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

NASA Astrophysics Data System (ADS)

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

2014-06-01

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

Test and Analysis Correlation of a Large-Scale, Orthogrid-Stiffened Metallic Cylinder without Weld Lands

NASA Technical Reports Server (NTRS)

Rudd, Michelle T.; Hilburger, Mark W.; Lovejoy, Andrew E.; Lindell, Michael C.; Gardner, Nathaniel W.; Schultz, Marc R.

2018-01-01

The NASA Engineering Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NESC with the primary objective to develop analysis-based buckling design factors and guidelines for metallic and composite launch-vehicle structures.1 A secondary objective of the project is to advance technologies that have the potential to increase the structural efficiency of launch-vehicles. The SBKF Project has determined that weld-land stiffness discontinuities can significantly reduce the buckling load of a cylinder. In addition, the welding process can introduce localized geometric imperfections that can further exacerbate the inherent buckling imperfection sensitivity of the cylinder. Therefore, single-piece barrel fabrication technologies can improve structural efficiency by eliminating these weld-land issues. As part of this effort, SBKF partnered with the Advanced Materials and Processing Branch (AMPB) at NASA Langley Research Center (LaRC), the Mechanical and Fabrication Branch at NASA Marshall Space Flight Center (MSFC), and ATI Forged Products to design and fabricate an 8-ft-diameter orthogrid-stiffened seamless metallic cylinder. The cylinder was subjected to seven subcritical load sequences (load levels that are not intended to induce test article buckling or material failure) and one load sequence to failure. The purpose of this test effort was to demonstrate the potential benefits of building cylindrical structures with no weld lands using the flow-formed manufacturing process. This seamless barrel is the ninth 8-ft-diameter metallic barrel and the first single-piece metallic structure to be tested under this program.

Final Assessment of Manual Ultrasonic Examinations Applied to Detect Flaws in Primary System Dissimilar Metal Welds at North Anna Power Station

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

Anderson, Michael T.; Diaz, Aaron A.; Cinson, Anthony D.

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 asmore » 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.« less

Microstructural and mechanical properties on friction welding of dissimilar metals used in motor vehicles

NASA Astrophysics Data System (ADS)

Jesudoss Hynes, N. Rajesh; Shenbaga Velu, P.

2018-02-01

In the last two decades, major car manufacturing companies are exploring the possibilities of joining magnesium with aluminium, via friction welding technique for many crucial automotive applications. Our primary objective, is to carry out an experimental investigation in order to study the behaviour of dissimilar joints. The microscopic structure at the welded joint interface was analysed using an optical microscopy and scanning electron microscope. It was found that, by increasing the value of friction time, the value of the tensile strength increases and the result of tensile strength is found to be 120 MPa at a friction time of 10 s. Micro hardness was found to be higher at the interface of the weldment due to the development of a brittle intermetallic compound. Micro structural studies using SEM reveals, distinct zones such as an unaffected parent metal zone, the heat affected zone, a thermo-mechanically affected zone and a fully deformed plasticised zone.

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

PubMed

Chai, Guo-Ming; Zhu, Yi-Feng

2010-04-01

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

Modeling and characterization of as-welded microstructure of solid solution strengthened Ni-Cr-Fe alloys resistant to ductility-dip cracking Part II: Microstructure characterization

NASA Astrophysics Data System (ADS)

Unfried-Silgado, Jimy; Ramirez, Antonio J.

2014-03-01

In part II of this work is evaluated the as-welded microstructure of Ni-Cr-Fe alloys, which were selected and modeled in part I. Detailed characterization of primary and secondary precipitates, subgrain and grain structures, partitioning, and grain boundary morphology were developed. Microstructural characterization was carried out using optical microscopy, SEM, TEM, EBSD, and XEDS techniques. These results were analyzed and compared to modeling results displaying a good agreement. The Hf additions produced the highest waviness of grain boundaries, which were related to distribution of Hf-rich carbonitrides. Experimental evidences about Mo distribution into crystal lattice have provided information about its possible role in ductility-dip cracking (DDC). Characterization results of studied alloys were analyzed and linked to their DDC resistance data aiming to establish relationships between as-welded microstructure and hot deformation performance. Wavy grain boundaries, primary carbides distribution, and strengthened crystal lattice are metallurgical characteristics related to high DDC resistance.

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.

Structure of welded joints obtained by contact weld in nanostructured titanium

NASA Astrophysics Data System (ADS)

Klimenov, V. A.; Klopotov, A. A.; Gnysov, S. F.; Vlasov, V. A.; Lychagin, D. V.; Chumaevskii, A. V.

2015-10-01

The paper presents the research of the weld structure of two Ti specimens of the type VT6 that have nano- and submicrocrystalline structures. Electrical contact welding is used to obtain welds. The acicular structure is formed in the weld area. Two types of defects are detected, namely micropores and microcracks.

Physicochemical Characterization of Aerosol Generated in the Gas Tungsten Arc Welding of Stainless Steel.

PubMed

Miettinen, Mirella; Torvela, Tiina; Leskinen, Jari T T

2016-10-01

Exposure to stainless steel (SS) welding aerosol that contain toxic heavy metals, chromium (Cr), manganese (Mn), and nickel (Ni), has been associated with numerous adverse health effects. The gas tungsten arc welding (GTAW) is commonly applied to SS and produces high number concentration of substantially smaller particles compared with the other welding techniques, although the mass emission rate is low. Here, a field study in a workshop with the GTAW as principal welding technique was conducted to determine the physicochemical properties of the airborne particles and to improve the understanding of the hazard the SS welding aerosols pose to welders. Particle number concentration and number size distribution were measured near the breathing zone (50cm from the arc) and in the middle of the workshop with condensation particle counters and electrical mobility particle sizers, respectively. Particle morphology and chemical composition were studied using scanning and transmission electron microscopy and energy-dispersive X-ray spectroscopy. In the middle of the workshop, the number size distribution was unimodal with the geometric mean diameter (GMD) of 46nm. Near the breathing zone the number size distribution was multimodal, and the GMDs of the modes were in the range of 10-30nm. Two different agglomerate types existed near the breathing zone. The first type consisted of iron oxide primary particles with size up to 40nm and variable amounts of Cr, Mn, and Ni replacing iron in the structure. The second type consisted of very small primary particles and contained increased proportion of Ni compared to the proportion of (Cr + Mn) than the first agglomerate type. The alterations in the distribution of Ni between different welding aerosol particles have not been reported previously. © The Author 2016. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.

Thermal Stir Welding Development at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Ding, Robert J.

2008-01-01

Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

Thermal Recovery of Plastic Deformation in Dissimilar Metal Weld

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

Qiao, Dongxiao; Yu, Xinghua; Zhang, Wei

Stainless steel has been widely used in challenging environments typical to nuclear power plant structures, due its excellent corrosion resistance. Nickel filler metals containing high chromium concentration, including Alloy 82/182, are used for joining stainless steel to carbon steel components to achieve similar high resistance to stress corrosion cracking. However, the joint usually experience weld metal stress corrosion cracking (SCC), which affects the safety and structural integrity of light water nuclear reactor systems. A primary driving force for SCC is the high tensile residual stress in these welds. Due to large dimension of pressure vessel and limitations in the field,more » non-destructive residual stress measurement is difficult. As a result, finite element modeling has been the de facto method to evaluate the weld residual stresses. Recent studies on this subject from researchers worldwide report different residual stress value in the weldments [5]. The discrepancy is due to the fact that most of investigations ignore or underestimate the thermal recovery in the heat-affect zone or reheated region in the weld. In this paper, the effect of heat treatment on thermal recovery and microhardness is investigated for materials used in dissimilar metal joint. It is found that high equivalent plastic strains are predominately accumulated in the buttering layer, the root pass, and the heat affected zone, which experience multiple welding thermal cycles. The final cap passes, experiencing only one or two welding thermal cycles, exhibit less plastic strain accumulation. Moreover, the experimental residual plastic strains are compared with those predicted using an existing weld thermo-mechanical model with two different strain hardening rules. The importance of considering the dynamic strain hardening recovery due to high temperature exposure in welding is discussed for the accurate simulation of weld residual stresses and plastic strains. In conclsuion, the experimental result reveals that the typical post-buttering heat treatment for residual stress relief may not be adequate to completely eliminate the residual plastic strains in the buttering layer.« less

Onset of Curved Dendrite Growth in an Al-Cu Welding Pool: A Phase Field Study

NASA Astrophysics Data System (ADS)

Wang, Lei; Wei, Yanhong

2018-02-01

A phase field model is developed to predict curved dendrite growth in the gas tungsten arc (GTA) welding pool of an Al-Cu alloy. The equations of temperature gradient, pulling velocity and dendrite growth orientation are proposed to consider the transient solidification process during welding. Solidification microstructures and solute diffusion along the fusion boundary in the welding pool are predicted by using the phase field model coupled with transient solidification conditions. Predicted primary dendrites are curved and point toward the welding direction. Welding experiments are carried out to observe solidification microstructures of the weld. Comparisons of simulation results with experimental measurements are conducted. Predicted dendritic morphology, dendrite growth orientation, primary dendrite arm spacing and initial cell spacing give a good agreement with experimental measurements.

Electron Beam Welding to Join Gamma Titanium Aluminide Articles

NASA Technical Reports Server (NTRS)

Kelly, Thomas Joseph (Inventor)

2008-01-01

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

Modelling the attenuation in the ATHENA finite elements code for the ultrasonic testing of austenitic stainless steel welds.

PubMed

Chassignole, B; Duwig, V; Ploix, M-A; Guy, P; El Guerjouma, R

2009-12-01

Multipass welds made in austenitic stainless steel, in the primary circuit of nuclear power plants with pressurized water reactors, are characterized by an anisotropic and heterogeneous structure that disturbs the ultrasonic propagation and makes ultrasonic non-destructive testing difficult. The ATHENA 2D finite element simulation code was developed to help understand the various physical phenomena at play. In this paper, we shall describe the attenuation model implemented in this code to give an account of wave scattering phenomenon through polycrystalline materials. This model is in particular based on the optimization of two tensors that characterize this material on the basis of experimental values of ultrasonic velocities attenuation coefficients. Three experimental configurations, two of which are representative of the industrial welds assessment case, are studied in view of validating the model through comparison with the simulation results. We shall thus provide a quantitative proof that taking into account the attenuation in the ATHENA code dramatically improves the results in terms of the amplitude of the echoes. The association of the code and detailed characterization of a weld's structure constitutes a remarkable breakthrough in the interpretation of the ultrasonic testing on this type of component.

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.

NDE Development for Inspection of the Ares I Crew Launch Vehicle

NASA Technical Reports Server (NTRS)

Richter, Joel; Russell, Sam S.

2007-01-01

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. Another impact is the proposed usage of an aluminum face sheet, phenolic honeycomb sandwich structure for a common bulkhead between the fuel and oxidizer tanks. This design was used on the second stage of Saturn IB and the second and third stages of Saturn V, but both the manufacturing and subsequent inspection were very costly and time consuming so a more efficient inspection method is sought. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Structural stability of super duplex stainless weld metals and its dependence on tungsten and copper

NASA Astrophysics Data System (ADS)

Nilsson, J.-O.; Huhtala, T.; Jonsson, P.; Karlsson, L.; Wilson, A.

1996-08-01

Three different superduplex stainless weld metals have been produced using manual metal arc welding under identical welding conditions. The concentration of the alloying elements tungsten and copper corresponded to the concentrations in commercial superduplex stainless steels (SDSS). Aging experiments in the temperature range 700 °C to 1110 °C showed that the formation of intermetallic phase was enhanced in tungsten-rich weld metal and also dissolved at higher temperatures compared with tungsten-poor and tungsten-free weld metals. It could be inferred from time-temperature-transformation (TTT) and continuous-cooling-transformation (CCT) diagrams produced in the present investigation that the critical cooling rate to avoid 1 wt pct of intermetallic phase was 2 times faster for tungsten-rich weld metal. Microanalysis in combination with thermodynamic calculations showed that tungsten was accommodated in χ phase, thereby decreasing the free energy. Experimental evidence supports the view that the formation of intermetallic phase is enhanced in tungsten-rich weld metal, owing to easier nucleation of nonequilibrium χ phase compared with σ phase. The formation of secondary austenite (γ2) during welding was modeled using the thermodynamic computer program Thermo-Calc. Satisfactory agreement between theory and practice was obtained. Thermo-Calc was capable of predicting observed lower concentrations of chromium and nitrogen in γ2 compared with primary austenite. The volume fraction of γ2 was found to be significantly higher in tungsten-rich and tungsten + copper containing weld metal. The results could be explained by a higher driving force for precipitation of γ2 in these.

Making on-orbit structural repairs to Space Station

NASA Technical Reports Server (NTRS)

Haber, Harry S.; Quinn, Alberta

1989-01-01

One of the key factors dictating the safety and durability of the proposed U.S. Space Station is the ability to repair structural damage while remaining in orbit. Consequently, studies are conducted to identify the engineering problems associated with accomplishing structural repairs on orbit, due to zero gravity environment and exposure to extreme temperature variations. There are predominant forms of structural failure, depending on the metallic or composite material involved. Aluminum is the primary metallic material used in space vehicle applications. Welding processes on aluminum alloy structures were tested, resulting in final selection of electron beam welding as the primary technique for metallic material repair in Space. Several composite structure repair processes were bench-tested to define their applicability to on-orbit EVA requirements: induction heating prevailed. One of the unique problems identified as inherent in the on-orbit repair process is that of debris containment. The Maintenance Work Station concept provides means to prevent module contamination from repair debris and ensure the creation of a facility for crew members to work easily in a microgravity environment. Different technologies were also examined for application to EVA repair activities, and the concept selected was a spring-loaded, collapsible, box-like Debris Containement and Collection Device with incorporated fold-down tool boards and handholes in the front panel.

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.

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.

Mars Atmosphere Effects on Arc Welds: Phase 1

NASA Technical Reports Server (NTRS)

Courtright, Z. S.

2016-01-01

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

Welding Behavior of Free Machining Stainless Steel

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

BROOKS,JOHN A.; ROBINO,CHARLES V.; HEADLEY,THOMAS J.

2000-07-24

The weld solidification and cracking behavior of sulfur bearing free machining austenitic stainless steel was investigated for both gas-tungsten arc (GTA) and pulsed laser beam weld processes. The GTA weld solidification was consistent with those predicted with existing solidification diagrams and the cracking response was controlled primarily by solidification mode. The solidification behavior of the pulsed laser welds was complex, and often contained regions of primary ferrite and primary austenite solidification, although in all cases the welds were found to be completely austenite at room temperature. Electron backscattered diffraction (EBSD) pattern analysis indicated that the nature of the base metalmore » at the time of solidification plays a primary role in initial solidification. The solid state transformation of austenite to ferrite at the fusion zone boundary, and ferrite to austenite on cooling may both be massive in nature. A range of alloy compositions that exhibited good resistance to solidification cracking and was compatible with both welding processes was identified. The compositional range is bounded by laser weldability at lower Cr{sub eq}/Ni{sub eq} ratios and by the GTA weldability at higher ratios. It was found with both processes that the limiting ratios were somewhat dependent upon sulfur content.« less

Welded tie plate feasibility study for ITER central solenoid structure

NASA Astrophysics Data System (ADS)

Walsh, R.; McRae, D.; Dalder, E.; Litherland, S.; Goddard, R.; Han, K.; Trosen, M.; Kuhlmann, D. D.

2014-01-01

The result of a Nitronic 50 (N50) weld-screening program conducted in support of CS-Tie Plate Structure Design and Development is reported here. The goal of this program is to evaluate four different weld practices and to select the best weld practice for thick section welding of the N50 tie plate structure. The structure design specifies both the weld and base metals have the same minimum mechanical properties requirements. The criteria for selecting the best weld practice are based on the combination of the 295 K tensile properties and the 4 K-tensile, fatigue, and fracture-toughness properties.

Friction stir welding and processing of oxide dispersion strengthened (ODS) alloys

DOEpatents

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.

LDEF mechanical systems

NASA Technical Reports Server (NTRS)

Spear, W. Steve; Dursch, Harry W.

1992-01-01

Following LDEF retrieval, a number of studies were made of mechanical hardware and structure flown on the LDEF. The primary objectives are to determine the effects of long term space exposure on (1) mechanisms either used on LDEF or as part of individual experiments; (2) LDEF structural components; and (3) fasteners. Results from examination and testing of LDEF structure, fasteners, LDEF end support beam, environment exposure control canisters, experiment tray clamps, LDEF grapple fixtures, and viscous damper are presented. The most significant finding is the absence of space exposure related cold welding. The instances of seizure or removal difficulties initially attributed to cold welding were shown to have resulted from installation galling damage or improper removal techniques. Widespread difficulties encountered with removal of stainless steel fasteners underscore the need for effective thread lubrication schemes to ensure successful application of proposed orbital replacement units onboard Space Station Freedom.

Study of weld offset in longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. S.; Brunair, R. M.

1992-01-01

Welded joints are an essential part of rocket engine structures such as the Space Shuttle Main Engine (SSME) turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet X-rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered in this report. Using the FEM and beamlike plate approximations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thicknesses on both sides of the joint. Following the study, some conclusions are derived for the weld offsets.

46 CFR 154.180 - Contiguous hull structure: Welding procedure.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 46 Shipping 5 2012-10-01 2012-10-01 false Contiguous hull structure: Welding procedure. 154.180 Section 154.180 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS... Equipment Hull Structure § 154.180 Contiguous hull structure: Welding procedure. Welding procedure tests for...

46 CFR 154.180 - Contiguous hull structure: Welding procedure.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 46 Shipping 5 2013-10-01 2013-10-01 false Contiguous hull structure: Welding procedure. 154.180 Section 154.180 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS... Equipment Hull Structure § 154.180 Contiguous hull structure: Welding procedure. Welding procedure tests for...

46 CFR 154.180 - Contiguous hull structure: Welding procedure.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 46 Shipping 5 2011-10-01 2011-10-01 false Contiguous hull structure: Welding procedure. 154.180 Section 154.180 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS... Equipment Hull Structure § 154.180 Contiguous hull structure: Welding procedure. Welding procedure tests for...

46 CFR 154.180 - Contiguous hull structure: Welding procedure.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 46 Shipping 5 2014-10-01 2014-10-01 false Contiguous hull structure: Welding procedure. 154.180 Section 154.180 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS... Equipment Hull Structure § 154.180 Contiguous hull structure: Welding procedure. Welding procedure tests for...

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

NASA Astrophysics Data System (ADS)

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

2002-12-01

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

46 CFR 154.180 - Contiguous hull structure: Welding procedure.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 46 Shipping 5 2010-10-01 2010-10-01 false Contiguous hull structure: Welding procedure. 154.180... Equipment Hull Structure § 154.180 Contiguous hull structure: Welding procedure. Welding procedure tests for contiguous hull structure designed for a temperature colder than −18 °C (0 °F) must meet § 54.05-15 and...

Trailing Shield For Welding On Pipes

NASA Technical Reports Server (NTRS)

Coby, John B., Jr.; Gangl, Kenneth J.

1991-01-01

Trailing shield ensures layer of inert gas covers hot, newly formed bead between two tubes or pipes joined by plasma arc welding. Inert gas protects weld bead from oxidation by air until cooler and less vulnerable to oxidation. Intended for use on nickel-base alloy pipes, on which weld beads remain hot enough to oxidize after primary inert-gas purge from welding-torch cup has passed.

Nanoindentation of Electropolished FeCrAl Alloy Welds

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

Weaver, Jordan; Aydogan, Eda; Mara, Nathan Allan

The present report summarizes Berkovich nanoindentation modulus and hardness measurements on two candidate FeCrAl alloys (C35M and C37M) on as-received (AR) and welded samples. In addition, spherical nanoindentation stress-strain measurements were performed on individual grains to provide further information and demonstrate the applicability of these protocols to mechanically characterizing welds in FeCrAl alloys. The indentation results are compared against the reported tensile properties for these alloys to provide relationships between nanoindentation and tensile tests and insight into weldsoftening for these FeCrAl alloys. Hardness measurements revealed weld-softening for both alloys in good agreement with tensile test results. C35M showed a largermore » reduction in hardness at the weld center from the AR material compared to C37M; this is also consistent with tensile tests. In general, nanohardness was shown to be a good predictor of tensile yield strength and ultimate tensile stress for FeCrAl alloys. Spherical nanoindentation measurements revealed that the fusion zone (FZ) + heat affected zone (HAZ) has a very low defect density typical of well-annealed metals as indicated by the frequent pop-in events. Spherical nanoindentation yield strength, Berkovich hardness, and tensile yield strength measurements on the welded material all show that the C37M welded material has a higher strength than C35M welded material. From the comparison of nanoindentation and tensile tests, EBSD microstructure analysis, and information on the processing history, it can be deduced that the primary driver for weld-softening is a change in the defect structure at the grain-scale between the AR and welded material. These measurements serve as baseline data for utilizing nanoindentation for studying the effects of radiation damage on these alloys.« less

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

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-11-01

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

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

NASA Astrophysics Data System (ADS)

Florea, Radu Stefanel

This comprehensive study is the first to quantify the fatigue performance, failure loads, and microstructure of resistance spot welding (RSW) in 6061-T6 aluminum (Al) alloy according to welding parameters and process sensitivity. The extensive experimental, theoretical and simulated analyses will provide a framework to optimize the welding of lightweight structures for more fuel-efficient automotive and military applications. The research was executed in four primary components. The first section involved using electron back scatter diffraction (EBSD) scanning, tensile testing, laser beam profilometry (LBP) measurements, and optical microscopy(OM) images to experimentally investigate failure loads and deformation of the Al-alloy resistance spot welded joints. Three welding conditions, as well as nugget and microstructure characteristics, were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that increasing the applied welding current deepened the weld imprints. The EBSD scans revealed the strong dependency between the grain sizes and orientation function on the process parameters. For the second section, the fatigue behavior of the RSW'ed joints was experimentally investigated. The process optimization included consideration of the forces, currents, and times for both the main weld and post-heating. Load control cyclic tests were conducted on single weld lap-shear joint coupons to characterize the fatigue behavior in spot welded specimens. Results demonstrate that welding parameters do indeed significantly affect the microstructure and fatigue performance for these welds. The third section comprised residual strains of resistance spot welded joints measured in three different directions, denoted as in-plane longitudinal, in-plane transversal, and normal, and captured on the fusion zone, heat affected zone and base metal of the joints. Neutron diffraction results showed residual stresses in the weld are approximately 40% lower than the yield strength of the parent material, with maximum variation occurring in the vertical position of the specimen because of the orientation of electrode clamping forces that produce a non-uniform solidification pattern. In the final section a theoretical continuum modeling framework for 6061-T6 aluminum resistance spot welded joints is presented.

Vacuum encapsulated, high temperature diamond amplified cathode capsule and method for making same

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

Rao, Triveni; Walsh, Josh; Gangone, Elizabeth

2015-12-29

A vacuum encapsulated, hermetically sealed cathode capsule for generating an electron beam of secondary electrons, which generally includes a cathode element having a primary emission surface adapted to emit primary electrons, an annular insulating spacer, a diamond window element comprising a diamond material and having a secondary emission surface adapted to emit secondary electrons in response to primary electrons impinging on the diamond window element, a first high-temperature solder weld disposed between the diamond window element and the annular insulating spacer and a second high-temperature solder weld disposed between the annular insulating spacer and the cathode element. The cathode capsulemore » is formed by a high temperature weld process under vacuum such that the first solder weld forms a hermetical seal between the diamond window element and the annular insulating spacer and the second solder weld forms a hermetical seal between the annular spacer and the cathode element whereby a vacuum encapsulated chamber is formed within the capsule.« less

Vacuum encapsulated hermetically sealed diamond amplified cathode capsule and method for making same

DOEpatents

Rao, Triveni; Walsh, John; Gangone, Elizabeth

2014-12-30

A vacuum encapsulated, hermetically sealed cathode capsule for generating an electron beam of secondary electrons, which generally includes a cathode element having a primary emission surface adapted to emit primary electrons, an annular insulating spacer, a diamond window element comprising a diamond material and having a secondary emission surface adapted to emit secondary electrons in response to primary electrons impinging on the diamond window element, a first cold-weld ring disposed between the cathode element and the annular insulating spacer and a second cold-weld ring disposed between the annular insulating spacer and the diamond window element. The cathode capsule is formed by a vacuum cold-weld process such that the first cold-weld ring forms a hermetical seal between the cathode element and the annular insulating spacer and the second cold-weld ring forms a hermetical seal between the annular spacer and the diamond window element whereby a vacuum encapsulated chamber is formed within the capsule.

Study of the structure and properties of laser-welded joints of the Al-Mg-Li alloy

NASA Astrophysics Data System (ADS)

Pugacheva, N. B.; Antenorova, N. P.; Senaeva, E. I.

2015-12-01

The macro- and microstructures, the distribution of chemical elements and of the values of the microhardness over the width of the zones of remelting and heat-affected zone have been studied after the laser welding of sheets of an Al-Mg-Li alloy. It has been shown that the material of the zone of remelting (1.2 mm thick) represents in itself finely dispersed misoriented dendrites, in the primary branches of which particles of the strengthening δ' phase (Al3Li) with dimensions of no more than 10 nm and in the interdendrite spaces, dispersed particles of the S phase (Al2MgLi and FeAl2) have been revealed. The hardness of the material of the zone of remelting was 108-123 HV 0.05; the hardness of the basic alloy, 150-162 HV 0.05. In the heat-affected zones of thickness 2 mm, the primary recrystallization occurred only in a narrow zone directly at the boundary with the weld. The strength of the welded junction was 470-490 MPa, which corresponds to the regulated degree of strength of the aluminum alloys of this class. The relative elongation of the material of the weld proved to be considerably less than that in the alloy matrix because of the microporosity of the weld material. It is shown that the convective stirring of the melt in the welding pool upon the laser welding made it possible to avoid the appearance of macroscopic defects, but on the microlevel there are observed micropores in the form of spheres with dimensions of 5-50 μm. The solidification of the alloy occurred in such a way that the dendrites had time to grow around the gas bubbles prior to their collapse, forming a sufficiently strong carcass. Inside the dendritic carcass, there have been revealed coarse inclusions (to 200 μm) that consist of oxides (Al2O3, Fe2O3, MgO, SiO2, CaO), of an iron-based alloy, and of the host aluminum alloy.

CHARACTERIZATION OF DEFECTS IN ALLOY 152, 52 AND 52M WELDS

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

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

2009-08-27

Defect distributions have been documented by optical metallography, scanning electron microscopy and electron backscatter diffraction in alloy 152 and 52 mockups welds, alloy 52 and 52M overlay mockups and an alloy 52M inlay. Primary defects were small cracks at grain boundaries except for more extensive cracking in the dilution zone of an alloy 52 overlay on 304SS. Detailed characterizations of the dilution zone cracks were performed by analytical transmission electron microscopy identifying grain boundary titanium-nitride precipitation associated with the intergranular separations. I. INTRODUCTION Weldments continue to be a primary location of stress-corrosion cracking (SCC) in light-water reactor systems. While problemsmore » related to heat-affected-zone (HAZ) sensitization and intergranular (IG) SCC of austenitic stainless alloys in boiling-water reactors (BWRs) have been significantly reduced, SCC has now been observed in HAZs of non-sensitized materials and in dissimilar metal welds where Ni-base alloy weld metals are used. IGSCC in weld metals has been observed in both BWRs and pressurized water reactors (PWRs) with recent examples for PWR pressure vessel penetrations producing the most concern. This has led to the replacement of alloy 600/182/82 welds with higher Cr, more corrosion-resistant replacement materials (alloy 690/152/52/52M). Complicating this issue has been a known susceptibility to cracking during welding [1-7] of these weld metals. There is a critical need for an improved understanding of the weld metal metallurgy and defect formation in Ni-base alloy welds to effectively assess long-term performance. A series of macroscopic to microscopic examinations were performed on available mockup welds made with alloy 52 or alloy 152 plus selected overlay and inlay mockups. The intent was to expand our understanding of weld metal structures in simulated LWR service components with a focus on as-welded defects. Microstructural features, defect distributions, defect characteristics and weld residual strains were examined by optical metallography, scanning electron microscopy, electron backscatter diffraction and transmission electron microscopy. Industry-supplied mock-up welds were characterized including alloy 52 and 152 weldments, alloy 52M overlay and inlay welds, and an alloy 52 overlay. II. WELDMENTS II.A. Alloy 52 and 152 Weld Mockups The alloy 52 and 152 weld mockups were fabricated by MHI for the Kewaunee reactor and were obtained from the EPRI NDE Center. The mockups were U-groove welds joining two plates of 304SS as shown in Figure 1. Alloy 152 butter (heat 307380) was placed on the U-groove surface for both mockups by shielded metal arc welding (SMAW). For the alloy 152 weld mockup, the alloy 152 fill (heat 307380) was also applied using SMAW while for the alloy 52 weld mockup, the alloy 52 fill (heat NX2686JK) was applied using gas tungsten arc welding (GTAW). Welding parameters for the fill materials were substantially different with the alloy 152 SMAW having a deposition speed of 4-25 cm/min with a current of 95-145 A and the alloy 52 GTAW having a deposition speed of 4-10 cm/min with a current of 150-300 A. One prominent feature in these mockup welds is the presence of a crack starting at the 304SS butt joint at the bottom of the U-groove and extending up into the weld. It appears that the 304SS plate on either side of the butt joint acted as an anchor for the weld resulting in a stress rise across the slit that drove crack formation and extension up into the fill weld. As will be shown in the next section, the extent of the cracking around this stress riser was much greater in the MHI 52 weld mockup.« less

Comparative study on the welded structure fatigue strength assessment method

NASA Astrophysics Data System (ADS)

Hu, Tao

2018-04-01

Due to the welding structure is widely applied in various industries, especially the pressure container, motorcycle, automobile, aviation, ship industry, such as large crane steel structure, so for welded structure fatigue strength evaluation is particularly important. For welded structure fatigue strength evaluation method mainly has four kinds of, the more from the use of two kinds of welded structure fatigue strength evaluation method, namely the nominal stress method and the hot spot stress evaluation method, comparing from its principle, calculation method for the process analysis and research, compare the similarities and the advantages and disadvantages, the analysis of practical engineering problems to provide the reference for every profession and trade, as well as the future welded structure fatigue strength and life evaluation method put forward outlook.

Reactor Materials Program - Baseline Material Property Handbook - Mechanical Properties of 1950's Vintage Stainless Steel Weldment Components, Task Number 89-23-A-1

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

Stoner, K.J.

1999-11-05

The Process Water System (primary coolant) piping of the nuclear production reactors constructed in the 1950''s at Savannah River Site is comprised primarily of Type 304 stainless steel with Type 308 stainless steel weld filler. A program to measure the mechanical properties of archival PWS piping and weld materials (having approximately six years of service at temperatures between 25 and 100 degrees C) has been completed. The results from the mechanical testing has been synthesized to provide a mechanical properties database for structural analyses of the SRS piping.

75 FR 7628 - Davis-Besse Nuclear Power Station; Notice of Consideration of Issuance of Amendment to Facility...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-02-22

... potential primary water stress corrosion cracking (PWSCC) of the existing welds. These welds provide a... application of a PWSCC resistant weld overlay that has the added benefit of producing compressive stresses on the inner portion of the existing welds. Acceptable residual stresses for purposes of satisfying this...

Predicting Welding Distortion in a Panel Structure with Longitudinal Stiffeners Using Inherent Deformations Obtained by Inverse Analysis Method

PubMed Central

Liang, Wei; Murakawa, Hidekazu

2014-01-01

Welding-induced deformation not only negatively affects dimension accuracy but also degrades the performance of product. If welding deformation can be accurately predicted beforehand, the predictions will be helpful for finding effective methods to improve manufacturing accuracy. Till now, there are two kinds of finite element method (FEM) which can be used to simulate welding deformation. One is the thermal elastic plastic FEM and the other is elastic FEM based on inherent strain theory. The former only can be used to calculate welding deformation for small or medium scale welded structures due to the limitation of computing speed. On the other hand, the latter is an effective method to estimate the total welding distortion for large and complex welded structures even though it neglects the detailed welding process. When the elastic FEM is used to calculate the welding-induced deformation for a large structure, the inherent deformations in each typical joint should be obtained beforehand. In this paper, a new method based on inverse analysis was proposed to obtain the inherent deformations for weld joints. Through introducing the inherent deformations obtained by the proposed method into the elastic FEM based on inherent strain theory, we predicted the welding deformation of a panel structure with two longitudinal stiffeners. In addition, experiments were carried out to verify the simulation results. PMID:25276856

Predicting welding distortion in a panel structure with longitudinal stiffeners using inherent deformations obtained by inverse analysis method.

PubMed

Liang, Wei; Murakawa, Hidekazu

2014-01-01

Welding-induced deformation not only negatively affects dimension accuracy but also degrades the performance of product. If welding deformation can be accurately predicted beforehand, the predictions will be helpful for finding effective methods to improve manufacturing accuracy. Till now, there are two kinds of finite element method (FEM) which can be used to simulate welding deformation. One is the thermal elastic plastic FEM and the other is elastic FEM based on inherent strain theory. The former only can be used to calculate welding deformation for small or medium scale welded structures due to the limitation of computing speed. On the other hand, the latter is an effective method to estimate the total welding distortion for large and complex welded structures even though it neglects the detailed welding process. When the elastic FEM is used to calculate the welding-induced deformation for a large structure, the inherent deformations in each typical joint should be obtained beforehand. In this paper, a new method based on inverse analysis was proposed to obtain the inherent deformations for weld joints. Through introducing the inherent deformations obtained by the proposed method into the elastic FEM based on inherent strain theory, we predicted the welding deformation of a panel structure with two longitudinal stiffeners. In addition, experiments were carried out to verify the simulation results.

Effects of nitrogen in shielding gas on microstructure evolution and localized corrosion behavior of duplex stainless steel welding joint

NASA Astrophysics Data System (ADS)

Zhang, Zhiqiang; Jing, Hongyang; Xu, Lianyong; Han, Yongdian; Zhao, Lei; Zhou, Chao

2017-05-01

The effects of nitrogen addition in shielding gas on microstructure evolution and localized corrosion behavior of duplex stainless steel (DSS) welds were studied. N2-supplemented shielding gas facilitated the primary austenite formation, suppressed the Cr2N precipitation in weld root, and increased the microhardnesses of weld metal. Furthermore, N2-supplemented shielding gas increased pitting resistance equivalent number (PREN) of austenite, but which decreased slightly PREN of ferrite. The modified double loop electrochemical potentiokinetic reactivation in 2 M H2SO4 + 1 M HCl was an effective method to study the localized corrosion of the different zones in the DSS welds. The adding 2% N2 to pure Ar shielding gas improved the localized corrosion resistance in the DSS welds, which was due to compensation for nitrogen loss and promoting nitrogen further solution in the austenite phases, suppression of the Cr2N precipitation in the weld root, and increase of primary austenite content with higher PREN than the ferrite and secondary austenite. Secondary austenite are prone to selective corrosion because of lower PREN compared with ferrite and primary austenite. Cr2N precipitation in the pure Ar shielding weld root and heat affected zone caused the pitting corrosion within the ferrite and the intergranular corrosion at the ferrite boundary. In addition, sigma and M23C6 precipitation resulted in the intergranular corrosion at the ferrite boundary.

Structure and phase composition of welded joints modified by different welding techniques

NASA Astrophysics Data System (ADS)

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

2017-12-01

The paper presents the results of transmission electron microscopy (TEM) during the study of structure and phase composition of heat-affected zone (HAZ) of welded joints modified via four welding techniques, namely: electrode welding and electropercussive welding both with and without artificial flaws. The artificial flows represent aluminum pieces. TEM studies are carried out within the heat-affected zone, i.e. between the deposited and base metal, at 0.5 mm distance to the former. The 0.09C-2Mn-1Si-Fe steel type is used for welding. It is shown how the type of welding affects steel morphology, phase composition, defect structure and its parameters. The type of carbide phase is detected as well as the shape and location of particles. Volume fractions are estimated for the structural steel components, alongside with such parameters as the size of α-phase fragments, scalar and excess dislocation densities, and bending-torsion amplitude of the crystal lattice. Based on these results, we determine the welding technique and the structural component thus launching a mechanism of microcrack nucleation.

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

PubMed

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

2017-09-15

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

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

PubMed Central

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

2017-01-01

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

Repair welding of gamma titanium aluminide castings

NASA Astrophysics Data System (ADS)

Kelly, T. J.

This paper examines the GTA repair welding of cast Ti-48Al-2Cr-2Nb gamma titanium aluminide. Pre-weld heat treatment, preheat and welding parameters are evaluated and discussed. A wide range of GTAW parameters is demonstrated for use with this alloy and the resulting weld structure is examined. The effects of postweld heat treatment on the structure of the weld deposit is also determined.

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.

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

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

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

Strength of laser welded joints of polypropylene composites

NASA Astrophysics Data System (ADS)

Votrubec, V.; Hisem, P.; Vinšová, L.; Lukášová, V.

2017-11-01

This paper deals with experimental tests of laser welded polypropylene composites. Polymers, such as polypropylene, are often filled with fibres in order to increase their mechanical properties. The welding procedure can also influence material properties nearby weld joints. Therefore the strength of weld joints is lower than strength of primary materials. This effect is proved by realized shear tests. Polymer specimens were filled with 20 % and 40 % of glass fibres and all possible combinations of specimens were welded for experiments. There is also discussed influence of volume fraction of glass fibres in polypropylene on the strength of weld joint.

Investigation on the Effect of Initial Welding Imperfection on Fatigue strength of Tubular Member by FEM

NASA Astrophysics Data System (ADS)

Chang, Kyong-Ho; Shin, Wang Sub; Nguyen Van Vuong, Do; Lee, Chin Hyeong

2018-04-01

Steel tube structure is used for steel structure such as offshore platform, bridges and so on. Also, all circular members of tubular structures are mainly connected by welding. When the steel tubular structures are subjected to repeated loading, not only the load carrying capacity is reduced but also fatigue cracks may develop at the joint part of steel tubular members which are connected by welding. Carrying out welding, welding initial imperfection such as welding deformation and residual stress are inevitably generated at weld part. It was well known that the effect of welding residual and welding deformation on fatigue strength. However, It’s not clear which affects fatigue strength more. However, it’s difficult to clear the effect on fatigue strength by experiment. To clarify these effect, fatigue analysis was carried out by FEM which is based on continuum damage mechanics. On the other hand, coupled three-dimensional non-steady heat conduction analysis, and the thermal elastic-plastic analysis was carried out to reproduce the initial weld state of tubular member. From the result, not only the fatigue strength of welded tubular member but also the fatigue life could be found by FEM fatigue analysis.

SCC of Alloy 690 and its Weld Metals

NASA Astrophysics Data System (ADS)

Andresen, Peter L.; Morra, Martin M.; Ahluwalia, Kawaljit

Alloy 690 base metal, HAZ and weld metal were tested in representative PWR primary water at 290 to 360°C. Intergranular cracking was observed in all materials. Growth rates as high as 1.2 × 10-6 mm/s were observed in the S-L orientation with micro structural banded material after cold rolling or forging to align the planes of banding, rolling and cracking. However, not all banded material has exhibited such high growth rates. Growth rates on homogeneous Alloy 690, including extruded CRDM tubing, often showed growth rates in the range of 2 - 8 × 10-8 mm/s in cold worked condition and an S-L orientation. Crack growth rates in some Alloy 690 tests were in the range of 1 to 10 × 10-9 mm/s, primarily in orientations other than S-L. For cracks aligned along the HAZ, growth rates as high as 1.2 × 10-8 mm/s were observed. Alloy 152/52/52i weld metals always exhibited low growth rates, apart from a weld that was further cold worked by 20%, which grew at 7 × 10-9 mm/s.

Microstructure and Mechanical Properties of Dissimilar Joints of Al-Mg2Si and 5052 Aluminum Alloy by Friction Stir Welding

NASA Astrophysics Data System (ADS)

Huang, B. W.; Qin, Q. D.; Zhang, D. H.; Wu, Y. J.; Su, X. D.

2018-03-01

Al-Mg2Si alloy and 5052 Al alloy were welded successfully by friction stir welding (FSW) in this study. The results show that the alloy consists of three distinct zones after FSW: the base material zone (BMZ), the transitional zone, and the weld nugget (WN). The morphologies of the primary Mg2Si phases are identified as coarse equiaxed crystals for Al-Mg2Si alloys in the BMZ. The WN is a mixture of rich Al-Mg2Si and rich 5052 alloy, and a banded structure is formed in the zone. Interestingly, in the WN, the equiaxed crystals changed to polygonal particles with substantially reduced sizes in the rich Al-Mg2Si zone. However, in addition to the white rich Mg phase appearing in the rich 5052 zone near the interface, the 5052 alloy does not show obvious changes. The hardness gradually increases from the BMZ of the 5052 to the welded joint to the Al-Mg2Si BMZ. In addition, the ultimate tensile strength (UTS) of the welded joint is higher than that of the base material of the Al-Mg2Si, whereas it is lower than that of the 5052 base alloy. The results of the elongation are similar to the UTS results. The fracture mechanism is also investigated.

The Influence of Friction Stir Weld Tool Form and Welding Parameters on Weld Structure and Properties: Nugget Bulge in Self-Reacting Friction Stir Welds

NASA Technical Reports Server (NTRS)

Schneider, Judy; Nunes, Arthur C., Jr.; Brendel, Michael S.

2010-01-01

Although friction stir welding (FSW) was patented in 1991, process development has been based upon trial and error and the literature still exhibits little understanding of the mechanisms determining weld structure and properties. New concepts emerging from a better understanding of these mechanisms enhance the ability of FSW engineers to think about the FSW process in new ways, inevitably leading to advances in the technology. A kinematic approach in which the FSW flow process is decomposed into several simple flow components has been found to explain the basic structural features of FSW welds and to relate them to tool geometry and process parameters. Using this modelling approach, this study reports on a correlation between the features of the weld nugget, process parameters, weld tool geometry, and weld strength. This correlation presents a way to select process parameters for a given tool geometry so as to optimize weld strength. It also provides clues that may ultimately explain why the weld strength varies within the sample population.

73rd American Welding Society annual meeting

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

Not Available

1992-01-01

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

Parametric study in weld mismatch of longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. L.; Brunair, R. M.

1991-01-01

Welded joints are an essential part of pressure vessels such as the Space Shuttle Main Engine (SSME) Turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet x rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered. Using the finite element method and mathematical formulations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thickness on both sides of the joint. From the study, the finite element results and theoretical solutions are presented.

Microstructure Evolution during Friction Stir Welding of Mill-Annealed Ti-6Al-4V (Preprint)

DTIC Science & Technology

2011-05-01

welding . One of the primary concerns regarding FSW of higher temperature materials like titanium is the welding tool. High temperature materials... welds as compared to aluminum alloys. This is related to the low thermal conductivity of titanium alloys which is typically lower than that of the...of the tools and workpieces in aluminum and titanium friction stir welds . Aluminum has a greater conductivity and thermal diffusivity than the tool

Contribution to applications of EBW in instrument techniques

NASA Astrophysics Data System (ADS)

Hrabovsky, Miroslav

1999-07-01

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

The seam visual tracking method for large structures

NASA Astrophysics Data System (ADS)

Bi, Qilin; Jiang, Xiaomin; Liu, Xiaoguang; Cheng, Taobo; Zhu, Yulong

2017-10-01

In this paper, a compact and flexible weld visual tracking method is proposed. Firstly, there was the interference between the visual device and the work-piece to be welded when visual tracking height cannot change. a kind of weld vision system with compact structure and tracking height is researched. Secondly, according to analyze the relative spatial pose between the camera, the laser and the work-piece to be welded and study with the theory of relative geometric imaging, The mathematical model between image feature parameters and three-dimensional trajectory of the assembly gap to be welded is established. Thirdly, the visual imaging parameters of line structured light are optimized by experiment of the weld structure of the weld. Fourth, the interference that line structure light will be scatters at the bright area of metal and the area of surface scratches will be bright is exited in the imaging. These disturbances seriously affect the computational efficiency. The algorithm based on the human eye visual attention mechanism is used to extract the weld characteristics efficiently and stably. Finally, in the experiment, It is verified that the compact and flexible weld tracking method has the tracking accuracy of 0.5mm in the tracking of large structural parts. It is a wide range of industrial application prospects.

Effects of various conditions in cold-welding of copper nanowires: A molecular dynamics study

NASA Astrophysics Data System (ADS)

Zhou, Hongjian; Wu, Wen-ping; Wu, Runni; Hu, Guoming; Xia, Re

2017-11-01

Cold-welding possesses such desirable environment as low temperature and low applied stress, thus becoming the prime candidate for nanojointing and nanoassembly techniques. To explore the welding mechanism of nanoscale structures, here, molecular dynamics was performed on copper nanowires under different welding conditions and various original characteristics to obtain an atomic-level depiction of their cold-welding behavior. By analyzing the mechanical properties of as-welded nanowires, the relations between welding quality and welding variables are revealed and identified. This comparison study will be of great importance to future mechanical processing and structural assembly of metallic nanowires.

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

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

Temperature Histories of Structural Steel Laser and Hybrid Laser-GMA Welds Calculated Using Multiple Constraints

DTIC Science & Technology

2015-12-10

Naval Research Laboratory Washington, DC 20375-5320 NRL/MR/6390--15-9665 Temperature Histories of Structural Steel Laser and Hybrid Laser-GMA Welds ...NUMBER OF PAGES 17. LIMITATION OF ABSTRACT Temperature Histories of Structural Steel Laser and Hybrid Laser-GMA Welds Calculated Using Multiple...structures. These analyses provide parametric representations of weld temperature histories that can be adopted as input data to various types of

Temperature Histories of Structural Steel Laser and Hybrid Laser-GMA Welds Calculated Using Multiple Constraints

DTIC Science & Technology

2015-12-10

Naval Research Laboratory Washington, DC 20375-5320 NRL/MR/6390--15-9665 Temperature Histories of Structural Steel Laser and Hybrid Laser-GMA Welds ...NUMBER OF PAGES 17. LIMITATION OF ABSTRACT Temperature Histories of Structural Steel Laser and Hybrid Laser-GMA Welds Calculated Using Multiple...202) 767-2601 Inverse thermal analyses of structural steel deep-penetration welds are presented. These analyses employ a methodology that is in terms of

Investigation of precipitation and hardening response of maraging stainless steels 17-4 and 13-8+Mo during multi-pass welding

NASA Astrophysics Data System (ADS)

Hamlin, Robert J.

Martensitic precipitation strengthened stainless steels 17-4 and 13-8+Mo are candidate alloys for high strength military applications. These applications will require joining by fusion welding processes thus, it is necessary to develop an understanding of microstructural and mechanical property changes that occur during welding. Previous investigations on these materials have demonstrated that significant softening occurs in the heat affected zone (HAZ) during welding, due to dissolution of the strengthen precipitates. It was also observed that post weld heat treatments (PWHT's) were required to restore the properties. However, PWHT's are expensive and cannot be applied when welding on a large scale or making a repair in the field. Thus, the purpose of the current work is to gain a fundamental understanding of the precipitation kinetics in these systems so that optimized welding procedures can be developed that do not require a PWHT. Multi-pass welding provides an opportunity to restore the strengthening precipitates that dissolve during primary weld passes using the heat from secondary weld passes. Thus, a preliminary investigation was performed to determine whether the times and temperatures associated with welding thermal cycles were sufficient to restore the strength in these systems. A Gleeble thermo-mechanical simulator was used to perform multi-pass welding simulations on samples of each material using a 1000 J/mm and 2000 J/mm heat input. Additionally, base metal and weld metal samples were used as starting conditions to evaluate the difference in precipitation response between each. Hardness measurements were used to estimate the extent of precipitate dissolution and growth. Microstructures were characterized using light optical microscopy (LOM), scanning electron microscopy (SEM), and energy dispersive spectrometry (EDS). It was determined that precipitate dissolution occurred during primary welding thermal cycles and that significant hardening could be achieved using secondary welding thermal cycles for both heat inputs. Additionally, it was observed that the weld metal and base metal had similar precipitation responses. The preliminary multi-pass welding simulations demonstrated that the times and temperatures associated with welding thermal cycles were sufficient to promote precipitation in each system. Furthermore, these findings indicate that controlled weld metal deposition may be a viable method for optimizing welding procedures and eliminating the need for a PWHT. Next, an in-depth Gleeble study was performed to develop a fundamental understanding of the reactions that occur in 17-4 and 13-8+Mo during exposure to times and temperatures representative of multi-pass welding. Samples of each material were subjected to a series of short isothermal holds at high temperatures and hardness measurements were recorded to investigate the dissolution behavior of each alloy. Additional secondary isothermal experiments were performed on samples that had been subjected to a high temperature primary thermal cycle and hardness measurements were recorded. Matrix microstructures were characterized by LOM and reverted austenite measurements were recorded using X-ray diffraction techniques. The hardness data from the secondary heating tests was used in combination with Avrami kinetics equations to develop a relationship between the hardness and fraction transformed of the strengthening precipitates. It was determined that the Avrami relationships provide a useful approximation of the precipitation behavior at times and temperatures representative of welding thermal cycles. Finally, an autogenous gas tungsten arc (GTA) welding study was performed to demonstrate the utility of multi-pass welding for strength restoration in these alloys. Dual-pass welds were made on samples of each material using a range of heat inputs and secondary weld pass overlap percentages. Hardness mapping was then performed to estimate the extent of precipitate growth and dissolution. It was determined that significant softening occurs after primary weld passes and that secondary weld passes, using a high heat input, restored much of the strength. Furthermore, optimal weld overlap percentages were approximated. It was concluded that controlled weld metal deposition can significantly improve the properties of 17-4 and 13-8+Mo and potentially eliminate the need for costly PWHT's.

Theoretical prediction of welding distortion in large and complex structures

NASA Astrophysics Data System (ADS)

Deng, De-An

2010-06-01

Welding technology is widely used to assemble large thin plate structures such as ships, automobiles, and passenger trains because of its high productivity. However, it is impossible to avoid welding-induced distortion during the assembly process. Welding distortion not only reduces the fabrication accuracy of a weldment, but also decreases the productivity due to correction work. If welding distortion can be predicted using a practical method beforehand, the prediction will be useful for taking appropriate measures to control the dimensional accuracy to an acceptable limit. In this study, a two-step computational approach, which is a combination of a thermoelastic-plastic finite element method (FEM) and an elastic finite element with consideration for large deformation, is developed to estimate welding distortion for large and complex welded structures. Welding distortions in several representative large complex structures, which are often used in shipbuilding, are simulated using the proposed method. By comparing the predictions and the measurements, the effectiveness of the two-step computational approach is verified.

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

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

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

A Weld Position Recognition Method Based on Directional and Structured Light Information Fusion in Multi-Layer/Multi-Pass Welding.

PubMed

Zeng, Jinle; Chang, Baohua; Du, Dong; Wang, Li; Chang, Shuhe; Peng, Guodong; Wang, Wenzhu

2018-01-05

Multi-layer/multi-pass welding (MLMPW) technology is widely used in the energy industry to join thick components. During automatic welding using robots or other actuators, it is very important to recognize the actual weld pass position using visual methods, which can then be used not only to perform reasonable path planning for actuators, but also to correct any deviations between the welding torch and the weld pass position in real time. However, due to the small geometrical differences between adjacent weld passes, existing weld position recognition technologies such as structured light methods are not suitable for weld position detection in MLMPW. This paper proposes a novel method for weld position detection, which fuses various kinds of information in MLMPW. First, a synchronous acquisition method is developed to obtain various kinds of visual information when directional light and structured light sources are on, respectively. Then, interferences are eliminated by fusing adjacent images. Finally, the information from directional and structured light images is fused to obtain the 3D positions of the weld passes. Experiment results show that each process can be done in 30 ms and the deviation is less than 0.6 mm. The proposed method can be used for automatic path planning and seam tracking in the robotic MLMPW process as well as electron beam freeform fabrication process.

29 CFR 1910.254 - Arc welding and cutting.

Code of Federal Regulations, 2010 CFR

2010-07-01

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

Layer Structure of a Refractory Multilayer Ti/Al Composite After Pressure Diffusion Welding

NASA Astrophysics Data System (ADS)

Karpov, M. I.; Korzhov, V. P.; Zheltyakova, I. S.

2016-05-01

A composite refractory material with layer structure obtained by the method of pressure diffusion welding of multilayer Ti/Al packets composed of Ti- and Al-foils is studied. The welding temperature of the packets does not exceed 1200 - 1250°C. A layer structure forms in the process of interdiffusion of titanium and aluminum during welding of the packets.

Nickel aluminide-copper backing for butt joint welding

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

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

1996-12-31

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

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

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

Effect of the Grain Size of the Initial Structure of 1565chM Alloy on the Structure and Properties of the Joints Fabricated by Friction Stir Welding

NASA Astrophysics Data System (ADS)

Ovchinnikov, V. V.; Drits, A. M.; Gureeva, M. A.; Malov, D. V.

2017-12-01

The effect of the initial grain size in the structure of the aluminum 1565chM alloy on the mechanical properties of the welded joints formed by friction stir welding and on the grain size in the weld core is studied. It is shown that the design of tool and, especially, the parameters of a screw groove exert a great effect on the grain size in the weld core.

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

NASA Astrophysics Data System (ADS)

Rule, William K.

1992-12-01

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

[Mechanical properties of weld area soldered by lasers and structural changes in hot reaction zone].

PubMed

Wu, H; Cui, Y; Mu, W

2001-05-01

To analyse and measure the welding depths and strengths of three kinds of welding materials under different laser welding conditions as well as the structural changes of the heat affected zone. Under different voltages and pulse duration three kinds of measuring sticks, including Co-Cr alloy, Ni-Cr alloy and pure titanium were welded and their strengths were compared with that of control group. At the same time, the structure of the heat-affected zone was analysed by means of the gold-phase method. The welding depth and strength of Co-Cr alloy were in direct proportion to the setting voltage, with averages of 335MPa (250V) to 573MPa(330V). At the heat-affected zone, the crystal particle was small and the end point of welding by laser bean presented the shape of the mountain peak and the interval of finger shape. The center of measuring sticks had a black zone with the circle shape. The setting voltage was in direct proportion to the welding depth of pure titanium and in inverse proportion to the welding strength with averages of 221MPa(250V) to 154MPa (330V). The crystal particle in the heat affected zone grew large and the solid phase expanded, the interval of the crystal oxidised, and the structure showed honeycomb changes. The laser welding is favourable to the welding properties of Co-Cr and Ni-Cr alloys, but its effect on the welding properties of pure titanium needs further discussion.

Influence of Heat Input on the Content of Delta Ferrite in the Structure of 304L Stainless Steel GTA Welded Joints

NASA Astrophysics Data System (ADS)

Sejč, Pavol; Kubíček, Rastislav

2011-12-01

Welding of austenitic stainless steel has its specific issues, even when the weldability is considered good. The main problems of austenitic stainless steel welding are connected with its metallurgical weldability. The amount of the components presented in the structure of stainless steel welded joint affect its properties, therefore the understanding of the behavior of stainless steel during its welding is important for successful processing and allows the fabricators the possibility to manage the resulting issues. This paper is focused on the influence of heat input on the structural changes in GTA welded joints of austenitic stainless steel designated: ASTM SA TP 304L.

Application of welding simulation to block joints in shipbuilding and assessment of welding-induced residual stresses and distortions

NASA Astrophysics Data System (ADS)

Fricke, Wolfgang; Zacke, Sonja

2014-06-01

During ship design, welding-induced distortions are roughly estimated as a function of the size of the component as well as the welding process and residual stresses are assumed to be locally in the range of the yield stress. Existing welding simulation methods are very complex and time-consuming and therefore not applicable to large structures like ships. Simplified methods for the estimation of welding effects were and still are subject of several research projects, but mostly concerning smaller structures. The main goal of this paper is the application of a multi-layer welding simulation to the block joint of a ship structure. When welding block joints, high constraints occur due to the ship structure which are assumed to result in accordingly high residual stresses. Constraints measured during construction were realized in a test plant for small-scale welding specimens in order to investigate their and other effects on the residual stresses. Associated welding simulations were successfully performed with fine-mesh finite element models. Further analyses showed that a courser mesh was also able to reproduce the welding-induced reaction forces and hence the residual stresses after some calibration. Based on the coarse modeling it was possible to perform the welding simulation at a block joint in order to investigate the influence of the resulting residual stresses on the behavior of the real structure, showing quite interesting stress distributions. Finally it is discussed whether smaller and idealized models of definite areas of the block joint can be used to achieve the same results offering possibilities to consider residual stresses in the design process.

Automated generation of weld path trajectories.

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

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

2003-06-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

Advanced characterization techniques in understanding the roles of nickel in enhancing strength and toughness of submerged arc welding high strength low alloy steel multiple pass welds in the as-welded condition

NASA Astrophysics Data System (ADS)

Sham, Kin-Ling

Striving for higher strength along with higher toughness is a constant goal in material properties. Even though nickel is known as an effective alloying element in improving the resistance of a steel to impact fracture, it is not fully understood how nickel enhances toughness. It was the goal of this work to assist and further the understanding of how nickel enhanced toughness and maintained strength in particular for high strength low alloy (HSLA) steel submerged arc welding multiple pass welds in the as-welded condition. Using advanced analytical techniques such as electron backscatter diffraction, x-ray diffraction, electron microprobe, differential scanning calorimetry, and thermodynamic modeling software, the effect of nickel was studied with nickel varying from one to five wt. pct. in increments of one wt. pct. in a specific HSLA steel submerged arc welding multiple pass weldment. The test matrix of five different nickel compositions in the as-welded and stress-relieved condition was to meet the targeted mechanical properties with a yield strength greater than or equal to 85 ksi, a ultimate tensile strength greater than or equal to 105 ksi, and a nil ductility temperature less than or equal to -140 degrees F. Mechanical testing demonstrated that nickel content of three wt. pct and greater in the as-welded condition fulfilled the targeted mechanical properties. Therefore, one, three, and five wt. pct. nickel in the as-welded condition was further studied to determine the effect of nickel on primary solidification mode, nickel solute segregation, dendrite thickness, phase transformation temperatures, effective ferrite grain size, dislocation density and strain, grain misorientation distribution, and precipitates. From one to five wt. pct nickel content in the as-welded condition, the primary solidification was shown to change from primary delta-ferrite to primary austenite. The nickel partitioning coefficient increased and dendrite/cellular thickness was refined. Austenite decomposition temperatures into different ferrite products were also suppressed to refine the effective ferrite grain size with increasing nickel. Finally, dislocation density and strain increased and a more preferred orientation behavior was observed. At five wt. pct nickel, a precipitate in the form of MnNi3 or FeNi3 was observed. Its presence in both inter and intragranular regions enhanced strength and toughness by limiting the ferrite grain size and precipitation strengthening.

46 CFR 154.182 - Contiguous hull structure: Production weld test.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 46 Shipping 5 2010-10-01 2010-10-01 false Contiguous hull structure: Production weld test. 154.182... Equipment Hull Structure § 154.182 Contiguous hull structure: Production weld test. If a portion of the contiguous hull structure is designed for a temperature colder than −34 °C (−30 °F) and is not part of the...

46 CFR 154.182 - Contiguous hull structure: Production weld test.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 46 Shipping 5 2011-10-01 2011-10-01 false Contiguous hull structure: Production weld test. 154.182... Equipment Hull Structure § 154.182 Contiguous hull structure: Production weld test. If a portion of the contiguous hull structure is designed for a temperature colder than −34 °C (−30 °F) and is not part of the...

46 CFR 154.182 - Contiguous hull structure: Production weld test.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 46 Shipping 5 2012-10-01 2012-10-01 false Contiguous hull structure: Production weld test. 154.182... Equipment Hull Structure § 154.182 Contiguous hull structure: Production weld test. If a portion of the contiguous hull structure is designed for a temperature colder than −34 °C (−30 °F) and is not part of the...

46 CFR 154.182 - Contiguous hull structure: Production weld test.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 46 Shipping 5 2014-10-01 2014-10-01 false Contiguous hull structure: Production weld test. 154.182... Equipment Hull Structure § 154.182 Contiguous hull structure: Production weld test. If a portion of the contiguous hull structure is designed for a temperature colder than −34 °C (−30 °F) and is not part of the...

46 CFR 154.182 - Contiguous hull structure: Production weld test.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 46 Shipping 5 2013-10-01 2013-10-01 false Contiguous hull structure: Production weld test. 154.182... Equipment Hull Structure § 154.182 Contiguous hull structure: Production weld test. If a portion of the contiguous hull structure is designed for a temperature colder than −34 °C (−30 °F) and is not part of the...

Numerical and Experimental Evaluation on the Residual Stresses of Welded Joints

NASA Astrophysics Data System (ADS)

Huh, Sun Chul; Park, Wonjo; Yang, Haesug; Jung, Haeyoung; Kim, Chuyoung

Wings for the defense industry such as fighters, missiles, and rockets should show no deformation or damage on the structure. The structures of existing wings had holes for weight reduction. The plates and frames were fixed with rivets or screws, which limited the weight reduction possible. In this study, an improvement was made in jointing methods through EB welding and laser welding. Welding strength was measured through tension testing. In addition, finite element analysis was performed for the welding process so as to deduce the optimum welding condition.

75 FR 62847 - Notice of Issuance of Final Determination Concerning an ADFLOTM

Federal Register 2010, 2011, 2012, 2013, 2014

2010-10-13

... country of origin of an Adflo TM Respiration System used in a welding environment. Based upon the facts... used for respiratory protection in a welding environment. The Adflo TM respiration system utilizes a... by the user in a welding environment. The helmet provides the primary protection for the user's head...

Accurate modelling of anisotropic effects in austenitic stainless steel welds

NASA Astrophysics Data System (ADS)

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

2014-02-01

The ultrasonic inspection of austenitic steel welds is challenging due to the formation of highly anisotropic and heterogeneous structures post-welding. This is due to the intrinsic crystallographic structure of austenitic steel, driving the formation of dendritic grain structures on cooling. The anisotropy is manifested as both a `steering' of the ultrasonic beam and the back-scatter of energy due to the macroscopic granular structure of the weld. However, the quantitative effects and relative impacts of these phenomena are not well-understood. A semi-analytical simulation framework has been developed to allow the study of anisotropic effects in austenitic stainless steel welds. Frequency-dependent scatterers are allocated to a weld-region to approximate the coarse grain-structures observed within austenitic welds and imaged using a simulated array. The simulated A-scans are compared against an equivalent experimental setup demonstrating excellent agreement of the Signal to Noise (S/N) ratio. Comparison of images of the simulated and experimental data generated using the Total Focusing Method (TFM) indicate a prominent layered effect in the simulated data. A superior grain allocation routine is required to improve upon this.

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

NASA Technical Reports Server (NTRS)

Witt, R. H.

1972-01-01

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

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.

Formation of Gradient Structures in the Zone of Joining a Deformable Nickel Alloy and a Single-Crystal Intermetallic Alloy during Thermodiffusion Pressure Welding and Subsequent Heat Treatment

NASA Astrophysics Data System (ADS)

Povarova, K. B.; Valitov, V. A.; Drozdov, A. A.; Bazyleva, O. A.; Galieva, E. V.; Arginbaeva, E. G.

2018-01-01

The possibility of formation of a high-quality solid-phase joint of an Ni3Al-based single-crystal intermetallic VKNA-25 blade alloy with a high-temperature deformable EP975 disk alloy by pressure welding is studied to create high-performance one-piece blisk unit for the next-generation aviation gas turbine engines and to decrease the unit mass. The influence of the conditions of thermodiffusion pressure welding under the hightemperature superplasticity of the disk alloy and the influence of heat treatment of welded joints on the gradient structures in the welded joint zone and the structure at the periphery of the welded samples are investigated.

Discussion on Influence of High Strength Bolt’s Parameters on the Weld Reinforced Combined Connection with Bolts and Welds

NASA Astrophysics Data System (ADS)

Ma, Jiansuo; Wang, Yuanqing; Li, Mingfeng; Bai, Runshan; Ban, Huiyong

2018-03-01

In the process of existing steel structure operation, in order to prevent the bolted joints from being damaged by insufficient carrying capacity, welds can be used for reinforcement. Weld reinforced combined connection with bolts and weld consists with high strength bolts and side fillet weld composition. The parameters and properties of high strength bolts and fillet welds have a direct effect on the connection. Based on the test results, We explore the influence that welding seam reinforcement and the performance of the connection between the number of high strength bolts and specifications changes in this paper. It will provide a theoretical reference for the design of connection nodes of steel structure reinforcement project.

Application of lap laser welding technology on stainless steel railway vehicles

NASA Astrophysics Data System (ADS)

Wang, Hongxiao; Wang, Chunsheng; He, Guangzhong; Li, Wei; Liu, Liguo

2016-10-01

Stainless steel railway vehicles with so many advantages, such as lightweight, antirust, low cost of maintenance and simple manufacturing process, so the production of high level stainless steel railway vehicles has become the development strategy of European, American and other developed nations. The current stainless steel railway vehicles body and structure are usually assembled by resistance spot welding process. The weak points of this process are the poor surface quality and bad airtight due to the pressure of electrodes. In this study, the partial penetration lap laser welding process was investigated to resolve the problems, by controlling the laser to stop at the second plate in the appropriate penetration. The lap laser welding joint of stainless steel railway vehicle car body with partial penetration has higher strength and surface quality than those of resistance spot welding joint. The biggest problem of lap laser welding technology is to find the balance of the strength and surface quality with different penetrations. The mechanism of overlap laser welding of stainless steel, mechanical tests, microstructure analysis, the optimization of welding parameters, analysis of fatigue performance, the design of laser welding stainless steel railway vehicles structure and the development of non-destructive testing technology were systematically studied before lap laser welding process to be applied in manufacture of railway vehicles. The results of the experiments and study show that high-quality surface state and higher fatigue strength can be achieved by the partial penetration overlap laser welding of the side panel structure, and the structure strength of the car body can be higher than the requirements of En12663, the standard of structural requirements of railway vehicles bodies. Our company has produced the stainless steel subway and high way railway vehicles by using overlap laser welding technology. The application of lap laser welding will be a big change of railway vehicles manufacturing technology.

Microstructure and abrasive wear properties of Fe-Cr-C hardfacing alloy cladding manufactured by Gas Tungsten Arc Welding (GTAW)

NASA Astrophysics Data System (ADS)

Chen, Jie-Hao; Hsieh, Chih-Chun; Hua, Pei-Shing; Chang, Chia-Ming; Lin, Chi-Ming; Wu, Paxon Ti-Yuan; Wu, Weite

2013-01-01

A series of Fe-Cr-C hardfacing alloys is deposited by gas tungsten arc welding and subjected to abrasive wear testing. Pure Fe with various amounts of CrC (Cr:C=4:1) powders are mixed as the fillers and used to deposit hardfacing alloys on low carbon steel. Depending on the various CrC additions to the alloy fillers, the claddings mainly contain hypoeutectic, near eutectic, or hypereutectic microstructures of austenite γ-Fe phase and (Cr,Fe)7C3 carbides on hardfacing alloys, respectively. When 30% CrC is added to the filler, the finest microstructure is achieved, which corresponds to the γ-Fe+(Cr,Fe)7C3 eutectic structure. With the addition of 35% and 40% CrC to the fillers, the results show that the cladding consists of the massive primary (Cr,Fe)7C3 as the reinforcing phase and interdendritic γ-Fe+(Cr,Fe)7C3 eutectics as the matrix. The (Cr,Fe)7C3 carbide-reinforced claddings have high hardness and excellent wear resistance under abrasive wear test conditions. Concerning the abrasive wear feature observable on the worn surface, the formation and fraction of massive primary (Cr,Fe)7C3 carbides predominates the wear resistance of hardfacing alloys. Abrasive particles result in continuous plastic grooves when the cladding has primary γ-Fe phase in a hypoeutectic structure.

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

NASA Astrophysics Data System (ADS)

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

2016-01-01

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

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

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

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

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 propagatedmore » 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.« less

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

NASA Astrophysics Data System (ADS)

Echer, L.; Marczak, R. J.

2018-02-01

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

Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

NASA Astrophysics Data System (ADS)

Vasantharaja, P.; Vasudevan, M.

2012-02-01

Low Activation Ferritic-Martensitic steels (LAFM) are chosen as the candidate material for structural components in fusion reactors. The structural components are generally fabricated by welding processes. Activated Tungsten Inert Gas (A-TIG) welding is an emerging process for welding of thicker components. In the present work, attempt was made to develop A-TIG welding technology for LAFM steel plates of 10 mm thick. Activated flux was developed for LAFM steel by carrying out various bead-on-plate TIG welds without flux and with flux. The optimum flux was identified as one which gave maximum depth of penetration at minimum heat input values. With the optimized flux composition, LAFM steel plate of 10 mm thickness was welded in square butt weld joint configuration using double side welding technique. Optical and Scanning Electron Microscopy was used for characterizing the microstructures. Microhardness measurements were made across the weld cross section for as welded and post weld heat treated samples. Tensile and impact toughness properties were determined. The mechanical properties values obtained in A-TIG weld joint were comparable to that obtained in weld joints of LAFM steel made by Electron beam welding process.

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

The Light Plane Calibration Method of the Laser Welding Vision Monitoring System

NASA Astrophysics Data System (ADS)

Wang, B. G.; Wu, M. H.; Jia, W. P.

2018-03-01

According to the aerospace and automobile industry, the sheet steels are the very important parts. In the recent years, laser welding technique had been used to weld the sheet steel part. The seam width between the two parts is usually less than 0.1mm. Because the error of the fixture fixed can’t be eliminated, the welding parts quality can be greatly affected. In order to improve the welding quality, the line structured light is employed in the vision monitoring system to plan the welding path before welding. In order to improve the weld precision, the vision system is located on Z axis of the computer numerical control (CNC) tool. The planar pattern is placed on the X-Y plane of the CNC tool, and the structured light is projected on the planar pattern. The vision system stay at three different positions along the Z axis of the CNC tool, and the camera shoot the image of the planar pattern at every position. Using the calculated the sub-pixel center line of the structure light, the world coordinate of the center light line can be calculated. Thus, the structured light plane can be calculated by fitting the structured light line. Experiment result shows the effective of the proposed method.

Predicting laser weld reliability with stochastic reduced-order models. Predicting laser weld reliability

DOE PAGES

Emery, John M.; Field, Richard V.; Foulk, James W.; ...

2015-05-26

Laser welds are prevalent in complex engineering systems and they frequently govern failure. The weld process often results in partial penetration of the base metals, leaving sharp crack-like features with a high degree of variability in the geometry and material properties of the welded structure. Furthermore, accurate finite element predictions of the structural reliability of components containing laser welds requires the analysis of a large number of finite element meshes with very fine spatial resolution, where each mesh has different geometry and/or material properties in the welded region to address variability. We found that traditional modeling approaches could not bemore » efficiently employed. Consequently, a method is presented for constructing a surrogate model, based on stochastic reduced-order models, and is proposed to represent the laser welds within the component. Here, the uncertainty in weld microstructure and geometry is captured by calibrating plasticity parameters to experimental observations of necking as, because of the ductility of the welds, necking – and thus peak load – plays the pivotal role in structural failure. The proposed method is exercised for a simplified verification problem and compared with the traditional Monte Carlo simulation with rather remarkable results.« less

Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Cantrell, Mark; Carter, Robert

2003-01-01

Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading the way for future circumferential weld implementation.

Influence of microstructure and elemental partitioning on pitting corrosion resistance of duplex stainless steel welding joints

NASA Astrophysics Data System (ADS)

Zhang, Zhiqiang; Jing, Hongyang; Xu, Lianyong; Han, Yongdian; Zhao, Lei; Zhang, Jianli

2017-02-01

The influences of microstructure and elemental partitioning on pitting corrosion resistance of duplex stainless steel joints welded by gas tungsten arc welding (GTAW) and flux-cored arc welding (FCAW) with different shielding gas compositions were studied by optical microscopy, electron backscatter diffraction, scanning electron microscopy, transmission electron microscopy, energy dispersive spectroscopy, electron probe microanalysis, and potentiostatic and potentiodynamic polarization methods The adding 2% N2 in shielding gas facilitated primary austenite formation in GTAW weld metal (WM) and suppressed Cr2N precipitation in GTAW weld root. In the HAZ, the banded microstructure disappeared while the coarse ferrite grains maintained same orientation as the banded ferrite in the BM. In the WM, the ferrite had one single orientation throughout a grain, whereas several families of austenite appeared. The austenite both in BM and WM enriched in Ni and nitro`gen, while Cr and Mo were concentrated in the ferrite and thus no element showed clear dendritic distribution in the WM (ER2209 and E2209T1). In addition, the secondary austenite had higher Ni content but lower Cr and Mo content than the primary austenite. The N2-supplemented shielding gas promoted nitrogen solid-solution in the primary and secondary austenite. Furthermore, the secondary austenite had relatively lower pitting resistance equivalent number (PREN) than the ferrite and primary austenite, thereby resulting in its preferential corrosion. The Cr2N precipitation led to relatively poor resistance to pitting corrosion in three HAZs and pure Ar shielding GTAW weld root. The N2-supplemented shielding gas improved pitting corrosion resistance of GTAW joint by increasing PREN of secondary austenite and suppressing Cr2N precipitation. In addition, the FCAW WM had much poorer resistance to pitting corrosion than the GTAW WM due to many O-Ti-Si-Mn inclusions. In the BM, since the austenite with lower PREN compared to the ferrite, the pitting corrosion occurred at the ferrite and austenite interface or within the austenite.

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.

Structure and Microhardness of Cu-Ta Joints Produced by Explosive Welding

PubMed Central

Maliutina, Iu. N.; Mali, V. I.; Bataev, I. A.; Bataev, A. A.; Esikov, M. A.; Smirnov, A. I.; Skorokhod, K. A.

2013-01-01

The structure and microhardness of Cu-Ta joints produced by explosive welding were studied. It was found that, during explosive welding, an intermediate layer 20⋯40 μm thick with a finely dispersed heterophase structure, formed between the welded copper and tantalum plates. The structure of the layer was studied by scanning and transmission electron microscopy. Microvolumes with tantalum particles distributed in a copper matrix and microvolumes of copper particles in a tantalum matrix were detected. The tantalum particles in copper have a size of 5⋯500 nm, with a predominance of 5⋯50 nm particles. A mechanism for the formation of the finely dispersed heterophase structure in explosive welding is proposed. The microhardness of interlayers with the heterophase structure reaches 280 HV, which far exceeds the microhardness of copper (~130 HV) and tantalum (~160 HV). Many twins of deformation origin were found in the structure of the copper plate. The effect of heating temperature in the range from 100 to 900°C on the microhardness of copper, tantalum, and the Cu-Ta welded joint was studied. Upon heating to 900°C, the microhardness of the intermediate layer decreases from 280 to 150 HV. The reduction in the strength properties of the weld material is mainly due to structural transformations in copper. PMID:24453818

Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

Shear Bond Strength of Intraoral Laser Welding and its Effect on Intrapulpal Temperature Rise in Primary Teeth: An in Vitro Study.

PubMed

Aglarci, Cahide; Yildiz, Esma; Isman, Eren; Kazak, Mine

2016-03-01

This study compared the shear bond strength (SBS) of conventional welding (CW) and intraoral laser welding (LW) on fixed space maintainers (SMs), and investigated the intrapulpal temperature change (ITC) during LW. Lasers have been used for intraoral welding. The SBS test used 26 molar bands divided into two groups, CW and LW. Stainless steel wires were welded to the middle of the buccal and lingual aspects of all the bands, using an Nd:YAG laser for the LW group and silver solder and flux soldering media for the CW group. The samples, fixed to acrylic resin blocks, were subjected to shear testing. In the ITC test, 25 exfoliated primary second molar teeth were used to adapt molar bands. J-type thermocouple wire was positioned in the pulp chamber. ITCs were determined during Nd:YAG laser welding of stainless steel wires to the bands. Mann-Whitney U test was used to determine differences in SBS between the groups. ITCs were analyzed by paired t test. The SBS between groups showed significant differences (LW: 489.47 ± 135.70; CW: 49.71 ± 17.76; p < 0.001). The mean ITC during LW was 3.64 ± 0.79 (min: 2.4; max: 5.10). None of the samples' ITCs exceeded the critical threshold value (5.5 °C). LW obtained a higher-strength joint than CW. ITCs during LW do not present a thermal risk to primary teeth. The intraoral use of LW for SMs in primary teeth is recommended in terms of strength and ITCs.

Simulation of Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes

DTIC Science & Technology

2015-11-01

induced residual stresses and distortions from weld simulations in the SYSWELD software code in structural Finite Element Analysis ( FEA ) simulations...performed in the Abaqus FEA code is presented. The translation of these results is accomplished using a newly developed Python script. Full details of...Local Weld Model in Structural FEA ....................................................15 CONCLUSIONS

Strategic Alliances: Making a Difference One Warfighter At a Time

DTIC Science & Technology

2011-03-12

Prototype Integration Planning Machining / CNC / Metals Welding Assembly / Paint Integration •Field-Experienced Veterans •Component, Subsystems...Wiring Harness •CAD/CAM CNC Programming •Quick reaction of parts - CNC , Lathes, Mills, Water Jet/Laser Cutting Design •Mechanical, Electrical...DEFORMATION RESISTANCE WELDING • Tubular Structural welding, Light weight structures COMBINED PLASMA -MIG ARC WELDING • Faster than any other

Transport and Deposition of Welding Fume Agglomerates in a Realistic Human Nasal Airway.

PubMed

Tian, Lin; Inthavong, Kiao; Lidén, Göran; Shang, Yidan; Tu, Jiyuan

2016-07-01

Welding fume is a complex mixture containing ultra-fine particles in the nanometer range. Rather than being in the form of a singular sphere, due to the high particle concentration, welding fume particles agglomerate into long straight chains, branches, or other forms of compact shapes. Understanding the transport and deposition of these nano-agglomerates in human respiratory systems is of great interest as welding fumes are a known health hazard. The neurotoxin manganese (Mn) is a common element in welding fumes. Particulate Mn, either as soluble salts or oxides, that has deposited on the olfactory mucosa in human nasal airway is transported along the olfactory nerve to the olfactory bulb within the brain. If this Mn is further transported to the basal ganglia of the brain, it could accumulate at the part of the brain that is the focal point of its neurotoxicity. Accounting for various dynamic shape factors due to particle agglomeration, the current computational study is focused on the exposure route, the deposition pattern, and the deposition efficiency of the inhaled welding fume particles in a realistic human nasal cavity. Particular attention is given to the deposition pattern and deposition efficiency of inhaled welding fume agglomerates in the nasal olfactory region. For particles in the nanoscale, molecular diffusion is the dominant transport mechanism. Therefore, Brownian diffusion, hydrodynamic drag, Saffman lift force, and gravitational force are included in the model study. The deposition efficiencies for single spherical particles, two kinds of agglomerates of primary particles, two-dimensional planar and straight chains, are investigated for a range of primary particle sizes and a range of number of primary particles per agglomerate. A small fraction of the inhaled welding fume agglomerates is deposited on the olfactory mucosa, approximately in the range 0.1-1%, and depends on particle size and morphology. The strong size dependence of the deposition in olfactory mucosa on particle size implies that the occupation deposition of welding fume manganese can be expected to vary with welding method. © The Author 2016. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.

Investigation of the structure and properties of a composite insert applied at laser welding of steel with titanium

NASA Astrophysics Data System (ADS)

Pugacheva, N. B.; Cherepanov, A. N.; Orishich, A. M.; Malikov, A. G.; Drozdov, V. O.; Mali, V. I.; Senaeva, E. I.

2017-10-01

Production of welded bimetallic structures of titanium and steel using a laser beam is a very urgent and important task in the shipbuilding, airspace and power engineering. Laser welding using an intermediate insert is one of the ways to solve this problem. In this paper, we present the results of experimental studies of formation of the structure and properties of composite insert, obtained by explosion welding, after its application at laser welding steel with titanium. A study of a four-layer composite insert obtained by explosion welding showed that it has no brittle intermetallic phases and defects in the form of cracks and pores. The boundaries between the plates to be welded in the composite insert have a characteristic wavy structure with narrow zones of mutual diffusion penetration of elements of the adjacent metals. It is established that the strength of the composite insert is comparable with the maximum strength of Grade 4 alloy, and the destruction of the product during the tensile tests in most cases occurred along the weakest component of the composite insert, i.e. the copper layer, whose strength was significantly increased due to the hardening that took place in the explosion welding.

Summary of Results of Tests Made by Aluminum Research Laboratories of Spot-welded Joints and Structural Elements

NASA Technical Reports Server (NTRS)

HARTMANN E C; Stickley, G W

1942-01-01

Available information concerning spot welding as a means of joining aluminum-alloy parts has been summarized and comparisons have been made of the relative merits of spot-welded and riveted aluminum-alloy structural elements. The results indicated that spot welding was as satisfactory as riveting insofar as resistance to static loads is concerned. Spot welds showed slightly lower resistance to impact loads but definitely lower resistance to repeated loads than rivets.

Microstructural analysis of laser weld fusion zone in Haynes 282 superalloy

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

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

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

Research on Ultrasonic Flaw Detection of Steel Weld in Spatial Grid Structure

NASA Astrophysics Data System (ADS)

Du, Tao; Sun, Jiandong; Fu, Shengguang; Zhang, Changquan; Gao, Qing

2017-06-01

The welding quality of spatial grid member is an important link in quality control of steel structure. The paper analyzed the reasons that the welding seam of small-bore pipe with thin wall grid structure is difficult to be detected by ultrasonic wave from the theoretical and practical aspects. A series of feasible detection methods was also proposed by improving probe and operation approaches in this paper, and the detection methods were verified by project cases. Over the years, the spatial grid structure is widely used the engineering by virtue of its several outstanding characteristics such as reasonable structure type, standard member, excellent space integrity and quick installation. The wide application of spatial grid structure brings higher requirements on nondestructive test of grid structure. The implementation of new Code for Construction Quality Acceptance of Steel Structure Work GB50205-2001 strengthens the site inspection of steel structure, especially the site inspection of ultrasonic flaw detection in steel weld. The detection for spatial grid member structured by small-bore and thin-walled pipes is difficult due to the irregular influence of sound pressure in near-field region of sound field, sound beam diffusion generated by small bore pipe and reduction of sensitivity. Therefore, it is quite significant to select correct detecting conditions. The spatial grid structure of welding ball and bolt ball is statically determinate structure with high-order axial force which is connected by member bars and joints. It is welded by shrouding or conehead of member bars and of member bar and bolt-node sphere. It is obvious that to ensure the quality of these welding positions is critical to the quality of overall grid structure. However, the complexity of weld structure and limitation of ultrasonic detection method cause many difficulties in detection. No satisfactory results will be obtained by the conventional detection technology, so some special approaches must be used.

A Scanning Transmission Electron Microscopy Method for Determining Manganese Composition in Welding Fume as a Function of Primary Particle Size

PubMed Central

Richman, Julie D.; Livi, Kenneth J.T.; Geyh, Alison S.

2011-01-01

Increasing evidence suggests that the physicochemical properties of inhaled nanoparticles influence the resulting toxicokinetics and toxicodynamics. This report presents a method using scanning transmission electron microscopy (STEM) to measure the Mn content throughout the primary particle size distribution of welding fume particle samples collected on filters for application in exposure and health research. Dark field images were collected to assess the primary particle size distribution and energy-dispersive X-ray and electron energy loss spectroscopy were performed for measurement of Mn composition as a function of primary particle size. A manual method incorporating imaging software was used to measure the primary particle diameter and to select an integration region for compositional analysis within primary particles throughout the size range. To explore the variation in the developed metric, the method was applied to 10 gas metal arc welding (GMAW) fume particle samples of mild steel that were collected under a variety of conditions. The range of Mn composition by particle size was −0.10 to 0.19 %/nm, where a positive estimate indicates greater relative abundance of Mn increasing with primary particle size and a negative estimate conversely indicates decreasing Mn content with size. However, the estimate was only statistically significant (p<0.05) in half of the samples (n=5), which all had a positive estimate. In the remaining samples, no significant trend was measured. Our findings indicate that the method is reproducible and that differences in the abundance of Mn by primary particle size among welding fume samples can be detected. PMID:21625364

A Scanning Transmission Electron Microscopy Method for Determining Manganese Composition in Welding Fume as a Function of Primary Particle Size.

PubMed

Richman, Julie D; Livi, Kenneth J T; Geyh, Alison S

2011-06-01

Increasing evidence suggests that the physicochemical properties of inhaled nanoparticles influence the resulting toxicokinetics and toxicodynamics. This report presents a method using scanning transmission electron microscopy (STEM) to measure the Mn content throughout the primary particle size distribution of welding fume particle samples collected on filters for application in exposure and health research. Dark field images were collected to assess the primary particle size distribution and energy-dispersive X-ray and electron energy loss spectroscopy were performed for measurement of Mn composition as a function of primary particle size. A manual method incorporating imaging software was used to measure the primary particle diameter and to select an integration region for compositional analysis within primary particles throughout the size range. To explore the variation in the developed metric, the method was applied to 10 gas metal arc welding (GMAW) fume particle samples of mild steel that were collected under a variety of conditions. The range of Mn composition by particle size was -0.10 to 0.19 %/nm, where a positive estimate indicates greater relative abundance of Mn increasing with primary particle size and a negative estimate conversely indicates decreasing Mn content with size. However, the estimate was only statistically significant (p<0.05) in half of the samples (n=5), which all had a positive estimate. In the remaining samples, no significant trend was measured. Our findings indicate that the method is reproducible and that differences in the abundance of Mn by primary particle size among welding fume samples can be detected.

Accurate modelling of anisotropic effects in austenitic stainless steel welds

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

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

2014-02-18

The ultrasonic inspection of austenitic steel welds is challenging due to the formation of highly anisotropic and heterogeneous structures post-welding. This is due to the intrinsic crystallographic structure of austenitic steel, driving the formation of dendritic grain structures on cooling. The anisotropy is manifested as both a ‘steering’ of the ultrasonic beam and the back-scatter of energy due to the macroscopic granular structure of the weld. However, the quantitative effects and relative impacts of these phenomena are not well-understood. A semi-analytical simulation framework has been developed to allow the study of anisotropic effects in austenitic stainless steel welds. Frequency-dependent scatterersmore » are allocated to a weld-region to approximate the coarse grain-structures observed within austenitic welds and imaged using a simulated array. The simulated A-scans are compared against an equivalent experimental setup demonstrating excellent agreement of the Signal to Noise (S/N) ratio. Comparison of images of the simulated and experimental data generated using the Total Focusing Method (TFM) indicate a prominent layered effect in the simulated data. A superior grain allocation routine is required to improve upon this.« less

Weldability of an iron meteorite by Friction Stir Spot Welding: A contribution to in-space manufacturing

NASA Astrophysics Data System (ADS)

Evans, William Todd; Neely, Kelsay E.; Strauss, Alvin M.; Cook, George E.

2017-11-01

Friction Stir Welding has been proposed as an efficient and appropriate method for in space welding. It has the potential to serve as a viable option for assembling large scale space structures. These large structures will require the use of natural in space materials such as those available from iron meteorites. Impurities present in most iron meteorites limit its ability to be welded by other space welding techniques such as electron beam laser welding. This study investigates the ability to weld pieces of in situ Campo del Cielo meteorites by Friction Stir Spot Welding. Due to the rarity of the material, low carbon steel was used as a model material to determine welding parameters. Welded samples of low carbon steel, invar, and Campo del Cielo meteorite were compared and found to behave in similar ways. This study shows that meteorites can be Friction Stir Spot Welded and that they exhibit properties analogous to that of FSSW low carbon steel welds. Thus, iron meteorites can be regarded as another viable option for in-space or Martian construction.

Laser-Assisted Stir Welding of 25-mm-Thick HSLA-65 Plate

NASA Astrophysics Data System (ADS)

Williamson, Keith M.

2002-12-01

Laser-assisted stir welding is a hybrid process that combines energy from a laser with functional heating and mechanical energy to join materials in the solid state. The technology is an adaptation of friction stir welding which is particularly suited for joining thick plates. Aluminum plates up to 75 mm thick have been successfully joined using friction stir welding. Since joining occurs in the solid state, stir technology offers the capability for fabricating full penetration joints in thick plates with better mechanical properties and less weld distortion than is possible by fusion processes. Currently friction stir welding is being used in several industries to improve productivity, reduce weight, and increase the strength of welded structures. Examples include: (a) the aircraft/aerospace industry where stir technology is currently being used to fabricate the space shuttle's external tank as well as components of the Delta family of rockets; (b) the shipping industry where container manufacturers are using stir technology to produce lighter containers with more payload capacity; and (c) the oil industry where offshore platform manufactures are using automated stir welding plants to fabricate large panels and structures up to 16 meters long with widths as required. In all these cases, stir technology has been restricted to aluminum alloys; however, stainless and HSLA 65 steels have been recently stir welded with friction as the primary heat source. One of the difficulties in adapting stir welding to steel is tool wear aggravated by the high tool rubbing velocities needed to provide frictional heat input into the material. Early work showed that the tool shoulder reached temperatures above 1000 C and the weld seam behind the tool stayed within this temperature range for up to 25 mm behind the tool. Cross sections of stir welded samples showed that the heat-affected zone is relatively wide and follows the profile of the tool shoulder. Besides minimizing the tool wear by increasing the energy into the material, another benefit of the proposed Laser Assisted Stir Welding (LASW is to reduce the width of the heat affected zone which typically has the lowest hardness in the weld region. Additionally, thermal modeling of the friction stir process shows that the heat input is asymmetric and suggests that the degree of asymmetry could improve the efficiency of the process. These asymmetries occur because the leading edge of the tool supplies heat to cold material while the trailing edge provides heat to material already preheated by the leading edge. As a result, flow stresses on the advancing side of the joint are lower than corresponding values on the retreating side. The proposed LASW process enhances these asymmetries by providing directional heating to increase the differential in flow stress across the joint and improve the stir tool efficiency. Theoretically the LASW process can provide the energy input to allow the flow stresses on the advancing side to approach zero and the stir efficiency to approach 100 percent. Reducing the flow stresses on the advancing side of the weld creates the greatest pressure differential across the stir weld and eliminates the possibility of voids on the advancing side of the joint. Small pressure differentials result in poor stir welds because voids on the advancing side are not filled by the plastic flow of material from the retreating side.

A Cross Structured Light Sensor and Stripe Segmentation Method for Visual Tracking of a Wall Climbing Robot

PubMed Central

Zhang, Liguo; Sun, Jianguo; Yin, Guisheng; Zhao, Jing; Han, Qilong

2015-01-01

In non-destructive testing (NDT) of metal welds, weld line tracking is usually performed outdoors, where the structured light sources are always disturbed by various noises, such as sunlight, shadows, and reflections from the weld line surface. In this paper, we design a cross structured light (CSL) to detect the weld line and propose a robust laser stripe segmentation algorithm to overcome the noises in structured light images. An adaptive monochromatic space is applied to preprocess the image with ambient noises. In the monochromatic image, the laser stripe obtained is recovered as a multichannel signal by minimum entropy deconvolution. Lastly, the stripe centre points are extracted from the image. In experiments, the CSL sensor and the proposed algorithm are applied to guide a wall climbing robot inspecting the weld line of a wind power tower. The experimental results show that the CSL sensor can capture the 3D information of the welds with high accuracy, and the proposed algorithm contributes to the weld line inspection and the robot navigation. PMID:26110403

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

NASA Astrophysics Data System (ADS)

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

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

Improving Processes of Mechanized Pulsed Arc Welding of Low-Frequency Range Variation of Mode Parameters

NASA Astrophysics Data System (ADS)

Saraev, Yu N.; Solodskiy, S. A.; Ulyanova, O. V.

2016-04-01

A new technology of low-frequency modulation of the arc current in MAG and MIG welding is presented. The technology provides control of thermal and crystallization processes, stabilizes the time of formation and crystallization of the weld pool. Conducting theoretical studies allowed formulating the basic criteria for obtaining strong permanent joints for high-duty structures, providing conditions for more equilibrium structure of the deposited metal and the smaller width of the HAZ. The stabilization of time of the formation and crystallization of the weld pool improves the formation of the weld and increases productivity in welding thin sheet metal.

Experimental Investigation on Laser Impact Welding of Fe-Based Amorphous Alloys to Crystalline Copper

PubMed Central

Wang, Xiao; Luo, Yapeng; Huang, Tao; Liu, Huixia

2017-01-01

Recently, amorphous alloys have attracted many researchers’ attention for amorphous structures and excellent properties. However, the welding of amorphous alloys to traditional metals in the microscale is not easy to realize in the process with amorphous structures unchanged, which restrains the application in industry. In this paper, a new method of welding Fe-based amorphous alloys (GB1K101) to crystalline copper by laser impact welding (LIW) is investigated. A series of experiments was conducted under different laser energies, during which Fe-based amorphous alloys and crystalline copper were welded successfully by LIW. In addition, the microstructure and mechanical properties of welding joints were observed and measured, respectively. The results showed that the surface wave and springback were observed on the flyer plate after LIW. The welding interface was straight or wavy due to different plastic deformation under different laser energies. The welding interface was directly bonded tightly without visible defects. No visible element diffusion and intermetallic phases were found in the welding interface. The Fe-based amorphous alloys retained amorphous structures after LIW under the laser energy of 835 mJ. The nanoindentation hardness across the welding interface showed an increase on both sides of the welding interface. The results of the lap shearing test showed that the fracture position was on the side of copper coil. PMID:28772886

Experimental Investigation on Laser Impact Welding of Fe-Based Amorphous Alloys to Crystalline Copper.

PubMed

Wang, Xiao; Luo, Yapeng; Huang, Tao; Liu, Huixia

2017-05-12

Recently, amorphous alloys have attracted many researchers' attention for amorphous structures and excellent properties. However, the welding of amorphous alloys to traditional metals in the microscale is not easy to realize in the process with amorphous structures unchanged, which restrains the application in industry. In this paper, a new method of welding Fe-based amorphous alloys (GB1K101) to crystalline copper by laser impact welding (LIW) is investigated. A series of experiments was conducted under different laser energies, during which Fe-based amorphous alloys and crystalline copper were welded successfully by LIW. In addition, the microstructure and mechanical properties of welding joints were observed and measured, respectively. The results showed that the surface wave and springback were observed on the flyer plate after LIW. The welding interface was straight or wavy due to different plastic deformation under different laser energies. The welding interface was directly bonded tightly without visible defects. No visible element diffusion and intermetallic phases were found in the welding interface. The Fe-based amorphous alloys retained amorphous structures after LIW under the laser energy of 835 mJ. The nanoindentation hardness across the welding interface showed an increase on both sides of the welding interface. The results of the lap shearing test showed that the fracture position was on the side of copper coil.

Effect of welding structure and δ-ferrite on fatigue properties for TIG welded austenitic stainless steels at cryogenic temperatures

NASA Astrophysics Data System (ADS)

Yuri, Tetsumi; Ogata, Toshio; Saito, Masahiro; Hirayama, Yoshiaki

2000-04-01

High-cycle and low-cycle fatigue properties of base and weld metals for SUS304L and SUS316L and the effects of welding structure and δ-ferrite on fatigue properties were investigated at cryogenic temperatures in order to evaluate the long-life reliability of the structural materials to be used in liquid hydrogen supertankers and storage tanks and to develop a welding process for these applications. The S-N curves of the base and weld metals shifted towards higher levels, i.e., the longer life side, with decreasing test temperatures. High-cycle fatigue tests demonstrated the ratios of fatigue strength at 10 6 cycles to tensile strength of the weld metals to be 0.35-0.7, falling below those of base metals with decreasing test temperatures. Fatigue crack initiation sites in SUS304L weld metals were mostly at blowholes with diameters of 200-700 μm, and those of SUS316L weld metals were at weld pass interface boundaries. Low-cycle fatigue tests revealed the fatigue lives of the weld metals to be somewhat lower than those of the base metals. Although δ-ferrite reduces the toughness of austenitic stainless steels at cryogenic temperatures, the effects of δ-ferrite on high-cycle and low-cycle fatigue properties are not clear or significant.

Quasi-Rayleigh waves in butt-welded thick steel plate

NASA Astrophysics Data System (ADS)

Kamas, Tuncay; Giurgiutiu, Victor; Lin, Bin

2015-03-01

This paper discusses theoretical and experimental analyses of weld guided surface acoustic waves (SAW) through the guided wave propagation (GWP) analyses. The GWP analyses have been carried out by utilizing piezoelectric wafer active sensors (PWAS) for in situ structural inspection of a thick steel plate with butt weld as the weld bead is ground flush. Ultrasonic techniques are commonly used for validation of welded structures in many in-situ monitoring applications, e.g. in off-shore structures, in nuclear and pressure vessel industries and in a range of naval applications. PWAS is recently employed in such ultrasonic applications as a resonator as well as a transducer. Quasi-Rayleigh waves a.k.a. SAW can be generated in relatively thick isotropic elastic plate having the same phase velocity as Rayleigh waves whereas Rayleigh waves are a high frequency approximation of the first symmetric (S0) and anti-symmetric (A0) Lamb wave modes. As the frequency becomes very high the S0 and the A0 wave speeds coalesce, and both have the same value. This value is exactly the Rayleigh wave speed and becomes constant along the frequency i.e. Rayleigh waves are non-dispersive guided surface acoustic waves. The study is followed with weld-GWP tests through the pitch-catch method along the butt weld line. The tuning curves of quasi-Rayleigh wave are determined to show the tuning and trapping effect of the weld bead that has higher thickness than the adjacent plates on producing a dominant quasi-Rayleigh wave mode. The significant usage of the weld tuned and guided quasi-Rayleigh wave mode is essentially discussed for the applications in the in-situ inspection of relatively thick structures with butt weld such as naval offshore structures. The paper ends with summary, conclusions and suggestions for future work.

Heat treatment stabilizes welded aluminum jigs and tool structures

NASA Technical Reports Server (NTRS)

Mehnert, R. S.

1966-01-01

Heat treatment processes, applied after welding but before machining, imparts above normal stability to welded aluminum jigs and tool structures. Weight saving will not be realized in these tools if rigidity equal to that of a comparable steel tool is required.

Mechanistic Models of Friction Stir Welding

NASA Technical Reports Server (NTRS)

Stewart, Michael B.

1998-01-01

Friction stir welding is a welding process developed at The Welding Institute (TWI) in England. The method uses very large strain plastic deformation of the material to join two pieces of metal together. The material is deformed using a tool which is forced between the two pieces which rotates causing a bond. Beyond this, very little is actually known although many people working in the field are willing to speculate on the detailed mechanisms involved. Some measurements made using sacrificial thermocouples at the weld joint indicate that the maximum temperature during the weld process is on the order of 370C - well below the melting temperature of the material. However, at this temperature, the material properties are highly temperature dependent, and the yield stress is approximately an order of magnitude less at this temperature than it is at room temperature. As expected, there are many interpretations of the physical mechanisms occurring during the weld process. Although there is very little published concerned with FSW, some of the anecdotal theories will be described. One describes the primary mechanism as frictional heating at the front of the tool caused by slip between the tool and the material. At elevated temperatures, the weld material becomes soft and deforms around the tool but not essentially altered by the tool rotation, similar to an extrusion. As the material meets again at the rear of the tool, the temperatures and pressures are sufficient to cause the material to bond. All other structures seen are secondary and unimportant. Another theory examined last summer at NASA's Marshall Space Flight Center (MSFC) was that there was no slip between the tool and the material resulting in a rotating mass of plastic weld material traveling at a variety of angular velocities - the greatest at the tool surface diminishing to zero at the outer edge of the plastic mass surrounding the tool. This conceptual model was followed by simplified calculations which showed that the balance of moments through the weld plug was not possible under steady state conditions and realistic temperature profiles. This led to some consideration of a quasi-steady oscillating process. Later when force measurements became available some models were modified and new ones were proposed.

Influence of the welding temperature and the welding speed on the mechanical properties of friction stir welds in EN AW-2219-T87

NASA Astrophysics Data System (ADS)

Bachmann, A.; Krutzlinger, M.; Zaeh, M. F.

2018-06-01

Friction Stir Welding (FSW) is an innovative joining technique, which has proven to produce high quality joints in high strength aluminum alloys. Consequently, it is commonly used to manufacture lightweight aerospace structures with stringent requirements. For these structures, it is necessary to ensure a high ultimate tensile strength (UTS). Various studies have reported that the UTS is significantly influenced by the welding parameters. Samples welded with different parameter sets showed a considerably different UTS, despite being free from detectable welding defects (e.g. tunnel defect, voids, or lack of penetration). Based on the observations in the literature, a hypothesis was posed. The welding temperature along with the welding speed determine the UTS of the weld. This study aims to prove this hypothesis experimentally by using temperature-controlled FSW to join plates of EN AW-2219-T87 in butt joint configuration. The welded samples were examined using visual inspection, metallography, X-ray imaging, and uniaxial tensile tests. Finally, a statistical analysis was conducted. Hereby, the hypothesis was confirmed.

Joining technologies for the 1990s: Welding, brazing, soldering, mechanical, explosive, solid-state, adhesive

NASA Technical Reports Server (NTRS)

Buckley, John D. (Editor); Stein, Bland A. (Editor)

1986-01-01

A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Society, 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.

Studying heat-affected zone deformations of electric arc welding

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Double shroud delivery of silica precursor for reducing hexavalent chromium in welding fume.

PubMed

Wang, Jun; Kalivoda, Mark; Guan, Jianying; Theodore, Alexandros; Sharby, Jessica; Wu, Chang-Yu; Paulson, Kathleen; Es-Said, Omar

2012-01-01

The welding process yields a high concentration of nanoparticles loaded with hexavalent chromium (Cr(6+)), a known human carcinogen. Previous studies have demonstrated that using tetramethylsilane (TMS) as a shielding gas additive can significantly reduce the Cr(6+) concentration in welding fume particles. In this study, a novel insulated double shroud torch (IDST) was developed to further improve the reduction of airborne Cr(6+) concentration by separating the flows of the primary shielding gas and the TMS carrier gas. Welding fumes were collected from a welding chamber in the laboratory and from a fixed location near the welding arc in a welding facility. The Cr(6+) content was analyzed with ion chromatography and X-ray photoelectron spectroscopy (XPS). Results from the chamber sampling demonstrated that the addition of 3.2 ≈ 5.1% of TMS carrier gas to the primary shielding gas resulted in more than a 90% reduction of airborne Cr(6+) under all shielding gas flow rates. The XPS result confirmed complete elimination of Cr(6+) inside the amorphous silica shell. Adding 100 ≈ 1000 ppm of nitric oxide or carbon monoxide to the shielding gas could also reduce Cr(6+) concentrations up to 57% and 35%, respectively; however, these reducing agents created potential hazards from the release of unreacted agents. Results of the field test showed that the addition of 1.6% of TMS carrier gas to the primary shielding gas reduced Cr(6+) concentration to the limitation of detection (1.1 μg/m(3)). In a worst-case scenario, if TMS vapor leaked into the environment without decomposition and ventilation, the estimated TMS concentration in the condition of field sampling would be a maximum 5.7 ppm, still well below its flammability limit (1%). Based on a previously developed cost model, the use of TMS increases the general cost by 3.8%. No visual deterioration of weld quality caused by TMS was found, although further mechanical testing is necessary.

Effect of a microstructure and surface hydrogen alloying of a VT6 alloy on diffusion welding

NASA Astrophysics Data System (ADS)

Senkevich, K. S.; Skvortsova, S. V.; Kudelina, I. M.; Knyazev, M. I.; Zasypkin, V. V.

2014-01-01

The effect of a structural type (lamellar, fine, gradient) and additional surface alloying with hydrogen on the diffusion bonding of titanium alloy VT6 samples is studied. It is shown that the surface alloying of VT6 alloy parts with hydrogen allows one to decrease the diffusion welding temperature by 50-100°C, to obtain high-quality pore-free bonding, and to remove the "structural" boundary between materials to be welded that usually forms during welding of titanium alloys with a lamellar structure.

An evaluation of GTAW-P versus GTA welding of alloy 718

NASA Technical Reports Server (NTRS)

Gamwell, W. R.; Kurgan, C.; Malone, T. W.

1991-01-01

Mechanical properties were evaluated to determine statistically whether the pulsed current gas tungsten arc welding (GTAW-P) process produces welds in alloy 718 with room temperature structural performance equivalent to current Space Shuttle Main Engine (SSME) welds manufactured by the constant current GTAW-P process. Evaluations were conducted on two base metal lots, two filler metal lots, two heat input levels, and two welding processes. The material form was 0.125-inch (3.175-mm) alloy 718 sheet. Prior to welding, sheets were treated to either the ST or STA-1 condition. After welding, panels were left as welded or heat treated to the STA-1 condition, and weld beads were left intact or machined flush. Statistical analyses were performed on yield strength, ultimate tensile strength (UTS), and high cycle fatigue (HCF) properties for all the post welded material conditions. Analyses of variance were performed on the data to determine if there were any significant effects on UTS or HCF life due to variations in base metal, filler metal, heat input level, or welding process. Statistical analyses showed that the GTAW-P process does produce welds with room temperature structural performance equivalent to current SSME welds manufactured by the GTAW process, regardless of prior material condition or post welding condition.

A novel ultrasonic NDE for shrink fit welded structures using interface waves.

PubMed

Lee, Jaesun; Park, Junpil; Cho, Younho

2016-05-01

Reactor vessel inspection is a critical part of safety maintenance in a nuclear power plant. The inspection of shrink fit welded structures in a reactor nozzle can be a challenging task due to the complicated geometry. Nozzle inspection using pseudo interface waves allows us to inspect the nozzle from outside of the nuclear reactor. In this study, layered concentric pipes were manufactured with perfect shrink fit conditions using stainless steel 316. The displacement distributions were calculated with boundary conditions for a shrink fit welded structure. A multi-transducer guided wave phased array system was employed to monitor the welding quality of the nozzle end at a distance from a fixed position. The complicated geometry of a shrink fit welded structure can be overcome by using the pseudo interface waves in identifying the location and size of defects. The experimental results demonstrate the feasibility of detecting weld delamination and defects. Copyright © 2016 Elsevier B.V. All rights reserved.

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

An Approach to Maximize Weld Penetration During TIG Welding of P91 Steel Plates by Utilizing Image Processing and Taguchi Orthogonal Array

NASA Astrophysics Data System (ADS)

Singh, Akhilesh Kumar; Debnath, Tapas; Dey, Vidyut; Rai, Ram Naresh

2017-10-01

P-91 is modified 9Cr-1Mo steel. Fabricated structures and components of P-91 has a lot of application in power and chemical industry owing to its excellent properties like high temperature stress corrosion resistance, less susceptibility to thermal fatigue at high operating temperatures. The weld quality and surface finish of fabricated structure of P91 is very good when welded by Tungsten Inert Gas welding (TIG). However, the process has its limitation regarding weld penetration. The success of a welding process lies in fabricating with such a combination of parameters that gives maximum weld penetration and minimum weld width. To carry out an investigation on the effect of the autogenous TIG welding parameters on weld penetration and weld width, bead-on-plate welds were carried on P91 plates of thickness 6 mm in accordance to a Taguchi L9 design. Welding current, welding speed and gas flow rate were the three control variables in the investigation. After autogenous (TIG) welding, the dimension of the weld width, weld penetration and weld area were successfully measured by an image analysis technique developed for the study. The maximum error for the measured dimensions of the weld width, penetration and area with the developed image analysis technique was only 2 % compared to the measurements of Leica-Q-Win-V3 software installed in optical microscope. The measurements with the developed software, unlike the measurements under a microscope, required least human intervention. An Analysis of Variance (ANOVA) confirms the significance of the selected parameters. Thereafter, Taguchi's method was successfully used to trade-off between maximum penetration and minimum weld width while keeping the weld area at a minimum.

Robot welding process control

NASA Technical Reports Server (NTRS)

Romine, Peter L.

1991-01-01

This final report documents the development and installation of software and hardware for Robotic Welding Process Control. Primary emphasis is on serial communications between the CYRO 750 robotic welder, Heurikon minicomputer running Hunter & Ready VRTX, and an IBM PC/AT, for offline programming and control and closed-loop welding control. The requirements for completion of the implementation of the Rocketdyne weld tracking control are discussed. The procedure for downloading programs from the Intergraph, over the network, is discussed. Conclusions are made on the results of this task, and recommendations are made for efficient implementation of communications, weld process control development, and advanced process control procedures using the Heurikon.

Use of photostress to characterize the mechanical behavior of weldments

NASA Technical Reports Server (NTRS)

Gambrell, S. C., Jr.

1992-01-01

Welded aluminum is an important part of many space structures. Knowledge of the properties and behavior of weld material and the material surrounding the weld is important for modeling and design of the structures. Photoelastic coatings (Photostress) and strain gages were used to determine behavior of heat treated and as welded joints made from 2219T87 parent material and 2319 weld material subjected to tensile loads. TIG welds of 1/8, 1/2, and 1.4 inches thickness were investigated. Discontinuous yielding was observed in all tests and highly non-uniform behavior through the weld thickness was observed in joints having welds 1.4 inches thick. Joints having welds 1/8 and 1/2 inches thick had only small differences in behavior through the thickness of the weld. Joints in the 1/2 inch thick material contained distinct zones of constant strain within the normal strain gradient extending outward from the weld centerline. These zones had different thickness and locations. Points at the weld centerline, and for a distance of nearly one inch from the centerline, exhibited very nonlinear behavior during the first loading but exhibited near perfect strain hardening during the second loading.

Mechanical Property Analysis in the Retracted Pin-Tool (RPT) Region of Friction Stir Welded (FSW) Aluminum Lithium 2195

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey; Oelgoetz, Peter A.

1999-01-01

The "Auto-Adjustable Pin Tool for Friction Stir Welding", was developed at The Marshall Space Flight Center to address process deficiencies unique to the FSW process. The auto-adjustable pin tool, also called the retractable pin-tool (R.PT) automatically withdraws the welding probe of the pin-tool into the pin-tool's shoulder. The primary function of the auto-adjustable pin-tool is to allow for keyhole closeout, necessary for circumferential welding and localized weld repair, and, automated pin-length adjustment for the welding of tapered material thickness. An overview of the RPT hardware is presented. The paper follows with studies conducted using the RPT. The RPT was used to simulate two capabilities; welding tapered material thickness and closing out the keyhole in a circumferential weld. The retracted pin-tool regions in aluminum- lithium 2195 friction stir weldments were studied through mechanical property testing and metallurgical sectioning. Correlation's can be =de between retractable pin-tool programmed parameters, process parameters, microstructure, and resulting weld quality.

Automatic programming of arc welding robots

NASA Astrophysics Data System (ADS)

Padmanabhan, Srikanth

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

Thermal Management in Friction-Stir Welding of Precipitation-Hardening Aluminum Alloys

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

Upadhyay, Piyush; Reynolds, Anthony

2015-05-25

Process design and implementation in FSW is mostly dependent on empirical information gathered through experience. Basic science of friction stir welding and processing can only be complete when fundamental interrelationships between process control parameters and response variables and resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters like tool rotation and translation rate and forge axis force have complicated and interactive relationships to the process response variables such as peak temperature, time at temperature etc. Of primary influence to the other process response parameters are temperature and its gradient atmore » the deformation and heat affected zones. Through review of pertinent works in the literature and some experimental results from boundary condition work performed in precipitation hardening aluminum alloys this paper will partially elucidate the nature and effects of temperature transients caused by variation of thermal boundaries in Friction Stir Welding.« less

Nondestructive Evaluation of the Friction Weld Process on 2195/2219 Grade Aluminum

NASA Technical Reports Server (NTRS)

Suits, Michael W.; Clark, Linda S.; Cox, Dwight E.

1999-01-01

In 1996, NASA's Marshall Space Flight Center began an ambitious program designed to find alternative methods of repairing conventional TIG (Tungsten Inert Gas) welds and VPPA (Variable Polarity Plasma Arc) welds on the Space Shuttle External Tank without producing additional heat-related anomalies or conditions. Therefore, a relatively new method, invented by The Welding Institute (TWI) in Cambridge, England, called Friction Stir Welding (FSW), was investigated for use in this application, as well as being used potentially as an initial weld process. As with the conventional repair welding processes, nondestructive evaluation (NDE) plays a crucial role in the verification of these repairs. Since it was feared that conventional NDE might have trouble with this type of weld structure (due to shape of nugget, grain structure, etc.) it was imperative that a complete study be performed to address the adequacy of the NDE process. This paper summarizes that process.

Flaws detection and localization in weld structure using the topological energy method

NASA Astrophysics Data System (ADS)

Lubeigt, Emma; Mensah, Serge; Rakotonarivo, Sandrine; Chaix, Jean-François; Gobillot, Gilles; Baqué, François

2017-02-01

The non-destructive testing of austenitic welds using ultrasound plays an important role in the assessment of the structural integrity and safety of critical structures in a nuclear reactor. The bedspring and the deck are complex welded structures of very restricted access; the ability to reliably detect and locate defects like cracks is therefore a difficult challenge. Ultrasonic testing is a well-recognized non-invasive technique which exhibits high characterization performances in homogeneous media (steel). However, its capabilities are hampered when operating in heterogeneous and anisotropic austenitic welds because of deviation and splitting of the ultrasonic beam. In order to rise to this important challenge, a model-based method is proposed, which takes into account a prior knowledge corresponding to the welding procedure specifications that condition the austenitic grains orientation within the weld and thus the wave propagation. The topological imaging method implemented is a differential approach which, compares signals from the reference defect-free medium to the inspected medium. It relies on combinations of two computed ultrasonic fields, one forward and one adjoint. Numerical simulations and experiments have been carried out to validate the practical relevance of this approach to detect and locate a flaw in a weld.

Grain Refinement of AZ31 Magnesium Alloy Weldments by AC Pulsing Technique

NASA Astrophysics Data System (ADS)

Kishore Babu, N.; Cross, C. E.

2012-11-01

The current study has investigated the influence of alternating current pulsing on the structure and mechanical properties of AZ31 magnesium alloy gas tungsten arc (GTA) weldments. Autogenous full penetration bead-on-plate GTA welds were made under a variety of conditions including variable polarity (VP), variable polarity mixed (VPM), alternating current (AC), and alternating current pulsing (ACPC). AC pulsing resulted in significant refinement of weld metal when compared with the unpulsed conditions. AC pulsing leads to relatively finer and more equiaxed grain structure in GTA welds. In contrast, VP, VPM, and AC welding resulted in predominantly columnar grain structures. The reason for this grain refinement may be attributed to the periodic variations in temperature gradient and solidification rate associated with pulsing as well as weld pool oscillation observed in the ACPC welds. The observed grain refinement was shown to result in an appreciable increase in fusion zone hardness, tensile strength, and ductility.

A density-adaptive SPH method with kernel gradient correction for modeling explosive welding

NASA Astrophysics Data System (ADS)

Liu, M. B.; Zhang, Z. L.; Feng, D. L.

2017-09-01

Explosive welding involves processes like the detonation of explosive, impact of metal structures and strong fluid-structure interaction, while the whole process of explosive welding has not been well modeled before. In this paper, a novel smoothed particle hydrodynamics (SPH) model is developed to simulate explosive welding. In the SPH model, a kernel gradient correction algorithm is used to achieve better computational accuracy. A density adapting technique which can effectively treat large density ratio is also proposed. The developed SPH model is firstly validated by simulating a benchmark problem of one-dimensional TNT detonation and an impact welding problem. The SPH model is then successfully applied to simulate the whole process of explosive welding. It is demonstrated that the presented SPH method can capture typical physics in explosive welding including explosion wave, welding surface morphology, jet flow and acceleration of the flyer plate. The welding angle obtained from the SPH simulation agrees well with that from a kinematic analysis.

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

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

Tang, Wei; Chen, Gaoqiang; Chen, Jian

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

Effect of welding on creep damage evolution in P91B steel

NASA Astrophysics Data System (ADS)

Baral, J.; Swaminathan, J.; Chakrabarti, D.; Ghosh, R. N.

2017-07-01

Study of creep behavior of base metal (without weld) and welded specimens of P91B steel over a range of temperatures (600-650 °C) and stresses (50-180 MPa) showed similar values of minimum creep-rates for both specimens at higher stress regime (>100 MPa) whilst, significantly higher creep rates in the case of welded specimens at lower stress regime. Considering that welded specimen is comprised of two distinct structural regimes, i.e. weld affected zone and base metal, a method has been proposed for estimating the material parameters describing creep behavior of those regimes. Stress-strain distribution across welded specimen predicted from finite element analysis based on material parameters revealed preferential accumulation of stress and creep strain at the interface between weld zone and base metal. This is in-line with the experimental finding that creep rupture preferentially occurs at inter-critical heat affected zone in welded specimens owing to ferrite-martensite structure with coarse Cr23C6 particles.

Fabrication of complex structures or assemblies by Hot Isostatic Pressure (HIP) welding

NASA Technical Reports Server (NTRS)

Ashurst, A. N.; Goldstein, M.; Ryan, M. J.; Lessmann, G. G.; Bryant, W. A.

1974-01-01

HIP welding is effective method for fabricating complex structures or assemblies such as alternator rotors, regeneratively-cooled rocket-motor thrust chambers, and jet engine turbine blades. It can be applied to fabrication of many assemblies which require that component parts be welded together along complex interfaces.

Report Summarizing the Effort Required to Initiate Welding of Irradiated Materials within the Welding Cubicle

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

Frederick, Greg; Sutton, Benjamin J.; Tatman, Jonathan K.

The advanced welding facility within a hot cell at the Radiochemical Engineering Development Center of Oak Ridge National Laboratory (ORNL), which has been jointly funded by the U.S. Department of Energy (DOE), Office of Nuclear Energy, Light Water Reactor Sustainability Program and the Electric Power Research Institute, Long Term Operations Program and the Welding and Repair Technology Center, is in the final phase of development. Research and development activities in this facility will involve direct testing of advanced welding technologies on irradiated materials in order to address the primary technical challenge of helium induced cracking that can arise when conventionalmore » fusion welding techniques are utilized on neutron irradiated stainless steels and nickel-base alloys. This report details the effort that has been required since the beginning of fiscal year 2017 to initiate welding research and development activities on irradiated materials within the hot cell cubicle, which houses welding sub-systems that include laser beam welding (LBW) and friction stir welding (FSW) and provides material containment within the hot cell.« less

Space Fabrication Demonstration System

NASA Technical Reports Server (NTRS)

1977-01-01

Progress on fabrication facility (beam builder) support structure control, clamp/weld block, and welding and truss cut off is discussed. The brace attachment design was changed and the design of the weld mechanism was modified which achieved the following system benefits: (1) simplified weld electrode life; (2) reduced weld power requirements; and (3) simplified brace attachment mechanisms. Static and fatigue characteristics of spot welded 2024T3 aluminum joints are evaluated.

Microstructure and mechanical properties of friction stir welded and laser welded high entropy alloy CrMnFeCoNi

NASA Astrophysics Data System (ADS)

Jo, Min-Gu; Kim, Han-Jin; Kang, Minjung; Madakashira, Phaniraj P.; Park, Eun Soo; Suh, Jin-Yoo; Kim, Dong-Ik; Hong, Sung-Tae; Han, Heung Nam

2018-01-01

The high entropy alloy CrMnFeCoNi has been shown to have promising structural properties. For a new alloy to be used in a structural application it should be weldable. In the present study, friction stir welding (FSW) and laser welding (LW) techniques were used to butt weld thin plates of CrMnFeCoNi. The microstructure, chemical homogeneity and mechanical behavior of the welds were characterized and compared with the base metal. The tensile stress-strain behavior of the welded specimens were reasonable when compared with that of the base metal. FSW refined the grain size in the weld region by a factor of ˜14 when compared with the base metal. High-angle annular dark field transmission electron microscopy in combination with energy dispersive X-ray spectroscopy showed chemical inhomogeneity between dendritic and interdendritic regions in the fusion zone of LW. Large fluctuations in composition (up to 15 at%) did not change the crystal structure in the fusion zone. Hardness measurements were carried out in the weld cross section and discussed in view of the grain size, low angle grain boundaries and twin boundaries in FSW specimens and the dendritic microstructure in LW specimens.

Microstructure and Plastic Deformation of the As-Welded Invar Fusion Zones

NASA Astrophysics Data System (ADS)

Yao, D. J.; Zhou, D. R.; Xu, P. Q.; Lu, F. G.

2017-05-01

The as-welded Invar fusion zones were fabricated between cemented carbides and carbon steel using a Fe-Ni Invar interlayer and laser welding method. Three regions in the as-welded Invar fusion zones were defined to compare microstructures, and these were characterized and confirmed by scanning electron microscopy and X-ray diffractometry. The structure and plastic deformation mechanism for initial Invar Fe-Ni alloys and the as-welded Invar fusion zones are discussed. (1) After undergoing high-temperature thermal cycles, the microstructure of the as-welded Invar fusion zones contains γ-(Fe, Ni) solid solution (nickel dissolving in γ-Fe) with a face-centered cubic (fcc) crystal structure and mixed carbides (eutectic colonies, mixed carbides between two adjacent grains). The mixed carbides exhibited larger, coarser eutectic microstructures with a decrease in welding speed and an increase in heat input. (2) The structure of the initial Invar and the as-welded Invar is face-centered cubic γ-(Fe, Ni). (3) The as-welded Invar has a larger plastic deformation than initial Invar with an increase in local strain field and dislocation density. Slip deformation is propagated along the (111) plane. This finding helps us to understand microstructure and the formation of dislocation and plastic deformation when the Invar Fe-Ni alloy undergoes a high-temperature process.

The Mechanical Metallurgy of Armour Steels

DTIC Science & Technology

2016-10-01

21 7.A. Cracking associated with Welding ...associated with Welding A range of defects, including cracks can be caused by welding processes, examples of which are shown in Figure 19, many of...which can lead to structural cracking problems. The avoidance of weld defects, particularly cracking, is the reason why armour steel welding processes

On-orbit NDE: A novel approach to tube weld inspection

NASA Technical Reports Server (NTRS)

Michaels, Kerry; Hughes, Greg

1994-01-01

The challenge of fabrication and repair of structures in space must be met if we are to utilize and maintain long-duration space facilities. Welding techniques have been demonstrated to provide the most reliable means to accomplish this task. Over the past few years, methods have been developed to perform orbital tube welding employing space-based welding technology pioneered by the former Soviet Union. Welding can result in the formation of defects, which threaten the structural integrity of the welded joint. Implementation of welding on-orbit, therefore, must also include methods to evaluate the quality and integrity of the welded joints. To achieve this goal, the development of an on-orbit tube weld inspection system, utilizing alternating current field measurement (ACFM) technology, has been under taken. This paper describes the development of the ACFM on-orbit tube weld inspection tool. Topics discussed include: requirements for on-orbit NDE, basic theory of ACFM, its advantages over other NDE methods for on-orbit applications, and the ACFM NDE system design. System operation and trial inspection results are also discussed. Future work with this technology is also considered.

Structural Degradation of the Welded Joint of the Gas Main after a Long-Term Operation in Sub-Acid Soil

NASA Astrophysics Data System (ADS)

Maruschak, P. O.; Bishchak, R. T.; Maruschak, O. V.; Panin, S. V.

2018-01-01

The authors investigated the main regularities in the structural and mechanical degradation of steel and a welded joint of the “Soyuz” gas main in operation. It is established that the defect accumulation kinetics in welds are determined both by technological disruptions in their manufacture and by hydrogenation of the weld during a long operating time. A weakening of the mechanical properties of the weld after a prolonged operation is shown, which in some cases led to the appearance of cracks and fracture of the gas main.

Joining of polymer composite materials

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

Magness, F.H.

1990-11-01

Under ideal conditions load bearing structures would be designed without joints, thus eliminating a source of added weight, complexity and weakness. In reality the need for accessibility, repair, and inspectability, added to the size limitations imposed by the manufacturing process and transportation/assembly requirements mean that some minimum number of joints will be required in most structures. The designer generally has two methods for joining fiber composite materials, adhesive bonding and mechanical fastening. As the use of thermoplastic materials increases, a third joining technique -- welding -- will become more common. It is the purpose of this document to provide amore » review of the available sources pertinent to the design of joints in fiber composites. The primary emphasis is given to adhesive bonding and mechanical fastening with information coming from documentary sources as old as 1961 and as recent as 1989. A third, shorter section on composite welding is included in order to provide a relatively comprehensive treatment of the subject.« less

Vibration stress relief of DH 36 rectangle welded plates

NASA Astrophysics Data System (ADS)

Li, Shuqi; Fang, Hongyuan

2018-03-01

Vibration stress relief (VSR) is widely used in reducing residual stress in welded structures. However, the effectiveness of this method is still instable in some circumstance. In this study, a covert negative treatment phenomenon was investigated, i.e. natural frequency of welded structures decreased after VSR but residual stress in one direction increased. When the alteration of natural frequency after VSR is significant, the residual stresses in both the longitudinal and transversal directions shall decrease. Otherwise, residual stresses may increase on one direction. Thus, sufficient power shall be applied to the welded structures to avoid negative results.

Hybrid FSWeld-bonded joint fatigue behaviour

NASA Astrophysics Data System (ADS)

Lertora, Enrico; Mandolfino, Chiara; Gambaro, Carla; Pizzorni, Marco

2018-05-01

Aluminium alloys, widely used in aeronautics, are increasingly involved in the automotive industry due to the good relationship between mechanical strength and specific weight. The lightening of the structures is the first objective, which allows the decreasing in the weight in motion. The use of aluminium alloys has also seen the introduction of the Friction Stir Welding (FSW) technique for the production of structural overlapping joints. FSW allows us to weld overlap joints free from defects, but with the presence of a structural notch further aggravated by the presence of a "hook" defect near the edge of the weld. Furthermore, FSW presents a weld penetration area connected to the tool geometry and penetration. The experimental activity will be focused on the combination of two different joining techniques, which can synergistically improve the final joint resistance. In particular, the welding and bonding process most commonly known as weld-bonding is defined as a hybrid process, as it combines two different junction processes. In this paper we analyse FSWelded AA6082 aluminium alloy overlapped joint with the aim of quantitatively evaluating the improvement provided by the presence of an epoxy adhesive between the plates. After optimising the weld-bonding process, the mechanical behaviour of welded joints will be analysed by static and dynamic tests. The presence of the adhesive should limit the negative effect of the structural notch inevitable in a FSW overlapped joint.

Coil Welding Aid

NASA Technical Reports Server (NTRS)

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

1983-01-01

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

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

NASA Astrophysics Data System (ADS)

Lakshminarayanan, A. K.; Balasubramanian, V.

2012-04-01

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

Development of a CCTV system for welder training and monitoring of Space Shuttle Main Engine welds

NASA Technical Reports Server (NTRS)

Gordon, S. S.; Flanigan, L. A.; Dyer, G. E.

1987-01-01

A Weld Operator's Remote Monitoring System (WORMS) for remote viewing of manual and automatic GTA welds has been developed for use in Space Shuttle Main Engine (SSME) manufacturing. This system utilizes fiberoptics to transmit images from a receiving lens to a small closed-circuit television (CCTV) camera. The camera converts the image to an electronic signal, which is sent to a videotape recorder (VTR) and a monitor. The overall intent of this system is to provide a clearer, more detailed view of welds than is available by direct observation. This system has six primary areas of application: (1) welder training; (2) viewing of joint penetration; (3) viewing visually inaccessible welds; (4) quality control and quality assurance; (5) remote joint tracking and adjustment of variables in machine welds; and (6) welding research and development. This paper describes WORMS and how it applies to each application listed.

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

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

Hollar, D.L.

1990-05-01

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

Welding processes for Inconel 718- A brief review

NASA Astrophysics Data System (ADS)

Tharappel, Jose Tom; Babu, Jalumedi

2018-03-01

Inconel 718 is being extensively used for high-temperature applications, rocket engines, gas turbines, etc. due to its ability to maintain high strength at temperatures range 450-700°C complimented by excellent oxidation and corrosion resistance and its outstanding weldability in either the age hardened or annealed condition. Though alloy 718 is reputed to possess good weldability in the context of their resistance to post weld heat treatment cracking, heat affected zone (HAZ) and weld metal cracking problems persist. This paper presents a brief review on welding processes for Inconel 718 and the weld defects, such as strain cracking during post weld heat treatment, solidification cracking, and liquation cracking. The effect of alloy chemistry, primary and secondary processing on the HAZ cracking susceptibility, influence of post/pre weld heat treatments on precipitation, segregation reactions, and effect of grain size etc. discussed and concluded with future scope for research.

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."

Phenomenological Models and Animations of Welding and their Impact

NASA Astrophysics Data System (ADS)

DebRoy, Tarasankar

Professor Robertson's recognized research on metallurgical thermodynamics and kinetics for over 40 years facilitated the emergence of rigorous quantitative understanding of many complex metallurgical processes. The author had the opportunity to work with Professor Robertson on liquid metals in the 1970s. This paper is intended to review the advances in the quantitative understanding of welding processes and weld metal attributes in recent decades. Over this period, phenomenological models have been developed to better understand and control various welding processes and the structure and properties of welded materials. Numerical models and animations of melting, solidification and the evolution of micro and macro-structural features will be presented to critically examine their impact on the practice of welding and the underlying science.

Welding at the Kennedy Space Center.

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1973-01-01

Brief description of the nature of the mechanical equipment at a space launch complex from a welding viewpoint. including an identification of the major welding applications used in the construction of this complex. The role played by welding in the ground support equipment is noted, including the welded structures and systems required in the vehicle assembly building, the mobile launchers, transporters, mobile service structure, launch pad and launch site, the propellants system, the pneumatics system, and the environmental control system. The welding processes used at the Kennedy Space Center are reviewed, and a particularly detailed account is given of the design and fabrication of the liquid hydrogen and liquid oxygen storage spheres and piping. Finally, the various methods of testing and inspecting the storage spheres are cited.

Plasma arc welding repair of space flight hardware

NASA Technical Reports Server (NTRS)

Hoffman, David S.

1993-01-01

A technique to weld repair the main combustion chamber of Space Shuttle Main Engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloy-Z, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloy-Z while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Grain refinement control in gas-shielded arc welding of aluminum tubing

NASA Technical Reports Server (NTRS)

Iceland, W. F.; Whiffen, E. L.

1974-01-01

When sections are being welded, operator varies pulse rate of power supply and simultaneously monitors signal on oscilloscope until rate is found which produces maximum arc gas voltage. Remainder of welding is performed with power supply set at this pulse rate, producing desired maximum weld puddle agitation and fine uniform weld of grain structure.

Calculation of optimal modes for electric-contact welding of rails of mine haulage tracks

NASA Astrophysics Data System (ADS)

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

2017-09-01

The choice of thermal regime is based on the exclusion of formation of quenching structures (martensite and bainite), causing additional stresses and cracks which lead to the destruction of rails. After welded joint upset and cooling at the time of reaching the required temperature it is proposed to perform quasi-isothermal exposure by passing pulses of alternating current through the welded joint. The method for calculating the quasi-isothermal exposure is described that depends on the strength of the welding current and different rails section. It is suggested that after welding the rails during quenching, a quasi-isothermal holding is carried out in the temperature range of the formation of the fine-dispersed structure by passing pulses of alternating electric current through the welded joint maintaining this temperature until the end of the transformation. It is shown that the use of quasi-isothermal exposure at a chosen temperature of 600 - 650 °C makes it possible to obtain a finely dispersed structure of the welded seam of rails of mine haulage tracks without additional heat treatment.

Quasi-Rayleigh waves in butt-welded thick steel plate

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

Kamas, Tuncay, E-mail: kamas@email.sc.edu, E-mail: victorg@sc.edu, E-mail: linbin@cec.sc.edu; Giurgiutiu, Victor, E-mail: kamas@email.sc.edu, E-mail: victorg@sc.edu, E-mail: linbin@cec.sc.edu; Lin, Bin, E-mail: kamas@email.sc.edu, E-mail: victorg@sc.edu, E-mail: linbin@cec.sc.edu

2015-03-31

This paper discusses theoretical and experimental analyses of weld guided surface acoustic waves (SAW) through the guided wave propagation (GWP) analyses. The GWP analyses have been carried out by utilizing piezoelectric wafer active sensors (PWAS) for in situ structural inspection of a thick steel plate with butt weld as the weld bead is ground flush. Ultrasonic techniques are commonly used for validation of welded structures in many in-situ monitoring applications, e.g. in off-shore structures, in nuclear and pressure vessel industries and in a range of naval applications. PWAS is recently employed in such ultrasonic applications as a resonator as wellmore » as a transducer. Quasi-Rayleigh waves a.k.a. SAW can be generated in relatively thick isotropic elastic plate having the same phase velocity as Rayleigh waves whereas Rayleigh waves are a high frequency approximation of the first symmetric (S0) and anti-symmetric (A0) Lamb wave modes. As the frequency becomes very high the S0 and the A0 wave speeds coalesce, and both have the same value. This value is exactly the Rayleigh wave speed and becomes constant along the frequency i.e. Rayleigh waves are non-dispersive guided surface acoustic waves. The study is followed with weld-GWP tests through the pitch-catch method along the butt weld line. The tuning curves of quasi-Rayleigh wave are determined to show the tuning and trapping effect of the weld bead that has higher thickness than the adjacent plates on producing a dominant quasi-Rayleigh wave mode. The significant usage of the weld tuned and guided quasi-Rayleigh wave mode is essentially discussed for the applications in the in-situ inspection of relatively thick structures with butt weld such as naval offshore structures. The paper ends with summary, conclusions and suggestions for future work.« less

Weld residual stresses and plastic deformation

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

Rybicki, E.; Shiratori, M.

1989-01-01

Residual stresses due to welding can play a primary role in the performance of piping systems and pressure vessels. The stresses are high, in the range of the yield stress of the material, and can influence the fatigue and fracture behavior as well as component service life. Thus, it is important to have an understanding of weld residual stresses. The papers in this section address the important topic of residual stresses and failure analysis. The paper by Boyles reviews computer simulation in the prediction and analysis of fatigue, fracture, and creep of welded structures. The growing use of expert systemsmore » for these purposes is also covered. Karisson, et al, determine the deformations and stresses during the butt-welding of a pipe. The determination of residual deformations and stresses is also presented. Oddy, Goldak, and McDill propose a method to incorporate transformation plasticity in a finite element program. A three-dimensional analysis of a short longitudinal pipe weld in a typical pressure vessel steel is presented. Chaaban, Morin, Ma, and Bazergui study the influence of ligament thickness, strain hardening, expansion sequence, and level of applied expansion pressure on the interference fit in a model of a tube-to-tubesheet joint in a heat exchanger. This section contains papers dealing with models for plastic deformation. Imatani, Teraura, and Inoue formulate a viscoplastic constitutive model based on an anisotropic yield criterion. Comparisons with experimental results obtained using thin walled tubular specimens made from SUS 304 stainless steel show that the present yield criterion adequately accounts for prior deformation history. Niitsu, Horiguchi, and Ikegami investigate the plastic behavior of S25C mild steel tubular specimens subjected to combined axial and torsional loading at both constant and variable temperatures.« less

Space Shuttle ET Friction Stir Weld Machines

NASA Technical Reports Server (NTRS)

Thompson, Jack M.

2003-01-01

NASA and Lockheed-Martin approached the FSW machine vendor community with a specification for longitudinal barrel production FSW weld machines and a shorter travel process development machine in June of 2000. This specification was based on three years of FSW process development on the Space Shuttle External Tank alloys, AL2 195-T8M4 and AL22 19-T87. The primary motivations for changing the ET longitudinal welds from the existing variable polarity Plasma Arc plasma weld process included: (1) Significantly reduced weld defect rates and related reduction in cycle time and uncertainty; (2) Many fewer process variables to control (5 vs. 17); (3) Fewer manufacturing steps; (4) Lower residual stresses and distortion; (5) Improved weld strengths, particularly at cryogenic temperatures; (6) Fewer hazards to production personnel. General Tool was the successful bidder. The equipment is at this writing installed and welding flight hardware. This paper is a means of sharing with the rest of the FSW community the unique features developed to assure NASA/L-M of successful production welds.

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

PubMed

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

2004-11-01

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

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

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

Nowers, O.; Duxbury, D. J.; Velichko, A.

2015-03-31

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

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.

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

NASA Astrophysics Data System (ADS)

Balle, Frank; Magin, Jens

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

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

NASA Astrophysics Data System (ADS)

Daavari, Morteza; Vanini, Seyed Ali Sadough

2015-09-01

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

46 CFR 38.05-4 - Design and construction of nonpressure vessel type cargo tanks-TB/ALL.

Code of Federal Regulations, 2010 CFR

2010-10-01

... precooling or cooling during loading shall be included in the design. (g) All weld intersections or crossings... intersection. All other welding in the primary tank and in the secondary barrier shall be spot radiographed in...

46 CFR 38.05-4 - Design and construction of nonpressure vessel type cargo tanks-TB/ALL.

Code of Federal Regulations, 2014 CFR

2014-10-01

... precooling or cooling during loading shall be included in the design. (g) All weld intersections or crossings... intersection. All other welding in the primary tank and in the secondary barrier shall be spot radiographed in...

46 CFR 38.05-4 - Design and construction of nonpressure vessel type cargo tanks-TB/ALL.

Code of Federal Regulations, 2013 CFR

2013-10-01

... precooling or cooling during loading shall be included in the design. (g) All weld intersections or crossings... intersection. All other welding in the primary tank and in the secondary barrier shall be spot radiographed in...

46 CFR 38.05-4 - Design and construction of nonpressure vessel type cargo tanks-TB/ALL.

Code of Federal Regulations, 2011 CFR

2011-10-01

... precooling or cooling during loading shall be included in the design. (g) All weld intersections or crossings... intersection. All other welding in the primary tank and in the secondary barrier shall be spot radiographed in...

46 CFR 38.05-4 - Design and construction of nonpressure vessel type cargo tanks-TB/ALL.

Code of Federal Regulations, 2012 CFR

2012-10-01

... precooling or cooling during loading shall be included in the design. (g) All weld intersections or crossings... intersection. All other welding in the primary tank and in the secondary barrier shall be spot radiographed in...

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 on...

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 on...

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 on...

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 on...

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 on...

Metallurgy and mechanical properties variation with heat input,during dissimilar metal welding between stainless and carbon steel

NASA Astrophysics Data System (ADS)

Ramdan, RD; Koswara, AL; Surasno; Wirawan, R.; Faturohman, F.; Widyanto, B.; Suratman, R.

2018-02-01

The present research focus on the metallurgy and mechanical aspect of dissimilar metal welding.One of the common parameters that significantly contribute to the metallurgical aspect on the metal during welding is heat input. Regarding this point, in the present research, voltage, current and the welding speed has been varied in order to observe the effect of heat input on the metallurgical and mechanical aspect of both welded metals. Welding was conducted by Gas Metal Arc Welding (GMAW) on stainless and carbon steel with filler metal of ER 309. After welding, hardness test (micro-Vickers), tensile test, macro and micro-structure characterization and Energy Dispersive Spectroscopy (EDS) characterization were performed. It was observed no brittle martensite observed at HAZ of carbon steel, whereas sensitization was observed at the HAZ of stainless steel for all heat input variation at the present research. Generally, both HAZ at carbon steel and stainless steel did not affect tensile test result, however the formation of chromium carbide at the grain boundary of HAZ structure (sensitization) of stainless steel, indicate that better process and control of welding is required for dissimilar metal welding, especially to overcome this issue.

Friction Stir Weld Failure Mechanisms in Aluminum-Armor Structures Under Ballistic Impact Loading Conditions

DTIC Science & Technology

2013-01-01

REPORT Friction Stir Weld Failure Mechanisms in Aluminum -Armor Structures Under Ballistic Impact Loading Conditions 14. ABSTRACT 16. SECURITY...Stir Weld Failure Mechanisms in Aluminum -Armor Structures Under Ballistic Impact Loading Conditions M. Grujicic, B. Pandurangan, A. Arakere, C-F. Yen...K.O. Pedersen, Fracture Mechanisms of Aluminum Alloy AA7075-T651 Under Various Loading Conditions , Int. J. Impact Eng., 2010, 37, p 537–551 24. T

Aircraft landing dynamics facility carriage weld test program

NASA Technical Reports Server (NTRS)

Lawson, A. G.

1984-01-01

A welded tubular structure constructed of low alloy high strength quenched and tempered steel was tested. The consistency of the mechanical strengths and chemical composition and the degree of difficulty of obtaining full strength welds with these steels is characterized. The results of constructing and testing two typical connections which are used in the structure design are reported.

Review of Literature on Probability of Detection for Magnetic Particle Nondestructive Testing

DTIC Science & Technology

2013-01-01

4 3.2 Offshore welded structures..................................................................................... 8 3.3 Aerospace...presented in Section 6. 2. Overview of Magnetic Particle Testing MPT is used in heavy engineering to inspect welds for surface-breaking... welded structures, and concluding with a summary of reliability information embedded in aerospace standards. 3.1 Aerospace It appears that the

Influence of the parameters of a high-frequency acoustic wave on the structure, properties, and plastic flow of metal in the zone of a joint of materials welded by ultrasound-assisted explosive welding

NASA Astrophysics Data System (ADS)

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

2017-05-01

The results of an investigation of the influence of the parameters of high-frequency acoustic wave on the structure and properties of the zone of joint of homogeneous metals bonded by explosive welding under the action of ultrasound have been presented. The influence of the frequency and amplitude of ultrasonic vibrations on the structure and properties of the explosively welded joints compared with the samples welded without the application of ultrasound has been established. The action of high-frequency acoustic waves on the metal leads to a reduction in the dynamic yield stress, which changes the properties of the surface layers of the metal and the conditions of the formation of the joint of the colliding plates upon the explosive welding. It has been shown that the changes in the length and amplitude of waves that arise in the weld joint upon the explosive welding with the simultaneous action of ultrasonic vibrations are connected with a decrease in the magnitude of the deforming pulse and time of action of the compressive stresses that exceed the dynamic yield stress beyond the point of contact.

Hot Corrosion of Inconel 625 Overlay Weld Cladding in Smelting Off-Gas Environment

NASA Astrophysics Data System (ADS)

Mohammadi Zahrani, E.; Alfantazi, A. M.

2013-10-01

Degradation mechanisms and hot corrosion behavior of weld overlay alloy 625 were studied. Phase structure, morphology, thermal behavior, and chemical composition of deposited salt mixture on the weld overlay were characterized utilizing XRD, SEM/EDX, DTA, and ICP/OES, respectively. Dilution level of Fe in the weldment, dendritic structure, and degradation mechanisms of the weld were investigated. A molten phase formed on the weld layer at the operating temperature range of the boiler, which led to the hot corrosion attack in the water wall and the ultimate failure. Open circuit potential and weight-loss measurements and potentiodynamic polarization were carried out to study the hot corrosion behavior of the weld in the simulated molten salt medium at 873 K, 973 K, and 1073 K (600 °C, 700 °C, and 800 °C). Internal oxidation and sulfidation plus pitting corrosion were identified as the main hot corrosion mechanisms in the weld and boiler tubes. The presence of a significant amount of Fe made the dendritic structure of the weld susceptible to preferential corrosion. Preferentially corroded (Mo, Nb)-depleted dendrite cores acted as potential sites for crack initiation from the surface layer. The penetration of the molten phase into the cracks accelerated the cracks' propagation mainly through the dendrite cores and further crack branching/widening.

Features of residual stresses in duplex stainless steel butt welds

NASA Astrophysics Data System (ADS)

Um, Tae-Hwan; Lee, Chin-Hyung; Chang, Kyong-Ho; Nguyen Van Do, Vuong

2018-04-01

Duplex stainless steel finds increasing use as an alternative to austenitic stainless steel, particularly where chloride or sulphide stress corrosion cracking is of primary concern, due to the excellent combination of strength and corrosion resistance. During welding, duplex stainless steel does not create the same magnitude or distribution of weld-induced residual stresses as those in welded austenitic stainless steel due to the different physical and mechanical properties between them. In this work, an experimental study on the residual stresses in butt-welded duplex stainless steel is performed utilizing the layering technique to investigate the characteristics of residual stresses in the weldment. Three-dimensional thermos-mechanical-metallurgical finite element analysis is also performed to confirm the residual stress measurements.

Fatigue crack growth of 316NG austenitic stainless steel welds at 325 °C

NASA Astrophysics Data System (ADS)

Li, Y. F.; Xiao, J.; Chen, Y.; Zhou, J.; Qiu, S. Y.; Xu, Q.

2018-02-01

316NG austenitic stainless steel is a commonly-used material for primary coolant pipes of pressurized water reactor systems. These pipes are usually joined together by automated narrow gap welding process. In this study, welds were prepared by narrow gap welding on 316NG austenitic stainless steel pipes, and its microstructure of the welds was characterized. Then, fatigue crack growth tests were conducted at 325 °C. Precipitates enriched with Mn and Si were found in the fusion zone. The fatigue crack path was out of plane and secondary cracks initiated from the precipitate/matrix interface. A moderate acceleration of crack growth was also observed at 325°Cair and water (DO = ∼10 ppb) with f = 2 Hz.

Laser welded steel sandwich panel bridge deck development : finite element analysis and stake weld strength tests.

DOT National Transportation Integrated Search

2009-09-01

This report summarizes the analysis of laser welded steel sandwich panels for use in bridge structures and : static testing of laser stake welded lap shear coupons. Steel sandwich panels consist of two face sheets : connected by a relatively low-dens...

Grain structure, texture and mechanical property evolution of automotive aluminium sheet during high power ultrasonic welding

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

Haddadi, Farid, E-mail: farid.haddadi@gmail.com

High power ultrasonic spot welding (HPUSW) is a joining technique which is performed within less than a second and provides a more energy-efficient alternative to friction stir spot welding (FSSW), which is considered a longer cycle manufacturing process for joining automotive alloys. To date, only a few reports exist on the deformation mechanisms that take place during high power ultrasonic spot welding. In this work, dynamic recrystallization and grain growth were examined using electron backscatter diffraction (EBSD). HPUSW causes extensive deformation within the weld zone where the temperature increases to 440 °C. An ultra-fine grain structure was observed in amore » thin band of flat weld interface within a short welding time of 0.10 s. With increasing welding time the interface was displaced and ‘folds’ or ‘crests’ appeared together with shear bands. The weld interface progressively changed from flat to sinusoidal and eventually to a convoluted wave-like pattern when the tool fully penetrated the workpiece, having a wavelength of ~ 1 mm after 0.40 s. Finally, the microstructure and texture varied significantly depending on the location within the weld. Although the texture near the weld interface was relatively weak, a shift was observed with increasing welding time from an initially Cube-dominated texture to one where the typical β-fibre Brass component prevailed. - Highlights: •Lap shear strength of ~2.9 kN was achieved in 0.30 sec welding time. •Temperature approached 440 °C along the weld centreline for the highest welding time. •The texture near the teeth was dominated by Brass, P and S components at optimum condition. •The weld interface showed typical β-fibre deformation texture at optimum condition.« less

Joining of polypropylene/polypropylene and glass fiber reinforced polypropylene composites

NASA Astrophysics Data System (ADS)

Zhang, Jianguang

Joining behavior of polypropylene (PP) to PP and long glass fiber reinforced polypropylene (LFT) to LFT were investigated. Adhesive bonding was used to join PP/PP. Both adhesive bonding and ultrasonic welding were used to join LFT/LFT. Single-lap shear testing and low velocity impact (LVI) testing were used to evaluate the performance of bonded structures. The two-part acrylic adhesive DP8005 was determined to be the best among the three adhesive candidates, which was attributed to its low surface energy. The impact resistance of LFT/LFT joints, normalized with respect to thickness, was higher than that of PP/PP joints because of higher stiffness of LFT/LFT joints. The stress states in the adhesive layer of adhesively bonded structures were analyzed using ANSYS and LS-DYNA to simulate the single-lap shear testing and LVI testing, respectively. The shear and peel stresses peaked at the edges of the adhesive layer. Compared to LFT/LFT joints, higher peel stress occurred in the adhesive layer in the PP/PP joints in tension. Impact response of adhesively bonded structures as evaluated by LS-DYNA showed good agreement with the experimental results. The effect of weld time and weld pressure on the shear strength of ultrasonically welded LFT/LFT was evaluated. With higher weld pressure, less time was required to obtain a complete weld. At longer weld times, lower weld pressure was required. From the 15 weld conditions studied, a weld map was obtained that provides conditions to achieve a complete weld. Nanoindentation was used to evaluate the effect of ultrasonic weld on the modulus and hardness of the PP matrix. Modulus and hardness of the PP matrix were slightly decreased by ultrasonic welding possibly due to the decrease in the molecular weight. The temperature profile in LFT/LFT in the transverse direction during ultrasonic welding was analyzed by two ANSYS-based thermal models: (a) one in which heat generated by interfacial friction was treated as a heat flux and (b) one in which heat was generated in a thin slab at the interface. The weld map obtained from the thin slab model was closer to the one obtained experimentally.

A fundamental study on the structural integrity of magnesium alloys joined by friction stir welding

NASA Astrophysics Data System (ADS)

Rao, Harish Mangebettu

The goal of this research is to study the factors that influence the physical and mechanical properties of lap-shear joints produced using friction stir welding. This study focuses on understanding the effect of tool geometry and weld process parameters including the tool rotation rate, tool plunge depth and dwell time on the mechanical performance of similar magnesium alloy and dissimilar magnesium to aluminum alloy weld joints. A variety of experimental activities were conducted including tensile and fatigue testing, fracture surface and failure analysis, microstructure characterization, hardness measurements and chemical composition analysis. An investigation on the effect of weld process conditions in friction stir spot welding of magnesium to magnesium produced in a manner that had a large effective sheet thickness and smaller interfacial hook height exhibited superior weld strength. Furthermore, in fatigue testing of friction stir spot welded of magnesium to magnesium alloy, lap-shear welds produced using a triangular tool pin profile exhibited better fatigue life properties compared to lap-shear welds produced using a cylindrical tool pin profile. In friction stir spot welding of dissimilar magnesium to aluminum, formation of intermetallic compounds in the stir zone of the weld had a dominant effect on the weld strength. Lap-shear dissimilar welds with good material mixture and discontinues intermetallic compounds in the stir zone exhibited superior weld strength compared to lap-shear dissimilar welds with continuous formation of intermetallic compounds in the stir zone. The weld structural geometry like the interfacial hook, hook orientation and bond width also played a major role in influencing the weld strength of the dissimilar lap-shear friction stir spot welds. A wide scatter in fatigue test results was observed in friction stir linear welds of aluminum to magnesium alloys. Different modes of failure were observed under fatigue loading including crack propagation into the top sheet, into the bottom sheet, and interfacial separation. Investigation of the tested welds revealed that the voids in the weld nugget reduced the weld strength, resulting in lower fatigue life. A thin layer of IMCs formed along the faying surface which accelerated the fatigue failure.

Characterization of microstructure and texture across dissimilar super duplex/austenitic stainless steel weldment joint by super duplex filler metal

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

Eghlimi, Abbas, E-mail: a.eghlimi@ma.iut.ac.ir; Shamanian, Morteza; Eskandarian, Masoomeh

In the present paper, microstructural changes across an as-welded dissimilar austenitic/duplex stainless steel couple welded by a super duplex stainless steel filler metal using gas tungsten arc welding process is characterized with optical microscopy and electron back-scattered diffraction techniques. Accordingly, variations of microstructure, texture, and grain boundary character distribution of base metals, heat affected zones, and weld metal were investigated. The results showed that the weld metal, which was composed of Widmanstätten austenite side-plates and allotriomorphic grain boundary austenite morphologies, had the weakest texture and was dominated by low angle boundaries. The welding process increased the ferrite content but decreasedmore » the texture intensity at the heat affected zone of the super duplex stainless steel base metal. In addition, through partial ferritization, it changed the morphology of elongated grains of the rolled microstructure to twinned partially transformed austenite plateaus scattered between ferrite textured colonies. However, the texture of the austenitic stainless steel heat affected zone was strengthened via encouraging recrystallization and formation of annealing twins. At both interfaces, an increase in the special character coincident site lattice boundaries of the primary phase as well as a strong texture with <100> orientation, mainly of Goss component, was observed. - Graphical abstract: Display Omitted - Highlights: • Weld metal showed local orientation at microscale but random texture at macroscale. • Intensification of <100> orientated grains was observed adjacent to the fusion lines. • The austenite texture was weaker than that of the ferrite in all duplex regions. • Welding caused twinned partially transformed austenites to form at SDSS HAZ. • At both interfaces, the ratio of special CSL boundaries of the primary phase increased.« less

Structure formation of 5083 alloy during friction stir welding

NASA Astrophysics Data System (ADS)

Zaikina, A. A.; Kolubaev, A. V.; Sizova, O. V.; Ivanov, K. V.; Filippov, A. V.; Kolubaev, E. A.

2017-12-01

This paper provides a comparative study of structures obtained by friction stir welding and sliding friction of 5083 Al alloy. Optical and electron microscopy reveals identical fine-grained structures with a grain size of ˜5 µm both in the weld nugget zone and subsurface layer in friction independently of the initial grain size of the alloy. It has been suggested that the grain boundary sliding is responsible for the specific material flow pattern in both techniques considered.

High Power Laser Welding. [of stainless steel and titanium alloy structures

NASA Technical Reports Server (NTRS)

Banas, C. M.

1972-01-01

A review of recent developments in high power, carbon dixoide laser welding is presented. Deep penetration welding in stainless steel to 0.5-in. thick, high speed welding in thin gage rimmed steel and gas shielded welding in Ti-6Al-4V alloy are described. The effects of laser power, power density, focusing optics, gas-shielding techniques, material properties and weld speed on weld quality and penetration are discussed. It is shown that laser welding performance in thin materials is comparable to that of electron beams. It is further shown that high quality welds, as evidenced by NDT, mechanical and metal-lographic tests, can be achieved. The potential of the laser for industrial welding applications is indicated.

Comparison between hybrid laser-MIG welding and MIG welding for the invar36 alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Li, Yubo; Ou, Wenmin; Yu, Fengyi; Chen, Jie; Wei, Yanhong

2016-11-01

The invar36 alloy is suitable to produce mold of composite materials structure because it has similar thermal expansion coefficient with composite materials. In the present paper, the MIG welding and laser-MIG hybrid welding methods are compared to get the more appropriate method to overcome the poor weldability of invar36 alloy. According to the analysis of the experimental and simulated results, it has been proved that the Gauss and cone combined heat source model can characterize the laser-MIG hybrid welding heat source well. The total welding time of MIG welding is 8 times that of hybrid laser-MIG welding. The welding material consumption of MIG welding is about 4 times that of hybrid laser-MIG welding. The stress and deformation simulation indicate that the peak value of deformation during MIG welding is 3 times larger than that of hybrid laser-MIG welding.

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

NASA Astrophysics Data System (ADS)

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

2016-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Advances in welding science: A perspective

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

Development of explosive welding procedures to fabricate channeled nozzle structures

NASA Technical Reports Server (NTRS)

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

1976-01-01

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

Improving Stiffness-to-weight Ratio of Spot-welded Structures based upon Nonlinear Finite Element Modelling

NASA Astrophysics Data System (ADS)

Zhang, Shengyong

2017-07-01

Spot welding has been widely used for vehicle body construction due to its advantages of high speed and adaptability for automation. An effort to increase the stiffness-to-weight ratio of spot-welded structures is investigated based upon nonlinear finite element analysis. Topology optimization is conducted for reducing weight in the overlapping regions by choosing an appropriate topology. Three spot-welded models (lap, doubt-hat and T-shape) that approximate “typical” vehicle body components are studied for validating and illustrating the proposed method. It is concluded that removing underutilized material from overlapping regions can result in a significant increase in structural stiffness-to-weight ratio.

Two examples of subaqueously welded ash-flow tuffs: the Visean of southern Vosges (France) and the Upper Cretaceous of northern Anatolia (Turkey)

NASA Astrophysics Data System (ADS)

Schneider, Jean-Luc; Fourquin, Claude; Paicheler, Jean-Claude

1992-02-01

Pyroclastic deposits interpreted as subaqueous ash-flow tuff have been recognized within Archean to Recent marine and lacustrine sequences. Several authors proposed a high-temperature emplacement for some of these tuffs. However, the subaqueous welding of pyroclastic deposits remains controversial. The Visean marine volcaniclastic formations of southern Vosges (France) contain several layers of rhyolitic and rhyodacitic ash-flow tuff. These deposits include, from proximal to distal settings, breccia, lapilli and fine-ash tuff. The breccia and lapilli tuff are partly welded, as indicated by the presence of fiamme, fluidal and axiolitic structures. The lapilli tuff form idealized sections with a lower, coarse and welded unit and an upper, bedded and unwelded fine-ash tuff. Sedimentary structures suggest that the fine-ash tuff units were deposited by turbidity currents. Welded breccias, interbedded in a thick submarine volcanic complex, indicate the close proximity of the volcanic source. The lapilli and fine-ash tuff are interbedded in a thick marine sequence composed of alternating sandstones and shales. Presence of a marine stenohaline fauna and sedimentary structures attest to a marine depositional environment below storm-wave base. In northern Anatolia, thick massive sequences of rhyodacitic crystal tuff are interbedded with the Upper Cretaceous marine turbidites of the Mudurnu basin. Some of these tuffs are welded. As in southern Vosges, partial welding is attested by the presence of fiamme and fluidal structures. The latter are frequent in the fresh vitric matrix. These tuff units contain a high proportion of vitroclasis, and were emplaced by ash flows. Welded tuff units are associated with non-welded crystal tuff, and contain abundant bioclasts which indicate mixing with water during flowage. At the base, basaltic breccia beds are associated with micritic beds containing a marine fauna. The welded and non-welded tuff sequences are interbedded in an alternation of limestones and marls. These limestones are rich in pelagic microfossils. The evidence above strongly suggest that in both examples, tuff beds are partly welded and were emplaced at high temperature by subaqueous ash flows in a permanent marine environment. The sources of the pyroclastic material are unknown in both cases. We propose that the ash flows were produced during submarine fissure eruptions. Such eruptions could produce non-turbulent flows which were insulated by a steam carapace before deposition and welding. The welded ash-flow tuff deposits of southern Vosges and northern Anatolia give strong evidence for existence of subaqueous welding.

Finite element normal mode analysis of resistance welding jointed of dissimilar plate hat structure

NASA Astrophysics Data System (ADS)

Nazri, N. A.; Sani, M. S. M.

2017-10-01

Structural joints offer connection between structural element (beam, plate, solid etc.) in order to build a whole assembled structure. The complex behaviour of connecting elements plays a valuable role in characteristics of dynamic such as natural frequencies and mode shapes. In automotive structures, the trustworthiness arrangement of the structure extremely depends on joints. In this paper, top hat structure is modelled and designed with spot welding joint using dissimilar materials which is mild steel 1010 and stainless steel 304, using finite element software. Different types of connector elements such as rigid body element (RBE2), welding joint element (CWELD), and bar element (CBAR) are applied to represent real connection between two dissimilar plates. Normal mode analysis is simulated with different types of joining element in order to determine modal properties. Natural frequencies using RBE2, CBAR and CWELD are compared to equivalent rigid body method. Connection that gives the lowest percentage error among these three will be selected as the most reliable joining for resistance spot weld. From the analysis, it is shown that CWELD is better compared to others in term of weld joining among dissimilar plate materials. It is expected that joint modelling of finite element plays significant role in structural dynamics.

Use of Infrared Thermography for the Inspection of Welds in the Shop and Field

DOT National Transportation Integrated Search

2017-12-01

This report represents an initial, proof-of-concept study to explore the feasibility of infrared ultra-time domain (IR-UTD) technology for the detection of defects in welds. The report includes two primary sections. The first section provides some ba...

Effect of Continuous and Pulsed Current Gas Tungsten Arc Welding on Dissimilar Weldments Between Hastelloy C-276/AISI 321 Austenitic Stainless Steel

NASA Astrophysics Data System (ADS)

Sharma, Sumitra; Taiwade, Ravindra V.; Vashishtha, Himanshu

2017-03-01

In the present investigation, an attempt has been made to join Hastelloy C-276 nickel-based superalloy and AISI 321 austenitic stainless steel using ERNiCrMo-4 filler. The joints were fabricated by continuous and pulsed current gas tungsten arc welding processes. Experimental studies to ascertain the structure-property co-relationship with or without pulsed current mode were carried out using an optical microscope and scanning electron microscope. Further, the energy-dispersive spectroscope was used to evaluate the extent of microsegregation. The microstructure of fusion zone was obtained as finer cellular dendritic structure for pulsed current mode, whereas columnar structure was formed with small amount of cellular structure for continuous current mode. The scanning electron microscope examination witnessed the existence of migrated grain boundaries at the weld interfaces. Moreover, the presence of secondary phases such as P and μ was observed in continuous current weld joints, whereas they were absent in pulsed current weld joints, which needs to be further characterized. Moreover, pulsed current joints resulted in narrower weld bead, refined morphology, reduced elemental segregation and improved strength of the welded joints. The outcomes of the present investigation would help in obtaining good quality dissimilar joints for industrial applications and AISI 321 ASS being cheaper consequently led to cost-effective design also.

Plasma arc welding repair of space flight hardware

NASA Technical Reports Server (NTRS)

Hoffman, David S.

1993-01-01

Repair and refurbishment of flight and test hardware can extend the useful life of very expensive components. A technique to weld repair the main combustion chamber of space shuttle main engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloyZ, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloyZ while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Microwave heating for thermoplastic composites - Could the technology be used for welding applications?

NASA Astrophysics Data System (ADS)

Barasinski, Anaïs; Tertrais, Hermine; Bechtel, Stéphane; Chinesta, Francisco

2018-05-01

Welding primary structure thermoplastic composites parts is still an issue today, many technologies have been extensively studied: induction, ultrasonic, resistive welding, none is today entirely viable for this application due to various implementation reasons. On the other hand, microwave solutions are not very common in composites forming process, although being widespread in homes. Microwave (MW) technology relies on volumetric heating. Thermal energy is transferred from an electromagnetic field to materials that can absorb it at specific frequencies. Volumetric heating enables better process temperature control and less overall energy losses, which can results in shorter processing cycles and higher process efficiency. Nowadays, the main drawback of this technology is that the complex physics involved in the conversion of electromagnetic energy in thermal energy (heating) is not entirely understood and controlled for complex materials. In that work, the authors propose to look deeper in that way, first proposing a simulation tool, based on a coupling between a commercial code and a home made one, allowing the following of the electromagnetic field very precisely in the thickness of a laminate composite part, the last consisting of a stack of layers with different orientations, each layer made of a resin matrix and carbon fibers. Thermal fields are then computed and validated by experimental measurements. In a second part, the authors propose to look at a common welding case of a stringer, on a skin.

Intertidal Sandbar Welding as a Primary Source of Sediment for Dune Growth: Evidence from a Large Scale Field Experiment

NASA Astrophysics Data System (ADS)

Cohn, N.; Ruggiero, P.; de Vries, S.

2016-12-01

Dunes provide the first line of defense from elevated water levels in low-lying coastal systems, limiting potentially major flooding, economic damages, and loss of livelihood. Despite the well documented importance of healthy dunes, our predictive ability of dune growth, particularly following erosive storm events, remains poor - resulting in part from traditionally studying the wet and dry beach as separate entities. In fact, however, dune recovery and growth is closely tied to the subtidal morphology and the nearshore hydrodynamic conditions, necessitating treating the entire coastal zone from the shoreface to the backshore as an integrated system. In this context, to further improve our understanding of the physical processes allowing for beach and dune growth during fair weather conditions, a large field experiment, the Sandbar-aEolian Dune EXchange EXperiment, was performed in summer 2016 in southwestern Washington, USA. Measurements of nearshore and atmospheric hydrodynamics, in-situ sediment transport, and morphology change provide insight into the time and space scales of nearshore-beach-dune exchanges along a rapidly prograding stretch of coast over a 6 week period. As part of this experiment, the hypothesis that dune growth is limited by the welding of intertidal sandbars to the shoreline (Houser, 2009) was tested. Using laser particle counters, bed elevation sensors (sonar altimeters and Microsoft Kinect), continuously logging sediment traps, RGB and IR cameras, and repeat morphology surveys (terrestrial lidar, kite based structure from motion, and RTK GPS), spatial and temporal trends in aeolian sediment transport were assessed in relation to the synoptic onshore migration and welding of intertidal sandbars. Observations from this experiment demonstrate that (1) the intertidal zone is the primary source of sediment to the dunes during non-storm conditions, (2) rates of saltation increase during later stages of bar welding but equivalent wind conditions, and (3) alongshore variability in rates of backshore fluxes appear to be related to alongshore variability in intertidal morphology. These observations quantitatively support the Houser (2009) bar welding hypothesis and provide valuable new insights on nearshore-beach-dune sediment exchanges

Alterations in welding process voltage affect the generation of ultrafine particles, fume composition, and pulmonary toxicity.

PubMed

Antonini, James M; Keane, Michael; Chen, Bean T; Stone, Samuel; Roberts, Jenny R; Schwegler-Berry, Diane; Andrews, Ronnee N; Frazer, David G; Sriram, Krishnan

2011-12-01

The goal was to determine if increasing welding voltage changes the physico-chemical properties of the fume and influences lung responses. Rats inhaled 40 mg/m³ (3 h/day × 3 days) of stainless steel (SS) welding fume generated at a standard voltage setting of 25 V (regular SS) or at a higher voltage (high voltage SS) of 30 V. Particle morphology, size and composition were characterized. Bronchoalveolar lavage was performed at different times after exposures to assess lung injury. Fumes collected from either of the welding conditions appeared as chain-like agglomerates of nanometer-sized primary particles. High voltage SS welding produced a greater number of ultrafine-sized particles. Fume generated by high voltage SS welding was higher in manganese. Pulmonary toxicity was more substantial and persisted longer after exposure to the regular SS fume. In summary, a modest raise in welding voltage affected fume size and elemental composition and altered the temporal lung toxicity profile.

Information flow analysis and Petri-net-based modeling for welding flexible manufacturing cell

NASA Astrophysics Data System (ADS)

Qiu, T.; Chen, Shanben; Wang, Y. T.; Wu, Lin

2000-10-01

Due to the development of advanced manufacturing technology and the introduction of Smart-Manufacturing notion in the field of modern industrial production, welding flexible manufacturing system (WFMS) using robot technology has become the inevitable developing direction on welding automation. In WFMS process, the flexibility for different welding products and the realizing on corresponding welding parameters control are the guarantees for welding quality. Based on a new intelligent arc-welding flexible manufacturing cell (WFMC), the system structure and control policies are studied in this paper. Aiming at the different information flows among every subsystem and central monitoring computer in this WFMC, Petri net theory is introduced into the process of welding manufacturing. With its help, a discrete control model of WFMC has been constructed, in which the system status is regarded as place and the control process is regarded as transition. Moreover, grounded on automation Petri net principle, the judging and utilizing of information obtained from welding sensors are imported into net structure, which extends the traditional Petri net concepts. The control model and policies researched in this paper have established foundation for further intelligent real-time control on WFMC and WFMS.

Microstructural development at weld interface between Zr-based glassy alloy and stainless steel by resistance microwelding

NASA Astrophysics Data System (ADS)

Fukumoto, S.; Minami, M.; Soeda, A.; Matsushima, M.; Takahashi, M.; Yokoyama, Y.; Fujimoto, K.

2012-08-01

Zr-based bulk metallic glasses are expected to be welded to conventional structural alloys. Dissimilar welding of metallic glasses to stainless steel was carried out by resistance microwelding. The metallurgical analysis of the weld interface revealed the welding mechanism. A thin reaction layer was formed between the two liquid materials. The melting of stainless steel should be limited to obtain sound joints.

Naval Research Reviews. Volume XXXIII. Number 2,

DTIC Science & Technology

1981-01-01

and filler metal addition. ratio weld is a characteristic of a keyhole -produced The most distinctive feature of LB welding , weld . T /h III laser Ii...evolved from these radiation for precision operation, such as hole-drill- efforts include a 3kW CO. laser /workstation system ing, trimming, and welding ...asso- Laser Surface Modifications ciated with thick-section welding of naval structure and surface modification for improved corrosion and The high

Effect of welding speed on butt joint quality of Ti-6Al-4V alloy welded using a high-power Nd:YAG laser

NASA Astrophysics Data System (ADS)

Cao, X.; Jahazi, M.

2009-11-01

Annealed Ti-6Al-4V alloy sheets with 1 and 2 mm thickness are welded using a 4 kW Nd:YAG laser system. The effects of welding speed on surface morphology and shape, welding defects, microstructure, hardness and tensile properties are investigated. Weld joints without or with minor cracks, porosity and shape defects were obtained indicating that high-power Nd:YAG laser welding is a suitable method for Ti-6Al-4V alloy. The fusion zone consists mainly of acicular α' martensite leading to an increase of approximately 20% in hardness compared with that in the base metal. The heat-affected zone consists of a mixture of α' martensite and primary α phases. Significant gradients of microstructures and hardness are obtained over the narrow heat-affected zone. The laser welded joints have similar or slightly higher joint strength but there is a significant decrease in ductility. The loss of ductility is related to the presence of micropores and aluminum oxide inclusions.

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.

Improving Fatigue Performance of AHSS Welds

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

Feng, Zhili; Yu, Xinghua; Erdman, III, Donald L.

Reported herein is technical progress on a U.S. Department of Energy CRADA project with industry cost-share aimed at developing the technical basis and demonstrate the viability of innovative in-situ weld residual stresses mitigation technology that can substantially improve the weld fatigue performance and durability of auto-body structures. The developed technology would be costeffective and practical in high-volume vehicle production environment. Enhancing weld fatigue performance would address a critical technology gap that impedes the widespread use of advanced high-strength steels (AHSS) and other lightweight materials for auto body structure light-weighting. This means that the automotive industry can take full advantage ofmore » the AHSS in strength, durability and crashworthiness without the concern of the relatively weak weld fatigue performance. The project comprises both technological innovations in weld residual stress mitigation and due-diligence residual stress measurement and fatigue performance evaluation. Two approaches were investigated. The first one was the use of low temperature phase transformation (LTPT) weld filler wire, and the second focused on novel thermo-mechanical stress management technique. Both technical approaches have resulted in considerable improvement in fatigue lives of welded joints made of high-strength steels. Synchrotron diffraction measurement confirmed the reduction of high tensile weld residual stresses by the two weld residual stress mitigation techniques.« less

Brittle crack arrestability of thick steel plate welds in large structure

NASA Astrophysics Data System (ADS)

An, Gyu Baek; Park, Joon Sik

2011-10-01

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

Optimization and Prediction of Angular Distortion and Weldment Characteristics of TIG Square Butt Joints

NASA Astrophysics Data System (ADS)

Narang, H. K.; Mahapatra, M. M.; Jha, P. K.; Biswas, P.

2014-05-01

Autogenous arc welds with minimum upper weld bead depression and lower weld bead bulging are desired as such welds do not require a second welding pass for filling up the upper bead depressions (UBDs) and characterized with minimum angular distortion. The present paper describes optimization and prediction of angular distortion and weldment characteristics such as upper weld bead depression and lower weld bead bulging of TIG-welded structural steel square butt joints. Full factorial design of experiment was utilized for selecting the combinations of welding process parameter to produce the square butts. A mathematical model was developed to establish the relationship between TIG welding process parameters and responses such as upper bead width, lower bead width, UBD, lower bead height (bulging), weld cross-sectional area, and angular distortions. The optimal welding condition to minimize UBD and lower bead bulging of the TIG butt joints was identified.

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

PubMed Central

Yang, Jingwei; Cao, Biao; Lu, Qinghua

2017-01-01

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

Evaluation of Residual Stress Measurements Before and After Post-Weld Heat Treatment in the Weld Repairs

NASA Astrophysics Data System (ADS)

Pardowska, Anna M.; Price, John W. H.; Finlayson, Trevor R.; Ibrahim, R.

2010-11-01

Welding repairs are increasingly a structural integrity concern for aging pressure vessel and piping components. It has been demonstrated that the residual stress distribution near repair welds can be drastically different from that of the original weld. Residual stresses have a significant effect on the lifetime performance of a weld, and a reduction of these stresses is normally desirable. The aim of this paper is to investigate residual stresses in various weld repair arrangements using the non-destructive neutron diffraction technique. This research is focused on characterization of the residual stress distribution: (i) in the original weld; (ii) in a shallow toe weld repair; and (iii) after conventional post-weld heat treatment. The focus of the measurements is on the values of the subsurface strain/stress variations across the weld.

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

PubMed

Yang, Jingwei; Cao, Biao; Lu, Qinghua

2017-02-16

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

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

NASA Astrophysics Data System (ADS)

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

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

EB welding of launch vehicles

NASA Astrophysics Data System (ADS)

Szabo, Attila

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

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

NASA Technical Reports Server (NTRS)

Russell, C.

2001-01-01

The objective of this research was to assess the B218 weld filler wire for Super Lightweight External Tank production, which could improve current production welding and repair productivity. We took the following approaches: (1) Perform a repair weld quick look evaluation between 4043/B218 and B218/B218 weld filler wire combinations and evaluation tensile properties for planished and unplanished conditions; and (2) Perform repair weld evaluation on structural simulation panel using 4043-B218 and B218/B218 weld filler wire combinations and evaluation tensile and simulated service fracture properties for planished and unplanished conditions.

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

DEVELOPMENT OF WELDED SEAL FOR S3G REACTOR VESSEL

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

Rogers, J.W.

1958-01-01

The development program consisted of preliminary design, welding accessibility and feasibility, pressure and displacement cycling, theoretical analysis and life computation, photoelastic analysis, and comparison of PWR straight sample cycling. Design ''C'' of the three primary designs considered proved more satisfactory from a fatigue life standpoint. (W.D. M.)

A Concurrent Product-Development Approach for Friction-Stir Welded Vehicle-Underbody Structures

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, G.; Hariharan, A.; Pandurangan, B.

2012-04-01

High-strength aluminum and titanium alloys with superior blast/ballistic resistance against armor piercing (AP) threats and with high vehicle light-weighing potential are being increasingly used as military-vehicle armor. Due to the complex structure of these vehicles, they are commonly constructed through joining (mainly welding) of the individual components. Unfortunately, these alloys are not very amenable to conventional fusion-based welding technologies [e.g., gas metal arc welding (GMAW)] and to obtain high-quality welds, solid-state joining technologies such as friction-stir welding (FSW) have to be employed. However, since FSW is a relatively new and fairly complex joining technology, its introduction into advanced military-vehicle-underbody structures is not straight forward and entails a comprehensive multi-prong approach which addresses concurrently and interactively all the aspects associated with the components/vehicle-underbody design, fabrication, and testing. One such approach is developed and applied in this study. The approach consists of a number of well-defined steps taking place concurrently and relies on two-way interactions between various steps. The approach is critically assessed using a strengths, weaknesses, opportunities, and threats (SWOT) analysis.

Friction Pull Plug Welding in Aluminum Alloys

NASA Technical Reports Server (NTRS)

Brooke, Shane A.; Bradford, Vann

2012-01-01

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

Structural Phase Evolution in Ultrasonic-Assisted Friction Stir Welded 2195 Aluminum Alloy Joints

NASA Astrophysics Data System (ADS)

Eliseev, A. A.; Fortuna, S. V.; Kalashnikova, T. A.; Chumaevskii, A. V.; Kolubaev, E. A.

2017-10-01

The authors examined the structural and phase state of fixed joints produced by method of friction stir welding (FSW) and ultrasonic-assisted friction stir welding (UAFSW) from extruded profile of aluminum alloy AA2195. In order to identify the role of ultrasonic application in the course of welding, such characteristics, as volume fraction and average size of secondary particles are compared in the base material and stir zones of FSW and UAFSW joints. By applying the methods of SEM and TEM analysis, researchers established the complex character of phase transitions as a result of ultrasonic application.

Temperature profiles induced by a stationary CW laser beam in a multi-layer structure - Application to solar cell interconnect welding

NASA Astrophysics Data System (ADS)

Oh, J. E.; Ianno, N. J.; Ahmed, A. U.

A three-dimensional heat transfer model for heating of a multilayer structure by a stationary Gaussian CW CO2 laser beam is developed and applied to solar cell interconnect welding. This model takes into account the temperature dependence of the thermal conductivity and diffusivity as well as free carrier absorption of the incident beam in the silicon where appropriate. Finally, the theoretical temperature profiles are used to determine the weld spot size and these values are compared to results obtained from a simple welding experiment, where excellent agreement is obtained.

Gas-tungsten arc welding of aluminum alloys

DOEpatents

Frye, Lowell D.

1984-01-01

A gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to provide a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surfaces are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy contiguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

Design of reinforcement welding machine within steel framework for marine engineering

NASA Astrophysics Data System (ADS)

Wang, Gang; Wu, Jin

2017-04-01

In this project, a design scheme that reinforcement welding machine is added within the steel framework is proposed according to the double-side welding technology for box-beam structure in marine engineering. Then the design and development of circuit and transmission mechanism for new welding equipment are completed as well with one sample machine being made. Moreover, the trial running is finished finally. Main technical parameters of the equipment are: the working stroke: ≥1500mm, the welding speed: 8˜15cm/min and the welding sheet thickness: ≥20mm.

Grain refinement control in TIG arc welding

NASA Technical Reports Server (NTRS)

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

1975-01-01

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

Quantitative ultrasonic testing of acoustically anisotropic materials with verification on austenitic and dissimilar weld joints

NASA Astrophysics Data System (ADS)

Boller, C.; Pudovikov, S.; Bulavinov, A.

2012-05-01

Austenitic stainless steel materials are widely used in a variety of industry sectors. In particular, the material is qualified to meet the design criteria of high quality in safety related applications. For example, the primary loop of the most of the nuclear power plants in the world, due to high durability and corrosion resistance, is made of this material. Certain operating conditions may cause a range of changes in the integrity of the component, and therefore require nondestructive testing at reasonable intervals. These in-service inspections are often performed using ultrasonic techniques, in particular when cracking is of specific concern. However, the coarse, dendritic grain structure of the weld material, formed during the welding process, is extreme and unpredictably anisotropic. Such structure is no longer direction-independent to the ultrasonic wave propagation; therefore, the ultrasonic beam deflects and redirects and the wave front becomes distorted. Thus, the use of conventional ultrasonic testing techniques using fixed beam angles is very limited and the application of ultrasonic Phased Array techniques becomes desirable. The "Sampling Phased Array" technique, invented and developed by Fraunhofer IZFP, allows the acquisition of time signals (A-scans) for each individual transducer element of the array along with fast image reconstruction techniques based on synthetic focusing algorithms. The reconstruction considers the sound propagation from each image pixel to the individual sensor element. For anisotropic media, where the sound beam is deflected and the sound path is not known a-priori, a novel phase adjustment technique called "Reverse Phase Matching" is implemented. By taking into account the anisotropy and inhomogeneity of the weld structure, a ray tracing algorithm for modeling the acoustic wave propagation and calculating the sound propagation time is applied. This technique can be utilized for 2D and 3D real time image reconstruction. The "Gradient Constant Descent Method" (GECDM), an iterative algorithm, is implemented, which is essential for examination of inhomogeneous anisotropic media having unknown properties (elastic constants). The Sampling Phased Array technique with Reverse Phase Matching extended by GECDM-technique determines unknown elastic constants and provides reliable and efficient quantitative flaw detection in the austenitic welds. The validation of ray-tracing algorithm and GECDM-method is performed by number of experiments on test specimens with artificial as well as natural material flaws. A mechanized system for ultrasonic testing of stainless steel and dissimilar welds is developed. The system works on both conventional and Sampling Phased Array techniques. The new frontend ultrasonic unit with optical data link allows the 3D visualization of the inspection results in real time.

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

NASA Astrophysics Data System (ADS)

Biradar, N. S.; Raman, R.

2012-09-01

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

Damage Tolerance Assessment of Friction Pull Plug Welds in an Aluminum Alloy

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

Friction stir welding is a solid state welding process used in the fabrication of cryogenic propellant tanks. Self-reacting friction stir welding is one variation of the friction stir weld process being developed for manufacturing tanks. Friction pull plug welding is used to seal the exit hole that remains in a circumferential self-reacting friction stir weld. A friction plug weld placed in a self-reacting friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data relating residual strength capability to flaw size in an aluminum alloy friction plug weld will be presented.

The Analysis of the General Performance and Mechanical Behavior of Unirradiated FeCrAl Alloys Before and After Welding

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

Gussev, Maxim N.; Field, Kevin G.; Yamamoto, Yukinori

2016-06-03

The present report summarizes and discusses the preliminary results for the in-depth characterization of the modern, nuclear-grade FeCrAl alloys currently under development. The alloys were designed for enhanced radiation tolerance and weldability, and the research is currently being pursued by the Department of Energy (DOE) Nuclear Energy Enabling Technologies (NEET) program. Last year, seven candidate FeCrAl alloys with well-controlled chemistry and microstructures were designed and produced; welding was performed under well-controlled conditions. The structure and general performance of unirradiated alloys were assessed using standardized and advanced microstructural characterization techniques and mechanical testing. The primary objective is to identify the bestmore » candidate alloy, or at a minimum to identify the contributing factors that increase the weldability and radiation tolerance of FeCrAl alloys, therefore enabling future generations of FeCrAl alloys to deliver better performance parameters. This report is structured so as to describe these critical assessments of the weldability; radiation tolerance will be reported on in later reports from this program.« less

Microscopic analysis of structural changes in diode-laser-welded corneal stroma

NASA Astrophysics Data System (ADS)

Matteini, Paolo; Rossi, Francesca; Menabuoni, Luca; Pini, Roberto

2007-02-01

Diode laser welding of the cornea is a technique used to provide immediate sealing of corneal wounds: the cut is stained with a water solution of Indocyanine Green and is then irradiated with an 810 nm laser at low power densities (12-16 W/cm2), which induces a localized heating of the stroma in the range 55-66 °C range. In this study, we present a microscopic analysis aimed at evaluating the structural modifications induced in the stromal collagen of pig eyes during the laser welding of corneal wounds. Cornea samples obtained from twenty freshly-enucleated eyes were cut with a pre-calibrated knife and subjected to the laser welding procedure. Histological slices of the laser-welded stroma were examined by means of optical and transmission electron microscopy. These analyses indicated that bridges of lamellar structures crossed the wound edges with no presence of a coagulation effect. After laser welding, collagen fibrils appeared differently oriented among themselves in comparison with those of the control samples, but with similar mean fibril diameters. The laser-induced effect appeared to be confined to the ICG stained area of the cut walls, and no heat damage was observed at the operative power levels of laser corneal welding.

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

NASA Astrophysics Data System (ADS)

Shenghai, Zhang; Yifu, Shen; Huijuan, Qiu

2013-06-01

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

Critical evaluation of sequential leaching procedures for the determination of Ni and Mn species in welding fumes.

PubMed

Berlinger, B; Náray, M; Sajó, I; Záray, G

2009-06-01

In this work, welding fume samples were collected in a welding plant, where corrosion-resistant steel and unalloyed structural steel were welded by gas metal arc welding (GMAW) and manual metal arc welding (MMAW) techniques. The welding fumes were sampled with a fixed-point sampling strategy applying Higgins-Dewell cyclones. The following solutions were used to dissolve the different species of Ni and Mn: ammonium citrate solution [1.7% (m/v) diammonium hydrogen citrate and 0.5% (m/v) citric acid monohydrate] for 'soluble' Ni, 50:1 methanol-bromine solution for metallic Ni, 0.01 M ammonium acetate for soluble Mn, 25% acetic acid for Mn(0) and Mn(2+) and 0.5% hydroxylammonium chloride in 25% acetic acid for Mn(3+) and Mn(4+). 'Insoluble' Ni and Mn contents of the samples were determined after microwave-assisted digestion with the mixture of concentrated (cc). HNO(3), cc. HCl and cc. HF. The sample solutions were analysed by inductively coupled plasma quadrupole mass spectrometry and inductively coupled plasma atomic emission spectrometry. The levels of total Ni and Mn measured in the workplace air were different because of significant differences of the fume generation rates and the distributions of the components in the welding fumes between the welding processes. For quality control of the leaching process, dissolution of the pure stoichiometric Mn and Ni compounds and their mixtures weighing was investigated using the optimized leaching conditions. The results showed the adequacy of the procedure for the pure metal compounds. Based on the extraction procedures, the predominant oxidation states of Ni and Mn proved to be very different depending on the welding techniques and type of the welded steels. The largest amount of Mn in GMAW fumes were found as insoluble Mn (46 and 35% in case of corrosion-resistant steel and unalloyed structural steel, respectively), while MMAW fumes contain mainly soluble Mn, Mn(0) and Mn(2+) (78%) and Mn(3+) and Mn(4+) (54%) in case of corrosion-resistant steel and unalloyed structural steel, respectively. According to the results of the leaching procedures, GMAW fumes are rich in oxidic Ni (79%), while Ni compounds in welding fumes generated during MMAW are mainly in easily soluble form (44%). The crystalline phases were identified in each welding fume by X-ray powder diffraction (XRPD) technique as well. From the XRPD spectra, it is clear that GMAW fumes contain predominantly magnetite (FeFe(2)O(4)). In case of structural steel welding, there was a little amount of ferrite (alpha-Fe) also found. Welding fume generated during MMAW of structural steel contained a complex alkali-alkali earth fluoride phase (KCaF(3)-CaF(2)) and some magnetite and jakobsite (MnFe(2)O(4)). The XRPD results did not fully confirm the ones obtained from the extraction experiments. However, some results, for example the rate of soluble Ni and Mn compounds compared to the total, can be useful for further investigations of welding fumes.

Improved simulation method of automotive spot weld failure with an account of the mechanical properties of spot welds

NASA Astrophysics Data System (ADS)

Wu, H.; Meng, X. M.; Fang, R.; Huang, Y. F.; Zhan, S.

2017-12-01

In this paper, the microstructure and mechanical properties of spot weld were studied, the hardness of nugget and heat affected zone (HAZ) were also tested by metallographic microscope and microhardness tester. The strength of the spot weld with the different parts' area has been characterized. According to the experiments result, CAE model of spot weld with HAZ structure was established, and simulation results of different lap-shear CAE models were analyzed. The results show that the spot weld model which contained the HAZ has good performance and more suitable for engineering application in spot weld simulation.

Manufacturing Methods and Technology Application of High Energy Laser Welding Process.

DTIC Science & Technology

1980-08-01

surface appearance and the lowest porosity of the three beam shapes evaluated. Welds made with the pure annular beam resembled a TIG weld in both surface...improper starts and stops when welding with a conventional MIG or TIG process. Figure 16 left and center illustrates cracking due to fast freezing conditions...REPORT RL-82-2 0 MANUFACTURING METHODS AND TECHNOLOGY APPLICATION _OF HIGH ENERGY LASER WELDING PROCESS 0John V. Melonas Structures Directorate, U S

Fibre Laser Welding of HY-80 Steel: Procedure Development and Testing

DTIC Science & Technology

2010-09-01

2 Welding The material used in this study was quenched and tempered martensitic HY80 steel which conforms to MIL-S-1621 [2]. The testing...Journal, 1977. [4] AWS, D1.6 in Structural Welding Code Stainless Steel . 2007, American Welding Society: Miami Florida. [5] DefStan, 02-770 Part 2...Canada Fibre Laser Welding of HY-80 Steel Proceedure Development and Testing Christopher Bayley DLP Neil Aucoin DLP Xinjin Cao NRC IAR AMTC Technical

Hot cracking of Structural Steel during Laser Welding

NASA Astrophysics Data System (ADS)

Pineda Huitron, Rosa M.; Vuorinen, Esa

2017-10-01

Laser welding is an important technique in many industries due to its high precision in operation, its local and fast processing, narrow welds and its good weld surface quality. However, the process can involve some complications due to the rapid heating and cooling of the material processed, resulting in physical and metallurgical effects as thermal contraction during solidification, giving as a result the presence of residual stresses in the narrow weld. Formation of defects during the process is an important topic to be evaluated in order to achieve better performance of the steels in use. In the present work, defects formed during laser welding of a structural steel have been investigated. The defects formed have been identified and the causes of the defects are discussed. Possible strategies for improvement of the welding procedure and final weld result are proposed. The defects were analysed by optical and scanning electron microscopy and hardness measurement. Cracks were located in the middle of the fusion zone and followed both inter-granular and trans-granular paths. Impurities as manganese sulphides were found along the welding direction, and could act as sites for crack formation. The cracks formed during solidification of the weld are identified as solidification cracks. This kind of cracks is usually caused by solidification shrinkage and thermal contractions during the process, which appear in the fusion zone and sometimes in the heat affected zone.

Effects of various tool pin profiles on mechanical and metallurgical properties of friction stir welded joints of cryorolled AA2219 aluminium alloy

NASA Astrophysics Data System (ADS)

Kamal Babu, Karupannan; Panneerselvam, Kavan; Sathiya, Paulraj; Noorul Haq, Abdul Haq; Sundarrajan, Srinivasan; Mastanaiah, Potta; Srinivasa Murthy, Chunduri Venkata

2018-02-01

Friction stir welding (FSW) process was conducted on cryorolled (CR) AA2219 plate using different tool pin profiles such as cylindrical pin, threaded cylindrical pin, square pin and hexagonal pin profiles. The FSW was carried out with pairs of 6 mm thick CR aluminium plates with different tool pin profiles. The different tool pin profile weld portions' behaviors like mechanical (tensile strength, impact and hardness) and metallurgical characteristics were analyzed. The results of the mechanical analysis revealed that the joint made by the hexagonal pin tool had good strength compared to other pin profiles. This was due to the pulsating action and material flow of the tool resulting in dynamic recrystallization in the weld zone. This was confirmed by the ultra fine grain structure formation in Weld Nugget (WN) of hexagonal pin tool joint with a higher percentage of precipitate dissolution. The fractograph of the hexagonal tool pin weld portion confirmed the finer dimple structure morphology without having any interior defect compared to other tool pin profiles. The lowest weld joint strength was obtained from cylindrical pin profile weld joint due to insufficient material flow during welding. The Transmission Electron Microscope and EDX analysis showed the dissolution of the metastable θ″, θ' (Al2Cu) partial precipitates in the WN and proved the influence of metastable precipitates on enhancement of mechanical behavior of weld. The XRD results also confirmed the Al2Cu precipitation dissolution in the weld zone.

Dose-dependent progression of parkinsonism in manganese-exposed welders

PubMed Central

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

2017-01-01

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

Investigation on fibrous collagen modifications during corneal laser welding by second harmonic generation microscopy

NASA Astrophysics Data System (ADS)

Matteini, Paolo; Ratto, Fulvio; Rossi, Francesca; Cicchi, Riccardo; Stringari, Chiara; Kapsokalyvas, Dimitrios; Pavone, Francesco S.; Pini, Roberto

2009-02-01

The structural modifications in the collagen lattice of corneal stroma induced by near-infrared laser welding were investigated with second-harmonic generation (SHG) imaging. The corneal laser welding procedure is performed by staining the wound edges with a saturated water solution of Indocyanine Green (ICG) followed by irradiation with a 810 nm diode laser operated in continuous (CWLW: continuous wave laser welding) or pulsed (PLW: pulsed laser welding) mode. Both these procedures can provide closure of corneal wounds by inducing different structural modifications in the extracellular matrix. SHG imaging of native corneal stroma revealed collagen bundles composed of many regularly aligned collagen fibrils. After CWLW the regular lamellar arrangement was lost; collagen bundles appeared densely packed with an increasing disordered arrangement toward the welded cut. The weld was characterized by a loss of details; nevertheless, the observation of the second harmonic signal at this site indicated the lack of collagen denaturation. By contrast, PLW mode produced welding spots at the interface between donor and recipient corneal layers, which were characterized by a severe loss of the SHG signal, suggesting the occurrence of a complete collagen denaturation. SHG imaging appeared to be a powerful tool for visualizing the supramolecular morphological modifications in the collagen matrix after laser welding.

Laser and Pressure Resistance Weld of Thin-Wall Cladding for LWR Accident-Tolerant Fuels

NASA Astrophysics Data System (ADS)

Gan, J.; Jerred, N.; Perez, E.; Haggard, D. C.

2017-12-01

FeCrAl alloy with typical composition of approximately Fe-15Cr-5Al is considered a primary candidate cladding material for light water reactor accident-tolerant fuel because of its superior resistance to oxidation in high-temperature steam compared with Zircaloy cladding. Thin-walled FeCrAl cladding at 350 μm wall thickness is required, and techniques for joining endplug to cladding need to be developed. Fusion-based laser weld and solid-state joining with pressure resistance weld were investigated in this study. The results of microstructural characterization, mechanical property evaluation by tensile testing, and hydraulic pressure burst testing of the welds for the cladding-endplug specimen are discussed.

Laser and Pressure Resistance Weld of Thin-Wall Cladding for LWR Accident-Tolerant Fuels

NASA Astrophysics Data System (ADS)

Gan, J.; Jerred, N.; Perez, E.; Haggard, D. C.

2018-02-01

FeCrAl alloy with typical composition of approximately Fe-15Cr-5Al is considered a primary candidate cladding material for light water reactor accident-tolerant fuel because of its superior resistance to oxidation in high-temperature steam compared with Zircaloy cladding. Thin-walled FeCrAl cladding at 350 μm wall thickness is required, and techniques for joining endplug to cladding need to be developed. Fusion-based laser weld and solid-state joining with pressure resistance weld were investigated in this study. The results of microstructural characterization, mechanical property evaluation by tensile testing, and hydraulic pressure burst testing of the welds for the cladding-endplug specimen are discussed.

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

NASA Technical Reports Server (NTRS)

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

1993-01-01

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

Assessment of delta ferrite in multipass TIG welds of 40 mm thick SS 316L: A comparative study of ferrite number (FN) prediction and measurements

NASA Astrophysics Data System (ADS)

Buddu, Ramesh Kumar; Raole, P. M.; Sarkar, B.

2017-04-01

Austenitic stainless steels are widely used in the fabrication of fusion reactor major systems like vacuum vessel, divertor, cryostat and other structural components development. Multipass welding is used for the development of thick plates for the structural components fabrication. Due to the repeated weld thermal cycles, the microstructure adversely alters owing to the presence of complex phases like austenite, ferrite and delta ferrite and subsequently influences the mechanical properties like tensile and impact toughness of joints. The present paper reports the detail analysis of delta ferrite phase in welded region of 40 mm thick SS316L plates welded by special design multipass narrow groove TIG welding process under three different heat input conditions. The correlation of delta ferrite microstructure of different type structures acicular and vermicular is observed. The chemical composition of weld samples was used to predict the Ferrite Number (FN), which is representative form of delta ferrite in welds, with Schaeffler’s, WRC-1992 diagram and DeLong techniques by calculating the Creq and Nieq ratios and compared with experimental data of FN from Feritescope measurements. The low heat input conditions (1.67 kJ/mm) have produced higher FN (7.28), medium heat input (1.72 kJ/mm) shown FN (7.04) where as high heat input (1.87 kJ/mm) conditions has shown FN (6.68) decreasing trend and FN data is compared with the prediction methods.

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.

The Study of Complex (Ti, Zr, Cs) Nanopowder Influencing the Effective Ionization Potential of Arc Discharge When Mma Welding

NASA Astrophysics Data System (ADS)

Sapozhkov, S. B.; Burakova, E. M.

2016-08-01

Strength is one of the most important characteristics of a weld joint. Mechanical properties of a weld metal can be improved in a variety of ways. One of the possibilities is to add a nanopowder to the weld metal. Authors of the paper suggest changing the production process of MMA welding electrodes via adding nanopowder Ti, Zr, Cs to electrode components through liquid glass. Theoretical research into the nanopowder influence on the effective ionization potential (Ueff) of welding arc discharge is also necessitated. These measures support arcing stability, improve strength of a weld joint, as the consequence, ensure quality enhancing of a weld joint and the structure on the whole.

M551 metals melting experiment

NASA Technical Reports Server (NTRS)

Busch, G.

1977-01-01

Electron beam welding studies were conducted in the Skylab M551 metals melting experiment, on three different materials; namely 2219-T87 aluminum alloy, 304L stainless steel, and commercially pure tantalum (0.5 wt % columbium). Welds were made in both one gravity and zero gravity (Skylab) environments. Segments from each of the welds were investigated by microhardness, optical microscopy, scanning microscopy, and electron probe techniques. In the 2219-T87 aluminum alloy samples, macroscopic banding and the presence of an eutectic phase in the grain boundaries of the heat affected zone were observed. The stainless steel samples exhibited a sharp weld interface and macroscopic bands. The primary microstructural features found in the tantalum were the presence of either columnar grains (ground base) or equiaxed grains (Skylab). The factors contributing to these effects are discussed and the role of reduced gravity in welding is considered.

Numerical and experimental analysis for solidification and residual stress in the GMAW process for AISI 304 stainless steel

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

Choi, J.; Mazumder, J.

1996-12-31

Networking three fields of welding--thermal, microstructure, and stress--was attempted and produced a reliable model using a numerical method with the finite element analysis technique. Model prediction was compared with experimental data in order to validate the model. The effects of welding process parameters on these welding fields were analyzed and reported. The effort to correlate the residual stress and solidification was initiated, with some valuable results. The solidification process was simulated using the formulation based on the Hunt-Trivedi model. Based on the temperature history, solidification speed and primary dendrite arm spacing were predicted at given nodes of interest. Results showmore » that the variation during solidification is usually within an order of magnitude. The temperature gradient was generally in the range of 10{sup 4}--10{sup 5} K/m for the given welding conditions (welding power = 6 kW and welding speed = 3.3867 to 7.62 mm/sec), while solidification speed appeared to slow down from an order of 10{sup {minus}1} to 10{sup {minus}2} m/sec during solidification. SEM images revealed that the primary dendrite arm spacing (PDAS) fell in the range of 10{sup 1}--10{sup 2} {micro}m. For grain growth at the heat affected zone (HAZ), Ashby`s model was employed. The prediction was in agreement with experimental results. For the residual stress calculation, the same mesh generation used in the heat transfer analysis was applied to make the simulation consistent. The analysis consisted of a transient heat analysis followed by a thermal stress analysis. An experimentally measured strain history was compared with the simulated result. The relationship between microstructure and the stress/strain field of welding was also obtained. 64 refs., 18 figs., 9 tabs.« less

Changes in type I collagen following laser welding.

PubMed

Bass, L S; Moazami, N; Pocsidio, J; Oz, M C; LoGerfo, P; Treat, M R

1992-01-01

Selection of ideal laser parameters for tissue welding is inhibited by poor understanding of the mechanism. We investigated structural changes in collagen molecules extracted from rat tail tendon (> 90% type I collagen) after tissue welding using an 808 nm diode laser and indocyanine green dye applied to the weld site. Mobility patterns on SDS-PAGE were identical in the lasered and untreated tendon extracts with urea or acetic acid. Pepsin incubation after acetic acid extraction revealed a reduction of collagen alpha and beta bands in lasered compared with untreated specimens. Circular dichroism studies of rat tail tendon showed absence of helical structure in collagen from lasered tendon. No evidence for covalent bonding was present in laser-treated tissues. Collagen molecules are denatured by the laser wavelength and parameters used in this study. No significant amount of helical structure is regenerated on cooling. We conclude that non-covalent interactions between denatured collagen molecules may be responsible for the creation of tissue welding.

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

NASA Technical Reports Server (NTRS)

Martukanitz, R. P.; Jan. R.

1996-01-01

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

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

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

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, 0.027more » 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/iridium weld width ratio to achieve similar welds. Further weld trials using various thicknesses of molybdenum determined that 0.024 inch thick molybdenum material would best match the 0.027 inch thick iridium in achieving comparable welds when using the same welding parameters. Across the range of welding speeds, the characteristic weld pool shape and solidification grain structure in the two materials was also similar. With the similarity of welding characteristics confirmed, and the appropriate thickness of molybdenum determined, it has been concluded that the use of molybdenum discs and tube sections will greatly expand the weld testing opportunities prior to iridium weld qualification« less

Friction Pull Plug Welding in Aluminum Alloys

NASA Technical Reports Server (NTRS)

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

2011-01-01

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

Gas-tungsten arc welding of aluminum alloys

DOEpatents

Frye, L.D.

1982-03-25

The present invention is directed to a gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to profice a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surface are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy continguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

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

NASA Astrophysics Data System (ADS)

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

1992-10-01

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

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

NASA Technical Reports Server (NTRS)

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

1992-01-01

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

Microstructural Evolution and Fracture Behavior of Friction-Stir-Welded Al-Cu Laminated Composites

NASA Astrophysics Data System (ADS)

Beygi, R.; Kazeminezhad, Mohsen; Kokabi, A. H.

2014-01-01

In this study, we attempt to characterize the microstructural evolution during friction stir butt welding of Al-Cu-laminated composites and its effect on the fracture behavior of the joint. Emphasis is on the material flow and particle distribution in the stir zone. For this purpose, optical microscopy and scanning electron microscopy (SEM) images, energy-dispersive spectroscopy EDS and XRD analyses, hardness measurements, and tensile tests are carried out on the joints. It is shown that intermetallic compounds exist in lamellas of banding structure formed in the advancing side of the welds. In samples welded from the Cu side, the banding structure in the advancing side and the hook formation in the retreating side determine the fracture behavior of the joint. In samples welded from the Al side, a defect is formed in the advancing side of the weld, which is attributed to insufficient material flow. It is concluded that the contact surface of the laminate (Al or Cu) with the shoulder of the FSW tool influences the material flow and microstructure of welds.

HAZ and Structural Defects Control in Key-Hole Welding of Titanium Using a Reptitively-Pulsed Nd: Yag Laser

NASA Astrophysics Data System (ADS)

Hamudi, Walid K.

1996-12-01

HAZ, porosity and cracks were investigated when welding 0.9 mm thick titanium sheets using a 10 J pulsed Nd: Yag laser. The effects of welding speed, joints fit-up, shielding gas, and laser parameters are presented. For optimum welding quality, 0.25 m/min scanning speed, 10 ℓ/min gas flow rate and 72 Watt average power were used. Welds of narrow heat affected zone (HAZ) with small level of porosity were obtained.

Model-Based Structural Health Monitoring of Fatigue Damage Test-Bed Specimens

DTIC Science & Technology

2011-11-15

the hull welds or notches along component edges are good initial candidates for the hypothetical damage initiation areas. The branching process adds...to it off-center. The base plate and the stiffener plate are rigidly welded by a tungsten inert gas ( TIG ) weld . Three different crack paths...shown in Figure 9(a), an 18 in long stiffener plate has been welded to each of the tested plates with 0.625 in long discrete TIG welds at 5 locations

An online real time ultrasonic NDT system for the quality control of spot welding in the automotive industry

NASA Astrophysics Data System (ADS)

Athi, N.; Wylie, S. R.; Cullen, J. D.; Al-Jader, M.; Al-Shamma'a, A. I.; Shaw, A.

2009-07-01

Resistance spot welding is the main joining technique used for the fabrication of body-in-white structures in the automotive industry. The quality of the welds depends on the profile of the spot welding electrode cap. The increased use of zinc coated steel in the industry increases wear rate of the caps, making quality control more difficult. This paper presents a novel online real time ultrasonic NDE system for resistance spot welding which evaluates every weld as it is formed. SEM results are presented to show the alloying of the electrode caps.

Milestones in welding technology

NASA Astrophysics Data System (ADS)

Dolby, Richard E.

2013-09-01

Sir Alan's PhD thesis describes his research into cracking during arc welding of armour steels. Throughout his career, he had a strong interest in defects of all types, how they formed in metallic structures and how the larger ones could be detected and sized by non-destructive techniques. He was also vitally concerned with how defects impacted on the engineering integrity of welded structures, particularly the risk of fracture in nuclear plant. This study presents a view of some of the major milestones in global welding technology that took place over the 60 or more years of Sir Alan's career and highlights those where he had a personal and direct involvement.

Modelling Polymer Deformation and Welding Behaviour during 3D Printing

NASA Astrophysics Data System (ADS)

McIlroy, Claire; Olmsted, Peter

2016-11-01

3D printing has the potential to transform manufacturing processes, yet improving the strength of printed parts, to equal that of traditionally-manufactured parts, remains an underlying issue. The most common method, fused deposition modelling, involves melting a thermoplastic, followed by layer-by-layer extrusion of the material to fabricate a three-dimensional object. The key to the ensuring strength at the weld between these layers is successful inter-diffusion. However, as the printed layer cools towards the glass transition temperature, the time available for diffusion is limited. In addition, the extrusion process significantly deforms the polymer micro-structure prior to welding and consequently affects how the polymers "re-entangle" across the weld. We have developed a simple model of the non-isothermal printing process to explore the effects that typical printing conditions and amorphous polymer rheology have on the ultimate weld structure. In particular, we incorporate both the stretch and orientation of the polymer using the Rolie-Poly constitutive equation to examine how the melt flows through the nozzle and is deposited onto the build plate. We then address how this deformation relaxes and contributes to the thickness and structure of the weld. National Institute for Standards and Technology (NIST) and Georgetown University.

Development of a Robust and Cost-Effective Friction Stir Welding Process for Use in Advanced Military Vehicles

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, G.; Pandurangan, B.; Hariharan, A.; Yen, C.-F.; Cheeseman, B. A.

2011-02-01

To respond to the advent of more lethal threats, recently designed aluminum-armor-based military-vehicle systems have resorted to an increasing use of higher strength aluminum alloys (with superior ballistic resistance against armor piercing (AP) threats and with high vehicle-light weighing potential). Unfortunately, these alloys are not very amenable to conventional fusion-based welding technologies and in-order to obtain high-quality welds, solid-state joining technologies such as Friction stir welding (FSW) have to be employed. However, since FSW is a relatively new and fairly complex joining technology, its introduction into advanced military vehicle structures is not straight forward and entails a comprehensive multi-step approach. One such (three-step) approach is developed in the present work. Within the first step, experimental and computational techniques are utilized to determine the optimal tool design and the optimal FSW process parameters which result in maximal productivity of the joining process and the highest quality of the weld. Within the second step, techniques are developed for the identification and qualification of the optimal weld joint designs in different sections of a prototypical military vehicle structure. In the third step, problems associated with the fabrication of a sub-scale military vehicle test structure and the blast survivability of the structure are assessed. The results obtained and the lessons learned are used to judge the potential of the current approach in shortening the development time and in enhancing reliability and blast survivability of military vehicle structures.

Study of Compatibility of Stainless Steel Weld Joints with Liquid Sodium-Potassium Coolants for Fission Surface Power Reactors for Lunar and Space Applications

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

Grossbeck, Martin; Qualls, Louis

To make a manned mission to the surface of the moon or to Mars with any significant residence time, the power requirements will make a nuclear reactor the most feasible source of energy. To prepare for such a mission, NASA has teamed with the DOE to develop Fission Surface Power technology with the goal of developing viable options. The Fission Surface Power System (FSPS) recommended as the initial baseline design includes a liquid metal reactor and primary coolant system that transfers heat to two intermediate liquid metal heat transfer loops. Each intermediate loop transfers heat to two Stirling heat exchangersmore » that each power two Stirling converters. Both the primary and the intermediate loops will use sodium-potassium (NaK) as the liquid metal coolant, and the primary loop will operate at temperatures exceeding 600°C. The alloy selected for the heat exchangers and piping is AISI Type 316L stainless steel. The extensive experience with NaK in breeder reactor programs and with earlier space reactors for unmanned missions lends considerable confidence in using NaK as a coolant in contact with stainless steel alloys. However, the microstructure, chemical segregation, and stress state of a weld leads to the potential for corrosion and cracking. Such failures have been experienced in NaK systems that have operated for times less than the eight year goal for the FSPS. For this reason, it was necessary to evaluate candidate weld techniques and expose welds to high-temperature, flowing NaK in a closed, closely controlled system. The goal of this project was to determine the optimum weld configuration for a NaK system that will withstand service for eight years under FSPS conditions. Since the most difficult weld to make and to evaluate is the tube to tube sheet weld in the intermediate heat exchangers, it was the focus of this research. A pumped loop of flowing NaK was fabricated for exposure of candidate weld specimens at temperatures of 600°C, the expected temperature within the intermediate heat exchangers. Since metal transfer from a high-temperature region to a cooler region is a predominant mode of corrosion in liquid metal systems, specimens were placed at zones in the loop at the above temperature to evaluate the effects of both alloy component leaching and metal deposition. Microstructural analysis was performed to evaluate weld performance on control weld specimens. The research was coordinated with Oak Ridge National Laboratory (ORNL) where most of the weld samples were prepared. In addition, ORNL participated in the loop operation to assist in keeping the testing relevant to the project and to take advantage of the extensive experience in liquid metal research at ORNL.« less

Intelligent Modeling Combining Adaptive Neuro Fuzzy Inference System and Genetic Algorithm for Optimizing Welding Process Parameters

NASA Astrophysics Data System (ADS)

Gowtham, K. N.; Vasudevan, M.; Maduraimuthu, V.; Jayakumar, T.

2011-04-01

Modified 9Cr-1Mo ferritic steel is used as a structural material for steam generator components of power plants. Generally, tungsten inert gas (TIG) welding is preferred for welding of these steels in which the depth of penetration achievable during autogenous welding is limited. Therefore, activated flux TIG (A-TIG) welding, a novel welding technique, has been developed in-house to increase the depth of penetration. In modified 9Cr-1Mo steel joints produced by the A-TIG welding process, weld bead width, depth of penetration, and heat-affected zone (HAZ) width play an important role in determining the mechanical properties as well as the performance of the weld joints during service. To obtain the desired weld bead geometry and HAZ width, it becomes important to set the welding process parameters. In this work, adaptative neuro fuzzy inference system is used to develop independent models correlating the welding process parameters like current, voltage, and torch speed with weld bead shape parameters like depth of penetration, bead width, and HAZ width. Then a genetic algorithm is employed to determine the optimum A-TIG welding process parameters to obtain the desired weld bead shape parameters and HAZ width.

Welding Metallurgy and Weldability of Stainless Steels

NASA Astrophysics Data System (ADS)

Lippold, John C.; Kotecki, Damian J.

2005-03-01

Welding Metallurgy and Weldability of Stainless Steels, the first book in over twenty years to address welding metallurgy and weldability issues associated with stainless steel, offers the most up-to-date and comprehensive treatment of these topics currently available. The authors emphasize fundamental metallurgical principles governing microstructure evolution and property development of stainless steels, including martensistic, ferric, austenitic, duplex, and precipitation hardening grades. They present a logical and well-organized look at the history, evolution, and primary uses of each stainless steel, including detailed descriptions of the associated weldability issues.

Welding of a corrosion-resistant composite material based on VT14 titanium alloy obtained using an electron beam emitted into the atmosphere

NASA Astrophysics Data System (ADS)

Golkovski, M. G.; Samoylenko, V. V.; Polyakov, I. A.; Lenivtseva, O. G.; Chakin, I. K.; Komarov, P. N.; Ruktuev, A. A.

2017-01-01

The study investigates the possibility of inert gas arc welding of a double layer composite material on a titanium base with an anti-corrosive layer obtained by fused deposition of a powder mix containing tantalum and niobium over a titanium base using an electron beam emitted into the atmosphere. Butt welding and fillet welding options were tested with two types of edge preparation. Welds were subjected to a metallographic examination including a structural study and an analysis of the chemical and phase composition of the welds. A conclusion was made regarding the possibility of using welding for manufacturing of items from the investigated composite material.

Damage Tolerance Assessment of Friction Pull Plug Welds

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

Friction stir welding is a solid state welding process developed and patented by The Welding Institute in Cambridge, England. Friction stir welding has been implemented in the aerospace industry in the fabrication of longitudinal welds in pressurized cryogenic propellant tanks. As the industry looks to implement friction stir welding in circumferential welds in pressurized cryogenic propellant tanks, techniques to close out the termination hole associated with retracting the pin tool are being evaluated. Friction pull plug welding is under development as a one means of closing out the termination hole. A friction pull plug weld placed in a friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite, plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size in the test or service environments. Test data relating residual strength capability to flaw size in two aluminum alloy friction plug weld configurations is presented.

Prediction and Verification of Ductile Crack Growth from Simulated Defects in Strength Overmatched Butt Welds

NASA Technical Reports Server (NTRS)

Nishioka, Owen S.

1997-01-01

Defects that develop in welds during the fabrication process are frequently manifested as embedded flaws from lack of fusion or lack of penetration. Fracture analyses of welded structures must be able to assess the effect of such defects on the structural integrity of weldments; however, the transferability of R-curves measured in laboratory specimens to defective structural welds has not been fully examined. In the current study, the fracture behavior of an overmatched butt weld containing a simulated buried, lack-of-penetration defect is studied. A specimen designed to simulate pressure vessel butt welds is considered; namely, a center crack panel specimen, of 1.25 inch by 1.25 inch cross section, loaded in tension. The stress-relieved double-V weld has a yield strength 50% higher than that of the plate material, and displays upper shelf fracture behavior at room temperature. Specimens are precracked, loaded monotonically while load-CMOD measurements are made, then stopped and heat tinted to mark the extent of ductile crack growth. These measurements are compared to predictions made using finite element analysis of the specimens using the fracture mechanics code Warp3D, which models void growth using the Gurson-Tvergaard dilitant plasticity formulation within fixed sized computational cells ahead of the crack front. Calibrating data for the finite element analyses, namely cell size and initial material porosities are obtained by matching computational predictions to experimental results from tests of welded compact tension specimens. The R-curves measured in compact tension specimens are compared to those obtained from multi-specimen weld tests, and conclusions as to the transferability of R-curves is discussed.

Proton-irradiation technology for high-frequency high-current silicon welding diode manufacturing

NASA Astrophysics Data System (ADS)

Lagov, P. B.; Drenin, A. S.; Zinoviev, M. A.

2017-05-01

Different proton irradiation regimes were tested to provide more than 20 kHz-frequency, soft reverse recovery “snap-less” behavior, low forward voltage drop and leakage current for 50 mm diameter 7 kA/400 V welding diode Al/Si/Mo structure. Silicon diode with such parameters is very suitable for high frequency resistance welding machines of new generation for robotic welding.

Acoustic Emission Weld Monitoring in the 2195 Aluminum-Lithium Alloy

NASA Technical Reports Server (NTRS)

Walker, James L.

2005-01-01

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

Welding-Induced Microstructure Evolution of a Cu-Bearing High-Strength Blast-Resistant Steel

NASA Astrophysics Data System (ADS)

Caron, Jeremy L.; Babu, Sudarsanam Suresh; Lippold, John C.

2011-12-01

A new high strength, high toughness steel containing Cu for precipitation strengthening was recently developed for naval, blast-resistant structural applications. This steel, known as BlastAlloy160 (BA-160), is of nominal composition Fe-0.05C-3.65Cu-6.5Ni-1.84Cr-0.6Mo-0.1V (wt pct). The evident solidification substructure of an autogenous gas tungsten arc (GTA) weld suggested fcc austenite as the primary solidification phase. The heat-affected zone (HAZ) hardness ranged from a minimum of 353 HV in the coarse-grained HAZ (CGHAZ) to a maximum of 448 HV in the intercritical HAZ (ICHAZ). After postweld heat treatment (PWHT) of the spot weld, hardness increases were observed in the fusion zone (FZ), CGHAZ, and fine-grained HAZ (FGHAZ) regions. Phase transformation and metallographic analyses of simulated single-pass HAZ regions revealed lath martensite to be the only austenitic transformation product in the HAZ. Single-pass HAZ simulations revealed a similar hardness profile for low heat-input (LHI) and high heat-input (HHI) conditions, with higher hardness values being measured for the LHI samples. The measured hardness values were in good agreement with those from the GTA weld. Single-pass HAZ regions exhibited higher Charpy V-notch impact toughness than the BM at both test temperatures of 293 K and 223 K (20 °C and -50 °C). Hardness increases were observed for multipass HAZ simulations employing an initial CGHAZ simulation.

Laser beam welding of Waspaloy: Characterization and corrosion behavior evaluation

NASA Astrophysics Data System (ADS)

Shoja Razavi, Reza

2016-08-01

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

A Micro-Electrochemical Study of Friction Stir Welded Aluminum 6061-T6

NASA Technical Reports Server (NTRS)

Hintze, Paul E.; Calle, Luz M.

2005-01-01

The corrosion behavior of friction stir welded Aluminum alloy 606 1-T6 was studied using a micro-electrochemical cell. The micro-electrochemical cell has a measurement area of about 0.25 square mm which allows for measurement of corrosion properties at a very small scale. The corrosion and breakdown potentials were measured at many points inside and outside the weld along lines perpendicular to the weld. The breakdown potential is approximately equal inside and outside the weld; however, it is lower in the narrow border between the weld and base material. The results of electrochemical measurements were correlated to micro-structural analysis. The corrosion behavior of the friction stir welded samples was compared to tungsten inert gas (TIG) welded samples of the same material.

Size effect on cold-welding of gold nanowires investigated using molecular dynamics simulations

NASA Astrophysics Data System (ADS)

Wu, Cheng-Da; Fang, Te-Hua; Wu, Chung-Chin

2016-03-01

The size effect on the cold-welding mechanism and mechanical properties of Au nanowires (NWs) in head-to-head contact are studied using molecular dynamics simulations based on the second-moment approximation of the many-body tight-binding potential. The results are discussed in terms of atomic trajectories, slip vectors, stress, radial distribution function, and weld strength ratio. Simulation results show that during the cold-welding process, a few disordered atoms/defects in the jointing area rearrange themselves and transform into a face-centered cubic crystalline structure. With an increase in contact between the two NWs, dislocations gradually form on the (111) slip plane and then on a twin plane, leading to an increase in the lateral deformation of 4-nm-wide NWs. The effect of structural instability increases with decreasing NW width, making the alignment of the two NWs more difficult. The elongation ability of the welded NWs increases with increasing NW width. Smaller NWs have better weld strength.

Microstructure and Porosity of Laser Welds in Cast Ti-6Al-4V with Addition of Boron

NASA Astrophysics Data System (ADS)

Tolvanen, Sakari; Pederson, Robert; Klement, Uta

2018-03-01

Addition of small amounts of boron to cast Ti-6Al-4V alloy has shown to render a finer microstructure and improved mechanical properties. For such an improved alloy to be widely applicable for large aerospace structural components, successful welding of such castings is essential. In the present work, the microstructure and porosity of laser welds in a standard grade cast Ti-6Al-4V alloy as well as two modified alloy versions with different boron concentrations have been investigated. Prior-β grain reconstruction revealed the prior-β grain structure in the weld zones. In fusion zones of the welds, boron was found to refine the grain size significantly and rendered narrow elongated grains. TiB particles in the prior-β grain boundaries in the cast base material restricted grain growth in the heat-affected zone. The TiB particles that existed in the as cast alloys decreased in size in the fusion zones of welds. The hardness in the weld zones was higher than in the base material and boron did not have a significant effect on hardness of the weld zones. The fusion zones were smaller in the boron-modified alloys as compared with Ti-6Al-4V without boron. Computed tomography X-ray investigations of the laser welds showed that pores in the FZ of the boron modified alloys were confined to the lower part of the welds, suggesting that boron addition influences melt pool flow.

The Microstructure and Gamma Prime Distributions in Inertia Friction Welded Joint of P/M Superalloy FGH96

NASA Astrophysics Data System (ADS)

Zhang, Chi; Shen, Wenfei; Zhang, Liwen; Xia, Yingnan; Li, Ruiqin

2017-04-01

A gamma prime ( γ') precipitation ( 35% in volume)-hardened powder metallurgy (P/M) superalloy FGH96 was welded using inertia friction welding (IFW). The microstructure and γ' distributions in the joints in two conditions, hot isostatic pressed state and solution-treated and aged state, were characterized. The recrystallization of grains, the dissolution and re-precipitation of γ' in the joints were discussed in terms of the temperature evolutions which were calculated by finite element model analysis. Regardless of the initial states, fully recrystallized fine grain structure formed at welded zone. Meanwhile, very fine γ' precipitations were re-precipitated at the welded zone. These recrystallized grain structure and fine re-precipitated γ' resulted in increasing hardness of IFW joint while making the hardness dependent on the microstructure and γ' precipitation.

Special Features of Structure Formation in an Explosion-Welded Magnesium-Aluminum Composite Under Deformation and Subsequent Heat Treatment

NASA Astrophysics Data System (ADS)

Gurevich, L. M.; Arisova, V. N.; Trykov, Yu. P.; Ponomareva, I. A.; Trudov, A. F.

2016-07-01

The effect of bending deformation and subsequent heat treatment on the variation of microhardness and structure of explosion-welded magnesium-aluminum layered composite material MA2-1 - AD1 is studied.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-07-01

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

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

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

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

Effect of Low-Temperature Sensitization on the Corrosion Behavior of AISI Type 304L SS Weld Metal in Simulated Groundwater

NASA Astrophysics Data System (ADS)

Suresh, Girija; Nandakumar, T.; Viswanath, A.

2018-04-01

The manuscript presents the investigations carried out on the effect of low-temperature sensitization (LTS) of 304L SS weld metal on its corrosion behavior in simulated groundwater, for its application as a canister material for long-term storage of nuclear vitrified high-level waste in geological repositories. AISI type 304L SS weld pad was fabricated by multipass gas tungsten arc welding process using 308L SS filler wire. The as-welded specimens were subsequently subjected to carbide nucleation and further to LTS at 500 °C for 11 days to simulate a temperature of 300 °C for 100-year life of the canister in geological repositories. Delta ferrite (δ-ferrite) content of the 304L SS weld metal substantially decreased on carbide nucleation treatment and further only a marginal decrease occurred on LTS treatment. The microstructure of the as-welded consisted of δ-ferrite as a minor phase distributed in austenite matrix. The δ-ferrite appeared fragmented in the carbide-nucleated and LTS-treated weld metal. The degree of sensitization measured by double-loop electrochemical potentokinetic reactivation method indicated an increase in carbide nucleation treatment when compared to the as-welded specimens, and further increase occurred on LTS treatment. Potentiodynamic anodic polarization investigations in simulated groundwater indicated a substantial decrease in the localized corrosion resistance of the carbide-nucleated and LTS 304L SS weld metals, when compared to the as-welded specimens. Post-experimental micrographs indicated pitting as the primary mode of attack in the as-welded, while pitting and intergranular corrosion (IGC) occurred in the carbide-nucleated weld metal. LTS-treated weld metal predominantly underwent IGC attack. The decrease in the localized corrosion resistance of the weld metal after LTS treatment was found to have a direct correlation with the degree of sensitization and the weld microstructure. The results are detailed in the manuscript.

Effect of Low-Temperature Sensitization on the Corrosion Behavior of AISI Type 304L SS Weld Metal in Simulated Groundwater

NASA Astrophysics Data System (ADS)

Suresh, Girija; Nandakumar, T.; Viswanath, A.

2018-05-01

The manuscript presents the investigations carried out on the effect of low-temperature sensitization (LTS) of 304L SS weld metal on its corrosion behavior in simulated groundwater, for its application as a canister material for long-term storage of nuclear vitrified high-level waste in geological repositories. AISI type 304L SS weld pad was fabricated by multipass gas tungsten arc welding process using 308L SS filler wire. The as-welded specimens were subsequently subjected to carbide nucleation and further to LTS at 500 °C for 11 days to simulate a temperature of 300 °C for 100-year life of the canister in geological repositories. Delta ferrite ( δ-ferrite) content of the 304L SS weld metal substantially decreased on carbide nucleation treatment and further only a marginal decrease occurred on LTS treatment. The microstructure of the as-welded consisted of δ-ferrite as a minor phase distributed in austenite matrix. The δ-ferrite appeared fragmented in the carbide-nucleated and LTS-treated weld metal. The degree of sensitization measured by double-loop electrochemical potentokinetic reactivation method indicated an increase in carbide nucleation treatment when compared to the as-welded specimens, and further increase occurred on LTS treatment. Potentiodynamic anodic polarization investigations in simulated groundwater indicated a substantial decrease in the localized corrosion resistance of the carbide-nucleated and LTS 304L SS weld metals, when compared to the as-welded specimens. Post-experimental micrographs indicated pitting as the primary mode of attack in the as-welded, while pitting and intergranular corrosion (IGC) occurred in the carbide-nucleated weld metal. LTS-treated weld metal predominantly underwent IGC attack. The decrease in the localized corrosion resistance of the weld metal after LTS treatment was found to have a direct correlation with the degree of sensitization and the weld microstructure. The results are detailed in the manuscript.

Lamb wave line sensing for crack detection in a welded stiffener.

PubMed

An, Yun-Kyu; Kim, Jae Hong; Yim, Hong Jae

2014-07-18

This paper proposes a novel Lamb wave line sensing technique for crack detection in a welded stiffener. The proposed technique overcomes one of the biggest technical challenges of Lamb wave crack detection for real structure applications: crack-induced Lamb waves are often mixed with multiple reflections from complex waveguides. In particular, crack detection in a welded joint, one of the structural hot spots due to stress concentration, is accompanied by reflections from the welded joint as well as a crack. Extracting and highlighting crack-induced Lamb wave modes from Lamb wave responses measured at multi-spatial points along a single line can be accomplished through a frequency-wavenumber domain analysis. The advantages of the proposed technique enable us not only to enhance the crack detectability in the welded joint but also to minimize false alarms caused by environmental and operational variations by avoiding the direct comparison with the baseline data previously accumulated from the pristine condition of a target structure. The proposed technique is experimentally and numerically validated in vertically stiffened metallic structures, revealing that it successfully identifies and localizes subsurface cracks, regardless of the coexistence with the vertical stiffener.

Thermal Management in Friction-Stir Welding of Precipitation-Hardened Aluminum Alloys

NASA Astrophysics Data System (ADS)

Upadhyay, Piyush; Reynolds, Anthony P.

2015-05-01

Process design and implementation in friction-stir welding (FSW) is mostly dependent on empirical information. Basic science of FSW and processing can only be complete when fundamental interrelationships between the process control parameters and response variables and the resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters such as tool rotation, translation rates, and forge axis force have complicated and interactive relationships to process-response variables such as peak temperature and time at temperature. Of primary influence on the other process-response parameters are temperature and its gradient in the deformation and heat-affected zones. Through a review of pertinent works in the literature and results from boundary condition experiments performed in precipitation-hardening aluminum alloys, this article partially elucidates the nature and effects of temperature transients caused by variation of thermal boundaries in FSW.

The tensile strength characteristics study of the laser welds of biological tissue using the nanocomposite solder

NASA Astrophysics Data System (ADS)

Rimshan, I. B.; Ryabkin, D. I.; Savelyev, M. S.; Zhurbina, N. N.; Pyanov, I. V.; Eganova, E. M.; Pavlov, A. A.; Podgaetsky, V. M.; Ichkitidze, L. P.; Selishchev, S. V.; Gerasimenko, A. Y.

2016-04-01

Laser welding device for biological tissue has been developed. The main device parts are the radiation system and adaptive thermal stabilization system of welding area. Adaptive thermal stabilization system provided the relation between the laser radiation intensity and the weld temperature. Using atomic force microscopy the structure of composite which is formed by the radiation of laser solder based on aqua- albuminous dispersion of multi-walled carbon nanotubes was investigated. AFM topograms nanocomposite solder are mainly defined by the presence of pores in the samples. In generally, the surface structure of composite is influenced by the time, laser radiation power and MWCNT concentration. Average size of backbone nanoelements not exceeded 500 nm. Bulk density of nanoelements was in the range 106-108 sm-3. The data of welding temperature maintained during the laser welding process and the corresponding tensile strength values were obtained. Maximum tensile strength of the suture was reached in the range 50-55°C. This temperature and the pointwise laser welding technology (point area ~ 2.5mm) allows avoiding thermal necrosis of healthy section of biological tissue and provided reliable bonding construction of weld join. In despite of the fact that tensile strength values of the samples are in the range of 15% in comparison with unbroken strips of pigskin leather. This situation corresponds to the initial stage of the dissected tissue connection with a view to further increasing of the joint strength of tissues with the recovery of tissue structure; thereby achieved ratio is enough for a medical practice in certain cases.

Laboratory Investigation of a Leaking Type 316 Socket Weld in a Boron Injection Tank Sampling Line

NASA Astrophysics Data System (ADS)

Xu, Hongqing; Fyfitch, Steve; Hosier, Ryan; Hyres, James

A leak was discovered in a Type 316 stainless steel socket weld in the sampling line for the boron injection tank. A section of the pipeline containing the leaking weld was removed for laboratory investigation that included visual and Stereovisual inspections, liquid penetrant (PT) testing, metallography, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and ferrite content determinations. The leak path was a through-wall transgranular crack in the socket weld. Cracking initiated along the weld-metal-to-base-metal interface at the tip of the crevice between the socket and pipe. The crevice was exposed to oxygenated boron solution at <180°F. Shallow intergranular attack (IGA) was found in the exposed base metal inside the crevice. Based on the investigation results, it was concluded that transgranular stress corrosion cracking (TGSCC) is the primary cracking mechanism.

Characterization and Optimization of Ni-WC Composite Weld Matrix Deposited by Plasma-Transferred Arc Process

NASA Astrophysics Data System (ADS)

Tahaei, Ali; Horley, Paul; Merlin, Mattia; Torres-Torres, David; Garagnani, Gian Luca; Praga, Rolando; Vázquez, Felipe J. García; Arizmendi-Morquecho, Ana

2017-03-01

This work is dedicated to optimization of carbide particle system in a weld bead deposited by PTAW technique over D2 tool steel with high chromium content. The paper reports partial melting of the original carbide grains of the Ni-based filling powder, and growing of the secondary carbide phase (Cr, Ni)_3W_3C in the form of dendrites with wide branches that enhanced mechanical properties of the weld. The optimization of bead parameters was made with design of experiment methodology complemented by a complex sample characterization including SEM, EDXS, XRD, and nanoindentation measurements. It was shown that the preheat of the substrate to a moderate temperature 523 K (250° C) establishes linear pattern of metal flow in the weld pool, resulting in the most homogeneous distribution of the primary carbides in the microstructure of weld bead.

Influence of scandium on the microstructure and strength properties of the welded joint at the laser welding of aluminum-lithium alloys

NASA Astrophysics Data System (ADS)

Malikov, A. G.; Golyshev, A. A.; Ivanova, M. Yu.

2017-10-01

Today, aeronautical equipment manufacture involves up-to-date high-strength aluminum alloys of decreased density resulting from lithium admixture. Various technologies of fusible welding of these alloys are being developed. Serious demands are imposed to the welded joints of aluminum alloys in respect to their strength characteristics. The paper presents experimental investigations of the optimization of the laser welding of aluminum alloys with the scandium-modified welded joint. The effect of scandium on the micro-and macro-structure has been studied as well as the strength characteristics of the welded joint. It has been found that scandium under in the laser welding process increases the welded joint elasticity for the system Al-Mg-Li, aluminum alloy 1420 by 20 %, and almost doubles the same for the system Al-Cu-Li, aluminum alloy 1441.

Microstructure and Mechanical Properties of Laser Welded Titanium 6Al-4V

NASA Astrophysics Data System (ADS)

Mazumder, J.; Steen, W. M.

1982-05-01

Laser butt welds were fabricated in a titanium alloy (Ti-6A1-4V, AMS 4911-Tal0 BSS, annealed) using a Control Laser 2 kW CW CO2 laser. The relationships between the weld microstructure and mechanical properties are described and compared to the theoretical thermal history of the weld zone as calculated from a three-dimensional heat transfer model of the process. The structure of the weld zone was examined by radiography to detect any gross porosity as well as by both optical and electron microscopy in order to identify the microstructure. The oxygen pick-up during gas shielded laser welding was analyzed to correlate further with the observed mechanical properties. It was found that optimally fabricated laser welds have a very good combination of weld microstructure and mechanical properties, ranking this process as one which can produce high quality welds.

Probing heat transfer, fluid flow and microstructural evolution during fusion welding of alloys

NASA Astrophysics Data System (ADS)

Zhang, Wei

The composition, geometry, structure and properties of the welded joints are affected by the various physical processes that take place during fusion welding. Understanding these processes has been an important goal in the contemporary welding research to achieve structurally sound and reliable welds. In the present thesis research, several important physical processes including the heat transfer, fluid flow and microstructural evolution in fusion welding were modeled based on the fundamentals of transport phenomena and phase transformation theory. The heat transfer and fluid flow calculation is focused on the predictions of the liquid metal convection in the weld pool, the temperature distribution in the entire weldment, and the shape and size of the fusion zone (FZ) and heat affected zone (HAZ). The modeling of microstructural evolution is focused on the quantitative understanding of phase transformation kinetics during welding of several important alloys under both low and high heating and cooling conditions. Three numerical models were developed in the present thesis work: (1) a three-dimensional heat transfer and free surface flow model for the gas metal arc (GMA) fillet welding considering the complex weld joint geometry, (2) a phase transformation model based on the Johnson-Mehl-Avrami (JMA) theory, and (3) a one-dimensional numerical diffusion model considering multiple moving interfaces. To check the capabilities of the developed models, several cases were investigated, in which the predictions from the models were compared with the experimental results. The cases studied are the follows. For the modeling of heat transfer and fluid flow, the welding processes studied included gas tungsten arc (GTA) linear welding, GTA transient spot welding, and GMA fillet welding. The calculated weldment geometry and thermal cycles was validated against the experimental data under various welding conditions. For the modeling of microstructural evolution, the welded materials investigated included AISI 1005 low-carbon steel, 1045 medium-carbon steel, 2205 duplex stainless steel (DSS) and Ti-6Al-4V alloy. The calculated phase transformation kinetics were compared with the experimental results obtained using an x-ray diffraction technique by Dr. John W. Elmer of Lawrence Livermore National Laboratory. (Abstract shortened by UMI.)

CRADA Final Report: Weld Predictor App

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

Billings, Jay Jay

Welding is an important manufacturing process used in a broad range of industries and market sectors, including automotive, aerospace, heavy manufacturing, medical, and defense. During welded fabrication, high localized heat input and subsequent rapid cooling result in the creation of residual stresses and distortion. These residual stresses can significantly affect the fatigue resistance, cracking behavior, and load-carrying capacity of welded structures during service. Further, additional fitting and tacking time is often required to fit distorted subassemblies together, resulting in non-value added cost. Using trial-and-error methods to determine which welding parameters, welding sequences, and fixture designs will most effectively reduce distortionmore » is a time-consuming and expensive process. For complex structures with many welds, this approach can take several months. For this reason, efficient and accurate methods of mitigating distortion are in-demand across all industries where welding is used. Analytical and computational methods and commercial software tools have been developed to predict welding-induced residual stresses and distortion. Welding process parameters, fixtures, and tooling can be optimized to reduce the HAZ softening and minimize weld residual stress and distortion, improving performance and reducing design, fabrication and testing costs. However, weld modeling technology tools are currently accessible only to engineers and designers with a background in finite element analysis (FEA) who work with large manufacturers, research institutes, and universities with access to high-performance computing (HPC) resources. Small and medium enterprises (SMEs) in the US do not typically have the human and computational resources needed to adopt and utilize weld modeling technology. To allow an engineer with no background in FEA and SMEs to gain access to this important design tool, EWI and the Ohio Supercomputer Center (OSC) developed the online weld application software tool “WeldPredictor” ( https://eweldpredictor.ewi.org ). About 1400 users have tested this application. This project marked the beginning of development on the next version of WeldPredictor that addresses many outstanding features of the original, including 3D models, allow more material hardening laws, model material phase transformation, and uses open source finite element solvers to quickly solve problems (as opposed to expensive commercial tools).« less

Microstructural Characteristics and Mechanical Properties of Friction Stir Welded Thick 5083 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Imam, Murshid; Sun, Yufeng; Fujii, Hidetoshi; Ma, Ninshu; Tsutsumi, Seiichiro; Murakawa, Hidekazu

2017-01-01

Joining thick sections of aluminum alloys by friction stir welding (FSW) in a single pass needs to overcome many challenges before it comes to full-scale industrial use. Important parameters controlling the structure-properties relationships both across weld cross-section and through thickness direction were investigated through mechanical testing, electron backscatter diffraction technique, transmission electron microscopy, and occurrence of serrated plastic flow. The evolution of the properties in the weld cross-section shows that the presence of undissolved and fragmented Al_6MnFe particles cause discrepancies in establishing the Hall-Petch relationship, and derive the strengthening from the Orowan strengthening mechanism. A `stop action' friction stir weld has been prepared to understand the role of geometrical features of the tool probe in the development of the final microstructure after complete weld. Sectioning through the `stop action' weld with the probe in situ displays the individual effect of thread and flat on the grain structure formation. The material at the thread surface experiences more severe deformation than the material at flat surface. Both the high-angle boundaries and mean grain size are found to be higher at the thread surface. The strain hardening capacity, stress serration amplitude, and frequency are observed to be higher in the stir zone than other weld regions.

Advanced ultrasonic techniques for nondestructive testing of austenitic and dissimilar welds in nuclear facilities

NASA Astrophysics Data System (ADS)

Juengert, Anne; Dugan, Sandra; Homann, Tobias; Mitzscherling, Steffen; Prager, Jens; Pudovikov, Sergey; Schwender, Thomas

2018-04-01

Austenitic stainless steel welds as well as dissimilar metal welds with nickel alloy filler material, used in safety relevant parts of nuclear power plants, still challenge the ultrasonic inspection. The weld material forms large oriented grains that lead, on the one hand, to high sound scattering and, on the other hand, to inhomogeneity and to the acoustic anisotropy of the weld structure. The ultrasonic wave fronts do not propagate linearly, as in ferritic weld joints, but along the curves, which depend on the specific grain structure of the weld. Due to the influence of these phenomena, it is difficult to analyze the inspection results and to classify the ultrasonic indications, which could be both from the weld geometry and from the material defects. A correct flaw sizing is not possible. In an ongoing research project, different techniques to improve the reliability of ultrasonic testing at these kinds of welds are investigated. In a first step (in the previous research project) two ultrasonic inspection techniques were developed and validated on plane test specimens with artificial and realistic flaws. In the ongoing project, these techniques are applied to circumferential pipe welds with longitudinal and transverse flaws. The technique developed at the Federal Institute for Materials Research and Testing (BAM) in Germany uses a combination of ray tracing and synthetic aperture focusing technique (SAFT). To investigate the unknown grain structure, the velocity distribution of weld-transmitting ultrasound waves is measured and used to model the weld by ray tracing. The second technique, developed at the Fraunhofer Institute for Nondestructive Testing (IZFP) in Germany, uses Sampling Phased Array (Full Matrix Capture) combined with the reverse phase matching (RPM) and the gradient elastic constant descent algorithm (GECDM). This inspection method is able to estimate the elastic constants of the columnar grains in the weld and offers an improvement of the reliability of ultrasonic testing through the correction of the sound field distortion. The unknown inhomogeneity and anisotropy are investigated using a reference indication and the special optimization algorithm. Both reconstruction techniques give quantitative inspection results and allow the defect sizing. They have been compared to conventional ultrasonic testing with techniques that are state of the art for components in nuclear power plants. The improvement will be quantified by the comparison of the probability of detection (POD) of each technique.

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

NASA Technical Reports Server (NTRS)

Russell, Carolyn; Ding, R. Jeffrey

1998-01-01

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

High-strength laser welding of aluminum-lithium scandium-doped alloys

NASA Astrophysics Data System (ADS)

Malikov, A. G.; Ivanova, M. Yu.

2016-11-01

The work presents the experimental investigation of laser welding of an aluminum alloy (system Al-Mg-Li) and aluminum alloy (system Al-Cu-Li) doped with Sc. The influence of nano-structuring of the surface layer welded joint by cold plastic deformation on the strength properties of the welded joint is determined. It is founded that, regarding the deformation degree over the thickness, the varying value of the welded joint strength is different for these aluminum alloys. The strength of the plastically deformed welded joint, aluminum alloys of the Al-Mg-Li and Al-Cu-Li systems reached 0.95 and 0.6 of the base alloy strength, respectively.

Systems and Methods for Fabricating Structures Including Metallic Glass-Based Materials Using Ultrasonic Welding

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C. (Inventor); Roberts, Scott N. (Inventor)

2017-01-01

Systems and methods in accordance with embodiments of the invention fabricate objects including metallic glass-based materials using ultrasonic welding. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: ultrasonically welding at least one ribbon to a surface; where at least one ribbon that is ultrasonically welded to a surface has a thickness of less than approximately 150.mu.m; and where at least one ribbon that is ultrasonically welded to a surface includes a metallic glass-based material.

Effect of heat treatment and diffusion welding conditions on the structure and properties of porous material workpieces made of titanium fibers

NASA Astrophysics Data System (ADS)

Kollerov, M. Yu.; Shlyapin, S. D.; Gusev, D. E.; Senkevich, K. S.; Runova, Yu. E.

2015-11-01

The effect of the diffusion welding conditions on the structure and properties of a porous material (PM) made of titanium fibers is studied. It is shown that the use of fibers produced by melt quenching and then joined to form workpieces or articles by diffusion welding can be a promising trend in the production of PMs for medicine applications. A change in the solidification rate of fibers and their contact substantially affects the mechanical properties of PM workpieces. As the diffusion welding temperature of both sheet and cylindrical workpieces increases, the strength of PM increases and the plasticity of PM decreases.

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

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

Brydon, A.M.; Nixon, J.H.

1995-12-31

For the last two years, Cranfield has been carrying out a program of process investigations into wet underwater welding (Graham and Nixon 1993, Nixon and Webb 1994), and has demonstrated that it is possible to markedly improve the stability and consistency of the process by using control techniques developed for hyperbaric welding. In the project reported below, an initial evaluation of wet flux cored arc welding was undertaken. Although there continues to be considerable resistance to the use of wet welding on structures in the North Sea, continued pressure to reduce repair and maintenance costs is causing the industry tomore » re-examine techniques previously discounted, such as wet welding (Anon 1993).« less

Structure and constitution of glass and steel compound in glass-metal composite

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

Lyubimova, Olga N.; Morkovin, Andrey V.; Dryuk, Sergey A.

2014-11-14

The research using methods of optical and scanning electronic microscopy was conducted and it discovered common factors on structures and diffusing zone forming after welding glass C49-1 and steel Ct3sp in technological process of creating new glass-metal composite. Different technological modes of steel surface preliminary oxidation welded with and without glass were investigated. The time of welding was varied from minimum encountering time to the time of stabilizing width of diffusion zone.

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

NASA Astrophysics Data System (ADS)

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

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

Quantification of Microtexture at Weld Nugget of Friction Stir-Welded Carbon Steel

NASA Astrophysics Data System (ADS)

Husain, Md M.; Sarkar, R.; Pal, T. K.; Ghosh, M.; Prabhu, N.

2017-05-01

Friction stir welding of C-Mn steel was carried out under 800-1400 rpm tool rotation. Tool traversing speed of 50 mm/min remained same for all joints. Effect of thermal state and deformation on texture and microstructure at weld nugget was investigated. Weld nugget consisted of ferrite + bainite/Widmanstatten ferrite with different matrix grain sizes depending on peak temperature. A texture around ( ϕ 2 = 0°, φ = 30°, ϕ 2 = 45°) was developed at weld nugget. Grain boundary misorientation at weld nugget indicated that continuous dynamic recrystallization influenced the development of fine equiaxed grain structure. Pole figures and orientation distribution function were used to determine crystallographic texture at weld nugget and base metal. Shear texture components D1, D2 and F were present at weld nugget. D1 shear texture was more prominent among all. Large number of high-angle grain boundaries ( 60-70%) was observed at weld nugget and was the resultant of accumulation of high amount of dislocation, followed by subgrain formation.

"Starfish" Heater Head For Stirling Engine

NASA Technical Reports Server (NTRS)

Vitale, N.

1993-01-01

Proposed "starfish" heater head for Stirling engine enables safe use of liquid sodium as heat-transfer fluid. Sodium makes direct contact with heater head but does not come in contact with any structural welds. Design concept minimizes number of, and simplifies nonstructural thermal welds and facilitates inspection of such welds.

Tensile strength of laser welded cobalt-chromium alloy with and without an argon atmosphere.

PubMed

Tartari, Anna; Clark, Robert K F; Juszczyk, Andrzej S; Radford, David R

2010-06-01

The tensile strength and depth of weld of two cobalt chromium alloys before and after laser welding with and without an argon gas atmosphere were investigated. Using two cobalt chromium alloys, rod shaped specimens (5 cm x 1.5 mm) were cast. Specimens were sand blasted, sectioned and welded with a pulsed Nd: YAG laser welding machine and tested in tension using an Instron universal testing machine. A statistically significant difference in tensile strength was observed between the two alloys. The tensile strength of specimens following laser welding was significantly less than the unwelded controls. Scanning electron microscopy showed that the micro-structure of the cast alloy was altered in the region of the weld. No statistically significant difference was found between specimens welded with or without an argon atmosphere.

Optimization of the A-TIG welding for stainless steels

NASA Astrophysics Data System (ADS)

Jurica, M.; Kožuh, Z.; Garašić, I.; Bušić, M.

2018-03-01

The paper presents the influence of the activation flux and shielding gas on tungsten inert gas (A-TIG) welding of the stainless steel. In introduction part, duplex stainless steel was analysed. The A-TIG process was explained and the possibility of welding stainless steels using the A-TIG process to maximize productivity and the cost-effectiveness of welded structures was presented. In the experimental part duplex, 7 mm thick stainless steel has been welded in butt joint. The influence of activation flux chemical composition upon the weld penetration has been investigated prior the welding. The welding process was performed by a robot with TIG equipment. With selected A-TIG welding technology preparation of plates and consumption of filler material (containing Cr, Ni and Mn) have been avoided. Specimens sectioned from the produced welds have been subjected to tensile strength test, macrostructure analysis and corrosion resistance analysis. The results have confirmed that this type of stainless steel can be welded without edge preparation and addition of filler material containing critical raw materials as Cr, Ni and Mn when the following welding parameters are set: current 200 A, welding speed 9,1 cm/min, heat input 1,2 kJ/mm and specific activation flux is used.

Influence of the arc plasma parameters on the weld pool profile in TIG welding

NASA Astrophysics Data System (ADS)

Toropchin, A.; Frolov, V.; Pipa, A. V.; Kozakov, R.; Uhrlandt, D.

2014-11-01

Magneto-hydrodynamic simulations of the arc and fluid simulations of the weld pool can be beneficial in the analysis and further development of arc welding processes and welding machines. However, the appropriate coupling of arc and weld pool simulations needs further improvement. The tungsten inert gas (TIG) welding process is investigated by simulations including the weld pool. Experiments with optical diagnostics are used for the validation. A coupled computational model of the arc and the weld pool is developed using the software ANSYS CFX. The weld pool model considers the forces acting on the motion of the melt inside and on the surface of the pool, such as Marangoni, drag, electromagnetic forces and buoyancy. The experimental work includes analysis of cross-sections of the workpieces, highspeed video images and spectroscopic measurements. Experiments and calculations have been performed for various currents, distances between electrode and workpiece and nozzle diameters. The studies show the significant impact of material properties like surface tension dependence on temperature as well as of the arc structure on the weld pool behaviour and finally the weld seam depth. The experimental weld pool profiles and plasma temperatures are in good agreement with computational results.

Transformation and Precipitation Reactions by Metal Active Gas Pulsed Welded Joints from X2CrNiMoN22-5-3 Duplex Stainless Steels

PubMed Central

Utu, Ion-Dragos; Mitelea, Ion; Urlan, Sorin Dumitru; Crăciunescu, Corneliu Marius

2016-01-01

The high alloying degree of Duplex stainless steels makes them susceptible to the formation of intermetallic phases during their exposure to high temperatures. Precipitation of these phases can lead to a decreasing of the corrosion resistance and sometimes of the toughness. Starting from the advantages of the synergic Metal Active Gas (MAG) pulsed welding process, this paper analyses the structure formation particularities of homogeneous welded joints from Duplex stainless steel. The effect of linear welding energy on the structure morphology of the welded joints was revealed by macro- and micrographic examinations, X-ray energy dispersion analyses, measurements of ferrite proportion and X-ray diffraction analysis. The results obtained showed that the transformation of ferrite into austenite is associated with the chromium, nickel, molybdenum and nitrogen distribution between these two phases and their redistribution degree is closely linked to the overall heat cycle of the welding process. The adequate control of the energy inserted in the welded components provides an optimal balance between the two microstructural constituents (Austenite and Ferrite) and avoids the formation of undesirable intermetallic phases. PMID:28773727

Transformation and Precipitation Reactions by Metal Active Gas Pulsed Welded Joints from X2CrNiMoN22-5-3 Duplex Stainless Steels.

PubMed

Utu, Ion-Dragos; Mitelea, Ion; Urlan, Sorin Dumitru; Crăciunescu, Corneliu Marius

2016-07-21

The high alloying degree of Duplex stainless steels makes them susceptible to the formation of intermetallic phases during their exposure to high temperatures. Precipitation of these phases can lead to a decreasing of the corrosion resistance and sometimes of the toughness. Starting from the advantages of the synergic Metal Active Gas (MAG) pulsed welding process, this paper analyses the structure formation particularities of homogeneous welded joints from Duplex stainless steel. The effect of linear welding energy on the structure morphology of the welded joints was revealed by macro- and micrographic examinations, X-ray energy dispersion analyses, measurements of ferrite proportion and X-ray diffraction analysis. The results obtained showed that the transformation of ferrite into austenite is associated with the chromium, nickel, molybdenum and nitrogen distribution between these two phases and their redistribution degree is closely linked to the overall heat cycle of the welding process. The adequate control of the energy inserted in the welded components provides an optimal balance between the two microstructural constituents (Austenite and Ferrite) and avoids the formation of undesirable intermetallic phases.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Effect of Heat Treatment on Microstructure and Hot Impact Toughness of Various Zones of P91 Welded Pipes

NASA Astrophysics Data System (ADS)

Pandey, C.; Mahapatra, M. M.

2016-06-01

The new generation super critical thermal power plants are required to operate at enhanced thermal efficiency of over 50% to reduce the fuel consumption and environmental pollution. Creep strength-enhanced ferritic steels, commonly known as Cr-Mo alloys such as P91 (X10CrMoVNb 9-1) are such material of choice for the next generation power plants. The operating requirement of these next generation power plants is that steam temperature of around 650 °C is maintained. For such high-temperature application, creep strength of material is the primary consideration together with adequate weld heat-affected zone (HAZ) toughness. Present work deals with the effect of high service temperature on impact toughness of P91 (X10CrMoVNb 9-1) base material, weld fusion zone, and HAZ. The impact toughness of HAZ for conventional weld groove design and narrow weld groove design has been evaluated experimentally in as-welded and at different post-weld heat treatment conditions. Fractography of the impact toughness specimens of base metal, weld fusion zone, and HAZ was carried out using scanning electron microscope. The effects of heat treatment schemes on the percentage of element present at the fracture surface were also studied.

Physical Nature of the Processes in Structure Forming, Phase and Chemical Composition of pipe Permanent Joints when MMA Welding

NASA Astrophysics Data System (ADS)

Il'yaschenko, D. P.; Chinakhov, D. A.; Danilov, V. I.; Sadykov, I. D.

2016-04-01

The paper outlines peculiarities of structure formation, phase and chemical composition in regard to heat content in molten electrode metal beads when pipe steel (steel 09G2S) welding using power sources with various energy characteristics. Mathematical calculations indicate an inverter power source provides minor heat content into the bead of electrode metal when welding. Experimental research has pointed at 4-9 % increase in impact strength of joints produced using an inverter power source in comparison with samples produced applying a diode rectifier. The following factors can possibly give rise to the increasing impact strength: difference in microstructures of weld joints, up to 50% shortening ferritic plates in metal of weld joint, change in dimensions of ferritic grains in the heat-affected zone by as much as 17.5 %, and decrease in the extent of heat-affected zone by 50%.

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.

Ultrasonic velocity testing of steel pipeline welded joints

NASA Astrophysics Data System (ADS)

Carreón, Hector

2017-04-01

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

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

PubMed

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

2016-08-01

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

A comparative evaluation of laser and GTA welds in a high-strength titanium alloy -- Ti-6-22-22S

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

Baeslack, W.A. III; Hurley, J.; Paskell, T.

1994-12-31

Titanium alloy Ti-6Al-2Sn-2Zr-2Mo-2Cr-025Si (hereafter designated Ti-6-22-22S)is an alpha-beta titanium alloy developed for deep hardenability, high strength, intermediate temperature creep resistance, and moderate toughness. As a potential structural material for next-generation aircraft and aerospace systems, the weldability of Ti-6-22-22S has recently become a subject of increasing importance and concern. In the welding of titanium sheet, achieving satisfactory ductility is the principal limitation to alloy weldability, with poor ductility promoted by a coarse beta grain structure in the weld fusion and near-heat-affected zones. Square-butt welds were produced in 1.6 mm thick Ti-6-22-22S sheet using automatic GTA and CO{sub 2} laser welding systems.more » Microstructure analysis and DPH hardness traverses were performed on mounted. polished and etched specimens. Three-point bend and tensile tests were performed on transverse-weld and longitudinal-weld oriented specimens. Microstructure analysis of the laser welds revealed a fine, columnar fusion zone beta grain macrostructure and a fully-martensitic transformed-beta microstructure. Consistent with the microstructural similarities, fusion zone hardnesses of the laser welds were comparable (385 and 390 DPG, respectively) and greater than that of the base metal (330 DPH). In general, laser welds did not exhibit markedly superior ductilities relative to the GTAW, which was attributed to differences in the nature of the intragranular transformed-beta microstructures, being coarser and softer for the GTAW, the response of these as-welded microstructures to heat treatment, and interactions between the transformed-beta microstructure and the beta grain macrostructure.« less

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

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

NASA Astrophysics Data System (ADS)

Kumar, B. Ramesh; Gangradey, R.

2012-11-01

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

Raising quality of maintenance and control of metallic structures in large-load technological machines

NASA Astrophysics Data System (ADS)

Drygin, M. Yu; Kuryshkin, N. P.

2018-01-01

Active growth of coal extraction and underinvestment of coal mining in Russia lead to the fact that technical state of more than 86% of technological machines at opencast coal mines is unacceptable. One of the most significant problems is unacceptable state of supporting metallic structures of excavators and mine dump trucks. The analysis has shown that defects in these metallic structures had been accumulated for a long time. Their removal by the existing method of repair welding was not effective - the flaws reappeared in 2-6 months of technological machines’ service. The authors detected the prime causes that did not allow to make a good repair welding joint. A new technology of repair welding had been tested and endorsed, and this allowed to reduce the number of welded joints’ flaws by 85% without additional raising welders’ qualification. As a result the number of flaws in metallic structures of the equipment had been reduced by 35 % as early as in the first year of using the new technology.

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

Tanaka, T.; Kameyama, M.; Urabe, Y.

At present, cast duplex stainless steel has been used for the primary coolant piping of PWRs in Japan and joints of dissimilar material have been applied for welding to reactor vessels and steam generators. For the primary coolant piping of the next APWR plants, application of low alloy steel that results in designing main loops with the same material is being studied. It means that there is no need to weld low alloy steel with stainless steel and that makes it possible to reduce the welding length. Attenuation of Ultra Sonic Wave Intensity is lower for low alloy steel thanmore » for stainless steel and they have advantageous inspection characteristics. In addition to that, the thermal expansion rate is smaller for low alloy steel than for stainless steel. In consideration of the above features of low alloy steel, the overall reliability of primary coolant piping is expected to be improved. Therefore, for the evaluation of crack stability of low alloy steel piping to be applied for primary loops, elastic-plastic future mechanics analysis was performed by means of a three-dimensioned FEM. The evaluation results for the low alloy steel pipings show that cracks will not grow into unstable fractures under maximum design load conditions, even when such a circumferential crack is assumed to be 6 times the size of the wall thickness.« less

Effective Use of Weld Metal Yield Strength for HY-Steels

DTIC Science & Technology

1983-01-01

Boiler and Pressure Vessel Code The ASME Boiler and Pressure Vessel Code (B&PV Code) is divided...As noted earlier, the ASME Boiler and Pressure Vessel Code makes only one exception to its overall philosophy of matching weld-metal strength and...material where toughness is of primary importance. REFERENCES American Society of Mechanical Engineers, Boiler and Pressure Vessel

Laser Welding in Electronic Packaging

NASA Technical Reports Server (NTRS)

2000-01-01

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

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

NASA Astrophysics Data System (ADS)

Pal, Kamal; Pal, Surjya K.

2018-05-01

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

Reduction of Biomechanical and Welding Fume Exposures in Stud Welding.

PubMed

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

2016-04-01

The welding of shear stud connectors to structural steel in construction requires a prolonged stooped posture that exposes ironworkers to biomechanical and welding fume hazards. In this study, biomechanical and welding fume exposures during stud welding using conventional methods were compared to exposures associated with use of a prototype system that allowed participants to weld from an upright position. The effect of base material (i.e. bare structural beam versus galvanized decking) on welding fume concentration (particle number and mass), particle size distribution, and particle composition was also explored. Thirty participants completed a series of stud welding simulations in a local apprenticeship training facility. Use of the upright system was associated with substantial reductions in trunk inclination and the activity levels of several muscle groups. Inhalable mass concentrations of welding fume (averaged over ~18 min) when using conventional methods were high (18.2 mg m(-3) for bare beam; 65.7 mg m(-3) for through deck), with estimated mass concentrations of iron (7.8 mg m(-3) for bare beam; 15.8 mg m(-3) for through deck), zinc (0.2 mg m(-3) for bare beam; 15.8 mg m(-3) for through deck), and manganese (0.9 mg m(-3) for bare beam; 1.5 mg m(-3) for through deck) often exceeding the American Conference of Governmental Industrial Hygienists Threshold Limit Values (TLVs). Number and mass concentrations were substantially reduced when using the upright system, although the total inhalable mass concentration remained above the TLV when welding through decking. The average diameters of the welding fume particles for both bare beam (31±17 nm) through deck conditions (34±34 nm) and the chemical composition of the particles indicated the presence of metallic nanoparticles. Stud welding exposes ironworkers to potentially high levels of biomechanical loading (primarily to the low back) and welding fume. The upright system used in this study improved exposure levels during stud welding simulations, but further development is needed before field deployment is possible. © The Author 2015. Published by Oxford University Press on behalf of the British Occupational Hygiene Society.

Reduction of Biomechanical and Welding Fume Exposures in Stud Welding

PubMed Central

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

2016-01-01

The welding of shear stud connectors to structural steel in construction requires a prolonged stooped posture that exposes ironworkers to biomechanical and welding fume hazards. In this study, biomechanical and welding fume exposures during stud welding using conventional methods were compared to exposures associated with use of a prototype system that allowed participants to weld from an upright position. The effect of base material (i.e. bare structural beam versus galvanized decking) on welding fume concentration (particle number and mass), particle size distribution, and particle composition was also explored. Thirty participants completed a series of stud welding simulations in a local apprenticeship training facility. Use of the upright system was associated with substantial reductions in trunk inclination and the activity levels of several muscle groups. Inhalable mass concentrations of welding fume (averaged over ~18min) when using conventional methods were high (18.2mg m−3 for bare beam; 65.7mg m−3 for through deck), with estimated mass concentrations of iron (7.8mg m−3 for bare beam; 15.8mg m−3 for through deck), zinc (0.2mg m−3 for bare beam; 15.8mg m−3 for through deck), and manganese (0.9mg m−3 for bare beam; 1.5mg m−3 for through deck) often exceeding the American Conference of Governmental Industrial Hygienists Threshold Limit Values (TLVs). Number and mass concentrations were substantially reduced when using the upright system, although the total inhalable mass concentration remained above the TLV when welding through decking. The average diameters of the welding fume particles for both bare beam (31±17nm) through deck conditions (34±34nm) and the chemical composition of the particles indicated the presence of metallic nanoparticles. Stud welding exposes ironworkers to potentially high levels of biomechanical loading (primarily to the low back) and welding fume. The upright system used in this study improved exposure levels during stud welding simulations, but further development is needed before field deployment is possible. PMID:26602453

Engineering aspects of the application of structural materials in the 5 MW-ESS-mercury-target

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

Guttek, B.

1996-06-01

A main problem of the ESS-Hg-target development and the design of the components of its primary Hg-circuit is the choice of structural materials. As designing, calculations and experiments with elected materials take time and are very costy, a preview on their successful application has to be done before as detailed as possible. One aspect on this is to have the knowledge of characteristics values of the structural material candidates under the occuring mechanical and thermal loads, irradiation, corrosion and erosion. Another point is the technology of engineering concerning the manufacturing, welding, surface treatment, and quality control of such parts andmore » components under the demand to reach maximum lifetime.« less

Relation between hardness and ultrasonic velocity on pipeline steel welded joints

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

Through-Thickness Residual Stress Profiles in Austenitic Stainless Steel Welds: A Combined Experimental and Prediction Study

NASA Astrophysics Data System (ADS)

Mathew, J.; Moat, R. J.; Paddea, S.; Francis, J. A.; Fitzpatrick, M. E.; Bouchard, P. J.

2017-12-01

Economic and safe management of nuclear plant components relies on accurate prediction of welding-induced residual stresses. In this study, the distribution of residual stress through the thickness of austenitic stainless steel welds has been measured using neutron diffraction and the contour method. The measured data are used to validate residual stress profiles predicted by an artificial neural network approach (ANN) as a function of welding heat input and geometry. Maximum tensile stresses with magnitude close to the yield strength of the material were observed near the weld cap in both axial and hoop direction of the welds. Significant scatter of more than 200 MPa was found within the residual stress measurements at the weld center line and are associated with the geometry and welding conditions of individual weld passes. The ANN prediction is developed in an attempt to effectively quantify this phenomenon of `innate scatter' and to learn the non-linear patterns in the weld residual stress profiles. Furthermore, the efficacy of the ANN method for defining through-thickness residual stress profiles in welds for application in structural integrity assessments is evaluated.

Correlation Between Microstructure and Low-Temperature Impact Toughness of Simulated Reheated Zones in the Multi-pass Weld Metal of High-Strength Steel

NASA Astrophysics Data System (ADS)

Kang, Yongjoon; Park, Gitae; Jeong, Seonghoon; Lee, Changhee

2018-01-01

A large fraction of reheated weld metal is formed during multi-pass welding, which significantly affects the mechanical properties (especially toughness) of welded structures. In this study, the low-temperature toughness of the simulated reheated zone in multi-pass weld metal was evaluated and compared to that of the as-deposited zone using microstructural analyses. Two kinds of high-strength steel welds with different hardenabilities were produced by single-pass, bead-in-groove welding, and both welds were thermally cycled to peak temperatures above Ac3 using a Gleeble simulator. When the weld metals were reheated, their toughness deteriorated in response to the increase in the fraction of detrimental microstructural components, i.e., grain boundary ferrite and coalesced bainite in the weld metals with low and high hardenabilities, respectively. In addition, toughness deterioration occurred in conjunction with an increase in the effective grain size, which was attributed to the decrease in nucleation probability of acicular ferrite; the main cause for this decrease changed depending on the hardenability of the weld metal.

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

NASA Astrophysics Data System (ADS)

Hashimoto, Toshiyuki; Takatsu, Hideyuki; Sato, Satoshi

1994-07-01

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

Clinical Cold Welding of the Modular Total Hip Arthroplasty Prosthesis.

PubMed

Whittaker, Robert K; Zaghloul, Ahmed M; Hothi, Harry S; Siddiqui, Imran A; Blunn, Gordon W; Skinner, John A; Hart, Alister J

2017-02-01

A head that is "clinically cold welded" to a stem is one of the commonest reasons for unplanned removal of the stem. It is not clear which hip designs are at greatest risk of clinical cold welding. This was a case-control study of consecutively received hip implant retrievals; we chose the design of hip that had the greatest number of truly cold-welded heads (n = 11). For our controls, we chose retrieved hips of the same design but without cold welding of the head (n = 35). We compared the clinical variables between these 2 groups using nonparametric Mann-Whitney tests to investigate the significance of differences between the cold-welded and non-cold-welded groups. The design that most commonly caused cold welding was a combination of a Ti stem and Ti taper: 11 out of 48 (23%) were truly cold welded. Comparison of the clinical data showed that no individual factor could be used to predict this preoperatively with none of the 4 predictors tested showing any significance: (1) time to revision (P = .687), (2) head size (P = .067), (3) patient age at primary (P = .380), and (4) gender (P = .054). We have shown that clinical cold welding is most prevalent in Ti-Ti combinations of the stem and taper; approximately 25% of cases received at our center were cold welded. Analysis of clinical variables showed that it is not possible to predict which will be cold welded preoperatively. Surgeons should be aware of this potential complication when revising a Ti-Ti stem/head junction. Copyright © 2016 Elsevier Inc. All rights reserved.

Influence of Welding Strength Matching Coefficient and Cold Stretching on Welding Residual Stress in Austenitic Stainless Steel

NASA Astrophysics Data System (ADS)

Lu, Yaqing; Hui, Hu; Gong, Jianguo

2018-05-01

Austenitic stainless steel is widely used in pressure vessels for the storage and transportation of liquid gases such as liquid nitrogen, liquid oxygen, and liquid hydrogen. Cryogenic pressure vessel manufacturing uses cold stretching technology, which relies heavily on welding joint performance, to construct lightweight and thin-walled vessels. Residual stress from welding is a primary factor in cases of austenitic stainless steel pressure vessel failure. In this paper, on the basis of Visual Environment 10.0 finite element simulation technology, the residual stress resulting from different welding strength matching coefficients (0.8, 1, 1.2, 1.4) for two S30408 plates welded with three-pass butt welds is calculated according to thermal elastoplastic theory. In addition, the stress field was calculated under a loading as high as 410 MPa and after the load was released. Path 1 was set to analyze stress along the welding line, and path 2 was set to analyze stress normal to the welding line. The welding strength matching coefficient strongly affected both the longitudinal residual stress (center of path 1) and the transverse residual stress (both ends of path 1) after the welding was completed. However, the coefficient had little effect on the longitudinal and transverse residual stress of path 2. Under the loading of 410 MPa, the longitudinal and transverse stress decreased and the stress distribution, with different welding strength matching coefficients, was less diverse. After the load was released, longitudinal and transverse stress distribution for both path 1 and path 2 decreased to a low level. Cold stretching could reduce the effect of residual stress to various degrees. Transverse strain along the stretching direction was also taken into consideration. The experimental results validated the reliability of the partial simulation.

Study on Dynamic Development of Three-dimensional Weld Pool Surface in Stationary GTAW

NASA Astrophysics Data System (ADS)

Huang, Jiankang; He, Jing; He, Xiaoying; Shi, Yu; Fan, Ding

2018-04-01

The weld pool contains abundant information about the welding process. In particular, the type of the weld pool surface shape, i. e., convex or concave, is determined by the weld penetration. To detect it, an innovative laser-vision-based sensing method is employed to observe the weld pool surface of the gas tungsten arc welding (GTAW). A low-power laser dots pattern is projected onto the entire weld pool surface. Its reflection is intercepted by a screen and captured by a camera. Then the dynamic development process of the weld pool surface can be detected. By observing and analyzing, the change of the reflected laser dots reflection pattern, for shape of the weld pool surface shape, was found to closely correlate to the penetration of weld pool in the welding process. A mathematical model was proposed to correlate the incident ray, reflected ray, screen and surface of weld pool based on structured laser specular reflection. The dynamic variation of the weld pool surface and its corresponding dots laser pattern were simulated and analyzed. By combining the experimental data and the mathematical analysis, the results show that the pattern of the reflected laser dots pattern is closely correlated to the development of weld pool, such as the weld penetration. The concavity of the pool surface was found to increase rapidly after the surface shape was changed from convex to concave during the stationary GTAW process.

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

NASA Technical Reports Server (NTRS)

Talia, George E.

1996-01-01

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

Tungsten Inert Gas and Friction Stir Welding Characteristics of 4-mm-Thick 2219-T87 Plates at Room Temperature and -196 °C

NASA Astrophysics Data System (ADS)

Lei, Xuefeng; Deng, Ying; Yin, Zhimin; Xu, Guofu

2014-06-01

2219-T87 aluminum alloy is widely used for fabricating liquid rocket propellant storage tank, due to its admirable cryogenic property. Welding is the dominant joining method in the manufacturing process of aerospace components. In this study, the tungsten inert gas welding and friction stir welding (FSW) characteristics of 4-mm-thick 2219-T87 alloy plate at room temperature (25 °C) and deep cryogenic temperature (-196 °C) were investigated by property measurements and microscopy methods. The studied 2219 base alloy exhibits a low strength plane anisotropy and excellent room temperature and cryogenic mechanical properties. The ultimate tensile strength values of TIG and FSW welding joints can reach 265 and 353 MPa at room temperature, and 342 and 438 MPa at -196 °C, respectively. The base metal consists of elongated deformed grains and many nano-scaled θ (Al2Cu) aging precipitates. Fusion zone and heat-affected zone (HAZ) of the TIG joint are characterized by coarsening dendritic grains and equiaxed recrystallized grains, respectively. The FSW-welded joint consists of the weld nugget zone, thermo-mechanically affected zone (TMAZ), and HAZ. In the weld nugget zone, a micro-scaled sub-grain structure is the main microstructure characteristic. The TMAZ and HAZ are both characterized by coarsened aging precipitates and elongated deformed grains. The excellent FSW welding properties are attributed to the preservation of the working structures and homogenous chemical compositions.

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.

Investigation of defect rate of lap laser welding of stainless steel railway vehicles car body

NASA Astrophysics Data System (ADS)

Wang, Hongxiao

2015-02-01

In order to resolve the disadvantages such as poor appearance quality, poor tightness, low efficiency of resistance spot welding of stainless steel rail vehicles, partial penetration lap laser welding process was investigated widely. But due to the limitation of processing technology, there will be local incomplete fusion in the lap laser welding seam. Defect rate is the ratio of the local incomplete fusion length to the weld seam length. The tensile shear strength under different defect rate and its effect on the car body static strength are not clear. It is necessary to find the biggest defect rate by numerical analysis of effects of different defect rates on the laser welding stainless steel rail vehicle body structure strength ,and tests of laser welding shear tensile strength.

The Morphology of Intermediate Structures Formed During Bainite Transformation in HSLA Steels

NASA Astrophysics Data System (ADS)

Seidurov, Mikhail N.; Kovalev, Sergey V.; Zubkov, Alexander S.

2017-10-01

The paper deals with the structure of bainite formed under the influence of thermal deformation cycles of welding in low-carbon bainitic class steels. Morphology features associated with the formation of mesoferrite and granular bainite determines the high cold resistance of welded joints.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Friction welding.

NASA Technical Reports Server (NTRS)

Moore, T. J.

1972-01-01

Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

Matrix phased array (MPA) imaging technology for resistance spot welds

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Gleeson, Sean T.

2014-02-01

A three-dimensional MPA probe has been incorporated with a high speed phased array electronic board to visualize nugget images of resistance spot welds. The primary application area of this battery operated portable MPA ultrasonic imaging system is in the automotive industry which a conventional destructive testing process is commonly adopted to check the quality of resistance spot welds in auto bodies. Considering an average of five-thousand spot welds in a medium size passenger vehicle, the amount of time and effort given to popping the welds and measuring nugget size are immeasurable in addition to the millions of dollars' worth of scrap metals recycled per plant per year. This wasteful labor intensive destructive testing process has become less reliable as auto body sheet metal has transitioned from thick and heavy mild steels to thin and light high strength steels. Consequently, the necessity of developing a non-destructive inspection methodology has become inevitable. In this paper, the fundamental aspects of the current 3-D probe design, data acquisition algorithms, and weld nugget imaging process are discussed.

Matrix phased array (MPA) imaging technology for resistance spot welds

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

Na, Jeong K.; Gleeson, Sean T.

2014-02-18

A three-dimensional MPA probe has been incorporated with a high speed phased array electronic board to visualize nugget images of resistance spot welds. The primary application area of this battery operated portable MPA ultrasonic imaging system is in the automotive industry which a conventional destructive testing process is commonly adopted to check the quality of resistance spot welds in auto bodies. Considering an average of five-thousand spot welds in a medium size passenger vehicle, the amount of time and effort given to popping the welds and measuring nugget size are immeasurable in addition to the millions of dollars' worth ofmore » scrap metals recycled per plant per year. This wasteful labor intensive destructive testing process has become less reliable as auto body sheet metal has transitioned from thick and heavy mild steels to thin and light high strength steels. Consequently, the necessity of developing a non-destructive inspection methodology has become inevitable. In this paper, the fundamental aspects of the current 3-D probe design, data acquisition algorithms, and weld nugget imaging process are discussed.« less

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

PubMed

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

2006-04-01

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

Welding And Cutting A Nickel Alloy By Laser

NASA Technical Reports Server (NTRS)

Banas, C. M.

1990-01-01

Technique effective and energy-efficient. Report describes evaluation of laser welding and cutting of Inconel(R) 718. Notes that electron-beam welding processes developed for In-718, but difficult to use on large or complex structures. Cutting of In-718 by laser fast and produces only narrow kerf. Cut edge requires dressing, to endure fatigue.

Metallurgical effects on titanium by laser welding on dental stone.

PubMed

Fujioka, Sonosuke; Kakimoto, Kazutoshi; Inoue, Taro; Okazaki, Joji; Komasa, Yutaka

2003-12-01

It is not known for certain that dental stone components influence titanium welding. In this study, we investigated metallurgical problems caused by laser welding on dental stones using wrought commercial pure (CP) titanium. A pulsed Nd:YAG laser irradiated a number of specimens' surfaces which were fixed on either a dental hard stone or a titanium plate. The metallurgical properties of the weld were evaluated using the Vickers hardness test, microstructure observation, fractured surface observation and quantitative analysis of oxygen and hydrogen. In the weld formed on the dental stone there was an increase in hardness, the existence of an acicular structure and a brittle fractured surface, and an increase in the oxygen and hydrogen concentrations compared with base metal. In the weld formed on the titanium plate, these changes were not observed. Therefore, it was demonstrated that laser welding on dental stones made the welds brittle.

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%.

Advances in Solid State Joining of High Temperature Alloys

NASA Technical Reports Server (NTRS)

Ding, Jeff; Schneider, Judy

2011-01-01

Many of the metals used in the oil and gas industry are difficult to fusion weld including Titanium and its alloys. Solid state joining processes are being pursued as an alternative process to produce robust structures more amenable to high pressure applications. Various solid state joining processes include friction stir welding (FSW) and a patented modification termed thermal stir welding (TSW). The configuration of TSWing utilizes an induction coil to preheat the material minimizing the burden on the weld tool extending its life. This provides the ability to precisely select and control the temperature to avoid detrimental changes to the microstructure. The work presented in this presentation investigates the feasibility of joining various titanium alloys using the solid state welding processes of FSW and TSW. Process descriptions and attributes of each weld process will be presented. Weld process set ]up and welding techniques will be discussed leading to the challenges experienced. Mechanical property data will also be presented.

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

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

Hardening Potential of an Al-Cu-Li Friction Stir Weld

NASA Astrophysics Data System (ADS)

Ivanov, Rosen; Boselli, Julien; Denzer, Diana; Larouche, Daniel; Gauvin, Raynald; Brochu, Mathieu

The evolution of the microstructure during friction stir welding of a third generation AA2199 Al-Li alloy has been described and related to the mechanical properties of welds. The coupling of electron microscopy and micro-hardness have helped generate an understanding of the relationship between grain structure, precipitate density and morphology behind the observed changes in mechanical properties during post weld artificial ageing. The ability of welds to recover hardness and strength during post weld heat treatment was linked to the limited formation of large scale precipitates which act as sinks for alloying elements. Welds obtained with high tool rotation speed (within parameters studied) showed ultimate tensile strength levels of about 93% of the base metal, an elongation of 6% at fracture, and hardness values ranging between 120-140 HV in the stir zone, thermo-mechanically affected zone, and heat affected zone upon post weld heat treatment.

Microstructural analysis of the 2195 aluminum-lithium alloy welds

NASA Technical Reports Server (NTRS)

Talia, George E.

1993-01-01

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

Fatigue Behavior of a Box-Type Welded Structure of Hydraulic Support Used in Coal Mine

PubMed Central

Zhao, Xiaohui; Li, Fuyong; Liu, Yu; Fan, Yanjun

2015-01-01

Hydraulic support is the main supporting equipment of the coal mining systems, and they are usually subjected to fatigue failure under the high dynamic load. The fracture positions are generally at welded joints where there is a serious stress concentration. In order to investigate and further improve the fatigue strength of hydraulic support, the present work first located the possible position where fatigue failure occurs through finite element analysis, and then fatigue tests were carried out on the different forms of welded joints for the dangerous parts. Finally, Fatigue strength-life (S-N) curves and fracture mechanism were studied. This research will provide a theoretical reference for the fatigue design of welded structures for hydraulic support. PMID:28793586

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

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

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.

Friction-Stir Welding of Large Scale Cryogenic Fuel Tanks for Aerospace Applications

NASA Technical Reports Server (NTRS)

Jones, Clyde S., III; Venable, Richard A.

1998-01-01

The Marshall Space Flight Center has established a facility for the joining of large-scale aluminum-lithium alloy 2195 cryogenic fuel tanks using the friction-stir welding process. Longitudinal welds, approximately five meters in length, were made possible by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and the spindle travel system will be described in this paper. Process controls and real-time data acquisition will also be described, and were critical elements contributing to successful weld operation.

Nondestructive online testing method for friction stir welding using acoustic emission

NASA Astrophysics Data System (ADS)

Levikhina, Anastasiya

2017-12-01

The paper reviews the possibility of applying the method of acoustic emission for online monitoring of the friction stir welding process. It is shown that acoustic emission allows the detection of weld defects and their location in real time. The energy of an acoustic signal and the median frequency are suggested to be used as informative parameters. The method of calculating the median frequency with the use of a short time Fourier transform is applied for the identification of correlations between the defective weld structure and properties of the acoustic emission signals received during welding.

Innovative Tools Advance Revolutionary Weld Technique

NASA Technical Reports Server (NTRS)

2009-01-01

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

Frequency response function (FRF) based updating of a laser spot welded structure

NASA Astrophysics Data System (ADS)

Zin, M. S. Mohd; Rani, M. N. Abdul; Yunus, M. A.; Sani, M. S. M.; Wan Iskandar Mirza, W. I. I.; Mat Isa, A. A.

2018-04-01

The objective of this paper is to present frequency response function (FRF) based updating as a method for matching the finite element (FE) model of a laser spot welded structure with a physical test structure. The FE model of the welded structure was developed using CQUAD4 and CWELD element connectors, and NASTRAN was used to calculate the natural frequencies, mode shapes and FRF. Minimization of the discrepancies between the finite element and experimental FRFs was carried out using the exceptional numerical capability of NASTRAN Sol 200. The experimental work was performed under free-free boundary conditions using LMS SCADAS. Avast improvement in the finite element FRF was achieved using the frequency response function (FRF) based updating with two different objective functions proposed.

Problems of Pore Formation in Welded Joints of Titanium Alloys

NASA Astrophysics Data System (ADS)

Murav'ev, V. I.

2005-07-01

Special features of formation of the connection zone in front of the front of molten pool and changes in the macro- and microstructure of the weld metal are considered for conditions of fusion welding of titanium alloys on an example of pseudo-α-titanium alloy VT20.Ways for forming macrotexture on the surface of joined preforms are determined with the aim of obtaining weld metal with structure and properties close to those of the base metal.

Tensile Properties of Friction Stir Welded Joints of AA 2024-T6 Alloy at Different Welding Speeds

NASA Astrophysics Data System (ADS)

Avula, Dhananjayulu; Devuri, Venkateswarlu; Cheepu, Muralimohan; Dwivedi, Dheerendra Kumar

2018-03-01

The influence of welding speed on the friction stir welded joint properties of hardness, tensile properties, defects and microstructure characterization are studied in the present study. The friction stir welding was conducted on AA2014-T6 heat treated alloy with 5 mm thickness plate in butt joint configuration. The welding speed was varied from 8 mm/min to 120 mm/min at the fixed travel speed and load conditions. It is observed that the welding speeds at higher rate with wide range can be possible to weld this alloy at higher rates of tool revolution suggesting that the inherent capability of friction stir welding technique for aluminum 2014 alloys. The strength of the joints gradually increases with enhancing of welding speed. The micro structural observations exhibited the formation of equiaxed grains in the stir zone and slightly in the thermo-mechanically affected zone. In addition, the size of the grains decreases with increase in welding speed owing to the presence of low heat input. Hence the hardness of the joints slightly increased in the stir zones over the other zones of the weld nugget. The joint strength initially increases with the welding speed and starts to decreases after reaching to the maximum value. The relationship between the welding conditions and friction stir welded joint properties has been discussed.

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

NASA Astrophysics Data System (ADS)

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

2008-03-01

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

Friction Stir Welding of Al-Cu Bilayer Sheet by Tapered Threaded Pin: Microstructure, Material Flow, and Fracture Behavior

NASA Astrophysics Data System (ADS)

Beygi, R.; Kazeminezhad, M.; Kokabi, A. H.; Loureiro, A.

2015-06-01

The fracture behavior and intermetallic formation are investigated after friction stir welding of Al-Cu bilayer sheets performed by tapered threaded pin. To do so, temperature, axial load, and torque measurements during welding, and also SEM and XRD analyses and tensile tests on the welds are carried out. These observations show that during welding from Cu side, higher axial load and temperature lead to formation of different kinds of Al-Cu intermetallics such as Al2Cu, AlCu, and Al4Cu9. Also, existence of Al(Cu)-Al2Cu eutectic structures, demonstrates liquation during welding. The presence of these intermetallics leads to highly brittle fracture and low strength of the joints. In samples welded from Al side, lower axial load and temperature are developed during welding and no intermetallic compound is observed which results in higher strength and ductility of the joints in comparison with those welded from Cu side.

Weldability of AA 5052 H32 aluminium alloy by TIG welding and FSW process - A comparative study

NASA Astrophysics Data System (ADS)

Shanavas, S.; Raja Dhas, J. Edwin

2017-10-01

Aluminium 5xxx series alloys are the strongest non-heat treatable aluminium alloy. Its application found in automotive components and body structures due to its good formability, good strength, high corrosion resistance, and weight savings. In the present work, the influence of Tungsten Inert Gas (TIG) welding parameters on the quality of weld on AA 5052 H32 aluminium alloy plates were analyzed and the mechanical characterization of the joint so produced was compared with Friction stir (FS) welded joint. The selected input variable parameters are welding current and inert gas flow rate. Other parameters such as welding speed and arc voltage were kept constant throughout the study, based on the response from several trial runs conducted. The quality of the weld is measured in terms of ultimate tensile strength. A double side V-butt joints were fabricated by double pass on one side to ensure maximum strength of TIG welded joints. Macro and microstructural examination were conducted for both welding process.

The effect of impurity gasses on variable polarity plasma arc welded 2219 aluminum

NASA Technical Reports Server (NTRS)

Mcclure, John C.; Torres, Martin R.; Gurevitch, Alan C.; Newman, Robert A.

1989-01-01

Variable polarity plasma arc (VPPA) welding has been used with considerable success by NASA for the welds on the Space Shuttle External Tank as well as by others concerned with high quality welded structures. The effects of gaseous contaminants on the appearance of VPPA welds on 2219 aluminum are examined so that a welder can recognize that such contamination is present and take corrective measures. There are many possible sources of such contamination including, contaminated gas bottles, leaks in the gas plumbing, inadequate shield gas flow, condensed moisture in the gas lines or torch body, or excessive contaminants on the workpiece. The gasses chosen for study in the program were nitrogen, oxygen, methane, and hydrogen. Welds were made in a carefully controlled environment and comparisons were made between welds with various levels of these contaminants and welds made with research purity (99.9999 percent) gasses. Photographs of the weld front and backside as well as polished and etched cross sections are presented.

Microstructural Evolution of Hypoeutectic, Near-Eutectic, and Hypereutectic High-Carbon Cr-Based Hard-Facing Alloys

NASA Astrophysics Data System (ADS)

Lin, Chi-Ming; Chang, Chia-Ming; Chen, Jie-Hao; Hsieh, Chih-Chun; Wu, Weite

2009-05-01

A series of high-carbon Cr-based hard-facing alloys were successfully fabricated on a substrate of 0.45 pct C carbon steel by gas tungsten arc welding (GTAW) process using various alloy fillers with chromium and chromium carbide, CrC (Cr:C = 4:1) powders. These claddings were designed to observe hypoeutectic, near-eutectic, and hypereutectic structures with various (Cr,Fe)23C6 and (Cr,Fe)7C3 carbides at room temperature. According to X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), and optical microscopy (OM), in 3.8 pct C cladding, the microstructure consisted of the primary carbides with outer shells (Cr,Fe)23C6 surrounding (Cr,Fe)7C3 cores and [ α + (Cr,Fe)23C6] eutectic structures. In 5.9 pct C cladding, the composite comprised primary (Cr,Fe)7C3 as the reinforcing phase and [α + (Cr,Fe)7C3] eutectic structures as matrix. Various morphologies of carbides were found in primary and eutectic (Cr,Fe)7C3 carbides, which included bladelike and rodlike (with a hexagonal cross section). The 5.9C cladding with great amounts of primary (Cr,Fe)7C3 carbides had the highest hardness (approximately HRC 63.9) of the all conditions.

Fatigue strength: effect of welding type and joint design executed in Ti-6Al-4V structures.

PubMed

Pantoja, Juliana M C Nuñez; Farina, Ana P; Vaz, Luis G; Consani, Rafael L X; Nóbilo, Mauro A de Arruda; Mesquita, Marcelo F

2012-06-01

This study evaluated the fatigue strength of Ti-6Al-4V-machined structures submitted to laser (L)-welding and TIG (TIG)-welding procedures, varying the joint designs. Seventy dumbbell rods were machined in Ti-6Al-4V alloy with central diameters of 3.5 mm. The specimens were sectioned and welded using TIG or L and three joint designs {'I' design, varying welding distances [0.0 mm (I00) or 0.6 mm (I06)], or 'X' [X] design}. The combinations of variables created six groups, which, when added to the intact group, made a total of seven groups (n = 10). L was executed as follows: 360 V/8 ms (X) and 390 V/9 ms (I00 and I06), with focus and frequency regulated to zero. TIG was executed using 2:2 (X) and 3:2 (I00 and I06) as welding parameters. Joints were finished, polished and submitted to radiographic examination to be analysed visually for the presence of porosity. The specimens were then subjected to mechanical cyclic tests, and the number of cycles completed until failure was recorded. The fracture surface was examined using a scanning electron microscope. The Kruskal-Wallis and Dunn test (α = 0.05) indicated that the number of cycles resisted for fracture was higher to X for both welding procedures. To L, I06 was as resistant as X. The Mann-Whitney U-test (α = 0.05) indicated that L joints were more resistant than TIG to I00 and I06. Spearman's correlation coefficient (α = 0.05) indicated a negative correlation between the number of cycles and presence of porosity. Thus, to weld Ti-6Al-4V structures, the best condition is X, independent of the welding method employed. © 2011 The Gerodontology Society and John Wiley & Sons A/S.

Effect of Heat Treatment on the Structure and Properties of Explosion Welded Bimetal Kh20N80 + AD1

NASA Astrophysics Data System (ADS)

Shmorgun, V. G.; Arisova, V. N.; Slautin, O. V.; Taube, A. O.; Bakuntseva, V. M.

2017-05-01

Results of a study of the effect of heat treatment on the microhardness, structure and phase composition of diffusion zone in explosion-welded `refractory nickel alloy Kh20N80 + aluminum alloy AD1' bimetal are presented.

Evaluating Fire Doors with Hose Ports.

DTIC Science & Technology

1987-06-01

cm) of approved mineral wool structural insulation was applied to the fire side of the steel bulkhead. Steel pins were welded to the bulkhead and the...steel bulkheads, by continuously welding the frame Cl]nce to the bulkhead, USCG approved mineral wool structural insulation was applied on one side of

Development of optimized techniques and requirements for computer enhancement of structural weld radiographs. Volume 1: Technical report

NASA Technical Reports Server (NTRS)

Adams, J. R.; Hawley, S. W.; Peterson, G. R.; Salinger, S. S.; Workman, R. A.

1971-01-01

A hardware and software specification covering requirements for the computer enhancement of structural weld radiographs was considered. Three scanning systems were used to digitize more than 15 weld radiographs. The performance of these systems was evaluated by determining modulation transfer functions and noise characteristics. Enhancement techniques were developed and applied to the digitized radiographs. The scanning parameters of spot size and spacing and film density were studied to optimize the information content of the digital representation of the image.

Microstructures and Mechanical Properties of Friction Tapered Stud Overlap Welding for X65 Pipeline Steel Under Wet Conditions

NASA Astrophysics Data System (ADS)

Xu, Y. C.; Jing, H. Y.; Han, Y. D.; Xu, L. Y.

2017-08-01

This paper exhibits a novel in situ remediation technique named friction tapered stud overlap welding (FTSOW) to repair a through crack in structures and components in extremely harsh environments. Furthermore, this paper presents variations in process data, including rotational speed, stud displacement, welding force, and torque for a typical FTSOW weld. In the present study, the effects of welding parameters on the microstructures and mechanical properties of the welding joints were investigated. Inapposite welding parameters consisted of low rotational speeds and welding forces, and when utilized, they increased the occurrence of a lack of bonding and unfilled defects within the weld. The microstructures with a welding zone and heat-affected zone mainly consisted of upper bainite. The hardness value was highest in the welding zone and lowest in the base material. During the pull-out tests, all the welds failed in the stud. Moreover, the defect-free welds broke at the interface of the lap plate and substrate during the cruciform uniaxial tensile test. The best tensile test results at different depths and shear tests were 721.6 MPa and 581.9 MPa, respectively. The favorable Charpy impact-absorbed energy was 68.64 J at 0 °C. The Charpy impact tests revealed a brittle fracture characteristic with a large area of cleavage.

Particulate and gaseous emissions when welding aluminum alloys.

PubMed

Cole, Homer; Epstein, Seymour; Peace, Jon

2007-09-01

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

Investigation on the hot melting temperature field simulation of HDPE water supply pipeline in gymnasium pool

NASA Astrophysics Data System (ADS)

Cai, Zhiqiang; Dai, Hongbin; Fu, Xibin

2018-06-01

In view of the special needs of the water supply and drainage system of swimming pool in gymnasium, the correlation of high density polyethylene (HDPE) pipe and the temperature field distribution during welding was investigated. It showed that the temperature field distribution has significant influence on the quality of welding. Moreover, the mechanical properties of the welded joint were analyzed by the bending test of the weld joint, and the micro-structure of the welded joint was evaluated by scanning electron microscope (SEM). The one-dimensional unsteady heat transfer model of polyethylene pipe welding joints was established by MARC. The temperature field distribution during welding process was simulated, and the temperature field changes during welding were also detected and compared by the thermo-couple temperature automatic acquisition system. Results indicated that the temperature of the end surface of the pipe does not reach the maximum value, when it is at the end of welding heating. Instead, it reaches the maximum value at 300 sand latent heat occurs during the welding process. It concludes that the weld quality is the highest when the welding pressure is 0.2 MPa, and the heating temperature of HDPE heat fusion welding is in the range of 210 °C-230 °C.

Deformation behavior of a 16-8-2 GTA weld as influenced by its solidification substructure

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

Foulds, J.R.; Moteff, J.; Sikka, V.K.

1983-07-01

Weldment sections from formed and welded type 316 stainless steel pipe are characterized with respect to some time-independent (tensile) and time-dependent (creep) mechanical properties at temperatures between 25/sup 0/C and 649/sup 0/C. The GTA weldment, welded with 16-8-2 filler metal, is sectioned from pipe in the formed + welded + solution annealed + straightened condition, as well as in the same condition with an additional re-solution treatment. Detailed room temperature microhardness measurements on these sections before and after reannealing enable a determination of the different recovery characteristics of weld and base metal. The observed stable weld metal solidification dislocation substructuremore » in comparison with the base metal random dislocation structure, in fact, adequately explains weld/base metal elevated temperature mechanical behavior differences from this recovery characteristic standpoint. The weld metal substructure is the only parameter common to the variety of austenitic stainless steel welds exhibiting the consistent parent/weld metal deformation behavior differences described. As such, it must be considered the key to understanding weldment mechanical behavior.« less

Numerical simulation of the laser welding process for the prediction of temperature distribution on welded aluminium aircraft components

NASA Astrophysics Data System (ADS)

Tsirkas, S. A.

2018-03-01

The present investigation is focused to the modelling of the temperature field in aluminium aircraft components welded by a CO2 laser. A three-dimensional finite element model has been developed to simulate the laser welding process and predict the temperature distribution in T-joint laser welded plates with fillet material. The simulation of the laser beam welding process was performed using a nonlinear heat transfer analysis, based on a keyhole formation model analysis. The model employs the technique of element ;birth and death; in order to simulate the weld fillet. Various phenomena associated with welding like temperature dependent material properties and heat losses through convection and radiation were accounted for in the model. The materials considered were 6056-T78 and 6013-T4 aluminium alloys, commonly used for aircraft components. The temperature distribution during laser welding process has been calculated numerically and validated by experimental measurements on different locations of the welded structure. The numerical results are in good agreement with the experimental measurements.

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

NASA Astrophysics Data System (ADS)

Harooni, Masoud

It is advantageous for the transportation industry to use lightweight components in the structure in order to save mass and reduce CO2 emissions. One of the lightest structural metals, magnesium, fulfills the need for mass reduction within the automotive industry. Many of the body structure components in the automotive industry are assembled using joining processes such as fusion welding. Furthermore, laser welding offers a low heat impact, high process rate, joining method which is becoming increasingly popular as the cost for laser systems continues to decrease. However, there is a limited body of work investigating the laser welding of magnesium and therefore, in the current study, different techniques and methods for laser welding of magnesium alloys are numerically and experimentally studied in order to optimize process parameters to achieve high quality welds. A feasibility study was designed in order to study the effect of various laser welding process parameters (such as laser power levels and welding speeds) on weld quality. Three regression models were developed to find the best fit model that relates process parameters to the shear load of the weld. Furthermore, to understand the effect of laser welding parameters on temperature distribution in laser welding of AZ31B magnesium alloy, a numerical model was developed. A rotary Gaussian volumetric body heat source was applied in this study to obtain the temperature history during the laser welding process. Cross-sectional views of the weld beads, temperature history recorded by thermocouples, and temperature history recorded by infrared camera were used to validate the numerical model. In order to study the real-time dynamic behavior of the molten pool and the keyhole during the welding process, a high speed charge-coupled device (CCD) assisted with a green laser as an illumination source was used. In order to observe the presence of pores, prior studies destructively evaluated the weld bead however; in the current study a non-destructive evaluation method based on spectroscopy is proposed to detect the presence of pores in the lap joint of laser welded AZ31B magnesium alloy. The electron temperature that is calculated by the Boltzmann plot method is correlated to the presence of pores in the weld bead. A separate series of experiments was performed to evaluate the effect of an oxide coating layer on the dynamic behavior of the molten pool in the laser welding of an AZ31B magnesium alloy in a zero-gap lap joint configuration. A high speed CCD camera assisted with a green laser as an illumination source was selected to record the weld pool dynamics. Another technique used in this study was two-pass laser welding process to join AZ31B magnesium sheet in a zero-gap, lap-shear configuration. Two groups of samples including one pass laser welding (OPLW) and two pass laser welding (TPLW) were studied. In the two pass laser welding procedure, the first pass is performed by a defocused laser beam on the top of the two overlapped sheets in order to preheat the faying surface prior to laser welding, while the second pass is applied to melt and eventually weld the samples. Tensile and microhardness tests were used to measure the mechanical properties of the laser welded samples. A spectrometer was also used in real-time to correlate pore formation with calculated electron temperature using the Boltzmann plot method. The results of calculated electron temperature confirmed the previous results in earlier chapter. Magnesium and aluminum are two alloys which are used in different industries mainly due to their light weight. The main use of these two alloys is in automotive industry. Since different parts of the automobiles can be manufactured with each of these two alloys, it is essential to evaluate the joining feasibility of dissimilar metals such as aluminum to magnesium. A 4 kW fiber laser is used to join AZ31B magnesium alloy to AA 6014 using an overlap joint configuration. Two different methods including focused beam laser welding (FBLW) and defocused beam laser welding (DBLW) are performed. The cross-sections of the welds were studied using an optical microscope, scanning electron microscope (SEM) as well as energy-dispersive X-ray spectroscopy (EDS) to reveal the quality of the obtained dissimilar welds. The mechanical properties of the welds were studied using a tensile test and microhardness testing machines. The results show that the defocused laser welding process could help to achieve a better quality of weld. (Abstract shortened by UMI.)

PWSCC Assessment by Using Extended Finite Element Method

NASA Astrophysics Data System (ADS)

Lee, Sung-Jun; Lee, Sang-Hwan; Chang, Yoon-Suk

2015-12-01

The head penetration nozzle of control rod driving mechanism (CRDM) is known to be susceptible to primary water stress corrosion cracking (PWSCC) due to the welding-induced residual stress. Especially, the J-groove dissimilar metal weld regions have received many attentions in the previous studies. However, even though several advanced techniques such as weight function and finite element alternating methods have been introduced to predict the occurrence of PWSCC, there are still difficulties in respect of applicability and efficiency. In this study, the extended finite element method (XFEM), which allows convenient crack element modeling by enriching degree of freedom (DOF) with special displacement function, was employed to evaluate structural integrity of the CRDM head penetration nozzle. The resulting stress intensity factors of surface cracks were verified for the reliability of proposed method through the comparison with those suggested in the American Society of Mechanical Engineering (ASME) code. The detailed results from the FE analyses are fully discussed in the manuscript.

Cold work study on a 316LN modified alloy for the ITER TF coil conduit

DOE PAGES

Walsh, Robert; Toplosky, V. J.; McRae, D. M.; ...

2012-06-01

The primary structural component of the cable-in-conduit conductor (CICC) magnets, such as the ITER TF coils is the conduit. This function creates requirements for 4 K strength, toughness, fatigue crack resistance, and ductility after exposure to the superconductor's reaction heat treatment. The tensile ductility of a steel is a quality factor related to fatigue and fracture resistance that can be evaluated more economically with tensile tests rather than fatigue and fracture tests. We subject 316LN modified base metal and welds to a range of cold work from 0% to 20% and a subsequent Nb 3Sn reaction heat treatment to evaluatemore » the effects on the tensile properties. With the addition of cold work, the 4 K yield strength increases while tensile elongation decreases in both the base metal and weld. Our results are compared to previously published data on the same alloy to evaluate the use of tensile ductility parameters as a materials qualification specification in magnet design.« less

Risk of lung cancer according to mild steel and stainless steel welding.

PubMed

Sørensen, Anita Rath; Thulstrup, Ane Marie; Hansen, Johnni; Ramlau-Hansen, Cecilia Høst; Meersohn, Andrea; Skytthe, Axel; Bonde, Jens Peter

2007-10-01

Whether the elevated risk of lung cancer observed among welders is caused by welding emissions or by confounding from smoking or asbestos exposure is still not resolved. This question was addressed in a cohort with a long follow-up and quantified estimates of individual exposure to welding fume particulates. Male metal workers employed at least 1 year at one or more Danish stainless or mild steel industrial companies from 1964 through 1984 were enrolled in a cohort. Data on occupational and smoking history were obtained by questionnaire in 1986. Welders in the cohort who started welding in 1960 or later (N=4539) were followed from April 1968 until December 2003, when information on cancer diagnosis was obtained from the Danish Cancer Registry. During the follow-up, 75 cases of primary lung cancer were identified. Lifetime accumulated exposure to welding fume particulates was estimated by combining questionnaire information and more than 1000 welding-process-specific measurements of fume particulates in the Danish welding industry. The standardized incidence ratio (SIR) for lung cancer was increased among the welders [SIR 1.35, 95% confidence interval (95% CI) 1.06-1.70)]. Among the stainless steel welders, the risk increased significantly with increasing accumulative welding particulate exposure, while no exposure-response relation was found for mild steel welders, even after adjustment for tobacco smoking and asbestos exposure. The study corroborates earlier findings that welders have an increased risk of lung cancer. While exposure-response relations indicate carcinogenic effects related to stainless steel welding, it is still unresolved whether the mild steel welding process carries a carcinogenic risk.

Low-Temperature Aging Characteristics of Type 316L Stainless Steel Welds: Dependence on Solidification Mode

NASA Astrophysics Data System (ADS)

Abe, Hiroshi; Watanabe, Yutaka

2008-06-01

Thermal aging embrittlement of light water reactor (LWR) components made of stainless steel cast has been recognized as a potential degradation issue, and careful attention has been paid to it. Although welds of austenitic stainless steels have γ-δ duplex microstructure, which is similar to that of the stainless steel cast, examination of the thermal aging characteristics of the stainless steel welds is very limited. In this investigation, two types of type 316L stainless steel weld metal with different solidification modes were prepared using two kinds of filler metals having tailored Ni equivalent and Cr equivalent. Differences between the two weld metals in the morphology of microstructure, in the composition of δ-ferrite, and in hardening behaviors with isothermal aging at 335 °C have been investigated. The hardness of the ferrite phase has increased with aging time, while the hardness of austenite phase has stayed the same. The mottled aspect has been observed in δ-ferrite of aged samples by transmission electron microscopy (TEM) observation. These characteristics suggest that spinodal decomposition has occurred in δ-ferrite by aging at 335 °C. The age-hardening rate of δ-ferrite was faster for the primary austenite solidification mode (AF mode) sample than the primary ferrite solidification mode (FA mode) sample in the initial stage of the aging up to 2000 hours. It has been suggested that the solidification mode can affect the kinetics of spinodal decomposition.

Intermetallic layers in temperature controlled Friction Stir Welding of dissimilar Al-Cu-joints

NASA Astrophysics Data System (ADS)

Marstatt, R.; Krutzlinger, M.; Luderschmid, J.; Constanzi, G.; Mueller, J. F. J.; Haider, F.; Zaeh, M. F.

2018-06-01

Friction Stir Welding (FSW) can be performed to join dissimilar metal combinations like aluminium and copper, which is of high interest in modern production of electrical applications. The amount of intermetallic phases in the weld seam is significantly reduced compared to traditional fusion welding technologies. Because the solidus temperature is typically not reached during FSW, the growth of intermetallic phases is impeded and the intermetallic layer thicknesses typically remains on the scale of a few hundred nanometres. These layers provide a substance-to-substance bond, which is the main joining mechanism. Latest research confirms that the layer formation is most likely driven by the heat input during processing. Hence, the welding temperature is the key to achieve high quality joints. In this study, aluminium and copper sheets were welded in lap joint configuration using temperature-controlled FSW. An advanced in-tool measurement set-up was used to determine precise temperature data. Scanning electron microscopy (SEM) was used to analyse metallurgical aspects (e.g. structure and composition of the intermetallic phases) of the joints. The results show a correlation between the welding temperature and the thickness of the intermetallic layer and its structure. The temperature control significantly improved the correlation compared to previous studies. This leads to an enhanced understanding of the dominating joining mechanisms.

Cold welding of gold nanoparticles on mica substrate: Self-adjustment and enhanced diffusion

PubMed Central

Cha, Song-Hyun; Park, Youmie; Han, Jeong Woo; Kim, Kyeounghak; Kim, Hyun-Seok; Jang, Hong-Lae; Cho, Seonho

2016-01-01

From the images of HR-TEM, FE-SEM, and AFM, the cold welding of gold nanoparticles (AuNPs) on a mica substrate is observed. The cold-welded gold nanoparticles of 25 nm diameters are found on the mica substrate in AFM measurement whereas the size of cold welding is limited to 10 nm for nanowires and 2~3 nm for nanofilms. Contrary to the nanowires requiring pressure, the AuNPs are able to rotate freely due to the attractive forces from the mica substrate and thus the cold welding goes along by adjusting lattice structures. The gold nanoparticles on the mica substrate are numerically modeled and whose physical characteristics are obtained by the molecular dynamic simulations of LAMMPS. The potential and kinetic energies of AuNPs on the mica substrate provide sufficient energy to overcome the diffusion barrier of gold atoms. After the cold welding, the regularity of lattice structure is maintained since the rotation of AuNPs is allowed due to the presence of mica substrate. It turns out that the growth of AuNPs can be controlled arbitrarily and the welded region is nearly perfect and provides the same crystal orientation and strength as the rest of the nanostructures. PMID:27597438

Gas metal arc welding in refurbishment of cobalt base superalloys

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

Cold welding of gold nanoparticles on mica substrate: Self-adjustment and enhanced diffusion

NASA Astrophysics Data System (ADS)

Cha, Song-Hyun; Park, Youmie; Han, Jeong Woo; Kim, Kyeounghak; Kim, Hyun-Seok; Jang, Hong-Lae; Cho, Seonho

2016-09-01

From the images of HR-TEM, FE-SEM, and AFM, the cold welding of gold nanoparticles (AuNPs) on a mica substrate is observed. The cold-welded gold nanoparticles of 25 nm diameters are found on the mica substrate in AFM measurement whereas the size of cold welding is limited to 10 nm for nanowires and 2~3 nm for nanofilms. Contrary to the nanowires requiring pressure, the AuNPs are able to rotate freely due to the attractive forces from the mica substrate and thus the cold welding goes along by adjusting lattice structures. The gold nanoparticles on the mica substrate are numerically modeled and whose physical characteristics are obtained by the molecular dynamic simulations of LAMMPS. The potential and kinetic energies of AuNPs on the mica substrate provide sufficient energy to overcome the diffusion barrier of gold atoms. After the cold welding, the regularity of lattice structure is maintained since the rotation of AuNPs is allowed due to the presence of mica substrate. It turns out that the growth of AuNPs can be controlled arbitrarily and the welded region is nearly perfect and provides the same crystal orientation and strength as the rest of the nanostructures.

Cold welding of gold nanoparticles on mica substrate: Self-adjustment and enhanced diffusion.

PubMed

Cha, Song-Hyun; Park, Youmie; Han, Jeong Woo; Kim, Kyeounghak; Kim, Hyun-Seok; Jang, Hong-Lae; Cho, Seonho

2016-09-06

From the images of HR-TEM, FE-SEM, and AFM, the cold welding of gold nanoparticles (AuNPs) on a mica substrate is observed. The cold-welded gold nanoparticles of 25 nm diameters are found on the mica substrate in AFM measurement whereas the size of cold welding is limited to 10 nm for nanowires and 2~3 nm for nanofilms. Contrary to the nanowires requiring pressure, the AuNPs are able to rotate freely due to the attractive forces from the mica substrate and thus the cold welding goes along by adjusting lattice structures. The gold nanoparticles on the mica substrate are numerically modeled and whose physical characteristics are obtained by the molecular dynamic simulations of LAMMPS. The potential and kinetic energies of AuNPs on the mica substrate provide sufficient energy to overcome the diffusion barrier of gold atoms. After the cold welding, the regularity of lattice structure is maintained since the rotation of AuNPs is allowed due to the presence of mica substrate. It turns out that the growth of AuNPs can be controlled arbitrarily and the welded region is nearly perfect and provides the same crystal orientation and strength as the rest of the nanostructures.

The influence of the corrosion product layer generated on the high strength low-alloy steels welded by underwater wet welding with stainless steel electrodes in seawater

NASA Astrophysics Data System (ADS)

Bai, Qiang; Zou, Yan; Kong, Xiangfeng; Gao, Yang; Dong, Sheng; Zhang, Wei

2017-02-01

The high strength low-alloy steels are welded by underwater wet welding with stainless steel electrodes. The micro-structural and electrochemical corrosion study of base metal (BM), weld zone (WZ) and heat affected zone (HAZ) are carried out to understand the influence of the corrosion product layer generated on the high strength low-alloy steels welded by underwater wet welding with stainless steel electrodes, methods used including, potentiodynamic polarization, electrochemical impedance spectroscopy (EIS) and scanning electron microscope (SEM). The results indicate that the WZ acts as a cathode and there is no corrosion product on it throughout the immersion period in seawater. The HAZ and BM acts as anodes. The corrosion rates of the HAZ and BM change with the immersion time increasing. In the initial immersion period, the HAZ has the highest corrosion rate because it has a coarse tempered martensite structure and the BM exhibites a microstructure with very fine grains of ferrite and pearlite. After a period of immersion, the BM has the highest corrosion rate. The reason is that the corrosion product layer on the HAZ is dense and has a better protective property while that on the BM is loose and can not inhibit the diffusion of oxygen.

Weld Metallurgy and Mechanical Properties of High Manganese Ultra-high Strength Steel Dissimilar Welds

NASA Astrophysics Data System (ADS)

Dahmen, Martin; Lindner, Stefan; Monfort, Damien; Petring, Dirk

The increasing demand for ultra-high strength steels in vehicle manufacturing leads to the application of new alloys. This poses a challenge on joining especially by fusion welding. A stainless high manganese steel sheet with excellent strength and deformation properties stands in the centre of the development. Similar and dissimilar welds with a metastable austenitic steel and a hot formed martensitic stainless steel were performed. An investigation of the mixing effects on the local microstructure and the hardness delivers the metallurgical features of the welds. Despite of carbon contents above 0.4 wt.% none of the welds have shown cracks. Mechanical properties drawn from tensile tests deliver high breaking forces enabling a high stiffness of the joints. The results show the potential for the application of laser beam welding for joining in assembly of structural parts.

Advanced concepts in joining by conventional processes

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

Edwards, G.R.; Fasching-James, A.A.; Onsoien, M.I.

1994-12-31

Innovations which can be made to conventional arc welding processes so that advanced materials can be more efficiently joined are considered. Three examples are discussed: (1) GTA welding of iron aluminides, (2) GMA welding of advanced steels, and (3) SMA welding of structural steels. Advanced materials present new challenges for the materials joining specialist. The three examples discussed in this paper demonstrate, however, that modest but creative alterations of conventional GTAW, GMAW, or SMAW processes can provide new and better controls for solving advanced materials joining problems.

Temperature Histories of Ti-6Al-4V Pulsed-Mode Laser Welds Calculated Using Multiple Constraints

DTIC Science & Technology

2015-08-12

Naval Research Laboratory Washington, DC 20375-5320 NRL/MR/6390--15-9621 Temperature Histories of Ti-6Al-4V Pulsed-Mode Laser Welds Calculated Using...b. ABSTRACT c. THIS PAGE 18. NUMBER OF PAGES 17. LIMITATION OF ABSTRACT Temperature Histories of Ti-6Al-4V Pulsed-Mode Laser Welds Calculated Using...plate structures. The results of the case studies provide parametric representations of weld temperature histories that can be adopted as input data to

Novel Process Revolutionizes Welding Industry

NASA Technical Reports Server (NTRS)

2008-01-01

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

Microscopic Evaluation of Friction Plug Welds- Correlation to a Processing Analysis

NASA Technical Reports Server (NTRS)

Rabenberg, Ellen M.; Chen, Poshou; Gorti, Sridhar

2017-01-01

Recently an analysis of dynamic forge load data from the friction plug weld (FPW) process and the corresponding tensile test results showed that good plug welds fit well within an analytically determined processing parameter box. There were, however, some outliers that compromised the predictions. Here the microstructure of the plug weld material is presented in view of the load analysis with the intent of further understanding the FPW process and how it is affected by the grain structure and subsequent mechanical properties.

Development of the weldbond process for joining titanium

NASA Technical Reports Server (NTRS)

Fields, D.

1972-01-01

High quality resistance spot welds were produced by welding through epoxy adhesive on titanium alloys. Weldbond joints were consistently stronger than those of either mechanical fasteners, structural adhesive bonds, or mechanical fasteners with adhesive at the joint interface. Weldbond joints and/or spot weld joints showed superior strength at all temperature ranges as compared to other joints tested.

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

NASA Astrophysics Data System (ADS)

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

2017-07-01

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

Hybrid welding of hollow section beams for a telescopic lifter

NASA Astrophysics Data System (ADS)

Jernstroem, Petteri

2003-03-01

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

Fatigue evaluation of socket welded piping in nuclear power plant

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

Vecchio, R.S.

1996-12-01

Fatigue failures in piping systems occur, almost without exception, at the welded connections. In nuclear power plant systems, such failures occur predominantly at the socket welds of small diameter piping ad fillet attachment welds under high-cycle vibratory conditions. Nearly all socket weld fatigue failures are identified by leaks which, though not high in volume, generally are costly due to attendant radiological contamination. Such fatigue cracking was recently identified in the 3/4 in. diameter recirculation and relief piping socket welds from the reactor coolant system (RCS) charging pumps at a nuclear power plant. Consequently, a fatigue evaluation was performed to determinemore » the cause of cracking and provide an acceptable repair. Socket weld fatigue life was evaluated using S-N type fatigue life curves for welded structures developed by AASHTO and the assessment of an effective cyclic stress range adjacent to each socket weld. Based on the calculated effective tress ranges and assignment of the socket weld details to the appropriate AASHTO S-N curves, the socket weld fatigue lives were calculated and found to be in excellent agreement with the accumulated cyclic life to-date.« less

The potential of a GAS can with payload G-169

NASA Technical Reports Server (NTRS)

Tamir, David

1988-01-01

The feasibility of using welding for the construction, expansion and emergency repair of space based structures is discussed and the advantages of gas tungsten arc welding (GTAW) over other welding techniques are briefly examined. The objective and design concept for the G-169 Get Away Special payload are described. The G-169 experiment will allow the comparison of a space GTA welded joint with a terrestrial GTA welded joint with all parameters held constant except for gravitational forces. Specifically, a bead-on-plate weld around the perimeter of a 2 inch diameter stainless steel pipe section will be performed. The use of Learjet microgravity simulation for the G-169 and other Get Away Special experiments is also addressed.

A Study to Increase Weld Penetration in P91 Steel During TIG Welding by using Activating Fluxes

NASA Astrophysics Data System (ADS)

Singh, Akhilesh Kumar; Kumar, Mayank; Dey, Vidyut; Naresh Rai, Ram

2017-08-01

Activated Flux TIG (ATIG) welding is a unique joining process, invented at Paton Institute of electric welding in 1960. ATIG welding process is also known as flux zoned TIG (FZTIG). In this process, a thin layer of activating flux is applied along the line on the surface of the material where the welding is to be carries out. The ATIG process aids to increase the weld penetration in thick materials. Activating fluxes used in the literature show the use of oxides like TiO2, SiO2, Cr2O3, ZnO, CaO, Fe2O3, and MnO2 during welding of steels. In the present study, ATIG was carried out on P-91 steel. Though, Tungsten Inert Gas welding gives excellent quality welds, but the penetration obtained in such welding is still demanding. P91 steel which is ferritic steel is used in high temperature applications. As this steel is, generally, used in thick sections, fabrication of such structures with TIG welding is limited, due to its low depth of penetration. To increase the depth of penetration in P91while welding with ATIG, the role of various oxides were investigated. Apart from the oxides mentioned above, in the present study the role of B2O3, V2O5 and MgO, during ATIG welding of P91 was investigated. It was seen that, compared to TIG welding, there was phenomenal increase in weld penetration during ATIG welding. Amongst all the oxides used in this study, maximum penetration was achieved in case of B2O3. The measurements of weld penetration, bead width and heat affected zone of the weldings were carried out using an image analysis technique.

On the hot cracking susceptibility of a semisolid aluminium 6061 weld: Application of a coupled solidification- thermomechanical model

NASA Astrophysics Data System (ADS)

Zareie Rajani, H. R.; Phillion, A. B.

2015-06-01

A coupled solidification-thermomechanical model is presented that investigates the hot tearing susceptibility of an aluminium 6061 semisolid weld. Two key phenomena are considered: excessive deformation of the semisolid weld, initiating a hot tear, and the ability of the semisolid weld to heal the hot tear by circulation of the molten metal. The model consists of two major modules: weld solidification and thermomechanical analysis. 1) By means of a multi-scale model of solidification, the microstructural evolution of the semisolid weld is simulated in 3D. The semisolid structure, which varies as a function of welding parameters, is composed of solidifying grains and a network of micro liquid channels. The weld solidification module is utilized to obtain the solidification shrinkage. The size of the micro liquid channels is used as an indicator to assess the healing ability of the semisolid weld. 2) Using the finite element method, the mechanical interaction between the weld pool and the base metal is simulated to capture the transient force field deforming the semisolid weld. Thermomechanical stresses and shrinkage stresses are both considered in the analysis; the solidification contractions are extracted from the weld solidification module and applied to the deformation simulation as boundary conditions. Such an analysis enables characterization of the potential for excessive deformation of the weld. The outputs of the model are used to study the effect of welding parameters including welding current and speed, and also welding constraint on the hot cracking susceptibility of an aluminium alloy 6061 semisolid weld.

A Fundamental Investigation into the Joining of Advanced Light Materials

DTIC Science & Technology

1991-11-25

discontinuities), the evolution and nature of the metallurgical structure and correspondingly the joint mechanical properties must be developed. In...metallurgical phenomena associated with formation of the weld structure and its corresponding influence on mechanical properties . During the course of...temperature mechanical properties . Work by the same authors on GTA and electron-beam weld fusion zone structures in 2 090-T8 determined strengthening

Fabrication of thick multilayered steel structure using A516 Grade 70 by multipass friction stir welding †

DOE PAGES

Lim, Y. C.; Sanderson, S.; Mahoney, M.; ...

2016-04-06

Here, we fabricated a thick-sectioned multilayered steel structure by multipass friction stir welding on A516 Grade 70 steel. Tensile strength of the multilayered samples was comparable to that of the base metal. Failure was located in the base metal when a defect-free sample was tested. Charpy impact toughness was higher in the stir zone and heat affected zone than in the base metal. For higher microhardness values were found in the stir zone and heat affected zone than the base metal due to grain refinement and modification of the microstructures. As a result, improved mechanical properties compared to the basemore » metal were found in the weld zones of friction stir welded A516 Grade 70 steel.« less

Studies on Fusion Welding of High Nitrogen Stainless Steel: Microstructure, Mechanical and corrosion Behaviour

NASA Astrophysics Data System (ADS)

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

2018-03-01

An attempt has been made in the present investigation to weld high nitrogen steel of 5mm thick plates using various process i.e., shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW) and autogenous electron beam welding (EBW) process. Present work is aimed at studying the microstructural changes and its effects on mechanical properties and corrosion resistance. Microstructure is characterized by optical, scanning electron microscopy and electron back scattered diffraction technique. Vickers hardness, tensile properties, impact toughness and face bend ductility testing of the welds was carried out. Pitting corrosion resistance of welds was determined using potentio-dynamic polarization testing in 3.5%NaCl solution. Results of the present investigation established that SMA welds made using Cr-Mn-N electrode were observed to have a austenite dendritic grain structure in the weld metal and is having poor mechanical properties but good corrosion resistance. GTA welds made using 18Ni (MDN 250) filler wire were observed to have a reverted austenite in martensite matrix of the weld metal and formation of unmixed zone at the fusion boundary which resulted in better mechanical properties and poor corrosion resistance. Fine grains and uniform distribution of delta ferrite in the austenite matrix and narrow width of weld zone are observed in autogeneous electron beam welds. A good combination of mechanical properties and corrosion resistance was achieved for electron beam welds of high nitrogen steel when compared to SMA and GTA welds.

The characteristics of welded joints for air conditioning application

NASA Astrophysics Data System (ADS)

Weglowski, M. St.; Weglowska, A.; Miara, D.; Kwiecinski, K.; Błacha, S.; Dworak, J.; Rykala, J.; Pikula, J.; Ziobro, G.; Szafron, A.; Zimierska-Nowak, P.; Richert, M.; Noga, P.

2017-10-01

In the paper the results of metallographic examination of welded joints for air-conditioning elements are presented. The European directives 2006/40/EC on the greenhouse gasses elimination demand to stop using traditional refrigerant and to change it to R744 (CO2) medium in air conditioning installation. The R744 refrigerant is environmental friendly medium if compared with standard solution such as R12, R134a or R1234yf and safer for passengers than R1234yf. The non-standard thermodynamic parameters of the R744 which translate into high pressure and high temperature require specific materials to develop the shape and to specify the technology of manufacturing for the particular elements of the conduits and moreover the technologies of joining for the whole structure, which would meet the exploitation requirements of the new air-conditioning system. To produce the test welded joints of stainless steels four different joining technologies were applied: laser welding, plasma welding, electron beam welding as well as high speed rotation welding. This paper describes the influence of the selected welding process on the macrostructure and microstructure of welded joints of AISI 304 and AISI 316L steels. The results indicated that plasma welding laser welding and electron beam welding technologies guaranty the proper quality of welded joints and can be used for the air conditioning application in automotive industry. However, high speed rotation welding not guarantee the good quality of welded joints and cannot be used for above application.

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

NASA Astrophysics Data System (ADS)

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

2017-05-01

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

Formation of A Non-detachable Welded Titanium-aluminium Compound by Laser Action

NASA Astrophysics Data System (ADS)

Murzin, Serguei P.

2018-01-01

Progressive in the welding of dissimilar materials is the use of laser technology. With the use of the ROFIN StarWeld Manual Performance laser, an aluminium alloy AK4 and a titanium alloy VT5-1 were welded. Processing regimes have been determined, the realization of which during melting of materials in the zone of thermal influence makes it possible to obtain a homogeneous structure without voids and shells, which indicates a potential sufficiently high serviceability of the welded joint. To create the required power density distribution in the cross section of the laser beam, it is expedient to use diffractive optical elements.

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

PubMed Central

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

2015-01-01

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

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

PubMed

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

2015-06-11

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

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

NASA Astrophysics Data System (ADS)

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

2015-06-01

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

Analysis of properties laser welded RAK 40/70 steel sheets

NASA Astrophysics Data System (ADS)

Evin, E.; Tomáš, M.; Fujda, M.

2017-11-01

Both, the ecological production and operation of vehicles demand using such materials for deformation zones’ structural parts, which show some specific properties and use innovative technologies to process them. Specific requirements for functionality (strength, stiffness, deformation work, fatigue properties) are closely linked to processability (formability). In the paper are presented results for multiphase TRIP steel RAK40/70 when welded by pulse solid-state fiber laser YLS-5000. Based on microstructure analysis in the fusion zone and heat affected zone the welding parameters were optimised. The influence of laser welding on the strength and deformation properties was verified by characteristics of strength, stiffness and deformation work, as they were calculated from mechanical properties measured by tensile test and three-point bending test. The knowledge gathered in the field of laser welding influence on the strength and deformation properties of multiphase TRIP steel RAK40/70 should help designers when design the lightweight structural parts of the car body.

Structure of AA5056 after friction drilling

NASA Astrophysics Data System (ADS)

Eliseev, A. A.; Kalashnikova, T. A.; Fortuna, S. V.

2017-12-01

Here we present data on the structure of AA5056 alloy after friction drilling to unveil potentials of the process for use in model experiments on friction stir welding. Our analysis of the average size and volume content of precipitates shows that their content decreases immediately beneath the friction surface and that the structure of this zone is the same as the structure of stirring zones formed in friction stir welding. The data suggest that both processes provide similar metal structures.

Investigation of dissimilar metal welds by energy-resolved neutron imaging

DOE PAGES

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

2016-06-09

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

Investigation of dissimilar metal welds by energy-resolved neutron imaging

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

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

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

Investigation of dissimilar metal welds by energy-resolved neutron imaging

PubMed Central

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

2016-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Improved microstructure and mechanical properties in gas tungsten arc welded aluminum joints by using graphene nanosheets/aluminum composite filler wires.

PubMed

Fattahi, M; Gholami, A R; Eynalvandpour, A; Ahmadi, E; Fattahi, Y; Akhavan, S

2014-09-01

In the present study, different amounts of graphene nanosheets (GNSs) were added to the 4043 aluminum alloy powders by using the mechanical alloying method to produce the composite filler wires. With each of the produced composite filler wires, one all-weld metal coupon was welded using the gas tungsten arc (GTA) welding process. The microstructure, mechanical properties and fracture surface morphology of the weld metals have been evaluated and the results are compared. As the amount of GNSs in the composition of filler wire is increased, the microstructure of weld metal was changed from the dendritic structure to fine equiaxed grains. Furthermore, the tensile strength and microhardness of weld metal was improved, and is attributed to the augmented nucleation and retarded growth. From the results, it was seen that the GNSs/Al composite filler wire can be used to improve the microstructure and mechanical properties of GTA weld metals of aluminum and its alloys. Copyright © 2014 Elsevier Ltd. All rights reserved.

Effects of heat input on the pitting resistance of Inconel 625 welds by overlay welding

NASA Astrophysics Data System (ADS)

Kim, Jun Seok; Park, Young IL; Lee, Hae Woo

2015-03-01

The objective of this study was to establish the relationship between the dilution ratio of the weld zone and pitting resistance depending on the heat input to welding of the Inconel alloy. Each specimen was produced by electroslag welding using Inconel 625 as the filler metal. In the weld zone of each specimen, dendrite grains were observed near the fusion line and equiaxed grains were observed on the surface. It was also observed that a melted zone with a high Fe content was formed around the fusion line, which became wider as the welding heat input increased. In order to evaluate the pitting resistance, potentiodynamic polarization tests and CPT tests were conducted. The results of these tests confirmed that there is no difference between the pitting resistances of each specimen, as the structures of the surfaces were identical despite the effect of the differences in the welding heat input for each specimen and the minor dilution effect on the surface.

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.

Effect of Zinc Coatings on Joint Properties and Interfacial Reactions in Aluminum to Steel Ultrasonic Spot Welding

NASA Astrophysics Data System (ADS)

Haddadi, F.; Strong, D.; Prangnell, P. B.

2012-03-01

Dissimilar joining of aluminum to steel sheet in multimaterial automotive structures is an important potential application of ultrasonic spot welding (USW). Here, the weldability of different zinc-coated steels with aluminum is discussed, using a 2.5-kW USW welder. Results show that soft hot-dipped zinc (DX56-Z)-coated steel results in better weld performance than hard (galv-annealed) zinc coatings (DX53-ZF). For Al to hard galv-annealed-coated steel welds, lap shear strengths reached a maximum of ~80% of the strength of an Al-Al joint after a 1.0 s welding time. In comparison, welds between Al6111-T4 and hot dipped soft zinc-coated steel took longer to achieve the same maximum strength, but nearly matched the Al-Al joint properties. The reasons for these different behaviors are discussed in terms of the interfacial reactions between the weld members.

Study of Radiographic Linear Indications and Subsequent Microstructural Features in Gas Tungsten Arc Welds of Inconel 718

NASA Technical Reports Server (NTRS)

Walley, J. L.; Nunes, A. C.; Clounch, J. L.; Russell, C. K.

2007-01-01

This study presents examples and considerations for differentiating linear radiographic indications produced by gas tungsten arc welds in a 0.05-in-thick sheet of Inconel 718. A series of welds with different structural features, including the enigma indications and other defect indications such as lack of fusion and penetration, were produced, radiographed, and examined metallographically. The enigma indications were produced by a large columnar grain running along the center of the weld nugget occurring when the weld speed was reduced sufficiently below nominal. Examples of respective indications, including the effect of changing the x-ray source location, are presented as an aid to differentiation. Enigma, nominal, and hot-weld specimens were tensile tested to demonstrate the harmlessness of the enigma indication. Statistical analysis showed that there is no difference between the strengths of these three weld conditions.

29 CFR 1926.6 - Incorporation by reference.

Code of Federal Regulations, 2014 CFR

2014-07-01

....1-1967, Safety in Welding and Cutting, IBR approved for § 1926.350(j). (27) USA Z53.1-1967 (also... approved for § 1926.603(a). (m) The following material is available for purchase from the American Welding...://www.aws.org/: (1) AWS D1.1/D1.1M:2002, Structural Welding Code—Steel, 18th ed., ANSI approved Aug. 31...

29 CFR 1926.6 - Incorporation by reference.

Code of Federal Regulations, 2013 CFR

2013-07-01

... Prevention Tags, IBR approved for § 1926.200(i). (26) ANSI Z49.1-1967, Safety in Welding and Cutting, IBR... approved for § 1926.603(a). (m) The following material is available for purchase from the American Welding...://www.aws.org/: (1) AWS D1.1/D1.1M:2002, Structural Welding Code—Steel, 18th ed., ANSI approved Aug. 31...

ManTech Affordability for Defense Weapon Systems

DTIC Science & Technology

2009-11-01

the Virginia Class Submarine Development of Friction Stir Welding for Navy Expeditionary Fighting Vehicle (EFV) Hull Components Procurement...Tile 2007 – Translational Friction Stir Welding 2006 – Engine Rotor Life Extension 2006 – Uncooled Focal Plane Array Producibility 2005 – Large...DDG 1000 with Hybrid Laser Arc Welding The Problem: T-Beam stiffeners, used extensively for decks, bulkheads, and other ship structures, are being

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

NASA Astrophysics Data System (ADS)

Chen, Bai-Qiao; Guedes Soares, C.

2018-03-01

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

A Study on the compensation margin on butt welding joint of Large Steel plates during Shipbuilding construction.

NASA Astrophysics Data System (ADS)

Kim, J.; Jeong, H.; Ji, M.; Jeong, K.; Yun, C.; Lee, J.; Chung, H.

2015-09-01

This paper examines the characteristics of butt welding joint shrinkage for shipbuilding and marine structures main plate. The shrinkage strain of butt welding joint which is caused by the process of heat input and cooling, results in the difference between dimensions of the actual parent metal and the dimensions of design. This, in turn, leads to poor quality in the production of ship blocks and reworking through period of correction brings about impediment on improvement of productivity. Through experiments on butt welding joint's shrinkage strain on large structures main plate, the deformation of welding residual stress in the form of I, Y, V was obtained. In addition, the results of experiments indicate that there is limited range of shrinkage in the range of 1 ∼ 2 mm in 11t ∼ 21.5t thickness and the effect of heat transfer of weld appears to be limited within 1000 mm based on one side of seam line so there was limited impact of weight of parent metal on the shrinkage. Finally, it has been learned that Shrinkage margin needs to be applied differently based on groove phenomenon in the design phase in order to minimize shrinkage.

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

The Plunge Phase of Friction Stir Welding

NASA Technical Reports Server (NTRS)

Nunes, Arthur; McClure, John; Avila, Ricardo

2005-01-01

Torque and plunge force during the initial plunge phase in Friction Stir Welding were measured for a 0.5 inch diameter pin entering a 2219 aluminum alloy plate. Weld structures were preserved for metallographic observation by making emergency stops at various plunge depths. The plunging pin tool is seen to be surrounded by a very fine grained layer of recrystallized metal extending substantially below the bottom of the pin, implying a shear interface in the metal below and not at the tool-metal interface. Torque and plunge force during the initial plunge phase in Friction Stir Welding are calculated from a straight forward model based on a concept to plastic flow in the vicinity of the plunging tool compatible with structural observations. The concept: a disk of weld metal seized to and rotating with the bottom of the pin is squeezed out laterally by the plunge force and extruded upwards in a hollow cylinder around the tool. As the shear surface separating rotating disk from stationary weld metal engulfs fresh metal, the fresh metal is subjected to severe shear deformation, which results in its recrystallization. Encouraging agreement between computations and measured torque and plunge force is obtained.

Fiber Laser Welding-Brazing Characteristics of Dissimilar Metals AZ31B Mg Alloys to Copper with Mg-Based Filler

NASA Astrophysics Data System (ADS)

Zhao, Xiaoye; Tan, Caiwang; Meng, Shenghao; Chen, Bo; Song, Xiaoguo; Li, Liqun; Feng, Jicai

2018-03-01

Fiber laser welding-brazing of 1-mm-thick AZ31B Mg alloys to 1.5-mm-thick copper (T2) with Mg-based filler was performed in a lap configuration. The weld appearance, interfacial microstructure and mechanical properties were investigated with different heat inputs. The results indicated that processing windows for optimizing appropriate welding parameters were relatively narrow in this case. Visually acceptable joints with certain strength were achieved at appropriate welding parameters. The maximum tensile-shear fracture load of laser-welded-brazed Mg/Cu joint could reach 1730 N at the laser power of 1200 W, representing 64.1% joint efficiency relative to AZ31Mg base metal. The eutectic structure (α-Mg + Mg2Cu) and Mg-Cu intermetallic compound was observed at the Mg/Cu interface, and Mg-Al-Cu ternary intermetallic compound were identified between intermetallics and eutectic structure at high heat input. All the joints fractured at the Mg-Cu interface. However, the fracture mode was found to differ. For laser power of 1200 W, the surface was characterized by tearing edge, while that with poor joint strength was almost dominated by smooth surface or flat tear pattern.

Structural Properties of EB-Welded AlSi10Mg Thin-Walled Pressure Vessels Produced by AM-SLM Technology

NASA Astrophysics Data System (ADS)

Nahmany, Moshe; Stern, Adin; Aghion, Eli; Frage, Nachum

2017-10-01

Additive manufacturing of metals by selective laser melting (AM-SLM) is hampered by significant limitations in product size due to the limited dimensions of printing trays. Electron beam welding (EBW) is a well-established process that results in relatively minor metallurgical modifications in workpieces due to the ability of EBW to pass high-density energy to the related substance. The present study aims to evaluate structural properties of EB-welded AlSi10Mg thin-walled pressure vessels produced from components prepared by SLM technology. Following the EB welding process, leak and burst tests were conducted, as was fractography analysis. The welded vessels showed an acceptable holding pressure of 30 MPa, with a reasonable residual deformation up to 2.3% and a leak rate better than 1 × 10-8 std-cc s-1 helium. The failures that occurred under longitudinal stresses reflected the presence of two weak locations in the vessels, i.e., the welded joint region and the transition zone between the vessel base and wall. Fractographic analysis of the fracture surfaces of broken vessels displayed the ductile mode of the rupture, with dimples of various sizes, depending on the failure location.

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

PubMed Central

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

2016-01-01

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

Effect of acoustic softening on the thermal-mechanical process of ultrasonic welding.

PubMed

Chen, Kunkun; Zhang, Yansong; Wang, Hongze

2017-03-01

Application of ultrasonic energy can reduce the static stress necessary for plastic deformation of metallic materials to reduce forming load and energy, namely acoustic softening effect (ASE). Ultrasonic welding (USW) is a rapid joining process utilizing ultrasonic energy to form a solid state joint between two or more pieces of metals. Quantitative characterization of ASE and its influence on specimen deformation and heat generation is essential to clarify the thermal-mechanical process of ultrasonic welding. In the present work, experiments were set up to found out mechanical behavior of copper and aluminum under combined effect of compression force and ultrasonic energy. Constitutive model was proposed and numerical implemented in finite element model of ultrasonic welding. Thermal-mechanical analysis was put forward to explore the effect of ultrasonic energy on the welding process quantitatively. Conclusions can be drawn that ASE increases structural deformation significantly, which is beneficial for joint formation. Meanwhile, heat generation from both frictional work and plastic deformation is slightly influenced by ASE. Based on the proposed model, relationship between ultrasonic energy and thermal-mechanical behavior of structure during ultrasonic welding was constructed. Copyright © 2016 Elsevier B.V. All rights reserved.

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

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

Ghomashchi, Reza, E-mail: reza.ghomashchi@adelaide.edu.au; Costin, Walter; Kurji, Rahim

2015-09-15

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

On the Similarity of Deformation Mechanisms During Friction Stir Welding and Sliding Friction of the AA5056 Alloy

NASA Astrophysics Data System (ADS)

Kolubaev, A. V.; Zaikina, A. A.; Sizova, O. V.; Ivanov, K. V.; Filippov, A. V.; Kolubaev, E. A.

2018-04-01

A comparative investigation of the structure of an aluminum-manganese alloy is performed after its friction stir welding and sliding friction. Using the methods of optical and electron microscopy, it is shown that during friction identical ultrafine-grained structures are formed in the weld nugget and in the surface layer, in which the grains measure 5 μm irrespective of the initial grain size of the alloy. An assumption is made that the microstructure during both processes under study is formed by the mechanism of rotational plasticity.

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.

Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures

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

Brust, Frederick W.; Punch, Edward F.; Twombly, Elizabeth Kurth

This report summarizes the final product developed for the US DOE Small Business Innovation Research (SBIR) Phase II grant made to Engineering Mechanics Corporation of Columbus (Emc 2) between April 16, 2014 and August 31, 2016 titled ‘Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures’. Many US companies have moved fabrication and production facilities off shore because of cheaper labor costs. A key aspect in bringing these jobs back to the US is the use of technology to render US-made fabrications more cost-efficient overall with higher quality. One significant advantage thatmore » has emerged in the US over the last two decades is the use of virtual design for fabrication of small and large structures in weld fabrication industries. Industries that use virtual design and analysis tools have reduced material part size, developed environmentally-friendly fabrication processes, improved product quality and performance, and reduced manufacturing costs. Indeed, Caterpillar Inc. (CAT), one of the partners in this effort, continues to have a large fabrication presence in the US because of the use of weld fabrication modeling to optimize fabrications by controlling weld residual stresses and distortions and improving fatigue, corrosion, and fracture performance. This report describes Emc 2’s DOE SBIR Phase II final results to extend an existing, state-of-the-art software code, Virtual Fabrication Technology (VFT®), currently used to design and model large welded structures prior to fabrication - to a broader range of products with widespread applications for small and medium-sized enterprises (SMEs). VFT® helps control distortion, can minimize and/or control residual stresses, control welding microstructure, and pre-determine welding parameters such as weld-sequencing, pre-bending, thermal-tensioning, etc. VFT® uses material properties, consumable properties, etc. as inputs. Through VFT®, manufacturing companies can avoid costly design changes after fabrication. This leads to the concept of joint design/fabrication where these important disciplines are intimately linked to minimize fabrication costs. Finally service performance (such as fatigue, corrosion, and fracture/damage) can be improved using this product. Emc 2’s DOE SBIR Phase II effort successfully adapted VFT® to perform efficiently in an HPC environment independent of commercial software on a platform to permit easy and cost effective access to the code. This provides the key for SMEs to access this sophisticated and proven methodology that is quick, accurate, cost effective and available “on-demand” to address weld-simulation and fabrication problems prior to manufacture. In addition, other organizations, such as Government agencies and large companies, may have a need for spot use of such a tool. The open source code, WARP3D, a high performance finite element code used in fracture and damage assessment of structures, was significantly modified so computational weld problems can be solved efficiently on multiple processors and threads with VFT®. The thermal solver for VFT®, based on a series of closed form solution approximations, was extensively enhanced for solution on multiple processors greatly increasing overall speed. In addition, the graphical user interface (GUI) was re-written to permit SMEs access to an HPC environment at the Ohio Super Computer Center (OSC) to integrate these solutions with WARP3D. The GUI is used to define all weld pass descriptions, number of passes, material properties, consumable properties, weld speed, etc. for the structure to be modeled. The GUI was enhanced to make it more user-friendly so that non-experts can perform weld modeling. Finally, an extensive outreach program to market this capability to fabrication companies was performed. This access will permit SMEs to perform weld modeling to improve their competitiveness at a reasonable cost.« less

Small-scale explosive seam welding. [using ribbon explosive encased in lead sheath

NASA Technical Reports Server (NTRS)

Bement, L. J.

1972-01-01

A unique small scale explosive seam welding technique is reported that has successfully joined a variety of aluminum alloys and alloy combinations in thicknesses to 0.125 inch, as well as titanium in thicknesses to 0.056 inch. The explosively welded joints are less than one-half inch in width and apparently have no long length limitation. The ribbon explosive developed in this study contains very small quantities of explosive encased in a flexible thin lead sheath. The evaluation and demonstration of this welding technique was accomplished in three phases: evaluation and optimization of ten major explosive welding variables, the development of four weld joints, and an applicational analysis which included photomicrographs, pressure integrity tests, vacuum effects, and fabrication of some potentially useful structures in aluminum and titanium.

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

NASA Technical Reports Server (NTRS)

Jemian, W. A.

1985-01-01

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

Weld-brazing - a new joining process. [combination resistance spot welding and brazing of titanium alloys

NASA Technical Reports Server (NTRS)

Bales, T. T.; Royster, D. M.; Arnold, W. E., Jr.

1972-01-01

A joining process designated weld brazing which combines resistance spot welding and brazing has been developed. Resistance spot welding is used to position and align the parts as well as to establish a suitable faying surface gap for brazing. Fabrication is then completed by capillary flow of the braze alloy into the joint. The process has been used successfully to fabricate Ti-6Al-4V titanium alloy joints using 3003 aluminum braze alloy. Test results obtained on single overlap and hat-stiffened structural specimens show that weld brazed joints are superior in tensile shear, stress rupture, fatigue, and buckling than joint fabricated by spotwelding or brazing. Another attractive feature of the process is that the brazed joints is hermetically sealed by the braze material.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

New Tool Creates a Big Stir

NASA Technical Reports Server (NTRS)

2001-01-01

A new self-adjusting, retractable pin tool for friction stir welding is now used in the manufacturing of components for NASA Space Shuttles. Friction stir welding is a process that makes straight-line welds without bringing the parent material to a liquid state. This is accomplished through high-speed rotation, which generates frictional heat between the welding tool and the piece being welded. This heat causes the material to soften to the point of plasticity without allowing it to melt. The plasticized material is then transferred from the front edge of the welding tool to the trail edge, where it joins the pieces being welded. However, a major flaw of this method is its reliance on a single-piece pin tool. The weld is left unfinished and a hole remains where the pin was inserted. The hole must be covered with a rivet in order to preserve the integrity of the weld. The NASA-developed pin tool, however, eliminates the need for this finishing step, as its retraction allows continuous rewelding at lesser depths, until the hole is completely closed. With this NASA technology, welding of higher strength alloys, as well as non-planer and variable thickness structures can be achieved.

Critical Initial Flaw Size Analysis

NASA Technical Reports Server (NTRS)

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

2008-01-01

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

Modeling of plasma and thermo-fluid transport in hybrid welding

NASA Astrophysics Data System (ADS)

Ribic, Brandon D.

Hybrid welding combines a laser beam and electrical arc in order to join metals within a single pass at welding speeds on the order of 1 m min -1. Neither autonomous laser nor arc welding can achieve the weld geometry obtained from hybrid welding for the same process parameters. Depending upon the process parameters, hybrid weld depth and width can each be on the order of 5 mm. The ability to produce a wide weld bead increases gap tolerance for square joints which can reduce machining costs and joint fitting difficulty. The weld geometry and fast welding speed of hybrid welding make it a good choice for application in ship, pipeline, and aerospace welding. Heat transfer and fluid flow influence weld metal mixing, cooling rates, and weld bead geometry. Cooling rate affects weld microstructure and subsequent weld mechanical properties. Fluid flow and heat transfer in the liquid weld pool are affected by laser and arc energy absorption. The laser and arc generate plasmas which can influence arc and laser energy absorption. Metal vapors introduced from the keyhole, a vapor filled cavity formed near the laser focal point, influence arc plasma light emission and energy absorption. However, hybrid welding plasma properties near the opening of the keyhole are not known nor is the influence of arc power and heat source separation understood. A sound understanding of these processes is important to consistently achieving sound weldments. By varying process parameters during welding, it is possible to better understand their influence on temperature profiles, weld metal mixing, cooling rates, and plasma properties. The current literature has shown that important process parameters for hybrid welding include: arc power, laser power, and heat source separation distance. However, their influence on weld temperatures, fluid flow, cooling rates, and plasma properties are not well understood. Modeling has shown to be a successful means of better understanding the influence of processes parameters on heat transfer, fluid flow, and plasma characteristics for arc and laser welding. However, numerical modeling of laser/GTA hybrid welding is just beginning. Arc and laser welding plasmas have been previously analyzed successfully using optical emission spectroscopy in order to better understand arc and laser plasma properties as a function of plasma radius. Variation of hybrid welding plasma properties with radial distance is not known. Since plasma properties can affect arc and laser energy absorption and weld integrity, a better understanding of the change in hybrid welding plasma properties as a function of plasma radius is important and necessary. Material composition influences welding plasma properties, arc and laser energy absorption, heat transfer, and fluid flow. The presence of surface active elements such as oxygen and sulfur can affect weld pool fluid flow and bead geometry depending upon the significance of heat transfer by convection. Easily vaporized and ionized alloying elements can influence arc plasma characteristics and arc energy absorption. The effects of surface active elements on heat transfer and fluid flow are well understood in the case of arc and conduction mode laser welding. However, the influence of surface active elements on heat transfer and fluid flow during keyhole mode laser welding and laser/arc hybrid welding are not well known. Modeling has been used to successfully analyze the influence of surface active elements during arc and conduction mode laser welding in the past and offers promise in the case of laser/arc hybrid welding. A critical review of the literature revealed several important areas for further research and unanswered questions. (1) The understanding of heat transfer and fluid flow during hybrid welding is still beginning and further research is necessary. (2) Why hybrid welding weld bead width is greater than that of laser or arc welding is not well understood. (3) The influence of arc power and heat source separation distance on cooling rates during hybrid welding are not known. (4) Convection during hybrid welding is not well understood despite its importance to weld integrity. (5) The influence of surface active elements on weld geometry, weld pool temperatures, and fluid flow during high power density laser and laser/arc hybrid welding are not known. (6) Although the arc power and heat source separation distance have been experimentally shown to influence arc stability and plasma light emission during hybrid welding, the influence of these parameters on plasma properties is unknown. (7) The electrical conductivity of hybrid welding plasmas is not known, despite its importance to arc stability and weld integrity. In this study, heat transfer and fluid flow are analyzed for laser, gas tungsten arc (GTA), and laser/GTA hybrid welding using an experimentally validated three dimensional phenomenological model. By evaluating arc and laser welding using similar process parameters, a better understanding of the hybrid welding process is expected. The role of arc power and heat source separation distance on weld depth, weld pool centerline cooling rates, and fluid flow profiles during CO2 laser/GTA hybrid welding of 321 stainless steel are analyzed. Laser power is varied for a constant heat source separation distance to evaluate its influence on weld temperatures, weld geometry, and fluid flow during Nd:YAG laser/GTA hybrid welding of A131 structural steel. The influence of oxygen and sulfur on keyhole and weld bead geometry, weld temperatures, and fluid flow are analyzed for high power density Yb doped fiber laser welding of (0.16 %C, 1.46 %Mn) mild steel. Optical emission spectroscopy was performed on GTA, Nd:YAG laser, and Nd:YAG laser/GTA hybrid welding plasmas for welding of 304L stainless steel. Emission spectroscopy provides a means of determining plasma temperatures and species densities using deconvoluted measured spectral intensities, which can then be used to calculate plasma electrical conductivity. In this study, hybrid welding plasma temperatures, species densities, and electrical conductivities were determined using various heat source separation distances and arc currents using an analytical method coupled calculated plasma compositions. As a result of these studies heat transfer by convection was determined to be dominant during hybrid welding of steels. The primary driving forces affecting hybrid welding fluid flow are the surface tension gradient and electromagnetic force. Fiber laser weld depth showed a negligible change when increasing the (0.16 %C, 1.46 %Mn) mild steel sulfur concentration from 0.006 wt% to 0.15 wt%. Increasing the dissolved oxygen content in weld pool from 0.0038 wt% to 0.0257 wt% increased the experimental weld depth from 9.3 mm to 10.8 mm. Calculated partial pressure of carbon monoxide increased from 0.1 atm to 0.75 atm with the 0.0219 wt% increase in dissolved oxygen in the weld metal and may explain the increase in weld depth. Nd:YAG laser/GTA hybrid welding plasma temperatures were calculated to be approximately between 7927 K and 9357 K. Increasing the Nd:YAG laser/GTA hybrid welding heat source separation distance from 4 mm to 6 mm reduced plasma temperatures between 500 K and 900 K. Hybrid welding plasma total electron densities and electrical conductivities were on the order of 1 x 1022 m-3 and 3000 S m-1, respectively.

The effect of welding parameters on high-strength SMAW all-weld-metal. Part 1: AWS E11018-M

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

Vercesi, J.; Surian, E.

Three AWS A5.5-81 all-weld-metal test assemblies were welded with an E110180-M electrode from a standard production batch, varying the welding parameters in such a way as to obtain three energy inputs: high heat input and high interpass temperature (hot), medium heat input and medium interpass temperature (medium) and low heat input and low interpass temperature (cold). Mechanical properties and metallographic studies were performed in the as-welded condition, and it was found that only the tensile properties obtained with the test specimen made with the intermediate energy input satisfied the AWS E11018-M requirements. With the cold specimen, the maximal yield strengthmore » was exceeded, and with the hot one, neither the yield nor the tensile minimum strengths were achieved. The elongation and the impact properties were high enough to fulfill the minimal requirements, but the best Charpy-V notch values were obtained with the intermediate energy input. Metallographic studies showed that as the energy input increased the percentage of the columnar zones decreased, the grain size became larger, and in the as-welded zone, there was a little increment of both acicular ferrite and ferrite with second phase, with a consequent decrease of primary ferrite. These results showed that this type of alloy is very sensitive to the welding parameters and that very precise instructions must be given to secure the desired tensile properties in the all-weld-metal test specimens and under actual working conditions.« less

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

NASA Astrophysics Data System (ADS)

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

2002-04-01

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

Phase-field simulation of weld solidification microstructure in an Al Cu alloy

NASA Astrophysics Data System (ADS)

Farzadi, A.; Do-Quang, M.; Serajzadeh, S.; Kokabi, A. H.; Amberg, G.

2008-09-01

Since the mechanical properties and the integrity of the weld metal depend on the solidification behaviour and the resulting microstructural characteristics, understanding weld pool solidification is of importance to engineers and scientists. Thermal and fluid flow conditions affect the weld pool geometry and solidification parameters. During solidification of the weld pool, a columnar grain structure develops in the weld metal. Prediction of the formation of the microstructure during welding may be an important and supporting factor for technology optimization. Nowadays, increasing computing power allows direct simulations of the dendritic and cell morphology of columnar grains in the molten zone for specific temperature conditions. In this study, the solidification microstructures of the weld pool at different locations along the fusion boundary are simulated during gas tungsten arc welding of Al-3wt%Cu alloy using the phase-field model for the directional solidification of dilute binary alloys. A macroscopic heat transfer and fluid flow model was developed to assess the solidification parameters, notably the temperature gradient and solidification growth rate. The effect of the welding speed is investigated. Computer simulations of the solidification conditions and the formation of a cellular morphology during the directional solidification in gas tungsten arc welding are described. Moreover, the simulation results are compared with existing theoretical models and experimental findings.

Working, Welding and Structural Drafting, Drafting--Intermediate: 9255.03.

ERIC Educational Resources Information Center

Dade County Public Schools, Miami, FL.

The course introduces the student to working welding drawings, both detail and assembly, as related to all fields of drafting and structural drafting, and provides him with the opportunity to work with various types of tools and equipment. Prior to entry in this course, the vocational student must display mastery of the skills indicated in…

Limit load solution for electron beam welded joints with single edge weld center crack in tension

NASA Astrophysics Data System (ADS)

Lu, Wei; Shi, Yaowu; Li, Xiaoyan; Lei, Yongping

2012-05-01

Limit loads are widely studied and several limit load solutions are proposed to some typical geometry of weldments. However, there are no limit load solutions exist for the single edge crack weldments in tension (SEC(T)), which is also a typical geometry in fracture analysis. The mis-matching limit load for thick plate with SEC(T) are investigated and the special limit load solutions are proposed based on the available mis-matching limit load solutions and systematic finite element analyses. The real weld configurations are simplified as a strip, and different weld strength mis-matching ratio M, crack depth/width ratio a/ W and weld width 2H are in consideration. As a result, it is found that there exists excellent agreement between the limit load solutions and the FE results for almost all the mis-matching ration M, a/ W and ligament-to-weld width ratio ( W-a)/ H. Moreover, useful recommendations are given for evaluating the limit loads of the EBW structure with SEC(T). For the EBW joints with SEC(T), the mis-matching limit loads can be obtained assuming that the components are wholly made of base metal, when M changing from 1.6 to 0.6. When M decreasing to 0.4, the mis-matching limit loads can be obtained assuming that the components are wholly made of base metal only for large value of ( W-a)/ H. The recommendations may be useful for evaluating the limit loads of the EBW structures with SEC(T). The engineering simplifications are given for assessing the limit loads of electron beam welded structure with SEC(T).

Microstructure Stability During Creep of Friction Stir Welded AA2024-T3 Alloy

NASA Astrophysics Data System (ADS)

Regev, Michael; Rashkovsky, Tal; Cabibbo, Marcello; Spigarelli, Stefano

2018-01-01

The poor weldability of the AA2024 aluminum alloy limits its use in industrial applications. Because friction stir welding (FSW) is a non-fusion welding process, it seems to be a promising solution for welding this alloy. In the current study, FSW was applied to butt weld AA2024-T3 aluminum alloy plates. Creep tests were conducted at 250 and at 315 °C on both the parent material and the friction stir welded specimens. The microstructures of the welded and non-welded AA2024-T3 specimens before and after the creep tests were studied and compared. A comprehensive transmission electron microscopy study together with a high-resolution scanning electron microscopy study and energy-dispersive x-ray spectroscopy analysis was conducted to investigate the microstructure stability. The parent material seems to contain two kinds of Cu-rich precipitates—coarse precipitates of a few microns each and uniformly dispersed fine nanosized precipitates. Unlike the parent material, the crept specimens were found to contain the two kinds of precipitates mentioned above together with platelet-like precipitates. In addition, extensive decoration of the grain boundaries with precipitates was clearly observed in the crept specimens. Controlled aging experiments for up to 280 h at the relevant temperatures were conducted on both the parent material and the welded specimens in order to isolate the contribution of exposure to high temperatures to the microstructure changes. TEM study showed the development of dislocation networks into a cellular dislocation structure in the case of the parent metal. Changes in the dislocation structure as a function of the creep strain and the FSW process were recorded. A detailed creep data analysis was conducted, taking into account the instability of the microstructure.

Calculation methods study on hot spot stress of new girder structure detail

NASA Astrophysics Data System (ADS)

Liao, Ping; Zhao, Renda; Jia, Yi; Wei, Xing

2017-10-01

To study modeling calculation methods of new girder structure detail's hot spot stress, based on surface extrapolation method among hot spot stress method, a few finite element analysis models of this welded detail were established by finite element software ANSYS. The influence of element type, mesh density, different local modeling methods of the weld toe and extrapolation methods was analyzed on hot spot stress calculation results at the toe of welds. The results show that the difference of the normal stress in the thickness direction and the surface direction among different models is larger when the distance from the weld toe is smaller. When the distance from the toe is greater than 0.5t, the normal stress of solid models, shell models with welds and non-weld shell models tends to be consistent along the surface direction. Therefore, it is recommended that the extrapolated point should be selected outside the 0.5t for new girder welded detail. According to the results of the calculation and analysis, shell models have good grid stability, and extrapolated hot spot stress of solid models is smaller than that of shell models. So it is suggested that formula 2 and solid45 should be carried out during the hot spot stress extrapolation calculation of this welded detail. For each finite element model under different shell modeling methods, the results calculated by formula 2 are smaller than those of the other two methods, and the results of shell models with welds are the largest. Under the same local mesh density, the extrapolated hot spot stress decreases gradually with the increase of the number of layers in the thickness direction of the main plate, and the variation range is within 7.5%.

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

NASA Astrophysics Data System (ADS)

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

2018-02-01

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

Flexible Trailing Shield for Welding Reactive Metals.

DTIC Science & Technology

torch, a conduit for receiving gas into the housing, a foraminous material to uniformly distribute the gas within the housing, and a pervious structure through which the gas is dispersed over the weld surface.

Compression Buckling Behavior of Large-Scale Friction Stir Welded and Riveted 2090-T83 Al-Li Alloy Skin-Stiffener Panels

NASA Technical Reports Server (NTRS)

Hoffman, Eric K.; Hafley, Robert A.; Wagner, John A.; Jegley, Dawn C.; Pecquet, Robert W.; Blum, Celia M.; Arbegast, William J.

2002-01-01

To evaluate the potential of friction stir welding (FSW) as a replacement for traditional rivet fastening for launch vehicle dry bay construction, a large-scale friction stir welded 2090-T83 aluminum-lithium (Al-Li) alloy skin-stiffener panel was designed and fabricated by Lockheed-Martin Space Systems Company - Michoud Operations (LMSS) as part of NASA Space Act Agreement (SAA) 446. The friction stir welded panel and a conventional riveted panel were tested to failure in compression at the NASA Langley Research Center (LaRC). The present paper describes the compression test results, stress analysis, and associated failure behavior of these panels. The test results provide useful data to support future optimization of FSW processes and structural design configurations for launch vehicle dry bay structures.

NDE and DE of PWSCC Found in the J-Groove Weld of a Removed-From-Service Control Rod Drive Mechanism

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

Cumblidge, Stephen E.; Doctor, Steven R.; Schuster, George J.

2008-01-01

Studies conducted at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington focused on assessing the effectiveness of nondestructive examination (NDE) techniques for inspecting control rod drive mechanism (CRDM) nozzles and J-groove weldments. The primary objective of this work is to provide information to the United States Nuclear Regulatory Commission (US NRC) on the effectiveness of NDE methods as related to the in-service inspection of CRDM nozzles and J-groove weldments, and to enhance the knowledge base of primary water stress corrosion cracking (PWSCC) through destructive characterization of the CRDM assemblies. Two CRDM assemblies were removed from service, decontaminated, and thenmore » used in a series of laboratory NDE and DE measurements; this report addresses the following questions: 1) What did each NDE technique detect?, 2) What did each NDE technique miss?, 3) How accurately did each NDE technique characterize the detected flaws?, and finally 4) What were the basis for the NDE techniques performance? Two CRDM assemblies including the CRDM nozzle, the J-groove weld, buttering, and a portion of the ferritic head material were selected for this study. This paper focuses on a CRDM assembly that contained suspected PWSCC, based on in-service inspection data and through-wall leakage. The laboratory NDE measurements used to examine the CRDM assembly followed standard industry techniques for conducting in-service inspections of CRDM nozzles and the crown of the J-groove welds and buttering. These techniques included eddy current testing, time of flight diffraction ultrasound, and penetrant testing. In addition, other laboratory-based NDE methods were employed to conduct inspections of the CRDM assembly with particular emphasis on inspecting the J-groove weld and buttering. These techniques included volumetric ultrasonic inspection of the J-groove weld metal, visual testing via replicant material of the J-groove weld and high resolution photography of the J-groove weld crown and buttering. The results from these NDE studies were used to guide the development of the destructive characterization plan. The NDE studies found several crack-like indications. The NDE and DE studies determined that one of these was a through-weld radially-oriented PWSCC crack in the wetted surface of the J-groove weld, located at the transition point between the weld and the buttering. The crack was 6 mm long on the surface and quickly grew to 25 mm long at a depth of 8 mm, covering the length of the weld between the penetration tube and the carbon steel. The NDE studies found that only ET was able to detect the through-weld crack. The crack was oriented poorly for the ultrasonic testing, and was too tight for accurate PT or VT. The ET voltage response of the flaw was 30% that of a deep EDM notch. The DE performed on the crack consisted of slicing the crack into thin sections, polishing the sections, and then using optical and scanning electron microscopy (SEM) to characterize the crack. DE shows the crack was PWSCC and that it initiated on the wetted surface, grew and expanded through the weld metal, and exited into the annulus. The SEM examinations showed the crack followed the weld grain boundaries as it progressed through the weld. The crack was branched and discontinuous along its length.« less

Experimental Investigation of Tensile Test on Connection of Cold-formed Cut-curved Steel Section

NASA Astrophysics Data System (ADS)

Sani, Mohd Syahrul Hisyam Mohd; Muftah, Fadhluhartini; Rahman, Nurul Farraheeda Abdul; Fakri Muda, Mohd

2017-08-01

Cold-formed steel (CFS) is widely used as structural and non-structural components such as roof trusses and purlin. A CFS channel section with double intermediate web stiffener and lipped is chosen based on the broader usage in roof truss construction. CFS section is cut to form cold-formed pre-cut-curved steel section and lastly strengthened by several types of method or likely known as connection to establish the cold-formed cut-curved steel (CFCCS) section. CFCCS is proposed to be used as a top chord section in the roof truss system. The CFCCS is to resist the buckling phenomena of the roof truss structure and reduced the compression effect on the top chord. The tensile test connection of CFCCS section, especially at the flange element with eight types of connection by welding, plate with self-drilling screw and combination is investigated. The flange element is the weakest part that must be solved first other than the web element because they are being cut totally, 100% of their length for curving process. The testing is done using a universal testing machine for a tensile load. From the experiment, specimen with full welding has shown as a good result with an ultimate load of 13.37 kN and reported having 35.41% when compared with normal specimen without any of connection methods. Furthermore, the experimental result is distinguished by using Eurocode 3. The failure of a full welding specimen is due to breaking at the welding location. Additionally, all specimens with either full weld or spot weld or combination failed due to breaking on weld connection, but specimen with flange plate and self-drilling screw failed due to tilting and bearing. Finally, the full welding specimen is chosen as a good connection to perform the strengthening method of CFCCS section.

Room temperature crack growth rates and -20 deg F fracture toughness of welded 1 1/4 inch A-285 steel plate

NASA Technical Reports Server (NTRS)

Shannon, J. L., Jr.; Rzasnicki, W.

1977-01-01

Data are presented which were developed in support of a structural assessment of NASA-LEWIS' 10-foot by 10-foot supersonic wind tunnel, critical portions of which are fabricated from rolled and welded 1 1/4 inch thick A-285 steel plate. Test material was flame cut from the tunnel wall and included longitudinal and circumferential weld joints. Parent metal, welds, and weld heat affected zone were tested. Tensile strength and fracture toughness were determined at -20 F, the estimated lowest tunnel operating temperature. Crack growth rates were measured at room temperature, where growth rates in service are expected to be highest.

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

PubMed Central

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-01-01

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique–ultrasonic spot welding (USW)–at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with “river-flow” patterns and characteristic fatigue striations. PMID:28772809

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy.

PubMed

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-04-25

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique-ultrasonic spot welding (USW)-at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with "river-flow" patterns and characteristic fatigue striations.

Evaluation of a self-equilibrium cutting strategy for the contour method of residual stress measurement

DOE PAGES

Muránsky, Ondrej; Hamelin, Cory J.; Hosseinzadeh, F.; ...

2017-04-06

An assessment of cutting-induced plasticity (CIP) is performed, by finite element (FE) prediction of the plastic strain accumulation along the cut tip when the EDM wire sections the NeT TG4 weld benchmark specimen along two cutting directions. The first direction corresponds to a conventional (C) cutting strategy, whereby the EDM wire cuts through the thickness of the weld specimen and travels in a direction transverse to the weld. The second direction corresponds to a self-equilibrating cutting (SE) strategy, whereby the EDM wire cuts across the transverse direction of the weld specimens and travels through the thickness of the plate. Themore » cutting thus progresses simultaneously through the compression-tension-compression regions of present weld residual stress (WRS) field. This type of cutting strategy is believed to minimize the CIP by minimising residual stress redistribution during cutting, due to stress equilibration across the sectioned material. The simulated cutting procedures are conducted under a range of clamping conditions to assess whether mechanical restraint has a primary or secondary influence on CIP accumulation. Both predictions of CIP and the resultant back-calculated WRS demonstrate that (i) mechanical restraint is the primary variable influencing CIP development, and (ii) under no circumstance does a self-equilibrating cutting strategy perform significantly better than a conventional cutting approach. Furthermore, the reason that self-equilibrating cuts are not effective is illustrated by calculating the Mode I (K I) stress intensity factor (SIF) along the cut tip, and correlating trends in K I to CIP development.« less

Evaluation of a self-equilibrium cutting strategy for the contour method of residual stress measurement

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

Muránsky, Ondrej; Hamelin, Cory J.; Hosseinzadeh, F.

An assessment of cutting-induced plasticity (CIP) is performed, by finite element (FE) prediction of the plastic strain accumulation along the cut tip when the EDM wire sections the NeT TG4 weld benchmark specimen along two cutting directions. The first direction corresponds to a conventional (C) cutting strategy, whereby the EDM wire cuts through the thickness of the weld specimen and travels in a direction transverse to the weld. The second direction corresponds to a self-equilibrating cutting (SE) strategy, whereby the EDM wire cuts across the transverse direction of the weld specimens and travels through the thickness of the plate. Themore » cutting thus progresses simultaneously through the compression-tension-compression regions of present weld residual stress (WRS) field. This type of cutting strategy is believed to minimize the CIP by minimising residual stress redistribution during cutting, due to stress equilibration across the sectioned material. The simulated cutting procedures are conducted under a range of clamping conditions to assess whether mechanical restraint has a primary or secondary influence on CIP accumulation. Both predictions of CIP and the resultant back-calculated WRS demonstrate that (i) mechanical restraint is the primary variable influencing CIP development, and (ii) under no circumstance does a self-equilibrating cutting strategy perform significantly better than a conventional cutting approach. Furthermore, the reason that self-equilibrating cuts are not effective is illustrated by calculating the Mode I (K I) stress intensity factor (SIF) along the cut tip, and correlating trends in K I to CIP development.« less

Zirconium as a Structural Material for Naval Systems

DTIC Science & Technology

1985-03-29

case with the technologically critical chemical elements chromium and cobalt, for example, from a military perspective. The case, therefore, for...By adding small amounts of tin, iron, nickel, and chromium , the impurities were effectively bound or coalesced within the metal and the corrosion...and nitrogen from the atmosphere, embrittling the weld. The techniques used for zirconium welding are gas tungsten arc welding ( GTAW ), tungsten inert

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

NASA Astrophysics Data System (ADS)

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

2011-01-01

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

Effect of A-TIG Welding Process on the Weld Attributes of Type 304LN and 316LN Stainless Steels

NASA Astrophysics Data System (ADS)

Vasudevan, M.

2017-03-01

The specific activated flux has been developed for enhancing the penetration performance of TIG welding process for autogenous welding of type 304LN and 316LN stainless steels through systematic study. Initially single-component fluxes were used to study their effect on depth of penetration and tensile properties. Then multi-component activated flux was developed which was found to produce a significant increase in penetration of 10-12 mm in single-pass TIG welding of type 304LN and 316LN stainless steels. The significant improvement in penetration achieved using the activated flux developed in the present work has been attributed to the constriction of the arc and as well as reversal of Marangoni flow in the molten weld pool. The use of activated flux has been found to overcome the variable weld penetration observed in 316LN stainless steel with <50 ppm of sulfur. There was no degradation in the microstructure and mechanical properties of the A-TIG welds compared to that of the welds produced by conventional TIG welding on the contrary the transverse strength properties of the 304LN and 316LN stainless steel welds produced by A-TIG welding exceeded the minimum specified strength values of the base metals. Improvement in toughness values were observed in 316LN stainless steel produced by A-TIG welding due to refinement in the weld microstructure in the region close to the weld center. Thus, activated flux developed in the present work has greater potential for use during the TIG welding of structural components made of type 304LN and 316LN stainless steels.

Effect of laser beam offset on microstructure and mechanical properties of pulsed laser welded BTi-6431S/TA15 dissimilar titanium alloys

NASA Astrophysics Data System (ADS)

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

2015-11-01

Laser beam welding was used to weld dissimilar joints in BTi-6431S/TA15 titanium alloys. The effect of laser beam offset on microstructural characterizations and mechanical properties of the joints were investigated. Microstructural evolution of the joints was characterized by optical microscopy (OM) and X-ray diffraction (XRD). Tensile testing was conducted at room temperature and at 550 °C. The results demonstrated that with the exception of some porosity, a good quality joint could be achieved. Martensite α' and acicular α structures were present in the fusion zone (FZ). The amount of martensite α' present with the -0.2 mm beam offset was less than that with the 0.2 mm beam offset. Acicular α and martensite α' transformations occurred in the high temperature heat-affected zone (HT-HAZ) of both the BTi-6431S and TA15 alloys. In the low-temperature heat-affected zone (LT-HAZ), the BTi-6431S and TA15 alloy microstructures exhibited a mixture of secondary α, primary α, and prior β phases. The microhardness values in the FZ followed the order: -0.2 mm> 0 mm> 0.2 mm. Tensile testing at room temperature and at 550 °C resulted in fracture of the TA15 alloy base metal. The fracture morphology exhibited a ductile dimple feature.

Texture Development and Material Flow Behavior During Refill Friction Stir Spot Welding of AlMgSc

NASA Astrophysics Data System (ADS)

Shen, Junjun; Lage, Sara B. M.; Suhuddin, Uceu F. H.; Bolfarini, Claudemiro; dos Santos, Jorge F.

2018-01-01

The microstructural evolution during refill friction stir spot welding of an AlMgSc alloy was studied. The primary texture that developed in all regions, with the exception of the weld center, was determined to be 〈110〉 fibers and interpreted as a simple shear texture with the 〈110〉 direction aligned with the shear direction. The material flow is mainly driven by two components: the simple shear acting on the horizontal plane causing an inward-directed spiral flow and the extrusion acting on the vertical plane causing an upward-directed or downward-directed flow. Under such a complex material flow, the weld center, which is subjected to minimal local strain, is the least recrystallized. In addition to the geometric effects of strain and grain subdivision, thermally activated high-angle grain boundary migration, particularly continuous dynamic recrystallization, drives the formation of refined grains in the stirred zone.

Transitional behaviour of thickness effects in shipbuilding materials (MS plate)

NASA Astrophysics Data System (ADS)

Mahmud, S. M. Ikhtiar; Razib, Amirul Hasan; Rahman, Md. Rabab Raiyatur

2017-12-01

Majority of the crack propagation in ships and offshore structures are caused due to fatigue. Previously, it was known that fatigue strength of notched specimen is dependent on size, but recently it came to light that fatigue strength of some welded joints depends on the thickness. Much investigation is done on the fatigue growth of welded joints. Fatigue often results in fracture accidents, which starts from the sites of structural discontinuities because of the reason that they may induce local stress concentrations. Structural discontinuities include notches, holes, sharp corners, and weld defects. Weld defects include undercut, porosity, lack of fusion, slag inclusion, incomplete weld root penetration, and misalignments. In order to investigate the effects of plate thickness on fatigue strength, semi-elliptical side notches (U and V shaped) in plates are studied in the present research. First consider a simple problem of crack emanating from notches in plates where the solution of stress intensity factor is given by an empirical formula so that the thickness effect on fatigue strength can easily be investigated for a variety of geometrical parameters. The present study aims to investigate the transitional behaviour of thickness effect in plates on fatigue strength. In order to calculate the stress, finite element analysis is carried by using ANSYS.

Development of a pseudo phased array technique using EMATs for DM weld testing

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

Cobb, Adam C., E-mail: adam.cobb@swri.org; Fisher, Jay L., E-mail: adam.cobb@swri.org; Shiokawa, Nobuyuki

2015-03-31

Ultrasonic inspection of dissimilar metal (DM) welds in piping with cast austenitic stainless steel (CASS) has been an area ongoing research for many years given its prevalence in the petrochemical and nuclear industries. A typical inspection strategy for pipe welds is to use an ultrasonic phased array system to scan the weld from a sensor located on the outer surface of the pipe. These inspection systems generally refract either longitudinal or shear vertical (SV) waves at varying angles to inspect the weld radially. In DM welds, however, the welding process can produce a columnar grain structure in the CASS materialmore » in a specific orientation. This columnar grain structure can skew ultrasonic waves away from their intended path, especially for SV and longitudinal wave modes. Studies have shown that inspection using the shear horizontal (SH) wave mode significantly reduces the effect of skewing. Electromagnetic acoustic transducers (EMATs) are known to be effective for producing SH waves in field settings. This paper presents an inspection strategy that seeks to reproduce the scanning and imaging capabilities of a commercial phase array system using EMATs. A custom-built EMAT was used to collect data at multiple propagation angles, and a processing strategy known as the synthetic aperture focusing technique (SAFT) was used to combine the data to produce an image. Results are shown using this pseudo phased array technique to inspect samples with a DM weld and artificial defects, demonstrating the potential of this approach in a laboratory setting. Recommendations for future work to transition the technique to the field are also provided.« less

Evaluation of weldments in type 21-6-9 stainless steel for compact ignition tokamak structural applications, phase 1

NASA Astrophysics Data System (ADS)

Alexander, D. J.; Goodwin, G. M.; Bloom, E. E.

1991-06-01

Primary design considerations for the Compact Ignition Tokamak toroidal field-coil cases are yield strength and toughness in the temperature range from 77 to 300 K. Type 21-6-9 stainless steel, also still known by its original Armco Steel Company trade name Nitronic 40, is the proposed alloy for this application. It has high yield strength and usually adequate base metal toughness, but weldments in thick sections have not been adequately characterized in terms of mechanical properties or hot-cracking propensity. In this study, weldability of the alloy in heavy sections and the mechanical properties of the resultant welds were investigated including tensile yield strength and Charpy V-notch toughness at 77 K and room temperature. Weldments were made in four different base metals using seven different filler metals. None of the weldments showed any indication of hot-cracking problems. All base metals, including weldment heat-affected zones, were found to have adequate strength and impact toughness at both test temperatures. Weld metals, on the other hand, except ERNiCr-3 and ENiCrFe-3, had impact toughnesses of less than 67 J at 77 K. Inconel 82 had an average weld metal impact toughness of over 135 J at 77 K, and although its strength at 77 K is less than that of type 21-6-9 base metal, at this point it is considered to be the first-choice filler metal. Phase 2 of this program will concentrate on composition refinement and process/procedure optimization for the generic ERNiCr-3 composition and will generate a design data base for base and weld metal, including tensile, fracture toughness, and crack growth rate data.

The Effect of Weld Reinforcement and Post-Welding Cooling Cycles on Fatigue Strength of Butt-Welded Joints under Cyclic Tensile Loading.

PubMed

Araque, Oscar; Arzola, Nelson; Hernández, Edgar

2018-04-12

This research deals with the fatigue behavior of butt-welded joints, by considering the geometry and post-welding cooling cycles, as a result of cooling in quiet air and immersed in water. ASTM A-36 HR structural steel was used as the base metal for the shielded metal arc welding (SMAW) process with welding electrode E6013. The welding reinforcement was 1 mm and 3 mm, respectively; axial fatigue tests were carried out to determine the life and behavior in cracks propagation of the tested welded joints, mechanical characterization tests of properties in welded joints such as microhardness, Charpy impact test and metallographic analysis were carried out. The latter were used as input for the analysis by finite elements which influence the initiation and propagation of cracks and the evaluation of stress intensity factors (SIF). The latter led to obtaining the crack propagation rate and the geometric factor. The tested specimens were analyzed, by taking photographs of the cracks at its beginning in order to make a count of the marks at the origin of the crack. From the results obtained and the marks count, the fatigue crack growth rate and the influence of the cooling media on the life of the welded joint are validated, according to the experimental results. It can be concluded that the welded joints with a higher weld reinforcement have a shorter fatigue life. This is due to the stress concentration that occurs in the vicinity of the weld toe.