMed

    Meo, Sultan A; Al-Khlaiwi, Thamir

    2003-11-01

    Even in the twenty-first century, welding is still a common and a highly skilled occupation. The hazardous agents associated with welding processes are acetylene, carbon monoxide, oxides of nitrogen, ozone, phosgene, tungsten, arsenic, beryllium, cadmium, chromium, cobalt, copper, iron, lead, manganese, nickel, silver, tin, and zinc. All welding processes involve the potential hazards for inhalation exposures that may lead to acute or chronic respiratory diseases. According to literature described earlier it has been suggested that welding fumes cause the lung function impairment, obstructive and restrictive lung disease, cough, dyspnea, rhinitis, asthma, pneumonitis, pneumoconiosis, carcinoma of the lungs. In addition, welding workers suffer from eye irritation, photokeratitis, cataract, skin irritation, erythema, pterygium, non-melanocytic skin cancer, malignant melanoma, reduced sperm count, motility and infertility. Most of the studies have been attempted previously to evaluate the effects of welding fumes. However, no collectively effort illuminating the general effects of welding fumes on different organs or systems or both in human has not been published. Therefore, the aim of this review is to gather the potential toxic effects of welding fumes documented by individual efforts and provide informations to community on hazards of welding.

  10. Thick SS316 materials TIG welding development activities towards advanced fusion reactor vacuum vessel applications

    NASA Astrophysics Data System (ADS)

    Kumar, B. Ramesh; Gangradey, R.

    2012-11-01

    Advanced fusion reactors like ITER and up coming Indian DEMO devices are having challenges in terms of their materials design and fabrication procedures. The operation of these devices is having various loads like structural, thermo-mechanical and neutron irradiation effects on major systems like vacuum vessel, divertor, magnets and blanket modules. The concept of double wall vacuum vessel (VV) is proposed in view of protecting of major reactor subsystems like super conducting magnets, diagnostic systems and other critical components from high energy 14 MeV neutrons generated from fusion plasma produced by D-T reactions. The double walled vacuum vessel is used in combination with pressurized water circulation and some special grade borated steel blocks to shield these high energy neutrons effectively. The fabrication of sub components in VV are mainly used with high thickness SS materials in range of 20 mm- 60 mm of various grades based on the required protocols. The structural components of double wall vacuum vessel uses various parts like shields, ribs, shells and diagnostic vacuum ports. These components are to be developed with various welding techniques like TIG welding, Narrow gap TIG welding, Laser welding, Hybrid TIG laser welding, Electron beam welding based on requirement. In the present paper the samples of 20 mm and 40 mm thick SS 316 materials are developed with TIG welding process and their mechanical properties characterization with Tensile, Bend tests and Impact tests are carried out. In addition Vickers hardness tests and microstructural properties of Base metal, Heat Affected Zone (HAZ) and Weld Zone are done. TIG welding application with high thick SS materials in connection with vacuum vessel requirements and involved criticalities towards welding process are highlighted.

  11. Laser beam welding of any metal.

    SciTech Connect

    Leong, K. H.

    1998-10-01

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

  12. Mechanics and mechanisms of ultrasonic metal welding

    NASA Astrophysics Data System (ADS)

    de Vries, Edgar

    During ultrasonic welding of sheet metal, normal and shear forces act on the parts to be welded and the weld interface. These forces are a result of the ultrasonic vibrations of the tool, pressed onto the parts to be welded. Furthermore they determine the weld quality and the power that is needed to produce the weld. The main goal in this study is to measure and calculate the tangential forces during ultrasonic metal welding that act on the parts and the weld interface and correlate them to weld quality. In this study a mechanics based model was developed which included a model for the temperature generation during welding and its effect on the mechanical material properties. This model was then used to calculate the interface forces during welding. The model results were in good agreement with the experimental results, which included the measured shear force during welding. With the knowledge of the forces that act at the interface it might be possible to control weld quality (strength) and avoid sonotrode welding (sticking of the sonotrode to the parts). Without a solution to these two problems USMW will never be applicable to large scale automated production use, despite its advantages. In the experiments the influence of part dimensions, friction coefficient, normal force and vibration amplitude on weld quality and sonotrode adhesion were examined. The presented model is capable of predicting and explaining unfavorable welding conditions, therefore making it possible to predetermine weld locations on larger parts or what surface preparation of the parts to be welded would lead to an improved welding result. Furthermore shear force at the anvil measured during welding could be correlated to changing welding conditions. This is a new approach of explaining the process of USMW, because it is based on mechanical considerations. The use of a shear force measuring anvil has the potential to be implemented into welding systems and the shear force would provide an

  13. Comparison Between Keyhole Weld Model and Laser Welding Experiments

    SciTech Connect

    Wood, B C; Palmer, T A; Elmer, J W

    2002-09-23

    A series of laser welds were performed using a high-power diode-pumped continuous-wave Nd:YAG laser welder. In a previous study, the experimental results of those welds were examined, and the effects that changes in incident power and various welding parameters had on weld geometry were investigated. In this report, the fusion zones of the laser welds are compared with those predicted from a laser keyhole weld simulation model for stainless steels (304L and 21-6-9), vanadium, and tantalum. The calculated keyhole depths for the vanadium and 304L stainless steel samples fit the experimental data to within acceptable error, demonstrating the predictive power of numerical simulation for welds in these two materials. Calculations for the tantalum and 21-6-9 stainless steel were a poorer match to the experimental values. Accuracy in materials properties proved extremely important in predicting weld behavior, as minor changes in certain properties had a significant effect on calculated keyhole depth. For each of the materials tested, the correlation between simulated and experimental keyhole depths deviated as the laser power was increased. Using the model as a simulation tool, we conclude that the optical absorptivity of the material is the most influential factor in determining the keyhole depth. Future work will be performed to further investigate these effects and to develop a better match between the model and the experimental results for 21-6-9 stainless steel and tantalum.

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

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

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

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

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

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

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

    ERIC Educational Resources Information Center

    Missouri Univ., Columbia. Instructional Materials Lab.

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

  17. 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.

  18. 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.

  19. Control of back weld pool shape in MIG welding by using switch back method

    SciTech Connect

    Jin, B.; Kaneko, Yasuyoshi; Soeda, Masahiro; Ohshima, Kenji

    1995-12-31

    This paper deals with the problem concerning the sensing and controlling of weld pool shape in MIG welding of plate. In the robotic one side MIG welding process without backing plate, for obtaining the good quality of the weld, it is important to control the weld pool shape so as to prevent the melting metal from burning through. The method of controlling the weld pool shape is discussed. The moving torch is repeat switch change, which is named switch back method. The primary welding experimental results have proved that the switch back method is effective and satisfactory for controlling the back weld pool shape in one side MIG welding process without backing plate.

  20. A study of the radiation of a Nd:YAG laser-MIG hybrid plasma

    NASA Astrophysics Data System (ADS)

    Li, Zhiyong; Wang, Wei; Wang, Xuyou; Li, Huan

    2010-02-01

    To study the coupling of a Nd:YAG laser beam and a MIG arc with the spectrum of the plasma, a new hollow probe method is used to collect radiation from specific points within the arc plasma. With the probe, the spatial distributions of the MIG arc radiation with and without the Nd:YAG laser hybrid plasma are collected and analyzed by a fiber spectrometer. Through analysis of the spectrum, radiation in the ultraviolet (Fe II dominated), visible (Fe I dominated) and infra (Ar I dominated) spectral zones are acquired for comparison of the difference between the MIG and Laser-MIG hybrid welding processes. The electronic temperature is calculated using the Boltzmann plot method and the electronic density is calculated using the Stark broadening method. The results show that the Laser-MIG hybrid welding processes cause the plasma energy to focus on the center of the welding arc and approach the welding pool. An ionizing duct abundant with Fe ions will be formed near the position of the impinging laser beam, which makes the welding arc stable. The electronic temperature of the Laser-MIG hybrid welding arc is a little higher than that of the MIG. The electronic density of Laser-MIG hybrid welding is higher than that of the MIG.

  1. [New welding processes and health effects of welding].

    PubMed

    La Vecchia, G Marina; Maestrelli, Piero

    2011-01-01

    This paper describes some of the recent developments in the control technology to enhance capability of Pulse Gas Metal Arc Welding. Friction Stir Welding (FSW) processing has been also considered. FSW is a new solid-state joining technique. Heat generated by friction at the rotating tool softens the material being welded. FSW can be considered a green and energy-efficient technique without deleterious fumes, gas, radiation, and noise. Application of new welding processes is limited and studies on health effects in exposed workers are lacking. Acute and chronic health effects of conventional welding have been described. Metal fume fever and cross-shift decline of lung function are the main acute respiratory effects. Skin and eyes may be affected by heat, electricity and UV radiations. Chronic effects on respiratory system include chronic bronchitis, a benign pneumoconiosis (siderosis), asthma, and a possible increase in the incidence of lung cancer. Pulmonary infections are increased in terms of severity, duration, and frequency among welders.

  2. Narrow groove welding gas diffuser assembly and welding torch

    SciTech Connect

    Rooney, Stephen J.

    2000-02-04

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

  3. Narrow groove welding gas diffuser assembly and welding torch

    DOEpatents

    Rooney, Stephen J.

    2001-01-01

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

  4. Plating To Reinforce Welded Joints

    NASA Technical Reports Server (NTRS)

    Otousa, J. E.

    1982-01-01

    Electrodeposition used to strengthen welded joints gouged, nicked, or suffered other mechanical damage. Plating cell, typically of acrylic plastic such as poly (Methylmetacrylate), is assembled around part to be plated. Areas not to be plated are masked with plater's tape. Weld area is plated in standard nickel-plating process.

  5. Fibrogenic potential of welding fumes.

    PubMed

    Stern, R M; Pigott, G H; Abraham, J L

    1983-02-01

    A search of 3600 indexed pathology cases has disclosed pulmonary fibrosis in 29 welders. Scanning electron microscopy of biopsy material revealed macrophages laden with inorganic particulates which have characteristics compatible with welding aerosols. In order to establish a possible relationship between fibrotic reaction and welding-fume exposure, the fibrogenic potential fo some 11 different welding fumes and metallic aerosols, considered to be reference standard surrogates for the commonly used welding technologies and applications responsible for 70% of welders exposure, were screened using the Rat Peritoneal Macrophage in vitro bioassay. Only one class of fumes, that from the manual metal arc welding of stainless steel, showed distinct fibrogenic potential. This fume is, however, not common to more than four or five of the heretofore 90 cases of pulmonary fibrosis reported among welders. Thus, although insoluble Cr(VI) is probably the active fibrogen in stainless steel fumes, an etiological factor common to all fibrogenic welding exposures must be sought. It is tentatively proposed to be NO2, a potential experimental in vivo fibrogen copiously produced by certain welding processes and ubiquitous at low concentrations in the welding environment.

  6. New explosive seam welding concepts

    NASA Technical Reports Server (NTRS)

    Bement, L. J.

    1973-01-01

    Recently developed techniques provide totally-confined linear explosive seam welding and produce scarf joint with linear explosive seam welding. Linear ribbon explosives are utilized in making narrow, continuous, airtight joints in variety of aluminum alloys, titanium, copper, brass, and stainless steel.

  7. Welding--Trade or Profession?

    ERIC Educational Resources Information Center

    Albright, C. E.; Smith, Kenneth

    2006-01-01

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

  8. Metal Working and Welding Operations.

    ERIC Educational Resources Information Center

    Marine Corps Inst., Washington, DC.

    This student guide, one of a series of correspondence training courses designed to improve the job performance of members of the Marine Corps, deals with the skills needed by metal workers and welders. Addressed in the six individual units of the course are the following topics: weldable metals and their alloys, arc welding, gas welding,…

  9. Welding Education Research (1964-1984).

    ERIC Educational Resources Information Center

    Bacon, Charles Frederick

    A research project, which involved a review of welding education research and surveys of welders in two states and the presidents of chapters of the American Welding Society throughout the United States, was conducted to gather empirical data from which welding curricula may be revised so as to reflect the changes in the welding industry caused by…

  10. Redundant Grounding Circuit For Arc Welding

    NASA Technical Reports Server (NTRS)

    Burley, Richard K.

    1988-01-01

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

  11. 49 CFR 195.214 - Welding procedures.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler...

  12. 49 CFR 195.214 - Welding procedures.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler...

  13. 49 CFR 195.214 - Welding procedures.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler...

  14. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 29 Labor 5 2014-07-01 2014-07-01 false Resistance welding. 1910.255 Section 1910.255 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.255 Resistance welding. (a.... Ignitron tubes used in resistance welding equipment shall be equipped with a thermal protection switch....

  15. 49 CFR 195.214 - Welding procedures.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler...

  16. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 29 Labor 5 2012-07-01 2012-07-01 false Resistance welding. 1910.255 Section 1910.255 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.255 Resistance welding. (a.... Ignitron tubes used in resistance welding equipment shall be equipped with a thermal protection switch....

  17. 49 CFR 179.300-9 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.300-9 Section 179.300-9... Specifications for Multi-Unit Tank Car Tanks (Classes DOT-106A and 110AW) § 179.300-9 Welding. (a) Longitudinal... fusion welded on class DOT-110A tanks. Welding procedures, welders and fabricators must be approved...

  18. 29 CFR 1910.255 - Resistance welding.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 29 Labor 5 2013-07-01 2013-07-01 false Resistance welding. 1910.255 Section 1910.255 Labor... OCCUPATIONAL SAFETY AND HEALTH STANDARDS Welding, Cutting and Brazing § 1910.255 Resistance welding. (a.... Ignitron tubes used in resistance welding equipment shall be equipped with a thermal protection switch....

  19. 49 CFR 195.214 - Welding procedures.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler...

  20. Clamp and Gas Nozzle for TIG Welding

    NASA Technical Reports Server (NTRS)

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

    1982-01-01

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

  1. Highly efficient welding power supply

    NASA Astrophysics Data System (ADS)

    Thommes, J. M.

    1980-09-01

    The results and findings of an energy efficient welding power development project are presented. The power source developed is to be used for electric arc welding processes in which 3.5 trillion Btu of energy can be saved annually. The power source developed incorporates the use of switch mode power supply techniques in order to convert industrial supply mains to appropriate welding voltages and currents. A series capacitor switch mode power circuit was the circuit technique chosen in order to optimize energy efficiency, costs, reliability, size/weight, and welding performance. Test results demonstrated an effective efficiency (taking into account idle power consumption) of 80 to 91 percent for the energy efficient power source while the conventional types of power sources tested ranged from 41 to 74 percent efficiency. Line power factor was also improved for the energy efficient power source. Field tests indicated additional refinements of weld process performance and power source audible noise emission reduction could be beneficial.

  2. Welding of high chromium steels

    NASA Technical Reports Server (NTRS)

    Miller, W B

    1928-01-01

    A brief description is given of different groups of high chromium steels (rustless iron and stainless steels) according to their composition and more generally accepted names. The welding procedure for a given group will be much the same regardless of the slight variations in chemical composition which may exist within a certain group. Information is given for the tensile properties (yield point and ultimate strength) of metal sheets and welds before and after annealing on coupons one and one-half inches wide. Since welds in rustless iron containing 16 to 18 percent chromium and 7 to 12 percent nickel show the best combination of strength and ductility in the 'as welded' or annealed condition, it is considered the best alloy to use for welded construction.

  3. Displaced electrode process for welding

    DOEpatents

    Heichel, L.J.

    1975-08-26

    A method is described for the butt-welding of a relatively heavy mass to a relatively small mass such as a thin-wall tube. In butt-welding heat is normally applied at the joint between the two pieces which are butt-welded together. The application of heat at the joint results in overheating the tube which causes thinning of the tube walls and porosity in the tube material. This is eliminated by displacing the welding electrode away from the seam toward the heavier mass so that heat is applied to the heavy mass and not at the butt seam. Examples of the parameters used in welding fuel rods are given. The cladding and end plugs were made of Zircalloy. The electrode used was of 2 percent thoriated tungsten. (auth)

  4. Reduction of Biomechanical and Welding Fume Exposures in Stud Welding.

    PubMed

    Fethke, Nathan B; Peters, Thomas M; Leonard, Stephanie; Metwali, Mahmoud; Mudunkotuwa, Imali A

    2016-04-01

    The welding of shear stud connectors to structural steel in construction requires a prolonged stooped posture that exposes ironworkers to biomechanical and welding fume hazards. In this study, biomechanical and welding fume exposures during stud welding using conventional methods were compared to exposures associated with use of a prototype system that allowed participants to weld from an upright position. The effect of base material (i.e. bare structural beam versus galvanized decking) on welding fume concentration (particle number and mass), particle size distribution, and particle composition was also explored. Thirty participants completed a series of stud welding simulations in a local apprenticeship training facility. Use of the upright system was associated with substantial reductions in trunk inclination and the activity levels of several muscle groups. Inhalable mass concentrations of welding fume (averaged over ~18 min) when using conventional methods were high (18.2 mg m(-3) for bare beam; 65.7 mg m(-3) for through deck), with estimated mass concentrations of iron (7.8 mg m(-3) for bare beam; 15.8 mg m(-3) for through deck), zinc (0.2 mg m(-3) for bare beam; 15.8 mg m(-3) for through deck), and manganese (0.9 mg m(-3) for bare beam; 1.5 mg m(-3) for through deck) often exceeding the American Conference of Governmental Industrial Hygienists Threshold Limit Values (TLVs). Number and mass concentrations were substantially reduced when using the upright system, although the total inhalable mass concentration remained above the TLV when welding through decking. The average diameters of the welding fume particles for both bare beam (31±17 nm) through deck conditions (34±34 nm) and the chemical composition of the particles indicated the presence of metallic nanoparticles. Stud welding exposes ironworkers to potentially high levels of biomechanical loading (primarily to the low back) and welding fume. The upright system used in this study improved exposure

  5. Method for controlling gas metal arc welding

    DOEpatents

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

    1989-01-01

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

  6. Method for controlling gas metal arc welding

    DOEpatents

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

    1987-08-10

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

  7. Automatic welding of stainless steel tubing

    NASA Technical Reports Server (NTRS)

    Clautice, W. E.

    1978-01-01

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

  8. U-Groove aluminum weld strength improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1996-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe peaking, which induces bending under uniaxial loading. The filler strain-hardening decreased with increasing filler pass sequence, producing the weakest welds on the last pass side. Current welding schedules unknowingly compound these effects which reduce the weld strength. A depeaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve depeaking in the welding process. The intent is to combine the strongest weld pass side with the peaking induced bending tension to provide a more uniform stress and stronger weld under axial tensile loading.

  9. U-groove aluminum weld strength improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1995-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe peaking which induces bending under uniaxial loading. The filler strain-hardening deceased with increasing filler pass sequence, producing the weakest welds on the last pass side. Current welding schedules unknowingly compound these effects which reduce the weld strength. A de-peaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve de-peaking in the welding process. Intent is to combine the strongest weld pass side with the peaking induced bending tension to provide a more uniform stress and stronger weld under axial tensile loading.

  10. 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.

  11. X-ray tomographic in-service inspection of girth welds - The European project TomoWELD

    NASA Astrophysics Data System (ADS)

    Ewert, Uwe; Redmer, Bernhard; Walter, David; Thiessenhusen, Kai-Uwe; Bellon, Carsten; Nicholson, P. Ian; Clarke, Alan L.; Finke-Härkönen, Klaus-Peter

    2015-03-01

    The new standard 'ISO 17636-2:2013: Non-destructive testing of welds - Radiographic testing - Part 2: X- and gamma-ray techniques with digital detectors', defines the practice for radiographic inspection of welded pipes for manufacturing and in-service inspection. It is applied in Europe for inspections of pipe welds in nuclear power plants as well as in chemical plants and allows a faster inspection with digital detector arrays (DDA) than with film. Nevertheless, it does not allow the evaluation of the depth and shape of volumetric and planar indications. In 2001 a planar tomography scanner, TomoCAR, was introduced for mechanized radiographic testing (RT) inspection and non-destructive measurement of cross sections. The project TomoWELD is based on a new concept of the scan geometry, an enhanced GPU based reconstruction, and the application of a new generation of photon counting DDAs based on CdTe crystal CMOS hybrids. The new detector permits the selection of energy thresholds to obtain an optimum energy range and reduction of the influence of scattered radiation. The concept and first measurements are presented. Flaw depth and shape of volumetric and planar irregularities can be determined.

  12. X-ray tomographic in-service inspection of girth welds - The European project TomoWELD

    SciTech Connect

    Ewert, Uwe Redmer, Bernhard Walter, David Thiessenhusen, Kai-Uwe Bellon, Carsten; Nicholson, P. Ian; Clarke, Alan L.; Finke-Härkönen, Klaus-Peter

    2015-03-31

    The new standard 'ISO 17636-2:2013: Non-destructive testing of welds - Radiographic testing - Part 2: X- and gamma-ray techniques with digital detectors', defines the practice for radiographic inspection of welded pipes for manufacturing and in-service inspection. It is applied in Europe for inspections of pipe welds in nuclear power plants as well as in chemical plants and allows a faster inspection with digital detector arrays (DDA) than with film. Nevertheless, it does not allow the evaluation of the depth and shape of volumetric and planar indications. In 2001 a planar tomography scanner, TomoCAR, was introduced for mechanized radiographic testing (RT) inspection and non-destructive measurement of cross sections. The project TomoWELD is based on a new concept of the scan geometry, an enhanced GPU based reconstruction, and the application of a new generation of photon counting DDAs based on CdTe crystal CMOS hybrids. The new detector permits the selection of energy thresholds to obtain an optimum energy range and reduction of the influence of scattered radiation. The concept and first measurements are presented. Flaw depth and shape of volumetric and planar irregularities can be determined.

  13. Versatile Friction Stir Welding/Friction Plug Welding System

    NASA Technical Reports Server (NTRS)

    Carter, Robert

    2006-01-01

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

  14. NASA Design Strengthens Welds

    NASA Technical Reports Server (NTRS)

    2008-01-01

    Friction Stir Welding (FSW) is a solid-state joining process-a combination of extruding and forging-ideal for use when the original metal characteristics must remain as unchanged as possible. While exploring methods to improve the use of FSW in manufacturing, engineers at Marshall Space Flight Center created technologies to address the method's shortcomings. MTS Systems Corporation, of Eden Prairie, Minnesota, discovered the NASA-developed technology and then signed a co-exclusive license agreement to commercialize Marshall's design for use in high-strength structural alloys. The resulting process offers the added bonuses of being cost-competitive, efficient, and most importantly, versatile.

  15. Study of Gasdynamic Effect Upon the Weld Geometry When Concumable Electrode Welding

    NASA Astrophysics Data System (ADS)

    Chinakhov, D. A.; Grigorieva, E. G.; Mayorova, E. I.

    2016-04-01

    The paper considers the ways of weld geometry controlling when consumable electrode welding under single-jet and double-jet gas shielding. The authors provide comparative results of experimental studies on the effects of shielding gas supply upon the weld geometry in weld joints produced from construction carbon steel 45. It has been established that gas-dynamic effect of the shielding gas has a significant impact upon shaping and weld geometry when consumable electrode welding under double-jet gas shielding.

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

    DOEpatents

    Heiple, C.R.; Burgardt, P.

    1984-03-13

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

  17. Deformation During Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    White, Henry J.

    2002-01-01

    Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.

  18. Laser welding of fused quartz

    DOEpatents

    Piltch, Martin S.; Carpenter, Robert W.; Archer, III, McIlwaine

    2003-06-10

    Refractory materials, such as fused quartz plates and rods are welded using a heat source, such as a high power continuous wave carbon dioxide laser. The radiation is optimized through a process of varying the power, the focus, and the feed rates of the laser such that full penetration welds may be accomplished. The process of optimization varies the characteristic wavelengths of the laser until the radiation is almost completely absorbed by the refractory material, thereby leading to a very rapid heating of the material to the melting point. This optimization naturally occurs when a carbon dioxide laser is used to weld quartz. As such this method of quartz welding creates a minimum sized heat-affected zone. Furthermore, the welding apparatus and process requires a ventilation system to carry away the silicon oxides that are produced during the welding process to avoid the deposition of the silicon oxides on the surface of the quartz plates or the contamination of the welds with the silicon oxides.

  19. A study of weld quality in ultrasonic spot welding of similar and dissimilar metals

    NASA Astrophysics Data System (ADS)

    Al-Sarraf, Z.; Lucas, M.

    2012-08-01

    Several difficulties are faced in joining thinner sheets of similar and dissimilar materials from fusion welding processes such as resistance welding and laser welding. Ultrasonic metal welding overcomes many of these difficulties by using high frequency vibration and applied pressure to create a solid-state weld. Ultrasonic metal welding is an effective technique in joining small components, such as in wire bonding, but is also capable of joining thicker sheet, depending on the control of welding conditions. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal welding device. The ultrasonic welding horn is modelled using finite element analysis and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. Control of the vibration amplitude profile through the weld cycle is used to enhance weld strength and quality, providing an opportunity to reduce part marking. Optical microscopic examination and scanning electron microscopy (SEM) were employed to investigate the weld quality. The results show how the weld quality is particularly sensitive to the combination of clamping force and vibration amplitude of the welding tip.

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

    SciTech Connect

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

    2007-10-01

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

  1. Residual stresses in welded plates

    NASA Technical Reports Server (NTRS)

    Bernstein, Edward L.

    1994-01-01

    The purpose of this project was to develop a simple model which could be used to study residual stress. The mechanism that results in residual stresses in the welding process starts with the deposition of molten weld metal which heats the immediately adjacent material. After solidification of weld material, normal thermal shrinkage is resisted by the adjacent, cooler material. When the thermal strain exceeds the elastic strain corresponding to the yield point stress, the stress level is limited by this value, which decreases with increasing temperature. Cooling then causes elastic unloading which is restrained by the adjoining material. Permanent plastic strain occurs, and tension is caused in the region immediately adjacent to the weld material. Compression arises in the metal farther from the weld in order to maintain overall static equilibrium. Subsequent repair welds may add to the level of residual stresses. The level of residual stress is related to the onset of fracture during welding. Thus, it is of great importance to be able to predict the level of residual stresses remaining after a weld procedure, and to determine the factors, such as weld speed, temperature, direction, and number of passes, which may affect the magnitude of remaining residual stress. It was hoped to use traditional analytical modeling techniques so that it would be easier to comprehend the effect of these variables on the resulting stress. This approach was chosen in place of finite element methods so as to facilitate the understanding of the physical processes. The accuracy of the results was checked with some existing experimental studies giving residual stress levels found from x-ray diffraction measurements.

  2. Automated Variable-Polarity Plasma-Arc Welding

    NASA Technical Reports Server (NTRS)

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

    1984-01-01

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

  3. Laser welding and post weld treatment of modified 9Cr-1MoVNb steel.

    SciTech Connect

    Xu, Z.

    2012-04-03

    Laser welding and post weld laser treatment of modified 9Cr-1MoVNb steels (Grade P91) were performed in this preliminary study to investigate the feasibility of using laser welding process as a potential alternative to arc welding methods for solving the Type IV cracking problem in P91 steel welds. The mechanical and metallurgical testing of the pulsed Nd:YAG laser-welded samples shows the following conclusions: (1) both bead-on-plate and circumferential butt welds made by a pulsed Nd:YAG laser show good welds that are free of microcracks and porosity. The narrow heat affected zone has a homogeneous grain structure without conventional soft hardness zone where the Type IV cracking occurs in conventional arc welds. (2) The laser weld tests also show that the same laser welder has the potential to be used as a multi-function tool for weld surface remelting, glazing or post weld tempering to reduce the weld surface defects and to increase the cracking resistance and toughness of the welds. (3) The Vicker hardness of laser welds in the weld and heat affected zone was 420-500 HV with peak hardness in the HAZ compared to 240 HV of base metal. Post weld laser treatment was able to slightly reduce the peak hardness and smooth the hardness profile, but failed to bring the hardness down to below 300 HV due to insufficient time at temperature and too fast cooling rate after the time. Though optimal hardness of weld made by laser is to be determined for best weld strength, methods to achieve the post weld laser treatment temperature, time at the temperature and slow cooling rate need to be developed. (4) Mechanical testing of the laser weld and post weld laser treated samples need to be performed to evaluate the effects of laser post treatments such as surface remelting, glazing, re-hardening, or tempering on the strength of the welds.

  4. Novel Process Revolutionizes Welding Industry

    NASA Technical Reports Server (NTRS)

    2008-01-01

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

  5. Welding tritium exposed stainless steel

    SciTech Connect

    Kanne, W.R. Jr.

    1994-11-01

    Stainless steels that are exposed to tritium become unweldable by conventional methods due to buildup of decay helium within the metal matrix. With longer service lives expected for tritium containment systems, methods for welding on tritium exposed material will become important for repair or modification of the systems. Solid-state resistance welding and low-penetration overlay welding have been shown to mitigate helium embrittlement cracking in tritium exposed 304 stainless steel. These processes can also be used on stainless steel containing helium from neutron irradiation, such as occurs in nuclear reactors.

  6. 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.

  7. Weld peaking on heavy aluminum structures

    NASA Technical Reports Server (NTRS)

    Bayless, E.; Poorman, R.; Sexton, J.

    1978-01-01

    Weld peaking is usually undesirable in any welded structure. In heavy structures, the forces involved in the welding process become very large and difficult to handle. With the shuttle's solid rocket booster, the weld peaking resulted in two major problems: (1) reduced mechanical properties across the weld joint, and (2) fit-up difficulties in subsequent assembly operation. Peaking from the weld shrinkage forces can be fairly well predicted in simple structures; however, in welding complicated assemblies, the amount of peaking is unpredictable because of unknown stresses from machining and forming, stresses induced by the fixturing, and stresses from welds in other parts of the assembly. When excessive peaking is encountered, it can be corrected using the shrinkage forces resulting from the welding process. Application of these forces is discussed in this report.

  8. Materials participation in welded joints manufacturing

    NASA Astrophysics Data System (ADS)

    Ghenghea, L. D.

    2016-08-01

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

  9. 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.

  10. Gas Shielding Technology for Welding and Brazing

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur J.; Gradl, Paul R.

    2012-01-01

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

  11. Welding process modelling and control

    NASA Technical Reports Server (NTRS)

    Romine, Peter L.; Adenwala, Jinen A.

    1993-01-01

    The research and analysis performed, and software developed, and hardware/software recommendations made during 1992 in development of the PC-based data acquisition system for support of Welding Process Modeling and Control is reported. A need was identified by the Metals Processing Branch of NASA Marshall Space Flight Center, for a mobile data aquisition and analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC-based system was chosen. The Welding Measurement System (WMS) is a dedicated instrument, strictly for the use of data aquisition and analysis. Although the WMS supports many of the functions associated with the process control, it is not the intention for this system to be used for welding process control.

  12. Welding Development W87 Baseline

    SciTech Connect

    A. Newman; G. Gibbs; G. K. Hicken

    1998-11-01

    This report covers the development activities used to qualify the Gas Tungsten Arc (FTA) girth weld and the resistance stem attachments on the W87 Base Line (W87BL). Design of experiments was used throughout the development activities.

  13. Etchant for incoloy-903 welds

    NASA Technical Reports Server (NTRS)

    Gerstmeyer, J. A.

    1980-01-01

    Special reagent consists of 1 part 90% lactic acid, 1 part 70% nitric acid, and 4 part, 37% hydrochloric acid. Solution etches parent and weld metals at same rate, without overetching. Underlying grain structure of both metals is revealed.

  14. Study of solar cell welds

    NASA Technical Reports Server (NTRS)

    Workman, G. L.

    1978-01-01

    The thermal imaging technique was evaluated for its capabilities in the nondestructive evaluation of solar cell welds. The temperature and spatial resolution of state of the art instrumentation was sufficient for both qualitative and quantitative determination of the quality of solar cell welds. The addition of color digitized thermography enhanced the aspects of the thermographic display and allowed easily computerized testing procedures. For automated testing systems an accurate correlation of weld quality with temperature profiles of the welds needs to be performed. In comparison, the holographic technique was complementary with the thermal imaging technique, except that the holographic analysis appeared to be more quantitative at the present time. However, the thermal imaging approach is much more versatile in overall capabilities.

  15. Automatic Control Of Length Of Welding Arc

    NASA Technical Reports Server (NTRS)

    Iceland, William F.

    1991-01-01

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

  16. Weld bonding of titanium with polyimide adhesives

    NASA Technical Reports Server (NTRS)

    Vaughan, R. W.; Sheppard, C. H.; Orell, M. K.

    1975-01-01

    A conductive adhesive primer and a capillary flow adhesive were developed for weld bonding titanium alloy joints. Both formulations contained ingredients considered to be non-carcinogenic. Lap-shear joint test specimens and stringer-stiffened panels were weld bonded using a capillary flow process to apply the adhesive. Static property information was generated for weld bonded joints over the temperature range of 219K (-65 F) to 561K (550 F). The capillary flow process was demonstrated to produce weld bonded joints of equal strength to the weld through weld bonding process developed previously.

  17. Laser based spot weld characterization

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

  18. Pyrothermal treatment of welded joints

    SciTech Connect

    Serikov, S.V.; Idiyatullin, R.S.; Myakushkin, S.N.; Yaufman, V.V.

    1992-03-01

    The results of investigation of the structure and distribution of residual stresses in welded joints in pipes after heat treatment, which includes heating of the surface being treated due to combustion of plates formed from a thermite-type material of pyrotechnic composition, placed around the perimeter of the welded joint, and also an assessment of the level of residual stresses prior to and after pyrotechnic treatment demonstrated the promising nature of the proposed method. 5 refs., 5 figs.

  19. Alignment Tool For Welding Sensor

    NASA Technical Reports Server (NTRS)

    Gilbert, Jeffrey L.; Steffins, Alfred P.

    1992-01-01

    Alignment tool enables accurate positioning of optoelectronic sensor measuring weld penetration. Designed for use on tungsten/inert-gas welding apparatus, used to adjust position of sensor so photodiode puts out maximum signal. Tangs of slotted cap bent slightly inward to provide spring force holding cap snugly on sensor mount. Tool installed and removed without aid of other tools. Length of pointer adjusted with set-screws. Used with variety of gas cup and electrode lengths.

  20. Underwater welding, cutting and inspection

    SciTech Connect

    Tsai, C.L. . Ohio Underwater Welding Center)

    1995-02-01

    Underwater welding, cutting and inspection of offshore, inland waterway and port facilities are becoming a requirement for both military and industrial communities, as maintenance and repair costs continue to escalate, and as many of the facilities are in operation well beyond their intended design life. In nuclear applications, underwater welding, cutting and inspection for repair and modification of irradiated nuclear power plant components are also a requirement. This article summarizes recent developments in this emerging underwater technology.

  1. Pipe weld crown removal device

    DOEpatents

    Sword, Charles K.; Sette, Primo J.

    1992-01-01

    A device is provided for grinding down the crown of a pipe weld joining aligned pipe sections so that the weld is substantially flush with the pipe sections joined by the weld. The device includes a cage assembly comprising a pair of spaced cage rings adapted to be mounted for rotation on the respective pipe sections on opposite sides of the weld, a plurality of grinding wheels, supported by the cage assembly for grinding down the crown of the weld, and a plurality of support shafts, each extending longitudinally along the joined pipe sections, parallel thereto, for individually mounting respective grinding wheels. Each end of the support shafts is mounted for rotation in a bearing assembly housed within a radially directed opening in a corresponding one of the cage rings so as to provide radial movement of the associated shaft, and thus of the associated grinding wheel, towards and away from the weld. A first drive sprocket provides rotation of the cage assembly around the pipe sections while a second drive unit, driven by a common motor, provides rotation of the grinding wheels.

  2. Laser Welding in Electronic Packaging

    NASA Technical Reports Server (NTRS)

    2000-01-01

    The laser has proven its worth in numerous high reliability electronic packaging applications ranging from medical to missile electronics. In particular, the pulsed YAG laser is an extremely flexible and versatile too] capable of hermetically sealing microelectronics packages containing sensitive components without damaging them. This paper presents an overview of details that must be considered for successful use of laser welding when addressing electronic package sealing. These include; metallurgical considerations such as alloy and plating selection, weld joint configuration, design of optics, use of protective gases and control of thermal distortions. The primary limitations on use of laser welding electronic for packaging applications are economic ones. The laser itself is a relatively costly device when compared to competing welding equipment. Further, the cost of consumables and repairs can be significant. These facts have relegated laser welding to use only where it presents a distinct quality or reliability advantages over other techniques of electronic package sealing. Because of the unique noncontact and low heat inputs characteristics of laser welding, it is an ideal candidate for sealing electronic packages containing MEMS devices (microelectromechanical systems). This paper addresses how the unique advantages of the pulsed YAG laser can be used to simplify MEMS packaging and deliver a product of improved quality.

  3. Totally confined explosive welding

    NASA Technical Reports Server (NTRS)

    Bement, L. J. (Inventor)

    1978-01-01

    The undesirable by-products of explosive welding are confined and the association noise is reduced by the use of a simple enclosure into which the explosive is placed and in which the explosion occurs. An infrangible enclosure is removably attached to one of the members to be bonded at the point directly opposite the bond area. An explosive is completely confined within the enclosure at a point in close proximity to the member to be bonded and a detonating means is attached to the explosive. The balance of the enclosure, not occupied by explosive, is filled with a shaped material which directs the explosive pressure toward the bond area. A detonator adaptor controls the expansion of the enclosure by the explosive force so that the enclosure at no point experiences a discontinuity in expansion which causes rupture. The use of the technique is practical in the restricted area of a space station.

  4. NASA welding assessment program

    NASA Technical Reports Server (NTRS)

    Stofel, E. J.

    1984-01-01

    A long duration test has been conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules have been thermally cycled for 36,000 cycles between -80 and +80 C on this JPL and NASA Lewis Research Center sponsored work. This test simulates the environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the Earth's shadow. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived his extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

  5. NASA welding assessment program

    NASA Technical Reports Server (NTRS)

    Stofel, E. J.

    1984-01-01

    A long duration test was conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules were thermally cycled for 36,000 cycles between -80 and +80 C. The environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the earth's shadow was simulated. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived this extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

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

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.

    1985-01-01

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

  7. Upgraded HFIR Fuel Element Welding System

    SciTech Connect

    Sease, John D

    2010-02-01

    The welding of aluminum-clad fuel plates into aluminum alloy 6061 side plate tubing is a unique design feature of the High Flux Isotope Reactor (HFIR) fuel assemblies as 101 full-penetration circumferential gas metal arc welds (GMAW) are required in the fabrication of each assembly. In a HFIR fuel assembly, 540 aluminum-clad fuel plates are assembled into two nested annular fuel elements 610 mm (24-inches) long. The welding process for the HFIR fuel elements was developed in the early 1960 s and about 450 HFIR fuel assemblies have been successfully welded using the GMAW process qualified in the 1960 s. In recent years because of the degradation of the electronic and mechanical components in the old HFIR welding system, reportable defects in plate attachment or adapter welds have been present in almost all completed fuel assemblies. In October 2008, a contract was awarded to AMET, Inc., of Rexburg, Idaho, to replace the old welding equipment with standard commercially available welding components to the maximum extent possible while maintaining the qualified HFIR welding process. The upgraded HFIR welding system represents a major improvement in the welding system used in welding HFIR fuel elements for the previous 40 years. In this upgrade, the new inner GMAW torch is a significant advancement over the original inner GMAW torch previously used. The innovative breakthrough in the new inner welding torch design is the way the direction of the cast in the 0.762 mm (0.030-inch) diameter aluminum weld wire is changed so that the weld wire emerging from the contact tip is straight in the plane perpendicular to the welding direction without creating any significant drag resistance in the feeding of the weld wire.

  8. U-Groove Aluminum Weld Strength Improvement

    NASA Technical Reports Server (NTRS)

    Verderaime, V.; Vaughan, R.

    1997-01-01

    Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. One is the source of peaking in which the extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe angular distortion that induces bending under uniaxial loading. The other is the filler strain hardening decreasing with increasing filler pass sequences, producing the weakest welds on the last weld pass side. Both phenomena are governed by weld pass sequences. Many industrial welding schedules unknowingly compound these effects, which reduce the weld strength. A depeaking index model was developed to select filler pass thickness, pass numbers, and sequences to improve depeaking in the welding process. The result was to select the number and sequence of weld passes to reverse the peaking angle such as to combine the strongest weld pass side with the peaking induced bending tension component side to provide a more uniform stress and stronger weld under axial tensile loading.

  9. Graphite composite truss welding and cap section forming subsystems. Volume 1: Executive summary. [large space structures

    NASA Technical Reports Server (NTRS)

    1980-01-01

    A rolltrusion process was developed for forming of a hybrid, single-ply woven graphite and glass fiber cloth, impregnated with a polysulfone resin and coated with TI02 pigmented P-1700 resin into strips for the on-orbit fabrication of triangular truss segments. Ultrasonic welding in vacuum showed no identifiable effects on weld strength or resin flow characteristics. An existing bench model cap roll forming machine was modified and used to roll form caps for the prototype test truss and for column test specimens in order to test local buckling and torsional instability characteristics.

  10. Development of technique for laser welding of biological tissues using laser welding device and nanocomposite solder.

    PubMed

    Gerasimenko, A; Ichcitidze, L; Podgaetsky, V; Ryabkin, D; Pyankov, E; Saveliev, M; Selishchev, S

    2015-08-01

    The laser device for welding of biological tissues has been developed involving quality control and temperature stabilization of weld seam. Laser nanocomposite solder applied onto a wound to be weld has been used. Physicochemical properties of the nanocomposite solder have been elucidated. The nature of the tissue-organizing nanoscaffold has been analyzed at the site of biotissue welding. PMID:26738200

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

    NASA Astrophysics Data System (ADS)

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

    1996-11-01

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

  12. A Study on the Welding Characteristics of Tailor Welded Blank Metal Sheets Using GTAW and Laser Welding

    NASA Astrophysics Data System (ADS)

    Thasanaraphan, Pornsak

    In this study, a computational and experimental effort was carried out to qualitatively understand the weld pool shape, distortion and residual stress for continuous laser welding and manual pulsed gas metal arc welding. For all the welding simulations given in this dissertation, a welding specific finite element package, SYSWELD, is used. This research focuses on the welding behavior observed in light-weight metal structures known as the tailor-welded blanks, TWBs. They are a combination of two or more metal sheets with different thickness and/or different materials that are welded together in a single plane prior to forming, e.g., stamping. They made from the low carbon steel. As laser welding experiment results show, the weld pool shape at the top and bottom surface, is strongly influenced by surface tension, giving it a characteristic hourglass shape. In order to simulate the hourglass shape, a new volumetric heat source model was developed to predict the transient temperature profile and weld pool shape, including the effect of surface tension. Tailor welded blanks with different thicknesses were examined in the laser welding process. All major physical phenomena such as thermal conduction, heat radiation and convection heat losses are taken into account in the model development as well as temperature-dependant thermal and mechanical material properties. The model is validated for the case of butt joint welding of cold rolled steel sheets. The results of the numerical simulations provide temperature distributions representing the shape of the molten pool, distortion and residual stress with varying laser beam power and welding speed. It is demonstrated that the finite element simulation results are in good agreement with the experiment results. This includes the weld pool shape and sheet metal distortion. While there is no experimental data to compare directly with residual stress results, the distorted shape provides an indirect measure of the welding

  13. The distinctive feature of weld joints structure by adding the nanomodifying to the weld pool

    NASA Astrophysics Data System (ADS)

    Shlyakhova, Galina; Danilov, Vladimir; Kuznetsov, Maxim; Zernin, Evgeny; Kartashov, Evgeny

    2015-10-01

    The experimental studies were carried on for the test samples of welds of the steel 12X18H10T; the results are presented. The effect produced by the nanostructured modifying powders added to the weld pool on the quality of weld joints was examined. The weld joints were obtained by arc welding in argon atmosphere using consumable electrode. Due to the weld pool modification, the dendrite size was found to decrease and a more equilibrium microstructure would form in the weld material.

  14. Study of Welding Distortion and Residual Stress Considering Nonlinear Yield Stress Curves and Multi-constraint Equations

    NASA Astrophysics Data System (ADS)

    Rong, Youmin; Zhang, Guojun; Huang, Yu

    2016-10-01

    Inherent strain analysis has been successfully applied to predict welding deformations of large-scale structural components, while thermal-elastic-plastic finite element method is rarely used for its disadvantages of long calculation period and large storage space. In this paper, a hybrid model considering nonlinear yield stress curves and multi-constraint equations to thermal-elastic-plastic analysis is further proposed to predict welding distortions and residual stresses of large-scale structures. For welding T-joint structural steel S355JR by metal active gas welding, the published experiment results of temperature and displacement fields are applied to illustrate the credibility of the proposed integration model. By comparing numerical results of four different cases with the experiment results, it is verified that prediction precision of welding deformations and residual stresses is apparently improved considering the power-law hardening model, and computational time is also obviously shortened about 30.14% using multi-constraint equations. On the whole, the proposed hybrid method can be further used to precisely and efficiently predict welding deformations and residual stresses of large-scale structures.

  15. Study of Welding Distortion and Residual Stress Considering Nonlinear Yield Stress Curves and Multi-constraint Equations

    NASA Astrophysics Data System (ADS)

    Rong, Youmin; Zhang, Guojun; Huang, Yu

    2016-08-01

    Inherent strain analysis has been successfully applied to predict welding deformations of large-scale structural components, while thermal-elastic-plastic finite element method is rarely used for its disadvantages of long calculation period and large storage space. In this paper, a hybrid model considering nonlinear yield stress curves and multi-constraint equations to thermal-elastic-plastic analysis is further proposed to predict welding distortions and residual stresses of large-scale structures. For welding T-joint structural steel S355JR by metal active gas welding, the published experiment results of temperature and displacement fields are applied to illustrate the credibility of the proposed integration model. By comparing numerical results of four different cases with the experiment results, it is verified that prediction precision of welding deformations and residual stresses is apparently improved considering the power-law hardening model, and computational time is also obviously shortened about 30.14% using multi-constraint equations. On the whole, the proposed hybrid method can be further used to precisely and efficiently predict welding deformations and residual stresses of large-scale structures.

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

    NASA Astrophysics Data System (ADS)

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

    2016-05-01

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

  17. Ultrasonic vibration aided laser welding of Al alloys: Improvement of laser-welding quality

    SciTech Connect

    Kim, J.S.; Watanabe, T.; Yoshida, Y.

    1995-03-01

    Using a pulsed YAG laser, meltability of Al-Mg and Al-Mg-Si alloys were investigated by a single-pass irradiation. In order to improve the quality in laser welding, the effectiveness of the Ultrasonic Vibration Laser Welding (UVLW) method proposed in this paper was investigated experimentally. The proposed method was also compared with the traditional welding methods of Normal Laser Welding (NLW) and preHeating Laser Welding (HLW). The welding methods were evaluated from the geometry in the melt zone generated by a single pulse of the laser beam. It was suggested that ultrasonic vibration suppressed welding defects and improved the melt characteristics due to cavitation effects and dispersion of particles in the molten pool during laser welding. The influence on melt characteristics of the melt zone by preheating was also investigated. In these experiments, UVLW was the most useful laser welding method from the point of view of improving the laser welding quality of Al alloys.

  18. Apparatus for welding blades to rotors

    NASA Technical Reports Server (NTRS)

    Holko, K. H.; Moore, T. J. (Inventor)

    1973-01-01

    Using magnetic force upset welding to form T-joints between dissimilar thickness parts. This type of resistance welding is used to join compressor and turbine parts thereby reducing the weight and cost of a jet engine.

  19. Welding mechanics for advanced component safety assessment

    NASA Astrophysics Data System (ADS)

    Siegele, Dieter

    2011-06-01

    Numerical methods are nowadays a useful tool for the calculation of distortion and residual stresses as a result from the welding process. Modern finite element codes not only allow for calculation of deformations and stresses due to the welding process but also take into account the change of microstructure due to different heating and cooling rates. As an extension to the pure welding simulation, the field of welding mechanics combines the mechanics and the material behaviour from the welding process with the assessment of service behaviour of welded components. In the paper, new results of experimental and numerical work in the field of welding mechanics are described. Through examples from automotive, nuclear and pipe-line applications it is demonstrated that an equilibrated treatment and a close interaction of "process", "properties" and "defects" are necessary to come up with an advanced fitness-forservice assessment of welded components.

  20. Automatic monitoring of vibration welding equipment

    SciTech Connect

    Spicer, John Patrick; Chakraborty, Debejyo; Wincek, Michael Anthony; Wang, Hui; Abell, Jeffrey A; Bracey, Jennifer; Cai, Wayne W

    2014-10-14

    A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.

  1. Polyimide weld bonding for titanium alloy joints

    NASA Technical Reports Server (NTRS)

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

    1974-01-01

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

  2. Repair welding of fusion reactor components

    SciTech Connect

    Chin, B.A.

    1993-05-15

    Experiments have shown that irradiated Type 316 stainless steel is susceptible to heat-affected-zone (HAZ) cracking upon cooling when welded using the gas tungsten arc (GTA) process under lateral constraint. The cracking has been hypothesized to be caused by stress-assisted helium bubble growth and rupture at grain boundaries. This study utilized an experimental welding setup which enabled different compressive stresses to be applied to the plates during welding. Autogenous GTA welds were produced in Type 316 stainless steel doped with 256 appm helium. The application of a compressive stress, 55 MPa, during welding suppressed the previously observed catastrophic cracking. Detailed examinations conducted after welding showed a dramatic change in helium bubble morphology. Grain boundary bubble growth along directions parallel to the weld was suppressed. Results suggest that stress-modified welding techniques may be used to suppress or eliminate helium-induced cracking during joining of irradiated materials.

  3. 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.

  4. Influence of Welding With Two-Jet Gas Shielding On the Shaping of a Welding Joint

    NASA Astrophysics Data System (ADS)

    Chinakhov, D. A.; Chinakhova, E. D.; Grichin, S. V.; Gotovschik, Y. M.

    2016-04-01

    The author considers gas-dynamic influence upon microhardness and weld configuration of single-pass welds from steel 30HGSA when welding with consumable electrode under double-jet shielding. The relations to the chosen controlled welding parameters (Q, L, I) are developed and the controlling influence of the gas-dynamic affect of dynamic shield gas jet over formation of welds from alloy-treated steel 30HGSA is determined.

  5. Preventing Contamination In Electron-Beam Welds

    NASA Technical Reports Server (NTRS)

    Goodin, Wesley D.; Gulbrandsen, Kevin A.; Oleksiak, Carl

    1990-01-01

    Simple expedient eliminates time-consuming, expensive manual hand grinding. Use of groove and backup tube greatly reduces postweld cleanup in some electron-beam welding operations. Tube-backup method developed for titanium parts, configurations of which prevents use of solid-block backup. In new welding configuration, tube inserted in groove to prevent contact between alumina beads and molten weld root. When welding complete and beads and tube removed, only minor spatter remains and is ground away easily.

  6. Pre-resistance-welding resistance check

    DOEpatents

    Destefan, Dennis E.; Stompro, David A.

    1991-01-01

    A preweld resistance check for resistance welding machines uses an open circuited measurement to determine the welding machine resistance, a closed circuit measurement to determine the parallel resistance of a workpiece set and the machine, and a calculation to determine the resistance of the workpiece set. Any variation in workpiece set or machine resistance is an indication that the weld may be different from a control weld.

  7. Thermal treatment of dissimilar steels' welded joints

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

  8. Full-Field Strain Measurement On Titanium Welds And Local Elasto-Plastic Identification With The Virtual Fields Method

    SciTech Connect

    Tattoli, F.; Casavola, C.; Pierron, F.; Rotinat, R.; Pappalettere, C.

    2011-01-17

    One of the main problems in welding is the microstructural transformation within the area affected by the thermal history. The resulting heterogeneous microstructure within the weld nugget and the heat affected zones is often associated with changes in local material properties. The present work deals with the identification of material parameters governing the elasto--plastic behaviour of the fused and heat affected zones as well as the base material for titanium hybrid welded joints (Ti6Al4V alloy). The material parameters are identified from heterogeneous strain fields with the Virtual Fields Method. This method is based on a relevant use of the principle of virtual work and it has been shown to be useful and much less time consuming than classical finite element model updating approaches applied to similar problems. The paper will present results and discuss the problem of selection of the weld zones for the identification.

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

    NASA Astrophysics Data System (ADS)

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

    2009-11-01

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

  10. Automatic Guidance System for Welding Torches

    NASA Technical Reports Server (NTRS)

    Smith, H.; Wall, W.; Burns, M. R., Jr.

    1984-01-01

    Digital system automatically guides welding torch to produce squarebutt, V-groove and lap-joint weldments within tracking accuracy of +0.2 millimeter. Television camera observes and traverses weld joint, carrying welding torch behind. Image of joint digitized, and resulting data used to derive control signals that enable torch to track joint.

  11. Low Speed Control for Automatic Welding

    NASA Technical Reports Server (NTRS)

    Iceland, W. E.

    1982-01-01

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

  12. Neural-Network Modeling Of Arc Welding

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  13. Preventing Arc Welding From Damaging Electronics

    NASA Technical Reports Server (NTRS)

    Sargent, Noel; Mareen, D.

    1988-01-01

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

  14. 49 CFR 195.224 - Welding: Weather.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Welding: Weather. 195.224 Section 195.224 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.224 Welding: Weather. Welding must be protected from weather conditions...

  15. 49 CFR 195.224 - Welding: Weather.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding: Weather. 195.224 Section 195.224 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.224 Welding: Weather. Welding must be protected from weather conditions...

  16. 49 CFR 195.224 - Welding: Weather.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding: Weather. 195.224 Section 195.224 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.224 Welding: Weather. Welding must be protected from weather conditions...

  17. 49 CFR 195.224 - Welding: Weather.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding: Weather. 195.224 Section 195.224 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.224 Welding: Weather. Welding must be protected from weather conditions...

  18. 49 CFR 195.224 - Welding: Weather.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding: Weather. 195.224 Section 195.224 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... PIPELINE Construction § 195.224 Welding: Weather. Welding must be protected from weather conditions...

  19. 49 CFR 179.100-9 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.100-9 Section 179.100-9... Specifications for Pressure Tank Car Tanks (Classes DOT-105, 109, 112, 114 and 120) § 179.100-9 Welding. (a) All..., appendix W (IBR, see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall...

  20. 30 CFR 77.408 - Welding operations.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Welding operations. 77.408 Section 77.408 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE SAFETY AND HEALTH... for Mechanical Equipment § 77.408 Welding operations. Welding operations shall be shielded and...

  1. 49 CFR 179.11 - Welding certification.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding certification. 179.11 Section 179.11 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... § 179.11 Welding certification. (a) Welding procedures, welders and fabricators shall be approved. (b)...

  2. 49 CFR 179.11 - Welding certification.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding certification. 179.11 Section 179.11 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... § 179.11 Welding certification. (a) Welding procedures, welders and fabricators shall be approved. (b)...

  3. 46 CFR 154.665 - Welding procedures.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 46 Shipping 5 2013-10-01 2013-10-01 false Welding procedures. 154.665 Section 154.665 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS... Construction § 154.665 Welding procedures. Welding procedure tests for cargo tanks for a design...

  4. 49 CFR 179.400-11 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.400-11 Section 179.400-11...-11 Welding. (a) Except for closure of openings and a maximum of two circumferential closing joints in... subchapter). (d) Each welding procedure, welder, and fabricator must be approved....

  5. 46 CFR 154.665 - Welding procedures.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 5 2010-10-01 2010-10-01 false Welding procedures. 154.665 Section 154.665 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS... Construction § 154.665 Welding procedures. Welding procedure tests for cargo tanks for a design...

  6. 49 CFR 179.220-10 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.220-10 Section 179.220-10... Specifications for Non-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.220-10 Welding. (a) All joints... of this subchapter). Welding procedures, welders, and fabricators shall be approved. (b)...

  7. 49 CFR 179.300-9 - Welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding. 179.300-9 Section 179.300-9...-Unit Tank Car Tanks (Classes DOT-106A and 110AW) § 179.300-9 Welding. (a) Longitudinal joints must be... class DOT-110A tanks. Welding procedures, welders and fabricators must be approved in accordance...

  8. 30 CFR 77.408 - Welding operations.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Welding operations. 77.408 Section 77.408 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE SAFETY AND HEALTH... for Mechanical Equipment § 77.408 Welding operations. Welding operations shall be shielded and...

  9. 49 CFR 179.200-10 - Welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding. 179.200-10 Section 179.200-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.200-10 Welding. (a) All joints shall be fusion... § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  10. 49 CFR 179.100-9 - Welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding. 179.100-9 Section 179.100-9... Tank Car Tanks (Classes DOT-105, 109, 112, 114 and 120) § 179.100-9 Welding. (a) All joints shall be..., see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  11. 46 CFR 154.660 - Pipe welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 46 Shipping 5 2010-10-01 2010-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet Part 57 of this chapter. (b) Longitudinal butt...

  12. 49 CFR 179.100-9 - Welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding. 179.100-9 Section 179.100-9... Tank Car Tanks (Classes DOT-105, 109, 112, 114 and 120) § 179.100-9 Welding. (a) All joints shall be..., see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  13. 49 CFR 179.200-10 - Welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding. 179.200-10 Section 179.200-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.200-10 Welding. (a) All joints shall be fusion... § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  14. 49 CFR 179.300-9 - Welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding. 179.300-9 Section 179.300-9...-Unit Tank Car Tanks (Classes DOT-106A and 110AW) § 179.300-9 Welding. (a) Longitudinal joints must be... class DOT-110A tanks. Welding procedures, welders and fabricators must be approved in accordance...

  15. 49 CFR 179.400-11 - Welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding. 179.400-11 Section 179.400-11... Liquid Tank Car Tanks and Seamless Steel Tanks (Classes DOT-113 and 107A) § 179.400-11 Welding. (a... welding procedure, welder, and fabricator must be approved....

  16. 46 CFR 154.660 - Pipe welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 46 Shipping 5 2014-10-01 2014-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet part 57 of this chapter. (b) Longitudinal butt...

  17. 49 CFR 179.11 - Welding certification.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding certification. 179.11 Section 179.11 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... § 179.11 Welding certification. (a) Welding procedures, welders and fabricators shall be approved. (b)...

  18. 49 CFR 179.220-10 - Welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding. 179.220-10 Section 179.220-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.220-10 Welding. (a) All joints must be fusion... subchapter). Welding procedures, welders, and fabricators shall be approved. (b) Radioscopy of the...

  19. 49 CFR 179.11 - Welding certification.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding certification. 179.11 Section 179.11 Transportation Other Regulations Relating to Transportation PIPELINE AND HAZARDOUS MATERIALS SAFETY... Design Requirements § 179.11 Welding certification. (a) Welding procedures, welders and fabricators...

  20. 49 CFR 179.200-10 - Welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding. 179.200-10 Section 179.200-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.200-10 Welding. (a) All joints shall be fusion... § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  1. 49 CFR 179.400-11 - Welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding. 179.400-11 Section 179.400-11... Liquid Tank Car Tanks and Seamless Steel Tanks (Classes DOT-113 and 107A) § 179.400-11 Welding. (a... welding procedure, welder, and fabricator must be approved....

  2. 49 CFR 179.100-9 - Welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding. 179.100-9 Section 179.100-9... Tank Car Tanks (Classes DOT-105, 109, 112, 114 and 120) § 179.100-9 Welding. (a) All joints shall be..., see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  3. 49 CFR 179.220-10 - Welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding. 179.220-10 Section 179.220-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.220-10 Welding. (a) All joints must be fusion... subchapter). Welding procedures, welders, and fabricators shall be approved. (b) Radioscopy of the...

  4. 30 CFR 77.408 - Welding operations.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Welding operations. 77.408 Section 77.408 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE SAFETY AND HEALTH... for Mechanical Equipment § 77.408 Welding operations. Welding operations shall be shielded and...

  5. 49 CFR 179.200-10 - Welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding. 179.200-10 Section 179.200-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.200-10 Welding. (a) All joints shall be fusion... § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  6. 49 CFR 179.220-10 - Welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding. 179.220-10 Section 179.220-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.220-10 Welding. (a) All joints must be fusion... subchapter). Welding procedures, welders, and fabricators shall be approved. (b) Radioscopy of the...

  7. 49 CFR 179.300-9 - Welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding. 179.300-9 Section 179.300-9...-Unit Tank Car Tanks (Classes DOT-106A and 110AW) § 179.300-9 Welding. (a) Longitudinal joints must be... class DOT-110A tanks. Welding procedures, welders and fabricators must be approved in accordance...

  8. 46 CFR 154.660 - Pipe welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 5 2011-10-01 2011-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet Part 57 of this chapter. (b) Longitudinal butt...

  9. 49 CFR 179.11 - Welding certification.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Welding certification. 179.11 Section 179.11 Transportation Other Regulations Relating to Transportation (Continued) PIPELINE AND HAZARDOUS MATERIALS SAFETY... § 179.11 Welding certification. (a) Welding procedures, welders and fabricators shall be approved. (b)...

  10. 46 CFR 154.660 - Pipe welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 5 2012-10-01 2012-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet part 57 of this chapter. (b) Longitudinal butt...

  11. 46 CFR 154.665 - Welding procedures.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 46 Shipping 5 2014-10-01 2014-10-01 false Welding procedures. 154.665 Section 154.665 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS... Construction § 154.665 Welding procedures. Welding procedure tests for cargo tanks for a design...

  12. 49 CFR 179.400-11 - Welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding. 179.400-11 Section 179.400-11... Liquid Tank Car Tanks and Seamless Steel Tanks (Classes DOT-113 and 107A) § 179.400-11 Welding. (a... welding procedure, welder, and fabricator must be approved....

  13. 30 CFR 77.408 - Welding operations.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Welding operations. 77.408 Section 77.408 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE SAFETY AND HEALTH... for Mechanical Equipment § 77.408 Welding operations. Welding operations shall be shielded and...

  14. 49 CFR 179.300-9 - Welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding. 179.300-9 Section 179.300-9...-Unit Tank Car Tanks (Classes DOT-106A and 110AW) § 179.300-9 Welding. (a) Longitudinal joints must be... class DOT-110A tanks. Welding procedures, welders and fabricators must be approved in accordance...

  15. 30 CFR 77.408 - Welding operations.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Welding operations. 77.408 Section 77.408 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR COAL MINE SAFETY AND HEALTH... for Mechanical Equipment § 77.408 Welding operations. Welding operations shall be shielded and...

  16. 46 CFR 154.660 - Pipe welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 46 Shipping 5 2013-10-01 2013-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet part 57 of this chapter. (b) Longitudinal butt...

  17. 46 CFR 154.665 - Welding procedures.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 46 Shipping 5 2011-10-01 2011-10-01 false Welding procedures. 154.665 Section 154.665 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS... Construction § 154.665 Welding procedures. Welding procedure tests for cargo tanks for a design...

  18. 49 CFR 179.220-10 - Welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Welding. 179.220-10 Section 179.220-10...-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.220-10 Welding. (a) All joints must be fusion... subchapter). Welding procedures, welders, and fabricators shall be approved. (b) Radioscopy of the...

  19. 46 CFR 154.665 - Welding procedures.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 46 Shipping 5 2012-10-01 2012-10-01 false Welding procedures. 154.665 Section 154.665 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS... Construction § 154.665 Welding procedures. Welding procedure tests for cargo tanks for a design...

  20. 49 CFR 179.200-10 - Welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 2 2010-10-01 2010-10-01 false Welding. 179.200-10 Section 179.200-10... Specifications for Non-Pressure Tank Car Tanks (Classes DOT-111AW and 115AW) § 179.200-10 Welding. (a) All joints... W (IBR, see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall...

  1. 49 CFR 179.100-9 - Welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Welding. 179.100-9 Section 179.100-9... Tank Car Tanks (Classes DOT-105, 109, 112, 114 and 120) § 179.100-9 Welding. (a) All joints shall be..., see § 171.7 of this subchapter). Welding procedures, welders and fabricators shall be approved. (b)...

  2. 49 CFR 179.400-11 - Welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Welding. 179.400-11 Section 179.400-11... Liquid Tank Car Tanks and Seamless Steel Tanks (Classes DOT-113 and 107A) § 179.400-11 Welding. (a... welding procedure, welder, and fabricator must be approved....

  3. Calibration Check For Programmed Welding Robot

    NASA Technical Reports Server (NTRS)

    Sliwinski, Karen E.; Anderson, Ronald R.; Osterloh, Mark R.

    1992-01-01

    Preweld calibration check helps to ensure welding torch on computer-controlled welding robot mounted properly, right gas cup selected, and length of extension of electrode adjusted correctly. Performed by operator just before dry run for each set of parts welded. Procedure takes 2 to 3 minutes and enables correction of errors before parts or equipment damaged.

  4. Welding Using Chilled-Inert-Gas Purging

    NASA Technical Reports Server (NTRS)

    Mcgee, William F.; Rybicki, Daniel J.

    1995-01-01

    Report describes study of fusion welding using chilled inert gas. Marked improvement shown in welding of aluminum using chilled helium gas. Chilling inert gas produces two additional benefits: 1) creation of ultradense inert atmosphere around welds; 2) chilled gas cools metal more quickly down to temperature at which metals not reactive.

  5. Electron Beam Welding to Join Gamma Titanium Aluminide Articles

    NASA Technical Reports Server (NTRS)

    Kelly, Thomas Joseph (Inventor)

    2008-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-09-01

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

  7. Contamination and solid state welds.

    SciTech Connect

    Mills, Bernice E.

    2007-05-01

    Since sensitivity to contamination is one of the verities of solid state joining, there is a need for assessing contamination of the part(s) to be joined, preferably nondestructively while it can be remedied. As the surfaces that are joined in pinch welds are inaccessible and thus provide a greater challenge, most of the discussion is of the search for the origin and effect of contamination on pinch welding and ways to detect and mitigate it. An example of contamination and the investigation and remediation of such a system is presented. Suggestions are made for techniques for nondestructive evaluation of contamination of surfaces for other solid state welds as well as for pinch welds. Surfaces that have good visual access are amenable to inspection by diffuse reflection infrared Fourier transform (DRIFT) spectroscopy. Although other techniques are useful for specific classes of contaminants (such as hydrocarbons), DRIFT can be used most classes of contaminants. Surfaces such as the interior of open tubes or stems that are to be pinch welded can be inspected using infrared reflection spectroscopy. It must be demonstrated whether or not this tool can detect graphite based contamination, which has been seen in stems. For tubes with one closed end, the technique that should be investigated is emission infrared spectroscopy.

  8. High-power Laser Welding of Thick Steel-aluminum Dissimilar Joints

    NASA Astrophysics Data System (ADS)

    Lahdo, Rabi; Springer, André; Pfeifer, Ronny; Kaierle, Stefan; Overmeyer, Ludger

    According to the Intergovernmental Panel on Climate Change (IPCC), a worldwide reduction of CO2-emissions is indispensable to avoid global warming. Besides the automotive sector, lightweight construction is also of high interest for the maritime industry in order to minimize CO2-emissions. Using aluminum, the weight of ships can be reduced, ensuring lower fuel consumption. Therefore, hybrid joints of steel and aluminum are of great interest to the maritime industry. In order to provide an efficient lap joining process, high-power laser welding of thick steel plates (S355, t = 5 mm) and aluminum plates (EN AW-6082, t = 8 mm) is investigated. As the weld seam quality greatly depends on the amount of intermetallic phases within the joint, optimized process parameters and control are crucial. Using high-power laser welding, a tensile strength of 10 kN was achieved. Based on metallographic analysis, hardness tests, and tensile tests the potential of this joining method is presented.

  9. The effect of axial force and contact angle on the welded area of plastic tube welded by ultrasonic welding

    NASA Astrophysics Data System (ADS)

    Thinvongpituk, C.; Bootwong, A.; Watanabe, Y.

    2010-03-01

    This study was aimed to apply the use of ultrasonic welding to weld round plastic tubes. The ultrasonic welding machine was designed to be able to work with a normal ultrasonic welding transducer by rotating the tube while it is being welded. The specimens used in this study were round plastic tubes (PMMA) with diameter of 35 mm and 2 mm thickness. End of each tube was machined to have angle of 2.8, 3.8 and 5.7 degree in order to create contact angle at the interface. The specimens were welded with frequency of 28 kHz and tube rotational speeds of 25 rpm, 45 rpm and 100 rpm. The axial force was applied to the tube in order to enhance the quality of joint. The experimental result revealed that the modified ultrasonic welding machine can generate the welded area around the circumference of tube. It was found that the axial force and contact angle have some effect to the quality of joint. The contact angle of 2.8/2.8 provided highest welded area compared to 3.8/3.8 and 5.7/5.7 degree of contact angle. In addition, the axial force between 80 N - 120 N provided high value of welded area. The pattern of welded area is also presented and discussed in the paper.

  10. The effect of axial force and contact angle on the welded area of plastic tube welded by ultrasonic welding

    NASA Astrophysics Data System (ADS)

    Thinvongpituk, C.; Bootwong, A.; Watanabe, Y.

    2009-12-01

    This study was aimed to apply the use of ultrasonic welding to weld round plastic tubes. The ultrasonic welding machine was designed to be able to work with a normal ultrasonic welding transducer by rotating the tube while it is being welded. The specimens used in this study were round plastic tubes (PMMA) with diameter of 35 mm and 2 mm thickness. End of each tube was machined to have angle of 2.8, 3.8 and 5.7 degree in order to create contact angle at the interface. The specimens were welded with frequency of 28 kHz and tube rotational speeds of 25 rpm, 45 rpm and 100 rpm. The axial force was applied to the tube in order to enhance the quality of joint. The experimental result revealed that the modified ultrasonic welding machine can generate the welded area around the circumference of tube. It was found that the axial force and contact angle have some effect to the quality of joint. The contact angle of 2.8/2.8 provided highest welded area compared to 3.8/3.8 and 5.7/5.7 degree of contact angle. In addition, the axial force between 80 N - 120 N provided high value of welded area. The pattern of welded area is also presented and discussed in the paper.

  11. 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.

  12. Intraluminal tissue welding for anastomosis

    DOEpatents

    Glinsky, M.; London, R.; Zimmerman, G.; Jacques, S.

    1998-10-27

    A method and device are provided for performing intraluminal tissue welding for anastomosis of a hollow organ. A retractable catheter assembly is delivered through the hollow organ and consists of a catheter connected to an optical fiber, an inflatable balloon, and a biocompatible patch mounted on the balloon. The disconnected ends of the hollow organ are brought together on the catheter assembly, and upon inflation of the balloon, the free ends are held together on the balloon to form a continuous channel while the patch is deployed against the inner wall of the hollow organ. The ends are joined or ``welded`` using laser radiation transmitted through the optical fiber to the patch. A thin layer of a light-absorbing dye on the patch can provide a target for welding. The patch may also contain a bonding agent to strengthen the bond. The laser radiation delivered has a pulse profile to minimize tissue damage. 8 figs.

  13. Cold welded laser mirror assembly

    SciTech Connect

    Chaffee, E.G.

    1989-02-07

    A gas laser apparatus is described comprising: (a) a gas laser tube having a bore extending between cathode and anode ends; (b) the laser tube terminating at each end with a bellows assembly operative to extend the length of the tube bore; (c) each bellows assembly comprising: (i) an adjustably positionable metal bellows secured to a selected end of the tube; (ii) a tubular pedestal secured at one end to the bellows to form an extension thereof and at the opposite end providing a mirror mount surface; (iii) a mirror secured to the surface; (iv) a cold weld material located between the mirror and mirror mount surface; and (v) retaining means secured to the pedestal encasing the outer portion of the mirror and operative to apply pressure to the cold weld material to establish a cold weld seal between the mirror and mirror mount surface to retain the mirror on and prevent shifting of the mirror with respect to the mirror mount surface.

  14. Intraluminal tissue welding for anastomosis

    DOEpatents

    Glinsky, Michael; London, Richard; Zimmerman, George; Jacques, Steven

    1998-10-27

    A method and device are provided for performing intraluminal tissue welding for anastomosis of a hollow organ. A retractable catheter assembly is delivered through the hollow organ and consists of a catheter connected to an optical fiber, an inflatable balloon, and a biocompatible patch mounted on the balloon. The disconnected ends of the hollow organ are brought together on the catheter assembly, and upon inflation of the balloon, the free ends are held together on the balloon to form a continuous channel while the patch is deployed against the inner wall of the hollow organ. The ends are joined or "welded" using laser radiation transmitted through the optical fiber to the patch. A thin layer of a light-absorbing dye on the patch can provide a target for welding. The patch may also contain a bonding agent to strengthen the bond. The laser radiation delivered has a pulse profile to minimize tissue damage.

  15. Grain refinement control in TIG arc welding

    NASA Technical Reports Server (NTRS)

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

    1975-01-01

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

  16. Advances in welding science - a perspective

    SciTech Connect

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

    1995-02-01

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

  17. Optical penetration sensor for pulsed laser welding

    DOEpatents

    Essien, Marcelino; Keicher, David M.; Schlienger, M. Eric; Jellison, James L.

    2000-01-01

    An apparatus and method for determining the penetration of the weld pool created from pulsed laser welding and more particularly to an apparatus and method of utilizing an optical technique to monitor the weld vaporization plume velocity to determine the depth of penetration. A light source directs a beam through a vaporization plume above a weld pool, wherein the plume changes the intensity of the beam, allowing determination of the velocity of the plume. From the velocity of the plume, the depth of the weld is determined.

  18. Repair welding of fusion reactor components

    SciTech Connect

    Chin, B.A.

    1992-05-20

    Recent experimental investigations indicate that the repair welding of irradiated materials containing greater than 1 to 2.5 appm helium leads to catastrophic cracking in the heat affected zone of the weld. The high temperatures and cooling tensile stresses which occur during the welding process lead to enhanced helium bubble growth in the heat affected zone region, resulting in catastrophic cracking upon cooling. An investigation is proposed which seeks to determine the effect of stress state on the helium bubble growth process and develop engineering modifications to the welding process based upon this understanding in an attempt to alleviate or eliminate the weld cracking problem in type 316 stainless steel materials.

  19. Specific welds for test blanket modules

    NASA Astrophysics Data System (ADS)

    Rieth, Michael; Rey, Jörg

    2009-04-01

    Fabrication and assembling test blanket modules needs a variety of different welding techniques. Therefore, an evaluation of plate joining for breeder units by tungsten-inert-gas, laser, and electron beam welding was performed by qualification of relevant mechanical properties like hardness, charpy, and creep strength. The focus was laid on the study of post-weld heat treatments at lowest possible temperatures and for maximum recovery of the joints. The most important result is that thin EUROFER plates may be welded by EB or laser techniques without the necessity of post-welding heat treatments that include an austenitization step.

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

    NASA Astrophysics Data System (ADS)

    Weishaupt, Eric Raymond

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

  1. 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.

  2. Laser welding of micro plastic parts

    NASA Astrophysics Data System (ADS)

    Haberstroh, E.; Hoffmann, W.-M.

    2007-02-01

    Most welding processes for plastics do not meet the demands of micro technology and thus cannot be applied in this innovative industrial sector. One of the few techniques which are applicable in this sector is the laser transmission welding, which has distinctive advantages like low mechanical and thermal load of the joining parts. This makes the laser particularly suitable for the welding of micro plastics parts. Thereby, contour welding is a process variant of laser transmission welding enabling the welding of complex and even three-dimensional weld contours. But so far it has not yet been applied for welding plastics parts of micro scale in the industrial practice. Recent research at the Institute of Plastics Processing (IKV) at the RWTH Aachen University shows the feasibility of this process to weld small and complex micro parts. Good mechanical properties can be achieved. However, it is necessary to apply measures to reduce the formation of flash. Moreover, it can be shown that there is a strong influence of some material parameters on the laser welding process so that some plastics are more suitable than others for the contour welding in micro technology.

  3. Shimmed electron beam welding process

    DOEpatents

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

    2002-01-01

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

  4. Weld penetration and defect control. Final report

    SciTech Connect

    Chin, B.A.

    1992-05-15

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

  5. Welding of gamma titanium aluminide alloys

    NASA Technical Reports Server (NTRS)

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

    1998-01-01

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

  6. Sensor Control of Robot Arc Welding

    NASA Technical Reports Server (NTRS)

    Sias, F. R., Jr.

    1983-01-01

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

  7. APPARATUS AND METHOD FOR ARC WELDING

    DOEpatents

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

    1960-05-10

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

  8. Mathematical Model Of Variable-Polarity Plasma Arc Welding

    NASA Technical Reports Server (NTRS)

    Hung, R. J.

    1996-01-01

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

  9. Application Of A Control Algorithm To Vertical-Up Welding

    NASA Technical Reports Server (NTRS)

    Fernandez, Kenneth R.; Cook, George E.; Andersen, Kristinn; Barnett, Robert J.; Zein-Sabattou, Saleh

    1993-01-01

    Report describes application of generalized control algorithm for automatic robotic arc welding in vertical-up configuration. Applicable to variety of welding processes, previously applied to welding in downhand configuration. Generalized algorithm and application to downhand welding described in "Method for Automatic Downhand Welding" (MFS-27209).

  10. Internal Filler-Wire Feed For Arc Welding

    NASA Technical Reports Server (NTRS)

    Morgan, Gene E.; Dyer, Gerald E.

    1990-01-01

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

  11. 49 CFR 192.235 - Preparation for welding.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material...

  12. 49 CFR 192.235 - Preparation for welding.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material...

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

    ERIC Educational Resources Information Center

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

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

  14. 49 CFR 192.235 - Preparation for welding.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material...

  15. 49 CFR 192.235 - Preparation for welding.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material...

  16. 49 CFR 192.235 - Preparation for welding.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 3 2011-10-01 2011-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material...

  17. Advanced fusion welding processes, solid state joining and a successful marriage. [production of aerospace structures

    NASA Technical Reports Server (NTRS)

    Miller, F. R.

    1972-01-01

    Joining processes for aerospace systems combine fusion welding and solid state joining during production of metal structures. Detailed characteristics of electron beam welding, plasma arc welding, diffusion welding, inertia welding and weldbond processes are discussed.

  18. 75 FR 14243 - Pipeline Safety: Girth Weld Quality Issues Due to Improper Transitioning, Misalignment, and...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2010-03-24

    ... Improper Transitioning, Misalignment, and Welding Practices of Large Diameter Line Pipe AGENCY: Pipeline... girth weld failures due to welding quality issues. Misalignment during welding of large diameter line... bevel and wall thickness transitions, and other improper welding practices that occurred...

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

    NASA Astrophysics Data System (ADS)

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

    2016-11-01

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

  20. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2014-07-01

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

  2. Metal nanoparticles and IR laser applications in medicine for biotissue ablation and welding

    NASA Astrophysics Data System (ADS)

    Lalayan, A. A.; Israelyan, S. S.

    2016-05-01

    We report the possibility of laser welding and ablation of biotissue by using metal and hybrid metal nanoparticles (NPs) and infrared laser irradiation spectrally located far from plasmon resonances. A nanosecond YAG:Nd laser of wavelength 1064 nm has been used for synthesis of metal NPs. The Ag, Au, Cu, Ti and Ni, as well as Au–Ag and Au–Cu hybrid metal colloidal NPs were formed in a liquid medium. The diagnostic technique of second harmonic generation (SHG) has been applied to determine the biotissue ablation area after IR laser irradiation. The effectiveness of biotissue ablation was 4–5 times larger in the case of a tissue sample colored with metal NPs than for an uncolored sample. IR laser welding has been demonstrated for deep-located biotissue layers colored by metal NPs.

  3. Welding torch gas cup extension

    NASA Technical Reports Server (NTRS)

    Gordon, Stephen S. (Inventor)

    1988-01-01

    The invention relates to a gas shielded electric arc welding torch having a detachable gas cup extension which may be of any desired configuration or length. The gas cup extension assembly is mounted on a standard electric welding torch gas cup to enable welding in areas with limited access. The gas cup assembly has an upper tubular insert that fits within the gas cup such that its lower portion protrudes thereform and has a lower tubular extension that is screwed into the lower portion. The extension has a rim to define the outer perimeter of the seat edge about its entrance opening so a gasket may be placed to effect an airtight seal between the gas cup and extension. The tubular extension may be made of metal or cermaic material that can be machined. The novelty lies in the use of an extension assembly for a standard gas cup of an electric arc welding torch which extension assembly is detachable permitting the use of a number of extensions which may be of different configurations and materials and yet fit the standard gas cup.

  4. Welded oil well pump rod

    SciTech Connect

    Hughes, R.F.

    1986-06-10

    A friction welded multiple component oil well sucker rod is described which consists of an elongated cylindrical rod section and apposed coupling end portions welded to opposite ends of the rod section, the coupling end portions being of a nominal maximum diameter at least 1.5 times greater than the rod section and including means for connecting the sucker rod to an adjacent rod in end to end relationship. The couplings end portions each include an axial tapered portion between the connecting means and an end face adapted to be butted to the rod section, the coupling end portions being butted against the opposed end portions of the rod section during a friction welding operation to form a radially outward projecting bulge of displaced material on the rod section and the coupling end portions, respectively. A greater cross-sectional area is formed at the transition of the rod section to the coupling end portion to reduce the unit tensile stress on the sucker rod in the vicinity of the weld, wherein the displaced material is machined to form a tapered surface between the rod section and the axial tapered portion of the coupling end portion, the tapered surface having an angle of taper with respect to the longitudinal axis of the sucker rod less than the angle of taper of the coupling end portion.

  5. TAT Welding Technology Training Program.

    ERIC Educational Resources Information Center

    Rogers, Everette N.; Cook, Jerry L.

    The Training and Technology (TAT) Welding Technology Training Program is an intensive industrial training program conducted by Oak Ridge Associated Universities and Union Carbide Corporation designed to upgrade the skills of unemployed and underemployed individuals so they can command good jobs in industry. The document provides an introduction…

  6. Mechanics Model of Plug Welding

    NASA Technical Reports Server (NTRS)

    Zuo, Q. K.; Nunes, A. C., Jr.

    2015-01-01

    An analytical model has been developed for the mechanics of friction plug welding. The model accounts for coupling of plastic deformation (material flow) and thermal response (plastic heating). The model predictions of the torque, energy, and pull force on the plug were compared to the data of a recent experiment, and the agreements between predictions and data are encouraging.

  7. Welding. FOS: Fundamentals of Service.

    ERIC Educational Resources Information Center

    John Deere Co., Moline, IL.

    This manual on modern gas and arc welding is one of a series of power mechanics texts and visual aids on the servicing of automotive and off-the-road agricultural and construction equipment. Materials provide basic information with illustrations for use by vocational students and teachers as well as shop servicemen and laymen. The eight sections…

  8. Fundamentals of Welding. Teacher Edition.

    ERIC Educational Resources Information Center

    Fortney, Clarence; And Others

    These instructional materials assist teachers in improving instruction on the fundamentals of welding. The following introductory information is included: use of this publication; competency profile; instructional/task analysis; related academic and workplace skills list; tools, materials, and equipment list; and 27 references. Seven units of…

  9. Applied Welding Technology Curriculum Guide.

    ERIC Educational Resources Information Center

    Idaho State Dept. of Education, Boise. Div. of Vocational Education.

    This Idaho state curriculum guide provides lists of tasks, performance objectives, and enabling objectives for instruction in welding. Following an introduction and a list of tasks, the bulk of the document consists of 10 modules, each of which is a list of tasks and the performance objectives and enabling objectives that pertain to each task. The…

  10. Welding. Ohio's Competency Analysis Profile.

    ERIC Educational Resources Information Center

    Ohio State Univ., Columbus. Vocational Instructional Materials Lab.

    This Ohio Competency Analysis Profile (OCAP), derived from a modified Developing a Curriculum (DACUM) process, is a comprehensive and verified employer competency list for a welding program. It contains units (with or without subunits), competencies, and competency builders that identify the occupational, academic, and employability skills needed…

  11. Welding Series. Duty Task List.

    ERIC Educational Resources Information Center

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

    This document contains the occupational duty/task lists for six occupations in the welding series. Each occupation is divided into a number of duties. A separate page for each duty in the occupation lists the tasks in that duty along with its code number and columns to indicate whether that particular duty has been taught and to provide space for…

  12. Dynamics of near-alpha titanium welding

    NASA Astrophysics Data System (ADS)

    Neuberger, Brett William

    Typically, when gas tungsten arc welding (GTAW) is employed to join near-alpha titanium alloys, the resulting weld fusion zone (FZ) is much harder than that of the base metal (BM), thereby leading to lost ductility. The aim of this investigation was to improve FZ ductility of Ti-5Al-1Sn-1V-1Zr-0.8Mo by modifying filler metal chemistry. In this regard, metallic yttrium was added to the filler metal and aluminum concentration reduced. It was believed that additions of yttrium would lead to formation of yttria in the weld melt, thereby promoting heterogeneous nucleation. Since oxygen and aluminum both act as alpha-stabilizers, expected pickup of oxygen during the welding process will be offset by the aluminum reduction. Tensile testing indicated that modified filler metal welds showed a dramatic increase in ductility of the FZ. Fracture toughness testing showed that while JIC values decreased in all welds, the tearing modulus, T, in modified filler metal welds was significantly higher than that of matching filler metal welds. Microhardness mapping of the weld zones illustrated that modified filler metal welds were significantly softer than matching filler metal welds. Microstructural examinations were completed through the use of optical, SEM and TEM studies, indicating that there was a presence of nano-particles in the weld FZ. XPS analysis identified these particles as yttrium oxysulfate. WDS analysis across the welds' heat affected zones demonstrated that there is an internal diffusion of oxygen from the BM into the FZ. Research results indicate yttrium oxysulfide particles form in the weld pool, act as a drag force on the solidification front and limit growth of prior-beta grain boundaries. The reduced prior-beta grain size and removal of interstitial oxygen from the matrix in modified filler metal welds, further enhanced by oxidation of yttrium oxysulfide to yttrium oxysulfate, leads to increased ductility in the weld's FZ. Addition of yttrium to the weld also

  13. Ultrasound in arc welding: a review.

    PubMed

    da Cunha, Tiago Vieira; Bohórquez, Carlos Enrique Niño

    2015-02-01

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

  14. Nondestructive Ultrasonic Inspection of Friction Stir Welds

    NASA Astrophysics Data System (ADS)

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

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

  15. Ultrasound in arc welding: a review.

    PubMed

    da Cunha, Tiago Vieira; Bohórquez, Carlos Enrique Niño

    2015-02-01

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

  16. Low cost laser weld monitoring system

    SciTech Connect

    Leong, K.H.

    1997-04-01

    Laser beam welding is a joining technology that has gained increased acceptance because of its high speed, precision, and low heat effects compared to conventional arc welding methods. Argonne National Laboratory in collaboration with the automotive industry has developed a robust on-line weld monitor capable of sensing weld surface changes and penetration. The development of the weld monitor took tin account the constraints and operating environment of the factor floor in addition to monitoring needs for quality assurance. The on-line non-intrusive weld monitor developed is rugged and simple to use, does not require power to operate, is weld spatter protected and low cost; features that are desired for the factor floor. The weld monitoring technology is available for licensing. An exclusive license has been awarded to Spawr Industries for an inline weld monitor for CO{sub 2} laser applications. Licensing of the weld monitor for other implementations in CO{sub 2} and Nd:YAG laser applications are available.

  17. Improving fatigue performance of rail thermite welds

    NASA Astrophysics Data System (ADS)

    Jezzini-Aouad, M.; Flahaut, P.; Hariri, S.; Winiar, L.

    2010-06-01

    Rail transport development offers economic and ecological interests. Nevertheless, it requires heavy investments in rolling material and infrastructure. To be competitive, this transportation means must rely on safe and reliable infrastructure, which requires optimization of all implemented techniques and structure. Rail thermite (or aluminothermic) welding is widely used within the railway industry for in-track welding during re-rail and defect replacement. The process provides numerous advantages against other welding technology commonly used. Obviously, future demands on train traffic are heavier axle loads, higher train speeds and increased traffic density. Thus, a new enhanced weld should be developed to prevent accidents due to fracture of welds and to lower maintenance costs. In order to improve such assembly process, a detailed metallurgical study coupled to a thermomechanical modelling of the phenomena involved in the thermite welding process is carried out. Obtained data enables us to develop a new improved thermite weld (type A). This joint is made by modifying the routinely specified procedure (type B) used in a railway rail by a standard gap alumino-thermic weld. Joints of type A and B are tested and compared. Based on experimental temperature measurements, a finite element analysis is used to calculate the thermal residual stresses induced. In the vicinity of the weld, the residual stress patterns depend on the thermal conditions during welding as it also shown by litterature [1, 2]. In parallel, X-Ray diffraction has been used to map the residual stress field that is generated in welded rail of types A and B. Their effect on fatigue crack growth in rail welds is studied. An experimental study based on fatigue tests of rails welded by conventional and improved processes adjudicates on the new advances and results will be shown.

  18. Plastic preforms facilitate fabrication of welded cordwood electronic modules

    NASA Technical Reports Server (NTRS)

    Sturman, J. C.

    1968-01-01

    Molded plastic preform facilitates the fabrication of small lots of welded cordwood circuits. The preforms retain the components during welding and electrical checkout and facilitate encapsulation of the welded module when used with a conventional potting shell.

  19. FRICTION-STIR-LAP-WELDS OF AA6111 ALUMINUM ALLOY

    SciTech Connect

    Yadava, Manasij; Mishra, Rajiv S.; Chen, Y. L.; Gayden, X.; Grant, Glenn J.

    2007-01-09

    Lap joints of 1 mm thick AA6111 aluminum sheets were made by friction stir welding, using robotic and conventional machines. Welds were made for advancing as well as retreating side loading. Thinning in welds was quantified. Lap shear test of welds was conducted in as-welded and paint-baked conditions. Conventional machine welds showed less thinning and better strength than robotic machine welds. Process forces in conventional machine welding were higher. Paint bake treatment improved the weld strength; but the improvement varied with process parameters. Advancing side loaded welds achieved higher strength than the retreating side loaded welds. Fracture location was found to occur on the loaded side of the weld and along the thinning defect.

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

  1. In-process weld sampling during hot end welds of type W overpacks

    SciTech Connect

    Barnes, G.A.

    1998-08-27

    Establish the criteria and process controls to be used in obtaining, testing, and evaluating in-process weld sample during the hot end welding of Type W Overpack capsules used to overpack CsCl capsules for storage at WESF.

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

    NASA Astrophysics Data System (ADS)

    Pal, Kamal; Pal, Surjya K.

    2011-08-01

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

  3. The science and practice of welding. Volume 2: The practice of welding, 10th edition

    SciTech Connect

    Davies, A.C.

    1993-01-01

    The book is comprised of 8 chapters that treat the various welding practices, and 11 appendices. Chapter 1 is a good introduction to basic welding (shielded metal arc), and US readers will be able to use this section as a rough guide to British and EN terms. The next three chapters cover MIG, TIG, and resistance welding, while Chapter 5 is titled ''Additional Processes of Welding.'' In that chapter, submerged arc welding is given the most extensive treatment. Chapter 6 and 7 deal with oxyacetylene welding and cutting processes, respectively, and Chapter 8 contains a wonderful introductory treatise on the welding of plastics. Among the 11 appendices, some appear to be little more than advertising. In general, this book is not a college level text for a welding engineer. At best it is a good occasional reference manual for shop owners so that they can appear knowledgeable to the engineers in the employ.

  4. Linear Anomaly in Welded 2219-T87 Aluminum Alloy

    NASA Technical Reports Server (NTRS)

    Jemian, Wartan A.

    1987-01-01

    Study of causes and significance of two types of linear anomalies sometimes appearing in radiographs of welds described in preliminary report. Manifested as light or dark linear features parallel to weld line in radiograph of weld. Contains diagrams and descriptions of phenomena occurring during welding process. Includes microdensitometer traces from x-radiographs of actual welds and from computer simulations based calculation of x-ray transmission through assumed weld structures. Concludes anomalies not unique to 2219-T87 aluminum alloy.

  5. Development of narrow gap welding technology for extremely thick steel

    NASA Astrophysics Data System (ADS)

    Imai, K.; Saito, T.; Okumura, M.

    In the field of extremely thick steel, various narrow gap welding methods were developed on the basis of former welding methods and are used in practice. It is important to develop and improve automatic narrow gap welding, J edge preparation by gas cutting, the prevention of welding defects, wires for narrow gap welding and so on in order to expand the scope of application of the method. Narrow gap welding technologies are described, based on new concepts developed by Nippon Steel Corporation.

  6. Laser welding of automotive aluminum alloys to achieve defect-free, structurally sound and reliable welds

    SciTech Connect

    DebRoy, T.

    2000-11-17

    The objective of this program was to seek improved process control and weldment reliability during laser welding of automotive aluminum alloys while retaining the high speed and accuracy of the laser beam welding process. The effects of various welding variables on the loss of alloying elements and the formation of porosity and other geometric weld defects such as underfill and overfill were studied both experimentally and theoretically.

  7. Friction Stir Welding of Tapered Thickness Welds Using an Adjustable Pin Tool

    NASA Technical Reports Server (NTRS)

    Adams, Glynn; Venable, Richard; Lawless, Kirby

    2003-01-01

    Friction stir welding (FSW) can be used for joining weld lands that vary in thickness along the length of the weld. An adjustable pin tool mechanism can be used to accomplish this in a single-pass, full-penetration weld by providing for precise changes in the pin length relative to the shoulder face during the weld process. The difficulty with this approach is in accurately adjusting the pin length to provide a consistent penetration ligament throughout the weld. The weld technique, control system, and instrumentation must account for mechanical and thermal compliances of the tooling system to conduct tapered welds successfully. In this study, a combination of static and in-situ measurements, as well as active control, is used to locate the pin accurately and maintain the desired penetration ligament. Frictional forces at the pin/shoulder interface were a source of error that affected accurate pin position. A traditional FSW pin tool design that requires a lead angle was used to join butt weld configurations that included both constant thickness and tapered sections. The pitch axis of the tooling was fixed throughout the weld; therefore, the effective lead angle in the tapered sections was restricted to within the tolerances allowed by the pin tool design. The sensitivity of the FSW process to factors such as thickness offset, joint gap, centerline offset, and taper transition offset were also studied. The joint gap and the thickness offset demonstrated the most adverse affects on the weld quality. Two separate tooling configurations were used to conduct tapered thickness welds successfully. The weld configurations included sections in which the thickness decreased along the weld, as well as sections in which the thickness increased along the weld. The data presented here include weld metallography, strength data, and process load data.

  8. Automated Fuel Element Closure Welding System

    SciTech Connect

    Wahlquist, D.R.

    1993-01-01

    The Automated Fuel Element Closure Welding System is a robotic device that will load and weld top end plugs onto nuclear fuel elements in a highly radioactive and inert gas environment. The system was developed at Argonne National Laboratory-West as part of the Fuel Cycle Demonstration. The welding system performs four main functions, it (1) injects a small amount of a xenon/krypton gas mixture into specific fuel elements, and (2) loads tiny end plugs into the tops of fuel element jackets, and (3) welds the end plugs to the element jackets, and (4) performs a dimensional inspection of the pre- and post-welded fuel elements. The system components are modular to facilitate remote replacement of failed parts. The entire system can be operated remotely in manual, semi-automatic, or fully automatic modes using a computer control system. The welding system is currently undergoing software testing and functional checkout.

  9. Automated Fuel Element Closure Welding System

    SciTech Connect

    Wahlquist, D.R.

    1993-03-01

    The Automated Fuel Element Closure Welding System is a robotic device that will load and weld top end plugs onto nuclear fuel elements in a highly radioactive and inert gas environment. The system was developed at Argonne National Laboratory-West as part of the Fuel Cycle Demonstration. The welding system performs four main functions, it (1) injects a small amount of a xenon/krypton gas mixture into specific fuel elements, and (2) loads tiny end plugs into the tops of fuel element jackets, and (3) welds the end plugs to the element jackets, and (4) performs a dimensional inspection of the pre- and post-welded fuel elements. The system components are modular to facilitate remote replacement of failed parts. The entire system can be operated remotely in manual, semi-automatic, or fully automatic modes using a computer control system. The welding system is currently undergoing software testing and functional checkout.

  10. Friction Stir Welding of Steel Alloys

    NASA Technical Reports Server (NTRS)

    Ding, R. Jeffrey; Munafo, Paul M. (Technical Monitor)

    2001-01-01

    The friction stir welding process has been developed primarily for the welding of aluminum alloys. Other higher melting allows such, as steels are much more difficult to join. Special attention must be given to pin tool material selection and welding techniques. This paper addresses the joining of steels and other high melting point materials using the friction stir welding process. Pin tool material and welding parameters will be presented. Mechanical properties of weldments will also be presented. Significance: There are many applications for the friction stir welding process other than low melting aluminum alloys. The FSW process can be expanded for use with high melting alloys in the pressure vessel, railroad and ship building industries.

  11. Pearson's Functions to Describe FSW Weld Geometry

    SciTech Connect

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

    2011-01-17

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

  12. Laser Peening Effects on Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Hatamleh, Omar

    2011-01-01

    Friction Stir Welding (FSW) is a welding technique that uses frictional heating combined with forging pressure to produce high strength bonds. It is attractive for aerospace applications. Although residual stresses in FSW are generally lower when compared to conventional fusion welds, recent work has shown that significant tensile residual stresses can be present in the weld after fabrication. Therefore, laser shock peening was investigated as a means of moderating the tensile residual stresses produced during welding. This slide presentation reviews the effect of Laser Peening on the weld, in tensile strength, strain, surface roughness, microhardness, surface wear/friction, and fatigue crack growth rates. The study concluded that the laser peening process can result in considerable improvement to crack initiaion, propagation and mechanical properties in FSW.

  13. 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.

  14. 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.

  15. 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.

  16. 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

  17. Automated IR-weld seam control

    NASA Astrophysics Data System (ADS)

    Balle, Michel

    1990-03-01

    In 1975 the concept of visualizing, measuring and studying the thermal condition of welded seams was investigated by a laboratory of the French ministry of defense (at the request of a metal constructor). Gilbert Gaussorgues, the founding father of the company HGH was at the time in charge of the infrared laboratory in question, a department of the general administration of Armament in Toulon, France. His idea was to apply military IR-Technology to above mentioned welding application. Having developed a prototype, tests readily confirmed the validity of using IR-emission from the weld seam close to the actual moment of welding as an indicator of the quality of the fmal assembly. Nearly ten years later, in 1984, HGH decided, due to an increasing demand, to develop above preliminary tests to a complete product/application package designed specifically for welding process-control. The inspection oftubing and of the integrity welds of barrels with hazardous content, were the first applications.

  18. Dilution in single pass arc welds

    SciTech Connect

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

    1996-06-01

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

  19. Passively damped vibration welding system and method

    SciTech Connect

    Tan, Chin-An; Kang, Bongsu; Cai, Wayne W.; Wu, Tao

    2013-04-02

    A vibration welding system includes a controller, welding horn, an anvil, and a passive damping mechanism (PDM). The controller generates an input signal having a calibrated frequency. The horn vibrates in a desirable first direction at the calibrated frequency in response to the input signal to form a weld in a work piece. The PDM is positioned with respect to the system, and substantially damps or attenuates vibration in an undesirable second direction. A method includes connecting the PDM having calibrated properties and a natural frequency to an anvil of an ultrasonic welding system. Then, an input signal is generated using a weld controller. The method includes vibrating a welding horn in a desirable direction in response to the input signal, and passively damping vibration in an undesirable direction using the PDM.

  20. Femtosecond fiber laser welding of dissimilar metals.

    PubMed

    Huang, Huan; Yang, Lih-Mei; Bai, Shuang; Liu, Jian

    2014-10-01

    In this paper, welding of dissimilar metals was demonstrated for the first time, to the best of our knowledge, by using a high-energy high-repetition-rate femtosecond fiber laser. Metallurgical and mechanical properties were investigated and analyzed under various processing parameters (pulse energy, repetition rate, and welding speed). Results showed that the formation of intermetallic brittle phases and welding defects could be effectively reduced. Strong welding quality with more than 210 MPa tensile strength for stainless steel-aluminum and 175 MPa tensile strength for stainless steel-magnesium has been demonstrated. A minimal heat affected zone and uniform and homogenous phase transformation in the welding region have been demonstrated. This laser-welding technique can be extended for various applications in semiconductor, automobile, aerospace, and biomedical industries.