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Sample records for metal weld part

  1. Hard metal interstitial pulmonary disease associated with a form of welding in a metal parts coating plant

    SciTech Connect

    Figueroa, S.; Gerstenhaber, B.; Welch, L.; Klimstra, D.; Smith, G.J.; Beckett, W. )

    1992-01-01

    We describe two cases of hard metal pulmonary disease (one fatal) in workers employed in the same area of a metal coating plant using the detonation gun process for applying a durable metal surface to metal parts. In this form of welding, a mixture of powdered metals, including tungsten carbide and cobalt, is heated by ignition of a flammable gas and propelled from the end of the gun' at high temperature and velocity to form a welded metal coating. This process is done in an enclosed chamber and with each application, large volumes of fine aerosols are created. Inhalation exposure to hard metal may occur during the mounting and removal of the metal parts between applications, in spite of engineering controls and industrial hygiene surveillance. One of the cases presented with minimal chest x-ray abnormalities and an obstructive pattern on pulmonary function testing, although subsequent open lung biopsy showed diffuse interstitial pulmonary fibrosis. The fact that two cases of hard metal pulmonary interstitial disease occurred where thorough exposure control procedures and a surveillance program for cobalt were in place may indicate the need for revisions of the current technology used when hard metal is applied in the detonation gun process.

  2. Hard metal interstitial pulmonary disease associated with a form of welding in a metal parts coating plant.

    PubMed

    Figueroa, S; Gerstenhaber, B; Welch, L; Klimstra, D; Smith, G J; Beckett, W

    1992-01-01

    We describe two cases of hard metal pulmonary disease (one fatal) in workers employed in the same area of a metal coating plant using the detonation gun process for applying a durable metal surface to metal parts. In this form of welding, a mixture of powdered metals, including tungsten carbide and cobalt, is heated by ignition of a flammable gas and propelled from the end of the "gun" at high temperature and velocity to form a welded metal coating. This process is done in an enclosed chamber and with each application, large volumes of fine aerosols are created. Inhalation exposure to hard metal may occur during the mounting and removal of the metal parts between applications, in spite of engineering controls and industrial hygiene surveillance. One of the cases presented with minimal chest x-ray abnormalities and an obstructive pattern on pulmonary function testing, although subsequent open lung biopsy showed diffuse interstitial pulmonary fibrosis. The fact that two cases of hard metal pulmonary interstitial disease occurred where thorough exposure control procedures and a surveillance program for cobalt were in place may indicate the need for revisions of the current technology used when hard metal is applied in the detonation gun process.

  3. 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

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

    DOEpatents

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

    1985-11-29

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

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

    DOEpatents

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

    1987-01-01

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

  6. 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…

  7. 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.

  8. 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…

  9. 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.

  10. 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,…

  11. Nature and evolution of the fusion boundary in ferritic-austenitic dissimilar weld metals. Part 1 -- Nucleation and growth

    SciTech Connect

    Nelson, T.W.; Lippold, J.C.; Mills, M.J.

    1999-10-01

    A fundamental investigation of fusion boundary microstructure evolution in dissimilar-metal welds (DMWs) between ferritic base metals and a face-centered-cubic (FCC) filler metal was conducted. The objective of the work presented here was to characterize the nature and character of the elevated-temperature fusion boundary to determine the nucleation and growth characteristics of DMWs. Type 409 ferritic stainless steel and 1080 pearlitic steel were utilized as base metal substrates, and Monel (70Ni-30Cu) was used as the filler metal. The Type 409 base metal provided a fully ferritic or body-centered-cubic (BCC) substrate at elevated temperatures and exhibited no on-cooling phase transformations to mask or disguise the original character of the fusion boundary. The 1080 pearlitic steel was selected because it is austenitic at the solidus temperature, providing an austenite substrate at the fusion boundary. The weld microstructure generated with each of the base metals in combination with Monel was fully austenitic. In the Type 409/Monel system, there was no evidence of epitaxial nucleation and growth as normally observed in homogeneous weld metal combinations. The fusion boundary in this system exhibited random grain boundary misorientations between the heat-affected zone (HAZ) and weld metal grains. In the 1080/Monel system, evidence of normal epitaxial growth was observed at the fusion boundary, where solidification and HAZ grain boundaries converged. The fusion boundary morphologies are a result of the crystal structure present along the fusion boundary during the initial stages of solidification. Based on the results of this investigation, a model for heterogeneous nucleation along the fusion boundary is proposed when the base and weld metals exhibit ferritic (BCC) and FCC crystal structures, respectively.

  12. 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.

  13. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2015-03-01

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

  15. 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.

  16. 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.

  17. Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plates

    PubMed

    Tsujino; Ueoka; Kashino; Sugahara

    2000-03-01

    Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plate specimens, using a 27 kHz complex vibration disk welding tip vibrating in transverse and torsional vibration modes, were studied. Using a complex vibration welding system with a welding tip vibrating in elliptical or circular locus, thick plate specimens can be welded with a more uniform and larger area compared to a conventional ultrasonic welding system. The disk welding tip vibrates in an elliptical or circular locus. The complex vibration system can continuously weld multiple parts of metal plate specimens such as heat sinks with a large number of fins.

  18. 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.

  19. Sensing the gas metal arc welding process

    NASA Technical Reports Server (NTRS)

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

    1994-01-01

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

  20. Nitrogen in plasmas and steel weld metal

    NASA Astrophysics Data System (ADS)

    Palmer, Todd Allen

    Nitrogen concentrations, well above those predicted by Sieverts' Law, are observed during the arc welding of iron and steel. Several models, which take into account the absorption of monatomic nitrogen and a competition between nitrogen absorption and desorption, have been developed. None, though, provides a means for accurately calculating the nitrogen concentration in a steel weldment, as a function of the welding variables. The aim of this work is therefore to develop a comprehensive model to accurately predict the nitrogen concentration in the weld pool and validate the model with experimental data. Transport phenomena, plasma physics, and thermodynamic calculations have been combined to produce realistic calculations of the nitrogen concentration in the weld metal. The computed residual nitrogen concentrations are affected by complex factors, including the amount of nitrogen in the feed gas, the electron temperature distribution above the weld pool, and the nature of the fluid flow in the weld pool. Each of these factors has been taken into consideration here. Of primary importance in the calculation of the nitrogen concentration is the effect of desorption of dissolved nitrogen from the weld pool via bubble formation. Based on a comparison of modeling and experimental results, it is found that a supersaturation of nitrogen in the liquid metal 50 to 100% greater than the equilibrium nitrogen solubility with one atmosphere of diatomic nitrogen at the weld pool surface is required for bubbles to nucleate. These calculated values have been compared with residual nitrogen concentrations measured for various welding conditions. Experimental nitrogen concentrations fall between 400 and 650 ppm, and the manner in which the nitrogen concentration changes with the nitrogen partial pressure in the feed gas is affected by the changes in the welding speed. Model calculations compare favorably with these experimental results. In total, therefore, this work represents the

  1. 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…

  2. 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.

  3. Metal Flow in Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur C., Jr.

    2006-01-01

    The plastic deformation field in Friction Stir Welding (FSW) is compared to that in metal cutting. A shear surface around the FSW tool analogous to the metal cutting shear plane is identified and comprises the basis of the "rotating plug" flow field model and the "wiping" model of tool interaction with weld metal. Within the context of these models: The FSW shear rate is estimated to be comparable to metal cutting shear rates. The effect of tool geometry on the FSW shear surface is discussed and related to published torque measurements. Various FS W structural features are explained, including a difference in structure of bimetallic welds when alloys on the advancing and retreating sides of the weld seam are exchanged. The joining mechanism and critical parameters of the FSW process are made clear.

  4. Advance in friction welding and ultrasonic welding of ceramics to metals

    SciTech Connect

    Greitmann, M.J.; Weib, R.

    1997-11-01

    The authors have joined four different ceramic materials (MgO-PSZ, Al{sub 2}O{sub 3}, SiC and Si{sub 3}N{sub 4} cylinders 10 mm in diameter and 50 mm in length) to the aluminum alloy Al-Si1MgMn by friction welding. Process parameters such as friction speed, axial force, burn-off and torque have been recorded continuously. For some specimens the authors recorded the temperature at the interface using thermocouples. The joints obtained were tested in tension. Fracture occurred either in the ceramic or at the interface. Heat conduction calculations to estimate the temperature distribution during welding have been conducted by the Finite Element Method (FEM), using experimental data for input. Afterwards, residual stresses introduced through thermal expansion mismatch and stresses introduced through a tensile test have been determined by FEM. Applying multiaxial Weibull statistics to the ceramic specimen, tensile strength for different geometries of the joint and different material combinations was estimated. Ultrasonic welded joints of MgO-PSZ and Steel X 4 CrNi 18-10 according to DIN EN (comparable to the US-steel AISI No. 304) could be realized using aluminum interlayers. In addition to a conventional ultrasonic welding equipment for metal welding a new molecular coldwelding technique (ultrasonic torsional welding system) was tested. In comparison to friction welding the ultrasonic welding technique results in limited deformation of the ceramic-metal joint parts and in a decreased welding time. Nevertheless a special solution must be found to the problem of tool wear and the vibration conditions.

  5. Understanding metal vaporizaiton from laser welding.

    SciTech Connect

    DebRoy, Tarasankar; Fuerschbach, Phillip William; He, Xiuli; Norris, Jerome T.

    2003-09-01

    The production of metal vapor as a consequence of high intensity laser irradiation is a serious concern in laser welding. Despite the widespread use of lasers in manufacturing, little fundamental understanding of laser/material interaction in the weld pool exists. Laser welding experiments on 304 stainless steel have been completed which have advanced our fundamental understanding of the magnitude and the parameter dependence of metal vaporization in laser spot welding. Calculations using a three-dimensional, transient, numerical model were used to compare with the experimental results. Convection played a very important role in the heat transfer especially towards the end of the laser pulse. The peak temperatures and velocities increased significantly with the laser power density. The liquid flow is mainly driven by the surface tension and to a much less extent, by the buoyancy force. Heat transfer by conduction is important when the liquid velocity is small at the beginning of the pulse and during weld pool solidification. The effective temperature determined from the vapor composition was found to be close to the numerically computed peak temperature at the weld pool surface. At very high power densities, the computed temperatures at the weld pool surface were found to be higher than the boiling point of 304 stainless steel. As a result, vaporization of alloying elements resulted from both total pressure and concentration gradients. The calculations showed that the vaporization was concentrated in a small region under the laser beam where the temperature was very high.

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

    NASA Technical Reports Server (NTRS)

    Schaper, V. D.; Pollack, A.

    1972-01-01

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

  7. Refractory metals welded or brazed with tungsten inert gas equipment

    NASA Technical Reports Server (NTRS)

    Wisner, J. P.

    1965-01-01

    Appropriate brazing metals and temperatures facilitate the welding or brazing of base metals with tungsten inert gas equipment. The highest quality bond is obtained when TIG welding is performed in an inert atmosphere.

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

    NASA Astrophysics Data System (ADS)

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

    2013-05-01

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

  9. Influence of Filler Metals in Welding Wires on the Phase and Chemical Composition of Weld Metal

    NASA Astrophysics Data System (ADS)

    Kozyrev, N. A.; Osetkovskiy, I. V.; Kozyreva, O. A.; Zernin, E. A.; Kartsev, D. S.

    2016-04-01

    The influence of filler metals used in welding wires on the phase and chemical composition of the metal, which is surfaced to mining equipment exposed to abrasive wear, has been investigated. Under a laboratory environment, samples of Mo-V-B and Cr-Mn-Mo-V wires were made. The performed experiments have revealed that fillers of the Cr-Mn-Mo-V system used in powder wire show better wear resistance of the weld metal than that of the Mn-Mo-V-B system; the absence of boron, which promotes grain refinement in the Mn-Mo-V-B system, significantly reduces wear resistance; the Mn-Mo-V-B weld metal has a finer structure than the Cr-Mn-Mo-V weld metal.

  10. Improved torch increases weld quality in refractory metals

    NASA Technical Reports Server (NTRS)

    Lessman, G. G.; Sprecace, R.

    1968-01-01

    Specially designed torch welds refractory metals in a vacuum purged, inert gas backfilled welding chamber /weld box/ with practically zero contamination resulting from its use. Included in the torch design is a radiation shield to protect the operators hands when welding at high amperages.

  11. Automatic laser welding of metal bellows with precision seam tracker

    SciTech Connect

    Chang, D.U.

    1996-12-31

    Metal bellows were laser edge-welded satisfactorily with the aid of a precision seam tracking system. The welding speed was five to ten times faster than conventional arc welding. The weld quality was excellent and the cost savings are expected to be substantial.

  12. A study of laser-beam welding conducted at the Centre for Laser Technologies of Metals

    NASA Astrophysics Data System (ADS)

    Antoszewski, Bogdan; Gradoń, Ryszard; Trela, Paweł; Cendrowicz, Edward

    2013-01-01

    The study reported here is part of a larger research project on laser-beam welding conducted at the Centre for Laser Technologies of Metals. The primary objectives were to compare laser-beam welding with a conventional process when used for longitudinal seams in street lamp posts, to select the process parameters for girth welds in cylindrical high-strength steel machine elements, and to assess whether laser-beam welding can be used for magnesium alloys. The paper includes recommendations for the selection of welding parameters.

  13. Plutonium metal and oxide container weld development and qualification

    SciTech Connect

    Fernandez, R.; Horrell, D.R.; Hoth, C.W.; Pierce, S.W.; Rink, N.A.; Rivera, Y.M.; Sandoval, V.D.

    1996-01-01

    Welds were qualified for a container system to be used for long-term storage of plutonium metal and oxide. Inner and outer containers are formed of standard tubing with stamped end pieces gas-tungsten-arc (GTA) welded onto both ends. The weld qualification identified GTA parameters to produce a robust weld that meets the requirements of the Department of Energy standard DOE-STD-3013-94, ``Criteria for the Safe Storage of Plutonium Metals and Oxides.``

  14. 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

  15. Microstructure Improvement in Weld Metal under the Ultrasonic Application

    SciTech Connect

    Cui, Yan; Xu, Cailu; Han, Qingyou

    2007-01-01

    When considering the operational performance of weldments in the engineering projects, the most important issues to be considered are weld metal mechanical properties, integrity of the welded joint, and weldability 1 . These issues are closely related to the microstructure of the weld metal. A significant amount of research has been carried out to alter the process variables and to use external devices to obtain microstructure control of the weldments. It has been reported that grain refined microstructure not only reduces cracking behavior of alloys including solidification cracking, cold cracking and reheat cracking, 2 - 5 but also improves the mechanical properties of the weld metal, such as toughness, ductility, strength, and fatigue life. 6, 7 Weld pool stirring, 8 arc oscillation, 9, 10 arc pulsation, 11 , and magnetic arc oscillator 12, 13 have been applied to fusion welding to refine the microstructures. This article describes initial experimental results on the use of power ultrasonic vibration to refine the microstructure of weld metals.

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

    ERIC Educational Resources Information Center

    Fortney, Clarence; And Others

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

  17. Analysis of thermal stresses and metal movement during welding

    NASA Technical Reports Server (NTRS)

    Muraki, T.; Pattee, F. M.; Masubuchi, K.

    1974-01-01

    Finite element computer programs were developed to determine thermal stresses and metal movement during butt welding of flat plates and bead-on-plate welding along the girth of a cylindrical shell. Circular cylindrical shells of 6061 aluminum alloy were used for the tests. Measurements were made of changes in temperature and thermal strains during the welding process.

  18. Corrosion resistance of weld metal in caustic soda

    SciTech Connect

    Lazebnov, P.P.; Aleksandrov, A.G.; Kibal'chich, A.P.

    1983-09-01

    The effect of alloying elements and microstructures on the corrosion resistance of weld metal was studied in order to select electrodes for arc welding equipment made of steel 12Kh18NIOT designed for operating in alkaline media. The chemical composition of metal deposit, and the new results of the corrosion tests are given. It was established that chromium, nickel, and niobium in the specimens tested reduced the rate of corrosion. A dependence was noticed between the corrosion rate of specimens and the content of delta-ferrite in the weld metal. Based on these results, electrodes ensuring weld metal with an austenitic-ferritic structure were recommended.

  19. 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.

  20. Submodeling Simulations in Fusion Welds: Part II

    NASA Astrophysics Data System (ADS)

    Bonifaz, E. A.

    2013-11-01

    In part I, three-dimensional transient non-linear sub modeling heat transfer simulations were performed to study the thermal histories and thermal cycles that occur during the welding process at the macro, meso and micro scales. In the present work, the corresponding non-uniform temperature changes were imposed as load conditions on structural calculations to study the evolution of localized plastic strains and residual stresses at these sub-level scales. To reach the goal, a three-dimensional finite element elastic-plastic model (ABAQUS code) was developed. The sub-modeling technique proposed to be used in coupling phase-field (and/or digital microstructures) codes with finite element codes, was used to mesh a local part of the model with a refined mesh based on interpolation of the solution from an initial, relatively coarse, macro global model. The meso-sub-model is the global model for the subsequent micro sub-model. The strategy used to calculate temperatures, strains and residual stresses at the macro, meso and micro scale level, is very flexible to be used to any number of levels. The objective of this research was to initiate the development of microstructural models to identify fusion welding process parameters for preserving the single crystal nature of gas turbine blades during repair procedures. The multi-scale submodeling approach can be used to capture weld pool features at the macro-meso scale level, and micro residual stress and secondary dendrite arm spacing features at the micro scale level.

  1. Simulation on friction taper plug welding of AA6063-20Gr metal matrix composite

    NASA Astrophysics Data System (ADS)

    Hynes, N. Rajesh Jesudoss; Nithin, Abeyram M.

    2016-05-01

    Friction taper plug welding a variant of friction welding is useful in welding of similar and dissimilar materials. It could be used for joining of composites to metals in sophisticated aerospace applications. In the present work numerical simulation of friction taper plug welding process is carried out using finite element based software. Graphite reinforced AA6063 is modelled using the software ANSYS 15.0 and temperature distribution is predicted. Effect of friction time on temperature distribution is numerically investigated. When the friction time is increased to 30 seconds, the tapered part of plug gets detached and fills the hole in the AA6063 plate perfectly.

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

    NASA Astrophysics Data System (ADS)

    Uhrlandt, D.

    2016-08-01

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

  4. Laser welding on trough panel: 3D body part

    NASA Astrophysics Data System (ADS)

    Shirai, Masato; Hisano, Hirohiko

    2003-03-01

    Laser welding for automotive bodies has been introduced mainly by European car manufacturers since more than 10 years ago. Their purposes of laser welding introduction were mainly vehicle performance improvement and lightweight. And laser welding was applied to limited portion where shapes of panels are simple and easy to fit welded flanges. Toyota also has introduced laser welding onto 3 dimensional parts named trough panel since 1999. Our purpose of the introduction was common use of equipment. Trough panel has a complex shape and different shapes in each car type. In order to realize common use of welding equipment, we introduced parts locating equipment which had unique, small & simple jigs fo each car type and NC (Numerical Controlled) locators and air-cooled small laser head developed by ourselves to the trough welding process. Laser welding replaced spot welding and was applied linearly like stitches. Length of laser welding was determined according to comparison with statistic tensile strength and fatigue strength of spot welding.

  5. A numerical and experimental study of ultrasonic metal welding

    NASA Astrophysics Data System (ADS)

    Al-Sarraf, Z.; Lucas, M.; Harkness, P.

    2012-12-01

    Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively 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. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.

  6. Carbide-Free Bainitic Weld Metal: A New Concept in Welding of Armor Steels

    NASA Astrophysics Data System (ADS)

    Krishna Murthy, N.; Janaki Ram, G. D.; Murty, B. S.; Reddy, G. M.; Rao, T. J. P.

    2014-12-01

    Carbide-free bainite, a fine mixture of bainitic ferrite and austenite, is a relatively recent development in steel microstructures. Apart from being very strong and tough, the microstructure is hydrogen-tolerant. These characteristics make it well-suited for weld metals. In the current work, an armor-grade quenched and tempered steel was welded such that the fusion zone developed a carbide-free bainitic microstructure. These welds showed very high joint efficiency and ballistic performance compared to those produced, as per the current industrial practice, using austenitic stainless steel fillers. Importantly, these welds showed no vulnerability to cold cracking, as verified using oblique Y-groove tests. The concept of carbide-free bainitic weld metal thus promises many useful new developments in welding of high-strength steels.

  7. Localized weld metal corrosion in stainless steel water tanks

    SciTech Connect

    Strum, M.J.

    1995-05-25

    The rapidly developed leaks within the TFC and TFD tanks (LLNL groundwater treatment facilities) were caused by localized corrosion within the resolidified weld metal. The corrosion was initiated by the severe oxidation of the backsides of the welds which left the exposed surfaces in a condition highly susceptible to aqueous corrosion. The propagation of surface corrosion through the thickness of the welds occurred by localized corrosive attack. This localized attack was promoted by the presence of shielded aqueous environments provided by crevices at the root of the partial penetration welds. In addition to rapid corrosion of oxidized surfaces, calcium carbonate precipitation provided an additional source of physical shielding from the bulk tank environment. Qualification testing of alternate weld procedures showed that corrosion damage can be prevented in 304L stainless steel GTA welds by welding from both sides while preventing oxidation of the tank interior through the use of an inert backing gas such as argon. Corrosion resistance was also satisfactory in GMA welds in which oxidized surfaces were postweld cleaned by wire brushing and chemically passivated in nitric acid. Further improvements in corrosion resistance are expected from a Mo-containing grade of stainless steel such as type 316L, although test results were similar for type 304L sheet welded with type 308L filler metal and type 316L sheet welded with type 316L filler metal.

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

    ERIC Educational Resources Information Center

    Espy, John; Selleck, Ben

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

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

    ERIC Educational Resources Information Center

    Fortney, Clarence; Gregory, Mike

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

  10. Influence of Aluminum Content on Grain Refinement and Strength of AZ31 Magnesium GTA Weld Metal

    SciTech Connect

    Babu, N. Kishore; Cross, Carl E.

    2012-06-28

    The goal is to characterize the effect of Al content on AZ31 weld metal, the grain size and strength, and examine role of Al on grain refinement. The approach is to systematically vary the aluminum content of AZ31 weld metal, Measure average grain size in weld metal, and Measure cross-weld tensile properties and hardness. Conclusions are that: (1) increased Al content in AZ31 weld metal results in grain refinement Reason: higher undercooling during solidification; (2) weld metal grain refinement resulted in increased strength & hardness Reason: grain boundary strengthening; and (3) weld metal strength can be raised to wrought base metal levels.

  11. Process Simulation of Gas Metal Arc Welding Software

    2005-09-06

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

  12. Process Simulation of Gas Metal Arc Welding Software

    SciTech Connect

    Murray, Paul E.

    2005-09-06

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

  13. Control of arc length during gas metal arc welding

    SciTech Connect

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

    1994-12-31

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

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

    SciTech Connect

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

    1997-12-31

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

  15. Room-Temperature Chemical Welding and Sintering of Metallic Nanostructures by Capillary Condensation.

    PubMed

    Yoon, Sung-Soo; Khang, Dahl-Young

    2016-06-01

    Room-temperature welding and sintering of metal nanostructures, nanoparticles and nanowires, by capillary condensation of chemical vapors have successfully been demonstrated. Nanoscale gaps or capillaries that are abundant in layers of metal nanostructures have been found to be the preferred sites for the condensation of chemically oxidizing vapor, H2O2 in this work. The partial dissolution and resolidification at such nanogaps completes the welding/sintering of metal nanostructures within ∼10 min at room-temperature, while other parts of nanostructures remain almost intact due to negligible amount of condensation on there. The welded networks of Ag nanowires have shown much improved performances, such as high electrical conductivity, mechanical flexibility, optical transparency, and chemical stability. Chemically sintered layers of metal nanoparticles, such as Ag, Cu, Fe, Ni, and Co, have also shown orders of magnitude increase in electrical conductivity and improved environmental stability, compared to nontreated ones. Pertinent mechanisms involved in the chemical welding/sintering process have been discussed. Room-temperature welding and sintering of metal nanostructures demonstrated here may find widespread application in diverse fields, such as displays, deformable electronics, wearable heaters, and so forth.

  16. Room-Temperature Chemical Welding and Sintering of Metallic Nanostructures by Capillary Condensation.

    PubMed

    Yoon, Sung-Soo; Khang, Dahl-Young

    2016-06-01

    Room-temperature welding and sintering of metal nanostructures, nanoparticles and nanowires, by capillary condensation of chemical vapors have successfully been demonstrated. Nanoscale gaps or capillaries that are abundant in layers of metal nanostructures have been found to be the preferred sites for the condensation of chemically oxidizing vapor, H2O2 in this work. The partial dissolution and resolidification at such nanogaps completes the welding/sintering of metal nanostructures within ∼10 min at room-temperature, while other parts of nanostructures remain almost intact due to negligible amount of condensation on there. The welded networks of Ag nanowires have shown much improved performances, such as high electrical conductivity, mechanical flexibility, optical transparency, and chemical stability. Chemically sintered layers of metal nanoparticles, such as Ag, Cu, Fe, Ni, and Co, have also shown orders of magnitude increase in electrical conductivity and improved environmental stability, compared to nontreated ones. Pertinent mechanisms involved in the chemical welding/sintering process have been discussed. Room-temperature welding and sintering of metal nanostructures demonstrated here may find widespread application in diverse fields, such as displays, deformable electronics, wearable heaters, and so forth. PMID:27159354

  17. An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.

    1996-01-01

    In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several

  18. OXIDATION BEHAVIOR OF WELDED AND BASE METAL UNS N06025

    SciTech Connect

    Pint, Bruce A; Paul, Larry D.

    2007-01-01

    The oxidation behavior of specimens containing tungsten inert gas welds of UNS N06025 (NiCrFeAlY) was investigated in air for up to 5,000h at 900 -1000 C and 1,000h at 1100 -1200 C. In general, the microstructure was very homogeneous in the weld with smaller carbides and the Al2O3 penetrations were similar or smaller compared to those formed in the base metal. Above 1000 C, significant spallation was observed and Al and Cr depletion in the metal was observed to a similar extent in the weld and base metal. The maximum internal oxidation depth of the base metal at 900 and 1100 C was lower than several other commercial Ni-base alloys.

  19. Cleavage fracture in high strength low alloy weld metal

    SciTech Connect

    Bose, W.W.; Bowen, P.; Strangwood, M.

    1996-12-31

    The present investigation gives an evaluation of the effect of microstructure on the cleavage fracture process of High Strength Low Alloy (HSLA) multipass weld metals. With additions of alloying elements, such as Ti, Ni, Mo and Cr, the microstructure of C-Mn weld metal changes from the classical composition, i.e., allotriomorphic ferrite with acicular ferrite and Widmanstaetten ferrite, to bainite and low carbon martensite. Although the physical metallurgy of some HSLA weld metals has been studied before, more work is necessary to correlate the effect of the microstructure on the fracture behavior of such weld metals. In this work detailed microstructural analysis was carried out using optical and electron (SEM and TEM) microscopy. Single edge notched (SEN) bend testpieces were used to assess the cleavage fracture stress, {sigma}{sub F}. Inclusions beneath the notch surface were identified as the crack initiators of unstable cleavage fracture. From the size of such inclusions and the value of tensile stress predicted at the initiation site, the effective surface energy for cleavage was calculated using a modified Griffth energy balance for a penny shape crack. The results suggest that even though inclusions initiate cleavage fracture, the local microstructure may play an important role in the fracture process of these weld metals. The implications of these observations for a quantitative theory of the cleavage fracture of ferritic steels is discussed.

  20. Dynamic Electrode Forces in Gas Metal Arc Welding.

    NASA Astrophysics Data System (ADS)

    Jones, Lawrence Anthony

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

  1. Nanoconstruction by welding individual metallic nanowires together using nanoscale solder

    NASA Astrophysics Data System (ADS)

    Peng, Y.; Cullis, A. G.; Inkson, B. J.

    2010-07-01

    This work presents a new bottom-up nanowelding technique enabling building blocks to be assembled and welded together into complex 3D nanostructures using nanovolumes of metal solder. The building blocks of gold nanowires, (Co72Pt28/Pt)n multilayer nanowires, and nanosolder Sn99Au1 alloy nanowires were successfully fabricated by a template technique. Individual metallic nanowires were picked up and assembled together. Conductive nanocircuits were then welded together using similar or dissimilar nanosolder material. At the weld sites, nanoscale volumes of a chosen metal are deposited using nanosolder of a sacrificial nanowire, which ensures that the nanoobjects to be bonded retain their structural integrity. The whole nanowelding process is clean, controllable and reliable, and ensures both mechanically strong and electrically conductive contacts.

  2. Optimization of Gas Metal Arc Welding Process Parameters

    NASA Astrophysics Data System (ADS)

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

    2016-09-01

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

  3. 77 FR 60478 - Control of Ferrite Content in Stainless Steel Weld Metal

    Federal Register 2010, 2011, 2012, 2013, 2014

    2012-10-03

    ... COMMISSION Control of Ferrite Content in Stainless Steel Weld Metal AGENCY: Nuclear Regulatory Commission... Ferrite Content in Stainless Steel Weld Metal.'' This guide describes a method that the NRC staff considers acceptable for controlling ferrite content in stainless steel weld metal. Revision 4 updates...

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

    NASA Astrophysics Data System (ADS)

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

    2015-04-01

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

  5. Influence of PWHT on Toughness of High Chromium and Nickel Containing Martensitic Stainless Steel Weld Metals

    NASA Astrophysics Data System (ADS)

    Divya, M.; Das, Chitta Ranjan; Mahadevan, S.; Albert, S. K.; Pandian, R.; Kar, Sujoy Kumar; Bhaduri, A. K.; Jayakumar, T.

    2015-06-01

    Commonly used 12.5Cr-5Ni consumable specified for welding of martensitic stainless steels is compared with newly designed 14.5Cr-5Ni consumable in terms of their suitability for repair welding of 410 and 414 stainless steels by gas tungsten arc welding process. Changes in microstructure and austenite evolution were investigated using optical, scanning electron microscopy, X-ray diffraction techniques and Thermo-Calc studies. Microstructure of as-welded 12.5Cr-5Ni weld metal revealed only lath martensite, whereas as-welded 14.5Cr-5Ni weld metal revealed delta-ferrite, retained austenite, and lath martensite. Toughness value of as-welded 12.5Cr-5Ni weld metal is found to be significantly higher (216 J) than that of the 14.5Cr-5Ni weld metal (15 J). The welds were subjected to different PWHTs: one at 923 K (650 °C) for 1, 2, 4 hours (single-stage PWHT) and another one at 923 K (650 °C)/4 h followed by 873 K (600 °C)/2 h or 873 K (600 °C)/4 h (two-stage heat treatment). Hardness and impact toughness of the weld metals were measured for these weld metals and correlated with the microstructure. The study demonstrates the importance of avoiding formation of delta-ferrite in the weld metal.

  6. Weld induced base metal microfissuring in high temperature alloys

    SciTech Connect

    Lingenfelter, A.C.; Shoemaker, L.E.

    1984-06-22

    Three variables control the weld-induced, base-metal microfissuring sensitivity of Ni-Cr and Ni-Cr-Fe: thermal/mechanical history of the base material, chemical analysis of the base material, and the welding process used. Elements which tend to segregate to the grain boundaries such as B, C, and Zr, and to a lesser extent P, Si, S and Mg, increase the sensitivity. Welding processes listed from most to least severe in their tendency to produce microfissures are: gas metal arc - spray transfer, electron beam, gas metal arc - pulsed transfer, gas metal arc - short circuiting transfer, gas tungsten arc, submerged arc, and shielded metal arc. Microfissuring is always intergranular in nature. Coarse-grain size, whether arrived at by hot-working procedures or pre-weld annealing treatment, increases the sensitivity to microfissuring. Literature data and data for alloy 617 developed at Huntington Alloys suggest that microfissures, at least to 0.030 in. in length, do not affect the fatigue life, room-temperature tensile, and stress-rupture properties of a weldment.

  7. Metal Cutting Theory and Friction Stir Welding Tool Design

    NASA Technical Reports Server (NTRS)

    Payton, Lewis N.

    2003-01-01

    Friction Stir Welding (FSW) is a relatively new industrial process that was invented at The Weld Institute (TWI, United Kingdom) and patented in 1992 under research funded by in part by the National Aeronautics and Space Administration (NASA). Often quoted advantages of the process include good strength and ductility along with minimization of residual stress and distortion. Less well advertised are the beneficial effects of this solid state welding process in the field of occupational and environmental safety. It produces superior weld products in difficult to weld materials without producing any toxic fumes or solid waste that must be controlled as hazardous waste. In fact, it reduces noise pollution in the workspace as well. In the early days of FSW, most welding was performed on modified machine tools, in particular on milling machines with modified milling cutters. In spite of the obvious milling heritage of the process, the techniques and lessons learned from almost 250 years of successful metalworking with milling machines have not been applied in the field of modern Friction Stir Welding. The goal of the current research was to study currently successful FSW tools and parameterize the process in such a way that the design of new tools for new materials could be accelerated. Along the way, several successful new tooling designs were developed for current issues at the Marshall Space Flight Center with accompanying patent disclosures

  8. Effect of rhenium on the structure and properties of the weld metal of a molybdenum alloy

    NASA Technical Reports Server (NTRS)

    Dyachenko, V. V.; Morozov, B. P.; Tylkina, M. A.; Savitskiy, Y. M.; Nikishanov, V. V.

    1984-01-01

    The structure and properties of welds made in molybdenum alloy VM-1 as a function of rhenium concentrations in the weld metal were studied. Rhenium was introduced into the weld using rhenium wire and tape or wires of Mo-47Re and Mo-52Re alloys. The properties of the weld metal were studied by means of metallographic techniques, electron microscopy, X-ray analysis, and autoradiography. The plasticity of the weld metal sharply was found to increase with increasing concentration of rhenium up to 50%. During welding, a decarburization process was observed which was more pronounced at higher concentrations of rhenium.

  9. Career Preparation Program Curriculum Guide for: Metal Fabrication, Welding.

    ERIC Educational Resources Information Center

    British Columbia Dept. of Education, Victoria. Curriculum Development Branch.

    This curriculum outline provides secondary and postsecondary instructors with detailed information on student learning outcomes for completion of the welding/metal fabrication program requirements. A program overview discusses the aims of education; secondary school philosophy; and career preparation programs and their goals, organization, and…

  10. Analysis of thermal stresses and metal movement during welding

    NASA Technical Reports Server (NTRS)

    Muraki, T.; Masubuchi, K.

    1973-01-01

    The research is reported concerning the development of a system of mathematical solutions and computer programs for one- and two-dimensional analyses for thermal stresses. Reports presented include: the investigation of thermal stress and buckling of tantalum and columbium sheet; and analysis of two dimensional thermal strains and metal movement during welding.

  11. The effect of weld stresses on weld quality. [stress fields and metal cracking

    NASA Technical Reports Server (NTRS)

    Chihoski, R. A.

    1972-01-01

    A narrow heat source raises the temperature of a spot on a solid piece of material like metal. The high temperature of the spot decreases with distance from the spot. This is true whether the heat source is an arc, a flame, an electron beam, a plasma jet, a laser beam, or any other source of intense, narrowly defined heat. Stress and strain fields around a moving heat source are organized into a coherent visible system. It is shown that five stresses act across the weld line in turn as an arc passes. Their proportions and positions are considerably altered by weld parameters or condition changes. These pushes and pulls affect the metallurgical character and integrity of the weld area even when there is no apparent difference between after-the-fact examples.

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

    SciTech Connect

    Murray, P.E.

    1998-07-01

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

  13. Systems to Control Molten Metal Transfer in Arc Welding

    NASA Astrophysics Data System (ADS)

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

    2015-09-01

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

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

    SciTech Connect

    Bednarova, O.; Janovec, J.

    2010-06-22

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

  15. Creep deformation and fracture behaviour of a nitrogen-bearing type 316 stainless steel weld metal

    NASA Astrophysics Data System (ADS)

    Sasikala, G.; Mathew, M. D.; Bhanu Sankara Rao, K.; Mannan, S. L.

    1999-08-01

    Creep properties of a nuclear grade type 316 stainless steel (SS) weld metal containing ˜0.08 wt% of nitrogen were studied at 873 and 923 K. These properties were compared with those of a type 316 SS weld metal without nitrogen. In general, the nitrogen-bearing weld metal exhibited better creep and rupture properties. The rupture strengths of the nitrogen-containing weld metal was ˜40% higher than that for the type 316 SS weld metal at both the temperatures. The steady-state (minimum) creep rates were up to two orders of magnitude lower for the nitrogen-containing weld metal compared to 316 SS weld metal. Rupture ductility of nitrogen-containing weld metal was lower at all the test conditions; the long-term ductility at 923 K was below 5%. The differences in creep behaviour of the two weld metals are discussed with respect to the influence of nitrogen on microstructural evolution in the two weld metals.

  16. Optimization of Laser Keyhole Welding Strategies of Dissimilar Metals by FEM Simulation

    NASA Astrophysics Data System (ADS)

    Garcia Navas, Virginia; Leunda, Josu; Lambarri, Jon; Sanz, Carmen

    2015-07-01

    Laser keyhole welding of dissimilar metals has been simulated to study the effect of welding strategies (laser beam displacements and tilts) and combination of metals to be welded on final quality of the joints. Molten pool geometry and welding penetration have been studied but special attention has been paid to final joint material properties, such as microstructure/phases and hardness, and especially to the residual stress state because it greatly conditions the service life of laser-welded components. For a fixed strategy (laser beam perpendicular to the joint) austenitic to carbon steel laser welding leads to residual stresses at the joint area very similar to those obtained in austenitic to martensitic steel welding, but welding of steel to Inconel 718 results in steeper residual stress gradients and higher area at the joint with detrimental tensile stresses. Therefore, when the difference in thermo-mechanical properties of the metals to be welded is higher, the stress state generated is more detrimental for the service life of the component, and consequently more relevant is the optimization of welding strategy. In laser keyhole welding of austenitic to martensitic stainless steel and austenitic to carbon steel, the optimum welding strategy is displacing the laser beam 1 mm toward the austenitic steel. In the case of austenitic steel to Inconel welding, the optimum welding strategy consists in setting the heat source tilted 45 deg and moved 2 mm toward the austenitic steel.

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

    PubMed Central

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

    1983-01-01

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

  18. Filler metal alloy for welding cast nickel aluminide alloys

    DOEpatents

    Santella, Michael L.; Sikka, Vinod K.

    1998-01-01

    A filler metal alloy used as a filler for welding east nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and east in copper chill molds.

  19. Filler metal alloy for welding cast nickel aluminide alloys

    DOEpatents

    Santella, M.L.; Sikka, V.K.

    1998-03-10

    A filler metal alloy used as a filler for welding cast nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and cast in copper chill molds. 3 figs.

  20. Fractal Analysis of Metal Transfer in Mig/mag Welding

    NASA Astrophysics Data System (ADS)

    Vieira, A. P.; Vasconcelos, H. H. M.; Gonçalves, L. L.; de Miranda, H. C.

    2009-03-01

    We apply techniques of fractal analysis in order to classify metal-transfer mode in MIG/MAG (metal inert/active gas) welding, which are among the most commonly employed arc-fusion processes for industrial applications. We work with voltage and current time series obtained during welding, and evaluate statistical fluctuations present in those series by Hurst, detrended-fluctuation, and detrended-cross-correlation analyses, for each of three different metal-transfer modes: short-circuiting, globular, and spray. For a given total timespan of each series, curves of fluctuation as a funtion of the time-window size are processed by using pattern-classification techniques, such as principal-component analysis and Karhunen-Loève expansions. We obtain near 100% success rate for the classification, with timespans as small as 100 miliseconds, with a processing time of the same order. This suggests that our set of tools can be incorporated into an industrial welding apparatus in order to guarantee automatic correction of a process requiring a single metal-transfer mode.

  1. 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.

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

    SciTech Connect

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

    1996-12-31

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

  3. STRESS CORROSION CRACK GROWTH RESPONSE FOR ALLOY 152/52 DISSIMILAR METAL WELDS IN PWR PRIMARY WATER

    SciTech Connect

    Toloczko, Mychailo B.; Olszta, Matthew J.; Overman, Nicole R.; Bruemmer, Stephen M.

    2015-08-15

    As part of ongoing research into primary water stress corrosion cracking (PWSCC) susceptibility of alloy 690 and its welds, SCC tests have been conducted on alloy 152/52 dissimilar metal (DM) welds with cracks positioned with the goal to assess weld dilution and fusion line effects on SCC susceptibility. No increased crack growth rate was found when evaluating a 20% Cr dilution zone in alloy 152M joined to carbon steel (CS) that had not undergone a post-weld heat treatment (PWHT). However, high SCC crack growth rates were observed when the crack reached the fusion line of that material where it propagated both on the fusion line and in the heat affected zone (HAZ) of the carbon steel. Crack surface and crack profile examinations of the specimen revealed that cracking in the weld region was transgranular (TG) with weld grain boundaries not aligned with the geometric crack growth plane of the specimen. The application of a typical pressure vessel PWHT on a second set of alloy 152/52 – carbon steel DM weld specimens was found to eliminate the high SCC susceptibility in the fusion line and carbon steel HAZ regions. PWSCC tests were also performed on alloy 152-304SS DM weld specimens. Constant K crack growth rates did not exceed 5x10-9 mm/s in this material with post-test examinations revealing cracking primarily on the fusion line and slightly into the 304SS HAZ.

  4. Control of Structure in Conventional Friction Stir Welds through a Kinematic Theory of Metal Flow

    NASA Technical Reports Server (NTRS)

    Rubisoff, H.A.; Schneider, J.A.; Nunes, A.C.

    2009-01-01

    In friction stir welding (FSW), a rotating pin is translated along a weld seam so as to stir the sides of the seam together. Metal is prevented from flowing up the pin, which would result in plowing/cutting instead of welding, by a shoulder on the pin. In conventional FSW, the weld metal rests on an "anvil", which supports the heavy "plunge" load on the tool. In this study, both embedded tungsten wires along and copper plating on the faying surfaces were used to trace the flow of AA2219 weld metal around the C-FSW tool. The effect of tool rotational speed, travel speed, plunge load, and pin thread pitch on the resulting weld metal flow was evaluated. Plan, longitudinal, and transverse section x-ray radiographs were examined to trace the metal flow paths. The results are interpreted in terms of a kinematic theory of metal flow in FSW.

  5. Cryogenic Treatment of Metal Parts

    SciTech Connect

    Chillar, Rahul; Agrawal, S. C.

    2006-03-31

    Cryogenic treatment and its variables have been described. Results of eight engineering tests carried out on cryotreated parts have been presented. Cryogenic treatment of metal parts enhances useful properties which in turn, improves various strengths. Our tests viz. Abrasion, Torsion, Fatigue, Tensile, Shear, Hardness and Impact on Mild steel, Cast Iron, Brass and Copper show that the cryogenic treatment improved useful properties of mild steel parts appreciably but did not show promise with brass and copper parts.

  6. 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.

  7. Friction welded nonconsumable electrode assembly and use thereof for electrolytic production of metals and silicon

    DOEpatents

    Byrne, Stephen C.; Ray, Siba P.; Rapp, Robert A.

    1984-01-01

    A nonconsumable electrode assembly suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a metal conductor and a ceramic electrode body connected by a friction weld between a portion of the body having a level of free metal or metal alloy sufficient to effect such a friction weld and a portion of the metal conductor.

  8. Factors affecting the strength of multipass low-alloy steel weld metal

    NASA Technical Reports Server (NTRS)

    Krantz, B. M.

    1972-01-01

    The mechanical properties of multipass high-strength steel weld metals depend upon several factors, among the most important being: (1) The interaction between the alloy composition and weld metal cooling rate which determines the as-deposited microstructure; and (2) the thermal effects of subsequent passes on each underlying pass which alter the original microstructure. The bulk properties of a multipass weld are therefore governed by both the initial microstructure of each weld pass and its subsequent thermal history. Data obtained for a high strength low alloy steel weld metal confirmed that a simple correlation exists between mechanical properties and welding conditions if the latter are in turn correlated as weld cooling rate.

  9. Determination of elastoplastic mechanical properties of the weld and heat affected zone metals in tailor-welded blanks by nanoindentation test

    NASA Astrophysics Data System (ADS)

    Ma, Xiangdong; Guan, Yingping; Yang, Liu

    2015-09-01

    The elastoplastic mechanical properties of the weld and heat affected zone metals have comparatively major impact on the forming process of tailor-welded blanks. A few scholars investigated the elastoplastic mechanical properties of the weld and heat affected zone, but they only simply assumed that it was a uniform distribution elastoplastic material different from the base materials. Four types of tailor-welded blanks which consist of ST12 and 304 stainless steel plates are selected as the research objects, the elastoplastic mechanical properties of the tailor-welded blanks weld and heat affected zone metals are obtained based on the nanoindentation tests, and the Erichsen cupping tests are conducted by combining numerical simulation with physical experiment. The nanoindentation tests results demonstrate that the elastoplastic mechanical properties of the weld and heat affected zone metals are not only different from the base materials, but also varying between the weld metals and the heat affected zone metals. Comparing the Erichsen cupping test resulted from numerical with that from experimental method, it is found that the numerical value of Erichsen cupping test which consider the elastoplastic mechanical properties of the weld and heat affected zone metals have a good agreement with the experimental result, and the relative error is only 4.8%. The proposed research provides good solutions for the inhomogeneous elastoplastic mechanical properties of the tailor-welded blanks weld and heat affected zone metals, and improves the control performance of tailor-welded blanks forming accuracy.

  10. [INVITED] Evaluation of process observation features for laser metal welding

    NASA Astrophysics Data System (ADS)

    Tenner, Felix; Klämpfl, Florian; Nagulin, Konstantin Yu.; Schmidt, Michael

    2016-06-01

    In the present study we show how fast the fluid dynamics change when changing the laser power for different feed rates during laser metal welding. By the use of two high-speed cameras and a data acquisition system we conclude how fast we have to image the process to measure the fluid dynamics with a very high certainty. Our experiments show that not all process features which can be measured during laser welding do represent the process behavior similarly well. Despite the good visibility of the vapor plume the monitoring of its movement is less suitable as an input signal for a closed-loop control. The features measured inside the keyhole show a good correlation with changes of process parameters. Due to its low noise, the area of the keyhole opening is well suited as an input signal for a closed-loop control of the process.

  11. Long Term Stability of Laser Joined Plastic Metal Parts

    NASA Astrophysics Data System (ADS)

    Roesner, A.; Olowinsky, A.; Gillner, A.

    To join plastic to metal a laser based two-step laser process is described. The first process step is the laser micro structuring of the metal surface to create microstructures with undercut grooves. The subsequent transmission joining process allows a selective heating of arbitrary component geometries and the local control of the joining temperature. Both parts are brought into direct contact prior to welding. The plastic part is melted and expands into the microstructures through the external clamping pressure. The joining results due to micro cramping after setting. The long term stability of the joining is described.

  12. Effects of weld metal profile on the fatigue life of integrally reinforced weld-on fittings

    SciTech Connect

    Woods, G.E. ); Rodabaugh, E.C. , Dublin, OH )

    1994-06-01

    The cyclic fatigue life of fabricated tee intersections, including integrally reinforced weld-on fittings, has been a topic of discussion in the recent past. The discussion has centered around questions concerning the accuracy of the ASME B31.3 Code equations in calculating the stress intensification factors, (SIFs), for these types of intersection geometries. The SIF of an intersection is an indicator of the fatigue life of the intersection when it is subjected to bending moments caused by thermal, flow, or mechanically induced cyclical displacements. Schneider, Rodabaugh, and Woods concur that inaccuracies in the Code SIF equations do exist and that these equations should be revised. This report presents new Markl type SIF data on the B.W.Pipet (BWP), an integrally reinforced weld-on branch fitting, manufactured by WFI International, Inc., in Houston, Texas. The scope of this research project was to determine the influence of the installation weld metal profile of the Pipet to the run pipe on the SIF. The SIF data were then compared to calculated SIF values using equations from the American Society of Mechanical engineers (ASME) B31.1, ASME B31.3, and ASME Section 3, Subsection NC, for the purpose of determining which Code equation may be the most appropriate for calculating the SIF for these particular fittings.

  13. 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.

  14. Hydrogen-induced cracking along the fusion boundary of dissimilar metal welds

    SciTech Connect

    Rowe, M.D.; Nelson, T.W.; Lippold, J.C.

    1999-02-01

    Presented here are the results from a series of experiments in which dissimilar metals welds were made using the gas tungsten arc welding process with pure argon or argon-6% hydrogen shielding gas. The objective was to determine if cracking near the fusion boundary of dissimilar metal welds could be caused by hydrogen absorbed during welding and to characterize the microstructures in which cracking occurred. Welds consisted of ER308 and ER309LSi austenitic stainless steel and ERNiCr-3-nickel-based filler metals deposited on A36 steel base metal. Cracking was observed in welds made with all three filler metals. A ferrofluid color metallography technique revealed that cracking was confined to regions in the weld metal containing martensite. Microhardness indentations indicated that martensitic regions in which cracking occurred had hardness values from 400 to 550 HV. Cracks did not extend into bulk weld metal with hardness less than 350 HV. Martensite formed near the fusion boundary in all three filler metals due to regions of locally increased base metal dilution.

  15. Precise Truss Assembly using Commodity Parts and Low Precision Welding

    NASA Technical Reports Server (NTRS)

    Komendera, Erik; Reishus, Dustin; Dorsey, John T.; Doggett, William R.; Correll, Nikolaus

    2013-01-01

    We describe an Intelligent Precision Jigging Robot (IPJR), which allows high precision assembly of commodity parts with low-precision bonding. We present preliminary experiments in 2D that are motivated by the problem of assembling a space telescope optical bench on orbit using inexpensive, stock hardware and low-precision welding. An IPJR is a robot that acts as the precise "jigging", holding parts of a local assembly site in place while an external low precision assembly agent cuts and welds members. The prototype presented in this paper allows an assembly agent (in this case, a human using only low precision tools), to assemble a 2D truss made of wooden dowels to a precision on the order of millimeters over a span on the order of meters. We report the challenges of designing the IPJR hardware and software, analyze the error in assembly, document the test results over several experiments including a large-scale ring structure, and describe future work to implement the IPJR in 3D and with micron precision.

  16. Precise Truss Assembly Using Commodity Parts and Low Precision Welding

    NASA Technical Reports Server (NTRS)

    Komendera, Erik; Reishus, Dustin; Dorsey, John T.; Doggett, W. R.; Correll, Nikolaus

    2014-01-01

    Hardware and software design and system integration for an intelligent precision jigging robot (IPJR), which allows high precision assembly using commodity parts and low-precision bonding, is described. Preliminary 2D experiments that are motivated by the problem of assembling space telescope optical benches and very large manipulators on orbit using inexpensive, stock hardware and low-precision welding are also described. An IPJR is a robot that acts as the precise "jigging", holding parts of a local structure assembly site in place, while an external low precision assembly agent cuts and welds members. The prototype presented in this paper allows an assembly agent (for this prototype, a human using only low precision tools), to assemble a 2D truss made of wooden dowels to a precision on the order of millimeters over a span on the order of meters. The analysis of the assembly error and the results of building a square structure and a ring structure are discussed. Options for future work, to extend the IPJR paradigm to building in 3D structures at micron precision are also summarized.

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

    NASA Astrophysics Data System (ADS)

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

    2007-03-01

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

  18. Flexible solution of the fixturing problem in sheet metal laser butt welding

    NASA Astrophysics Data System (ADS)

    Olsen, Flemming O.

    1994-09-01

    In 20 years laser welding of sheet metal has been demonstrated as a possible high-tech metal joining process. However, the major obstacle to the introduction of laser welding in for example car body manufacturing has been and is the fixturing problem. In case of laser butt welding of 0.5 - 1 mm thick steel sheets, the maximum acceptable gab between the sheets to be welded is in the range of 40 - 50 micrometer. Out of this demand two major problems arise: (1) the high precision required in weld preparation in terms of precise shape of the two sheets to be welded. (2) the problem of maintaining a narrow gab under welding, where thermal distortions, even though they are relatively small in this process, still will open the gap as the welding beam proceeds along the seam. In this paper a unique technique to overcome these problems will be described. The results of the experimental work described in this paper demonstrates the technique in 2D welding, where high quality butt welds has been demonstrated with virtually no clamping forces applied by utilizing a special seam preparation technique. Possibilities in car body manufacturing and other 3D sheet metal assembly by means of the flexible laser welding technique will be discussed.

  19. Diffusion welded nonconsumable electrode assembly and use thereof for electrolytic production of metals and silicon

    DOEpatents

    Byrne, Stephen C.; Vasudevan, Asuri K.

    1984-01-01

    A nonconsumable electrode assembly suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a metal conductor diffusion welded to a portion of a ceramic electrode body having a level of free metal or metal alloy sufficient to effect a metal bond.

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

    SciTech Connect

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

    2010-02-15

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

  1. Metal cutting analogy for establishing Friction Stir Welding process parameters

    NASA Astrophysics Data System (ADS)

    Stafford, Sylvester Allen

    A friction stir weld (FSW) is a solid state joining operation whose processing parameters are currently determined by lengthy trial and error methods. To implement FSWing rapidly in various applications will require an approach for predicting process parameters based on the physics of the process. Based on hot working conditions for metals, a kinematic model has been proposed for calculating the shear strain and shear strain rates during the FSW process, validation of the proposed model with direct measuring is difficult however. Since the shear strain and shear strain rates predicted for the FSW process, are similar to those predicted in metal cutting, validation of the FSW algorithms with microstructural studies of metal chips may be possible leading to the ability to predict FSW processing parameters.

  2. 78 FR 63517 - Control of Ferrite Content in Stainless Steel Weld Metal

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-10-24

    ... Information The NRC published DG-1279 in the Federal Register on October 3, 2012 (77 FR 60479), for a 60-day... COMMISSION Control of Ferrite Content in Stainless Steel Weld Metal AGENCY: Nuclear Regulatory Commission... revision to Regulatory Guide (RG) 1.31, ``Control of Ferrite Content in Stainless Steel Weld Metal.''...

  3. Promising HE for explosive welding of thin metallic foils

    NASA Astrophysics Data System (ADS)

    Deribas, A. A.; Mikhaylov, A. L.; Titova, N. N.; Zocher, Marvin A.

    2012-03-01

    Experimental results are presented on the development of a high explosive (HE) suitable for the welding of thin metallic foils. The explosive is formed from a mixture of brisant HE (RDX or PETN) and an inert material, namely sodium bicarbonate. Sodium bicarbonate releases a rather large quantity of gas during decomposition, the effects of which are discussed. Measurements of detonation velocity and critical thickness for specific mixture combinations are presented. It is shown that particle size (of the RDX or PETN component) has a significant effect upon detonation velocity and critical thickness. Compositions were developed which have a stable detonation velocity ~2 km/s with a layer thickness ~ 2 mm.

  4. Advanced Testing Techniques to Measure the PWSCC Resistance of Alloy 690 and its Weld Metals

    SciTech Connect

    P.Andreson

    2004-10-01

    Wrought Alloy 600 and its weld metals (Alloy 182 and Alloy 82) were originally used in pressurized water reactors (PWRs) due to the material's inherent resistance to general corrosion in a number of aggressive environments and because of a coefficient of thermal expansion that is very close to that of low alloy and carbon steel. Over the last thirty years, stress corrosion cracking in PWR primary water (PWSCC) has been observed in numerous Alloy 600 component items and associated welds, sometimes after relatively long incubation times. The occurrence of PWSCC has been responsible for significant downtime and replacement power costs. As part of an ongoing, comprehensive program involving utilities, reactor vendors and engineering/research organizations, this report will help to ensure that corrosion degradation of nickel-base alloys does not limit service life and that full benefit can be obtained from improved designs for both replacement components and new reactors.

  5. Effect of Some Overlay Welding Regime With Longitudinal Magnetic Field on Hardness, Phase Composition And Welded Layer Wear By Arc Method With Flux Metal Wire

    NASA Astrophysics Data System (ADS)

    Nosov, D. G.; Peremitko, V. V.; Barashkin, M. H.

    2016-08-01

    The paper defines the range of overlay welding current, frequencies and induction of a longitudinal magnetic field that enhance the wear resistance of welded layer additing the flux. The conditions of their mutual influence on the process of structure formation are stated as well as the mathematical models linking the overlay welding current, frequency and induction of a longitudinal magnetic field with hardness, wear resistance and phase composition of the welded layer, the use of which will allow to determine the welding modes to provide the necessary properties of the weld metal.

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

    NASA Astrophysics Data System (ADS)

    Murphy, Anthony B.

    2013-06-01

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

  7. Effect of Heat Treatment on Low Temperature Toughness of Reduced Pressure Electron Beam Weld Metal of Type 316L Stainless Steel

    SciTech Connect

    Nakagawa, H.; Fujii, H.; Tamura, M.

    2006-03-31

    Austenitic stainless steels are considered to be the candidate materials for liquid hydrogen vessels and the related equipments, and those welding parts that require high toughness at cryogenic temperature. The authors have found that the weld metal of Type 316L stainless steel processed by reduced pressure electron beam (RPEB) welding has high toughness at cryogenic temperature, which is considered to be due to the single-pass welding process without reheating effect accompanied by multi-pass welding process.In this work, the effect of heat treatment on low temperature toughness of the RPEB weld metal of Type 316L was investigated by Charpy impact test at 77K. The absorbed energy decreased with higher temperature and longer holding time of heat treatment. The remarkable drop in the absorbed energy was found with heat treatment at 1073K for 2 hours, which is as low as that of conventional multi-pass weld metal such as tungsten inert gas welding. The observations of fracture surface and microstructure revealed that the decrease in the absorbed energy with heat treatment resulted from the precipitation of intermetallic compounds near delta-ferrite phase.

  8. Effect of Heat Treatment on Low Temperature Toughness of Reduced Pressure Electron Beam Weld Metal of Type 316L Stainless Steel

    NASA Astrophysics Data System (ADS)

    Nakagawa, H.; Fujii, H.; Tamura, M.

    2006-03-01

    Austenitic stainless steels are considered to be the candidate materials for liquid hydrogen vessels and the related equipments, and those welding parts that require high toughness at cryogenic temperature. The authors have found that the weld metal of Type 316L stainless steel processed by reduced pressure electron beam (RPEB) welding has high toughness at cryogenic temperature, which is considered to be due to the single-pass welding process without reheating effect accompanied by multi-pass welding process. In this work, the effect of heat treatment on low temperature toughness of the RPEB weld metal of Type 316L was investigated by Charpy impact test at 77K. The absorbed energy decreased with higher temperature and longer holding time of heat treatment. The remarkable drop in the absorbed energy was found with heat treatment at 1073K for 2 hours, which is as low as that of conventional multi-pass weld metal such as tungsten inert gas welding. The observations of fracture surface and microstructure revealed that the decrease in the absorbed energy with heat treatment resulted from the precipitation of intermetallic compounds near delta-ferrite phase.

  9. Effect of Boric Acid Concentration on Viscosity of Slag and Property of Weld Metal Obtained from Underwater Wet Welding

    NASA Astrophysics Data System (ADS)

    Guo, Ning; Guo, Wei; Xu, Changsheng; Du, Yongpeng; Feng, Jicai

    2015-06-01

    Underwater wet welding is a crucial repair and maintenance technology for nuclear plant. A boric acid environment raises a new challenge for the underwater welding maintenance of nuclear plant. This paper places emphasis on studying the influence of a boric acid environment in nuclear plant on the underwater welding process. Several groups of underwater wet welding experiments have been conducted in boric acid aqueous solution with different concentration (0-35000 ppm). The viscosity of the welding slag and the mechanical properties of welds, such as the hardness, strength, and elongation, have been studied. The results show that with increasing boric acid concentration, the viscosity of the slag decreases first and then increases at a lower temperature (less than 1441 °C). However, when the temperature is above 1480 °C, the differences between the viscosity measurements become less pronounced, and the viscosity tends to a constant value. The hardness and ductility of the joints can be enhanced significantly, and the maximum strength of the weld metal can be reached at 2300 ppm.

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

    NASA Astrophysics Data System (ADS)

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

    2015-01-01

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

  11. Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding.

    PubMed

    Ampaiboon, Anusit; Lasunon, On-Uma; Bubphachot, Bopit

    2015-01-01

    We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10-20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%.

  12. Welding.

    ERIC Educational Resources Information Center

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

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

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

    SciTech Connect

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

    2015-06-15

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

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

    PubMed

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

    2014-12-01

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

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

    PubMed

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

    2014-12-01

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

  16. 30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal....

  17. 30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal....

  18. 30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal....

  19. 30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal....

  20. 30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal....

  1. 30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal....

  2. 30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal....

  3. 30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal....

  4. 30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal....

  5. 30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal....

  6. Ultrasonic Evaluation of Two Dissimilar Metal Weld Overlay Specimens

    SciTech Connect

    Crawford, Susan L.; Cinson, Anthony D.; Prowant, Matthew S.; Moran, Traci L.; Anderson, Michael T.

    2012-06-30

    Two dissimilar metal weld (DMW) pipe-to-nozzle specimens were implanted with thermal fatigue cracks in the 13% to 90% through-wall depth range. The specimens were ultrasonically evaluated with phased-array probes having center frequencies of 0.8, 1.0, 1.5, and 2.0 megahertz (MHz). An Alloy 82/182 weld overlay (WOL) was applied and the specimens were ultrasonically re-evaluated for flaw detection and characterization. The Post-WOL flaw depths were approximately 10% to 56% through-wall. This study has shown the effectiveness of ultrasonic examinations of Alloy 82/182 overlaid DMW specimens. Phased-array probes with center frequency in the 0.8- to 1.0-MHz range provide a strong coherent signal but the greater ultrasonic wavelength and larger beam spot size prevent the reliable detection of small flaws. These small flaws had nominal through-wall depths of less than 15% and length in the 50-60 mm (2-2.4 in.) range. Flaws in the 19% and greater through-wall depth range were readily detected with all four probes. At the higher frequencies, the reflected signals are less coherent but still provide adequate signal for flaw detection and characterization. A single inspection at 2.0 MHz could provide adequate detection and sizing information but a supplemental inspection at 1.0 or 1.5 MHz is recommended.

  7. Influence of Alloy and Solidification Parameters on Grain Refinement in Aluminum Weld Metal due to Inoculation

    SciTech Connect

    Schempp, Philipp; Tang, Z.; Cross, Carl E.; Seefeld, T.; Pittner, A.; Rethmeier, M.

    2012-06-28

    The goals are: (1) Establish how much Ti/B grain refiner is need to completely refine aluminum weld metal for different alloys and different welding conditions; (2) Characterize how alloy composition and solidification parameters affect weld metal grain refinement; and (3) Apply relevant theory to understand observed behavior. Conclusions are: (1) additions of Ti/B grain refiner to weld metal in Alloys 1050, 5083, and 6082 resulted in significant grain refinement; (2) grain refinement was more effective in GTAW than LBW, resulting in finer grains at lower Ti content - reason is limited time available for equiaxed grain growth in LBW (inability to occlude columnar grain growth); (3) welding travel speed did not markedly affect grain size within GTAW and LBW clusters; and (4) application of Hunt CET analysis showed experimental G to be on the order of the critical G{sub CET}; G{sub CET} was consistently higher for GTAW than for LBW.

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

    NASA Astrophysics Data System (ADS)

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

    2013-11-01

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

  9. 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.

  10. Development of welded metal bellows having minimum effective diameter change

    NASA Technical Reports Server (NTRS)

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

    1972-01-01

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

  11. High power X-ray welding of metal-matrix composites

    SciTech Connect

    Rosenberg, Richard A.; Goeppner, George A.; Noonan, John R.; Farrell, William J.; Ma, Qing

    1997-12-01

    A method for joining metal-matrix composites (MMCs) by using high power x-rays as a volumetric heat source is provided. The method involves directing an x-ray to the weld line between two adjacent MMCs materials to create an irradiated region or melt zone. The x-rays have a power density greater than about 10{sup 4} watts/cm{sup 2} and provide the volumetric heat required to join the MMC materials. Importantly, the reinforcing material of the metal-matrix composites remains uniformly distributed in the melt zone, and the strength of the MMCs are not diminished. In an alternate embodiment, high power x-rays are used to provide the volumetric heat required to weld metal elements, including metal elements comprised of metal alloys. In an alternate embodiment, high power x-rays are used to provide the volumetric heat required to weld metal elements, including metal elements comprised of metal alloys.

  12. High power x-ray welding of metal-matrix composites

    DOEpatents

    Rosenberg, Richard A.; Goeppner, George A.; Noonan, John R.; Farrell, William J.; Ma, Qing

    1999-01-01

    A method for joining metal-matrix composites (MMCs) by using high power x-rays as a volumetric heat source is provided. The method involves directing an x-ray to the weld line between two adjacent MMCs materials to create an irradiated region or melt zone. The x-rays have a power density greater than about 10.sup.4 watts/cm.sup.2 and provide the volumetric heat required to join the MMC materials. Importantly, the reinforcing material of the metal-matrix composites remains uniformly distributed in the melt zone, and the strength of the MMCs are not diminished. In an alternate embodiment, high power x-rays are used to provide the volumetric heat required to weld metal elements, including metal elements comprised of metal alloys. In an alternate embodiment, high power x-rays are used to provide the volumetric heat required to weld metal elements, including metal elements comprised of metal alloys.

  13. Novel concepts in weld metal science: Role of gradients and composite structure

    SciTech Connect

    Matlock, D.K.; Olson, D.L.

    1991-12-01

    The effects of compositional and microstructural gradients on weld metal properties are being investigated. Crack propagation is solidified alloy structures is being characterized as to solidification orientation and the profile of the compositional variations. The effects of compositional gradients, are considered based on a thermodynamic analysis, referred to as the Cahn-Hillard analysis, which describes the degree to which a local surface energy is modified by the presence of a compositional gradient. The analysis predicts that both ductile and brittle fracture mechanisms are enhanced by the presence of a composition gradient. Special techniques to produce laboratory samples with microstructures which simulate the composition and microstructure gradients in solidified weld metal are used, along with appropriate mathematical models, to evaluate the properties of the composite weld metals. The composite modeling techniques are being applied to describe the effects of compositional and microstructural gradients on weld metal properties in Ni-Cu alloys. The development of metal matrix composition weld deposits on austenitic stainless steels has been studied. The particulate metal matrix composites were produced with ceramic or refractory metal powder filled cored wire, which was gas tungsten arc and gas metal arc welded.

  14. Alloying Elements Transition Into the Weld Metal When Using an Inventor Power Source

    NASA Astrophysics Data System (ADS)

    Mamadaliev, R. A.; Kuskov, V. N.; Popova, A. A.; Valuev, D. V.

    2016-04-01

    The temperature distribution over the surface of the welded 12Kh18N10T steel plates using the inventor power source ARC-200 has been calculated. In order to imitate multipass welding when conducting the thermal analysis the initial temperature was changed from 298K up to 798K in 100K increments. It has been determined that alloying elements transition into the weld metal depends on temperature. Using an inventor power source facilitates a uniform distribution of alloying elements along the length and height of the weld seam.

  15. High-cycle Fatigue Properties of Alloy718 Base Metal and Electron Beam Welded Joint

    NASA Astrophysics Data System (ADS)

    Ono, Yoshinori; Yuri, Tetsumi; Nagashima, Nobuo; Sumiyoshi, Hideshi; Ogata, Toshio; Nagao, Naoki

    High-cycle fatigue properties of Alloy 718 plate and its electron beam (EB) welded joint were investigated at 293 K and 77 K under uniaxial loading. At 293 K, the high-cycle fatigue strength of the EB welded joint with the post heat treatment exhibited somewhat lower values than that of the base metal. The fatigue strengths of both samples basically increased at 77 K. However, in longer life region, the EB welded joint fractured from a blow hole formed in the welded zone, resulting in almost the same fatigue strength at 107 cycles as that at 293 K.

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

    SciTech Connect

    Fazackerley, W.; Gee, R.

    1996-12-31

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

  17. Preventing Technique of Metal Deposition on Optical Devices in Space Diode Laser Welding for Space Applications

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Tanaka, Kenji; Ohtani, Masato; Shobako, Shinichiro; Terajima, Noboru; Hiraoka, Nobuaki

    In future space developments, the welding in space may be required for the repairs of the ISS and the constructions of lunar base and space structures. The authors have studied the space Gas Hollow Tungsten Arc (GHTA) welding process since 1993. This paper describes the results for space applying the space Diode Laser (DL) welding process which the authors proposed in 2002. It is necessary to prevent the metal deposition on optical devices in order to utilize the space DL welding process in space. The authors studied the preventing technique of metal deposition which covered optical devices with the nozzle and blew the shielding gas out from nozzle outlet. The metal deposition can be reduced by supplying the nozzle with inert gas and blowing the gas out from nozzle outlet. The shielding gas argon perfectly prevents the metal deposition on optical devices when argon pressurizes the nozzle to over 19.9 Pa and spouts out from the nozzle outlet.

  18. 3D display and image processing system for metal bellows welding

    NASA Astrophysics Data System (ADS)

    Park, Min-Chul; Son, Jung-Young

    2010-04-01

    Industrial welded metal Bellows is in shape of flexible pipeline. The most common form of bellows is as pairs of washer-shaped discs of thin sheet metal stamped from strip stock. Performing arc welding operation may cause dangerous accidents and bad smells. Furthermore, in the process of welding operation, workers have to observe the object directly through microscope adjusting the vertical and horizontal positions of welding rod tip and the bellows fixed on the jig, respectively. Welding looking through microscope makes workers feel tired. To improve working environment that workers sit in an uncomfortable position and productivity we introduced 3D display and image processing. Main purpose of the system is not only to maximize the efficiency of industrial productivity with accuracy but also to keep the safety standards with the full automation of work by distant remote controlling.

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

    PubMed Central

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

    2016-01-01

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

  20. The problems of weld metal or heat affected zone toughness in offshore structural steels

    SciTech Connect

    Hancock, P.; Spurrier, J.; Chubb, J.P.

    1996-12-01

    An extensive set of fracture toughness results for welded offshore structural steels, gathered from nine separate sponsoring companies, has been entered into a specially constructed database. With over eleven thousand Charpy results and over two thousand CTOD results available, it has been possible to analyze the occurrence of low toughness results with respect to variables such as thickness, PWHT, steel production route etc., even though the individual test programs were not specifically structured to do this. This paper concentrates on the toughness of the weld metal. The data demonstrates that the likelihood of a low toughness result from a CTOD test in weld metal at {minus}10 C is comparable with that from the HAZ region for welded offshore structural steels, and PWHT of the joint is beneficial in reducing the occurrence of low toughness values in the weld metal. It is therefore important that when the HAZ performance is assessed, either through weld procedure tests or plate prequalification procedures, adequate attention is also paid to the weld metal toughness.

  1. Genetic algorithm optimization of the forming process in case of a U-shaped part made from tailor welded blanks

    NASA Astrophysics Data System (ADS)

    Aurelian, Albut

    2013-05-01

    This paper presents an optimization method to minimize the springback phenomenon, which generate the main dimensional errors in case of sheet metal forming. The present work deals with numerical simulation related to draw bending and springback of U-shaped part made from tailor welded blanks. The base materials from tailor welded blanks have different springback behaviours, fact that must be taken in consideration in the optimisation process. The Dynaform 5.8.1 software was used to simulate the forming process, in which the blank holder is segmented in two parts in order to apply different holding force for each material. In this research the blank holder forces and the deformation speed take different numerical values. The factorial simulations test plan was made using the Design Experts 7.0 software to cover completely the variation domain. The part obtained after each simulation is analyzed and measured to quantify the errors caused by springback. Parameters as: angle between flange and sidewall, angle between sidewall and part bottom are recorded in a data base. The initial simulations plan together with the obtained results is used to understand the influence of the variable parameters on the springback behaviour of the U-shaped part made from tailor welded blanks. The gained knowledge is used to generate the objective function required by the genetic algorithm optimization method.

  2. Friction Stir Welding of Al Alloy 2219-T8: Part II-Mechanical and Corrosion

    NASA Astrophysics Data System (ADS)

    Kang, Ju; Feng, Zhi-Cao; Li, Ji-Chao; Frankel, G. S.; Wang, Guo-Qing; Wu, Ai-Ping

    2016-09-01

    In Part I of this series, abnormal agglomerations of θ particles with size of about 100 to 1000 µm were observed in friction stir welded AA2219-T8 joints. In this work, the effects of these agglomerated θ particles on the mechanical and corrosion properties of the joints are studied. Tensile testing with in situ SEM imaging was utilized to monitor crack initiation and propagation in base metal and weld nugget zone (WNZ) samples. These tests showed that cracks initiated in the θ particles and at the θ/matrix interfaces, but not in the matrix. The WNZ samples containing abnormal agglomerated θ particles had a similar ultimate tensile stress but 3 pct less elongation than other WNZ samples with only normal θ particles. Measurements using the microcell technique indicated that the agglomerated θ particles acted as a cathode causing the dissolution of adjacent matrix. The abnormal θ particle agglomerations led to more severe localized attack due to the large cathode/anode ratio. Al preferential dissolution occurred in the abnormal θ particle agglomerations, which was different from the corrosion behavior of normal size θ particles.

  3. Hydrogen Assisted Crack in Dissimilar Metal Welds for Subsea Service under Cathodic Protection

    NASA Astrophysics Data System (ADS)

    Bourgeois, Desmond

    Dissimilar metal welds (DMWs) are routinely used in the oil and gas industries for structural joining of high strength steels in order to eliminate the need for post weld heat treatment (PWHT) after field welding. There have been reported catastrophic failures in these DMWs, particularly the AISI 8630 steel - Alloy 625 DMW combination, during subsea service while under cathodic protection (CP). This is due to local embrittlement that occurs in susceptible microstructures that are present at the weld fusion boundary region. This type of cracking is known as hydrogen assisted cracking (HAC) and it is influenced by base/filler metal combination, and welding and PWHT procedures. DMWs of two material combinations (8630 steel -- Alloy 625 and F22 steel -- Alloy 625), produced with two welding procedures (BS1 and BS3) in as welded and PWHT conditions were investigated in this study. The main objectives included: 1) evaluation of the effect of materials composition, welding and PWHT procedures on the gradients of composition, microstructure, and properties in the dissimilar transition region and on the susceptibility to HAC; 2) investigation of the influence of microstructure on the HAC failure mechanism and identification of microstructural constituents acting as crack nucleation and propagation sites; 3) assessment of the applicability of two-step PWHT to improve the resistance to HAC in DMWs; 4) establishment of non-failure criterion for the delayed hydrogen cracking test (DHCT) that is applicable for qualification of DMWs for subsea service under cathodic protection (CP).

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

    NASA Astrophysics Data System (ADS)

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

    2007-01-01

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

  5. A new technique for the strengthening of aluminum tungsten inert gas weld metals: using carbon nanotube/aluminum composite as a filler metal.

    PubMed

    Fattahi, M; Nabhani, N; Rashidkhani, E; Fattahi, Y; Akhavan, S; Arabian, N

    2013-01-01

    The effect of multi-walled carbon nanotube (MWCNT) on the mechanical properties of aluminum multipass weld metal prepared by the tungsten inert gas (TIG) welding process was investigated. High energy ball milling was used to disperse MWCNT in the aluminum powder. Carbon nanotube/aluminum composite filler metal was fabricated for the first time by hot extrusion of ball-milled powders. After welding, the tensile strength, microhardness and MWCNT distribution in the weld metal were investigated. The test results showed that the tensile strength and microhardness of weld metal was greatly increased when using the filler metal containing 1.5 wt.% MWCNT. Therefore, according to the results presented in this paper, it can be concluded that the filler metal containing MWCNT can serve as a super filler metal to improve the mechanical properties of TIG welds of Al and its alloys.

  6. A new technique for the strengthening of aluminum tungsten inert gas weld metals: using carbon nanotube/aluminum composite as a filler metal.

    PubMed

    Fattahi, M; Nabhani, N; Rashidkhani, E; Fattahi, Y; Akhavan, S; Arabian, N

    2013-01-01

    The effect of multi-walled carbon nanotube (MWCNT) on the mechanical properties of aluminum multipass weld metal prepared by the tungsten inert gas (TIG) welding process was investigated. High energy ball milling was used to disperse MWCNT in the aluminum powder. Carbon nanotube/aluminum composite filler metal was fabricated for the first time by hot extrusion of ball-milled powders. After welding, the tensile strength, microhardness and MWCNT distribution in the weld metal were investigated. The test results showed that the tensile strength and microhardness of weld metal was greatly increased when using the filler metal containing 1.5 wt.% MWCNT. Therefore, according to the results presented in this paper, it can be concluded that the filler metal containing MWCNT can serve as a super filler metal to improve the mechanical properties of TIG welds of Al and its alloys. PMID:23948441

  7. Method and apparatus for holding two separate metal pieces together for welding

    NASA Technical Reports Server (NTRS)

    Mcclure, S. R. (Inventor)

    1980-01-01

    A method of holding two separate metal pieces together for welding is described including the steps of overlapping a portion of one of the metal pieces on a portion of the other metal piece, encasing the overlapping metal piece in a compressible device, drawing the compressible device into an enclosure, and compressing a portion of the compressible device around the overlapping portions of the metal pieces for holding the metal pieces under constant and equal pressure during welding. The preferred apparatus for performing the method utilizes a support mechanism to support the two separate metal pieces in an overlapping configuration; a compressible device surrounding the support mechanism and at least one of the metal pieces, and a compressing device surrounding the compressible device for compressing the compressible device around the overlapping portions of the metal pieces, thus providing constant and equal pressure at all points on the overlapping portions of the metal pieces.

  8. Picosecond laser welding of optical to metal components

    NASA Astrophysics Data System (ADS)

    Carter, Richard M.; Troughton, Michael; Chen, Jinanyong; Elder, Ian; Thomson, Robert R.; Lamb, Robert A.; Esser, M. J. Daniel; Hand, Duncan P.

    2016-03-01

    We report on practical, industrially relevant, welding of optical components to themselves and aluminum alloy components. Weld formation is achieved through the tight focusing of a 5.9ps, 400kHz Trumpf laser operating at 1030nm. By selecting suitable surface preparation, clamping and laser parameters, the plasma can be confined, even with comparatively rough surfaces, by exploiting the melt properties of the glass. The short interaction time allows for a permanent weld to form between the two materials with heating limited to a region ~300 µm across. Practical application of these weld structures is typically limited due to the induced stress within the glass and, critically, the issues surrounding post-weld thermal expansion. We report on the measured strength of the weld, with a particular emphasis on laser parameters and surface preparation.

  9. Fine micro-welding of thin metal sheet by high speed laser scanning

    NASA Astrophysics Data System (ADS)

    Okamoto, Yasuhiro; Gillner, Arnold; Olowinsky, Alexander; Gedicke, Jens; Uno, Yoshiyuki

    2007-05-01

    Recently, since the size of component becomes smaller, then the welding of thin metal sheet has been required. Besides, the flexibility of process is important according to the accessibility especially for small components. Fraunhofer Institute for Laser Technology had developed the SHADOW ® welding technology, in which the high speed joining with small distortion is possible using pulsed Nd:YAG laser. The possibility of high speed and high quality welding had been reported by using single-mode fiber laser. The combination of micro beam and high speed laser scanning has the advantages for thin metal sheet welding. Therefore, the characteristics of micro-welding for thin metal sheet were investigated by high speed laser scanning, in which the welding was carried out by high speed scanner system with single-mode fiber laser and pulsed Nd:YAG laser. The proper welding region was narrow by the laser beam with a large focus diameter of 160 μm without pulse control, while a small focus diameter of 22 μm can control the welding state widely. A small focus diameter can perform the excellent welding seam from the extreme beginning without pulse control. The penetration depth can be controlled by the energy density with a small focus diameter of 22 μm at the energy densities less than 1 J/mm2. Besides, the unique periodic structure appeared at the high velocity of beam scanning with a small focus diameter. Moreover, the overlap welding of 25 μm thickness sheet can be performed regardless of small gap distance between two sheets by the laser beam with a small focus diameter of 22 μm.

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

    ERIC Educational Resources Information Center

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

    2008-01-01

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

  11. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

  13. Microstructure and creep characteristics of dissimilar T91/TP316H martensitic/austenitic welded joint with Ni-based weld metal

    SciTech Connect

    Falat, Ladislav; Svoboda, Milan; Vyrostkova, Anna; Petryshynets, Ivan; Sopko, Martin

    2012-10-15

    This paper deals with characterization of microstructure and creep behavior of dissimilar weldment between the tempered martensitic steel T91 and the non-stabilized austenitic steel TP316H with Ni-based weld metal (Ni WM). Microstructure analyses were performed using light microscopy, scanning and transmission electron microscopy and energy-dispersive X-ray spectroscopy. The martensitic part of the welded joint exhibited a wide heat-affected zone (HAZ) with typical microstructural gradient from its coarse-grained to the fine-grained/intercritical region. In contrast, the HAZ of austenitic steel was limited to only a narrow region with coarsened polygonal grains. The microstructure of Ni WM was found to be very heterogeneous with respect to the size, morphology and distribution of grain boundaries and MC-type precipitates as a result of strong weld metal dilution effects and fast non-equilibrium solidification. Cross-weld creep tests were carried out in a temperature range from 600 to 650 Degree-Sign C at applied stresses from 60 to 140 MPa. The obtained values of apparent stress exponents and creep activation energies indicate thermally activated dislocation glide to be the governing creep deformation mechanism within the range of used testing conditions. The creep samples ruptured in the T91 intercritical HAZ region by the 'type IV cracking' failure mode and the creep fracture mechanism was identified to be the intergranular dimple tearing by microvoid coalescence at grain boundaries. The TEM observations revealed pronounced microstructural differences between the critical HAZ region and the T91 base material before as well as after the creep exposure. - Highlights: Black-Right-Pointing-Pointer Phase transformations affect the microstructures of T91 and TP316H HAZ regions. Black-Right-Pointing-Pointer High weld metal dilution results in heterogeneous microstructure with MC carbides. Black-Right-Pointing-Pointer Creep behavior of the studied weldment is controlled

  14. 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.

  15. A Comparison of Weld-Repaired and Base Metal for Inconel 718 and CRES 321 at Cryogenic and Room Temperatures

    NASA Technical Reports Server (NTRS)

    Newman, John A.; Smith, Stephen W.; Willard, Scott A.; Piascik, Robert S.

    2004-01-01

    Fatigue crack growth tests were conducted to characterize the performance of Inconel 718 and CRES 321 welds, weld heat-affect-zone and parent metal at room temperature laboratory air and liquid nitrogen (-196oC) environments. The results of this study were required to predict the damage tolerance behavior of proposed orbiter main engine hydrogen fuel liner weld repairs. Experimental results show that the room and cryogenic temperature fatigue crack growth characteristics of both alloys are not significantly degraded by the weld repair process. However, both Inconel 718 and CRES 321 exhibited lower apparent toughness within the weld repair region compared to the parent metal.

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

    SciTech Connect

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

    1992-01-01

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

  17. Pressure Resistance Welding of High Temperature Metallic Materials

    SciTech Connect

    N. Jerred; L. Zirker; I. Charit; J. Cole; M. Frary; D. Butt; M. Meyer; K. L. Murty

    2010-10-01

    Pressure Resistance Welding (PRW) is a solid state joining process used for various high temperature metallic materials (Oxide dispersion strengthened alloys of MA957, MA754; martensitic alloy HT-9, tungsten etc.) for advanced nuclear reactor applications. A new PRW machine has been installed at the Center for Advanced Energy Studies (CAES) in Idaho Falls for conducting joining research for nuclear applications. The key emphasis has been on understanding processing-microstructure-property relationships. Initial studies have shown that sound joints can be made between dissimilar materials such as MA957 alloy cladding tubes and HT-9 end plugs, and MA754 and HT-9 coupons. Limited burst testing of MA957/HT-9 joints carried out at various pressures up to 400oC has shown encouraging results in that the joint regions do not develop any cracking. Similar joint strength observations have also been made by performing simple bend tests. Detailed microstructural studies using SEM/EBSD tools and fatigue crack growth studies of MA754/HT-9 joints are ongoing.

  18. Chemical composition effect on VVER-1000 RPV weld metal thermal aging

    NASA Astrophysics Data System (ADS)

    Gurovich, B. A.; Chernobaeva, A. A.; Erak, D. Yu; Kuleshova, E. A.; Zhurko, D. A.; Papina, V. B.; Skundin, M. A.; Maltsev, D. A.

    2015-10-01

    Temperature and fast neutron flux simultaneously affect the material of welded joints of reactor pressure vessels under irradiation. Understanding thermal aging effects on the weld metal allows for an explanation of the mechanisms that govern an increase in the ductile-to-brittle transition temperature of the reactor pressure vessel materials under long term irradiation at operation temperature. This paper reports on new results and reassessment of the VVER-1000 weld metal surveillance specimen database performed at the National Research Center "Kurchatov Institute". The current database of VVER-1000 weld metal thermal aging at 310-320 °C includes 50 transition temperature values with the maximum holding time of 208,896 h. The updated database completed with the information on intergranular fracture shear and phosphorous content in the grain boundaries has allowed us to propose a new mechanism of VVER-1000 weld materials thermal aging at 310-320 °C and develop models of ductile-to-brittle transition temperature shift for VVER-1000 weld metal during a long-term exposure at 310-320 °C.

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

    PubMed

    Maxild, J; Andersen, M; Kiel, P

    1978-01-01

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

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

    ERIC Educational Resources Information Center

    Espy, John

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

  1. Pressure Resistance Welding of High Temperature Metallic Materials

    SciTech Connect

    Larry Zirker; Craig Tyler

    2010-08-01

    Engineers from the Idaho National Laboratory (INL) have demonstrated an innovative method for seal or pinch welding stainless steel tubing. Sometimes a tube has fuel or contamination that must be contained, or the tube needs to be shortened or cut for handling, and the tube needs to have a guaranteed sealed weld that is both quick and easy. This technique was demonstrated in a laboratory using a resistance welding system with specially designed electrodes to ensure a tube end is seal welded or if a long tube is to be shortened, the severed ends are seal welded. The unique electrodes design is integral to achieving the sealed ends. This process could readily be adapted for robotic--remote handling or for contact handling in a glovebox or hood.

  2. Rapid detection of transition metals in welding fumes using paper-based analytical devices.

    PubMed

    Cate, David M; Nanthasurasak, Pavisara; Riwkulkajorn, Pornpak; L'Orange, Christian; Henry, Charles S; Volckens, John

    2014-05-01

    Metals in particulate matter (PM) are considered a driving factor for many pathologies. Despite the hazards associated with particulate metals, personal exposures for at-risk workers are rarely assessed due to the cost and effort associated with monitoring. As a result, routine exposure assessments are performed for only a small fraction of the exposed workforce. The objective of this research was to evaluate a relatively new technology, microfluidic paper-based analytical devices (µPADs), for measuring the metals content in welding fumes. Fumes from three common welding techniques (shielded metal arc, metal inert gas, and tungsten inert gas welding) were sampled in two welding shops. Concentrations of acid-extractable Fe, Cu, Ni, and Cr were measured and independently verified using inductively coupled plasma-optical emission spectroscopy (ICP-OES). Results from the µPAD sensors agreed well with ICP-OES analysis; the two methods gave statistically similar results in >80% of the samples analyzed. Analytical costs for the µPAD technique were ~50 times lower than market-rate costs with ICP-OES. Further, the µPAD method was capable of providing same-day results (as opposed several weeks for ICP laboratory analysis). Results of this work suggest that µPAD sensors are a viable, yet inexpensive alternative to traditional analytic methods for transition metals in welding fume PM. These sensors have potential to enable substantially higher levels of hazard surveillance for a given resource cost, especially in resource-limited environments. PMID:24515892

  3. Rapid detection of transition metals in welding fumes using paper-based analytical devices.

    PubMed

    Cate, David M; Nanthasurasak, Pavisara; Riwkulkajorn, Pornpak; L'Orange, Christian; Henry, Charles S; Volckens, John

    2014-05-01

    Metals in particulate matter (PM) are considered a driving factor for many pathologies. Despite the hazards associated with particulate metals, personal exposures for at-risk workers are rarely assessed due to the cost and effort associated with monitoring. As a result, routine exposure assessments are performed for only a small fraction of the exposed workforce. The objective of this research was to evaluate a relatively new technology, microfluidic paper-based analytical devices (µPADs), for measuring the metals content in welding fumes. Fumes from three common welding techniques (shielded metal arc, metal inert gas, and tungsten inert gas welding) were sampled in two welding shops. Concentrations of acid-extractable Fe, Cu, Ni, and Cr were measured and independently verified using inductively coupled plasma-optical emission spectroscopy (ICP-OES). Results from the µPAD sensors agreed well with ICP-OES analysis; the two methods gave statistically similar results in >80% of the samples analyzed. Analytical costs for the µPAD technique were ~50 times lower than market-rate costs with ICP-OES. Further, the µPAD method was capable of providing same-day results (as opposed several weeks for ICP laboratory analysis). Results of this work suggest that µPAD sensors are a viable, yet inexpensive alternative to traditional analytic methods for transition metals in welding fume PM. These sensors have potential to enable substantially higher levels of hazard surveillance for a given resource cost, especially in resource-limited environments.

  4. Rapid Detection of Transition Metals in Welding Fumes Using Paper-Based Analytical Devices

    PubMed Central

    Volckens, John

    2014-01-01

    Metals in particulate matter (PM) are considered a driving factor for many pathologies. Despite the hazards associated with particulate metals, personal exposures for at-risk workers are rarely assessed due to the cost and effort associated with monitoring. As a result, routine exposure assessments are performed for only a small fraction of the exposed workforce. The objective of this research was to evaluate a relatively new technology, microfluidic paper-based analytical devices (µPADs), for measuring the metals content in welding fumes. Fumes from three common welding techniques (shielded metal arc, metal inert gas, and tungsten inert gas welding) were sampled in two welding shops. Concentrations of acid-extractable Fe, Cu, Ni, and Cr were measured and independently verified using inductively coupled plasma-optical emission spectroscopy (ICP-OES). Results from the µPAD sensors agreed well with ICP-OES analysis; the two methods gave statistically similar results in >80% of the samples analyzed. Analytical costs for the µPAD technique were ~50 times lower than market-rate costs with ICP-OES. Further, the µPAD method was capable of providing same-day results (as opposed several weeks for ICP laboratory analysis). Results of this work suggest that µPAD sensors are a viable, yet inexpensive alternative to traditional analytic methods for transition metals in welding fume PM. These sensors have potential to enable substantially higher levels of hazard surveillance for a given resource cost, especially in resource-limited environments. PMID:24515892

  5. 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.

  6. Direct welding of glass and metal by 1  kHz femtosecond laser pulses.

    PubMed

    Zhang, Guodong; Cheng, Guanghua

    2015-10-20

    In the welding process between similar or dissimilar materials, inserting an intermediate layer and pressure assistance are usually thought to be necessary. In this paper, the direct welding between alumina-silicate glass and metal (aluminum, copper, and steel), under exposure from 1 kHz femtosecond laser pulses without any auxiliary processes, is demonstrated. The micron/nanometer-sized metal particles induced by laser ablation were considered to act as the adhesive in the welding process. The welding parameters were optimized by varying the pulse energy and the translation velocity of the sample. The shear joining strength characterized by a shear force testing equipment was as high as 2.34 MPa. This direct bonding technology has potential for applications in medical devices, sensors, and photovoltaic devices. PMID:26560385

  7. A study on an efficient prediction of welding deformation for T-joint laser welding of sandwich panel PART I : Proposal of a heat source model

    NASA Astrophysics Data System (ADS)

    Kim, Jae Woong; Jang, Beom Seon; Kim, Yong Tai; Chun, Kwang San

    2013-09-01

    The use of I-Core sandwich panel has increased in cruise ship deck structure since it can provide similar bending strength with conventional stiffened plate while keeping lighter weight and lower web height. However, due to its thin plate thickness, i.e. about 4~6 mm at most, it is assembled by high power CO2 laser welding to minimize the welding deformation. This research proposes a volumetric heat source model for T-joint of the I-Core sandwich panel and a method to use shell element model for a thermal elasto-plastic analysis to predict welding deformation. This paper, Part I, focuses on the heat source model. A circular cone type heat source model is newly suggested in heat transfer analysis to realize similar melting zone with that observed in experiment. An additional suggestion is made to consider negative defocus, which is commonly applied in T-joint laser welding since it can provide deeper penetration than zero defocus. The proposed heat source is also verified through 3D thermal elasto-plastic analysis to compare welding deformation with experimental results. A parametric study for different welding speeds, defocus values, and welding powers is performed to investigate the effect on the melting zone and welding deformation. In Part II, focuses on the proposed method to employ shell element model to predict welding deformation in thermal elasto-plastic analysis instead of solid element model.

  8. Development of filler metals for welding of iron aluminide alloys. Final report

    SciTech Connect

    Goodwin, G.M.; Scott, J.L.

    1995-06-29

    Attempts were made to develop a coating formulation for shielded metal arc (SMA) welding electrodes for iron aluminide alloys. Core wires of various compositions were produced by aspiration casting at ORNL and coating formulation development was conducted by Devasco, Inc. It was found that, except for weld deposit compositions containing less than 10 weight % aluminum, all weld deposits exhibited extensive cold cracking and/or porosity. It was concluded that current coating formulation technology limits successful iron aluminide deposits to less than 10 weight % aluminum.

  9. Metallic parts fabrication using the SIS process

    NASA Astrophysics Data System (ADS)

    Mojdeh, Mehdi

    Since early 1980s, quite a few techniques of Rapid Prototyping (RP), also known as Layered Manufacturing, have been developed. By building three-dimensional parts in a layer-by-layer additive manner, these techniques allow freeform fabrication of parts of complex geometry. Despite recent advances in fabrication of polymer parts, most of the existing rapid prototyping processes are still not capable of fabrication of accurate metallic parts with acceptable mechanical properties. Insufficient dimensional accuracy, limited number of materials, proper mechanical properties, required post machining and lack of repeatability between builds have greatly limited the market penetration of these techniques. This dissertation presents an innovative layered manufacturing technique for fabrication of dense metallic parts called Selective Inhibition Sintering (SIS), developed at the University of Southern California. The SIS-Metal technology adapts RP capabilities and extends them to the field of fabrication of metallic parts for a variety of applications such as tooling and low volume production. Using this process, a metallic part, with varying 3 dimensional geometries, can be automatically constructed from a wide range of materials. SIS-Metal is the only RP process which is suitable for fabrication of dense, complex shaped, accurate objects using a variety of materials. In the SIS-Metal process a metallic part is built layer by layer by deposition for each layer of an inhibitor material which defines the corresponding layer boundary and then filling the voids of the created geometry with metal powder; and compacting the layer formed to reach a high powder density. The resulting green part is then sintered in a furnace to yield the final functional part. In this research different inhibition techniques were explored and a series of single and multi layer parts was fabricated using the most promising inhibition technique, namely, macro-mechanical inhibition. Dimensional

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

    SciTech Connect

    Ghomashchi, Reza Costin, Walter; Kurji, Rahim

    2015-09-15

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

  11. Numerical Simulation on Joining of Ceramics with Metal by Friction Welding Technique

    NASA Astrophysics Data System (ADS)

    Jesudoss Hynes, N. Rajesh; Nagaraj, P.; Basil, S. Joshua

    The joining of ceramic and metals can be done by different techniques such as ultrasonic joining, brazing, transient liquid phase diffusion bonding, and friction welding. Friction Welding is a solid state joining process that generates heat through mechanical friction between a moving workpiece and a stationary component. In this article, numerical simulation on thermal analysis of friction welded ceramic/metal joint has been carried out by using Finite Element Analysis (FEA) software. The finite element analysis helps in better understanding of the friction welding process of joining ceramics with metals and it is important to calculate temperature and stress fields during the welding process. Based on the obtained temperature distribution the graphs were plotted between the lengths of the joint corresponding to the temperatures. To increase the wettability, aluminium sheet was used as an interlayer. Hence, numerical simulation of friction welding process is done by varying the interlayer sheet thickness. Transient thermal analysis had been carried out for each cases and temperature distribution was studied. From the simulation studies, it is found that the increase in interlayer thickness reduces the heat affected zone and eventually improves the joint efficiency of alumina/aluminum alloy joints.

  12. Computed Tomography 3-D Imaging of the Metal Deformation Flow Path in Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Beshears, Ronald; Nunes, Arthur C., Jr.

    2005-01-01

    In friction stir welding (FSW), a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path is required. Marker studies are the principal method of studying the metal deformation flow path around the FSW pin tool. In our study, we have used computed tomography (CT) scans to reveal the flow pattern of a lead wire embedded in a FSW weld seam. At the welding temperature of aluminum, the lead becomes molten and is carried with the macro-flow of the weld metal. By using CT images, a 3-dimensional (3D) image of the lead flow pattern can be reconstructed. CT imaging was found to be a convenient and comprehensive way of collecting and displaying tracer data. It marks an advance over previous more tedious and ambiguous radiographic/metallographic data collection methods.

  13. Method for laser welding ultra-thin metal foils

    DOEpatents

    Pernicka, J.C.; Benson, D.K.; Tracy, C.E.

    1996-03-26

    A method for simultaneously cutting and welding ultra-thin foils having a thickness of less than 0.002 inches wherein two ultra-thin films are stacked and clamped together. A pulsed laser such as of the Neodymium: YAG type is provided and the beam of the laser is directed onto the stacked films to cut a channel through the films. The laser is moved relative to the stacked foils to cut the stacked foils at successive locations and to form a plurality of connected weld beads to form a continuous weld. 5 figs.

  14. Method for laser welding ultra-thin metal foils

    DOEpatents

    Pernicka, John C.; Benson, David K.; Tracy, C. Edwin

    1996-01-01

    A method for simultaneously cutting and welding ultra-thin foils having a thickness of less than 0.002 inches wherein two ultra-thin films are stacked and clamped together. A pulsed laser such as of the Neodymium: YAG type is provided and the beam of the laser is directed onto the stacked films to cut a channel through the films. The laser is moved relative to the stacked foils to cut the stacked foils at successive locations and to form a plurality of connected weld beads to form a continuous weld.

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

    SciTech Connect

    Hu, J.; Tsai, H. L.

    2006-09-01

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

  16. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2013-06-01

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

  19. Toenail metal concentration as a biomarker of occupational welding fume exposure

    PubMed Central

    Grashow, Rachel; Zhang, Jinming; Fang, Shona C.; Weisskopf, Marc G.; Christiani, David C.; Cavallari, Jennifer M.

    2014-01-01

    In populations exposed to heavy metals, there are few biomarkers that capture intermediate exposure windows. We sought to determine the correlation between toenail metal concentrations and prior 12 month work activity in welders with variable, metal-rich, welding fume exposures. Forty-eight participants, recruited through a local union, provided 69 sets of toenail clippings. Union-supplied and worker verified personal work histories were used to quantify hours welded and respirator use. Toenail samples were digested and analyzed for lead (Pb), manganese (Mn), cadmium (Cd), nickel (Ni) and arsenic (As) using ICP-MS. Spearman correlation coefficients were used to examine the correlation between toenail metal concentrations. Using mixed models to account for multiple participation times, we divided hours welded into three-month intervals and examined how weld hours correlated with log-transformed toenail Pb, Mn, Cd, Ni and As concentrations. Highest concentrations were found for Ni, followed by Mn, Pb and As, and Cd. All of the metals were significantly correlated with one another (rho range=0.28–0.51), with the exception of Ni and As (rho=0.20, p=0.17). Using mixed models adjusted for age, respirator use, smoking status and BMI, we found that Mn was associated with weld hours 7–9 months prior to clipping (p = 0.003), Pb was associated with weld hours 10–12 months prior to clipping (p=0.03) and over the entire year (p=0.04). Cd was associated with weld hours 10–12 months prior to clipping (p=0.05), and also with the previous year’s total hours welded (p=0.02). The association between Ni and weld hours 7–9 months prior to clipping approached significance (p=0.06). Toenail metal concentrations were not associated with the long-term exposure metric, years as a welder. Results suggest Mn, Pb, and Cd may have particular windows of relevant exposure that reflect work activity. In a population with variable exposure, toenails may serve as useful biomarkers for

  20. Explosive Welding of Aluminum, Titanium and Zirconium to Copper Sheet Metal

    NASA Technical Reports Server (NTRS)

    Hegazy, A. A.; Mote, J. D.

    1985-01-01

    The main material properties affecting the explosive weldability of a certain metal combination are the yield strength, the ductility, the density and the sonic velocity of the two metals. Successful welding of the metal combination depends mainly on the correct choice of the explosive welding parameters; i.e., the stand off distance, the weight of the explosive charge relative to the weight of the flyer plate and the detonation velocity of the explosive. Based on the measured and the handbook values of the properties of interest, the explosive welding parameters were calculated and the arrangements for the explosive welding of the Al alloy 6061-T6, titanium and zirconium to OFHC copper were determined. The relatively small sheet metal thickness (1/8") and the fact that the thickness of the explosive layer must exceed a certain minimum value were considered during the determination of the explosive welding conditions. The results of the metallographic investigations and the measurements of the shear strength at the interface demonstrate the usefulness of these calculations to minimize the number of experimental trials.

  1. Optimization and Prediction of Ultimate Tensile Strength in Metal Active Gas Welding

    PubMed Central

    Ampaiboon, Anusit; Lasunon, On-Uma; Bubphachot, Bopit

    2015-01-01

    We investigated the effect of welding parameters on ultimate tensile strength of structural steel, ST37-2, welded by Metal Active Gas welding. A fractional factorial design was used for determining the significance of six parameters: wire feed rate, welding voltage, welding speed, travel angle, tip-to-work distance, and shielded gas flow rate. A regression model to predict ultimate tensile strength was developed. Finally, we verified optimization of the process parameters experimentally. We achieved an optimum tensile strength (558 MPa) and wire feed rate, 19 m/min, had the greatest effect, followed by tip-to-work distance, 7 mm, welding speed, 200 mm/min, welding voltage, 30 V, and travel angle, 60°. Shield gas flow rate, 10 L/min, was slightly better but had little effect in the 10–20 L/min range. Tests showed that our regression model was able to predict the ultimate tensile strength within 4%. PMID:26491719

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

    SciTech Connect

    Liu Fei; Zhang Zhaodong; Liu Liming

    2012-07-15

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

  3. 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.

  4. 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…

  5. 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.…

  6. Design of a vision sensor for monitoring microplasma arc welding of metal bellows

    NASA Astrophysics Data System (ADS)

    Zhang, Wenzeng

    2005-02-01

    Metal bellows is one of important components for mechanical sealing. Because the seam is very thin, and its spatial position is strictly limited, it is very difficult to observe the welding seam in order to control the variables of welding in real-time, the welding quality can not usually be guaranteed under the traditional technology. A novel approach is proposed, which is able to provide an amplificatory and clear image of the micro-plasma welding seam observed from better perspective, then output the image to computer and process it so that the variables of welding can be controlled in real-time. A special optical sensor has been designed and realized according to the approach. The principle and main technologies of the sensor is described in detail. The results of applying the system in practice approved the approach is successful. The welding quality of the inner circle of metal bellows, as well as the working condition of welder has been improved after the system is applied.

  7. Computer Tomography 3-D Imaging of the Metal Deformation Flow Path in Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    Schneider, Judy; Beshears, Ronald; Nunes, Arthur C., Jr.

    2004-01-01

    In friction stir welding, a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. This solid-state technique has been successfully used in the joining of materials that are difficult to fusion weld such as aluminum alloys. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path is required. Marker studies are the principal method of studying the metal deformation flow path around the FSW pin tool. In our study, we have used computed tomography (CT) scans to reveal the flow pattern of a lead wire embedded in a FSW weld seam. At the welding temperature of aluminum, the lead becomes molten and thus tracks the aluminum deformation flow paths in a unique 3-dimensional manner. CT scanning is a convenient and comprehensive way of collecting and displaying tracer data. It marks an advance over previous more tedious and ambiguous radiographic/metallographic data collection methods.

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

    NASA Astrophysics Data System (ADS)

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

    2002-02-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1972-01-01

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

  10. 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.

  11. Characterization of the structural details of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor

    NASA Astrophysics Data System (ADS)

    Liu, Xia; Ji, Hui-jun; Liu, Peng; Wang, Peng; Lu, Feng-gui; Gao, Yu-lai

    2014-06-01

    The existence of residual austenite in weld metal plays an important role in determining the properties and dimensional accuracy of welded rotors. An effective corrosive agent and the metallographic etching process were developed to clearly reveal the characteristics of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor. Moreover, the details of the distribution, shape, length, length-to-width ratio, and the content of residual austenite were systematically characterized using the Image-Pro Plus image analysis software. The results revealed that the area fraction of residual austenite was approximately 6.3% in the observed weld seam; the average area, length, and length-to-width ratio of dispersed residual austenite were quantitatively evaluated to be (5.5 ± 0.1) μm2, (5.0 ± 0.1) μm, and (2.2 ± 0.1), respectively. The newly developed corrosive agent and etching method offer an appropriate approach to characterize residual austenite in the weld metal of welded rotors in detail.

  12. 29 CFR 1915.54 - Welding, cutting and heating of hollow metal containers and structures not covered by § 1915.12.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 29 Labor 7 2014-07-01 2014-07-01 false Welding, cutting and heating of hollow metal containers and... STANDARDS FOR SHIPYARD EMPLOYMENT Welding, Cutting and Heating § 1915.54 Welding, cutting and heating of... which have contained flammable substances shall, before welding, cutting, or heating is undertaken...

  13. 29 CFR 1915.54 - Welding, cutting and heating of hollow metal containers and structures not covered by § 1915.12.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 29 Labor 7 2010-07-01 2010-07-01 false Welding, cutting and heating of hollow metal containers and... STANDARDS FOR SHIPYARD EMPLOYMENT Welding, Cutting and Heating § 1915.54 Welding, cutting and heating of... which have contained flammable substances shall, before welding, cutting, or heating is undertaken...

  14. 29 CFR 1915.54 - Welding, cutting and heating of hollow metal containers and structures not covered by § 1915.12.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 29 Labor 7 2013-07-01 2013-07-01 false Welding, cutting and heating of hollow metal containers and... STANDARDS FOR SHIPYARD EMPLOYMENT Welding, Cutting and Heating § 1915.54 Welding, cutting and heating of... which have contained flammable substances shall, before welding, cutting, or heating is undertaken...

  15. 29 CFR 1915.54 - Welding, cutting and heating of hollow metal containers and structures not covered by § 1915.12.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 29 Labor 7 2011-07-01 2011-07-01 false Welding, cutting and heating of hollow metal containers and... STANDARDS FOR SHIPYARD EMPLOYMENT Welding, Cutting and Heating § 1915.54 Welding, cutting and heating of... which have contained flammable substances shall, before welding, cutting, or heating is undertaken...

  16. 29 CFR 1915.54 - Welding, cutting and heating of hollow metal containers and structures not covered by § 1915.12.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 29 Labor 7 2012-07-01 2012-07-01 false Welding, cutting and heating of hollow metal containers and... STANDARDS FOR SHIPYARD EMPLOYMENT Welding, Cutting and Heating § 1915.54 Welding, cutting and heating of... which have contained flammable substances shall, before welding, cutting, or heating is undertaken...

  17. Precipitation of sigma and chi phases in δ-ferrite of Type 316FR weld metals

    SciTech Connect

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

    2013-12-15

    The decomposition behavior and kinetics of δ-ferrite are examined using aging treatments between 873 and 1073 K for Type 316FR stainless steel weld metals with different solidification modes (316FR AF, 316FR FA). The dominant precipitates are sigma, chi, and secondary austenite nucleated at δ-ferrite/austenite interfaces or in the interior of the ferrite grains. These precipitates consume all the ferrite during isothermal aging in both 316FR AF and FA weld metals. Differences in the precipitation behavior (precipitation initiation time and precipitation speed) between weld metals can be explained by i) the degree of Cr and Mo microsegregation within δ-ferrite or austenite near ferrite and ii) the nucleation sites induced due to the solidification mode (AF or FA), such as the ferrite amount. For both weld materials, a Johnson–Mehl-type equation can express the precipitation behavior of the sigma + chi phases and quantitatively predict the behavior at the service-exposure temperatures of a fast breed reactor. - Highlights: • Precipitation of σ and χ phase in Type 316FR welds (two solidification modes) • Different precipitation behaviors: precipitation initiation time and growth speed • Johnson-Mehl–type equation is the most applicable to the precipitation behaviors • Precipitation behaviors are predicted under service conditions of FBRs.

  18. Unsteady marangoni flow in a molten pool when welding dissimilar metals

    NASA Astrophysics Data System (ADS)

    Wei, P. S.; Chung, F. K.

    2000-12-01

    The unsteady variations of transport processes in molten pools when welding dissimilar metals are systematically investigated. Convection is driven by Marangoni forces with different directions and magnitudes on a flat free surface. For a clear description without loss of generality, three-dimensional quasi-steady welding is stimulated by an unsteady two-dimensional process. Applying the volume of fluid (VOF) and enthalpy methods to determine the interfaces between the immiscible dissimilar metals and between solid and liquid, the computed results show in detail the unsteady variations in the velocity and temperature fields, the solute concentration on the free surface, and the shapes of the molten regions affected by varying the signs and magnitudes of the surface-tension coefficients. The predicted shapes of the fusion-zone and solute distributions agree with the available experimental results in welding iron to aluminum, copper and iron, and copper to nickle.

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

    NASA Technical Reports Server (NTRS)

    Hawkes, E. D.

    1969-01-01

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

  20. Stress corrosion cracking in canistered waste package containers: Welds and base metals

    SciTech Connect

    Huang, J.S.

    1998-03-01

    The current design of waste package containers include outer barrier using corrosion allowable material (CAM) such as A516 carbon steel and inner barrier of corrosion resistant material (CRM) such as alloy 625 and C22. There is concern whether stress corrosion cracking would occur at welds or base metals. The current memo documents the results of our analysis on this topic.

  1. Cardiovascular effects in rats after intratracheal instillation of metal welding particles

    PubMed Central

    Zheng, Wen; Antonini, James M.; Lin, Yen-Chang; Roberts, Jenny R.; Kashon, Michael L.; Castranova, Vincent; Kan, Hong

    2015-01-01

    Studies have indicated that pulmonary exposure to welding fumes can induce a series of adverse effects in the respiratory system, including infection, bronchitis, siderosis and decreased pulmonary function. Recent clinical and epidemiological studies have found that pulmonary exposure to welding fumes is also associated with a higher incidence of cardiovascular events. However, there is insufficient evidence to confirm a direct effect of welding fumes on the cardiovascular system. The present study investigated the effects of pulmonary exposure to welding fumes on the heart and the vascular system in rats. Two chemically distinct welding fumes generated from manual metal arc-hard surfacing (MMA-HS) and gas metal arc-mild steel (GMA-MS) welding were tested. Three groups of rats were instilled intratracheally with MMA-HS (2 mg/rat), GMA-MS (2 mg/rat) or saline as control once a week for seven weeks. On days 1 and 7 after the last treatment, basal cardiovascular function and the cardiovascular response to increasing doses of adrenoreceptor agonists were assessed. MMA-HS treatment reduced the basal levels of left ventricle end-systolic pressure and dP/dtmax at 1 day post-treatment, and decreased dP/dtmin in response to isoproterenol (ISO) at 7 days post-treatment. Unlike MMA-HS, GMA-MS only affected left ventricular end-diastolic pressure in response to ISO at 7 days post-treatment. Treatment with MMA-HS or GMA-MS did not alter heart rate and blood pressure. Our findings suggest that exposure to different welding fumes can induce different adverse effects on the cardiovascular system, and that cardiac contractility may be a sensitive indicator of cardiovascular dysfunction. PMID:25600139

  2. Cardiovascular effects in rats after intratracheal instillation of metal welding particles.

    PubMed

    Zheng, Wen; Antonini, James M; Lin, Yen-Chang; Roberts, Jenny R; Kashon, Michael L; Castranova, Vincent; Kan, Hong

    2015-01-01

    Studies have indicated that pulmonary exposure to welding fumes can induce a series of adverse effects in the respiratory system, including infection, bronchitis, siderosis and decreased pulmonary function. Recent clinical and epidemiological studies have found that pulmonary exposure to welding fumes is also associated with a higher incidence of cardiovascular events. However, there is insufficient evidence to confirm a direct effect of welding fumes on the cardiovascular system. The present study investigated the effects of pulmonary exposure to welding fumes on the heart and the vascular system in rats. Two chemically distinct welding fumes generated from manual metal arc-hard surfacing (MMA-HS) and gas metal arc-mild steel (GMA-MS) welding were tested. Three groups of rats were instilled intratracheally with MMA-HS (2 mg/rat), GMA-MS (2 mg/rat) or saline as control once a week for seven weeks. On days 1 and 7 after the last treatment, basal cardiovascular function and the cardiovascular response to increasing doses of adrenoreceptor agonists were assessed. MMA-HS treatment reduced the basal levels of left ventricle end-systolic pressure and dP/dt(max) at 1 day post-treatment, and decreased dP/dt(min) in response to isoproterenol (ISO) at 7 days post-treatment. Unlike MMA-HS, GMA-MS only affected left ventricular end-diastolic pressure in response to ISO at 7 days post-treatment. Treatment with MMA-HS or GMA-MS did not alter heart rate and blood pressure. Our findings suggest that exposure to different welding fumes can induce different adverse effects on the cardiovascular system, and that cardiac contractility may be a sensitive indicator of cardiovascular dysfunction. PMID:25600139

  3. Cardiovascular effects in rats after intratracheal instillation of metal welding particles.

    PubMed

    Zheng, Wen; Antonini, James M; Lin, Yen-Chang; Roberts, Jenny R; Kashon, Michael L; Castranova, Vincent; Kan, Hong

    2015-01-01

    Studies have indicated that pulmonary exposure to welding fumes can induce a series of adverse effects in the respiratory system, including infection, bronchitis, siderosis and decreased pulmonary function. Recent clinical and epidemiological studies have found that pulmonary exposure to welding fumes is also associated with a higher incidence of cardiovascular events. However, there is insufficient evidence to confirm a direct effect of welding fumes on the cardiovascular system. The present study investigated the effects of pulmonary exposure to welding fumes on the heart and the vascular system in rats. Two chemically distinct welding fumes generated from manual metal arc-hard surfacing (MMA-HS) and gas metal arc-mild steel (GMA-MS) welding were tested. Three groups of rats were instilled intratracheally with MMA-HS (2 mg/rat), GMA-MS (2 mg/rat) or saline as control once a week for seven weeks. On days 1 and 7 after the last treatment, basal cardiovascular function and the cardiovascular response to increasing doses of adrenoreceptor agonists were assessed. MMA-HS treatment reduced the basal levels of left ventricle end-systolic pressure and dP/dt(max) at 1 day post-treatment, and decreased dP/dt(min) in response to isoproterenol (ISO) at 7 days post-treatment. Unlike MMA-HS, GMA-MS only affected left ventricular end-diastolic pressure in response to ISO at 7 days post-treatment. Treatment with MMA-HS or GMA-MS did not alter heart rate and blood pressure. Our findings suggest that exposure to different welding fumes can induce different adverse effects on the cardiovascular system, and that cardiac contractility may be a sensitive indicator of cardiovascular dysfunction.

  4. Solar cell welded interconnection development program. [parallel gap and ultrasonic metal-metal bonding

    NASA Technical Reports Server (NTRS)

    Katzeff, J. S.

    1974-01-01

    Parallel gap welding and ultrasonic bonding techniques were developed for joining selected interconnect materials (silver, aluminum, copper, silver plated molybdenum and Kovar) to silver-titanium and aluminum contact cells. All process variables have been evaluated leading to establishment of optimum solar cell, interconnect, electrodes and equipment criteria for obtainment of consistent high quality welds. Applicability of nondestructive testing of solar cell welds has been studied. A pre-weld monitoring system is being built and will be utilized in the numerically controlled parallel gap weld station.

  5. Investigation of Friction Stir Welding and Laser Engineered Net Shaping of Metal Matrix Composite Materials

    NASA Technical Reports Server (NTRS)

    Diwan, Ravinder M.

    2002-01-01

    The improvement in weld quality by the friction stir welding (FSW) process invented by TWI of Cambridge, England, patented in 1991, has prompted investigation of this process for advanced structural materials including Al metal matrix composite (Al-MMC) materials. Such materials can have high specific stiffness and other potential beneficial properties for the extreme environments in space. Developments of discontinuous reinforced Al-MMCs have found potential space applications and the future for such applications is quite promising. The space industry has recognized advantages of the FSW process over conventional welding processes such as the absence of a melt zone, reduced distortion, elimination of the need for shielding gases, and ease of automation. The process has been well proven for aluminum alloys, and work is being carried out for ferrous materials, magnesium alloys and copper alloys. Development work in the FSW welding process for joining of Al-MMCs is relatively recent and some of this and related work can be found in referenced research publications. NASA engineers have undertaken to spear head this research development work for FSW process investigation of Al-MMCs. Some of the reported related work has pointed out the difficulty in fusion welding of particulate reinforced MMCs where liquid Al will react with SiC to precipitate aluminum carbide (Al4C3). Advantages of no such reaction and no need for joint preparation for the FSW process is anticipated in the welding of Al-MMCs. The FSW process has been best described as a combination of extrusion and forging of metals. This is carried out as the pin tool rotates and is slowly plunged into the bond line of the joint as the pin tool's shoulder is in intimate contact with the work piece. The material is friction-stirred into a quality weld. Al-MMCs, 4 in. x 12 in. plates of 0.25 in. (6.35mm) thickness, procured from MMCC, Inc. were butt welded using FSW process at Marshall Space Flight Center (MSFC) using

  6. Control of the electrode metal transfer by means of the welding current pulse generator

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

    The paper presents a generator of welding current pulses to transfer an electrode metal into the molten pool. A homogeneous artificial line is used to produce near rectangular pulses. The homogeneous artificial line provides the minimum heat input with in the pulse to transfer the electrode metal, and it significantly decreases the impact of disturbances affecting this transfer. The pulse frequency does not exceed 300 Hz, and the duration is 0.6 ÷ 0.9 ms.

  7. 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.

  8. The Metal-Lax method of stress reduction in welds

    SciTech Connect

    Not Available

    1991-01-01

    The preliminary project to evaluate the possibility of replacing or reducing thermal stress relief and preheat with sub-resonant vibration has been completed. Bonal Technologies manufactures the Meta-Lax system of sub-resonant vibration for use in industry and has met with success on many occasions. The uses are varied and cross into many industries, including fabrication, foundries, and marine construction. However, the specific engineering or scientific basis for the successes has proven to be very elusive. The purpose of this preliminary evaluation of the Meta-Lax system was to try and determine what is happening when sub-resonant vibration is introduced during and/or after welding operations. The final goal is to determine if this process can replace or reduce thermal stress relief and preheat now required on many welded assemblies. The potential savings could be enormous.

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

    PubMed

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

    1990-03-01

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

  10. An Assessment of Molten Metal Detachment Hazards for Electron Beam Welding in the Space Environment: Analysis and Test Results

    NASA Technical Reports Server (NTRS)

    Nunes, A. C., Jr.; Russell, C.; Bhat, B.; Fragomeni, J. M.

    1998-01-01

    Conditions under which molten metal detachments might occur in a space welding environment are analyzed. A weld pool detachment parameter specifying conditions for pool detachment by impact is derived and corroborated by experimental evidence. Impact detachment for the pool is unlikely. Impact detachment for a drop of metal on the end of the weld wire may be possible under extreme conditions. Other potential causes of molten metal detachment considered, vaporization pressure forces and wire flickout from the pool, did not appear to present significant detachment threats.

  11. Friction-Stir Welding - Heavy Inclusions in Bi-metallic welds of Al 2219/2195

    NASA Technical Reports Server (NTRS)

    Rietz, Ward W., Jr.

    2008-01-01

    Heavy Inclusions (HI) were detected for the first time by radiographic examination in aluminum alloy 2219forging/2195plate (advancing/retreating side) Friction Sir Welds (FSW) for the Space Shuttle External Tank (ET) Program. Radiographic HI indications appear as either small (approx.0.005"-0.025") individual particles or clusters of small particles. Initial work was performed to verify that the HI was not foreign material or caused by FSW pin tool debris. That and subsequent elemental analysis determined that the HI were large agglomerations of Al2Cu (theta phase), which is the strengthening precipitate in Al2219. A literature search on that subject determined that the agglomeration of phase has also been found in Al2219 bead on plate FSW [Ref. 1]. Since this was detected in ET space flight hardware, an investigative study of the effect of agglomerated theta phase particles in FSW Al2219f/2195p was performed. Numerous panels of various lengths were welded per ET weld procedures and radiographically inspected to determine if any HI was detected. Areas that had HI were sampled for room temperature and cyclic cryogenic (-423F) tensile testing and determined no significant adverse affect on mechanical properties when compared to test specimens without HI and historical data. Fracture surface examination using the Scanning Electron Microscope (SEM) revealed smaller phase agglomerations undetectable by radiographic inspection dispersed throughout the Al2219f/2195p FSW. This indicates that phase agglomeration is inherent to the Al2219f/2195p FSW process and only rarely creates agglomerations large enough to be detected by radiography. HI has not been observed in FSW of plate to plate material for either Al2219 or AL2195.

  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. Modeling primary dendrite arm spacings in resistance spot welds; Part 2: Experimental studies

    SciTech Connect

    Gould, J.E. )

    1994-05-01

    Hold time sensitivity is a potential concern when cold-rolled high-strength low-alloy sheet steels are used in resistance spot welded applications. Hold time sensitivity is defined by cracking, which occurs along the faying surface of the weld on peel testing when conventional hold times are used, and does not occur when reduces hold times are used. Hold time sensitivity is related to solidification cracking in the steel; however, it is believed that steel hardenability may also play a role. As an aid to understanding of solidification cracking in resistance spot welds, it is necessary to have an understanding of how the solidification structure develops. In this work, solidification structures in resistance spot welds have been characterized by the primary dendrite spacing. In Part 1 of this work, primary dendrite spacings were modeled by using a combination of numerical thermal modeling and closed-form primary dendrite spacings modeling. Numerical thermal modeling was used to predict solidification conditions in these welds. These solidification conditions were then used in the primary dendrite spacings model to predict the local spacings. In this paper, experimental studies were conducted to examine the validity of the modeling described in the previous paper. Experimentally, primary dendrite spacings were characterized for three grades of cold-rolled HSLA steel with nominal compositions of 0.05C-0.3Mn, 0.1C-1Mn and 0.15C-1.5Mn. For each steel, three separate thicknesses (nominally 0.8, 1.25 and 2.0 mm) were investigated. Primary dendrite spacings were determined at nominally the weld faying surface from deep-etched micrographs using an area-averaging technique.

  14. Characterization of Solid State Phase Transformation in Continuously Heated and Cooled Ferritic Weld Metal

    SciTech Connect

    Narayana, B; Mills, Michael J.; Specht, Eliot D; Santella, Michael L; Babu, Sudarsanam Suresh

    2010-12-01

    Arc welding processes involve cooling rates that vary over a wide range (1-100 K/s). The final microstructire is thus a product of the heating and cooling cycles experienced by the weld in addition to the weld composition. It has been shown that the first phase to form under weld cooling conditions may not be that predicted by equilibrium calculations. The partitioning of different interstitial/substitutional alloying elements at high temperatures can dramatically affect the subsequent phase transformations. In order to understand the effect of alloying on phase transformation temperatures and final microstructures time-resolved X-ray diffraction technique has been successfully used for characterization. The work by Jacot and Rappaz on pearlitic steels provided insight into austenitization of hypoeutectic steels using a finite volume model. However there is very little work done on the effect of heating and cooling rates on the phase transformation paths in bainitic/martensitic steels and weld metals. Previous work on a weld with higher aluminum content, deposited with a FCAW-S process indicated that even at aluminum levels where the primary phase to solidify from liquid should be delta ferrite, non-equilibrium austenite was observed. The presence of inhomogeneity in composition of the parent microstructure has been attributed to differences in transformation modes, temperatures and microstructures in dual-phase, TRIP steels and ferritic welds. The objectives of the work included the identification of the stability regions of different phases during heating and cooling, differences in the effect of weld heating and cooling rates on the phase transformation temperatures, and the variation in phase fractions of austenite and ferrite in the two phase regions as a function of temperature. The base composition used for the present work is a Fe-1%Al-2%Mn-1%Ni-0.04%C weld metal. A pseudo-binary phase diagram shows the expected solidification path under equilibrium

  15. Al-Si-Mn Alloy Coating on Aluminum Substrate Using Cold Metal Transfer (CMT) Welding Technique

    NASA Astrophysics Data System (ADS)

    Rajeev, G. P.; Kamaraj, M.; Bakshi, S. R.

    2014-06-01

    The cold metal transfer (CMT) process was explored as a weld overlay technique for synthesizing Al-Si-Mn alloy coating on a commercially pure Al plate. The effect of welding speed on the bead geometry, deposition rate, and the dilution were studied and the best parameter was used to synthesize the coatings. The CMT process can be used to produce thick coatings (>2.5 mm) without porosity and with low dilution levels. The Vickers hardness number of the Al substrate increased from 28 in the bulk to 57 in the coating. It is suggested that the CMT process can be an effective and energy-efficient technique for depositing thick coatings and is useful in weld repair of aluminum alloy components.

  16. Total fume and metal concentrations during welding in selected factories in Jeddah, Saudi Arabia.

    PubMed

    Balkhyour, Mansour Ahmed; Goknil, Mohammad Khalid

    2010-07-01

    Welding is a major industrial process used for joining metals. Occupational exposure to welding fumes is a serious occupational health problem all over the world. The degree of risk to welder's health from fumes depends on composition, concentration, and the length of exposure. The aim of this study was to investigate workers' welding fume exposure levels in some industries in Jeddah, Saudi Arabia. In each factory, the air in the breathing zone within 0.5 m from welders was sampled during 8-hour shifts. Total particulates, manganese, copper, and molybdenum concentrations of welding fumes were determined. Mean values of eight-hour average particulate concentrations measured during welding at the welders breathing zone were 6.3 mg/m(3) (Factory 1), 5.3 mg/m(3) (Factory 2), 11.3 mg/m(3) (Factory 3), 6.8 mg/m(3) (Factory 4), 4.7 mg/m(3) (Factory 5), and 3.0 mg/m(3) (Factory 6). Mean values of airborne manganese, copper, and molybdenum levels measured during welding were in the range of 0.010 mg/m(3)-0.477 mg/m(3), 0.001 mg/m(3)-0.080 mg/m(3) and 0.001 mg/m(3)-0.058 mg/m(3) respectively. Mean values of calculated equivalent exposure values were: 1.50 (Factory 1), 1.56 (Factory 2), 5.14 (Factory 3), 2.21 (Factory 4), 2.89 (Factory 5), and 1.20 (Factory 6). The welders in factories 1, 2, 3, and 4 were exposed to welding fume concentration above the SASO limit value, which may increase the risk of respiratory health problems. PMID:20717553

  17. Total Fume and Metal Concentrations during Welding in Selected Factories in Jeddah, Saudi Arabia

    PubMed Central

    Balkhyour, Mansour Ahmed; Goknil, Mohammad Khalid

    2010-01-01

    Welding is a major industrial process used for joining metals. Occupational exposure to welding fumes is a serious occupational health problem all over the world. The degree of risk to welder’s health from fumes depends on composition, concentration, and the length of exposure. The aim of this study was to investigate workers’ welding fume exposure levels in some industries in Jeddah, Saudi Arabia. In each factory, the air in the breathing zone within 0.5 m from welders was sampled during 8-hour shifts. Total particulates, manganese, copper, and molybdenum concentrations of welding fumes were determined. Mean values of eight-hour average particulate concentrations measured during welding at the welders breathing zone were 6.3 mg/m3 (Factory 1), 5.3 mg/m3 (Factory 2), 11.3 mg/m3 (Factory 3), 6.8 mg/m3 (Factory 4), 4.7 mg/m3 (Factory 5), and 3.0 mg/m3 (Factory 6). Mean values of airborne manganese, copper, and molybdenum levels measured during welding were in the range of 0.010 mg/m3–0.477 mg/m3, 0.001 mg/m3–0.080 mg/m3 and 0.001 mg/m3–0.058 mg/m3 respectively. Mean values of calculated equivalent exposure values were: 1.50 (Factory 1), 1.56 (Factory 2), 5.14 (Factory 3), 2.21 (Factory 4), 2.89 (Factory 5), and 1.20 (Factory 6). The welders in factories 1, 2, 3, and 4 were exposed to welding fume concentration above the SASO limit value, which may increase the risk of respiratory health problems. PMID:20717553

  18. Total fume and metal concentrations during welding in selected factories in Jeddah, Saudi Arabia.

    PubMed

    Balkhyour, Mansour Ahmed; Goknil, Mohammad Khalid

    2010-07-01

    Welding is a major industrial process used for joining metals. Occupational exposure to welding fumes is a serious occupational health problem all over the world. The degree of risk to welder's health from fumes depends on composition, concentration, and the length of exposure. The aim of this study was to investigate workers' welding fume exposure levels in some industries in Jeddah, Saudi Arabia. In each factory, the air in the breathing zone within 0.5 m from welders was sampled during 8-hour shifts. Total particulates, manganese, copper, and molybdenum concentrations of welding fumes were determined. Mean values of eight-hour average particulate concentrations measured during welding at the welders breathing zone were 6.3 mg/m(3) (Factory 1), 5.3 mg/m(3) (Factory 2), 11.3 mg/m(3) (Factory 3), 6.8 mg/m(3) (Factory 4), 4.7 mg/m(3) (Factory 5), and 3.0 mg/m(3) (Factory 6). Mean values of airborne manganese, copper, and molybdenum levels measured during welding were in the range of 0.010 mg/m(3)-0.477 mg/m(3), 0.001 mg/m(3)-0.080 mg/m(3) and 0.001 mg/m(3)-0.058 mg/m(3) respectively. Mean values of calculated equivalent exposure values were: 1.50 (Factory 1), 1.56 (Factory 2), 5.14 (Factory 3), 2.21 (Factory 4), 2.89 (Factory 5), and 1.20 (Factory 6). The welders in factories 1, 2, 3, and 4 were exposed to welding fume concentration above the SASO limit value, which may increase the risk of respiratory health problems.

  19. Origin and characteristics of excess Fe metal in lunar glass welded aggregates

    NASA Technical Reports Server (NTRS)

    Housley, R. M.; Grant, R. W.; Paton, N. E.

    1973-01-01

    We show that the characteristic features of lunar glass welded aggregates including their irregular shapes, vesicularity, and content of submicron Fe metal in the welding glass can be explained by a model in which they are predominantly formed by micrometeorite impacts into the solar wind saturated topmost surface of the regolith. The Fe metal is reduced from silicates by the solar wind gases. Other possible mechanisms of Fe metal formation are discussed and shown to play at most minor roles. It is shown that surface tension forces control vesicularity and that the low gravity and high vacuum conditions prevailing on the moon are unimportant. Consequences of this surface tension control to possible lunar eruptive volcanism and to the Ar-40/Ar-39 dating of impact events are discussed.

  20. Resistance Spot Welding of AA5052 Sheet Metal of Dissimilar Thickness

    NASA Astrophysics Data System (ADS)

    Mat Din, N. A.; Zuhailawati, H.; Anasyida, A. S.

    2016-02-01

    Resistance spot welding of dissimilar thickness of AA5052 aluminum alloy was performed in order to investigate the effect of metal thickness on the weldment strength. Resistance spot welding was done using a spot welder machine available in Coraza Systems Sdn Bhd using a hemispherical of chromium copper electrode tip with radius of 6.00 mm under 14 kA of current and 0.02 bar of pressure for all thickness combinations. Lap joint configuration was produced between 2.0 mm thick sheet and 1.2 - 3.2 mm thick sheet, respectively. Microstructure of joint showed asymmetrical nugget shape that was larger on the thicker side indicating larger molten metal volume. Joint 2.0 mm x 3.2 mm sheets has the lowest hardness in both transverse direction and through thickness direction because less heat left in the weld nugget. The microstructure shows that this joint has coarse grains of HAZ. As thickness of sheet metal increased, the failure load of the joints increased. However, there was no linear correlation established between joint strength and metal thickness due to different shape of fusion zone in dissimilar thickness sheet metal.

  1. Urinary neutrophil gelatinase-associated lipocalin is associated with heavy metal exposure in welding workers

    NASA Astrophysics Data System (ADS)

    Chuang, Kai-Jen; Pan, Chih-Hong; Su, Chien-Ling; Lai, Ching-Huang; Lin, Wen-Yi; Ma, Chih-Ming; Ho, Shu-Chuan; Bien, Mauo-Ying; Chen, Cheng-Hsien; Chuang, Hsiao-Chi

    2015-12-01

    Metals cause nephrotoxicity with acute and/or chronic exposure; however, few epidemiological studies have examined impacts of exposure to metal fumes on renal injury in welding workers. In total, 66 welding workers and 12 office workers were recruited from a shipyard located in southern Taiwan. Urine samples from each subject were collected at the beginning (baseline) and end of the work week (1-week exposure). Personal exposure to PM2.5 was measured. The 8-h mean PM2.5 was 50.3 μg/m3 for welding workers and 27.4 μg/m3 for office workers. iTRAQs coupled with LC-MS/MS were used to discover the pathways in response to welding PM2.5 in the urine, suggesting that extracellular matrix (ECM)-receptor interactions are a critical mechanism. ECM-receptor interaction-related biomarkers for renal injury, kidney injury molecule (KIM)-1 and neutrophil gelatinase-associated lipocalin (NGAL), were significantly elevated in welding workers post-exposure, as well as were urinary Al, Cr, Mn, Fe, Co, and Ni levels. NGAL was more significantly associated with Al (r = 0.737, p < 0.001), Cr (r = 0.705, p < 0.001), Fe (r = 0.709, p < 0.001), and Ni (r = 0.657, p < 0.001) than was KIM-1, suggesting that NGAL may be a urinary biomarker for welding PM2.5 exposure. Nephrotoxicity (e.g., renal tubular injury) may be an emerging concern in occupational health.

  2. Urinary neutrophil gelatinase-associated lipocalin is associated with heavy metal exposure in welding workers

    PubMed Central

    Chuang, Kai-Jen; Pan, Chih-Hong; Su, Chien-Ling; Lai, Ching-Huang; Lin, Wen-Yi; Ma, Chih-Ming; Ho, Shu-Chuan; Bien, Mauo-Ying; Chen, Cheng-Hsien; Chuang, Hsiao-Chi

    2015-01-01

    Metals cause nephrotoxicity with acute and/or chronic exposure; however, few epidemiological studies have examined impacts of exposure to metal fumes on renal injury in welding workers. In total, 66 welding workers and 12 office workers were recruited from a shipyard located in southern Taiwan. Urine samples from each subject were collected at the beginning (baseline) and end of the work week (1-week exposure). Personal exposure to PM2.5 was measured. The 8-h mean PM2.5 was 50.3 μg/m3 for welding workers and 27.4 μg/m3 for office workers. iTRAQs coupled with LC-MS/MS were used to discover the pathways in response to welding PM2.5 in the urine, suggesting that extracellular matrix (ECM)-receptor interactions are a critical mechanism. ECM-receptor interaction-related biomarkers for renal injury, kidney injury molecule (KIM)-1 and neutrophil gelatinase-associated lipocalin (NGAL), were significantly elevated in welding workers post-exposure, as well as were urinary Al, Cr, Mn, Fe, Co, and Ni levels. NGAL was more significantly associated with Al (r = 0.737, p < 0.001), Cr (r = 0.705, p < 0.001), Fe (r = 0.709, p < 0.001), and Ni (r = 0.657, p < 0.001) than was KIM-1, suggesting that NGAL may be a urinary biomarker for welding PM2.5 exposure. Nephrotoxicity (e.g., renal tubular injury) may be an emerging concern in occupational health. PMID:26673824

  3. Urinary neutrophil gelatinase-associated lipocalin is associated with heavy metal exposure in welding workers.

    PubMed

    Chuang, Kai-Jen; Pan, Chih-Hong; Su, Chien-Ling; Lai, Ching-Huang; Lin, Wen-Yi; Ma, Chih-Ming; Ho, Shu-Chuan; Bien, Mauo-Ying; Chen, Cheng-Hsien; Chuang, Hsiao-Chi

    2015-12-17

    Metals cause nephrotoxicity with acute and/or chronic exposure; however, few epidemiological studies have examined impacts of exposure to metal fumes on renal injury in welding workers. In total, 66 welding workers and 12 office workers were recruited from a shipyard located in southern Taiwan. Urine samples from each subject were collected at the beginning (baseline) and end of the work week (1-week exposure). Personal exposure to PM2.5 was measured. The 8-h mean PM2.5 was 50.3 μg/m(3) for welding workers and 27.4 μg/m(3) for office workers. iTRAQs coupled with LC-MS/MS were used to discover the pathways in response to welding PM2.5 in the urine, suggesting that extracellular matrix (ECM)-receptor interactions are a critical mechanism. ECM-receptor interaction-related biomarkers for renal injury, kidney injury molecule (KIM)-1 and neutrophil gelatinase-associated lipocalin (NGAL), were significantly elevated in welding workers post-exposure, as well as were urinary Al, Cr, Mn, Fe, Co, and Ni levels. NGAL was more significantly associated with Al (r = 0.737, p < 0.001), Cr (r = 0.705, p < 0.001), Fe (r = 0.709, p < 0.001), and Ni (r = 0.657, p < 0.001) than was KIM-1, suggesting that NGAL may be a urinary biomarker for welding PM2.5 exposure. Nephrotoxicity (e.g., renal tubular injury) may be an emerging concern in occupational health.

  4. Creep deformation and fracture behavior of types 316 and 316L(N) stainless steels and their weld metals

    NASA Astrophysics Data System (ADS)

    Sasikala, G.; Mannan, S. L.; Mathew, M. D.; Rao, K. Bhanu

    2000-04-01

    The creep properties of a nuclear-grade type 316(L) stainless steel (SS) alloyed with nitrogen (316L(N) SS) and its weld metal were studied at 873 and 923 K in the range of applied stresses from 100 to 335 MPa. The results were compared with those obtained on a nuclear-grade type 316 SS, which is lean in nitrogen. The creep rupture lives of the weld metals were found to be lower than those of the respective base metals by a factor of 5 to 10. Both the base and weld metals of 316L(N) SS exhibited better resistance to creep deformation compared to their 316 SS counterparts at identical test conditions. A power-law relationship between the minimum creep rate and applied stress was found to be obeyed for both the base and weld metals. Both the weld metals generally exhibited lower rupture elongation than the respective base metals; however, at 873 K, the 316 SS base and weld metals had similar rupture elongation at identical applied stresses. Comparison of the rupture lives of the two steels to the ASME curves for the expected minimum stress to rupture for 316 SS base and weld metals showed that, for 316L(N) SS, the specifications for maximum allowable stresses based on data for 316 SS could prove overconservative. The influence of nitrogen on the creep deformation and fracture behavior, especially in terms of its modifying the precipitation kinetics, is discussed in light of the microstructural observations. In welds containing δ ferrite, the kinetics of its transformation and the nature of the transformation products control the deformation and fracture behavior. The influence of nitrogen on the δ ferrite transformation behavior and coarsening kinetics is also discussed, on the basis of extensive characterization by metallographic techniques.

  5. Electrically driven rapidly vaporizing foils, wires and strips used for collision welding and sheet metal forming

    DOEpatents

    Vivek, Anupam; Daehn, Glenn S; Taber, Geoffrey A; Johnson, Jason R

    2015-05-05

    A method for forming a piece of a sheet metal is performed by positioning a consumable body, made of metal, proximate to the piece of the sheet metal. The consumable body is rapidly vaporized, and the gas pressure generated thereby is directed into the piece of the sheet metal. This results in acceleration of the piece of sheet metal, and it is collided into a stationary body at a velocity, generally in excess of 200 m/s. Depending upon the type of stationary body, the piece of sheet metal is deformed into a predetermined shape or is welded onto the stationary body. The vaporization is accomplished by passing a high current of electricity into the consumable body. The effect of the vaporized metal may be augmented by additional components in the consumable body.

  6. An investigation of the weld region on the SAE 1020 joined with metal active gas and determination of the mismatch factor

    SciTech Connect

    Meric, C.; Tokdemir, M.

    1999-10-01

    In this study, the joining process of SAE 1020 low carbon steel, generally used in the industry, has been completed using the metal active gas (MAG) weld method. The goal of this study was to examine the mismatch between base and weld metal. After the joining process, mechanical properties of the samples of the base metal (BM), the heat affected zone (HAZ), and the weld metal (WM) were investigated, and the crack tip opening displacement (CTOD) test was performed.

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

    NASA Astrophysics Data System (ADS)

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

    2014-11-01

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

  8. Microstructural characterization and analysis of inclusions in C-Mn steel and weld metals

    NASA Astrophysics Data System (ADS)

    Younes, C.; Heard, P. J.; Wild, R. K.; Flewitt, P. E. J.

    2000-03-01

    Ferritic steels used for the construction of welded pressure vessels may contain trace concentrations of impurity elements that can influence their overall mechanical properties. Often, the C-Mn ferritic steels and weld metals used for welded nuclear pressure vessels contain trace concentrations of boron (<10 ppm), and the role of this impurity element could be significantly different depending upon whether it is present as the free atomic species or incorporated into specific microstructural features, such as inclusions or precipitates, of these materials. In this article, the results of work designed to characterize the microstructure of C-Mn steels and weld metals used for the construction of Magnox nuclear pressure vessels are described. In particular, the type, size, distribution, and chemical composition of inclusions present are considered. A range of techniques are used to characterize the microstructure, but, in particular, two surface sensitive analytical techniques, namely, Auger electron spectroscopy (AES) and secondary ion mass spectroscopy (SIMS), are used to detect and quantitatively analyze impurity boron. The results are discussed with respect to the relationship of the boron to the stable silicate inclusions and the potential influence this may have on mechanical properties of these materials.

  9. Kinetics of the metal components of intratracheally instilled stainless steel welding fume suspensions in rats.

    PubMed

    Kalliomäki, P L; Hyvärinen, H K; Aitio, A; Lakoma, E L; Kalliomäki, K

    1986-02-01

    The kinetics of iron, chromium, nickel, and cobalt from manual metal arc and metal inert gas stainless steel welding fumes were studied. Neutron activated welding fumes, in aqueous suspensions, were instilled intratracheally into rats. The follow up continued for up to 106 days. From both fumes, approximately 10% of the injection bolus was immediately lost into the gastrointestinal tract, to be recovered in the faeces within three days. Thereafter, a pronounced difference was seen in the kinetics of the two types of fumes. After the first day, chromium, nickel, and iron were lost from the lungs with half times of about 53, 49, and 73 days after exposure to MMA/SS fumes, whereas practically no loss could be seen in the metal components of the metal inert gas welding fumes within two months. The disposition of chromium from MMA/SS fumes closely resembled that of intratracheally instilled water soluble chromates. On the other hand, the disappearance of trivalent chromium from MIS/SS fumes was considerably slower than that of the practically water insoluble chromates, or even of trivalent chromium salts. Thus the physical characteristics of the fume appreciably affect the kinetics of the clearance of chromium compounds from the lungs.

  10. Kinetics of the metal components of intratracheally instilled stainless steel welding fume suspensions in rats.

    PubMed Central

    Kalliomäki, P L; Hyvärinen, H K; Aitio, A; Lakoma, E L; Kalliomäki, K

    1986-01-01

    The kinetics of iron, chromium, nickel, and cobalt from manual metal arc and metal inert gas stainless steel welding fumes were studied. Neutron activated welding fumes, in aqueous suspensions, were instilled intratracheally into rats. The follow up continued for up to 106 days. From both fumes, approximately 10% of the injection bolus was immediately lost into the gastrointestinal tract, to be recovered in the faeces within three days. Thereafter, a pronounced difference was seen in the kinetics of the two types of fumes. After the first day, chromium, nickel, and iron were lost from the lungs with half times of about 53, 49, and 73 days after exposure to MMA/SS fumes, whereas practically no loss could be seen in the metal components of the metal inert gas welding fumes within two months. The disposition of chromium from MMA/SS fumes closely resembled that of intratracheally instilled water soluble chromates. On the other hand, the disappearance of trivalent chromium from MIS/SS fumes was considerably slower than that of the practically water insoluble chromates, or even of trivalent chromium salts. Thus the physical characteristics of the fume appreciably affect the kinetics of the clearance of chromium compounds from the lungs. PMID:3947567

  11. METAL FUSION AND FABRICATION WELDING. AGRICULTURAL MACHINERY--SERVICE OCCUPATIONS, MODULE, NUMBER 6.

    ERIC Educational Resources Information Center

    Ohio State Univ., Columbus. Center for Vocational and Technical Education.

    ONE IN A SERIES DESIGNED TO HELP TEACHERS PREPARE POSTSECONDARY STUDENTS FOR THE AGRICULTURAL MACHINERY SERVICE OCCUPATIONS AS PARTS MEN, MECHANICS, MECHANIC'S HELPERS, OR SERVICE SUPERVISORS, THIS GUIDE AIMS TO DEVELOP STUDENT UNDERSTANDING OF WELDING EQUIPMENT AND SUPPLIES, AND ABILITY TO PERFORM SKILLS REQUIRED OF AGRICULTURAL MECHANICS. IT WAS…

  12. The origin of transformation textures in steel weld metals containing acicular ferrite

    NASA Astrophysics Data System (ADS)

    Kluken, A. O.; Grong, Ø.; Hjelen, J.

    1991-03-01

    The present investigation is concerned with basic studies of the development of transformation textures in steel weld metals, using the electron backscattering pattern (EBSP) technique. It is shown that the acicular ferrite (AF) plates exhibit an orientation relationship with both the austenite and the prior delta ferrite columnar grains in which they grow. The observed orientation relationship lies within the Bain orientation region and can be described by three texture components, i.e., a <100> component and two complementary <111> components. Each of these texture components is orientated approximately parallel with the original cell/dendrite growth direction. Measurements of the spatial misorientation between neighboring plates confirm that the morphology of AF in low-alloy steel weld metals bears a close resemblance to upper bainite.

  13. Changes in Precipitate Distributions and the Microstructural Evolution of P24/P91 Dissimilar Metal Welds During PWHT

    NASA Astrophysics Data System (ADS)

    Dawson, Karl E.; Tatlock, Gordon J.; Chi, Kuangnan; Barnard, Peter

    2013-11-01

    The effect of post-weld heat treatments (PWHTs) on the evolution of precipitate phases in dissimilar metal welds made between 9 pct Cr P91 alloy and 2.25 pct Cr T/P24-type weld metal has been investigated. Sections of multi-pass fusion welds were analyzed in their as welded condition and after PWHTs of 2 and 8 hour duration at 1003 K (730 °C). Thin foil specimens and carbon extraction replicas have been examined in transmission electron microscopes in order to identify precipitate phases and substantiate their distributions in close proximity to the fusion line. The findings of these studies confirm that a carbon-depleted region develops in the lower alloyed weld material, adjacent to the weld interface, during thermal processing. A corresponding carbon enriched region is formed, simultaneously, in the coarse grain heat affected zone of the P91 parent alloy. It has been demonstrated that carbon depletion from the weld alloy results in the dissolution of M7C3 and M23C6 chromium carbides. However, micro-alloying additions of vanadium and niobium which are made to both the P24 and P91 alloys facilitate the precipitation of stable, nano-scale, MX carbonitride particles. This work demonstrates that these particles, which are of key importance to the strength of ferritic creep resistant alloys, are retained in carbon-depleted regions. The microstructural stability which is conferred by their retention means that the pernicious effects of recrystallization are largely avoided.

  14. Ultrasonic Phased Array Technique for Accurate Flaw Sizing in Dissimilar Metal Welds

    SciTech Connect

    Jonathan D Buttram

    2005-03-11

    Described is a manual,portable non-destructive technique to determine the through wall height of cracks present in dissimilar metal welds used in the primary coolling systems of pressure water and boiler light water reactors. Current manual methods found in industry have proven not to exhibit the sizing accuracy required by ASME inspection requirement. The technique described demonstrated an accuracy approximately three times that required to ASME Section XI, Appendix 8 qualification.

  15. 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.

  16. Solidification microstructures and phase transformations in Al-Ti-Si-Mn deoxidized steel weld metals

    NASA Astrophysics Data System (ADS)

    Kluken, A. O.; Grong, Ø.; Rørvik, G.

    1990-07-01

    The present investigation is concerned with basic studies of solidification mechanisms in Al-Ti-Si-Mn deoxidized steel weld metals. Assessment of the weld metal solidification micro-structures was done on the basis of optical microscopy in combination with secondary ion mass spectrometry (SIMS), while both scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were used for characterization of indigenous oxide inclusions. It is shown that nonmetallic inclusions play a critical role in the development of the weld metal columnar grain structure by acting as inert substrates for nucleation of delta ferrite ahead of the advancing interface. The nucleation potency of the oxides increases in the order SiO2-MnO, Al2O3-Ti2O3-SiO2-MnO, A12O3, reflecting a corresponding increase in the inclusion/liquid interfacial energy. Moreover, a shift in the peritectic reaction (which facilitates growth of the austenite grains across the phosphorus-rich boundaries of the primary delta ferrite phase) has been observed in the presence of A12O3 inclusions. Indications are that the resulting decrease in the local phosphorus concentrations at the austenite grain boundaries will strongly alter the kinetics of the subsequent solid-state transformation reactions by promoting growth of grain boundary ferrite sideplates at the expense of intragranularly nucleated acicular ferrite.

  17. Influence of thermal neutrons on embrittlement and hardening in weld metals

    NASA Astrophysics Data System (ADS)

    Moskovic, R.; Jordinson, C.

    1999-07-01

    The influence of thermal neutrons on embrittlement of a number of submerged arc weld metal steels has been studied in a series of experiments undertaken in a reactor which provided a highly thermalized flux spectrum with a ratio of thermal displacements per atom (dpa) (neutron energies <1 keV) to fast dpa (neutron energies >1 keV) of about two at an irradiation temperature of 240 °C. A statistical analysis set in a Bayes framework is presented for Charpy impact energy test data measured on the submerged arc weld metal specimens subjected to accelerated neutron irradiation for two different exposure periods. Prior to the accelerated irradiation, the specimens were subjected to neutron irradiation under surveillance conditions. The analysis presents models for changes of Charpy impact energy properties measured over a range of test temperatures extending from the lower to upper shelf energy levels, as a function of neutron irradiation dose. Markov chain Monte Carlo sampling was applied to obtain estimates of the posterior probability distributions of the model parameters. These parameters were then used to compute the ductile to brittle transition temperature shifts at the 40 J energy level in the Charpy impact energy against temperature curves. Using the results for the ductile to brittle transition temperature shifts, the effectiveness of the thermal neutrons can be estimated for submerged arc weld metal used in the construction of operating Magnox reactor steel pressure vessels.

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

    PubMed

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

    2007-08-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2013-05-01

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

  20. Factors Affecting the Capture Efficiency of a Fume Extraction Torch for Gas Metal Arc Welding.

    PubMed

    Bonthoux, Francis

    2016-07-01

    Welding fumes are classified as Group 2B 'possibly carcinogenic' and this prompts to the implementation of local exhaust ventilation (LEV). The fume extraction torch with LEV integrated into the tool is the most attractive solution but its capture efficiency is often disappointing in practice. This study assesses the main parameters affecting fume capture efficiency namely the extraction flow rate, the positioning of the suction openings on the torch, the angle of inclination of the torch to the workpiece during welding, the metal transfer modes, and the welding deposition rate. The theoretical velocity induced by suction, estimated from the extraction flow rate and the position of the suction openings, is the main parameter affecting effectiveness of the device. This is the design parameter and its value should never be <0.25 m s(-1) The angle of the torch relative to the workpiece also has a great deal of influence. To improve efficiency, work station layouts need to favour positions where the torch is held with angles closer to perpendicular (<15°). Welding with high deposition rates (>1.1g s(-1)) and spray transfer leads to low capture efficiency if induced velocities are <0.5 m s(-1) The results of the study can be used in the design of integrated on-torch extraction systems and provide information for fixing system objectives. PMID:27074798

  1. Factors Affecting the Capture Efficiency of a Fume Extraction Torch for Gas Metal Arc Welding.

    PubMed

    Bonthoux, Francis

    2016-07-01

    Welding fumes are classified as Group 2B 'possibly carcinogenic' and this prompts to the implementation of local exhaust ventilation (LEV). The fume extraction torch with LEV integrated into the tool is the most attractive solution but its capture efficiency is often disappointing in practice. This study assesses the main parameters affecting fume capture efficiency namely the extraction flow rate, the positioning of the suction openings on the torch, the angle of inclination of the torch to the workpiece during welding, the metal transfer modes, and the welding deposition rate. The theoretical velocity induced by suction, estimated from the extraction flow rate and the position of the suction openings, is the main parameter affecting effectiveness of the device. This is the design parameter and its value should never be <0.25 m s(-1) The angle of the torch relative to the workpiece also has a great deal of influence. To improve efficiency, work station layouts need to favour positions where the torch is held with angles closer to perpendicular (<15°). Welding with high deposition rates (>1.1g s(-1)) and spray transfer leads to low capture efficiency if induced velocities are <0.5 m s(-1) The results of the study can be used in the design of integrated on-torch extraction systems and provide information for fixing system objectives.

  2. Characterization of airborne particles generated from metal active gas welding process.

    PubMed

    Guerreiro, C; Gomes, J F; Carvalho, P; Santos, T J G; Miranda, R M; Albuquerque, P

    2014-05-01

    This study is focused on the characterization of particles emitted in the metal active gas welding of carbon steel using mixture of Ar + CO2, and intends to analyze which are the main process parameters that influence the emission itself. It was found that the amount of emitted particles (measured by particle number and alveolar deposited surface area) are clearly dependent on the distance to the welding front and also on the main welding parameters, namely the current intensity and heat input in the welding process. The emission of airborne fine particles seems to increase with the current intensity as fume-formation rate does. When comparing the tested gas mixtures, higher emissions are observed for more oxidant mixtures, that is, mixtures with higher CO2 content, which result in higher arc stability. These mixtures originate higher concentrations of fine particles (as measured by number of particles by cm(3) of air) and higher values of alveolar deposited surface area of particles, thus resulting in a more severe worker's exposure. PMID:24730680

  3. Characterization of airborne particles generated from metal active gas welding process.

    PubMed

    Guerreiro, C; Gomes, J F; Carvalho, P; Santos, T J G; Miranda, R M; Albuquerque, P

    2014-05-01

    This study is focused on the characterization of particles emitted in the metal active gas welding of carbon steel using mixture of Ar + CO2, and intends to analyze which are the main process parameters that influence the emission itself. It was found that the amount of emitted particles (measured by particle number and alveolar deposited surface area) are clearly dependent on the distance to the welding front and also on the main welding parameters, namely the current intensity and heat input in the welding process. The emission of airborne fine particles seems to increase with the current intensity as fume-formation rate does. When comparing the tested gas mixtures, higher emissions are observed for more oxidant mixtures, that is, mixtures with higher CO2 content, which result in higher arc stability. These mixtures originate higher concentrations of fine particles (as measured by number of particles by cm(3) of air) and higher values of alveolar deposited surface area of particles, thus resulting in a more severe worker's exposure.

  4. Factors Affecting the Capture Efficiency of a Fume Extraction Torch for Gas Metal Arc Welding

    PubMed Central

    Bonthoux, Francis

    2016-01-01

    Welding fumes are classified as Group 2B ‘possibly carcinogenic’ and this prompts to the implementation of local exhaust ventilation (LEV). The fume extraction torch with LEV integrated into the tool is the most attractive solution but its capture efficiency is often disappointing in practice. This study assesses the main parameters affecting fume capture efficiency namely the extraction flow rate, the positioning of the suction openings on the torch, the angle of inclination of the torch to the workpiece during welding, the metal transfer modes, and the welding deposition rate. The theoretical velocity induced by suction, estimated from the extraction flow rate and the position of the suction openings, is the main parameter affecting effectiveness of the device. This is the design parameter and its value should never be <0.25 m s−1. The angle of the torch relative to the workpiece also has a great deal of influence. To improve efficiency, work station layouts need to favour positions where the torch is held with angles closer to perpendicular (<15°). Welding with high deposition rates (>1.1g s−1) and spray transfer leads to low capture efficiency if induced velocities are <0.5 m s−1. The results of the study can be used in the design of integrated on-torch extraction systems and provide information for fixing system objectives. PMID:27074798

  5. Novel concepts in weld science: Role of gradients and composite structure. Final report

    SciTech Connect

    Matlock, D.K.; Olson, D.L.

    1994-03-01

    The effects of compositional and microstructural gradients on weld metal and simulated weld metal properties were evaluated in this multi-part study. The results obtained on single phase solid solution systems were used as a basis for a fundamental study of the effects of compositional gradients on crack growth, both at low temperatures, in fatigue and at high temperatures during creep. Methods to physically simulate gradients in weld metals with roll bonded laminate composites were applied to analyses of ferrite-austenite and ferrite-sigma-austenite multiphase systems. Finally, results of the physical simulation analyses were utilized to predict the effects of weld process parameters on weld metal properties.

  6. Summary of Dissimilar Metal Joining Trials Conducted by Edison Welding Institute

    SciTech Connect

    MJ Lambert

    2005-11-18

    Under the direction of the NASA-Glenn Research Center, the Edison Welding Institute (EWI) in Columbus, OH performed a series of non-fusion joining experiments to determine the feasibility of joining refractory metals or refractory metal alloys to Ni-based superalloys. Results, as reported by EWI, can be found in the project report for EWI Project 48819GTH (Attachment A, at the end of this document), dated October 10, 2005. The three joining methods used in this investigation were inertia welding, magnetic pulse welding, and electro-spark deposition joining. Five materials were used in these experiments: Mo-47Re, T-111, Hastelloy X, Mar M-247 (coarse-grained, 0.5 mm to several millimeter average grain size), and Mar M-247 (fine-grained, approximately 50 {micro}m average grain size). Several iterative trials of each material combination with each joining method were performed to determine the best practice joining method. Mo-47Re was found to be joined easily to Hastelloy X via inertia welding, but inertia welding of the Mo-alloy to both Mar M-247 alloys resulted in inconsistent joint strength and large reaction layers between the two metals. T-111 was found to join well to Hastelloy X and coarse-grained Mar M-247 via inertia welding, but joining to fine-grained Mar M-247 resulted in low joint strength. Magnetic pulse welding (MPW) was only successful in joining T-111 tubing to Hastelloy X bar stock. The joint integrity and reaction layer between the metals were found to be acceptable. This single joining trial, however, caused damage to the electromagnetic concentrators used in this process. Subsequent design efforts to eliminate the problem resulted in a loss of power imparted to the accelerating work piece, and results could not be reproduced. Welding trials of Mar M-247 to T-111 resulted in catastrophic failure of the bar stock, even at lower power. Electro-spark deposition joining of Mo-47Re, in which the deposited material was Hastelloy X, did not have a

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

    NASA Astrophysics Data System (ADS)

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

    2014-09-01

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

  8. Creep deformation and rupture behavior of 2.25Cr-1Mo steel weldments and its constituents (base metal, weld metal and simulated heat affected zones)

    SciTech Connect

    Laha, K.; Chandravathi, K.S.; Rao, K.B.S.; Mannan, S.L.

    1995-12-31

    Microstructure across a weldment base metal through transformed heat-affected zone (HAZ) to cast weld metal. HAZ of 2.25Cr-1Mo weldment consists of coarse-grain bainite, fine-grain bainite and intercritical region. These HAZ microstructures were simulated by isothermal heat-treatments. Creep tests were carried out on base metal, weld metal, weldment and the simulated HAZ structures. Creep deformation and fracture behavior of 2.25Cr-1Mo weldments has been assessed based on the properties of its constituents. Coarse-grain bainite with low ductility and intercritical structure with low strength are the critical components of HAZ determining performance of the weldments.

  9. Influence of modes of metal transfer on grain structure and direction of grain growth in low nickel austenitic stainless steel weld metals

    SciTech Connect

    Mukherjee, Manidipto; Saha, Saptarshi; Pal, Tapan Kumar; Kanjilal, Prasanta

    2015-04-15

    The present study elaborately discussed the effect of different modes of metal transfer (i.e., short circuit mode, spray mode and pulse mode) on grain structure and direction of grain growth in low nickel austenitic stainless steel weld metals. Electron backscattered diffraction (EBSD) analysis was used to study the grain growth direction and grain structure in weld metals. The changes in grain structure and grain growth direction were found to be essentially varied with the weld pool shape and acting forces induced by modes of metal transfer at a constant welding speed. Short circuit mode of metal transfer owing to higher Marangoni force (M{sub a}) and low electromagnetic force (R{sub m}) promotes the lower weld pool volume (Γ) and higher weld pool maximum radius (r{sub m}). Short circuit mode also shows curved and tapered columnar grain structures and the grain growth preferentially occurred in <001> direction. In contrast, spray mode of metal transfer increases the Γ and reduces the r{sub m} values due to very high R{sub m} and typically reveals straight and broad columnar grain structures with preferential growth direction in <111>. In the pulse mode of metal transfer relatively high M{sub a} and R{sub m} simultaneously increase the weld pool width and the primary penetration which might encourage relatively complex grain growth directions in the weld pool and cause a shift of major intensity from <001> to <111> direction. It can also be concluded that the fusion zone grain structure and direction of grain growth are solely dependent on modes of metal transfer and remain constant for a particular mode of metal transfer irrespective of filler wire used. - Highlights: • Welded joints of LNiASS were prepared by varying modes of metal transfer. • Weld pool shape, grain structure and grain growth direction were studied. • Short circuit mode shows curved and tapered grain growth in <001> direction. • Spray mode shows straight and broad columnar grain growth

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

    NASA Astrophysics Data System (ADS)

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

    2011-06-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-12-01

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

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

    PubMed

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

    2005-11-01

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

  13. Comparative irradiation study of reactor pressure-vessel steel weld metals

    SciTech Connect

    Leitz, C.; Gerscha, A.; Hofmann, G.; Strobel, H.J.

    1982-01-01

    Charpy-V specimens of several test welds made of MnMo, MnCrMo, MnNiMo and MnNiCrMo types were irradiated simultaneously in two series at 315/sup 0/C and 285/sup 0/C, respectively, with neutron fluences between 8 x 10/sup 18/ and 5 x 10/sup 19/ n/cm/sup 2/ (E > 1 MeV). The known influence of copper on the 41 J temperature shift (..delta..T/sub 41/) was clearly detected for variations from 0.08 to about 0.3%. A considerable variation in embrittlement of low copper (below 0.08%) welds was not traceable to copper or phosphorus. Obviously it is related to variations of the nickel content (up to 1.7%). The effects of copper and nickel seem to be independent on each other. Both, however, have an influence on the slope of the ..delta..T/sub 41/ against fluence curves. The effects of other elements as silicon, phosphorus, arsenic, manganese, chromium, molybdenum and of welding procedure and welding flux are discussed in the paper. Due to overlapping, these effects could not be clearly defined. The Charpy-V upper shelf energy drop shows an effect equivalent to overaging. The shelf drop recovers by further irradiation in the region of 1 to 4 x 10/sup 19/ n/cm/sup 2/ for all low copper weld metals except that with 1.7% nickel. The shelf drop sequence of the materials tested is in general similar to ..delta..T/sub 41/ sequence with some differences in detail.

  14. Microbiologically influenced corrosion of stainless steel weld and base metal -- 4 year field test results

    SciTech Connect

    Felder, C.M.; Stein, A.A.

    1994-12-31

    This paper presents the results obtained from a 4-year test program to determine the effects of microbiologically influenced corrosion (MIC) on piping materials under service conditions representative of a fresh water cooling water system. The test was performed in a field installed test loop and was constructed to operate under four typical flow conditions: continuous flow at 4--6 fps (1.2--1.8 m/s), continuous flow at 0.5--1 fps (0.15--0.3 m/s), intermittent flow, and stagnant. Test materials consisted of pipe spools as well as coupons fabricated from Type 304, Type 316, Type 316L, and 6-percent molybdenum stainless steel, and titanium pipe. The pipe spools and coupons contained girth welds; the stainless steel girth welds were made with high and low heat inputs. Two types of bacterial colonization, bulbous nodules and shiny flat deposits, were observed in both weld metal and base metal of the Type 300 series materials, including Type 316L. Three different MIC morphologies were observed: pits with small openings and extensive tunneling, open pits, and shallow surface attack. A correlation was found to exist between the type of bacteria colonization, the MIC morphology, and the metallurgical characteristics of the materials. The MIC was not preferential to sensitized regions but was found to be related to residual cold work in the material.

  15. Effects of heat input on mechanical properties of metal inert gas welded 1.6 mm thick galvanized steel sheet

    NASA Astrophysics Data System (ADS)

    Rafiqul, M. I.; Ishak, M.; Rahman, M. M.

    2012-09-01

    It is usually a lot easier and less expensive to galvanize steel before it is welded into useful products. Galvanizing afterwards is almost impossible. In this research work, Galvanized Steel was welded by using the ER 308L stainless steel filler material. This work was done to find out an alternative way of welding and investigate the effects of heat input on the mechanical properties of butt welded joints of Galvanized Steel. A 13.7 kW maximum capacity MIG welding machine was used to join 1.6 mm thick sheet of galvanized steel with V groove and no gap between mm. Heat inputs was gradually increased from 21.06 to 25.07 joules/mm in this study. The result shows almost macro defects free welding and with increasing heat input the ultimate tensile strength and welding efficiency decrease. The Vickers hardness also decreases at HAZ with increasing heat input and for each individual specimen; hardness was lowest in heat affected zone (HAZ), intermediate in base metal and maximum in welded zone. The fracture for all specimens was in the heat affected zone while testing in the universal testing machine.

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

    SciTech Connect

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

    1994-12-31

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

  17. 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.

  18. Assessment of the biological effects of welding fumes emitted from metal inert gas welding processes of aluminium and zinc-plated materials in humans.

    PubMed

    Hartmann, L; Bauer, M; Bertram, J; Gube, M; Lenz, K; Reisgen, U; Schettgen, T; Kraus, T; Brand, P

    2014-03-01

    The aim of this study was to investigate biological effects and potential health risks due to two different metal-inert-gas (MIG) welding fumes (MIG welding of aluminium and MIG soldering of zinc coated steel) in healthy humans. In a threefold cross-over design study 12 male subjects were exposed to three different exposure scenarios. Exposures were performed under controlled conditions in the Aachener Workplace Simulation Laboratory (AWSL). On three different days the subjects were either exposed to filtered ambient air, to welding fumes from MIG welding of aluminium, or to fumes from MIG soldering of zinc coated materials. Exposure was performed for 6 h and the average fume concentration was 2.5 mg m(-3). Before, directly after, 1 day after, and 7 days after exposure spirometric and impulse oscillometric measurements were performed, exhaled breath condensate (EBC) was collected and blood samples were taken and analyzed for inflammatory markers. During MIG welding of aluminium high ozone concentrations (up to 250 μg m(-3)) were observed, whereas ozone was negligible for MIG soldering. For MIG soldering, concentrations of high-sensitivity CRP (hsCRP) and factor VIII were significantly increased but remained mostly within the normal range. The concentration of neutrophils increased in tendency. For MIG welding of aluminium, the lung function showed significant decreases in Peak Expiratory Flow (PEF) and Mean Expiratory Flow at 75% vital capacity (MEF 75) 7 days after exposure. The concentration of ristocetin cofactor was increased. The observed increase of hsCRP during MIG-soldering can be understood as an indicator for asymptomatic systemic inflammation probably due to zinc (zinc concentration 1.5 mg m(-3)). The change in lung function observed after MIG welding of aluminium may be attributed to ozone inhalation, although the late response (7 days after exposure) is surprising.

  19. Phased array ultrasonic testing of dissimilar metal welds using geometric based referencing delay law technique

    NASA Astrophysics Data System (ADS)

    Han, Taeyoung; Schubert, Frank; Hillmann, Susanne; Meyendorf, Norbert

    2015-03-01

    Phased array ultrasonic testing (PAUT) techniques are widely used for the non-destructive testing (NDT) of austenitic welds to find defects like cracks. However, the propagation of ultrasound waves through the austenitic material is intricate due to its inhomogeneous and anisotropic nature. Such a characteristic leads beam path distorted which causes the signal to be misinterpreted. By employing a reference block which is cutout from the mockup of which the structure is a dissimilar metal weld (DMW), a new method of PAUT named as Referencing Delay Law Technique (RDLT) is introduced. With the RDLT, full matrix capture (FMC) was used for data acquisition. To reconstruct the images, total focusing method (TFM) was used. After the focal laws were calculated, PAUT was then performed. As a result, the flaws are more precisely positioned with significantly increased signal-to-noise ratio (SNR).

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

    PubMed

    Anzehaee, Mohammad Mousavi; Haeri, Mohammad

    2011-07-01

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

  1. Friction Stir Welding of Metal Matrix Composites for use in aerospace structures

    NASA Astrophysics Data System (ADS)

    Prater, Tracie

    2014-01-01

    Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as the Orion Crew Exploration Vehicle. A current focus of FSW research is to extend the process to new materials which are difficult to weld using conventional fusion techniques. Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramics and have a very high strength to weight ratio, a property which makes them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Since FSW occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This work characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. Based on the results of these experiments, a phenomenological model of the wear process was constructed based on the rotating plug model for FSW. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is explored. In-process force, torque, and

  2. 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.

  3. Effect of Post-Weld Heat Treatment on Mechanical and Electrochemical Properties of Gas Metal Arc-Welded 316L (X2CrNiMo 17-13-2) Stainless Steel

    NASA Astrophysics Data System (ADS)

    Muhammad, F.; Ahmad, A.; Farooq, A.; Haider, W.

    2016-08-01

    In the present research work, corrosion behavior of post-weld heat-treated (PWHT) AISI 316L (X2CrNiMo 17-13-2) specimens joined by gas metal arc welding is compared with as-welded samples by using potentiodynamic polarization technique. Welded samples were PWHT at 1323 K for 480 s and quenched. Mechanical properties, corrosion behavior and microstructures of as-welded and PWHT specimens were investigated. Microstructural studies have shown grain size refinement after PWHT. Ultimate tensile strength and yield strength were found maximum for PWHT samples. Bend test have shown that PWHT imparted ductility in welded sample. Fractographic analysis has evidenced ductile behavior for samples. Potentiodynamic polarization test was carried out in a solution composed of 1 M H2SO4 and 1 N NaCl. Corrosion rate of weld region was 127.6 mpy, but after PWHT, it was decreased to 13.12 mpy.

  4. Effect of Post-Weld Heat Treatment on Mechanical and Electrochemical Properties of Gas Metal Arc-Welded 316L (X2CrNiMo 17-13-2) Stainless Steel

    NASA Astrophysics Data System (ADS)

    Muhammad, F.; Ahmad, A.; Farooq, A.; Haider, W.

    2016-10-01

    In the present research work, corrosion behavior of post-weld heat-treated (PWHT) AISI 316L (X2CrNiMo 17-13-2) specimens joined by gas metal arc welding is compared with as-welded samples by using potentiodynamic polarization technique. Welded samples were PWHT at 1323 K for 480 s and quenched. Mechanical properties, corrosion behavior and microstructures of as-welded and PWHT specimens were investigated. Microstructural studies have shown grain size refinement after PWHT. Ultimate tensile strength and yield strength were found maximum for PWHT samples. Bend test have shown that PWHT imparted ductility in welded sample. Fractographic analysis has evidenced ductile behavior for samples. Potentiodynamic polarization test was carried out in a solution composed of 1 M H2SO4 and 1 N NaCl. Corrosion rate of weld region was 127.6 mpy, but after PWHT, it was decreased to 13.12 mpy.

  5. Assessment of Welders Exposure to Carcinogen Metals from Manual Metal Arc Welding in Gas Transmission Pipelines, Iran

    PubMed Central

    Golbabaei, F; Seyedsomea, M; Ghahri, A; Shirkhanloo, H; Khadem, M; Hassani, H; Sadeghi, N; Dinari, B

    2012-01-01

    Background: Welding can produce dangerous fumes containing various metals especially carcinogenic ones. Occupational exposure to welding fumes is associated with lung cancer. Therefore, welders in Gas Transmission Pipelines are known as a high-risk group. This study was designed to determinate the amounts of metals Cr, Ni, and Cd in breathing zone and urine of welders and to assess the possibility of introducing urinary metals as a biomarker due to occupational exposure. Methods: In this cross sectional study, 94 individuals from Gas Transmission Pipelines welders, Iran, Borujen in 2011 were selected and classified into 3 groups including Welders, Back Welders and Assistances. The sampling procedures were performed according to NIOSH 7300 for total chromium, nickel, and cadmium and NIOSH 7600 for Cr+6. For all participants urine samples were collected during the entire work shift and metals in urine were determined according to NIOSH 8310. Results: Back Welders and Assistances groups had maximum and minimum exposure to total fume and its elements, respectively. In addition, results showed that there are significant differences (P<0.05) between Welders and Back Welders with Assistances group in exposure with total fume and elements except Ni. Urinary concentrations of three metals including Cr, Cd and Ni among all welders were about 4.5, 12 and 14-fold greater than those detected in controls, respectively. Weak correlations were found between airborne and urinary metals concentrations (R2: Cr=0.45, Cd=0.298, Ni=0.362). Conclusion: Urinary metals concentrations could not be considerate as a biomarker for welders’ exposure assessment. PMID:23113226

  6. 19 CFR 19.22 - Withdrawal of metal refined in part from imported crude metal and in part from crude metal...

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 19 Customs Duties 1 2014-04-01 2014-04-01 false Withdrawal of metal refined in part from imported crude metal and in part from crude metal produced from imported materials. 19.22 Section 19.22 Customs... § 19.22 Withdrawal of metal refined in part from imported crude metal and in part from crude...

  7. 19 CFR 19.22 - Withdrawal of metal refined in part from imported crude metal and in part from crude metal...

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 19 Customs Duties 1 2013-04-01 2013-04-01 false Withdrawal of metal refined in part from imported crude metal and in part from crude metal produced from imported materials. 19.22 Section 19.22 Customs... § 19.22 Withdrawal of metal refined in part from imported crude metal and in part from crude...

  8. 19 CFR 19.22 - Withdrawal of metal refined in part from imported crude metal and in part from crude metal...

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 19 Customs Duties 1 2010-04-01 2010-04-01 false Withdrawal of metal refined in part from imported crude metal and in part from crude metal produced from imported materials. 19.22 Section 19.22 Customs... § 19.22 Withdrawal of metal refined in part from imported crude metal and in part from crude...

  9. 19 CFR 19.22 - Withdrawal of metal refined in part from imported crude metal and in part from crude metal...

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 19 Customs Duties 1 2012-04-01 2012-04-01 false Withdrawal of metal refined in part from imported crude metal and in part from crude metal produced from imported materials. 19.22 Section 19.22 Customs... § 19.22 Withdrawal of metal refined in part from imported crude metal and in part from crude...

  10. Precipitate microstructures and resulting properties of Al-Zn-Mg metal inert gas-weld heat-affected zones

    NASA Astrophysics Data System (ADS)

    Nicolas, M.; Deschamps, A.

    2004-05-01

    Using the combination of small-angle X-ray scattering (SAXS) and transmission electron microscopy (TEM), the precipitate microstructure is quantitatively investigated in the heat-affected zones (HAZs) of Al-Zn-Mg metal inert gas (MIG)-welds, and the resulting mechanical properties are determined by hardness measurements. Three initial states prior to welding (T4, T6, and T7) are investigated, and the subsequent microstructure evolution during natural aging and postwelding heat treatments (PWHTs) is assessed. The critical part of the HAZ is shown to be the transition region where partial dissolution of the initially present precipitates occurs. In this transition zone, precipitate coarsening is shown to occur for the T6 and T7 initial states, contrarily to the T4 material. After PWHT, the T6 and T7 materials experience a weak region related to this coarsening behavior, whereas the T4 material HAZ is able to recover a homogeneous microstructure after a suitably chosen PWHT. Simple model ramp heat treatments are shown to describe the main phenomena involved in the HAZ. Finally, a precipitation hardening model is successfully applied to the microstructural data to describe the hardness profiles in the various HAZs.

  11. Weldability and toughness evaluation of pressure vessel quality steel using the shielded metal arc welding (SMAW) process

    NASA Astrophysics Data System (ADS)

    Datta, R.; Mukerjee, D.; Mishra, S.

    1998-12-01

    The present study was carried out to assess the weldability properties of ASTM A 537 Cl. 1 pressure-vessel quality steel using the shielded metal arc welding (SMAW) process. Implant and elastic restraint cracking (ERC) tests were conducted under different welding conditions to determine the cold cracking susceptibility of the steel. The static fatigue limit values determined for the implant test indicate adequate resistance to cold cracking even with unbaked electrodes. The ERC test, however, established the necessity to rebake the electrodes before use. Lamellar tearing tests carried out using full-thickness plates under three welding conditions showed no incidence of lamellar tearing upon visual examination, ultrasonic inspection, and four-section macroexamination. Lamellar tearing tests were repeated using machined plates, such that the central segregated band located at the midthickness of the plate corresponded to the heat-affected zone (HAZ) of the weld. Only in one (no rebake, heat input: 14.2 kj cm-1, weld restraint load: 42 kg mm-2) of the eight samples tested was lamellar tearing observed. This was probably accentuated due to the combined effects of the presence of localized pockets of a hard phase (bainite) and a high hydrogen level (unbaked electrodes) in the weld joint. Optimal welding conditions were formulated based on the above tests. The weld joint was subjected to extensive tests and found to exhibit excellent strength (tensile strength: 56.8 kg mm-2, or 557 MPa), and low temperature impact toughness (7.4 and 4.5 kg-m at-20 °C for weld metal, WM, and HAZ) properties. Crack tip opening displacement tests carried out for the WM and HAZ resulted in δm values 0.36 and 0.27 mm, respectively, which indicates adequate resistance to brittle fracture.

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

    ERIC Educational Resources Information Center

    Knapp, John; Harper, Eddie

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

  13. Persistence of deposited metals in the lungs after stainless steel and mild steel welding fume inhalation in rats.

    PubMed

    Antonini, James M; Roberts, Jenny R; Stone, Samuel; Chen, Bean T; Schwegler-Berry, Diane; Chapman, Rebecca; Zeidler-Erdely, Patti C; Andrews, Ronnee N; Frazer, David G

    2011-05-01

    Welding generates complex metal fumes that vary in composition. The objectives of this study were to compare the persistence of deposited metals and the inflammatory potential of stainless and mild steel welding fumes, the two most common fumes used in US industry. Sprague-Dawley rats were exposed to 40 mg/m(3) of stainless or mild steel welding fumes for 3 h/day for 3 days. Controls were exposed to filtered air. Generated fume was collected, and particle size and elemental composition were determined. Bronchoalveolar lavage was done on days 0, 8, 21, and 42 after the last exposure to assess lung injury/inflammation and to recover lung phagocytes. Non-lavaged lung samples were analyzed for total and specific metal content as a measure of metal persistence. Both welding fumes were similar in particle morphology and size. Following was the chemical composition of the fumes-stainless steel: 57% Fe, 20% Cr, 14% Mn, and 9% Ni; mild steel: 83% Fe and 15% Mn. There was no effect of the mild steel fume on lung injury/inflammation at any time point compared to air control. Lung injury and inflammation were significantly elevated at 8 and 21 days after exposure to the stainless steel fume compared to control. Stainless steel fume exposure was associated with greater recovery of welding fume-laden macrophages from the lungs at all time points compared with the mild steel fume. A higher concentration of total metal was observed in the lungs of the stainless steel welding fume at all time points compared with the mild steel fume. The specific metals present in the two fumes were cleared from the lungs at different rates. The potentially more toxic metals (e.g., Mn, Cr) present in the stainless steel fume were cleared from the lungs more quickly than Fe, likely increasing their translocation from the respiratory system to other organs.

  14. Liquid Metal Embrittlement in Resistance Spot Welding and Hot Tensile Tests of Surface-refined TWIP Steels

    NASA Astrophysics Data System (ADS)

    Barthelmie, J.; Schram, A.; Wesling, V.

    2016-03-01

    Automotive industry strives to reduce vehicle weight and therefore fuel consumption and carbon dioxide emissions. Especially in the auto body, material light weight construction is practiced, but the occupant safety must be ensured. These requirements demand high-strength steels with good forming and crash characteristics. Such an approach is the use of high- manganese-content TWIP steels, which achieve strengths of around 1,000 MPa and fracture strains of more than 60%. Welding surface-refined TWIP steels reduces their elongation at break and produces cracks due to the contact with liquid metal and the subsequent liquid metal embrittlement (LME). The results of resistance spot welds of mixed joints of high-manganese- content steel in combination with micro-alloyed ferritic steel and hot tensile tests are presented. The influence of different welding parameters on the sensitivity to liquid metal embrittlement is investigated by means of spot welding. In a high temperature tensile testing machine, the influence of different parameters is determined regardless of the welding process. Defined strains just below or above the yield point, and at 25% of elongation at break, show the correlation between the applied strain and liquid metal crack initiation. Due to the possibility to carry out tensile tests on a wide range of temperatures, dependencies of different temperatures of the zinc coating to the steel can be identified. Furthermore, the attack time of the zinc on the base material is investigated by defined heating periods.

  15. Potential for EMU Fabric Damage by Electron Beam and Molten Metal During Space Welding for the International Space Welding Experiment

    NASA Technical Reports Server (NTRS)

    Fragomeni, James M.

    1998-01-01

    As a consequence of preparations concerning the International Space Welding Experiment (ISWE), studies were performed to better understand the effect of molten metal contact and electron beam impingement with various fabrics for space suit applications. The question arose as to what would occur if the electron beam from the Ukrainian Universal Hand Tool (UHT) designed for welding in space were to impinge upon a piece of Nextel AF-62 ceramic cloth designed to withstand temperatures up to 1427 C. The expectation was that the electron beam would lay down a static charge pattern with no damage to the ceramic fabric. The electron beam is capable of spraying the fabric with enough negative charge to repel further electrons from the fabric before significant heating occurs. The static charge pattern would deflect any further charge accumulation except for a small initial amount of leakage to the grounded surface of the welder. However, when studies were made of the effect of the electron beam on the insulating ceramic fabric it was surprisingly found that the electron beam did indeed burn through the ceramic fabric. It was also found that the shorter electron beam standoff distances had longer burnthrough times than did some greater electron beam standoff distances. A possible explanation for the longer burnthrough times for the small electron beam standoff distance would be outgassing of the fabric which caused the electron beam hand-tool to cycle on and off to provide some protection for the cathodes. The electron beam hand tool was observed to cycle off at the short standoff distance of two inches likely due to vapors being outgassed. During the electron beam welding process there is an electron leakage, or current leakage, flow from the fabric. A static charge pattern is initially laid down by the electron beam current flow. The static charge makes up the current leakage flow which initially slightly heats up the fabric. The initially laid down surface charge leaks a

  16. Weldability of thin sheet metals during small-scale resistance spot welding using an alternating-current power supply

    NASA Astrophysics Data System (ADS)

    Zhou, Y.; Gorman, P.; Tan, W.; Ely, K. J.

    2000-09-01

    The resistance weldability of 0.2-mm-thick sheet aluminum, brass, and copper in small-scale resistance spot welding (SSRSW) was studied. The effects of electrode materials and process parameters on joint strength and nugget size were investigated. The welding current ranges for SSRSW of the sheet metals were determined based on the minimum current that produced a required nugget diameter and maximum currents that did not result in electrode-sheet sticking or weld metal expulsion. A qualitative analysis indicated that resistance weldability of the metals is not only determined by their resistivity (or thermal conductivity) but is also affected by other physical properties (such as melting point, latent heat of fusion and specific heat).

  17. 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.

  18. 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.

  19. Welding for testability: An approach aimed at improving the ultrasonic testing of thick-walled austenitic and dissimilar metal welds

    SciTech Connect

    Wagner, Sabine; Dugan, Sandra; Barth, Martin; Schubert, Frank; Köhler, Bernd

    2014-02-18

    Austenitic and dissimilar welds in thick walled components show a coarse grained, dendritic microstructure. Therefore, ultrasonic testing has to deal with beam refraction, scattering and mode conversion effects. As a result, the testing techniques typically applied for isotropic materials yield dissatisfying results. Most approaches for improvement of ultrasonic testing have been based on modeling and improved knowledge of the complex wave propagation phenomena. In this paper, we discuss an alternative approach: is it possible to use a modified welding technology which eliminates the cause of the UT complications, i.e. the large-grained structure of the weld seams? Various modification parameters were tested, including: TIG current pulsing, additional DC and AC magnetic fields, and also additional external vibrations during welding. For all welds produced under different conditions, the grain structure of the weld seam was characterized by optical and GIUM microstructure visualizations on cross sections, wave field propagation measurements, and ultrasonic tests of correct detectability of flaws. The mechanical properties of the welds were also tested.

  20. 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.…

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

    NASA Astrophysics Data System (ADS)

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

    2009-10-01

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

  2. Evaluation of Molybdenum as a Surrogate for Iridium in the GPHS Weld Development

    SciTech Connect

    Stine, Andrew Martin; Pierce, Stanley W.; Moniz, Paul F.

    2015-10-17

    The welding equipment used for welding iridium containers (clads) at Los Alamos National Laboratory is twenty five years old and is undergoing an upgrade. With the upgrade, there is a requirement for requalification of the welding process, and the opportunity for process improvement. Testing of the new system and requalification will require several welds on iridium test parts and clads, and any efforts to improve the process will add to the need for iridium parts. The extreme high cost of iridium imposes a severe limitation on the extent of test welding that can be done. The 2 inch diameter, 0.027 inch thick, iridium blank disc that the clad cup is formed from, is useful for initial weld trials, but it costs $5000. The development clad sets needed for final tests and requalification cost $15,000 per set. A solution to iridium cost issue would be to do the majority of the weld development on a less expensive surrogate metal with similar weld characteristics. One such metal is molybdenum. Since its melting index (melting temperature x thermal conductivity) is closest to iridium, welds on molybdenum should be similar in size for a given weld power level. Molybdenum is inexpensive; a single 2 inch molybdenum disc costs only $9. In order to evaluate molybdenum as a surrogate for iridium, GTA welds were first developed to provide full penetration on 0.030 inch thick molybdenum discs at speeds of 20, 25, and 30 inches per minute (ipm). These weld parameters were then repeated on the standard 0.027 inch thick iridium blanks. The top surface and bottom surface (root) width and grain structure of the molybdenum and iridium welds were compared, and similarities were evident between the two metals. Due to material and thickness differences, the iridium welds were approximately 35% wider than the molybdenum welds. A reduction in iridium weld current of 35% produce welds slightly smaller than the molybdenum welds yet showed that current could be scaled according to molybdenum

  3. Relation between biomarkers in exhaled breath condensate and internal exposure to metals from gas metal arc welding.

    PubMed

    Hoffmeyer, Frank; Raulf-Heimsoth, Monika; Weiss, Tobias; Lehnert, Martin; Gawrych, Katarzyna; Kendzia, Benjamin; Harth, Volker; Henry, Jana; Pesch, Beate; Brüning, Thomas

    2012-06-01

    Concerning possible harmful components of welding fumes, besides gases and quantitative aspects of the respirable welding fumes, particle-inherent metal toxicity has to be considered.The objective of this study was to investigate the effect markers leukotriene B4 (LTB4),prostaglandin E2 (PGE2) and 8-isoprostane (8-Iso PGF2α) as well as the acid–base balance(pH) in exhaled breath condensate (EBC) of 43 full-time gas metal arc welders (20 smokers) in relation to welding fume exposure. We observed different patterns of iron, chromium and nickel in respirable welding fumes and EBC. Welders with undetectable chromium in EBC(group A, n = 24) presented high iron and nickel concentrations. In this group, higher 8-isoPGF2α and LTB4 concentrations could be revealed compared to welders with detectable chromium and low levels of both iron and nickel in EBC (group B): 8-iso PGF2α443.3 pg mL−1 versus 247.2 pg mL−1; p = 0.001 and LTB4 30.5 pg mL−1 versus 17.3 pgmL−1; p = 0.016. EBC-pH was more acid in samples of group B (6.52 versus 6.82; p = 0.011).Overall, effect markers in welders were associated with iron concentrations in EBC according to smoking habits--non-smokers/smokers: LTB4 (rs = 0.48; p = 0.02/rs = 0.21; p = 0.37),PGE2 (rs = 0.15; p = 0.59/rs = 0.47; p = 0.07), 8-iso PGF2α (rs = 0.18; p = 0.54/rs = 0.59;p = 0.06). Sampling of EBC in occupational research provides a matrix for the simultaneous monitoring of metal exposure and effects on target level. Our results suggest irritative effects in the airways of healthy welders. Further studies are necessary to assess whether these individual results might be used to identify welders at elevated risk for developing a respiratory disease. PMID:22622358

  4. Evolution of weld metals nanostructure and properties under irradiation and recovery annealing of VVER-type reactors

    NASA Astrophysics Data System (ADS)

    Gurovich, B.; Kuleshova, E.; Shtrombakh, Ya.; Fedotova, S.; Zabusov, O.; Prikhodko, K.; Zhurko, D.

    2013-03-01

    The results of VVER-440 steel Sv-10KhMFT and VVER-1000 steel SV-10KhGNMAA investigations by transmission electron microscopy, scanning electron microscopy, Auger-electron spectroscopy and mechanical tests are presented in this paper. The both types of weld metals with different content of impurities and alloying elements were studied after irradiations to fast neutron (E > 0.5 MeV) fluences in the wide range below and beyond the design values, after recovery annealing procedures and after re-irradiation following the annealing. The distinctive features of embrittlement kinetics of VVER-440 and VVER-1000 RPV weld metals conditioned by their chemical composition differences were investigated. It is shown that the main contribution into radiation strengthening within the design fluence can be attributed to radiation-induced precipitates, on reaching the design or beyond design values of fast neutron fluencies the main contribution into VVER-440 welds strengthening is made by radiation-induced dislocation loops, and in case of VVER-1000 welds - radiation-induced precipitates and grain-boundary phosphorous segregations. Recovery annealing of VVER-440 welds at 475 °C during 100 h causes irradiation-induced defects disappearance, transformation of copper enriched precipitates into bigger copper-rich precipitates with lower number density and leads to almost full recovery of mechanical properties followed by comparatively slow re-embrittlement rate. The recovery annealing temperature of VVER-1000 welds was higher - 565 °C during 100 h - to avoid temper brittleness. The annealing of VVER-1000 welds leads to almost full recovery of mechanical properties due to irradiation-induced defects disappearance and decrease in precipitates number density and grain-boundary segregation of phosphorus. The re-embrittlement rate of VVER-1000 weld during subsequent re-irradiation is at least not higher than the initial rate.

  5. Effect of Grain Boundary Character Distribution on the Impact Toughness of 410NiMo Weld Metal

    NASA Astrophysics Data System (ADS)

    Divya, M.; Das, C. R.; Chowdhury, Sandip Ghosh; Albert, S. K.; Bhaduri, A. K.

    2016-07-01

    Grain boundary character distributions in 410NiMo weld metal were studied in the as-welded, first-stage, and second-stage postweld heat treatment (PWHT) conditions, and these were correlated with the Charpy-V impact toughness values of the material. The high impact toughness values in the weld metal in the as-welded and first-stage PWHT conditions compared to that in the second-stage condition are attributed to the higher fraction of low-energy Σ boundaries. A higher volume fraction of retained austenite and coarser martensite after second-stage PWHT accompanied by the formation of the ideal cube component in the 2-hour heat-treated specimen led to a reduction in the toughness value. A subsequent increase in the PWHT duration at 873 K (600 °C) enhanced the formation of {111}<112>, which impedes the adverse effect of the cubic component, resulting in an increase in the impact toughness. In addition to this, grain refinement during 4-hour PWHT in the second stage also increased the toughness of the weld metal.

  6. Review of Dissimilar Metal Welding for the NGNP Helical-Coil Steam Generator

    SciTech Connect

    John N. DuPont

    2010-03-01

    The U.S. Department of Energy (DOE) is currently funding research and development of a new high temperature gas cooled reactor (HTGR) that is capable of providing high temperature process heat for industry. The steam generator of the HTGR will consist of an evaporator economizer section in the lower portion and a finishing superheater section in the upper portion. Alloy 800H is expected to be used for the superheater section, and 2.25Cr 1Mo steel is expected to be used for the evaporator economizer section. Dissimilar metal welds (DMW) will be needed to join these two materials. It is well known that failure of DMWs can occur well below the expected creep life of either base metal and well below the design life of the plant. The failure time depends on a wide range of factors related to service conditions, welding parameters, and alloys involved in the DMW. The overall objective of this report is to review factors associated with premature failure of DMWs operating at elevated temperatures and identify methods for extending the life of the 2.25Cr 1Mo steel to alloy 800H welds required in the new HTGR. Information is provided on a variety of topics pertinent to DMW failures, including microstructural evolution, failure mechanisms, creep rupture properties, aging behavior, remaining life estimation techniques, effect of environment on creep rupture properties, best practices, and research in progress to improve DMW performance. The microstructure of DMWs in the as welded condition consists of a sharp chemical concentration gradient across the fusion line that separates the ferritic and austenitic alloys. Upon cooling from the weld thermal cycle, a band of martensite forms within this concentration gradient due to high hardenability and the relatively rapid cooling rates associated with welding. Upon aging, during post weld heat treatment (PWHT), and/or during high temperature service, C diffuses down the chemical potential gradient from the ferritic 2.25Cr 1Mo steel

  7. Effect of Pin Tool Shape on Metal Flow During Friction Stir Welding

    NASA Technical Reports Server (NTRS)

    McClure, J. C.; Coronado, E.; Aloor, S.; Nowak, B.; Murr, L. M.; Nunes, Arthur C., Jr.; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    It has been shown that metal moves behind the rotating Friction Stir Pin Tool in two separate currents or streams. One current, mostly on the advancing side, enters a zone of material that rotates with the pin tool for one or more revolutions and eventually is abandoned behind the pin tool in crescent-shaped pieces. The other current, largely on the retreating side of the pin tool is moved by a wiping process to the back of the pin tool and fills in between the pieces of the rotational zone that have been shed by the rotational zone. This process was studied by using a faying surface copper trace to clarify the metal flow. Welds were made with pin tools having various thread pitches. Decreasing the thread pitch causes the large scale top-to-bottorn flow to break up into multiple vortices along the pin and an unthreaded pin tool provides insufficient vertical motion for there to be a stable rotational zone and flow of material via the rotational zone is not possible leading to porosity on the advancing side of the weld.

  8. Fusion boundary precipitation in thermally aged dissimilar metal welds studied by atom probe tomography and nanoindentation

    NASA Astrophysics Data System (ADS)

    Choi, Kyoung Joon; Kim, Taeho; Yoo, Seung Chang; Kim, Seunghyun; Lee, Jae Hyuk; Kim, Ji Hyun

    2016-04-01

    In this study, microstructural and mechanical characterizations were performed to investigate the effect of long-term thermal aging on the fusion boundary region between low-alloy steel and Nickel-based weld metal in dissimilar metal welds used in operating power plant systems. The effects of thermal aging treatment on the low-alloy steel side near the fusion boundary were an increase in the ratio of Cr constituents and Cr-rich precipitates and the formation and growth of Cr23C6. Cr concentrations were calculated using atom probe tomography. The accuracy of simulations of thermal aging effects of heat treatment was verified, and the activation energy for Cr diffusion in the fusion boundary region was calculated. The mechanical properties of fusion boundary region changed based on the distribution of Cr-rich precipitates, where the material initially hardened with the formation of Cr-rich precipitates and then softened because of the reduction of residual strain or coarsening of Cr-rich precipitates.

  9. Nuclear Technology. Course 28: Welding Inspection. Module 28-8, Filler Metal Control.

    ERIC Educational Resources Information Center

    Espy, John

    This eighth in a series of ten modules for a course titled Welding Inspection describes controls necessary to place the proper electrode or rod at each welding station. More specifically, the module describes use of the American Welding Society specifications, control of weld filler material after receipt from the supplier, and methods of ensuring…

  10. Mechanical Properties of INCONEL 718 Parts Manufactured by Shaped Metal Deposition (SMD)

    NASA Astrophysics Data System (ADS)

    Baufeld, Bernd

    2012-07-01

    INCONEL 718 parts have been manufactured by shaped metal deposition (SMD), an additive layer manufacturing technique applying wire-based tungsten inert gas welding. This technique is aimed toward mass customization of parts, omitting time- and scrap-intensive, subtractive fabrication routes. SMD results in dense, "near net-shaped" parts without pores, cracks, or fissures. The microstructure of the SMD parts exhibit large, columnar grains with a fine dendritic microstructure. The interdendritic boundaries are decorated by small Laves phase precipitates and by MC carbides. Tensile tests were performed with different strain rates (10-4, 10-3, and 2 × 10-3 1/s), but no dependency on strength or strain at failure was observed. The ultimate tensile strength was 828 ± 8 MPa, the true plastic strain at failure 28 ± 2%, the micro Vickers hardness 266 ± 21 HV200, and the dynamically measured Young's module was 154 ± 1 GPa.

  11. Is metal fume fever a determinant of welding related respiratory symptoms and/or increased bronchial responsiveness? A longitudinal study

    PubMed Central

    El-Zein, M; Infante-Rivard, C; Malo, J; Gautrin, D

    2005-01-01

    Background: The current prospective study investigated the hypothesis of metal fume fever (MFF) being a predictor for the development of respiratory symptoms and functional abnormalities. Methods: The study consisted of a pre-exposure and two follow up assessments of 286 welding apprentices during an average period of 15 months. A respiratory and a systemic symptom questionnaire, skin prick tests to common allergens and metal salts, spirometry, and methacholine challenge tests were administered. Results: Developing at least one positive skin prick test to a metallic salt solution was found in 11.8% of apprentices. Possible MFF (at least one of fever, feelings of flu, general malaise, chills, dry cough, metallic taste, or shortness of breath) was reported by 39.2% of apprentices. The presence of at least one welding related respiratory symptom (cough, wheezing, or chest tightness) suggestive of welding related asthma was reported by 13.8%. MFF was significantly associated with these respiratory symptoms (OR = 4.92, 95% CI 2.10 to 11.52), after adjusting for age, atopy, smoking, physician diagnosed asthma, and symptoms of non-welding related asthma. Apprentices with possible MFF, and no welding related respiratory symptoms suggestive of welding related asthma at the first follow up, had an increased risk of developing the latter symptoms by the second follow up visit (OR = 7.4, 95% CI 1.97 to 27.45) compared with those not having MFF. MFF was not significantly associated with an increase in bronchial responsiveness. Conclusion: MFF could be a predictor for the development of respiratory symptoms but not for functional abnormalities in welders. PMID:16169914

  12. Effect of Previous Agricultural Mechanics Training on Achievement in a Basic Metals and Welding Course at Iowa State University.

    ERIC Educational Resources Information Center

    Yoder, Benjamin Arthur

    The purposes of this study were to determine the effects of previous training in agricultural mechanics upon achievement of students enrolled in a college level agricultural mechanics course and to determine factors that affect performance in this course of basic metals and welding. Students enrolled in the course during the fall and winter…

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

    ERIC Educational Resources Information Center

    Harper, Eddie; Knapp, John

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

  14. Effect of rapid solidification on stainless steel weld metal microstructures and its implications on the Schaeffler diagram

    SciTech Connect

    David, S.A.; Vitek, J.M.; Reed, R.W.; Hebble, T.L.

    1987-09-01

    An investigation was carried out to determine the effect of rapid solidification on the weld metal microstructure of austenitic stainless steels and its implication on the ferrite constitution diagram. A wide variety of stainless steels were laser welded at different welding speeds and laser power levels. Results indicate that both weld pool cooling rate and the postsolidification solid state cooling rates have a profound effect on the microstructures. For the steels investigated, the microstructures ranged from duplex austenite (..gamma..) + ferrite (delta) to fully austenitic or fully ferritic. These microstructures were found to be sensitive to both cooling rates and composition. The observed results are rationalized based on rapid solidification theory. This investigation indicates that solidification rates and postsolidification cooling rates have a profound effect on the observed microstructures, thus making it impossible to predict the microstructures of rapidly cooled weld metal from the conventional constitution diagrams. The influence of the observations made in this investigation on the Schaeffler diagram is demonstrated, and possible corrections to the constitution diagram incorporating the cooling rate effects are proposed. 23 refs., 17 figs., 4 tabs.

  15. 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.

  16. Metallic layered composite materials produced by explosion welding: Structure, properties, and structure of the transition zone

    NASA Astrophysics Data System (ADS)

    Mal'tseva, L. A.; Tyushlyaeva, D. S.; Mal'tseva, T. V.; Pastukhov, M. V.; Lozhkin, N. N.; Inyakin, D. V.; Marshuk, L. A.

    2014-10-01

    The structure, morphology, and microhardness of the transition zone in multilayer metallic composite joints are studied, and the cohesion strength of the plates to be joined, the mechanical properties of the formed composite materials, and fracture surfaces are analyzed. The materials to be joined are plates (0.1-1 mm thick) made of D16 aluminum alloy, high-strength maraging ZI90-VI (03Kh12N9K4M2YuT) steel, BrB2 beryllium bronze, and OT4-1 titanium alloy. Composite materials made of different materials are shown to be produced by explosion welding. The dependence of the interface shape (smooth or wavelike) on the physicomechanical properties of the materials to be joined is found. The formation of a wavelike interface is shown to result in the formation of intense-mixing regions in transition zones. Possible mechanisms of layer adhesion are discussed.

  17. Relationship Between Microstructure, Strength, and Fracture in an Al-Zn-Mg Electron Beam Weld: Part I: Microstructure Characterization

    NASA Astrophysics Data System (ADS)

    Puydt, Quentin; Flouriot, Sylvain; Ringeval, Sylvain; De Geuser, Frédéric; Parry, Guillaume; Deschamps, Alexis

    2014-12-01

    This work presents a detailed, multiscale, spatially resolved study of the microstructure of an electron beam butt weld of the EN-AW 7020 (Al-Zn-Mg) alloy. Using a combination of optical, scanning and transmission electron microscopy, differential scanning calorimetry, and small-angle X-ray scattering, the distribution of phases in the different areas of the heat-affected zone and of the fusion zone is quantitatively characterized, for two different aging states: naturally aged after welding and artificially aged at 423 K (150 °C). The heat-affected zone consists of regions experiencing different levels of precipitate dissolution and coarsening during welding as well as new precipitation during post-welding heat treatment (PWHT). The microstructure of the fusion zone is typical from a fast solidification process, with a strong solute segregation in the interdendritic zones. The precipitate distribution after PWHT follows this solute distribution, and the resulting hardness is much lower than the relatively homogeneous value in the base metal and the heat-affected zone.

  18. Novel concepts in weld metal science: Role of gradients and composite structure. Annual technical progress report, January 1, 1991--December 31, 1991

    SciTech Connect

    Matlock, D.K.; Olson, D.L.

    1991-12-01

    The effects of compositional and microstructural gradients on weld metal properties are being investigated. Crack propagation is solidified alloy structures is being characterized as to solidification orientation and the profile of the compositional variations. The effects of compositional gradients, are considered based on a thermodynamic analysis, referred to as the Cahn-Hillard analysis, which describes the degree to which a local surface energy is modified by the presence of a compositional gradient. The analysis predicts that both ductile and brittle fracture mechanisms are enhanced by the presence of a composition gradient. Special techniques to produce laboratory samples with microstructures which simulate the composition and microstructure gradients in solidified weld metal are used, along with appropriate mathematical models, to evaluate the properties of the composite weld metals. The composite modeling techniques are being applied to describe the effects of compositional and microstructural gradients on weld metal properties in Ni-Cu alloys. The development of metal matrix composition weld deposits on austenitic stainless steels has been studied. The particulate metal matrix composites were produced with ceramic or refractory metal powder filled cored wire, which was gas tungsten arc and gas metal arc welded.

  19. Behavior of Ti-5Al-2.5Sn ELI titanium alloy sheet parent and weld metal in the presence of cracks at 20 K

    NASA Technical Reports Server (NTRS)

    Sullivan, T. L.

    1971-01-01

    Through- and surface-cracked specimens of two thicknesses were tested in uniaxial tension. Surface-cracked specimens were generally found to be stronger than through-cracked specimens with the same crack length. Apparent surface-crack fracture toughness calculated using the Anderson modified Irwin equation remained relatively constant for cracks as deep as 90 percent of the sheet thickness. Subcritical growth of surface cracks was investigated. Comparison of chamber and open air welds showed chamber welds to be slightly tougher. Both methods produced welds with toughness that compared favorably with that of the parent metal. Weld efficiencies were above 94 percent.

  20. Shear instability of plastically-deforming metals in high-velocity impact welding

    NASA Astrophysics Data System (ADS)

    Nassiri, Ali; Kinsey, Brad; Chini, Greg

    2016-10-01

    High-speed oblique impact of two metal plates results in the development of an intense shear region at their interface leading to interfacial profile distortion and interatomic bonding. If the relative velocity is sufficient, a distinct wavy morphology with a well-defined amplitude and wavelength is observed. Emergence of this morphology below the melting point of the metal plates is usually taken as evidence of a successful weld. Amongvarious proposed mechanisms, instability owing to large tangential velocity variations near the interface has received significant attention. With one exception, the few quantitative stability analyses of this proposed mechanism have treated an anti-symmetric/shear-layer base profile (i.e., a Kelvin-Helmholtz configuration) and employed an inviscid or Newtonian viscous fluid constitutive relation. The former stipulation implies the energy source for the instability is the presumed relative shearing motion of the two plates, while the latter is appropriate only if melting occurs locally near the interface. In this study, these restrictions, which are at odds with the conditions realized in high-velocity impact welding, are relaxed. A quantitative temporal linear stability analysis is performed to investigate whether the interfacial wave morphology could be the signature of a shear-driven high strain-rate instability of a perfectly plastic material undergoing a jet-like deformation near the interface. The resulting partial differential eigenvalue problem is solved numerically using a spectral collocation method in which customized boundary conditions near the interface are implemented to properly treat the singularity arising from the vanishing of the base flow strain-rate at the symmetry plane of the jet. The solution of the eigenvalue problem yields the wavelength and growth rate of the dominant wave-like disturbances along the interface and confirms that a shear instability of a plastically-deforming material is compatible with the

  1. Evaluation of Manual Ultrasonic Examinations Applied to Detect Flaws in Primary System Dissimilar Metal Welds at North Anna Power Station

    SciTech Connect

    Anderson, Michael T.; Diaz, Aaron A.; Doctor, Steven R.

    2012-06-01

    During a recent inservice inspection (ISI) of a dissimilar metal weld (DMW) in an inlet (hot leg) steam generator nozzle at North Anna Power Station Unit 1, several axially oriented flaws went undetected by the licensee's manual ultrasonic testing (UT) technique. The flaws were subsequently detected as a result of outside diameter (OD) surface machining in preparation for a full structural weld overlay. The machining operation uncovered the existence of two through-wall flaws, based on the observance of primary water leaking from the DMW. Further ultrasonic tests were then performed, and a total of five axially oriented flaws, classified as primary water stress corrosion cracking (PWSCC), were detected in varied locations around the weld circumference.

  2. Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive.

    PubMed

    Topham, Nathan; Wang, Jun; Kalivoda, Mark; Huang, Joyce; Yu, Kuei-Min; Hsu, Yu-Mei; Wu, Chang-Yu; Oh, Sewon; Cho, Kuk; Paulson, Kathleen

    2012-03-01

    Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 μg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium. PMID:22104317

  3. Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive.

    PubMed

    Topham, Nathan; Wang, Jun; Kalivoda, Mark; Huang, Joyce; Yu, Kuei-Min; Hsu, Yu-Mei; Wu, Chang-Yu; Oh, Sewon; Cho, Kuk; Paulson, Kathleen

    2012-03-01

    Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 μg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium.

  4. Study of austenitic stainless steel welded with low alloy steel filler metal. [tensile and impact strength tests

    NASA Technical Reports Server (NTRS)

    Burns, F. A.; Dyke, R. A., Jr.

    1979-01-01

    The tensile and impact strength properties of 316L stainless steel plate welded with low alloy steel filler metal were determined. Tests were conducted at room temperature and -100 F on standard test specimens machined from as-welded panels of various chemical compositions. No significant differences were found as the result of variations in percentage chemical composition on the impact and tensile test results. The weldments containing lower chromium and nickel as the result of dilution of parent metal from the use of the low alloy steel filler metal corroded more severely in a marine environment. The use of a protective finish, i.e., a nitrile-based paint containing aluminum powder, prevented the corrosive attack.

  5. Occupational exposure to dioxins by thermal oxygen cutting, welding, and soldering of metals.

    PubMed

    Menzel, H M; Bolm-Audorff, U; Turcer, E; Bienfait, H G; Albracht, G; Walter, D; Emmel, C; Knecht, U; Päpke, O

    1998-04-01

    This paper focuses on one aspect of occupational dioxin exposure that is novel and unexpected. Exposures in excess of the German threshold limit value of 50 pg international toxicity equivalent (I-TEQ)/m3 are very frequent, unpredictable, and sometimes very high--up to 6612 pg I-TEQ/m3--during thermal oxygen cutting at scrap metal and demolition sites. The same procedure involving virgin steel in steel trade and mass production of steel objects gave no such evidence, even though no final conclusions can be drawn because of the low number of samples analyzed. Low dioxin exposures during inert gas electric arc welding confirm previous literature findings, whereas soldering and thermal oxygen cutting in the presence of polyvinyl chloride give rise to concern. The consequences of occupational dioxin exposure were studied by analysis of the dioxin-blood concentration, the body burden, of men performing thermal oxygen cutting at scrap metal reclamation and demolition sites, in steel trade and producing plants as well as for industrial welders and white-collar workers. The results concerning body burdens are in excellent agreement with the dioxin exposure as characterized by dioxin air concentration in the workplace. The significant positive correlation between duration and frequency of performing thermal oxygen cutting at metal reclamation and demolition sites expressed in job-years and dioxin body burden speaks for the occupational origin of the observed overload after long times. The results reported here lead to consequences for occupational health, which are discussed and require immediate attention.

  6. Inert-gas welding and brazing enclosure fabricated from sheet plastic

    NASA Technical Reports Server (NTRS)

    Wisner, J. P.

    1965-01-01

    Custom-fabricated plastic bag maintains an inert-gas atmosphere for welding and brazing certain metals. The bag fits over part of the workpieces and the welding and brazing tools. It is also used for metal brazing and fusion plating which require an inert-gas atmosphere.

  7. Improvement of localised corrosion resistance of AISI 2205 Duplex Stainless Steel joints made by gas metal arc welding under electromagnetic interaction of low intensity

    NASA Astrophysics Data System (ADS)

    García-Rentería, M. A.; López-Morelos, V. H.; García-Hernández, R.; Dzib-Pérez, L.; García-Ochoa, E. M.; González-Sánchez, J.

    2014-12-01

    The resistance to localised corrosion of AISI 2205 duplex stainless steel plates joined by Gas Metal Arc Welding (GMAW) under the effect of electromagnetic interaction of low intensity (EMILI) was evaluated with sensitive electrochemical methods. Welds were made using two shielding gas mixtures: 98% Ar + 2% O2 (M1) and 97% Ar + 3% N2 (M2). Plates were welded under EMILI using the M1 gas with constant welding parameters. The modified microstructural evolution in the high temperature heat affected zone and at the fusion zone induced by application of EMILI during welding is associated with the increase of resistance to localised corrosion of the welded joints. Joints made by GMAW using the shielding gas M2 without the application of magnetic field presented high resistance to general corrosion but high susceptibility to undergo localised attack.

  8. Joining of parts via magnetic heating of metal aluminum powders

    DOEpatents

    Baker, Ian

    2013-05-21

    A method of joining at least two parts includes steps of dispersing a joining material comprising a multi-phase magnetic metal-aluminum powder at an interface between the at least two parts to be joined and applying an alternating magnetic field (AMF). The AMF has a magnetic field strength and frequency suitable for inducing magnetic hysteresis losses in the metal-aluminum powder and is applied for a period that raises temperature of the metal-aluminum powder to an exothermic transformation temperature. At the exothermic transformation temperature, the metal-aluminum powder melts and resolidifies as a metal aluminide solid having a non-magnetic configuration.

  9. 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.

  10. Effects of annealing time on the recovery of Charpy V-notch properties of irradiated high-copper weld metal

    SciTech Connect

    Iskander, S.K.; Sokolov, M.A.; Nanstad, R.K.

    1994-12-31

    One of the options to mitigate the effects of irradiation on reactor pressure vessels is to thermally anneal them to restore the toughness properties that have been degraded by neutron irradiation. An important issue to be resolved is the effect on the toughness properties of reirradiating a vessel that has been annealed. This paper describes the annealing response of irradiated high-copper submerged-arc weld HSSI 73W. For this study, the weld has been annealed at 454 C (850 F) for lengths of time varying between 1 and 14 days. The Charpy V-notch 41-J (30-ft-lb) transition temperature (TT{sub 41J}) almost fully recovered for the longest period studied, but recovered to a lesser degree for the shorter periods. No significant recovery of the TT{sub 41J} was observed for a 7-day anneal at 343 C (650 F). At 454 C for the durations studied, the values of the upper-shelf impact energy of irradiated and annealed weld metal exceeded the values in the unirradiated condition. Similar behavior was observed after aging the unirradiated weld metal at 460 and 490 C for 1 week.

  11. An Overview of Preformed Metal Crowns. Part 1: Conventional Technique.

    PubMed

    Rogers, Helen J; Batley, Haris A; Deery, Chris

    2015-12-01

    This article details the clinical techniques for conventional preformed metal crown placement. It aims to increase the readers' awareness of the clinical advantages of preformed metal crowns and the indications for their use. The second part will discuss the Hall Technique. CPD/Clinical Relevance: This two-part article aims to guide the reader through the conventional and alternative techniques available for placement of a preformed metal crown whilst providing an update of the evidence for each. PMID:26855999

  12. Effects of aging temperature on microstructural evolution at dissimilar metal weld interfaces

    NASA Astrophysics Data System (ADS)

    Choi, Kyoung Joon; Yoo, Seung Chang; Kim, Taeho; Bahn, Chi Bum; Kim, Ji Hyun

    2015-07-01

    From the earlier study which characterized the region of a fusion boundary between a low-alloy steel (LAS) and a Ni-based weld metal of as-welded and aged samples at 450 °C for a 30-y-equivalent time, it was observed in the microstructure that the aging treatment induced the formation and growth of Cr precipitates in the fusion boundary region because of the thermodynamic driving force. Now, this research extends the text matrix and continues the previous study by compiling all the test data, with an additional aging heat treatment conducted at 400 °C for 15- and 30-y-equivalent times (6450 and 12,911 h, respectively). The results for the extended test matrix primarily represent the common features of and disparities in the effects of thermal aging on the aged samples at two different heat-treatment temperatures (400 and 450 °C). Although no difference was expected between the samples, because the heat treatment conditions simulate thermal aging effects during the same service time of 30 y, the sample aged at 450 °C exhibited slightly more severe effects of thermal aging than the sample aged at 400 °C. Nevertheless, the trends for these effects are similar and the simulation of thermal aging effects for a light-water reactor appears to be reliable. However, according to a simulation of the same degree of thermal aging effects, it appears that the activation energy for Cr diffusion should be larger than the numerical value used in this study.

  13. Evaluation of Closed Stress Corrosion Cracks in Ni-Based Alloy Weld Metal Using Subharmonic Phased Array

    NASA Astrophysics Data System (ADS)

    Horinouchi, Satoshi; Ikeuchi, Masako; Shintaku, Yohei; Ohara, Yoshikazu; Yamanaka, Kazushi

    2012-07-01

    Closed stress corrosion cracks (SCCs) have been generated in Ni-based alloy weld metal in nuclear power plants. The ultrasonic inspection is difficult because of the crack closure. For the application of new inspection methods and training/educating of inspection engineers, realistic closed SCC specimens are required. However, there is no means for forming such SCC specimens in a reasonable amount of time. Here, we present a two-step method. The first step is to form an open SCC in chemical solution. The second step is to close the SCC by generating oxide films between the crack faces in high-temperature pressurized water (HTPW). To verify the crack closure, we used a closed-crack imaging apparatus, the subharmonic phased array for crack evaluation (SPACE). Consequently, we found that parts of the SCC after 1321 h immersion were closed in the HTPW. Thus, we verified the two-step method for forming realistic closed SCC specimens in a reasonable amount of time.

  14. 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.

  15. Method of forming and assembly of metal and ceramic parts

    DOEpatents

    Ripley, Edward B

    2014-04-22

    A method of forming and assembling at least two parts together that may be metal, ceramic, or a combination of metal and ceramic parts. Such parts may have different CTE. Individual parts that are formed and sintered from particles leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.

  16. 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.

  17. 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.

  18. Occupational exposure to dioxins by thermal oxygen cutting, welding, and soldering of metals.

    PubMed Central

    Menzel, H M; Bolm-Audorff, U; Turcer, E; Bienfait, H G; Albracht, G; Walter, D; Emmel, C; Knecht, U; Päpke, O

    1998-01-01

    This paper focuses on one aspect of occupational dioxin exposure that is novel and unexpected. Exposures in excess of the German threshold limit value of 50 pg international toxicity equivalent (I-TEQ)/m3 are very frequent, unpredictable, and sometimes very high--up to 6612 pg I-TEQ/m3--during thermal oxygen cutting at scrap metal and demolition sites. The same procedure involving virgin steel in steel trade and mass production of steel objects gave no such evidence, even though no final conclusions can be drawn because of the low number of samples analyzed. Low dioxin exposures during inert gas electric arc welding confirm previous literature findings, whereas soldering and thermal oxygen cutting in the presence of polyvinyl chloride give rise to concern. The consequences of occupational dioxin exposure were studied by analysis of the dioxin-blood concentration, the body burden, of men performing thermal oxygen cutting at scrap metal reclamation and demolition sites, in steel trade and producing plants as well as for industrial welders and white-collar workers. The results concerning body burdens are in excellent agreement with the dioxin exposure as characterized by dioxin air concentration in the workplace. The significant positive correlation between duration and frequency of performing thermal oxygen cutting at metal reclamation and demolition sites expressed in job-years and dioxin body burden speaks for the occupational origin of the observed overload after long times. The results reported here lead to consequences for occupational health, which are discussed and require immediate attention. Images Figure 1 PMID:9599722

  19. Assessment of weld quality of aerospace grade metals by using ultrasonic matrix phased array technology

    NASA Astrophysics Data System (ADS)

    Na, Jeong K.; Gleeson, Sean T.

    2014-03-01

    Advantages of two dimensional electronic ultrasonic beam focusing, steering and scanning with the matrix phased array (MPA) technology has been used to visualize the conditions of resistance spot welds in auto vehicle grade advanced high strength steel carbon steels nondestructively. Two of the commonly used joining techniques, resistance spot welding and resistance seam welding, for thin aerospace grade plates made of aluminum, titanium, and stainless steels have also been inspected with the same MPA NDE system. In this study, a detailed discussions of the current MPA based ultrasonic real time imaging methodology has been made followed by some of the NDT results obtained with various welded test coupons.

  20. Microstructural analysis of a single pass 2.25% Cr-1.0% Mo steel weld metal with different manganese contents

    SciTech Connect

    Guimares de Souza, Luis Felipe; Souza Bott, Ivani de; Ferreira Jorge, Jorge Carlos; Sauer Guimaraes, Ari; Pinheiro Rocha Paranhos, Ronaldo . E-mail: paranhos@uenf.br

    2005-07-15

    Weld metals of the 2.25% Cr-1.0% Mo type with 0.84%, 1.21% and 2.3% Mn produced by submerged-arc welding were analyzed in the as-welded (AW), post weld heat treatment (PWHT) and PWHT followed by step-cooling (SC) heat treatment conditions. Fracture surface analysis revealed an evolution in the mode of fracture due to Mn content variations and heat treatment conditions, the occurrence of intergranular fracture being observed in welds with 2.30% Mn that were step-cooled. Transmission electron microscopy revealed that the microstructure was predominantly composed of bainite, although martensite was also observed for high Mn contents. A marked carbide precipitation was observed, preferentially at grain boundaries. This could be attributed to the SC heat treatment and associated with the embrittlement. However, the application of a de-embrittlement heat treatment to this step cooled weld metal has proved efficient, because the impact energy levels after this heat treatment surpassed those obtained in the stress relieved condition. This indicates that segregation of impurities to grain boundaries was responsible for the low impact energy levels observed after SC of weld metal containing > 0.84% Mn.

  1. 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.

  2. 19 CFR 19.22 - Withdrawal of metal refined in part from imported crude metal and in part from crude metal...

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... CUSTOMS WAREHOUSES, CONTAINER STATIONS AND CONTROL OF MERCHANDISE THEREIN Smelting and Refining Warehouses... in refining, or smelting and refining, part of which metal was obtained from imported crude metal and part from crude metal produced by smelting imported materials, the warehouse account shall be...

  3. 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.

  4. Weldability of thin sheet metals by small-scale resistance spot welding using high-frequency inverter and capacitor-discharge power supplies

    NASA Astrophysics Data System (ADS)

    Zhou, Y.; Dong, S. J.; Ely, K. J.

    2001-08-01

    An investigation has been conducted of the weldability of 0.2-mm-thick sheet aluminum, brass, and copper in small-scale resistance spot welding using a high-frequency inverter and a capacitor-discharge power supply. The results have been compared to those of previous investigations using a line-frequency alternating current power supply. The effects of electrode materials and process parameters on joint strength, nugget diameter, weld-metal expulsion and electrode-sheet sticking were studied. This work has also provided practical guidelines for selection of power supplies, process parameters (welding current/pulse energy, welding time/pulse width, electrode forces, etc.) and electrode materials for small-scale resistance spot welding of thin sheet aluminum, brass and copper.

  5. Weldability aspects in the design and fabrication of aluminium structures subjected to fatigue loads. Part 1: Effect of welding on the structural integrity of joint types designed for repairing aluminium ship sections

    NASA Astrophysics Data System (ADS)

    Nevasmaa, P.; Peltonen, J.; Kuitunen, R.; Rahka, K.

    1993-05-01

    The Laboratory of Production Engineering and the Metals Laboratory of the Technical Research Center of Finland (VTT) have participated in a Nordic research project entitled 'New methods for joining of aluminium'. The results from Finnish work of the project will be presented in a report to be published in two parts. Part 1 of the report will evaluate the effects of welding on the structural integrity of some joint types primarily designed for repairing ship sections and sea crafts made from 6xxx (AlSiMg) series alloys.

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

    SciTech Connect

    Ghosh, D.

    1995-02-01

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

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

    NASA Astrophysics Data System (ADS)

    Yan, Qi

    2008-03-01

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

  8. Explosive force of primacord grid forms large sheet metal parts

    NASA Technical Reports Server (NTRS)

    1966-01-01

    Primacord which is woven through fish netting in a grid pattern is used for explosive forming of large sheet metal parts. The explosive force generated by the primacord detonation is uniformly distributed over the entire surface of the sheet metal workpiece.

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

    NASA Technical Reports Server (NTRS)

    Hordon, M. J.

    1970-01-01

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

  10. Fabrication and characterization of metal-packaged fiber Bragg grating sensor by one-step ultrasonic welding

    NASA Astrophysics Data System (ADS)

    Zhang, Yumin; Zhu, Lianqing; Luo, Fei; Dong, Mingli; Ding, Xiangdong; He, Wei

    2016-06-01

    A metallic packaging technique of fiber Bragg grating (FBG) sensors is developed for measurement of strain and temperature, and it can be simply achieved via one-step ultrasonic welding. The average strain transfer rate of the metal-packaged sensor is theoretically evaluated by a proposed model aiming at surface-bonded metallic packaging FBG. According to analytical results, the metallic packaging shows higher average strain transfer rate compared with traditional adhesive packaging under the same packaging conditions. Strain tests are performed on an elaborate uniform strength beam for both tensile and compressive strains; strain sensitivities of approximately 1.16 and 1.30 pm/μɛ are obtained for the tensile and compressive situations, respectively. Temperature rising and cooling tests are also executed from 50°C to 200°C, and the sensitivity of temperature is 36.59 pm/°C. All the measurements of strain and temperature exhibit good linearity and stability. These results demonstrate that the metal-packaged sensors can be successfully fabricated by one-step welding technique and provide great promise for long-term and high-precision structural health monitoring.

  11. Investigation of microstructure within metal welds by energy resolved neutron imaging

    NASA Astrophysics Data System (ADS)

    Tremsin, A. S.; Kockelmann, W.; Paradowska, A. M.; Zhang, Shu-Yan; Korsunsky, A. M.; Shinohara, T.; Feller, W. B.; Lehmann, E. H.

    2016-09-01

    The recent development of bright pulsed neutron sources and high resolution neutron counting detectors enables simultaneous acquisition of a neutron transmission spectrum for each pixel of the image. These spectra can be used to reconstruct microstructure parameters within welds, such as strain, texture and phase composition through Bragg edge analysis, and in some cases elemental composition through resonance absorption analysis. In this paper we demonstrate the potential of energy-resolved neutron imaging to study the microstructures of two steel welds, where the spatial distribution of residual strain within the welds, as well as some information on the texture, are obtained with sub-mm spatial resolution. A friction stir weld of two steel plates and a conventional weld of two steel pipes were studied at pulsed neutron facilities, where a Δλ/λ resolution as low as 0.2% can be attained over a wide range of neutron wavelengths ranging from 0.5 Å to 8 Å.

  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. Development of Weld Inspection of the Ares I Crew Launch Vehicle Upper Stage

    NASA Technical Reports Server (NTRS)

    Russell, Sam; Ezell, David

    2010-01-01

    NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. The metal microstructure and possible defects are different from other weld processes. Friction plug welds will be used to close out the hole remaining in the radial welds when friction stir welded. This plug welding also has unique challenges in inspection. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

  14. Weldability aspects in the design and fabrication of aluminium structures subjected to fatigue loads. Part 2: Weldability of aluminium alloys using advanced MIG and TIG techniques. Effect of the weld bead geometrical factors on the fatigue behavior of the welded joint

    NASA Astrophysics Data System (ADS)

    Nevasmaa, Pekka; Peltonen, Jorma; Kuitunen, Risto; Rahka, Klaus

    1993-05-01

    The project explored experimentally the weldability of high-strength aluminum alloys and suitable welding techniques. Part 2 of the report will examine welding procedures suitable for high-strength 5xxx (AlMg) and 6xxx (AlSiMg) series aluminum alloys using advanced MIG and TIG techniques and evaluate the weldability of these alloys, as well as the importance of the shape of the weld bead for fatigue strength of the welded joint.

  15. 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.

  16. Ultrasonic spot welding of dissimilar materials: characterization of welded joints and parametric optimization

    NASA Astrophysics Data System (ADS)

    Satpathy, M. P.; Sahoo, S. K.

    2016-02-01

    Material joining is one of the key manufacturing processes used to assemble metallic and non-metallic parts for several applications. But the industries are facing many difficulties in joining of thin sheets of dissimilar metals by the conventional welding process because of their differences in chemical composition, physical and mechanical properties. Thus, ultrasonic welding is a solid state joining process used for joining of small elements in microelectronics industries. In this process, acoustic horn and booster are the important assets. The accuracy and strength of the welding depend mainly on their geometry. This proposed work deals with the design and modelling of an acoustic stepped sonotrode with booster using finite element analysis (FEA). From this analysis, the actual length of the horn is obtained by gradually decreasing its theoretical length. The quality of the weld is reckoned by its weld strength and the combinations of different process parameters. These are examined using the principal components coupled with grey relational analysis approach which is showing good agreement between the predicted values with experimental results. Fractographic examination of weld zone and hardness are also used to explore the weld quality.

  17. Method of forming and assembly of metal parts and ceramic parts

    DOEpatents

    Ripley, Edward B.

    2011-11-22

    A method of forming and assembling at least two parts together that may be metal, ceramic, or a combination of metal and ceramic parts. Such parts may have different CTE. Individual parts that are formed and sintered from particles leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.

  18. Effects of Thermal Aging on Material Properties, Stress Corrosion Cracking, and Fracture Toughness of AISI 316L Weld Metal

    NASA Astrophysics Data System (ADS)

    Lucas, Timothy; Forsström, Antti; Saukkonen, Tapio; Ballinger, Ronald; Hänninen, Hannu

    2016-08-01

    Thermal aging and consequent embrittlement of materials are ongoing issues in cast stainless steels, as well as duplex, and high-Cr ferritic stainless steels. Spinodal decomposition is largely responsible for the well-known "748 K (475 °C) embrittlement" that results in drastic reductions in ductility and toughness in these materials. This process is also operative in welds of either cast or wrought stainless steels where δ-ferrite is present. While the embrittlement can occur after several hundred hours of aging at 748 K (475 °C), the process is also operative at lower temperatures, at the 561 K (288 °C) operating temperature of a boiling water reactor (BWR), for example, where ductility reductions have been observed after several tens of thousands of hours of exposure. An experimental program was carried out in order to understand how spinodal decomposition may affect changes in material properties in Type 316L BWR piping weld metals. The study included material characterization, nanoindentation hardness, double-loop electrochemical potentiokinetic reactivation (DL-EPR), Charpy-V, tensile, SCC crack growth, and in situ fracture toughness testing as a function of δ-ferrite content, aging time, and temperature. SCC crack growth rates of Type 316L stainless steel weld metal under simulated BWR conditions showed an approximate 2 times increase in crack growth rate over that of the unaged as-welded material. In situ fracture toughness measurements indicate that environmental exposure can result in a reduction of toughness by up to 40 pct over the corresponding at-temperature air-tested values. Material characterization results suggest that spinodal decomposition is responsible for the degradation of material properties measured in air, and that degradation of the in situ properties may be a result of hydrogen absorbed during exposure to the high-temperature water environment.

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

    NASA Astrophysics Data System (ADS)

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

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

  20. 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.

  1. 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,…

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

    SciTech Connect

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

    2012-11-15

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

  3. 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.

  4. 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.

  5. Waste minimization assessment for a manufacturer of iron castings and fabricated sheet metal parts

    SciTech Connect

    Fleischman, M.; Harris, J.J.; Handmaker, A.; Looby, G.P.

    1995-08-01

    The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. Waste Minimization Assessment Centers (WMACs) were established at selected universities and procedures were adapted from the EPA Waste Minimization Opportunity Assessment Manual. That document has been superseded by the Facility Pollution Prevention Guide. The WMAC team at the University of Louisville performed an assessment at a plant that manufactures iron castings and fabricated sheet metal parts. Foundry operations include mixing and mold formation, core making, metal pouring, shakeout, finishing, and painting. Cutting, shaping, and welding are the principal metal fabrication operations. The team`s report, detailing findings and recommendations indicated that paint-related wastes are generated in large quantities, and that significant waste reduction and cost savings could be realized by installing a dry powder coating system or by replacing conventional air spray paint guns with high-volume low-pressure spray guns. This research brief was developed by the principal investigators and EPA`s National Risk Management Research Laboratory, Cincinnati, OH, to announce key findings of an ongoing research project that is fully documented in a separate report of the same title available from University City Science Center.

  6. 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.

  7. Finite element based simulation on friction stud welding of metal matrix composites to steel

    NASA Astrophysics Data System (ADS)

    Hynes, N. Rajesh Jesudoss; Tharmaraj, R.; Velu, P. Shenbaga; Kumar, R.

    2016-05-01

    Friction welding is a solid state joining technique used for joining similar and dissimilar materials with high integrity. This new technique is being successfully applied to the aerospace, automobile, and ship building industries, and is attracting more and more research interest. The quality of Friction Stud Welded joints depends on the frictional heat generated at the interface. Hence, thermal analysis on friction stud welding of stainless steel (AISI 304) and aluminium silicon carbide (AlSiC) combination is carried out in the present work. In this study, numerical simulation is carried out using ANSYS software and the temperature profiles are predicted at various increments of time. The developed numerical model is found to be adequate to predict temperature distribution of friction stud weld aluminium silicon carbide/stainless steel joints.

  8. Simultaneous laser cutting and welding of metal foil to edge of a plate

    DOEpatents

    Pernicka, J.C.; Benson, D.K.; Tracy, C.E.

    1996-03-19

    A method is described for welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads. 7 figs.

  9. Simultaneous laser cutting and welding of metal foil to edge of a plate

    DOEpatents

    Pernicka, John C.; Benson, David K.; Tracy, C. Edwin

    1996-01-01

    A method of welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads.

  10. 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.

  11. A study on an efficient prediction of welding deformation for T-joint laser welding of sandwich panel Part II : Proposal of a method to use shell element model

    NASA Astrophysics Data System (ADS)

    Kim, Jae Woong; Jang, Beom Seon; Kang, Sung Wook

    2014-06-01

    I-core sandwich panel that has been used more widely is assembled using high power CO-laser welding. Kim et al. (2013) proposed a circular cone type heat source model for the T-joint laser welding between face plate and core. It can cover the negative defocus which is commonly adopted in T-joint laser welding to provide deeper penetration. In part I, a volumetric heat source model is proposed and it is verified thorough a comparison of melting zone on the cross section with experiment results. The proposed model can be used for heat transfer analysis and thermal elasto-plastic analysis to predict welding deformation that occurs during laser welding. In terms of computational time, since the thermal elasto-plastic analysis using 3D solid elements is quite time consuming, shell element model with multi-layers have been employed instead. However, the conventional layered approach is not appropriate for the application of heat load at T-Joint. This paper, Part II, suggests a new method to arrange different number of layers for face plate and core in order to impose heat load only to the face plate.

  12. 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.

  13. The corrosion behavior of Alloy 52 weld metal in cyclic hydrogenated and oxygenated water chemistry in high temperature aqueous environment

    NASA Astrophysics Data System (ADS)

    Xu, Jian; Shoji, Tetsuo

    2015-06-01

    The corrosion behavior of Alloy 52 weld metal in cyclic hydrogenated and oxygenated water chemistry in high temperature water is studied by in situ monitoring corrosion potential (Ecorr), contact electric resistance (CER) and electrochemical impedance measurements (EIS), and ex situ scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) analysis. The Ecorr and film resistance show large change when the environment is changed from hydrogenated water to oxygenated water and changeable with changing environment while the morphology and composition only show obvious distinction in the first cycle. The main factor controlling the electric/electrochemical properties of the oxide film is Ecorr.

  14. Nd:YAG Laser Welding of Sheet Metal Assembly: Transformation Induced Volume Strain Affect on Elastoplastic Model

    NASA Astrophysics Data System (ADS)

    Seang, C.; David, A. K.; Ragneau, E.

    This study presents the effect of transformation induced volume strain on the thermo-elastoplastic model in the simulation of Nd: YAG laser welding process applied for thin sheet metal dual phases steel DP600. The metallurgical phase transformations during heating and during cooling are used as the thermal expansion dependent parameters. The effect of transformation induced volumetric strain was identified where the comparisons of the elastoplastic model with and without metallurgical effect are based on the global distribution of residual stresses such as the longitudinal residual stresses and the transverse residual stresses.

  15. Laser transmission welding of composites - Part B: Experimental validation of numerical model

    NASA Astrophysics Data System (ADS)

    Akué Asséko, André Chateau; Cosson, Benoît; Schmidt, Fabrice; Le Maoult, Yannick; Gilblas, Rémi; Lafranche, Eric

    2015-11-01

    In this paper, experimental measurements are performed to confirm the global analytical model (refraction and absorption phenomena) presented in the previous work. Initially, an experimental approach to the estimation of the laser beam spread in a semi-transparent composite and at interface (width of the output beam) subjected to an incident heat flux, was presented. This parameter represents a fundamental input data for the global analytical model (refraction and absorption) during the numerical simulation of transmission infrared welding. Then, an experimental setup for the temperature measurement is performed using infrared camera, during infrared transmission welding of materials joints to validate the welding simulation results (a transient numerical model, based both on conduction and radiation mode heat transfer) with the developed analytical model. The commercial FEM software COMSOL Multiphysics® is used to compute temperature distribution by implementing a radiative source term. Numerical simulations are compared with experimental data. The agreement between simulations and experiments is fair, which gives confidence to use the developed model with acceptable accuracy.

  16. Laser welding process in PP moulding parts: Evaluation of seam performance

    NASA Astrophysics Data System (ADS)

    Oliveira, N.; Pontes, A. J.

    2015-12-01

    The Polypropylene is one of the most versatile polymer materials used in the industry. Due to this versatility, it is possible to use it in different products. This material can also be mixed with several additives namely glass fiber, carbon nanotubes, etc. This compatibility with different additives allows also obtaining products with characteristics that goes from an impact absorber to an electricity conductor. When is necessary to join components in PP they could be welded through hot plate, ultrasonic weld and also by laser. This study had the objective of study the influence of several variables, capable of influence the final quality of the seam. In this case were studied variables of the injection molding process as mold temperature and cooling time. Was also studied laser welding variables and different materials. The results showed that the variables that have the most influence were mould temperature, laser velocity and laser diameter. The seams were analyzed using Optical Microscopy technique. The seams showed perfect contact between the materials analyzed, despite the high standard variation presented in the mechanical testes.

  17. Characterization of Mg/Al butt joints welded by gas tungsten arc filling with Zn–29.5Al–0.5Ti filler metal

    SciTech Connect

    Liu, Fei; Wang, Hongyang; Liu, Liming

    2014-04-01

    The multivariate alloying design of a welding joint is used in the Mg to Al welding process. A Zn–29.5Al–0.5Ti alloy is added as filler metal in gas tungsten arc welding of Mg and Al alloy joint based on the analysis of Al and Mg alloy characteristics. The tensile strength, microstructure, and phase constitution of the weld seam are analyzed. The formation of brittle and hard Mg–Al intermetallic compounds is avoided because of the effects of Zn, Al, and Ti. The average tensile strength of the joint is 148 MPa. Al{sub 3}Ti is first precipitated and functions as the nucleus of heterogeneous nucleation during solidification. Moreover, the precipitated Al–MgZn{sub 2} hypoeutectic phase exhibited a feather-like structure, which enhances the property of the Mg–Al dissimilar joint. - Highlights: • Mg alloy AZ31B and Al alloy 6061 are butt welded by fusion welding. • The effect of Ti in filler metal is investigated. • The formation of Mg–Al intermetallic compounds is avoided.

  18. Study on laser welding of stainless steel/copper dissimilar materials

    NASA Astrophysics Data System (ADS)

    Besnea, D.; Dontu, O.; Avram, M.; Spânu, A.; Rizescu, C.; Pascu, T.

    2016-08-01

    In this paper stainless steel/copper laser welding was investigated by controlling the processing parameters like welding speed and laser power. Welding the dissimilar materials of stainless steel and copper presents a series of problems. Differences in the physical properties of the two metals, including the melting point, thermal conductivity and thermal dilatation are the main reasons for obtaining an inappropriate laser welding bead. Particularly, the laser welding process of copper is complex because of the very high reflectivity of cooper and in almost situations it requires a specific surface pre-treatment. The main objective of the study conducted in this work was to laser weld a structure used in pressure measuring and control equipments. In order to satisfy the conditions imposed by the sensor manufacturer, the difficulty of obtaining flawless joints was represented by the very small dimensions of the parts to be welded especially of the elastic spiral thickness made of steel.

  19. TRITIUM AGING EFFECTS ON THE FRACTURE TOUGHNESS PROPERTIES OF STAINLESS STEEL BASE METAL AND WELDS

    SciTech Connect

    Morgan, M.

    2009-07-30

    Tritium reservoirs are constructed from welded stainless steel forgings. While these steels are highly resistant to the embrittling effects of hydrogen isotopes and helium from tritium decay; they are not immune. Tritium embrittlement is an enhanced form of hydrogen embrittlement because of the presence of helium-3 from tritium decay which nucleates as nanometer-sized bubbles on dislocations, grain boundaries, and other microstructural defects. Steels with decay helium bubble microstructures are hardened and less able to deform plastically and become more susceptible to embrittlement by hydrogen and its isotopes. Ductility, elongation-to-failure, and fracture toughness are reduced by exposures to tritium and the reductions increase with time as helium-3 builds into the material from tritium permeation and radioactive decay. Material and forging specifications have been developed for optimal material compatibility with tritium. These specifications cover composition, mechanical properties, and select microstructural characteristics like grain size, flow-line orientation, inclusion content, and ferrite distribution. For many years, the forming process of choice for reservoir manufacturing was high-energy-rate forging (HERF), principally because the DOE forging facility owned only HERF hammers. Today, some reservoir forgings are being made that use a conventional, more common process known as press forging (PF or CF). One of the chief differences between the two forging processes is strain rate: Conventional hydraulic or mechanical forging presses deform the metal at 4-8 ft/s, about ten-fold slower than the HERF process. The material specifications continue to provide successful stockpile performance by ensuring that the two forging processes produce similar reservoir microstructures. While long-term life storage tests have demonstrated the general tritium compatibility of tritium reservoirs, fracture-toughness properties of both conventionally forged and high

  20. Closed Loop Welding Controller for Manufacturing Process

    NASA Astrophysics Data System (ADS)

    Bonaccorso, F.; Bruno, C.; Cantelli, L.; Longo, D.; Muscato, G.; Rapisarda, S.

    2011-12-01

    The aim of this paper is to investigate on the closed loop welding controller of a rapid manufacturing Shaped Metal Deposition (SMD) process. SMD was developed and patented by Rolls-Royce in order to produce mechanical parts directly from a CAD model. A simplified SMD plant has been set up in order to investigate the welding dynamics and parameters and to develop a SMD automatic controller. On the basis of the experience acquired, some basic control laws have been developed, and a closed loop controller has been implemented. This controller permits to find and to maintain the process stability condition, so that the final process results totally automatic. The control is performed adjusting the welding conditions on the basis of arc voltage information obtained from the welding machine during the deposition. The experimental results reported confirm the validity of the proposed strategy.

  1. Development of Fiber Laser Weld Parameters for Stainless Steel and Refractory Metals

    SciTech Connect

    Elmer, J; Pong, R

    2009-05-19

    Laser welds were made in 21-6-9 stainless steel, vanadium and tantalum using LLNL's new 6kW fiber laser to target 1 mm penetration depths. The materials were machined into flat coupon samples with standard step-joint geometries, and were welded in a continuous wave mode. The laser was characterized using the Primes laser beam diagnostic system so that the beams can be reproduced in the future. The optical configuration consisted of a 200 {micro}m fiber, 200 mm collimator and 250 mm focusing lens, which delivered electron-beam level power densities in the 5 to 20 kW/mm2 range. The three different materials required different power densities to produce the desired penetration, and this report summarizes the results of this screening study that was directed at developing a first approximation to the proper welding parameters for future work. The results show that 1 mm penetrations can be achieved using a 400W beam for 21-6-9 stainless steel, a 600W beam for vanadium, and a 1,100W beam for tantalum using sharp focus and a travel speed of 40 inch/min. Future welds should incorporate a trailing gas shield to prevent discoloration of the surface and to prevent oxygen and nitrogen pickup in the welds.

  2. Dynamic characteristics and mechanisms of compressible metallic vapor plume behaviors in transient keyhole during deep penetration fiber laser welding

    NASA Astrophysics Data System (ADS)

    Pang, Shengyong; Shao, Xinyu; Li, Wen; Chen, Xin; Gong, Shuili

    2016-07-01

    The compressible metallic vapor plume or plasma plume behaviors in the keyhole during deep penetration laser welding have significant effects on the joint quality. However, these behaviors and their responses to process parameter variations have not been well understood. In this paper, we first systematically study the dynamic characteristics and mechanisms of compressible metallic vapor plume behaviors in transient keyhole during fiber laser welding of 304 stainless steels based on a multiple timescale multiphase model. The time-dependent temperature, pressure, velocity and Mach number distributions of vapor plume under different process parameters are theoretically predicted. It is found that the distributions of the main physical characteristics of vapor plume such as pressure, velocity as well as Mach number in keyhole are usually highly uneven and highly time dependent. The peak difference of the velocity, pressure, temperature and Mach number of the vapor plume in a keyhole could be greater than 200 m/s, 20 kPa, 1000 K and 0.6 Mach, respectively. The vapor plume characteristics in a transient keyhole can experience significant changes within several hundreds of nanoseconds. The formation mechanisms of these dynamic characteristics are mainly due to the mesoscale keyhole hump (sized in several tens of microns) dynamics. It is also demonstrated that it is possible to suppress the oscillations of compressible vapor plume in the keyhole by improving the keyhole stability through decreasing the heat input. However, stabilizing the keyhole could only weaken, but not eliminate, the observed highly uneven and transient characteristics. This finding may pose new challenges for accurate experimental measurements of vapor plume induced by laser welding.

  3. Evaluation of crack arrest fracture toughness of parent plate, weld metal and heat affected zone of BIS 812 EMA ship plate steel

    NASA Astrophysics Data System (ADS)

    Burch, I. A.

    1993-10-01

    The steel chosen for the pressure hull of the Collins class submarine has undergone evaluation to compare the crack arrest fracture toughness, K(Ia), of the parent plate with that of weld metal and heat affected zone. The tests were conducted over a range of subzero temperatures on specimens slightly outside the ASTM standard test method specimen configuration. Shallow face grooved specimens were used to vary the propagating crack velocity from that of non face grooved specimens and determine if K(Ia), is sensitive to changes in crack velocity. The weld metal, heat affected zone (HAZ), and parent plate were assessed to determine if the welding process had a deleterious effect on the crack arrest properties of this particular steel. Tests on each of these regions revealed that, for the combination of parent plate, welding procedure and consumables, no adverse effect on crack arrest properties was encountered. Crack arrest fracture toughness of the weld metal and HAZ was superior to that of the parent plate at comparable temperatures.

  4. Effect of part thickness, glass fiber and crystallinity on light scattering during laser transmission welding of thermoplastics

    NASA Astrophysics Data System (ADS)

    Xu, Xin Feng; Parkinson, Alexander; Bates, Philip J.; Zak, Gene

    2015-12-01

    It is important to understand how laser energy scatters within the transparent component in order to predict and optimize the laser transmission welding process. This paper examines the influence of part thickness, glass fiber and crystallinity levels on the distribution of laser light after transmission through amorphous polycarbonate (PC) and semi-crystalline polymers such as polyamide 6 (PA6), polypropylene (PP), and polyethylene (PE). An experimental technique based on laser-scanned lines of progressively increasing power was used to assess the transmitted energy distribution. This distribution was characterized using a two-parameter model that captures scattered and un-scattered components of the laser beam. The results clearly show how the scattering is increased by increasing the numbers of interactions between laser light and phase boundaries either by increasing the particle concentration (i.e., glass fiber level and crystallinity) or increasing part thickness.

  5. Digital Radiography Qualification of Tube Welding

    NASA Technical Reports Server (NTRS)

    Carl, Chad

    2012-01-01

    The Orion Project will be directing Lockheed Martin to perform orbital arc welding on commodities metallic tubing as part of the Multi Purpose Crew Vehicle assembly and integration process in the Operations and Checkout High bay at Kennedy Space Center. The current method of nondestructive evaluation is utilizing traditional film based x-rays. Due to the high number of welds that are necessary to join the commodities tubing (approx 470), a more efficient and expeditious method of nondestructive evaluation is desired. Digital radiography will be qualified as part of a broader NNWG project scope.

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

    NASA Astrophysics Data System (ADS)

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

    1993-10-01

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

  7. 14 CFR Appendix C to Part 147 - Airframe Curriculum Subjects

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... conventional rivets. (3) 16. Form, lay out, and bend sheet metal. e. welding (1) 17. Weld magnesium and...-weld, and arc-weld steel. (1) 21. Weld aluminum and stainless steel. f. assembly and rigging (1)...

  8. Corrosion behaviour of welds and Ta in liquid lead

    NASA Astrophysics Data System (ADS)

    Heinzel, A.; Müller, G.; Weisenburger, A.

    2016-02-01

    Four specimens, P91 welded by friction stir welding with and without post heat treatment, P91 electromagnetic pulse welded (EMP) and 14Cr ODS (explosive welding) were exposed at 550 °C for up to 2131 h to Pb containing 10-6 wt% oxygen. After the exposure none of the samples showed dissolution attack, all were protected by an oxide layer at the surface. Nearly no effect on the oxidation due to welding was found in both friction stir welded specimens. Severe deformation and partial melting during explosive welding result in a slower oxide layer growth within the welding zone. The EMP sample was tested as delivered without post-heat treatment. No Pb penetrated into the tiny gap between the welded parts. After the test, the gap is filled up with oxides. Additionally, Ta, discussed as a pump impeller material, was exposed to Pb and PbBi at different temperatures (400-900 °C) and oxygen concentrations in liquid metal (saturated, 10-6 wt%, 10-8 wt% and reduced (<<10-8 wt%). Only the Ta specimens exposed to Pb with highly reduced oxygen content showed nearly no attack. All the others exhibited oxide scale formation that becomes severe above 400 °C test temperature.

  9. Friction Stir Welding of Al Alloy 2219-T8: Part I-Evolution of Precipitates and Formation of Abnormal Al2Cu Agglomerates

    NASA Astrophysics Data System (ADS)

    Kang, Ju; Feng, Zhi-Cao; Frankel, G. S.; Huang, I. Wen; Wang, Guo-Qing; Wu, Ai-Ping

    2016-09-01

    Friction stir welding was performed on AA2219-T8 plates with 6.31 wt pct Cu. The thermal cycles were measured in different regions of the joint during welding. Differential scanning calorimetry and transmission electron microscopy were utilized to analyze the evolution of precipitates in the joint. The relationships between welding peak temperature, precipitate evolution, and microhardness distribution are discussed. The temperature in the heat-affected zone (HAZ) ranged from 453 K to 653 K (180 °C to 380 °C). The θ″ and some θ' phases redissolved into the HAZ matrix, while the rest of the θ' phases coarsened. In the thermomechanically affected zone (TMAZ), the temperature range was from 653 K to 673 K (380 °C to 400 °C), causing both θ″ phase and θ' phase to redissolve. In the weld nugget zone (WNZ), all the θ″, θ', and some of the θ phase (Al2Cu) redissolved. Abnormal θ particles were observed in the WNZ, including agglomerated θ with sizes around 100 to 1000 µm and a ring-shaped distribution of normal size θ particles. The formation of abnormal θ particles resulted from metal plastic flow during welding and the high content of Cu in AA2219. No abnormal θ particles were observed in joints of another AA2219 plate, which had a lower Cu content of 5.83 wt pct.

  10. 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.

  11. Investigation of Friction Stir Welding of Al Metal Matrix Composite Materials

    NASA Technical Reports Server (NTRS)

    Diwan, Ravinder M.

    2003-01-01

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

  12. Analysis of a Defected Dissimilar Metal Weld in a PWR Power Plant

    SciTech Connect

    Efsing, P.; Lagerstrom, J.

    2002-07-01

    During the refueling outage 2000, inspections of the RC-loops of one of the Ringhals PWR-units, Ringhals 4, indicated surface breaking defects in the axial direction of the piping in a dissimilar weld between the Low alloy steel nozzle and the stainless safe end in the hot leg. In addition some indications were found that there were embedded defects in the weld material. These defects were judged as being insignificant to the structural integrity. The welds were inspected in 1993 with the result that no significant indications were found. The weld it self is a double U weld, where the thickness of the material is ideally 79,5 mm. Its is constructed by Inconel 182 weld material. At the nozzle a buttering was applied, also by Inconel 182. The In-service inspection, ISI, of the object indicated four axial defects, 9-16 mm deep. During fabrication, the areas where the defects are found were repaired at least three times, onto a maximum depth of 32 mm. To evaluate the defects, 6 boat samples from the four axial defects were cut from the perimeter and shipped to the hot-cell laboratory for further examination. This examination revealed that the two deep defects had been under sized by the ISI outside the requirement set by the inspection tolerances, while the two shallow defects were over sized, but within the tolerances of the detection system. When studying the safety case it became evident that there were several missing elements in the way this problems is handled with respect to the Swedish safety evaluation code. Among these the most notable at the beginning was the absence of reliable fracture mechanical data such as crack growth laws and fracture toughness at elevated temperature. Both these questions were handled by the project. The fracture mechanical evaluation has focused on a fit for service principal. Thus defects both in the unaffected zones and the disturbed zones, boat sample cutouts, of the weld have been analyzed. With reference to the Swedish safety

  13. 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.

  14. An investigation of the dynamic separation of spot welds under plane tensile pulses

    SciTech Connect

    Ma, Bohan; Fan, Chunlei; Chen, Danian Wang, Huanran; Zhou, Fenghua

    2014-08-07

    We performed ultra-high-speed tests for purely opening spot welds using plane tensile pulses. A gun system generated a parallel impact of a projectile plate onto a welded plate. Induced by the interactions of the release waves, the welded plate opened purely under the plane tensile pulses. We used the laser velocity interferometer system for any reflector to measure the velocity histories of the free surfaces of the free part and the spot weld of the welded plate. We then used a scanning electron microscope to investigate the recovered welded plates. We found that the interfacial failure mode was mainly a brittle fracture and the cracks propagated through the spot nugget, while the partial interfacial failure mode was a mixed fracture comprised ductile fracture and brittle fracture. We used the measured velocity histories to evaluate the tension stresses in the free part and the spot weld of the welded plate by applying the characteristic theory. We also discussed the different constitutive behaviors of the metals under plane shock loading and under uniaxial split Hopkinson pressure bar tests. We then compared the numerically simulated velocity histories of the free surfaces of the free part and the spot weld of the welded plate with the measured results. The numerical simulations made use of the fracture stress criteria, and then the computed fracture modes of the tests were compared with the recovered results.

  15. Assessment of Creep Strain Distribution Across Base Metal of 316LN Austenitic Stainless Steel Weld Joint by an EBSD-Based Parameter

    NASA Astrophysics Data System (ADS)

    Vijayanand, V. D.; Ganesan, V.; Ganesh Kumar, J.; Parameswaran, P.; Naveena; Laha, K.

    2015-11-01

    Electron backscatter diffraction (EBSD) analysis has been used to estimate the accumulated strain in base metal region of 316LN austenitic stainless steel weld joints, creep tested at 923 K (650 °C), and at stresses of 175 and 225 MPa. The variation in strength of weld metal, heat-affected zone (HAZ), and base metal-induced stress and strain gradients across the weld joint under creep exposure. Finite element analysis (FEA) of von-Mises stress distribution across the joint has been carried out on incorporating strength of different constituents of the joint, derived by miniature specimen testing techniques. The FEA simulations revealed preferential accumulation of von-Mises stress in the base metal region near to HAZ. The variation in accumulated plastic strain across the base metal has been estimated using a `crystal deformation' ( C d) parameter which quantifies the orientation spread within a grain. This parameter was obtained by EBSD analysis carried out using a scanning electron microscope. The trend in variation of accumulated plastic strain across the base metal accounted well with the von-Mises stress variation, which causes plastic deformation. The plastic strain in the base metal in both the stress levels was found to accumulate preferentially near to the HAZ and reduced steadily toward the ridge at the end of specimen. Transmission electron microscopic study has been carried out to substantiate the findings of the EBSD investigation.

  16. 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.

  17. Thermal cycling distortion of metal ceramics: Part II--Etiology.

    PubMed

    Campbell, S D; Pelletier, L B

    1992-08-01

    The three-dimensional geometry of conventional fixed prostheses complicates the study of the thermal cycling distortion in metal ceramic alloys. Any explanation of the etiology of thermal cycling distortion in metal ceramic restorations must account for the observed magnitude, timing, and direction of the deformation. The simplified experimental geometry developed in Part I was applied to elucidate the etiologic factors involved in metal ceramic deformation. Techniques to minimize the thermal cycling distortion were also studied. It was found that all of the significant distortion occurred during the first thermal cycling of the alloy (oxidation) and that no distortion resulted from the application of body porcelain. The specimens that were cold worked and then oxidized had significantly more distortion than any other group. A significant reduction in distortion was observed when the initial thermal cycling was completed before the specimens were cold worked. It was determined that the release of casting- and cold working-induced stresses had a synergistic effect. PMID:1501176

  18. 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.

  19. 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.

  20. Assessment of occupational exposure to manganese and other metals in welding fumes by portable X-ray fluorescence spectrometer.

    PubMed

    Laohaudomchok, Wisanti; Cavallari, Jennifer M; Fang, Shona C; Lin, Xihong; Herrick, Robert F; Christiani, David C; Weisskopf, Marc G

    2010-08-01

    Elemental analysis of welding fume samples can be done using several laboratory-based techniques. However, portable measurement techniques could offer several advantages. In this study, we sought to determine whether the portable X-ray fluorescence spectrometer (XRF) is suitable for analysis of five metals (manganese, iron, zinc, copper, and chromium) on 37-mm polytetrafluoroethylene filters. Using this filter fitted on a cyclone in line with a personal pump, gravimetric samples were collected from a group of boilermakers exposed to welding fumes. We assessed the assumption of uniform deposition of these metals on the filters, and the relationships between measurement results of each metal obtained from traditional laboratory-based XRF and the portable XRF. For all five metals of interest, repeated measurements with the portable XRF at the same filter area showed good consistency (reliability ratios are equal or close to 1.0 for almost all metals). The portable XRF readings taken from three different areas of each filter were not significantly different (p-values = 0.77 to 0.98). This suggested that the metal rich PM(2.5) deposits uniformly on the samples collected using this gravimetric method. For comparison of the two XRFs, the results from the portable XRF were well correlated and highly predictive of those from the laboratory XRF. The Spearman correlation coefficients were from 0.325 for chromium, to 0.995 for manganese and 0.998 for iron. The mean differences as a percent of the mean laboratory XRF readings were also small (<5%) for manganese, iron, and copper. The differences were greater for zinc and chromium, which were present at very low amounts in our samples and below the limits of detection of the portable XRF for many of the samples. These five metals were moderately to strongly correlated with the total fine particle fraction on filters (Spearman rho = 0.41 for zinc to 0.97 for iron). Such strong correlations and comparable results suggested that

  1. Assessment of occupational exposure to manganese and other metals in welding fumes by portable X-ray fluorescence spectrometer.

    PubMed

    Laohaudomchok, Wisanti; Cavallari, Jennifer M; Fang, Shona C; Lin, Xihong; Herrick, Robert F; Christiani, David C; Weisskopf, Marc G

    2010-08-01

    Elemental analysis of welding fume samples can be done using several laboratory-based techniques. However, portable measurement techniques could offer several advantages. In this study, we sought to determine whether the portable X-ray fluorescence spectrometer (XRF) is suitable for analysis of five metals (manganese, iron, zinc, copper, and chromium) on 37-mm polytetrafluoroethylene filters. Using this filter fitted on a cyclone in line with a personal pump, gravimetric samples were collected from a group of boilermakers exposed to welding fumes. We assessed the assumption of uniform deposition of these metals on the filters, and the relationships between measurement results of each metal obtained from traditional laboratory-based XRF and the portable XRF. For all five metals of interest, repeated measurements with the portable XRF at the same filter area showed good consistency (reliability ratios are equal or close to 1.0 for almost all metals). The portable XRF readings taken from three different areas of each filter were not significantly different (p-values = 0.77 to 0.98). This suggested that the metal rich PM(2.5) deposits uniformly on the samples collected using this gravimetric method. For comparison of the two XRFs, the results from the portable XRF were well correlated and highly predictive of those from the laboratory XRF. The Spearman correlation coefficients were from 0.325 for chromium, to 0.995 for manganese and 0.998 for iron. The mean differences as a percent of the mean laboratory XRF readings were also small (<5%) for manganese, iron, and copper. The differences were greater for zinc and chromium, which were present at very low amounts in our samples and below the limits of detection of the portable XRF for many of the samples. These five metals were moderately to strongly correlated with the total fine particle fraction on filters (Spearman rho = 0.41 for zinc to 0.97 for iron). Such strong correlations and comparable results suggested that

  2. Assessment of Occupational Exposure to Manganese and Other Metals in Welding Fumes by Portable X-ray Fluorescence Spectrometer

    PubMed Central

    Laohaudomchok, Wisanti; Cavallari, Jennifer M.; Fang, Shona C.; Lin, Xihong; Herrick, Robert F.; Christiani, David C.; Weisskopf, Marc G.

    2011-01-01

    Elemental analysis of welding fume samples can be done using several laboratory-based techniques. However, portable measurement techniques could offer several advantages. In this study, we sought to determine whether the portable X-ray fluorescence spectrometer (XRF) is suitable for analysis of five metals (manganese, iron, zinc, copper, and chromium) on 37-mm polytetrafluoroethylene filters. Using this filter fitted on a cyclone in line with a personal pump, gravimetric samples were collected from a group of boilermakers exposed to welding fumes. We assessed the assumption of uniform deposition of these metals on the filters, and the relationships between measurement results of each metal obtained from traditional laboratory-based XRF and the portable XRF. For all five metals of interest, repeated measurements with the portable XRF at the same filter area showed good consistency (reliability ratios are equal or close to 1.0 for almost all metals). The portable XRF readings taken from three different areas of each filter were not significantly different (p-values = 0.77 to 0.98). This suggested that the metal rich PM2.5 deposits uniformly on the samples collected using this gravimetric method. For comparison of the two XRFs, the results from the portable XRF were well correlated and highly predictive of those from the laboratory XRF. The Spearman correlation coefficients were from 0.325 for chromium, to 0.995 for manganese and 0.998 for iron. The mean differences as a percent of the mean laboratory XRF readings were also small (<5%) for manganese, iron, and copper. The differences were greater for zinc and chromium, which were present at very low amounts in our samples and below the limits of detection of the portable XRF for many of the samples. These five metals were moderately to strongly correlated with the total fine particle fraction on filters (Spearman ρ = 0.41 for zinc to 0.97 for iron). Such strong correlations and comparable results suggested that the

  3. 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.

  4. Influence of Frequency and Induction of Longitudinal Magnetic Field on The Electrode Metal Loss and its Spattering During MAG-Welding

    NASA Astrophysics Data System (ADS)

    Nosov, D. G.; Peremitko, V. V.

    2015-09-01

    It is possible to increase the MAG-welding efficiency by controlling the electrode metal mass transfer at the reduction of discharge coefficient on spattering by influence of longitudinal magnetic field on the arc. The paper identifies a range of longitudinal magnetic field frequencies and induction which provide the discharge coefficient reduction of the electrode metal; it has also been found the characteristics of their mutual influence on electrode metal mass transfer process; mathematical models correlating the frequency and induction of longitudinal magnetic field length with loss coefficient of electrode metal on spattering are presented; technological recommendations, the implementation of which will allow to improve the efficiency of MAG-welding in industrial environments, are given.

  5. Micro-Replication: Precision Metal parts from Electronformed Master Molds

    SciTech Connect

    James J. Kelly

    2002-01-01

    The possibility of using through-mask electrodeposition to fill features with active sidewalls was investigated. Both metal (Ni) and conductive substrates were employed; the demolding of electroformed Ni metal parts from metal substrates was difficult despite the use of various lubricants. Because of damage to the electrodeposited parts during the demolding process, conductive plastic substrates appear more feasible than metal substrates. Direct current was capable of filling features with low aspect ratios ({approx}2) with only minor voiding. For higher aspect ratio features ({approx}7), pulsed deposition and direct current with the leveling agent coumarin appeared to be more effective than pulsed reverse deposition. Since the characteristic diffusion time constant varies with the square of the feature depth, chloride ions are necessary to prevent passivation during the long pulse off-times required for uniform feature filling through a thick mask. It is shown that although thick masks require long pulse off-times, the recommended deposition rate for uniform filling (available in the literature) should not depend on the mask thickness (although the total deposition time will).

  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. 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.

  8. 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.

  9. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers.

    PubMed

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-01-01

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2'-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m(3) increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation. PMID:27641436

  10. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers.

    PubMed

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-09-19

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2'-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m(3) increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation.

  11. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers

    PubMed Central

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-01-01

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2’-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m3 increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation. PMID:27641436

  12. Physicochemistry and cardiovascular toxicity of metal fume PM2.5: a study of human coronary artery endothelial cells and welding workers

    NASA Astrophysics Data System (ADS)

    Lai, Chane-Yu; Lai, Ching-Huang; Chuang, Hsiao-Chi; Pan, Chih-Hong; Yen, Cheng-Chieh; Lin, Wen-Yi; Chen, Jen-Kun; Lin, Lian-Yu; Chuang, Kai-Jen

    2016-09-01

    Occupational exposure to welding fumes causes a higher incidence of cardiovascular disease; however, the association remains unclear. To clarify the possible association, exposure assessment of metal fumes with an aerodynamic diameter of <2.5 μm (PM2.5) in welding and office areas was characterized in a shipyard in Taiwan. Cardiovascular toxicity caused by PM2.5 was determined in workers (in both the welding and office areas). Significant amounts of bimodal metal fume particles with count median diameters (CMDs) of 14.1~15.1 and 126.3~135.8 nm were produced in the shipyard. Metal fume PM2.5 resulted in decreased cell viability and increased levels of 8-hydroxy-2’-deoxyguanosine (8-OHdG), interleukin (IL)-6, and nitric oxide (NO) in human coronary artery epithelial cells (HCAECs). We recruited 118 welding workers and 45 office workers for a personal PM2.5 exposure assessment and determination of urinary levels of 8-OHdG, 8-iso-prostaglandin F2α (8-iso-PGF2α), and various metals. We observed that a 10-μg/m3 increase in the mean PM2.5 concentration was associated with a 2.15% increase in 8-OHdG and an 8.43% increase in 8-iso-PGF2α in welding workers. Both 8-OHdG and 8-iso-PGF2α were associated with Fe and Zn in the urine. In conclusion, metal fume PM2.5 could increase the risk of cardiovascular toxicity after inhalation.

  13. The Application of Stress-Relaxation Test to Life Assessment of T911/T22 Weld Metal

    NASA Astrophysics Data System (ADS)

    Cao, Tieshan; Zhao, Jie; Cheng, Congqian; Li, Huifang

    2016-03-01

    A dissimilar weld metal was obtained through submerged arc welding of a T911 steel to a T22 steel, and its creep property was explored by stress-relaxation test assisted by some conventional creep tests. The creep rate information of the stress-relaxation test was compared to the minimum and the average creep rates of the conventional creep test. Log-log graph showed that the creep rate of the stress-relaxation test was in a linear relationship with the minimum creep rate of the conventional creep test. Thus, the creep rate of stress-relaxation test could be used in the Monkman-Grant relation to calculate the rupture life. The creep rate of the stress-relaxation test was similar to the average creep rate, and thereby the rupture life could be evaluated by a method of "time to rupture strain." The results also showed that rupture life which was assessed by the Monkman-Grant relation was more accurate than that obtained through the method of "time to rupture strain."

  14. Friction Stir Welding for Aluminum Metal Matrix Composites (MMC's) (Center Director's Discretionary Fund, Project No. 98-09)

    NASA Technical Reports Server (NTRS)

    Lee, J. A.; Carter, R. W.; Ding, J.

    1999-01-01

    This technical memorandum describes an investigation of using friction stir welding (FSW) process for joining a variety of aluminum metal matrix composites (MMC's) reinforced with discontinuous silicon-carbide (SiC) particulate and functional gradient materials. Preliminary results show that FSW is feasible to weld aluminum MMC to MMC or to aluminum-lithium 2195 if the SiC reinforcement is <25 percent by volume fraction. However, a softening in the heat-affected zone was observed and is known to be one of the major limiting factors for joint strength. The pin tool's material is made from a low-cost steel tool H-13 material, and the pin tool's wear was excessive such that the pin tool length has to be manually adjusted for every 5 ft of weldment. Initially, boron-carbide coating was developed for pin tools, but it did not show a significant improvement in wear resistance. Basically, FSW is applicable mainly for butt joining of flat plates. Therefore, FSW of cylindrical articles such as a flange to a duct with practical diameters ranging from 2-5 in. must be fully demonstrated and compared with other proven MMC joining techniques for cylindrical articles.

  15. The Metal-Lax method of stress reduction in welds. Final report

    SciTech Connect

    Not Available

    1991-12-31

    The preliminary project to evaluate the possibility of replacing or reducing thermal stress relief and preheat with sub-resonant vibration has been completed. Bonal Technologies manufactures the Meta-Lax system of sub-resonant vibration for use in industry and has met with success on many occasions. The uses are varied and cross into many industries, including fabrication, foundries, and marine construction. However, the specific engineering or scientific basis for the successes has proven to be very elusive. The purpose of this preliminary evaluation of the Meta-Lax system was to try and determine what is happening when sub-resonant vibration is introduced during and/or after welding operations. The final goal is to determine if this process can replace or reduce thermal stress relief and preheat now required on many welded assemblies. The potential savings could be enormous.

  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. 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.

  18. 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.

  19. 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.

  20. 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.

  1. Cleaning Process Development for Metallic Additively Manufactured Parts

    NASA Technical Reports Server (NTRS)

    Tramel, Terri L.; Welker, Roger; Lowery, Niki; Mitchell, Mark

    2014-01-01

    Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

  2. Lung tumor production and tissue metal distribution after exposure to manual metal ARC-stainless steel welding fume in A/J and C57BL/6J mice.

    PubMed

    Zeidler-Erdely, Patti C; Battelli, Lori A; Salmen-Muniz, Rebecca; Li, Zheng; Erdely, Aaron; Kashon, Michael L; Simeonova, Petia P; Antonini, James M

    2011-01-01

    Stainless steel welding produces fumes that contain carcinogenic metals. Therefore, welders may be at risk for the development of lung cancer, but animal data are inadequate in this regard. Our main objective was to examine lung tumor production and histopathological alterations in lung-tumor-susceptible (A/J) and -resistant C57BL/6J (B6) mice exposed to manual metal arc-stainless steel (MMA-SS) welding fume. Male mice were exposed to vehicle or MMA-SS welding fume (20 mg/kg) by pharyngeal aspiration once per month for 4 mo. At 78 wk postexposure, gross tumor counts and histopathological changes were assessed and metal analysis was done on extrapulmonary tissue (aorta, heart, kidney, and liver). At 78 wk postexposure, gross lung tumor multiplicity and incidence were unremarkable in mice exposed to MMA-SS welding fume. Histopathology revealed that only the exposed A/J mice contained minimal amounts of MMA-SS welding fume in the lung and statistically increased lymphoid infiltrates and alveolar macrophages. A significant increase in tumor multiplicity in the A/J strain was observed at 78 wk. Metal analysis of extrapulmonary tissue showed that only the MMA-SS-exposed A/J mice had elevated levels of Cr, Cu, Mn, and Zn in kidney and Cr in liver. In conclusion, this study further supports that MMA-SS welding fume does not produce a significant tumorigenic response in an animal model, but may induce a chronic lung immune response. In addition, long-term extrapulmonary tissue alterations in metals in the susceptible A/J mouse suggest that the adverse effects of this fume might be cumulative.

  3. 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.

  4. Evaluation of occupational exposure to toxic metals released in the process of aluminum welding.

    PubMed

    Matczak, Wanda; Gromiec, Jan

    2002-04-01

    The objective of this study was to evaluate occupational exposure to welding fumes and its elements on aluminum welders in Polish industry. The study included 52 MIG/Al fume samples and 18 TIG/Al samples in 3 plants. Air samples were collected in the breathing zone of welders (total and respirable dust). Dust concentration was determined gravimetrically, and the elements in the collected dust were determined by AAS. Mean time-weighted average (TWA) concentrations of the welding dusts/fumes and their components in the breathing zone obtained for different welding processes were, in mg/m3: MIG/Al fumes mean 6.0 (0.8-17.8), Al 2.1 (0.1-7.7), Mg 0.2 (< 0.1-0.9), Mn 0.014 (0.002-0.049), Cu 0.011 (0.002-0.092), Zn 0.016 (0.002-0.14), Pb 0.009 (0.005-0.025), Cr 0.003 (0.002-0.007), and TIG/Al fumes 0.7 (0.3-1.4), Al 0.17 (0.07-0.50). A correlation has been found between the concentration of the main components and the fume/dust concentrations in MIG/Al and TIG/Al fumes. Mean percentages of the individual components in MIG/Al fumes/dusts were Al: 30 (9-56) percent; Mg: 3 (1-5.6) percent; Mn: 0.2 (0.1-0.3) percent; Cu: 0.2 (< 0.1-1.8) percent; Zn: 0.2 (< 0.1-0.8) percent; Pb: 0.2 (< 0.1-1) percent; Cr: < 0.1 percent. The proportion of the respirable fraction in the fumes and their constituents varied between 10 percent and 100 percent. The results showed that MIG/Al fumes concentration was 1.2 times higher than the American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit value (TLV), and the index of the combined exposure to the determined agents was 2.3 (0.4-8.0), mostly because of high Al2O3 contribution. The background concentrations of the components (ca. 5-10 times lower than those in the breathing zone of the welders) did not exceed the Polish MAC value. The elemental composition of total and respirable fume/dust may differ considerably depending on welding methods, the nature of welding-related operations, and work environment conditions.

  5. Plastic Finite Element Analysis of D0 Toroid Iron Welds

    SciTech Connect

    Wands, R.; /Fermilab

    1987-11-23

    The assembly of the DO toroid iron involves the use of large groove welds to connect massive blocks of steel. These welds are very heavily constrained, and large thermal strains develop which have produced large cracks in the base metal near the weld. The effort to solve these problems has involved investigations of weld geometry, weld preparation, and the metallurgy of both the base metal and the welding rod. The purpose of this analysis was to compare the effects of two welding rods with markedly different yield strengths and post-yieding behaviour on the plastic strains developed in the base metal near the weld.

  6. Optical radiation hazards of laser welding processes. Part II: CO2 laser.

    PubMed

    Rockwell, R J; Moss, C E

    1989-08-01

    There has been an extensive growth within the last five years in the use of high-powered lasers in various metalworking processes. The two types of lasers used most frequently for laser welding/cutting processes are the Neodymium-yttrium-aluminum-garnet (Nd:YAG) and the carbon dioxide (CO2) systems. When such lasers are operated in an open beam configuration, they are designated as a Class IV laser system. Class IV lasers are high-powered lasers that may present an eye and skin hazard under most common exposure conditions, either directly or when the beam has been diffusely scattered. Significant control measures are required for unenclosed (open beam), Class IV laser systems since workers may be exposed to scattered or reflected beams during the operation, maintenance, and service of these lasers. In addition to ocular and/or skin exposure hazards, such lasers also may present a multitude of nonlaser beam occupational concerns. Radiant energy measurements are reported for both the scattered laser radiation and the plasma-related plume radiations released during typical high-powered CO2 laser-target interactions. In addition, the application of the nominal hazard zone (NHZ) and other control measures also are discussed with special emphasis on Class IV industrial CO2 laser systems. PMID:2508455

  7. Phased Array Ultrasonic Examination of Reactor Coolant System (Carbon Steel-to-CASS) Dissimilar Metal Weld Mockup Specimen

    SciTech Connect

    Crawford, S. L.; Cinson, A. D.; Diaz, A. A.; Anderson, M. T.

    2015-11-23

    In the summer of 2009, Pacific Northwest National Laboratory (PNNL) staff traveled to the Electric Power Research Institute (EPRI) NDE Center in Charlotte, North Carolina, to conduct phased-array ultrasonic testing on a large bore, reactor coolant pump nozzle-to-safe-end mockup. This mockup was fabricated by FlawTech, Inc. and the configuration originated from the Port St. Lucie nuclear power plant. These plants are Combustion Engineering-designed reactors. This mockup consists of a carbon steel elbow with stainless steel cladding joined to a cast austenitic stainless steel (CASS) safe-end with a dissimilar metal weld and is owned by Florida Power & Light. The objective of this study, and the data acquisition exercise held at the EPRI NDE Center, were focused on evaluating the capabilities of advanced, low-frequency phased-array ultrasonic testing (PA-UT) examination techniques for detection and characterization of implanted circumferential flaws and machined reflectors in a thick-section CASS dissimilar metal weld component. This work was limited to PA-UT assessments using 500 kHz and 800 kHz probes on circumferential flaws only, and evaluated detection and characterization of these flaws and machined reflectors from the CASS safe-end side only. All data were obtained using spatially encoded, manual scanning techniques. The effects of such factors as line-scan versus raster-scan examination approaches were evaluated, and PA-UT detection and characterization performance as a function of inspection frequency/wavelength, were also assessed. A comparative assessment of the data is provided, using length-sizing root-mean-square-error and position/localization results (flaw start/stop information) as the key criteria for flaw characterization performance. In addition, flaw signal-to-noise ratio was identified as the key criterion for detection performance.

  8. 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:…

  9. Pollution prevention assessment for a metal parts coater

    SciTech Connect

    Edwards, H.W.; Kostrzewa, M.F.; Spika, T.; Looby, G.P.

    1995-09-01

    The US Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. In an effort to assist these manufacturers Waste Minimization Assessment Centers (WMACs) were established at selected universities and procedures were adapted from the EPA Waste Minimization Opportunity Assessment Manual. The WMAC team at Colorado State University performed an assessment at a plant that applies corrosion resistant coatings to metal parts. Aluminum parts received from customers may be anodized or may receive a chromate conversion coating. Brass, copper, steel, and aluminum parts from customers are nickel plated--either by electrolytic or electroless plating. The assessment team`s report, detailing findings and recommendations, indicated that large quantities of wastewater and metal sludge are generated by the plant and that significant cost savings could be achieved through replacement of Freon used for degreasing. This Research Brief was developed by the principal investigators and EPA`s National Risk Management Research Laboratory, Cincinnati, OH, to announce key findings of an ongoing research project that is fully documented in a separate report of the same title available from University City Science Center.

  10. Friction-Stir Welding of Aluminum For the Space Program

    NASA Technical Reports Server (NTRS)

    Jones, Clyde S.; Smelser, Jerry W. (Technical Monitor)

    2002-01-01

    The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

  11. Effects Of Heat Sinks On VPPA Welds

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur C.; Steranka, Paul O., Jr.

    1991-01-01

    Report describes theoretical and experimental study of absorption of heat by metal blocks in contact with metal plate while plate subjected to variable-polarity plasma-arc (VPPA) welding. Purpose of study to contribute to development of comprehensive mathematical model of temperature in weld region. Also relevant to welding of thin sheets of metal to thick blocks of metal, heat treatment of metals, and hotspots in engines.

  12. Friction stir welding and processing of oxide dispersion strengthened (ODS) alloys

    SciTech Connect

    Ren, Weiju

    2014-11-11

    A method of welding including forming a filler material of a first oxide dispersoid metal, the first oxide dispersoid material having first strengthening particles that compensate for decreases in weld strength of friction stir welded oxide dispersoid metals; positioning the filler material between a first metal structure and a second metal structure each being comprised of at least a second oxide dispersoid metal; and friction welding the filler material, the first metal structure and the second metal structure to provide a weld.

  13. Part height control of laser metal additive manufacturing process

    NASA Astrophysics Data System (ADS)

    Pan, Yu-Herng

    Laser Metal Deposition (LMD) has been used to not only make but also repair damaged parts in a layer-by-layer fashion. Parts made in this manner may produce less waste than those made through conventional machining processes. However, a common issue of LMD involves controlling the deposition's layer thickness. Accuracy is important, and as it increases, both the time required to produce the part and the material wasted during the material removal process (e.g., milling, lathe) decrease. The deposition rate is affected by multiple parameters, such as the powder feed rate, laser input power, axis feed rate, material type, and part design, the values of each of which may change during the LMD process. Using a mathematical model to build a generic equation that predicts the deposition's layer thickness is difficult due to these complex parameters. In this thesis, we propose a simple method that utilizes a single device. This device uses a pyrometer to monitor the current build height, thereby allowing the layer thickness to be controlled during the LMD process. This method also helps the LMD system to build parts even with complex parameters and to increase material efficiency.

  14. 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.

  15. Process Windows for Sheet Metal Parts based on Metamodels

    NASA Astrophysics Data System (ADS)

    Harsch, D.; Heingärtner, J.; Hortig, D.; Hora, P.

    2016-08-01

    Achieving robust production of deep drawn sheet metal parts is challenging. The fluctuations of process and material properties often lead to robustness problems. Numerical simulations are used to validate the feasibility and to detect critical regions of a part. To enhance the consistency with the real process conditions, the measured material data and the force distribution are taken into account. The simulation metamodel contains the virtual knowledge of a particular forming process, which is determined based on a series of finite element simulations with variable input parameters. Based on the metamodels, process windows can be evaluated for different parameter configurations. This helps improving the operating point search, to adjust process settings if the process becomes unstable and to visualize the influence of arbitrary parameters on the process window.

  16. 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.

  17. CO2 laser welding fused silica.

    SciTech Connect

    Reed, Scott T.; MacCallum, Danny O'Neill; Knorovsky, Gerald Albert

    2005-08-01

    The feasibility of laser welding of fused silica (aka quartz) has been demonstrated recently by others. An application requiring hermetic sealing of a thin, pressure-bearing quartz diaphragm to a thicker frame led us to explore this technique. We found that laser welding techniques normally used for metallic parts caused scorching and uneven melting. Contrary to standard practices (near focus, high travel speed, high power density), successful welds in fused silica required a broad heat source applied over a large area under a slow rotation to gradually heat the glass through the annealing, softening and finally working temperatures. Furthermore, good mechanical contact between the parts to be joined played an even more important role in this process than in typical metallic joints. A 50 W CO2 laser with 4 f.l. ZnSe2 lens and rotary head was used to weld 0.425 OD, 0.006-0.010 thick, disks to 0.500 OD tubing with 0.125 walls. Several joint geometries and beam orientations were investigated. Temperature profiles were measured and compared to an FEM thermal model. We will discuss the effects of laser power, travel speed, number of passes, joint geometry and part thicknesses on achieving hermeticity and cosmetically-acceptable joints.

  18. 40 CFR Appendix A to Part 438 - Typical Products in Metal Products and Machinery Sectors

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... Parts AIRCRAFT Aircraft Engines & Engine Parts Aircraft Frames Manufacturing Aircraft Parts & Equipment..., & Surgical Supplies Pens, Mechanical Pencils, & Parts Process Control Instruments Search & Navigation... Combustion Engines Measuring & Dispensing Pumps Mechanical Power Transmission Equipment Metal...

  19. Gas Shielding Technology for Welding and Brazing

    NASA Technical Reports Server (NTRS)

    Nunes, Arthur J.; Gradl, Paul R.

    2012-01-01

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

  20. 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.

  1. Development and application of specially-focused ultrasonic transducers to location and sizing of defects in 75 mm- to 127 mm-thick austenitic stainless steel weld metals

    SciTech Connect

    Dalder, E.N.C.; Benson, S.; McKinley, B.J.; Carodiskey, T.

    1992-08-01

    Special UT transducer parts, capable of focusing incident signals within a 25 mm {times} 25 mm {times} 25 mm volume in an austenitic stainless weld metal at depths that varied from 25 mm to 127 mm, were developed and demonstrated to be capable of detecting a defect with cross section equivalent to that of a 4.76 mm-dia flat-bottom hole. Defect length sizing could be accomplished to {plus_minus}50% for 100% of the time and to {plus_minus}25% on selected defect types as follows: porosity groups, 100%; cracks, 67%; combined slag and porosity, 60%; and linear slag indications, 59%. Extensive linear elastic-fracture-mechanics analyses were performed to establish allowable defect sizes at functions of stress, based on a cyclic-life criterion of 10{sup 3} full power cycles of the MFTF-B magnet system. These defect sizes were used to determine which UT indicating were to be removed and repaired and which were to be retained and their recorded sizes and locations.

  2. Urethane/Silicone Adhesives for Bonding Flexing Metal Parts

    NASA Technical Reports Server (NTRS)

    Edwards, Paul D.

    2004-01-01

    Adhesives that are blends of commercially available urethane and silicone adhesives have been found to be useful for bonding metal parts that flex somewhat during use. These urethane/silicone adhesives are formulated for the specific metal parts to be bonded. The bonds formed by these adhesives have peel and shear strengths greater than those of bonds formed by double-sided tapes and by other adhesives, including epoxies and neat silicones. In addition, unlike the bonds formed by epoxies, the bonds formed by these adhesives retain flexibility. In the initial application for which the urethane/silicone adhesives were devised, there was a need to bond spring rings, which provide longitudinal rigidity for inflatable satellite booms, with the blades that provide the booms axial strength. The problem was to make the bonds withstand the stresses, associated with differences in curvature between the bonded parts, that arose when the booms were deflated and the springs were compressed. In experiments using single adhesives (that is, not the urethane/ silicone blends), the bonds were broken and, in each experiment, it was found that the adhesive bonded well with either the ring or with the blade, but not both. After numerous experiments, the adhesive that bonded best with the rings and the adhesive that bonded best with the blades were identified. These adhesives were then blended and, as expected, the blend bonded well with both the rings and the blades. The two adhesives are Kalex (or equivalent) high-shear-strength urethane and Dow Corning 732 (or equivalent) silicone. The nominal mixture ratio is 5 volume parts of the urethane per 1 volume part of the silicone. Increasing the proportion of silicone makes the bond weaker but more flexible, and decreasing the proportion of silicone makes the bond stronger but more brittle. The urethane/silicone blend must be prepared and used quickly because of the limited working time of the urethane: The precursor of the urethane

  3. Cytogenetic studies of stainless steel welders using the tungsten inert gas and metal inert gas methods for welding.

    PubMed

    Jelmert, O; Hansteen, I L; Langård, S

    1995-03-01

    Cytogenetic damage was studied in lymphocytes from 23 welders using the Tungsten Inert Gas (TIG), and 21 welders using the Metal Inert Gas (MIG) and/or Metal Active Gas (MAG) methods on stainless steel (SS). A matched reference group I, and a larger reference group II of 94 subjects studied during the same time period, was established for comparison. Whole blood conventional cultures (CC), cultures in which DNA synthesis and repair were inhibited (IC), and the sister chromatid exchange (SCE) assay were applied in the study. For the CC a statistically significant decrease in chromosome breaks and cells with aberrations was found for both TIG/SS and MIG/MAG/SS welders when compared with reference group II. A non-significant decrease was found for the corresponding parameters for the two groups of welders when compared with their matched referents. A statistically significant negative association was found between measurements of total chromium (Cr) in inhaled air and SCE, and a weaker negative correlation with hexavalent Cr (Cr(VI)) in air. In conclusion, no cytogenetic damage was found in welders exposed to the TIG/SS and MIG/MAG/SS welding fumes with low content of Cr and Ni. On the contrary, a decline in the prevalence of chromosomal aberrations was indicated in the TIG/SS and MIG/MAG/SS welders, possibly related to the suggested enhancement of DNA repair capacity at slightly elevated exposures. PMID:7885396

  4. Cytogenetic studies of stainless steel welders using the tungsten inert gas and metal inert gas methods for welding.

    PubMed

    Jelmert, O; Hansteen, I L; Langård, S

    1995-03-01

    Cytogenetic damage was studied in lymphocytes from 23 welders using the Tungsten Inert Gas (TIG), and 21 welders using the Metal Inert Gas (MIG) and/or Metal Active Gas (MAG) methods on stainless steel (SS). A matched reference group I, and a larger reference group II of 94 subjects studied during the same time period, was established for comparison. Whole blood conventional cultures (CC), cultures in which DNA synthesis and repair were inhibited (IC), and the sister chromatid exchange (SCE) assay were applied in the study. For the CC a statistically significant decrease in chromosome breaks and cells with aberrations was found for both TIG/SS and MIG/MAG/SS welders when compared with reference group II. A non-significant decrease was found for the corresponding parameters for the two groups of welders when compared with their matched referents. A statistically significant negative association was found between measurements of total chromium (Cr) in inhaled air and SCE, and a weaker negative correlation with hexavalent Cr (Cr(VI)) in air. In conclusion, no cytogenetic damage was found in welders exposed to the TIG/SS and MIG/MAG/SS welding fumes with low content of Cr and Ni. On the contrary, a decline in the prevalence of chromosomal aberrations was indicated in the TIG/SS and MIG/MAG/SS welders, possibly related to the suggested enhancement of DNA repair capacity at slightly elevated exposures.

  5. 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.

  6. High-Powered, Ultrasonically Assisted Thermal Stir Welding

    NASA Technical Reports Server (NTRS)

    Ding, Robert

    2013-01-01

    This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a

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

    PubMed Central

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

    2016-01-01

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

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

    PubMed

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

    2015-01-01

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

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

    PubMed

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

    2015-01-01

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

  10. The influence of Sc addition on the welding microstructure of Zr-based bulk metallic glass: The stability of the amorphous phase

    NASA Astrophysics Data System (ADS)

    Wang, Shing Hoa; Kuo, Pei Hung; Tsang, Hsiao Tsung; Jeng, Rong Ruey; Lin, Yu Lon

    2007-10-01

    Pulsed direct current autogeneous tungsten inert gas arc welding was conducted on rods of bulk metallic glasses (BMGs) Zr55Cu30Ni5Al10 and (Zr55Cu30Ni5Al10)99.98Sc0.02 under two different cooling conditions. The crystalline precipitates in the fusion zone of BMG Zr55Cu30Ni5Al10 were confirmed by microfocused x-ray diffraction pattern analysis as Zr2Ni and Zr2(Cu,Al) intermetallic compounds. In contrast, BMG with Sc addition (Zr55Cu30Ni5Al10)99.98Sc0.02 shows an excellent stable glass forming ability. The fusion zone of BMG (Zr55Cu30Ni5Al10)99.98Sc0.02 remains in the same amorphous state as that of the amorphous base metal when the weld is cooled with accelerated cooling.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. Development and characterization of polymers-metallic hot embossing process for manufacturing metallic micro-parts

    NASA Astrophysics Data System (ADS)

    Sahli, M.; Millot, C.; Gelin, J.-C.; Barrière, T.

    2011-01-01

    In the recent years, hot embossing process becomes a promising process for the replication of polymer micro-structures associated to its manufacturing capability related to a relatively low component cost. This rising demand has prompted the development of various micro-manufacturing techniques in an attempt to get micro-parts in large batch. The paper investigates the way to get metallic micro-parts through the hot embossing process. The micro-manufacturing process consists in three stages. In the first one, the different metallic feedstocks with 50 to 60% powder loading in volume have been prepared with adapted polymers/powders formulations. In a second stage, an elastomeric master has been used to obtain micro-parts on a plastic loaded substrate with developed mixture based on polypropylene, paraffin wax and stearic acid. Finally, a thermal debinding stage in nitrogen atmosphere followed by a solid state pre-sintering stage has been applied, in order to eliminate the pores between powder particles in the debinded components. Then the porous components are agglomerated by solid state diffusion after heating to a temperature slightly lower than the melting temperature related to the material used in the process, to form an homogenous structure when full densification is achieved. The advantages of this approach include: rapid manufacturing of injection tools with high-quality, easy demoulding of metallic parts from the elastomeric moulds and great flexibility related to the choices of material. The paper describes all the processing stages and the way to characterize the geometrical, physical and mechanical properties of the resulting micro-parts.

  18. 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.

  19. RTM of Italy applies power lasers to welding, hardening

    NASA Astrophysics Data System (ADS)

    Larane, A.

    1985-09-01

    The Institute for Mechanical Technology Research and Automation (RTM) has five power lasers, including one with a 15-kW output all lasers are used for process development like, sheet metal welding and spot hardening feasibility tests of mechanical part machining and surface treatment are described.

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

    NASA Technical Reports Server (NTRS)

    Tamir, David

    1992-01-01

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

  1. Automated process control for capacitor-discharge welding

    SciTech Connect

    Wilson, Rick D.; Paul, Brian K.

    1998-01-01

    Capacitor discharge welding (CDW) is an autogenous, rapid solidification, joining process ideal for joining small parts of similar or dissimilar metals. Potential applications include welding of electrical contacts, cutting tool inserts, and automotive valves. Because of high cooling rates in excess of one million °C/s, the production rate for CDW process is very high. However potential industrial users have been hesitant to use CDW due largely to the unavailability of automated process control. The objective of this research was to develop models for an on-line quality control feedback system for CDW. The system described monitors current and voltage curves produced during the welding cycle. These curves have been found to be good indicators of certain types of welding defects. A closed-loop automation architecture for future work will also be discussed.

  2. A comparison of LBW and GTAW processes in miniature closure welds

    SciTech Connect

    Knorovsky, G.A.; Fuerschbach, P.W.; Gianoulakis, S.E.; Burchett, S.N.

    1995-07-01

    When small electronic components with glass-to-metal seals are closure welded, residual stresses developed in the glass are of concern. If these stresses exceed allowable tensile levels` the resulting weld-induced seal failure may cause the entire component to be scrapped or reworked at substantial cost. Conventional wisdom says the best welding process for these applications is that which provides the least heat input, and that Laser Beam Welding (LBW) provides less heat input than Gas Tungsten Arc Welding. (GTAW); however, other concerns such as weld fit-up, part variability, and material weldability can modify the final choice of a welding process. In this paper we compare the characteristic levels of heat input and the residual stresses generated in the glass seals for the two processes (as calculated by 3D Finite Element Analysis) as a function of heat input and travel speed, and contrast some of the other manufacturing decisions that must be made to choose a production process. The geometry chosen is a standing edge corner weld in a cylindrical container about 20 mm diameter by 35 mm tall. Four metal pins are glassed into the part lid. The stresses calculated to result from continuous wave C0{sub 2} LBW are compared with those that result from GTAW. The total energy required by the laser weld is significantly less than for the equivalent size GTA weld. The energy input required for a given size weld is inversely proportional to the travel speed, but approaches a saturation level as the travel speed increases. LBW travel speeds ranging from 10 mm/sec to 50 mm/sec were examined.

  3. 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.

  4. 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.

  5. 40 CFR Appendix A to Part 438 - Typical Products in Metal Products and Machinery Sectors

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... Aircraft Engines & Engine Parts Aircraft Frames Manufacturing Aircraft Parts & Equipment Airports, Flying..., & Surgical Supplies Pens, Mechanical Pencils, & Parts Process Control Instruments Search & Navigation... Combustion Engines Measuring & Dispensing Pumps Mechanical Power Transmission Equipment Metal...

  6. Ultrasonic Additive Manufacturing: Weld Optimization for Aluminum 6061, Development of Scarf Joints for Aluminum Sheet Metal, and Joining of High Strength Metals

    NASA Astrophysics Data System (ADS)

    Wolcott, Paul J.

    Ultrasonic additive manufacturing (UAM) is a low temperature, solid-state manufacturing process that enables the creation of layered, solid metal structures with designed anisotropies and embedded materials. As a low temperature process, UAM enables the creation of active composites containing smart materials, components with embedded sensors, thermal management devices, and many others. The focus of this work is on the improvement and characterization of UAM aluminum structures, advancing the capabilities of ultrasonic joining into sheet geometries, and examination of dissimilar material joints using the technology. Optimized process parameters for Al 6061 were identified via a design of experiments study indicating a weld amplitude of 32.8 synum and a weld speed of 200 in/min as optimal. Weld force and temperature were not significant within the levels studied. A methodology of creating large scale builds is proposed, including a prescribed random stacking sequence and overlap of 0.0035 in. (0.0889 mm) for foils to minimize voids and maximize mechanical strength. Utilization of heat treatments is shown to significantly increase mechanical properties of UAM builds, within 90% of bulk material. The applied loads during the UAM process were investigated to determine the stress fields and plastic deformation induced during the process. Modeling of the contact mechanics via Hertzian contact equations shows that significant stress is applied via sonotrode contact in the process. Contact modeling using finite element analysis (FEA), including plasticity, indicates that 5000 N normal loads result in plastic deformation in bulk aluminum foil, while at 3000 N no plastic deformation occurs. FEA studies on the applied loads during the process, specifically a 3000 N normal force and 2000 N shear force, show that high stresses and plastic deformation occur at the edges of a welded foil, and base of the UAM build. Microstructural investigations of heat treated foils confirms

  7. Fatigue Crack Growth Rate Test Results for Al-Li 2195 Parent Metal, Variable Polarity Plasma Arc Welds and Friction Stir Welds

    NASA Technical Reports Server (NTRS)

    Hafley, Robert A.; Wagner, John A.; Domack, Marcia S.

    2000-01-01

    The fatigue crack growth rate of aluminum-lithium (Al-Li) alloy 2195 plate and weldments was determined at 200-F, ambient temperature and -320-F. The effects of stress ratio (R), welding process, orientation and thickness were studied. Results are compared with plate data from the Space Shuttle Super Lightweight Tank (SLWT) allowables program. Data from the current series of tests, both plate and weldment, falls within the range of data generated during the SLWT allowables program.

  8. 49 CFR 229.83 - Insulation or grounding of metal parts.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 49 Transportation 4 2011-10-01 2011-10-01 false Insulation or grounding of metal parts. 229.83 Section 229.83 Transportation Other Regulations Relating to Transportation (Continued) FEDERAL RAILROAD... System § 229.83 Insulation or grounding of metal parts. All unguarded noncurrent-carrying metal...

  9. 49 CFR 229.83 - Insulation or grounding of metal parts.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 4 2012-10-01 2012-10-01 false Insulation or grounding of metal parts. 229.83 Section 229.83 Transportation Other Regulations Relating to Transportation (Continued) FEDERAL RAILROAD... System § 229.83 Insulation or grounding of metal parts. All unguarded noncurrent-carrying metal...

  10. 49 CFR 229.83 - Insulation or grounding of metal parts.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 49 Transportation 4 2010-10-01 2010-10-01 false Insulation or grounding of metal parts. 229.83 Section 229.83 Transportation Other Regulations Relating to Transportation (Continued) FEDERAL RAILROAD... System § 229.83 Insulation or grounding of metal parts. All unguarded noncurrent-carrying metal...

  11. 49 CFR 229.83 - Insulation or grounding of metal parts.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 4 2014-10-01 2014-10-01 false Insulation or grounding of metal parts. 229.83 Section 229.83 Transportation Other Regulations Relating to Transportation (Continued) FEDERAL RAILROAD... System § 229.83 Insulation or grounding of metal parts. All unguarded noncurrent-carrying metal...

  12. 49 CFR 229.83 - Insulation or grounding of metal parts.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 4 2013-10-01 2013-10-01 false Insulation or grounding of metal parts. 229.83 Section 229.83 Transportation Other Regulations Relating to Transportation (Continued) FEDERAL RAILROAD... System § 229.83 Insulation or grounding of metal parts. All unguarded noncurrent-carrying metal...

  13. 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.

  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. 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.

  16. Evaluation of erythemal UV effective irradiance from UV lamp exposure and the application in shield metal arc welding processing.

    PubMed

    Chang, Cheng-Ping; Liu, Hung-Hsin; Peng, Chiung-Yu; Fang, Hsin-Yu; Tsao, Ta-Ho; Lan, Cheng-Hang

    2008-04-01

    Ultraviolet radiation (UVR) exposure is known to cause potential effects such as erythema in skin. For UV-induced erythema (sunburn), the action spectrum from the Commission Internationale de l'Eclairage, International Commission on Illumination (CIE) was adopted. Erythemal UV effects from UVR lamp exposure were investigated with commercial spectroradiometry devices in this research. Three kinds of portable UV germicidal lamps with broadband UVA (BB UVA, 350-400 nm), broadband UVB (BB UVB, 280-350 nm), and narrowband UVC (NB UVC, 254 nm) wavelengths served as the UVR emission sources. An action spectrum expresses the effectiveness of radiation for assessing the hazard of UVR in the erythemal action spectrum from 250-400 nm. The UV Index (UVI) is an irradiance scale computed by multiplying the CIE erythemal irradiance integral in milliwatts per square meter by 0.04 m mW. A comprehensive approach to detecting erythemal UVR magnitude was developed to monitor the effective exposure from UV lamps. The erythemal UVR measurement was established and the exposure assessment was applied to monitor erythemal UVR magnitude from shield metal arc welding (SMAW) processing. From this study, the erythemal UVR exposures were assessed and evaluated with environmental solar simulation of the UVI exposure.

  17. Evaluation of erythemal UV effective irradiance from UV lamp exposure and the application in shield metal arc welding processing.

    PubMed

    Chang, Cheng-Ping; Liu, Hung-Hsin; Peng, Chiung-Yu; Fang, Hsin-Yu; Tsao, Ta-Ho; Lan, Cheng-Hang

    2008-04-01

    Ultraviolet radiation (UVR) exposure is known to cause potential effects such as erythema in skin. For UV-induced erythema (sunburn), the action spectrum from the Commission Internationale de l'Eclairage, International Commission on Illumination (CIE) was adopted. Erythemal UV effects from UVR lamp exposure were investigated with commercial spectroradiometry devices in this research. Three kinds of portable UV germicidal lamps with broadband UVA (BB UVA, 350-400 nm), broadband UVB (BB UVB, 280-350 nm), and narrowband UVC (NB UVC, 254 nm) wavelengths served as the UVR emission sources. An action spectrum expresses the effectiveness of radiation for assessing the hazard of UVR in the erythemal action spectrum from 250-400 nm. The UV Index (UVI) is an irradiance scale computed by multiplying the CIE erythemal irradiance integral in milliwatts per square meter by 0.04 m mW. A comprehensive approach to detecting erythemal UVR magnitude was developed to monitor the effective exposure from UV lamps. The erythemal UVR measurement was established and the exposure assessment was applied to monitor erythemal UVR magnitude from shield metal arc welding (SMAW) processing. From this study, the erythemal UVR exposures were assessed and evaluated with environmental solar simulation of the UVI exposure. PMID:18332723

  18. Weld defect formation in FSWed coppers

    NASA Astrophysics Data System (ADS)

    Gheisari, Yousof; Pashazadeh, Hamed; Teimournezhad, Jamal; Masoumi, Abolfazl

    2014-06-01

    This work was undertaken to explore the formation of weld defects in FSWed copper metals via both numerical and experimental approaches. The 4 mm-thick copper sheets were friction stir welded at a tool rotational speed of 710 rpm and tool translational speed of 40 mm/min. Microstructural evaluations were performed on the welded specimens. Also a 3D arbitrary Lagrangian Eulerian numerical model was developed to obtain temperature and material velocity profiles. To this aim, DEFORM-3D was implemented for developing the numerical simulation. Numerical results for temperature values showed good agreement with the recorded experimental data. They also suggest that on the advancing side (AS) of the trailing side, the pin velocity has the minimum amount (zero), and this is the main reason for the formation of tunneling cavity. Experimental results show that a force is created between the reminder of material at the joint and the rim of AS. This force causes a prong of surface material from the AS rim to penetrate into lower parts of weld. It seems that the inadequate pressure (low values of the plunge depth), inadequate surface materials, and the trapped air are the main causes for the formation of the weld defects.

  19. 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…

  20. 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.…

  1. 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.

  2. A new strategy for stiffness evaluation of sheet metal parts

    NASA Astrophysics Data System (ADS)

    Cai, Q.; Volk, W.; Düster, A.; Rank, E.

    2011-08-01

    In the automotive industry, surfaces of styling models are shaped very often in physical models. For example, in the styling process of a car body important design work is realized by clay models and the resulting geometry information typically comes from optical scans. The scanned data is given in the form of point clouds which is then utilized in the virtual planning process for engineering work, e.g. to evaluate the load-carrying capacity. This is an important measure for the stiffness of the car body panels. In this contribution, the following two issues are discussed: what is the suitable geometric representation of the stiffness of the car body and how it is computed if only discrete point clouds exist. In the first part, the suitable geometric representation is identified by constructing continuous CAD models with different geometric parameters, e.g. Gaussian curvature and mean curvature. The stiffness of models is then computed in LS-DYNA and the influence of different geometric parameters is presented based on the simulation result. In the second part, the point clouds from scanned data, rather than continuous CAD models, are directly utilized to estimate the Gaussian curvature, which is normally derived from continuous surfaces. The discrete Gauss-Bonnet algorithm is applied to estimate the Gaussian curvature of the point clouds and the sensitivity of the algorithm with respect to the mesh quality is analyzed. In this way, the stiffness evaluation process in an early stage can be accelerated since the transformation from discrete data to continuous CAD data is labor-intensive. The discrete Gauss-Bonnet algorithm is finally applied to a sheet metal model of the BMW 3 series.

  3. Spectral diagnostics of a vapor-plasma plume produced during welding with a high-power ytterbium fiber laser

    NASA Astrophysics Data System (ADS)

    Uspenskiy, S. A.; Shcheglov, P. Yu.; Petrovskiy, V. N.; Gumenyuk, A. V.; Rethmeier, M.

    2013-07-01

    We have conducted spectroscopic studies of the welding plasma formed in the process of welding with an ytterbium fiber laser delivering output power of up to 20 kW. The influence of shielding gases (Ar, He) on different parts of the welding plume is investigated. The absorption coefficient of the laser radiation by the welding-plume plasma is estimated. Scattering of 532-nm probe radiation from particles of the condensed metal vapor within the caustic of a high-power fiber laser beam is measured. Based on the obtained results, conclusions are made on the influence of the plasma formation and metal vapor condensation on the radiation of the high-power fiber laser and the stability of the welding process.

  4. Final Assessment of Manual Ultrasonic Examinations Applied to Detect Flaws in Primary System Dissimilar Metal Welds at North Anna Power Station

    SciTech Connect

    Anderson, Michael T.; Diaz, Aaron A.; Cinson, Anthony D.; Crawford, Susan L.; Prowant, Matthew S.; Doctor, Steven R.

    2014-03-24

    PNNL conducted a technical assessment of the NDE issues and protocols that led to missed detections of several axially oriented flaws in a steam generator primary inlet dissimilar metal weld at North Anna Power Station, Unit 1 (NAPS-1). This particular component design exhibits a significant outside-diameter (OD) taper that is not included as a blind performance demonstration mock-up within the industry’s Performance Demonstration Initiative, administered by EPRI. For this reason, the licensee engaged EPRI to assist in the development of a technical justification to support the basis for a site-specific qualification. The service-induced flaws at NAPS-1 were eventually detected as a result of OD surface machining in preparation for a full structural weld overlay. The machining operation uncovered the existence of two through-wall flaws, based on the observance of primary water leaking from the dissimilar metal weld. A total of five axially oriented flaws were detected in varied locations around the weld circumference. The field volumetric examination that was conducted at NAPS-1 was a non-encoded, real-time manual ultrasonic examination. PNNL conducted both an initial assessment, and subsequently, a more rigorous technical evaluation (reported here), which has identified an array of NDE issues that may have led to the subject missed detections. These evaluations were performed through technical reviews and discussions with NRC staff, EPRI NDE Center personnel, industry and ISI vendor personnel, and ultrasonic transducer manufacturers, and laboratory tests, to better understand the underlying issues at North Anna.

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

    SciTech Connect

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

    2008-11-15

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

  6. Welding apparatus and methods for using ultrasonic sensing

    DOEpatents

    McJunkin, Timothy R.; Johnson, John A.; Larsen, Eric D.; Smartt, Herschel B.

    2006-08-22

    A welding apparatus using ultrasonic sensing is described and which includes a movable welder having a selectively adjustable welding head for forming a partially completed weld in a weld seam defined between adjoining metal substrates; an ultrasonic assembly borne by the moveable welder and which is operable to generate an ultrasonic signal which is directed toward the partially completed weld, and is further reflected from same; and a controller electrically coupled with the ultrasonic assembly and controllably coupled with the welding head, and wherein the controller receives information regarding the ultrasonic signal and in response to the information optimally positions the welding head relative to the weld seam.

  7. Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

    NASA Astrophysics Data System (ADS)

    Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

    2009-03-01

    Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

  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. New Tendencies in Development of Carbonaceous Additives for Welding Fluxes

    NASA Astrophysics Data System (ADS)

    Kozyrev, N. A.; Kryukov, R. E.; Kozyreva, O. A.

    2015-09-01

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

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

    ERIC Educational Resources Information Center

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

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

  11. 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.

  12. 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.

  13. Making Superconducting Welds between Superconducting Wires

    NASA Technical Reports Server (NTRS)

    Penanen, Konstantin I.; Eom, Byeong Ho

    2008-01-01

    A technique for making superconducting joints between wires made of dissimilar superconducting metals has been devised. The technique is especially suitable for fabrication of superconducting circuits needed to support persistent electric currents in electromagnets in diverse cryogenic applications. Examples of such electromagnets include those in nuclear magnetic resonance (NMR) and magnetic resonance imaging (MRI) systems and in superconducting quantum interference devices (SQUIDs). Sometimes, it is desirable to fabricate different parts of a persistent-current-supporting superconducting loop from different metals. For example, a sensory coil in a SQUID might be made of Pb, a Pb/Sn alloy, or a Cu wire plated with Pb/Sn, while the connections to the sensory coil might be made via Nb or Nb/Ti wires. Conventional wire-bonding techniques, including resistance spot welding and pressed contact, are not workable because of large differences between the hardnesses and melting temperatures of the different metals. The present technique is not subject to this limitation. The present technique involves the use (1) of a cheap, miniature, easy-to-operate, capacitor-discharging welding apparatus that has an Nb or Nb/Ti tip and operates with a continuous local flow of gaseous helium and (2) preparation of a joint in a special spark-discharge welding geometry. In a typical application, a piece of Nb foil about 25 m thick is rolled to form a tube, into which is inserted a wire that one seeks to weld to the tube (see figure). The tube can be slightly crimped for mechanical stability. Then a spark weld is made by use of the aforementioned apparatus with energy and time settings chosen to melt a small section of the niobium foil. The energy setting corresponds to the setting of a voltage to which the capacitor is charged. In an experiment, the technique was used to weld an Nb foil to a copper wire coated with a Pb/Sn soft solder, which is superconducting. The joint was evaluated as

  14. The effect of non-metallic inclusions on the fracture toughness master curve in high copper reactor pressure vessel welds

    NASA Astrophysics Data System (ADS)

    Oh, Yong-Jun; Lee, Bong-Sang; Hong, Jun-Hwa

    2002-03-01

    The fracture toughness of two high copper reactor pressure vessel welds having low upper shelf energy was evaluated in accordance with the master curve method of ASTM E1921. The resultant data were correlated to the metallurgical factors involved in the brittle fracture initiation to provide a metallurgical-based understanding of the master curve. The tests were performed using pre-cracked Charpy V-notched specimens and the master curve was made with an average of T0 values determined at different temperatures. In all specimens, the cleavage fracture initiated at non-metallic inclusion ranging from 0.7 to 3.5 μm in diameter showing a scatter with the specimens and testing temperatures. Temperature dependency of the triggering particle size was not found. The fracture toughness ( KJC) was inversely proportional to the square root of the triggering inclusion diameter ( di) at respective temperatures. From this relationship, we determined median KJC values which correspond to the average value of triggering inclusion diameter of all tested specimens and defined them as a modified median KJC ( K'JC(med) ). The obtained K'JC(med) values showed quite smaller deviation from the master curve at different temperatures than the experimental median KJC values. This suggests that the master curve is on the premise of a constant dimension of key microstructural factor in a material regardless of the testing temperature. But the inclusion size at trigger point played an important role in the absolute position of the master curve with temperature and the consequent T0 value.

  15. SRμCT study of crack propagation within laser-welded aluminum-alloy T-joints

    NASA Astrophysics Data System (ADS)

    Herzen, J.; Beckmann, F.; Riekehr, S.; Bayraktar, F. S.; Haibel, A.; Staron, P.; Donath, T.; Utcke, S.; Kocak, M.; Schreyer, A.

    2008-08-01

    Using laser welding in fabrication of metallic airframes reduces the weight and hence fuel consumption. Currently only limited parts of the airframes are welded. To increase laser beam welded parts, there is the need for a better understanding of crack propagation and crack-pore interaction within the welds. Laser beam welded Al-alloys may contain isolated small process pores and their role and interaction with growing crack need to be investigated. The present paper presents the first results of a crack propagation study in laser beam welded (LBW) Al-alloy T-joints using synchrotron radiation based micro computed tomography (SRμCT). A region-of-interest technique was used, since the specimens exceeded the field of view of the X-ray detector. As imaging with high density resolution at high photon energies is very challenging, a feasibility measurement on a small laser weld, cut cylindrically from the welded region of a T-joint, was done before starting the crack-propagation study. This measurement was performed at the beamline HARWI-II at DESY to demonstrate the potential of the SRμCT as non-destructive testing method. The result has shown a high density resolution, hence, the different Al alloys used in the T-joint and the weld itself were clearly separated. The quantitative image analysis of the 3D data sets allows visualizing non-destructively and calculating the pore size distribution.

  16. 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.

  17. 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.

  18. 4-kW fiber laser for metal cutting and welding

    NASA Astrophysics Data System (ADS)

    Kliner, Dahv A. V.; Chong, Kwang; Franke, Justin; Gordon, Thomas; Gregg, Jeff; Gries, Wolfgang; Hu, Helen; Ishiguro, Hiroaki; Issier, Vincent; Kharlamov, Boris; Kliner, Andrea; Kobayashi, Masanao; Liao, Kai-Hsiu; Lugo, Juan; Luu, Johnny; Meng, David; Morehead, James J.; Muendel, Martin H.; Myers, Lawrence E.; Nguyen, Kelvin; Sako, Hiroshi; Schneider, Kyle; Segall, Jeff; Shigeoka, Katherine; Srinivasan, Raman; Tucker, Derek; Woll, Dirk; Woods, David L.; Yu, Hongbo; Zhang, Chris

    2011-02-01

    We have developed a commercial 4-kW fiber laser consisting of seven, 600-W modules whose outputs are combined with a fused-fiber combiner. The system architecture has several practical advantages, including pumping with reliable single-emitter diodes, monolithic fused-fiber construction (no free-space beams), and end pumping using a 91:1 pump combiner (eliminating the need for complex pump/signal combiners). Typical results at 4-kW output power are a beamparameter product of 2.6 mm-mrad, 8-hr power stability of < 0.5% rms, central wavelength of 1080 nm, and linewidth of 1.2 nm FWHM. These lasers have been incorporated into Amada machines used for cutting metal sheet and plate and have been used to cut aluminum, mild steel, stainless steel, brass, titanium, and copper with a thickness up to 19 mm. A world-record cutting speed of 62 m/min has been demonstrated for 1-mm aluminum sheet metal.

  19. 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.

  20. 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

  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. 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…

  3. Adaptive Robotic Welding Using A Rapid Image Pre-Processor

    NASA Astrophysics Data System (ADS)

    Dufour, M.; Begin, G.

    1984-02-01

    The rapid pre-processor initially developed by NRCC and Leigh Instruments Inc. as part of the visual aid system of the space shuttle arm 1 has been adapted to perform real time seam tracking of multipass butt weld and other adaptive welding functions. The weld preparation profile is first enhanced by a projected laser target formed by a line and dots. A standard TV camera is used to observe the target image at an angle. Displacement and distorsion of the target image on a monitor are simple functions of the preparation surface distance and shape respectively. Using the video signal, the pre-processor computes in real time the area and first moments of the white level figure contained within four independent rectangular windows in the field of view of the camera. The shape, size, and position of each window can be changed dynamically for each successive image at the standard 30 images/sec rate, in order to track some target image singularities. Visual sensing and welding are done simultaneously. As an example, it is shown that thin sheet metal welding can be automated using a single window for seam tracking, gap width measurement and torch height estimation. Using a second window, measurement of sheet misalignment and their orientation in space were also achieved. The system can be used at welding speed of up to 1 m/min. Simplicity, speed and effectiveness are the main advantages of this system.

  4. 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.

  5. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

  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. Patterns of residual stresses due to welding

    NASA Technical Reports Server (NTRS)

    Botros, B. M.

    1983-01-01

    Residual stresses caused by welding result from the nonuniform rate of cooling and the restrained thermal contraction or non-uniform plastic deformation. From the zone of extremely high temperature at the weld, heat flows into both the adjoining cool body and the surrounding atmosphere. The weld metal solidifies under very rapid cooling. The plasticity of the hot metal allows adjustment initially, but as the structure cools the rigidity of the surrounding cold metal inhibits further contraction. The zone is compressed and the weld is put under tensile stresses of high magnitude. The danger of cracking in these structural elements is great. Change in specific volume is caused by the change in temperature.

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

    PubMed

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

    1997-01-01

    This paper describes the relationships between ultra-violet emission, ozone generation and CrVI production in MIG welding which were measured as a function of shield gas flow rate, welding voltage, electrode stick-out and shield gas composition using an automatic welding rig that permitted MIG welding under reproducible conditions. The experimental results are interpreted in terms of the physico-chemical processes occurring in the micro- and macro-environments of the arc as part of research into process modification to reduce occupational exposure to ozone and CrVI production rates in MIG welding. We believe the techniques described here, and in particular the use of what we have termed u.v.-ozone measurements, will prove useful in further study of ozone generation and CrVI formation and may be applied in the investigation of engineering control of occupational exposure in MIG and other welding process such as Manual Metal Arc (MMA) and Tungsten Inert Gas (TIG). PMID:9072953

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

    PubMed

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

    1997-01-01

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

  11. 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.

  12. 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.

  13. Tensile and Fatigue Testing and Material Hardening Model Development for 508 LAS Base Metal and 316 SS Similar Metal Weld under In-air and PWR Primary Loop Water Conditions

    SciTech Connect

    Mohanty, Subhasish; Soppet, William; Majumdar, Saurin; Natesan, Ken

    2015-09-01

    This report provides an update on an assessment of environmentally assisted fatigue for light water reactor components under extended service conditions. This report is a deliverable in September 2015 under the work package for environmentally assisted fatigue under DOE’s Light Water Reactor Sustainability program. In an April 2015 report we presented a baseline mechanistic finite element model of a two-loop pressurized water reactor (PWR) for systemlevel heat transfer analysis and subsequent thermal-mechanical stress analysis and fatigue life estimation under reactor thermal-mechanical cycles. In the present report, we provide tensile and fatigue test data for 508 low-alloy steel (LAS) base metal, 508 LAS heat-affected zone metal in 508 LAS–316 stainless steel (SS) dissimilar metal welds, and 316 SS-316 SS similar metal welds. The test was conducted under different conditions such as in air at room temperature, in air at 300 oC, and under PWR primary loop water conditions. Data are provided on materials properties related to time-independent tensile tests and time-dependent cyclic tests, such as elastic modulus, elastic and offset strain yield limit stress, and linear and nonlinear kinematic hardening model parameters. The overall objective of this report is to provide guidance to estimate tensile/fatigue hardening parameters from test data. Also, the material models and parameters reported here can directly be used in commercially available finite element codes for fatigue and ratcheting evaluation of reactor components under in-air and PWR water conditions.

  14. Microstructural characterization of an SA508–309L/308L–316L domestic dissimilar metal welded safe-end joint

    SciTech Connect

    Ming, Hongliang; Zhang, Zhiming; Wang, Jianqiu Han, En-Hou; Ke, Wei

    2014-11-15

    The microstructure of an SA508–309L/308L–316L domestic dissimilar metal welded safe-end joint was characterized in this work by optical microscopy, scanning electron microscopy (with electron back scattering diffraction) and micro-hardness testing. Epitaxial growth and competitive growth are evident in the 308L–316L fusion boundary regions. A martensite layer, carbon-depleted zones, and type-II and type-I boundaries are found in the SA508–309L fusion boundary regions, while only martensite and austenite mixed zones are observed in the SA508–308L fusion boundary regions. The microstructure near the fusion boundary and the microstructure transition in the SA508 heat affected zone are quite complex. Both for SA508–309L/308L and 308L–316L, the highest residual strain is located on the outside of the weldment. The residual strain and the grain boundary character distribution change with increasing distance from the fusion boundary in the heat affected zone of 316L. Micro-hardness measurements also reveal non-uniform mechanical properties across the weldment. - Highlights: • The microstructure of SA508 HAZ, especially near the FB, is very complex. • The outside of the dissimilar metal welded joint has the highest residual. • The micro-hardness distributions along the DMWJ are non-uniform.

  15. 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

  16. Ultrasonic energy welds copper to aluminium

    SciTech Connect

    Flood, G.

    1997-01-01

    Attempting to weld copper to aluminum by conventional means through the application of thermal energy to melt and fuse the two metals (fusion welding) can result in an unreliable weld. The oxide layer on aluminum is difficult to remove, the melt temperatures of the two metals are not close, the two metals exhibit high thermal conductivity and alloying of the two metals creates a brittle intermetallic that is mechanically and electrically unreliable. An alternative for design engineers is to weld copper to aluminum by applying ultrasonic energy, which joins the metals without melting. The ultrasonic process creates a high quality weld both mechanically and electrically without forming a brittle intermetallic and without intermediate steps. Ultrasonic welding of copper to aluminum has been shown to be efficient and effective as demonstrated by a number of practical production applications. The problems of tough oxides, high thermal conductivity, high electrical conductivity, intermetallics and brittle alloys are not significant with the ultrasonic welding process. And similarly, the problems associated with pre and postweld cleaning, fluxes, hot metal and high energy costs are eliminated. Modern ultrasonic welding equipment is capable of monitoring energy and controlling the critical welding process variables.

  17. Fibrogenic potential of welding fumes.

    PubMed

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

    1983-02-01

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

  18. 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...

  19. 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...

  20. 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...