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.

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.

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.

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.

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.

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.

The microstructure and microhardness of friction stir welded dissimilar copper/Al-5% Mg alloys

NASA Astrophysics Data System (ADS)

Kalashnikova, T. A.; Shvedov, M. A.; Vasilyev, P. A.

2017-12-01

A friction stir welded joint between copper and aluminum alloy has been investigated and characterized for the microstructure and microhardness number distribution. The microstructural evolution of the joint is studied using optical microscopy and microhardness. The mechanical characteristics in structural zones of FSW joints are determined by Vickers microhardness measurements. Samples were cut across the cross section. It is shown that intermetallic Cu/Al particles are formed at interfaces. The intermetallics microhardness in the dissimilar aluminum/cooper FSW joint differs from that of the joint produced by fusion welding. The grain structures obtained in different dissimilar joint zones are examined.

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.

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.

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.

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.

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.

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.

Microstructure Evolution and Mechanical Properties of Underwater Dry and Local Dry Cavity Welded Joints of 690 MPa Grade High Strength Steel

PubMed Central

Sun, Kun; Cui, Shuwan; Zeng, Min; Yi, Jianglong; Shen, Xiaoqin; Yi, Yaoyong

2018-01-01

Q690E high strength low alloy (HSLA) steel plays an important role in offshore structures. In addition, underwater local cavity welding (ULCW) technique was widely used to repair important offshore constructions. However, the high cooling rate of ULCW joints results in bad welding quality compared with underwater dry welding (UDW) joints. Q690E high strength low alloy steels were welded by multi-pass UDW and ULCW techniques, to study the microstructural evolution and mechanical properties of underwater welded joints. The microstructure and fracture morphology of welded joints were observed by scanning electron microscope and optical microscope. The elemental distribution in the microstructure was determined with an Electron Probe Microanalyzer. The results indicated that the microstructure of both two welded joints was similar. However, martensite and martensite-austenite components were significantly different with different underwater welding methods such that the micro-hardness of the HAZ and FZ in the ULCW specimen was higher than that of the corresponding regions in UDW joint. The yield strength and ultimate tensile strength of the ULCW specimen are 109 MPa lower and 77 MPa lower, respectively, than those of the UDW joint. The impact toughness of the UDW joint was superior to those of the ULCW joint. PMID:29361743

Microstructure Evolution and Mechanical Properties of Underwater Dry and Local Dry Cavity Welded Joints of 690 MPa Grade High Strength Steel.

PubMed

Shi, Yonghua; Sun, Kun; Cui, Shuwan; Zeng, Min; Yi, Jianglong; Shen, Xiaoqin; Yi, Yaoyong

2018-01-22

Q690E high strength low alloy (HSLA) steel plays an important role in offshore structures. In addition, underwater local cavity welding (ULCW) technique was widely used to repair important offshore constructions. However, the high cooling rate of ULCW joints results in bad welding quality compared with underwater dry welding (UDW) joints. Q690E high strength low alloy steels were welded by multi-pass UDW and ULCW techniques, to study the microstructural evolution and mechanical properties of underwater welded joints. The microstructure and fracture morphology of welded joints were observed by scanning electron microscope and optical microscope. The elemental distribution in the microstructure was determined with an Electron Probe Microanalyzer. The results indicated that the microstructure of both two welded joints was similar. However, martensite and martensite-austenite components were significantly different with different underwater welding methods such that the micro-hardness of the HAZ and FZ in the ULCW specimen was higher than that of the corresponding regions in UDW joint. The yield strength and ultimate tensile strength of the ULCW specimen are 109 MPa lower and 77 MPa lower, respectively, than those of the UDW joint. The impact toughness of the UDW joint was superior to those of the ULCW joint.

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.

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.

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.

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.

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.

Analysing the Friction Stir Welded Joints of AA2219 Al-Cu Alloy in Different Heat-Treated-State

NASA Astrophysics Data System (ADS)

Venkateswarlu, D.; Cheepu, Muralimohan; Kranthi kumar, B.; Mahapatra, M. M.

2018-03-01

Aluminium alloy AA2219 is widely used in light weight structural applications where the good corrosion resistance and specific weight required. The fabrication of this alloy using friction stir welding process is gaining interest towards finding the characteristics of the weld metal properties, since this process involved in the welded materials does not melt and recast. In the present investigation, friction stir welding process was used for different heat treated conditions of 2219-T87 and 2219-T62 aluminium alloys to find the influence of base metal on characteristics of the joints. The experimental output results exhibited that, mechanical properties, weld metal characteristics and joint failure locations are significantly affected by the different heat treatment conditions of the substrate. The joints tensile and yield strength of the 2219-T87 welds was higher than the 2219-T62 welds. Hardness distribution in the stir zone was significantly varied between two different heat treaded material conditions. The microstructural features of the 2219-T62 welds reveal the coarse grains formation in the thermo-mechanically affected zone and heat affected zone. The joint efficiency of the 2219- T82 welds is 59.87%, while that of 2219-T62 welds is 39.10%. In addition, the elongation of the joint also varied and the joints failure location characteristics are different for two different types heat treated condition joints.

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.

Shimmed electron beam welding process

DOEpatents

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

2002-01-01

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

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.

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

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.

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.

Microstructure evolution in dissimilar AA6060/copper friction stir welded joints

NASA Astrophysics Data System (ADS)

Kalashnikova, T. A.; Shvedov, M. A.; Vasilyev, P. A.

2017-12-01

Friction stir welding process has been applied for making a dissimilar copper/aluminum alloy joint. The grain microstructure and mechanical properties of the obtained joint were studied. The structure of the cross-section of the FSW compound was analyzed. The microstructural evolution of the joint was examined using optical microscopy. The mechanical properties of the intermetallic particles were evaluated by measuring the microhardness according to the Vickers method. The microhardness of the intermetallic particles was by a factor of 4 lower than that of the particles obtained by fusion welding. The results of the investigations enable using friction stir welding for making dissimilar joints.

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.

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.

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.

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.

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

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.

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

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

Fortuna, S. V., E-mail: s-fortuna@ispms.ru; Ivanov, K. V., E-mail: ikv@ispms.ru; Eliseev, A. A., E-mail: alan@ispms.ru

2015-10-27

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

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.

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.

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.

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.

Development of the weld-braze joining process

NASA Technical Reports Server (NTRS)

Bales, T. T.; Royster, D. M.; Arnold, W. E., Jr.

1973-01-01

A joining process, designated weld-brazing, was developed which combines resistance spot welding and brazing. Resistance spot welding is used to position and aline the parts, as well as to establish a suitable faying-surface gap for brazing. Fabrication is then completed at elevated temperature by capillary flow of the braze alloy into the joint. The process was used successfully to fabricate Ti-6Al-4V alloy joints by using 3003 aluminum braze alloy and should be applicable to other metal-braze systems. Test results obtained on single-overlap and hat-stiffened panel specimens show that weld-brazed joints were superior in tensile shear, stress rupture, fatigue, and buckling compared with joints fabricated by conventional means. Another attractive feature of the process is that the brazed joint is hermetically sealed by the braze material, which may eliminate many of the sealing problems encountered with riveted or spot welded structures. The relative ease of fabrication associated with the weld-brazing process may make it cost effective over conventional joining techniques.

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.

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

NASA Astrophysics Data System (ADS)

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

2016-02-01

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

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.

Thermographic Analysis of Stress Distribution in Welded Joints

NASA Astrophysics Data System (ADS)

Piršić, T.; Krstulović Opara, L.; Domazet, Ž.

2010-06-01

The fatigue life prediction of welded joints based on S-N curves in conjunction with nominal stresses generally is not reliable. Stress distribution in welded area affected by geometrical inhomogeneity, irregular welded surface and weld toe radius is quite complex, so the local (structural) stress concept is accepted in recent papers. The aim of this paper is to determine the stress distribution in plate type aluminum welded joints, to analyze the reliability of TSA (Thermal Stress Analysis) in this kind of investigations, and to obtain numerical values for stress concentration factors for practical use. Stress distribution in aluminum butt and fillet welded joints is determined by using the three different methods: strain gauges measurement, thermal stress analysis and FEM. Obtained results show good agreement - the TSA mutually confirmed the FEM model and stresses measured by strain gauges. According to obtained results, it may be stated that TSA, as a relatively new measurement technique may in the future become a standard tool for the experimental investigation of stress concentration and fatigue in welded joints that can help to develop more accurate numerical tools for fatigue life prediction.

Influence of structure on static cracking resistance and fracture of welded joints of pipe steels of strength class K60

NASA Astrophysics Data System (ADS)

Tereshchenko, N. A.; Tabatchikova, T. I.; Yakovleva, I. L.; Makovetskii, A. N.; Shander, S. V.

2017-07-01

The static cracking resistance of a number of welded joints made from pipe steels of K60 strength class has been determined. It has been established that the deformation parameter CTOD varies significantly at identical parameters of weldability of steels. The character of fracture has been investigated and the zone of local brittleness of welded joints has been studied. It has been shown that the ability of a metal to resist cracking is determined by the austenite grain size and by the bainite morphology in the region of overheating in the heat-affected zone of a welded joint.

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.

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.

The Effect of Weld Reinforcement and Post-Welding Cooling Cycles on Fatigue Strength of Butt-Welded Joints under Cyclic Tensile Loading

PubMed Central

Arzola, Nelson; Hernández, Edgar

2018-01-01

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. PMID:29649117

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.

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.

Experimental and Computational Investigation of Structural Integrity of Dissimilar Metal Weld Between Ferritic and Austenitic Steel

NASA Astrophysics Data System (ADS)

Santosh, R.; Das, G.; Kumar, S.; Singh, P. K.; Ghosh, M.

2018-03-01

The structural integrity of dissimilar metal welded (DMW) joint consisting of low-alloy steel and 304LN austenitic stainless steel was examined by evaluating mechanical properties and metallurgical characteristics. INCONEL 82 and 182 were used as buttering and filler materials, respectively. Experimental findings were substantiated through thermomechanical simulation of the weld. During simulation, the effect of thermal state and stress distribution was pondered based on the real-time nuclear power plant environment. The simulation results were co-related with mechanical and microstructural characteristics. Material properties were varied significantly at different fusion boundaries across the weld line and associated with complex microstructure. During in-situ deformation testing in a scanning electron microscope, failure occurred through the buttering material. This indicated that microstructure and material properties synergistically contributed to altering the strength of DMW joints. Simulation results also depicted that the stress was maximum within the buttering material and made its weakest zone across the welded joint during service exposure. Various factors for the failure of dissimilar metal weld were analyzed. It was found that the use of IN 82 alloy as the buttering material provided a significant improvement in the joint strength and became a promising material for the fabrication of DMW joint.

Experimental and Computational Investigation of Structural Integrity of Dissimilar Metal Weld Between Ferritic and Austenitic Steel

NASA Astrophysics Data System (ADS)

Santosh, R.; Das, G.; Kumar, S.; Singh, P. K.; Ghosh, M.

2018-06-01

The structural integrity of dissimilar metal welded (DMW) joint consisting of low-alloy steel and 304LN austenitic stainless steel was examined by evaluating mechanical properties and metallurgical characteristics. INCONEL 82 and 182 were used as buttering and filler materials, respectively. Experimental findings were substantiated through thermomechanical simulation of the weld. During simulation, the effect of thermal state and stress distribution was pondered based on the real-time nuclear power plant environment. The simulation results were co-related with mechanical and microstructural characteristics. Material properties were varied significantly at different fusion boundaries across the weld line and associated with complex microstructure. During in-situ deformation testing in a scanning electron microscope, failure occurred through the buttering material. This indicated that microstructure and material properties synergistically contributed to altering the strength of DMW joints. Simulation results also depicted that the stress was maximum within the buttering material and made its weakest zone across the welded joint during service exposure. Various factors for the failure of dissimilar metal weld were analyzed. It was found that the use of IN 82 alloy as the buttering material provided a significant improvement in the joint strength and became a promising material for the fabrication of DMW joint.

Microstructures and Mechanical Properties of Friction Stir Spot Welded Aluminum Alloy AA2014

NASA Astrophysics Data System (ADS)

Babu, S.; Sankar, V. S.; Janaki Ram, G. D.; Venkitakrishnan, P. V.; Madhusudhan Reddy, G.; Prasad Rao, K.

2013-01-01

Friction stir spot welding (FSSW) is a relatively recent development, which can provide a superior alternative to resistance spot welding and riveting for fabrication of aluminum sheet metal structures. In the current work, FSSW experiments were conducted in 3-mm thick sheets of aluminum alloy 2014 in T4 and T6 conditions, with and without Alclad layers. The effects of tool geometry and welding process parameters on joint formation were investigated. A good correlation between process parameters, bond width, hook height, joint strength, and fracture mode was observed. The presence of Alclad layers and the base metal temper condition were found to have no major effect on joint formation and joint strength. Friction stir spot welds produced under optimum conditions were found to be superior to riveted joints in lap-shear and cross-tension tests. The prospects of FSSW in aluminum sheet metal fabrication are discussed.

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.

Stress Corrosion Cracking Behavior of Multipass TIG-Welded AA2219 Aluminum Alloy in 3.5 wt pct NaCl Solution

NASA Astrophysics Data System (ADS)

Venugopal, A.; Sreekumar, K.; Raja, V. S.

2012-09-01

The stress corrosion cracking (SCC) behavior of the AA2219 aluminum alloy in the single-pass (SP) and multipass (MP) welded conditions was examined and compared with that of the base metal (BM) in 3.5 wt pct NaCl solution using a slow-strain-rate technique (SSRT). The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of both the BM and welded joints. The results showed that the ductility ratio ( ɛ NaCl/( ɛ air) was 0.97 and 0.96, respectively, for the BM and MP welded joint, and the same was marginally reduced to 0.9 for the SP welded joint. The fractographic examination of the failed samples revealed a typical ductile cracking morphology for all the base and welded joints, indicating the good environmental cracking resistance of this alloy under all welded conditions. To understand the decrease in the ductility of the SP welded joint, preexposure SSRT followed by microstructural observations were made, which showed that the decrease in ductility ratio of the SP welded joint was caused by the electrochemical pitting that assisted the nucleation of cracks in the form of corrosion induced mechanical cracking rather than true SCC failure of the alloy. The microstructural examination and polarization tests demonstrated a clear grain boundary (GB) sensitization of the PMZ, resulting in severe galvanic corrosion of the SP weld joint, which initiated the necessary conditions for the localized corrosion and cracking along the PMZ. The absence of PMZ and a refined fusion zone (FZ) structure because of the lesser heat input and postweld heating effect improved the galvanic corrosion resistance of the MP welded joint greatly, and thus, failure occurred along the FZ.

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.

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.

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.

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.

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 Al-Si Coating on Weld Microstructure and Properties of 22MnB5 Steel Joints for Hot Stamping

NASA Astrophysics Data System (ADS)

Lin, Wenhu; Li, Fang; Wu, Dongsheng; Chen, Xiaoguan; Hua, Xueming; Pan, Hua

2018-03-01

22MnB5 hot stamping steels are gradually being used in tailor-welded blank applications. In this experiment, 1-mm-thick Al-Si coated and de-coated 22MnB5 steels were laser-welded and then hot-stamped. The chemical compositions, solidification process, microstructure and mechanical properties were investigated to reveal the effect of Al-Si coating and heat treatment. In the welded condition, the coated joints had an Al content of approximately 2.5 wt.% in the fusion zone and the de-coated joints had 0.5 wt.% Al. The aluminum promoted the δ-ferrite formation as the skeletal structure during solidification. In the high-aluminum weld, the microstructure consisted of martensite and long and band-like δ-ferrite. Meanwhile, the low-aluminum weld was full of lath martensite. After the hot stamping process, the δ-ferrite fraction increased from 10 to 24% in the coated joints and the lath martensite became finer in the de-coated joints. The tensile strengths of the coated joints or de-coated joints were similar to that before hot stamping, but the strength of the coated joints was reduced heavily after hot stamping compared to the de-coated joints and base material. The effect of δ-ferrite on the tensile properties became stronger when the fusion zone was soft and deformed first in the hot-stamped specimens. The coated weld showed a brittle fracture surface with many cleavage planes, and the de-coated weld showed a ductile fracture surface with many dimples in hot-stamped conditions.

Structure and Mechanical Properties of Friction Stir Weld Joints of Magnesium Alloy AZ31

NASA Astrophysics Data System (ADS)

Nagasawa, T.; Otsuka, M.; Yokota, T.; Ueki, T.

The applicability of friction stir welding to hot rolled sheet of commercial magnesium alloy AZ31 plates has been investigated. Friction stir weld joint showed mechanical strength comparable to that of base material, though the ductility remained at one half of that of the latter. The results are consistent with the microstructure which is characterized by a fine grained bond layer bounded by-intermediate grained base metals. It is found that both anodizing treatment and insertion of aluminum foil between batting faces do not degrade the joint properties at all. The results suggest that friction stir welding can be potentially applied to magnesium alloy.

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.

Interfacial and Mechanical Behavior of AA5456 Filling Friction-Stir-Welded Lap Joints Using Similar and Dissimilar Pins

NASA Astrophysics Data System (ADS)

Behmand, Saleh Alaei; Mirsalehi, Seyyed Ehsan; Omidvar, Hamid; Safarkhanian, Mohammad Ali

2016-10-01

In this article, filling friction stir welding (FFSW) of the remaining exit holes of AA5456 alloy friction-stir-welded lap joints was studied. For this purpose, the influences of different rotating speeds, holding times, and pin materials, AA5456 and AA2024, on the metallurgical structure and joint strength were investigated. The observations showed that defect-free lap joints are successfully obtainable by this method using similar and dissimilar consumable pins. The results indicated that the higher rotating speed and holding time adversely affect the weld performance. The best result was achieved for 30 seconds holding time, 500 rpm rotating speed, and AA2024 consumable pin. In this condition, a lap shear strength of 10 pct higher than that of the nonfilled joint, equivalent to about 94 pct of the original defect-free FSW joint, was obtained, whereas the GTAW filled joint showed only approximately 87 pct of the continuous FSW joint strength.

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.

Radiographic inspection of porosity in Ti-6Al-4V laser-welded joints.

PubMed

Nuñez-Pantoja, Juliana Maria Costa; Takahashi, Jessica Mie Ferreira Koyama; Nóbilo, Mauro Antônio de Arruda; Consani, Rafael Leonardo Xediek; Mesquita, Marcelo Ferraz

2011-01-01

Widely used in dentistry, Ti-6Al-4V alloy is difficult to cast and solder, as it frequently exhibits pores inside the structure. This study was conducted to evaluate the effect of joint openings and diameters of laser-welded joints executed in Ti-6Al-4V structures on the presence of pores as checked by radiographic procedures. Sixty dumbbell rods with central diameters of 1.5, 2.0 and 3.5 mm were created from Ti-6Al-4V-wrought bars. Specimens were sectioned and welded using two joint openings (0.0 and 0.6 mm). The combination of variables created six groups (n = 10). Laser welding was executed using 360V/8ms (1.5 and 2.0 mm) and 380V/9ms (3.5 mm), with the focus and frequency set to zero. The joints were finished, polished and submitted to radiographic examination. The radiographs were visually examined for the presence of pores in the joints, qualitatively. The percentage of radiographic presence of pores was calculated without counting pores per joint. Data were analyzed using a chi-square test (α = 0.05). For the 1.5-mm specimens, the incidence of pore presence was significantly higher (p = 0.0001) when using 0.6-mm joint openings (40%) compared to 0.0-mm openings (0%). For the 2.0-mm specimens, there was no significant difference between groups (p = 0.2008). However, for the 3.5-mm specimens, the incidence of pore presence was lower (p = 0.0061) for 0.6-mm openings (50%) compared to 0.0-mm openings (70%). Therefore, laser welding of Ti-6Al-4V structures with thin diameters provides the best condition for the juxtaposition of the parts.

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.

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

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

Liu, Fei; Wang, Hongyang; Liu, Liming, E-mail: liulm@dlut.edu.cn

2014-04-01

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

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.

Experimental characterization of fatigue strength in butt welded joint considering the geometry and the effect of cooling rate of the weld

NASA Astrophysics Data System (ADS)

Arzola, Nelson; Hernández, Edgar

2017-05-01

In this work the experimental characterization of fatigue strength in butt welded joints considering the geometry and the post-weld cooling cycle was performed. ASTM A-36 structural steel was used as the base metal for the shielded metal arc welding process, with welding electrode E6013. Two experimental factors were established: weld bead geometry and the post-weld cooling rate. Two levels for each factor, the welding reinforcement (1 and 3 mm), and the rate of cooling, slow (quiet air) and fast (immersion in water) are evaluated respectively. For the uniaxial fatigue tests, 8 samples were selected for each treatment for a total of 32 specimens. The mechanical and fractomechanical properties of fusion zone, heat affected zone and base metal in relation to the analysis of failure mechanisms were analysed. The fatigue crack growth rates were estimated based on the counting of microstrations. Furthermore, experimental tests, such as uniaxial tension, microindentation hardness, Charpy impact and metallographic analysis, were made to know the influence of the experimental factors in the fatigue strength. On this research, about the 78.13% of the samples obtained a resistance higher than the recommended one by class FAT 100. The results showed that the geometry of the joint is the factor of greatest influence on fatigue strength for butt welded joints; the greater the weld reinforcement the lower the fatigue strength of the joint. Although it is also important to consider other geometric factors of less impact as it is the weld toe radius and the welding chord width.

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.

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.

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.

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

NASA Astrophysics Data System (ADS)

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

2014-05-01

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

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.

Comparison of Tensile Damage Evolution in Ti6A14V Joints Between Laser Beam Welding and Gas Tungsten Arc Welding

NASA Astrophysics Data System (ADS)

Gao, Xiao-Long; Zhang, Lin-Jie; Liu, Jing; Zhang, Jian-Xun

2014-12-01

The present paper studied the evolution of tensile damage in joints welded using laser beam welding (LBW) and gas tungsten arc welding (TIG) under a uniaxial tensile load. The damage evolution in the LBW joints and TIG-welded joints was studied by using digital image correlation (DIC) technology and monitoring changes in Young's modulus during tensile testing. To study the mechanism of void nucleation and growth in the LBW joints and TIG-welded joints, test specimens with various amounts of plastic deformation were analyzed using a scanning electron microscope (SEM). Compared with TIG-welded joints, LBW-welded joints have a finer microstructure and higher microhardness in the fusion zone. The SEM analysis and DIC test results indicated that the critical strain of void nucleation was greater in the LBW-welded joints than in the TIG-welded joints, while the growth rate of voids was lower in the LBW-welded joints than in the TIG-welded joints. Thus, the damage ratio in the LBW joints was lower than that in the TIG-welded joints during tensile testing. This can be due to the coarser martensitic α' and the application of TC-1 welding rods in the TIG-welded joint.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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.

Selenide isotope generators for the Galileo Mission: SIG hermetic bimetal weld transition joint

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

Barnett, W.J.

1979-08-01

The successful development of the commercial 6061-T651/Silver/304L explosive clad plate material as a bimetal weld transition joint material, as described herein, satisfies all SIG Galileo design requirements for hermetic weld attachment of stainless steel subassemblies to aluminum alloy generator housing or end cover structures. The application of this type weld transition joint to the hermetic attachment of stainless steel shell connectors is well-developed and tested. Based on on-going life tests of stainless steel receptacle/bimetal ring attachment assemblies and metallurgical characterization studies of this transition joint material, it appears evident that this transition joint material has more than adequate capability tomore » meet the 250 to 300/sup 0/F and 50,000 hr. design life of the SIG/Galileo mission. Its extended life temperture capability may well approach 350 to 400/sup 0/F.« 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.

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.

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

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

Shen, Junjun, E-mail: junjun.shen@hzg.de; Suhuddin, Uceu F. H.; Cardillo, Maria E. B.

2014-05-12

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

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

NASA Astrophysics Data System (ADS)

Dai, Hongbin; Peng, Jun

2017-05-01

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

Effect of Shielding Gas on the Properties of AW 5083 Aluminum Alloy Laser Weld Joints

NASA Astrophysics Data System (ADS)

Vyskoč, Maroš; Sahul, Miroslav; Sahul, Martin

2018-04-01

The paper deals with the evaluation of the shielding gas influence on the properties of AW 5083 aluminum alloy weld joints produced with disk laser. Butt weld joints were produced under different shielding gas types, namely Ar, He, Ar + 5 vol.% He, Ar + 30 vol.% He and without shielding weld pool. Light and electron microscopy, computed tomography, microhardness measurements and tensile testing were used for evaluation of weld joint properties. He-shielded weld joints were the narrowest ones. On the other hand, Ar-shielded weld joints exhibited largest weld width. The choice of shielding gas had significant influence on the porosity level of welds. The lowest porosity was observed in weld joint produced in Ar with the addition of 5 vol.% He shielding atmosphere (only 0.03%), while the highest level of porosity was detected in weld joint produced in pure He (0.24%). Except unshielded aluminum alloy weld joint, the lowest tensile strength was recorded in He-shielded weld joints. On the contrary, the highest average microhardness was measured in He-shielded weld joints.

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.

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.

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.

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.

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

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

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

New Equipment for Testing the Fatigue Strength of Riveted and Welded Joints

NASA Technical Reports Server (NTRS)

Muller, W

1940-01-01

The mechanical and electrical construction of a new experimental instrument for fatigue testing riveted and welded joints is described. This experimental device has the advantage of being able to stress, even with comparatively low magnetic exciter force, structural components in alternate bending by resonance vibrations up to incipient fatigue failure.

Fatigue performance of joints executed in pure titanium structures with several diameters.

PubMed

Nuñez-Pantoja, Juliana Maria Costa; Vaz, Luis Geraldo; Nóbilo, Mauro Antônio de Arruda; Mesquita, Marcelo Ferraz

2011-01-01

This study evaluated fatigue strength of CP-Ti laser-welded joints. Sixty (20/diameter) CP-Ti casted dumbbell rods with diameters of 1.5, 2.0, and 3.5 mm were sectioned and welded using two joint openings (0.0 (00) and 0.6 mm (06)). Six groups were formed, amounting to a total of 9 (n=10) with inclusion of intact groups. Welding was executed using 360 V/8 ms (1.5 and 2.0 mm) and 380 V/9 ms (3.5 mm). Joints were finished, polished, and submitted to radiographic examination to visually analyze presence of porosity (PP). Specimens were submitted to cyclic tests, and the number of cycles until failure (NC) was recorded. Fractured surfaces were examined by SEM. Kruskal-Wallis and Dunn (α=0.05) tests demonstrated that NC was lower for all diameters with 06, and for 3.5 mm/00. NC and PP were found to have a negative correlation (Spearman Coefficient). For CP-Ti frameworks with thin diameters, laser welding is better when structures are juxtaposed.

Molecular dynamics modeling of bonding two materials by atomic scale friction stir welding

NASA Astrophysics Data System (ADS)

Konovalenko S., Iv.; Konovalenko, Ig. S.; Psakhie, S. G.

2017-12-01

Molecular dynamics model of atomic scale friction stir welding has been developed. Formation of a butt joint between two crystallites was modeled by means of rotating rigid conical tool traveling along the butt joint line. The formed joint had an intermixed atomic structure composed of atoms initially belonged to the opposite mated piece of metal. Heat removal was modeled by adding the extra viscous force to peripheral atomic layers. This technique provides the temperature control in the tool-affected zone during welding. Auxiliary vibration action was added to the rotating tool. The model provides the variation of the tool's angular velocity, amplitude, frequency and direction of the auxiliary vibration action to provide modeling different welding modes.

The numerical high cycle fatigue damage model of fillet weld joint under weld-induced residual stresses

NASA Astrophysics Data System (ADS)

Nguyen Van Do, Vuong

2018-04-01

In this study, a development of nonlinear continuum damage mechanics (CDM) model for multiaxial high cycle fatigue is proposed in which the cyclic plasticity constitutive model has been incorporated in the finite element (FE) framework. T-joint FE simulation of fillet welding is implemented to characterize sequentially coupled three-dimensional (3-D) of thermo-mechanical FE formulation and simulate the welding residual stresses. The high cycle fatigue damage model is then taken account into the fillet weld joints under the various cyclic fatigue load types to calculate the fatigue life considering the residual stresses. The fatigue crack initiation and the propagation in the present model estimated for the total fatigue is compared with the experimental results. The FE results illustrated that the proposed high cycle fatigue damage model in this study could become a powerful tool to effectively predict the fatigue life of the welds. Parametric studies in this work are also demonstrated that the welding residual stresses cannot be ignored in the computation of the fatigue life of welded structures.

Effect of Welding Processes on the Microstructure, Mechanical Properties and Residual Stresses of Plain 9Cr-1Mo Steel Weld Joints

NASA Astrophysics Data System (ADS)

Nagaraju, S.; Vasantharaja, P.; Brahadees, G.; Vasudevan, M.; Mahadevan, S.

2017-12-01

9Cr-1Mo steel designated as P9 is widely used in the construction of power plants and high-temperature applications. It is chosen for fabricating hexcan fuel subassembly wrapper components of fast breeder reactors. Arc welding processes are generally used for fabricating 9Cr-1Mo steel weld joints. A-TIG welding process is increasingly being adopted by the industries. In the present study, shielded metal arc (SMA), tungsten inert gas (TIG) and A-TIG welding processes are used for fabricating the 9Cr-1Mo steel weld joints of 10 mm thickness. Effect of the above welding processes on the microstructure evolution, mechanical properties and residual stresses of the weld joints has been studied in detail. All the three weld joints exhibited comparable strength and ductility values. 9Cr-1Mo steel weld joint fabricated by SMAW process exhibited lower impact toughness values caused by coarser grain size and inclusions. 9Cr-1Mo steel weld joint fabricated by TIG welding exhibited higher toughness due to finer grain size, while the weld joint fabricated by A-TIG welding process exhibited adequate toughness values. SMA steel weld joint exhibited compressive residual stresses in the weld metal and HAZ, while TIG and A-TIG weld joint exhibited tensile residual stresses in the weld metal and HAZ.

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 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.

Assessment of Stress Corrosion Cracking Resistance of Activated Tungsten Inert Gas-Welded Duplex Stainless Steel Joints

NASA Astrophysics Data System (ADS)

Alwin, B.; Lakshminarayanan, A. K.; Vasudevan, M.; Vasantharaja, P.

2017-12-01

The stress corrosion cracking behavior of duplex stainless steel (DSS) weld joint largely depends on the ferrite-austenite phase microstructure balance. This phase balance is decided by the welding process used, heat input, welding conditions and the weld metal chemistry. In this investigation, the influence of activated tungsten inert gas (ATIG) and tungsten inert gas (TIG) welding processes on the stress corrosion cracking (SCC) resistance of DSS joints was evaluated and compared. Boiling magnesium chloride (45 wt.%) environment maintained at 155 °C was used. The microstructure and ferrite content of different weld zones are correlated with the outcome of sustained load, SCC test. Irrespective of the welding processes used, SCC resistance of weld joints was inferior to that of the base metal. However, ATIG weld joint exhibited superior resistance to SCC than the TIG weld joint. The crack initiation and final failure were in the weld metal for the ATIG weld joint; they were in the heat-affected zone for the TIG weld joint.

Influence of the Gap Width on the Geometry of the Welded Joint in Hybrid Laser-Arc Welding

NASA Astrophysics Data System (ADS)

Turichin, G.; Tsibulskiy, I.; Kuznetsov, M.; Akhmetov, A.; Mildebrath, M.; Hassel, T.

The aim of this research was the experimental investigation of the influence of the gap width and speed of the welding wire on the changes of the geometry in the welded joint in the hybrid laser-arc welding of shipbuilding steel RS E36. The research was divided into three parts. First, in order to understand the influence of the gap width on the welded joint geometry, experimental research was done using continuous wave fiber laser IPG YLS-15000 with arc rectifier VDU-1500DC. The second part involved study of the geometry of the welded joint and hardness test results. Three macrosections from each welded joint were obtained. Influence of the gap width and welding wire speed on the welded joint geometry was researched in the three lines: in the right side of the plates, middle welded joint and in the root welded joint.

High-Powered, Ultrasonically Assisted Thermal Stir Welding

NASA Technical Reports Server (NTRS)

Ding, Robert

2013-01-01

This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (˜13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (˜2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (˜13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.

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.

Effects of laser-weld joint opening size on fatigue strength of Ti-6Al-4V structures with several diameters.

PubMed

Nuñez-Pantoja, J M C; Vaz, L G; Nóbilo, M A A; Henriques, G E P; Mesquita, M F

2011-03-01

This study was conducted to evaluate the fatigue strength of Ti-6Al-4V laser-welded joints with several diameters and joint openings. Sixty dumbbell rods were machined in Ti-6Al-4V alloy with central diameters of 1·5, 2·0 and 3·5 mm. The specimens were sectioned and then welded using two joint openings (0·0 and 0·6 mm). The combination of variables created six groups, which when added to the intact groups made a total of nine groups (n = 10). Laser welding was executed as follows: 360 V per 8 ms (1·5 and 2·0 mm) and 380 V per 9 ms (3·5 mm) with focus and frequency regulated to zero. The joints were finished, polished and submitted to radiographic examination to be analysed visually for the presence of porosity. The specimens were then subjected to a mechanical cyclic test, and the number of cycles until failure was recorded. The fracture surface was examined with a scanning electron microscope (SEM). The Kruskal-Wallis test and Dunn test (α = 0·05) indicated that the number of cycles required for fracture was lower for all specimens with joint openings of 0·6 mm, and for 3·5-mm-diameter specimens with joint openings of 0·0 mm. The Spearman correlation coefficient (α = 0·05) indicated that there was a negative correlation between the number of cycles and the presence of porosity. So, laser welding of Ti-6Al-4V structures with a thin diameter provides the best conditions for the juxtaposition of parts. Radiographic examination allows for the detection of internal voids in titanium joints. © 2010 Blackwell Publishing Ltd.

Solid State Joining of Dissimilar Titanium Alloys

NASA Astrophysics Data System (ADS)

Morton, Todd W.

Solid state joining of titanium via friction stir welding and diffusion bonding have emerged as enablers of efficient monolithic structural designs by the eliminations fasteners for the aerospace industry. As design complexity and service demands increase, the need for joints of dissimilar alloys has emerged. Complex thermomechanical conditions in friction stir weld joints and high temperature deformation behavior differences between alloys used in dissimilar joints gives rise to a highly variable flow pattern within a stir zone. Experiments performed welding Ti-6Al-4V to beta21S show that mechanical intermixing of the two alloys is the primary mechanism for the generation of the localized chemistry and microstructure, the magnitude of which can be directly related to pin rotation and travel speed weld parameters. Mechanical mixing of the two alloys is heavily influenced by strain rate softening phenomena, and can be used to manipulate weld nugget structure by switching which alloy is subjected to the advancing side of the pin. Turbulent mixing of a weld nugget and a significant reduction in defects and weld forces are observed when the beta21S is put on the advancing side of the weld where higher strain rates are present. Chemical diffusion driven by the heat of weld parameters is characterized using energy dispersive x-ray spectroscopy (EDS) and is shown to be a secondary process responsible for generating short-range chemical gradients that lead to a gradient of alpha particle structures. Diffusion calculations are inconsistent with an assumption of steady-state diffusion and show that material interfaces in the weld nugget evolve through the break-down of turbulent interface features generated by material flows. A high degree of recrystallization is seen throughout the welds, with unique, hybrid chemistry grains that are generated at material interfaces in the weld nugget that help to unify the crystal structure of dissimilar alloys. The degree of recrystallization is tied to the localized thermal profile in the weld nugget as well as the heating rates of a given set of weld parameters. Slow kinetics of alpha dissolution relative to the heating rate and process times of friction stir welding suggest an alpha-particle assisted super-transus recrystallization process contributes to a refined grain size in weld parameters utilizing high travel speed.

Friction stir welding of T joints of dissimilar aluminum alloy: A review

NASA Astrophysics Data System (ADS)

Thakare, Shrikant B.; Kalyankar, Vivek D.

2018-04-01

Aluminum alloys are preferred in the mechanical design due to their advantages like high strength, good corrosion resistance, low density and good weldability. In various industrial applications T joints configuration of aluminum alloys are used. In different fields, T joints having skin (horizontal sheet) strengthen by stringers (vertical sheets) were used to increase the strength of structure without increasing the weight. T joints are usually carried out by fusion welding which has limitations in joining of aluminum alloy due to significant distortion and metallurgical defects. Some aluminum alloys are even non weldable by fusion welding. The friction stir welding (FSW) has an excellent replacement of conventional fusion welding for T joints. In this article, FSW of T joints is reviewed by considering aluminum alloy and various joint geometries for defect analysis. The previous experiments carried out on T joints shows the factors such as tool geometry, fixturing device and joint configurations plays significant role in defect free joints. It is essential to investigate the material flow during FSW to know joining mechanism and the formation of joint. In this study the defect occurred in the FSW are studied for various joint configurations and parameters. Also the effect of the parameters and defects occurs on the tensile strength are studied. It is concluded that the T-joints of different joint configurations can be pretended successfully. Comparing to base metal some loss in tensile strength was observed in the weldments as well as overall reduction of the hardness in the thermos mechanically affected zone also observed.

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.

Effect of Mg and Cu on mechanical properties of high-strength welded joints of aluminum alloys obtained by laser welding

NASA Astrophysics Data System (ADS)

Annin, B. D.; Fomin, V. M.; Karpov, E. V.; Malikov, A. G.; Orishich, A. M.

2017-09-01

Results of experimental investigations of welded joints of high-strength aluminum-lithium alloys of the Al-Cu-Li and Al-Mg-Li systems are reported. The welded joints are obtained by means of laser welding and are subjected to various types of processing for obtaining high-strength welded joints. A microstructural analysis is performed. The phase composition and mechanical properties of the welded joints before and after heat treatment are studied. It is found that combined heat treatment of the welded joint (annealing, quenching, and artificial ageing) increases the joint strength, but appreciably decreases the alloy strength outside the region thermally affected by the welding process.

Investigation on Microstructure and Mechanical Properties of ATIG welded alloy C-276 with Fe2O3 flux

NASA Astrophysics Data System (ADS)

Surve, Angad; Bhosage, Sharnappa; Mehta, Akshay; Srikanth, A.; Arivarasu, M.; Manikandan, M.; Gokulkumar, K.; Rajan, Deva. N.

2018-02-01

Alloy C-276 susceptible to hot cracking. The microsegregation occurs during solidification is the largely responsible for the hot cracking in the alloy. The present study investigates the microstructure and mechanical properties of alloy C-276 weld joint fabricated by ATIG welding technique. The macro examination was carried out assess the defects in the weld joints. Optical and scanning electron microscope examination was carried out to see the structural changes in the fusion zone. The tensile test was performed to evaluate the strength of the weld joints. The results show the defect free welding was achieved in the established process parameters. The macrograph shows the full depth of penetration was obtained in the single pass by the effect of Marangoni convection. Energy Dispersive X-ray spectroscopy (EDS) analysis illustrates the absence of microsegregation in the interdendritic zone. The tensile test shows the improved mechanical properties compared to the base metal.

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

NASA Astrophysics Data System (ADS)

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

2012-02-01

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

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.

Interfacial Characterization of Dissimilar Joints Between Al/Mg/Al-Trilayered Clad Sheet to High-Strength Low-Alloy Steel

NASA Astrophysics Data System (ADS)

Macwan, A.; Jiang, X. Q.; Chen, D. L.

2015-07-01

Magnesium (Mg) alloys are increasingly used in the automotive and aerospace sectors to reduce vehicle weight. Al/Mg/Al tri-layered clad sheets are deemed as a promising alternative to improve the corrosion resistance and formability of Mg alloys. The structural application of Al/Mg/Al tri-layered clad sheets inevitably involves welding and joining in the multi-material vehicle body manufacturing. This study aimed to characterize the bonding interface microstructure of the Al/Mg/Al-clad sheet to high-strength low-alloy steel with and without Zn coating using ultrasonic spot welding at different levels of welding energy. It was observed that the presence of Zn coating improved the bonding at the interface due to the formation of Al-Zn eutectic structure via enhanced diffusion. At a higher level of welding energy, characteristic flow patterns of Zn into Al-clad layer were observed with an extensive penetration mainly along some high angle grain boundaries. The dissimilar joints without Zn coating made at a high welding energy of 800 J failed partially from the Al/Fe weld interface and partially from the Al/Mg clad interface, while the joints with Zn coating failed from the Al/Mg clad interface due to the presence of brittle Al12Mg17 phase.

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.

An Optimized Trajectory Planning for Welding Robot

NASA Astrophysics Data System (ADS)

Chen, Zhilong; Wang, Jun; Li, Shuting; Ren, Jun; Wang, Quan; Cheng, Qunchao; Li, Wentao

2018-03-01

In order to improve the welding efficiency and quality, this paper studies the combined planning between welding parameters and space trajectory for welding robot and proposes a trajectory planning method with high real-time performance, strong controllability and small welding error. By adding the virtual joint at the end-effector, the appropriate virtual joint model is established and the welding process parameters are represented by the virtual joint variables. The trajectory planning is carried out in the robot joint space, which makes the control of the welding process parameters more intuitive and convenient. By using the virtual joint model combined with the B-spline curve affine invariant, the welding process parameters are indirectly controlled by controlling the motion curve of the real joint. To solve the optimal time solution as the goal, the welding process parameters and joint space trajectory joint planning are optimized.

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.

The interface microstructure, mechanical properties and corrosion resistance of dissimilar joints during multipass laser welding for nuclear power plants

NASA Astrophysics Data System (ADS)

Li, Gang; Lu, Xiaofeng; Zhu, Xiaolei; Huang, Jian; Liu, Luwei; Wu, Yixiong

2018-05-01

This study presents the interface microstructure, mechanical properties and corrosion resistance of dissimilar joints between Inconel 52M overlays and 316L stainless steel during multipass laser welding for nuclear power plants. The results indicate that the microstructure at the interface beside 316L stainless steel consists of cellular with the width of 30-40 μm, which also exhibits numerous Cr and Mo-rich precipitates like flocculent structure and in chains along grain boundaries as a mixed chemical solution for etching. Many dendritic structure with local melting characteristics and Nb-rich precipitates are exhibited at the interface beside Inconel 52M overlays. Such Nb-rich precipitates at the interface beside Inconel 52M overlays deteriorate the tensile strength and toughness of dissimilar joints at room temperature. The tensile strength of 316L stainless steel at 350 °C significantly decreases with the result that dissimilar joints are fractured in 316L stainless steel. The correlation between corrosion behavior and microstructure of weld metals is also discussed. The difference in high corrosion potential between Nb-rich precipitates and the matrix could result in establishing effective galvanic couples, and thus accelerating the corrosion of weld metals.

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.

Characterisation of metallic glass incorporated Zircaloy-2 weldments

NASA Astrophysics Data System (ADS)

Mishra, S.; Savalia, R. T.; Bhanumurthy, K.; Dey, G. K.; Banerjee, S.

1995-12-01

In this study the effect of incorporation of Zr based Fe and Ni bearing metallic glass in spot welds in Zircaloy components has been examined. A comparison of strength and microstructure of the welded joint with and without glass has been carried out. The welded joint with metallic glass has been found to be stronger than the one without metallic glass. The microstructure of the welded region with metallic glass has been found to comprise a large region having martensite. This large martensitic region has also been found to have considerable amount of excess solute (Fe, Ni). The higher strength of the weld with metallic glass seems to originate due to solid solution strengthening, small grain size and the presence of martensitic structure over a large region.

Special Features of the Structure of Laser-Welded Joints of Dissimilar Alloys Based on Titanium and Aluminum

NASA Astrophysics Data System (ADS)

Nikulina, A. A.; Smirnov, A. I.; Turichin, G. A.; Klimova-Korsmik, O. G.; Babkin, K. D.

2017-11-01

The structure of laser-welded joints of parts having different thicknesses fabricated from alloys based on aluminum and titanium has been studied. Results of transmission and scanning electron microscopy measurements and x-ray diffraction analysis show that the diffusion interaction of microvolumes of two alloys in the weld leads to the formation of two interlayers: (i) a continuous intermetallic TiAl layer with thickness below 1 μm adjacent to the titanium alloy and (ii) a layer consisting of TiAl3 intermetallic dendrites with thickness of 2 - 6 μm adjacent to the TiAl layer. The average microhardness of the intermetallic layer is about 490 HV.

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.

Welding abilities of UFG metals

NASA Astrophysics Data System (ADS)

Morawiński, Łukasz; Chmielewski, Tomasz; Olejnik, Lech; Buffa, Gianluca; Campanella, Davide; Fratini, Livan

2018-05-01

Ultrafine Grained (UFG) metals are characterized by an average grain size of <1 µm and mostly high angle grain boundaries. These materials exhibit exceptional improvements in strength, superplastic behaviour and in some cases enhanced biocompatibility. UFG metals barstock can be fabricated effectively by means of Severe Plastic Deformation (SPD) methods. However, the obtained welded joints with similar properties to the base of UFG material are crucial for the production of finished engineering components. Conventional welding methods based on local melting of the joined edges cannot be used due to the UFG microstructure degradation caused by the heat occurrence in the heat affected zone. Therefore, the possibility of obtaining UFG materials joints with different shearing plane (SP) positions by means of friction welded processes, which do not exceed the melting temperature during the process, should be investigated. The article focuses on the Linear Friction Welding (LFW) method, which belongs to innovative welding processes based on mixing of the friction-heated material in the solid state. LFW is a welding process used to joint bulk components. In the process, the friction forces work due to the high frequency oscillation and the pressure between the specimens is converted in thermal energy. Character and range of recrystallization can be controlled by changing LFW parameters. Experimental study on the welded UFG 1070 aluminum alloy by means of FLW method, indicates the possibility of reducing the UFG structure degradation in the obtained joint. A laboratory designed LFW machine has been used to weld the specimens with different contact pressure and oscillation frequency.

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.

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.

Creep rupture strength of activated-TIG welded 316L(N) stainless steel

NASA Astrophysics Data System (ADS)

Sakthivel, T.; Vasudevan, M.; Laha, K.; Parameswaran, P.; Chandravathi, K. S.; Mathew, M. D.; Bhaduri, A. K.

2011-06-01

316L(N) stainless steel plates were joined using activated-tungsten inert gas (A-TIG) welding and conventional TIG welding process. Creep rupture behavior of 316L(N) base metal, and weld joints made by A-TIG and conventional TIG welding process were investigated at 923 K over a stress range of 160-280 MPa. Creep test results showed that the enhancement in creep rupture strength of weld joint fabricated by A-TIG welding process over conventional TIG welding process. Both the weld joints fractured in the weld metal. Microstructural observation showed lower δ-ferrite content, alignment of columnar grain with δ-ferrite along applied stress direction and less strength disparity between columnar and equiaxed grains of weld metal in A-TIG joint than in MP-TIG joint. These had been attributed to initiate less creep cavitation in weld metal of A-TIG joint leading to improvement in creep rupture strength.

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.

A novel weld seam detection method for space weld seam of narrow butt joint in laser welding

NASA Astrophysics Data System (ADS)

Shao, Wen Jun; Huang, Yu; Zhang, Yong

2018-02-01

Structured light measurement is widely used for weld seam detection owing to its high measurement precision and robust. However, there is nearly no geometrical deformation of the stripe projected onto weld face, whose seam width is less than 0.1 mm and without misalignment. So, it's very difficult to ensure an exact retrieval of the seam feature. This issue is raised as laser welding for butt joint of thin metal plate is widely applied. Moreover, measurement for the seam width, seam center and the normal vector of the weld face at the same time during welding process is of great importance to the welding quality but rarely reported. Consequently, a seam measurement method based on vision sensor for space weld seam of narrow butt joint is proposed in this article. Three laser stripes with different wave length are project on the weldment, in which two red laser stripes are designed and used to measure the three dimensional profile of the weld face by the principle of optical triangulation, and the third green laser stripe is used as light source to measure the edge and the centerline of the seam by the principle of passive vision sensor. The corresponding image process algorithm is proposed to extract the centerline of the red laser stripes as well as the seam feature. All these three laser stripes are captured and processed in a single image so that the three dimensional position of the space weld seam can be obtained simultaneously. Finally, the result of experiment reveals that the proposed method can meet the precision demand of space narrow butt joint.

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

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.

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.

A Comparison Between Mechanical And Electrochemical Tests on Ti6Al4V Welded By LBW

NASA Astrophysics Data System (ADS)

Serroni, G.; Bitondo, C.; Astarita, A.; Scala, A.; Gloria, A.; Prisco, U.; Squillace, A.; Bellucci, F.

2011-05-01

Titanium and its alloys are nowadays widely used in many sectors: in the medical field (orthopedic and dental ones), in the architectural field, in the chemical plants field and in aeronautic. In this last field it is more and more used both for its contribution to make lightweight and time durable structures and for its compatibility with new materials, first of all Carbon Fiber Reinforced Plastics (CFRP). To this aim, lots of researches are now focusing on new and emerging technologies capable to make titanium objects and, at the same time, reducing the scrap, since titanium alloys for aeronautic application are very expensive. This paper examines Grade 5 Titanium Alloy (Ti6Al4V) welded by Laser Beam (LBW) in butt-joint configuration. The source was Nd:YAG laser, moreover two inert gases were used, in order to provide a shield both on the top and on the bottom of the weld bead. The joints were studied by varying two process parameters: welding speed and power of the laser beam. It was not possible to realize a full experimental plan, due to technological limits in making titanium laser beam welds. The joints were tested to measure their mechanical properties and the corrosion resistance. The process parameters do not significantly affect the maximum static strength of the joints. Microscopic analysis showed that welds made with high power and low welding speed have a uniform weld bead, and no macroscopic defect occurs. Fatigue test results, instead, show a marked influence of the morphology of the weld bead: the occurrence of some defects, such as the undercut, both on the top and on the bottom of the weld bead, dramatically reduced fatigue resistance of the joints. Corrosion resistance was studied using the electrochemical micro cell technique, which allows to distinguish electrochemical properties of each zone of the weld bead, even when, as in this case, they are very narrow. By a general point of view, it has been demonstrated that the joints showing the best mechanical performances also possess better electrochemical properties. What's more, in these cases, the weld bead shows a cathodic behavior with respect to the parent material.

Mechanical characteristics and microstructure of weld joint of high-temperature martensitic steel containing 9% Cr

NASA Astrophysics Data System (ADS)

Shakhova, Ya. E.; Belyakov, A. N.; Kaibyshev, R. O.

2016-04-01

The structure and mechanical characteristics of a weld joint of 10Kh9K3V2MFBR steel (0.097 C, 0.17.Si, 0.54 Mn, 8.75 Cr, 0.21 Ni, 0.51 Mo, 0.07 Nb, 0.23 V, 0.004 N, 0.003 B, 1.6 W, 0.15 Cu, and Fe for balance, wt %) have been studied; the joint was produced by hand welding in an argon atmosphere using 03Kh20N45M7G6B welding wire (0.3 C, 20 Cr, 45 Ni, 7 Mo, 6 Mn, and 1 Nb, wt %). The weld joint is divided into the zone of the base metal, a thermal effect zone, which consists of zones that contain fine and coarse original austenitic grains, and the zone of seam metal. It has been shown that the weld joint of 10Kh9K3V2MFBR steel possesses high strength characteristics at the room temperature under static loading and a satisfactorily impact toughness, which has the minimum value of 30 J/cm2 in the zone of the seam metal and does not depend on the temperature. With a decrease in the temperature from the room temperature to 253 K, a ductile-brittle transition occurs in the thermal effect zone. Creep tests carried out at the temperature of 923 K have shown that the long-term strength of the weld seam is lower than that of the base material in the entire stress range being tested. At stresses of 140 MPa or higher, the acceleration of creep in the weld seam is observed, while at low stresses of about 120 MPa, the rates of creep in the weld seam and in the base metal remain similar until the transition to the stage of accelerated fracture occurs. The difference in the values of the long-term strength is due to premature fracture, which occurs in the thermal effect zone with the finegrained structure.

Method and apparatus for in-process sensing of manufacturing quality

DOEpatents

Hartman, Daniel A [Santa Fe, NM; Dave, Vivek R [Los Alamos, NM; Cola, Mark J [Santa Fe, NM; Carpenter, Robert W [Los Alamos, NM

2005-02-22

A method for determining the quality of an examined weld joint comprising the steps of providing acoustical data from the examined weld joint, and performing a neural network operation on the acoustical data determine the quality of the examined weld joint produced by a friction weld process. The neural network may be trained by the steps of providing acoustical data and observable data from at least one test weld joint, and training the neural network based on the acoustical data and observable data to form a trained neural network so that the trained neural network is capable of determining the quality of a examined weld joint based on acoustical data from the examined weld joint. In addition, an apparatus having a housing, acoustical sensors mounted therein, and means for mounting the housing on a friction weld device so that the acoustical sensors do not contact the weld joint. The apparatus may sample the acoustical data necessary for the neural network to determine the quality of a weld joint.

Method and Apparatus for In-Process Sensing of Manufacturing Quality

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

Hartman, D.A.; Dave, V.R.; Cola, M.J.

2005-02-22

A method for determining the quality of an examined weld joint comprising the steps of providing acoustical data from the examined weld joint, and performing a neural network operation on the acoustical data determine the quality of the examined weld joint produced by a friction weld process. The neural network may be trained by the steps of providing acoustical data and observable data from at least one test weld joint, and training the neural network based on the acoustical data and observable data to form a trained neural network so that the trained neural network is capable of determining themore » quality of a examined weld joint based on acoustical data from the examined weld joint. In addition, an apparatus having a housing, acoustical sensors mounted therein, and means for mounting the housing on a friction weld device so that the acoustical sensors do not contact the weld joint. The apparatus may sample the acoustical data necessary for the neural network to determine the quality of a weld joint.« less

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.

Effect of friction stir welding parameters on defect formation

NASA Astrophysics Data System (ADS)

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

2015-10-01

Friction stir welding is a perspective method for manufacturing automotive parts, aviation and space technology. One of the major problems is the formation of welding defects and weld around the welding zone. The formation of defect is the main reason failure of the joint. A possible way to obtain defect-free welded joints is the selection of the correct welding parameters. Experimental results describing the effect of friction stir welding process parameters on the defects of welded joints on aluminum alloy AMg5M have been shown. The weld joint defects have been characterized using the non-destructive radioscopic and ultrasound phase array methods. It was shown how the type and size of defects determine the welded joint strength.

Microstructure Characterization of Fiber Laser Welds of S690QL High-Strength Steels

NASA Astrophysics Data System (ADS)

Li, Baoming; Xu, Peiquan; Lu, Fenggui; Gong, Hongying; Cui, Haichao; Liu, Chuangen

2018-02-01

The use of fiber laser welding to join S690QL steels has attracted interest in the field of construction and assembly. Herein, 13-mm-thick S690QL welded joints were obtained without filler materials using the fiber laser. The as-welded microstructures and the impact energies of the joints were characterized and measured using electron microscopy in conjunction with high-resolution transmission electron images, X-ray diffraction, and impact tests. The results indicated that a single-sided welding technique could be used to join S690QL steels up to a thickness of 12 mm (fail to fuse the joint in the root) when the laser power is equal to 12 kW (scan speed 1 m/min). Double-side welding technique allows better weld penetration and better control of heat distribution. Observation of the samples showed that the fusion zone exhibited bainitic and martensitic microstructures with increased amounts of martensites (Ms) compared with the base materials. Also, the grains in the fusion zone increased in coarseness as the heat input was increased. The fusion zone exhibited increased hardness (397 HV0.2) while exhibiting a simultaneous decrease in the impact toughness. The maximum impact energy value of 26 J was obtained from the single-side-welded sample, which is greater than those obtained from the double-side-welded samples (maximum of 18 J). Many more dislocations and plastic deformations were found in the fusion zone than the heat-affected zone in the joint, which hardened the joints and lowered the impact toughness. The microstructures characterized by FTEM-energy-dispersive X-ray spectrometer also exhibited laths of M, as well as stacking faults and dislocations featuring high-density, interfacial structure ledges that occur between the high-angle grain boundaries and the M and bainite.

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.

Microstructure and Mechanical Properties of Laser Welded Joints of DZ125L and IN718 Nickel Base Superalloys

NASA Astrophysics Data System (ADS)

Liang, Taosha; Wang, Lei; Liu, Yang; Song, Xiu

2018-05-01

The microstructure and mechanical properties of the laser welded joint of DZ125L and IN718 nickel base superalloys were investigated. The results show that the fusion zone (FZ) mainly consists of fine dendrite structure with fine γ', Laves phases and MC carbides inhomogeneously distributed. The high welding temperature induces the partial dissolution of γ' in the heat-affected zone (HAZ) of DZ125L and liquation of grain boundaries in both of the HAZs. After post-weld heat treatment (PWHT), fine γ″ and γ' phases precipitate in the FZ, IN718 HAZ and IN718 base metal (BM), and fine γ' precipitate in the γ channel of the HAZ and BM of DZ125L. With tensile testing, the joints after PWHT show higher strengths than that of the weaker DZ125L alloy. Plastic deformation mainly concentrates in the weaker DZ125L and the joint finally fails in the DZ125L BM.

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

NASA Astrophysics Data System (ADS)

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

2017-07-01

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

Alternate Design of ITER Cryostat Skirt Support System

NASA Astrophysics Data System (ADS)

Pandey, Manish Kumar; Jha, Saroj Kumar; Gupta, Girish Kumar; Bhattacharya, Avik; Jogi, Gaurav; Bhardwaj, Anil Kumar

2017-04-01

The skirt support of ITER cryostat is a support system which takes all the load of cryostat cylinder and dome during normal and operational condition. The present design of skirt support has full penetration weld joints at the bottom (shell to horizontal plate joint). To fulfil the requirements of tolerances and control the welding distortions, we have proposed to change the full penetration weld into fillet weld. A detail calculation is done to check the feasibility and structural impact due to proposed design. The calculations provide the size requirements of fillet weld. To verify the structural integrity during most severe load case, finite element analysis (FEA) has been done in line with ASME section VIII division 2 [1]. By FEA ‘Plastic Collapse’ and ‘Local Failure’ modes has been assessed. 5° sector of skirt clamp has been modelled in CATIA V5 R21 and used in FEA. Fillet weld at shell to horizontal plate joint has been modelled and symmetry boundary condition at ± 2.5° applied. ‘Elastic Plastic Analysis’ has been performed for the most severe loading case i.e. Category IV loading. The alternate design of Cryostat Skirt support system has been found safe by analysis against Plastic collapse and Local Failure Modes with load proportionality factor 2.3. Alternate design of Cryostat skirt support system has been done and validated by FEA. As per alternate design, the proposal of fillet weld has been implemented in manufacturing.

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.

Microstructures and Mechanical Properties of 12Cr1MoVG Tube Welded Joints With/Without Post-weld Heat Treatment

NASA Astrophysics Data System (ADS)

Wang, Jingjing; Sun, Jian; Yu, Xinhai; Chen, Guohong; Fu, Qiuhua; Gao, Chao; Tang, Wenming

2017-10-01

Small-caliber, thick-wall 12Cr1MoVG seamless steel tube welded joints were fabricated in this study by gas tungsten arc welding and shielded metal arc welding techniques, then the microstructures, mechanical properties, and residual stress distributions of the joints with or without post-weld heat treatment (PWHT) were compared. The welded joints are mainly composed of bcc ferrite (F), Fe3C, and M7C3 carbides. PWHT did not cause an apparent microstructure evolution in the joints, but promoted granular pearlite decomposition and growth of F grains and carbides, therefore decreasing the yield, tensile strength, and hardness while increasing the impact toughness and elongation of the welded joints. PWHT also released the circumferential residual stress and altered the stress state in the joint from tensile to compressive. Although the mechanical properties and bending performance of the small-caliber, thick-wall 12Cr1MoVG seamless welded joints without PWHT are acceptable, our results show that the joints with PWHT are more reliable.

Evaluation of Rhenium Joining Methods

NASA Technical Reports Server (NTRS)

Reed, Brian D.; Morren, Sybil H.

1995-01-01

Coupons of rhenium-to-Cl03 flat plate joints, formed by explosive and diffusion bonding, were evaluated in a series of shear tests. Shear testing was conducted on as-received, thermally-cycled (100 cycles, from 21 to 1100 C), and thermally-aged (3 and 6 hrs at 1100 C) joint coupons. Shear tests were also conducted on joint coupons with rhenium and/or Cl03 electron beam welded tabs to simulate the joint's incorporation into a structure. Ultimate shear strength was used as a figure of merit to assess the effects of the thermal treatment and the electron beam welding of tabs on the joint coupons. All of the coupons survived thermal testing intact and without any visible degradation. Two different lots of as-received, explosively-bonded joint coupons had ultimate shear strengths of 281 and 310 MPa and 162 and 223 MPa, respectively. As-received, diffusion-bonded coupons had ultimate shear strengths of 199 and 348 MPa. For the most part, the thermally-treated and rhenium weld tab coupons had shear strengths slightly reduced or within the range of the as-received values. Coupons with Cl03 weld tabs experienced a significant reduction in shear strength. The degradation of strength appeared to be the result of a poor heat sink provided during the electron beam welding. The Cl03 base material could not dissipate heat as effectively as rhenium, leading to the formation of a brittle rhenium-niobium intermetallic.

A Computational approach in optimizing process parameters of GTAW for SA 106 Grade B steel pipes using Response surface methodology

NASA Astrophysics Data System (ADS)

Sumesh, A.; Sai Ramnadh, L. V.; Manish, P.; Harnath, V.; Lakshman, V.

2016-09-01

Welding is one of the most common metal joining techniques used in industry for decades. As in the global manufacturing scenario the products should be more cost effective. Therefore the selection of right process with optimal parameters will help the industry in minimizing their cost of production. SA 106 Grade B steel has a wide application in Automobile chassis structure, Boiler tubes and pressure vessels industries. Employing central composite design the process parameters for Gas Tungsten Arc Welding was optimized. The input parameters chosen were weld current, peak current and frequency. The joint tensile strength was the response considered in this study. Analysis of variance was performed to determine the statistical significance of the parameters and a Regression analysis was performed to determine the effect of input parameters over the response. From the experiment the maximum tensile strength obtained was 95 KN reported for a weld current of 95 Amp, frequency of 50 Hz and peak current of 100 Amp. With an aim of maximizing the joint strength using Response optimizer a target value of 100 KN is selected and regression models were optimized. The output results are achievable with a Weld current of 62.6148 Amp, Frequency of 23.1821 Hz, and Peak current of 65.9104 Amp. Using Die penetration test the weld joints were also classified in to 2 categories as good weld and weld with defect. This will also help in getting a defect free joint when welding is performed using GTAW process.

Experimental and numerical evaluation of the fatigue behaviour in a welded joint

NASA Astrophysics Data System (ADS)

Almaguer, P.; Estrada, R.

2014-07-01

Welded joints are an important part in structures. For this reason, it is always necessary to know the behaviour of them under cyclic loads. In this paper a S - N curve of a butt welded joint of the AISI 1015 steel and Cuban manufacturing E6013 electrode is showed. Fatigue tests were made in an universal testing machine MTS810. The stress ratio used in the test was 0,1. Flaws in the fatigue specimens were characterized by means of optical and scanning electron microscopy. SolidWorks 2013 software was used to modeling the specimens geometry, while to simulate the fatigue behaviour Simulation was used. The joint fatigue limit is 178 MPa, and a cut point at 2 039 093 cycles. Some points of the simulations are inside of the 95% confidence band.

Weldability evaluation of high tensile plates using GMAW process

NASA Astrophysics Data System (ADS)

Datta, R.; Mukerjee, D.; Rohira, K. L.; Veeraraghavan, R.

1999-08-01

High tensile plates, SAILMA-450 high impact (HI) (yield strength, 45 kg/mm2 minimum; ultimate tensile strength, 57 kg/mm2 minimum; elongation, 19% minimum; Charpy impact energy 2.0 kg.m at -20 °C minimum) were successfully developed at the Steel Authority of India Ltd., up to 32 mm plate thickness. Since then the steel has been extensively used for the fabrication of impellers, bridges, excavators, and mining machineries, where welding is an important processing step. The present study deals with the weldability properties of SAILMA-450 HI plates employing the gas metal arc welding process and carbon dioxide gas. Implant and elastic restraint cracking tests were conducted to assess the cold cracking resistance of the weld joint under different welding conditions. The static fatigue limit values were found to be in excess of minimum specified yield strength at higher heat input levels (9.4 and 13.0 kJ/cm), indicating adequate cold cracking resistance. The critical restraint intensities, K cr, were found to vary between 720 and 1280 kg/mm2, indicating that the process can be utilized for fabrication of structures involving moderate to low restraint intensities (200 to 1000 kg/mm2). Lamellar tear tests conducted using full thickness plates at heat input levels ranging from 10 to 27 kJ/cm showed no incidence of lamellar tear upon visual, ultrasonic, and four-section macroexamination. These tests were repeated using machined plates, such that the midthickness of the plates (segregated zone) corresponded to the heat affected zone of the weld. No cracks were observed, indicating good lamellar tear resistance of the weld joint. Optimized welding conditions were formulated based on these tests. The weld joint was subjected to extensive tests to assess the physical properties and soundness of the weld joint. The weld joint exhibited good strength (64.7 kg/mm2) and impact toughness (5.7 and 3.5 kg.m at -20 °C for weld metal and heat affected zone properties. Crack tip opening displacement (CTOD) tests carried out for parent metal, heat-affected zone, and weld metal resulted in δm values of 0.41, 0.40, and 0.34 mm, respectively, which indicates adequate resistance to cleavage fracture. It was concluded that the weld joint conforms to the requirements of SAILMA-450 HI specification and ensures a high integrity of the fabricated products.

Cracking in dissimilar laser welding of tantalum to molybdenum

NASA Astrophysics Data System (ADS)

Zhou, Xingwen; Huang, Yongde; Hao, Kun; Chen, Yuhua

2018-06-01

Dissimilar joining of tantalum (Ta) to molybdenum (Mo) is of great interest in high temperature structural component applications. However, few reports were found about joining of these two hard-to-weld metals. The objective of this experimental study was to assess the weldability of laser butt joining of 0.2 mm-thick Ta and Mo. In order to study cracking mechanism in Ta/Mo joint, similar Ta/Ta and Mo/Mo joints were compared under the same welding conditions. An optical microscope observation revealed presence of intergranular cracks in the Mo/Mo joint, while both transgranular and intergranular cracks were observed in Ta/Mo joint. The cracking mechanism of the Ta/Mo joint was investigated further by micro-hardness testing, micro X-ray diffraction and scanning electron microscopy. The results showed that solidification cracking tendency of Mo is a main reason for crack initiation in the Ta/Mo joint. Low ductility feature in fusion zone most certainly played a role in the transgranular propagation of cracking.

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

DOE PAGES

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

2014-12-30

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

Fatigue properties of dissimilar metal laser welded lap joints

NASA Astrophysics Data System (ADS)

Dinsley, Christopher Paul

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

Research on Microstructure and Properties of Welded Joint of High Strength Steel

NASA Astrophysics Data System (ADS)

Zhu, Pengxiao; Li, Yi; Chen, Bo; Ma, Xuejiao; Zhang, Dongya; Tang, Cai

2018-01-01

BS960 steel plates were welded by Laser-MAG and MAG. The microstructure and properties of the welded joints were investigated by optical microscope, micro-hardness tester, universal tensile testing machine, impact tester, scanning electron microscope (SEM) and fatigue tester. By a series of experiments, the following results were obtained: The grain size of the coarse grain zone with Laser-MAG welded joint is 20μm, and that with MAG welded joint is about 32μm, both of the fine grain region are composed of fine lath martensite and granular bainite; the width of the heat affected region with Laser-MAG is lower than that with MAG. The strength and impact energy of welded joints with Laser-MAG is higher than that with MAG. The conditioned fatigue limit of welded joint with Laser-MAG is 280MPa; however, the conditioned fatigue limit of welded joint with MAG is 250MPa.

Upgrading weld quality of a friction stir welded aluminum alloys AMG6

NASA Astrophysics Data System (ADS)

Chernykh, I. K.; Vasil'ev, E. V.; Matuzko, E. N.; Krivonos, E. V.

2018-01-01

In the course of introduction of FSW technology into the industry there is a keen interest in this process; there are issues such as how does joining take place, what is the structure of the joint, and where there are dangerous zones. The objective of this research is to obtain information about the structure of the joint, what are the temperatures that arise during the joining, what strength is apply to the tool when joining the material, what tensile strength of joint, and where fracture tended to occur. Specimens were produced at different modes of welding at a tool rotation speed of 315 to 625 rpm and tool travel speed of 40 to 125 mm/min. During the experiment, the strength applied to the tool was measured, which reached 800016000 N (Fz) and 400-1400 N (Fx) and the temperature on the surface of the tool, which is in the range 250-400°C. Before the welding process the tool was heated to a temperature in the range of 100-250 degrees, but the tensile strength is not had a tangible impact. The tensile strength is about 80 % of that of the aluminum alloy base metal tensile strength, and fracture tended is occur not at the line of joint but follow the shape of the tool. In the transverse cross section of a FSW material there is a microstructural regions such as weld nugget, thermomechanically affected zone and heat-affected zone with parent material.

Evaluation of Weldability for MAG and LASER with Galvannealed Steel.

PubMed

Kim, Jong-Hee; Bang, Han-Sur; Bang, Hee-Seon

2018-03-01

Lower-arm, one of the components in automotive suspension module, has been fabricated by MAG welding in general which is lap jointed with 2 mm thick galvannealed steel sheet (SGAPH440). This welding process produces some problems such as significantly much spatters and weld defects of porosity in welded joint, which degrades productivity and weldability. Therefore, in order to solve these problems, this study has been tried to apply two types of solid wires with different chemical composition rate of Si and Mn, in MAG welding process. Moreover, the laser welding process has been adopted to fabricate the low-arm and compared with those of MAG welding, in terms of mechanical and metallurgical characteristics. It was observed that in MAG welded joints, much more spatters were occurred in using solid wire with higher Si and Mn contains. The maximum tensile-shear strength in laser welded joints was approximately 16.7 kN, which was almost equal to that of in MAG welded joints. The microstructure showed ferrite and martensite in weld metal in MAG and laser welded joints indicating no significantly grain size change.

Characteristics of Extra Narrow Gap Weld of HSLA Steel Welded by Single-Seam per Layer Pulse Current GMA Weld Deposition

NASA Astrophysics Data System (ADS)

Agrawal, B. P.; Ghosh, P. K.

2017-03-01

Butt weld joints are produced using pulse current gas metal arc welding process by employing the technique of centrally laid multi-pass single-seam per layer weld deposition in extra narrow groove of thick HSLA steel plates. The weld joints are prepared by using different combination of pulse parameters. The selection of parameter of pulse current gas metal arc welding is done considering a summarized influence of simultaneously interacting pulse parameters defined by a dimensionless hypothetical factor ϕ. The effect of diverse pulse parameters on the characteristics of weld has been studied. Weld joint is also prepared by using commonly used multi-pass multi-seam per layer weld deposition in conventional groove. The extra narrow gap weld joints have been found much superior to the weld joint prepared by multi-pass multi-seam per layer deposition in conventional groove with respect to its metallurgical characteristics and mechanical properties.

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.

Fatigue Strength and Related Characteristics of Aircraft Joints I : Comparison of Spot-Weld and Rivet Patterns in 24s-t Alclad and 75s-t Alclad

NASA Technical Reports Server (NTRS)

Russell, H W; Jackson, L R; Grover, H J; Beaver, W W

1944-01-01

Report contains detailed results of a number of fatigue tests on spot-welded joints in aluminum alloys. The tests described include: (1) fatigue tests on spot-welded lap joints in sheets of unequal thickness of alclad 24s-t. These tests indicate that the fatigue strength of a spot-welded joint in sheets of two different gages is slightly higher than that of a similar joint in two sheets of the thinner gage but definitely lower than that of a similar joint in two sheets of the thicker gage. (2) Fatigue tests on spot-welded alclad 75s-t spot-welded lap-joint specimens of alclad 75s-t were not any stronger in fatigue than similar specimens of alclad 24s-t. (3) Fatigue tests on lap-joint specimens spot -welded after various surface preparations--these included ac welding wire-brushed surfaces, dc welding wire-brushed surfaces, and dc welding chemically cleaned surfaces. While the ac welds were strongest statically, the dc welds on wire-brushed surfaces were strongest in fatigue. Specimens prepared in this way were very nearly as strong as the best riveted specimens tested for comparison. (4) Fatigue tests on specimens spot-welded with varying voltage so as to include a wide range of static spot-weld strengths. The fatigue strengths were in the same order as the static strengths but showed less range. (author)

Multiple pass and multiple layer friction stir welding and material enhancement processes

DOEpatents

Feng, Zhili [Knoxville, TN; David, Stan A [Knoxville, TN; Frederick, David Alan [Harriman, TN

2010-07-27

Processes for friction stir welding, typically for comparatively thick plate materials using multiple passes and multiple layers of a friction stir welding tool. In some embodiments a first portion of a fabrication preform and a second portion of the fabrication preform are placed adjacent to each other to form a joint, and there may be a groove adjacent the joint. The joint is welded and then, where a groove exists, a filler may be disposed in the groove, and the seams between the filler and the first and second portions of the fabrication preform may be friction stir welded. In some embodiments two portions of a fabrication preform are abutted to form a joint, where the joint may, for example, be a lap joint, a bevel joint or a butt joint. In some embodiments a plurality of passes of a friction stir welding tool may be used, with some passes welding from one side of a fabrication preform and other passes welding from the other side of the fabrication preform.

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.

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.

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.

Theoretical Investigation of Calculating Temperatures in the Combining Zone of Cu/Fe Composite Plate Jointed by Explosive Welding

NASA Astrophysics Data System (ADS)

Qu, Y. D.; Zhang, W. J.; Kong, X. Q.; Zhao, X.

2016-03-01

The heat-transfer behavior of the interface of Flyer plate (or Base Plate) has great influence on the microcosmic structures, stress distributions, and interface distortion of the welded interface of composite plates by explosive welding. In this paper, the temperature distributions in the combing zone are studied for the case of Cu/Fe composite plate jointed by explosive welding near the lower limit of explosive welding. The results show that Flyer plate (Cu plate) and Base Plate (Fe plate) firstly almost have the same melting rate in the explosive welding process. Then, the melting rate of Cu plate becomes higher than that of Fe plate. Finally, the melt thicknesses of Cu plate and Fe plate trend to be different constants, respectively. Meanwhile, the melting layer of Cu plate is thicker than that of Fe plate. The research could supply some theoretical foundations for calculating the temperature distribution and optimizing the explosive welding parameters of Cu/Fe composite plate to some extent.

Weld bonding of titanium with polyimide adhesives

NASA Technical Reports Server (NTRS)

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

1975-01-01

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

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

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

Hu, Z.L., E-mail: zhilihuhit@163.com; State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001; State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology

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

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

NASA Astrophysics Data System (ADS)

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

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

Effect of Heat Input on the Tensile Damage Evolution in Pulsed Laser Welded Ti6Al4V Titanium Sheets

NASA Astrophysics Data System (ADS)

Liu, Jing; Gao, Xiaolong; Zhang, Jianxun

2016-11-01

The present paper is focused on studying the effect of heat input on the tensile damage evolution of pulsed Nd:YAG laser welding of Ti6Al4V alloy under monotonic loading. To analyze the reasons that the tensile fracture site of the pulsed-laser-welded Ti6Al4V sheet joints changes with the heat input under monotonic loading, the microstructure of the sample with different nominal strain values was investigated by in situ observation. Experiment results show that the tensile ductility and fatigue life of welded joints with low heat input are higher than that of welded joints with high heat input. Under tensile loads, the critical engineering strain for crack initiation is much lower in the welded joint with high heat input than in the welded joints with low and medium heat input. And the microstructural damage accumulation is much faster in the fusion zone than in the base metal for the welded joints with high input, whereas the microstructural damage accumulation is much faster in the base metal than in the fusion zone for the welded joints with low input. Consequently, the welded joints fractured in the fusion zone for the welds with high heat input, whereas the welded joints ruptured in the base metal for the welds with low heat input. It is proved that the fine grain microstructure produced by low heat input can improve the critical nominal strain for crack initiation and the resistance ability of microstructural damage.

A New Perspective on Fatigue Performance of Advanced High- Strength Steels (AHSS) GMAW Joints

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

Feng, Zhili; Chiang, Dr. John; Kuo, Dr. Min

2008-01-01

Weld fatigue performance is a critical aspect for application of advanced high-strength steels (AHSS) in automotive body structures. A comparative study has been conducted to evaluate the fatigue life of AHSS welds. The material studied included seven AHSS of various strength levels - DP 600, DP 780, DP 980, M130, M220, solution annealed boron and fully hardened boron steels. Two conventional steels, HSLA 590 and DR 210, were also included for baseline comparison. Lap fillet welds were made on 2-mm nominal thick sheets by the gas metal arc welding process (GMAW). Fatigue test was conducted under a number of stressmore » levels to obtain the S/N curves of the weld joints. It was found that, unlike in the static and impact loading conditions, the fatigue performance of AHSS is not influenced by the HAZ softening in AHSS. There are appreciable differences in the fatigue lives among different AHSS. Changes in weld parameters can influence the fatigue life of the weld joints, particularly of these of higher strength AHSS. A model is developed to predict the fatigue performance of AHSS welds. The validity of the model is benchmarked with the experimental results. This model is capable to capture the effects of weld geometry and weld microstructure and strength on the fatigue performance experimentally observed. The theoretical basis and application of the newly developed fatigue modeling methodology will be discussed.« less

Simulation model of Al-Ti dissimilar laser welding-brazing and its experimental verification

NASA Astrophysics Data System (ADS)

Behúlová, M.; Babalová, E.; Nagy, M.

2017-02-01

Formation of dissimilar weld joints of light metals and alloys including Al-Ti joints is interesting mainly due to demands on the weight reduction and corrosion resistance of components and structures in automotive, aircraft, aeronautic and other industries. Joining of Al-Ti alloys represents quite difficult problem. Generally, the fusion welding of these materials can lead to the development of different metastable phases and formation of brittle intermetallic compounds. The paper deals with numerical simulation of the laser welding-brazing process of titanium Grade 2 and EN AW 5083 aluminum alloy sheets using the 5087 aluminum filler wire. Simulation model for welding-brazing of testing samples with the dimensions of 50 × 100 × 2 mm was developed in order to perform numerical experiments applying variable welding parameters and to design proper combination of these parameters for formation of sound Al-Ti welded-brazed joints. Thermal properties of welded materials in the dependence on temperature were computed using JMatPro software. The conical model of the heat source was exploited for description of the heat input to the weld due to the moving laser beam source. The sample cooling by convection and radiation to the surrounding air and shielding argon gas was taken into account. Developed simulation model was verified by comparison of obtained results of numerical simulation with the temperatures measured during real experiments of laser welding-brazing by the TruDisk 4002 disk laser.

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.

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

NASA Technical Reports Server (NTRS)

Moore, Thomas J.; Watson, Gordon K.

1994-01-01

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

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

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.

Microstructural and Mechanical Properties of Welded High Strength Steel Plate Using SMAW and SAW Method for LPG Storage Tanks

NASA Astrophysics Data System (ADS)

Winarto, Winarto; Riastuti, Rini; Kumeidi, Nur

2018-03-01

Indonesian government policy to convert energy consumption for domestic household from kerosene to liquefied petroleum gas (LPG) may lead to the increasing demand for LPG storage tank. LPG storage tank with a large capacity generally used the HSLA steel material of ASTM A516 Grade 70 joined by SMAW or combination between SMAW and SAW method. The heat input can affect the microstructure and mechanical properties of the weld area. The input heat is proportional to the welding current and the arc voltage, but inversely proportional to its welding speed. The result shows that the combination of SMAW-SAW process yield the lower hardness in the HAZ and the fusion zone compared to the singe SMAW process. PWHT mainly applied to reduce residual stress of welded joint. The result shows that PWHT can reduce the hardness in the HAZ and the fusion zone in comparing with the singe SMAW process. The microstructure of weld joint shows a coarser structure in the combined welding process (SMAW-SAW) comparing with the single welding process (SMAW).

Laser Welding of Shape Memory Alloys

NASA Astrophysics Data System (ADS)

Oliveira, Joao Pedro de Sousa

Joining of shape memory alloys is of great importance for both functional and structural applications as it can provide an increased design flexibility. In this work similar NiTi/NiTi, CuAlMn/CuAlMn and dissimilar NiTi/Ti6Al4V joints were produced by Nd:YAG laser. For the NiTi/NiTi joints the effect of process parameters (namely the heat input) on the superelastic and shape memory effects of the joints was assessed and correlated to its microstructure. Microstructural analysis was performed by means of X-ray diffraction using synchrotron radiation, which allowed for fine probing of the welded material. It was noticed the presence of martensite in the thermally affected regions, while the base material remained fully austenitic. The mechanisms for the formation of martensite, at room temperature, due to the welding procedure are presented and the influence of this phase on the functional properties of the joints is discussed. Additionally, the residual stresses were determined using synchrotron X-ray diffraction. For the dissimilar NiTi/Ti6Al4V joints, a Niobium interlayer was used to prevent the formation undesired brittle intermetallic compounds. Additionally, it was observed that positioning of the laser beam was of significant importance to obtain a sound joint. The mechanisms responsible for the joint formation are discussed based on observations with advanced characterization techniques, such as transmission electron microscopy. At the NiTi/Nb interface, an eutectic reaction promotes joining of the two materials, while at the Ti6Al4V/Nb interface fusion and, subsequent solidification of the Ti6Al4V was responsible for joining. Short distance diffusion of Nb to the fusion zone of Ti6Al4V was observed. Although fracture of the dissimilar welded joints occurred at a stress lower than the minimum required for the stress induced transformation, an improvement on the microstructure and mechanical properties, relatively to existing literature, was obtained. Finally, the first weldability study of superelastic CuAlMn alloy was performed. Superelasticity was preserved after welding. Post-weld laser processing improved the damping capability of the welded joint when compared to both as-welded and base materials, aiming for seismic construction. None None None None None None None None None None None None None None None None None None None None None None None None None None None None None None None

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.

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.

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.

Extended tensile testing of welded joints of polyethylene pipes

NASA Astrophysics Data System (ADS)

Danzanova, E. V.; Gerasimov, A. I.; Botvin, G. V.

2017-12-01

The paper introduces the results of testing joints welded in the open air at low climatic temperatures (below minus 15 °C) without heated facilities. Extended tensile testing in an active medium reveals that the same quality standard of welded joints is reached when welded parts are preheated when welding is performed under conditions of low climatic temperatures, and when they are welded at permissible temperatures.

Summary of Prior Work on Joining of Oxide Dispersion-Strengthened Alloys

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

Wright, Ian G; Tatlock, Gordon J; Badairy, H.

2009-08-01

There is a range of joining techniques available for use with ODS alloys, but care should be exercised in matching the technique to the final duty requirements of the joint. The goal for joining ODS alloys is a joint with no local disruption of the distribution of the oxide dispersion, and no significant change in the size and orientation of the alloy microstructure. Not surprisingly, the fusion welding processes typically employed with wrought alloys produce the least satisfactory results with ODS alloys, but some versions, such as fusion spot welding, and the laser and electron-beam welding technologies, have demonstrated potentialmore » for producing sound joints. Welds made using solid-state spot welding reportedly have exhibited parent metal properties. Thus, it is possible to employ processes that result in significant disruption of the alloy microstructure, as long as the processing parameters are adjustment to minimize the extent of or influence of the changes in the alloy microstructure. Selection among these joining approaches largely depends on the particular application and component configuration, and an understanding of the relationships among processing, alloy microstructure, and final properties is key. Recent developments have resulted in friction welding evolving to be a prime method for joining ODS sheet products, and variants of brazing/diffusion bonding have shown excellent promise for use with tubes and pipes. The techniques that come closest to the goal defined above involve solid-state diffusion bonding and, in particular, it has been found that secondary recrystallization of joints made by pulsed plasma-assisted diffusion can produce the desired, continuous, large alloy grain structure through the joint. Such joints have exhibited creep rupture failure at >82% of the load needed to fail the monolithic parent alloy at 1000 C.« less

Assessment of the Sensitivity of Welded Joints of Al -Mg - Si Alloys to Liquation Cracks Under Laser Welding

NASA Astrophysics Data System (ADS)

Ivanov, S. Yu.; Karkhin, V. A.; Mikhailov, V. G.; Martikainen, J.; Hiltunen, E.

2018-03-01

The microstructure and the distribution of chemical elements in laser-welded joints of Al - Mg - Si alloy 6005-T6 are studied. Segregations of chemical elements are detected over grain boundaries in the heat-affected zones of the welded joints. The joints fracture by the intergrain mechanism. A Gleeble 3800 device is used to determine the temperature dependences of the mechanical properties of the alloy with allowance for the special features of the welding cycle. Amethod for evaluating the sensitivity of welded joints of aluminum alloys to formation of liquation cracks with allowance for the local properties of the metal, the welding conditions, and the rigidity of the construction is suggested.

Two-Level Weld-Material Homogenization for Efficient Computational Analysis of Welded Structure Blast-Survivability

NASA Astrophysics Data System (ADS)

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

2012-06-01

The introduction of newer joining technologies like the so-called friction-stir welding (FSW) into automotive engineering entails the knowledge of the joint-material microstructure and properties. Since, the development of vehicles (including military vehicles capable of surviving blast and ballistic impacts) nowadays involves extensive use of the computational engineering analyses (CEA), robust high-fidelity material models are needed for the FSW joints. A two-level material-homogenization procedure is proposed and utilized in this study to help manage computational cost and computer storage requirements for such CEAs. The method utilizes experimental (microstructure, microhardness, tensile testing, and x-ray diffraction) data to construct: (a) the material model for each weld zone and (b) the material model for the entire weld. The procedure is validated by comparing its predictions with the predictions of more detailed but more costly computational analyses.

Microstructure and mechanical properties of China low activation martensitic steel joint by TIG multi-pass welding with a new filler wire

NASA Astrophysics Data System (ADS)

Huang, Bo; Zhang, Junyu; Wu, Qingsheng

2017-07-01

Tungsten Inner Gas (TIG) welding is employed for joining of China low activation martensitic (CLAM) steel. A new filler wire was proposed, and the investigation on welding with various heat input and welding passes were conducted to lower the tendency towards the residual of δ ferrite in the joint. With the optimized welding parameters, a butt joint by multi-pass welding with the new filler wire was prepared to investigate the microstructure and mechanical properties. The microstructure of the joint was observed by optical microscope (OM) and scanning electron microscope (SEM). The hardness, Charpy impact and tensile tests of the joint were implemented at room temperature (25 °C). The results revealed that almost full martensite free from ferrite in the joints were obtained by multipass welding with the heat input of 2.26 kJ/mm. A certain degree of softening occurred at the heat affected zone of the joint according to the results of tensile and hardness tests. The as welded joints showed brittle fracture in the impact tests. However, the joints showed toughness fracture after tempering and relatively better comprehensive performance were achieved when the joints were tempered at 740 °C for 2 h.

The Microstructure and Pitting Resistance of Weld Joints of 2205 Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Wu, Mingfang; Liu, Fei; Pu, Juan; Anderson, Neil E.; Li, Leijun; Liu, Dashuang

2017-11-01

2205 duplex stainless steel (DSS) was welded by submerged arc welding. The effects of both heat input and groove type on the ferrite/austenite ratio and elemental diffusion of weld joints were investigated. The relationships among welding joint preparation, ferrite/austenite ratio, elemental diffusion, and pitting corrosion resistance of weld joints were analyzed. When the Ni content of the weld wire deposit was at minimum 2-4% higher than that of 2205 DSS base metal, the desired ratio of ferrite/austenite and elemental partitioning between the austenite and ferrite phases were obtained. While the pitting sensitivity of weld metal was higher than that of base metal, the self-healing capability of the passive film of weld metal was better than that of the base metal when a single V-type groove was used. Furthermore, the heat input should be carefully controlled since pitting corrosion occurred readily in the coarse-grained heat-affected zone near the fusion line of welded joints.

Thick section aluminum weldments for SRB structures

NASA Technical Reports Server (NTRS)

Bayless, E.; Sexton, J.

1978-01-01

The Space Shuttle Solid Rocket Booster (SRB) forward and aft skirts were designed with fracture control considerations used in the design data. Fracture control is based on reliance upon nondestructive evaluation (NDE) techniques to detect potentially critical flaws. In the aerospace industry, welds on aluminum in the thicknesses (0.500 to 1.375 in.) such as those encountered on the SRB skirts are normally welded from both sides to minimize distortion. This presents a problem with the potential presence of undefined areas of incomplete fusion and the inability to detect these potential flaws by NDE techniques. To eliminate the possibility of an undetectable defect, weld joint design was revised to eliminate blind root penetrations. Weld parameters and mechanical property data were developed to verify the adequacy of the new joint design.

Practical small-scale explosive seam welding

NASA Technical Reports Server (NTRS)

Bement, L. J.

1983-01-01

A small-scale explosive seam welding process has been developed that can significantly contribute to remote metal joining operations under hazardous or inaccessible conditions, such as nuclear reactor repair and assembly of structure in space. This paper describes this explosive seam welding process in terms of joining principles, variables, types of joints created, capabilities, and applications. Very small quantities of explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long-length, uniform, hermetically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The practicality of this process has been demonstrated by its current acceptance, as well as its capabilities that are superior in many applications to the universally accepted joining processes, such as mechanical fasteners, fusion and resistance welding, and adhesives.

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.

Determination and Dependencies of Melt Pool Dimensions in Laser Micro Welding

NASA Astrophysics Data System (ADS)

Patschger, Andreas; Bliedtner, Jens

Melt pool dimensions such as width and length influence the properties of the resulting weld joint and should be considered when designing the laser welding process. The melt pool width and as a consequence the weld seam width determine the strength of the joint. The melt pool length is directly linked to the solidification time which affects the resulting metallurgical micro structure. The melt pool dimensions can be estimated by given analytical solutions based on the capillary diameter. In order to test the given estimations, melt pool dimensions of bead-on-plate welds in stainless steel foils were measured by means of high speed imaging and microscopy. The welds were obtained by applying different focal diameters between 25 μm and 204 μm to foil thicknesses of 50 μm and 100 μm. As a result, simplified correlations based on the focal diameter are derived which is less complex to determine in practice. Regression analyses ensure a statistical comparability.

Titanium Alloys Thin Sheet Welding with the Use of Concentrated Solar Energy

NASA Astrophysics Data System (ADS)

Pantelis, D. I.; Kazasidis, M.; Karakizis, P. N.

2017-12-01

The present study deals with the welding of titanium alloys thin sheets 1.3 mm thick, with the use of concentrated solar energy. The experimental part of the work took place at a medium size solar furnace at the installation of the Centre National de la Recherche Scientifique, at Odeillo, in Southern France, where similar and dissimilar defect-free welds of titanium Grades 4 and 6 were achieved, in the butt joint configuration. After the determination of the appropriate welding conditions, the optimum welded structures were examined and characterized microstructurally, by means of light optical microscopy, scanning electron microscopy, and microhardness testing. In addition, test pieces extracted from the weldments were tested under uniaxial tensile loading aiming to the estimation of the strength and the ductility of the joint. The analysis of the experimental results and the recorded data led to the basic concluding remarks which demonstrate increased hardness distribution inside the fusion area and severe loss of ductility, but adequate yield and tensile strength of the welds.

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

NASA Technical Reports Server (NTRS)

Looney, Alan

1991-01-01

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

Fusion welding studies using laser on Ti-SS dissimilar combination

NASA Astrophysics Data System (ADS)

Shanmugarajan, B.; Padmanabham, G.

2012-11-01

Laser welding investigations were carried out on dissimilar Ti-SS combination. The study is aimed to improve the weld strength and ductility by minimizing harmful intermetallics and taking advantage of high cooling rates in laser welding. Results of continuous wave 3.5 kW CO2 laser welding of totally dissimilar combination of Titanium and stainless steel (304) have been discussed. Bead on plate welding experiments were conducted to identify the laser welding parameters using depth of penetration as criteria. The welding of dissimilar combination has been attempted both autogenously and with interlayers such as Vanadium (V) and Tantalum (Ta) in the form of laser cladding as well as strip. Autogenous welds were carried out by varying the laser power, welding speed and position of the laser beam with respect to the joint centre. The resultant welds are characterized by macrostructure analysis, SEM/EDAX and XRD and as welded tensile test in UTM. The autogenous welds have exhibited extensive cracking even when welded at high speeds or by manipulating the beam position with respect to the joint. Similarly Vandaium as interlayer could not achieve crack free joint. A joint with 40 MPa strength could be made with Ta as interlayer. Results and analysis of these variants of laser welded joints are reported and discussed.

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

Effect of Multiple Local Repairs on Microstructure and Mechanical Properties of T24 Steel Welded Joint

NASA Astrophysics Data System (ADS)

Chaus, Alexander S.; Kuhajdová, Andrea; Marônek, Milan; Dománková, Mária

2018-05-01

The effect of multiple local repairs on the microstructure and mechanical properties of the T24 steel welded joints was studied. T24 steel tubes were butt-welded by the GTAW method. Peripheral welded joints were made in four locations of the tube. In order to simulate the repair procedure, the welds were cut off from the root and the first local repair was performed. Other two local repairs were carried out in the same way. After each local repair, the microstructure and mechanical properties of the joints were evaluated. The results of the mechanical tests demonstrate that only two local repairs can be performed on the T24 steel peripheral welded joint. After the third local repair, impact energy of the welded joint was lower than required value, which is attributed to the coarser martensite and the coarser carbide precipitates formed in the heat-affected zone, compared with the weld metal.

Microstructural Characteristics and Mechanical Properties of an Electron Beam-Welded Ti/Cu/Ni Joint

NASA Astrophysics Data System (ADS)

Zhang, Feng; Wang, Ting; Jiang, Siyuan; Zhang, Binggang; Feng, Jicai

2018-04-01

Electron beam welding experiments of TA15 titanium alloy to GH600 nickel superalloy with and without a copper sheet interlayer were carried out. Surface appearance, microstructure and phase constitution of the joint were examined by optical microscopy, scanning electron microscopy and x-ray diffraction analysis. Mechanical properties of Ti/Ni and Ti/Cu/Ni joint were evaluated based on tensile strength and microhardness tests. The results showed that cracking occurred in Ti/Ni electron beam weldment for the formation of brittle Ni-Ti intermetallics, while a crack-free electron beam-welded Ti/Ni joint can be obtained by using a copper sheet as filler metal. The addition of copper into the weld affected the welding metallurgical process of the electron beam-welded Ti/Ni joint significantly and was helpful for restraining the formation of Ti-Ni intermetallics in Ti/Ni joint. The microstructure of the weld was mainly characterized by a copper-based solid solution and Ti-Cu interfacial intermetallic compounds. Ti-Ni intermetallic compounds were almost entirely suppressed. The hardness of the weld zone was significantly lower than that of Ti/Ni joint, and the tensile strength of the joint can be up to 282 MPa.

Microstructural Characteristics and Mechanical Properties of an Electron Beam-Welded Ti/Cu/Ni Joint

NASA Astrophysics Data System (ADS)

Zhang, Feng; Wang, Ting; Jiang, Siyuan; Zhang, Binggang; Feng, Jicai

2018-05-01

Electron beam welding experiments of TA15 titanium alloy to GH600 nickel superalloy with and without a copper sheet interlayer were carried out. Surface appearance, microstructure and phase constitution of the joint were examined by optical microscopy, scanning electron microscopy and x-ray diffraction analysis. Mechanical properties of Ti/Ni and Ti/Cu/Ni joint were evaluated based on tensile strength and microhardness tests. The results showed that cracking occurred in Ti/Ni electron beam weldment for the formation of brittle Ni-Ti intermetallics, while a crack-free electron beam-welded Ti/Ni joint can be obtained by using a copper sheet as filler metal. The addition of copper into the weld affected the welding metallurgical process of the electron beam-welded Ti/Ni joint significantly and was helpful for restraining the formation of Ti-Ni intermetallics in Ti/Ni joint. The microstructure of the weld was mainly characterized by a copper-based solid solution and Ti-Cu interfacial intermetallic compounds. Ti-Ni intermetallic compounds were almost entirely suppressed. The hardness of the weld zone was significantly lower than that of Ti/Ni joint, and the tensile strength of the joint can be up to 282 MPa.

Thermomechanical treatment of welded joints of aluminum-lithium alloys modified by scandium

NASA Astrophysics Data System (ADS)

Malikov, A. G.

2017-12-01

At present, the aeronautical equipment manufacture involves up-to-date high-strength aluminum alloys of decreased density resulting from the lithium admixture. Various technologies of fusible welding of these alloys are being developed. The paper presents experimental investigations of the optimization of the laser welding of aluminum alloys with the scandium-modified welded joint after thermomechanical treatment. The effect of scandium on the micro- and macrostructure is studied along with strength characteristics of the welded joint. It is found that thermomechanical treatment allows us to obtain the strength of the welded joint 0.89 for the Al-Mg-Li system and 0.99 for the Al-Cu-Li system with the welded joint modified by scandium in comparison with the base alloy after treatment.

Fiber laser welding of nickel based superalloy Inconel 625

NASA Astrophysics Data System (ADS)

Janicki, Damian M.

2013-01-01

The paper describes the application of single mode high power fiber laser (HPFL) for the welding of nickel based superalloy Inconel 625. Butt joints of Inconel 625 sheets 0,8 mm thick were laser welded without an additional material. The influence of laser welding parameters on weld quality and mechanical properties of test joints was studied. The quality and mechanical properties of the joints were determined by means of tensile and bending tests, and micro hardness tests, and also metallographic examinations. The results showed that a proper selection of laser welding parameters provides non-porous, fully-penetrated welds with the aspect ratio up to 2.0. The minimum heat input required to achieve full penetration butt welded joints with no defect was found to be 6 J/mm. The yield strength and ultimate tensile strength of the joints are essentially equivalent to that for the base material.

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.

Effect of Brass Interlayer Sheet on Microstructure and Joint Performance of Ultrasonic Spot-Welded Copper-Steel Joints

NASA Astrophysics Data System (ADS)

Satpathy, Mantra Prasad; Kumar, Abhishek; Sahoo, Susanta Kumar

2017-07-01

Solid-state ultrasonic spot welding (USW) inevitably offers a potential solution for joining dissimilar metal combination like copper (Cu) and steel (SS). In this study, the USW has been performed on Cu (UNS C10100) and SS (AISI 304) with brass interlayer by varying various welding parameters, aiming to identify the interfacial reaction, changes in microstructure and weld strength. The highest tensile shear and T-peel failure loads of 1277 and 174 N are achieved at the optimum conditions like 68 µm of vibration amplitude, 0.42 MPa of weld pressure and 1 s of weld time. The fractured surface analysis of brass interlayer and AISI 304 stainless steel samples reveals the features like swirls, voids and intermetallic compounds (IMCs). These IMCs are composed of CuZn and FeZn composite-like structures with 1.0 μm thickness. This confirms that the weld quality is specifically sensitive to the levels of input parameter combinations as well as the type of material present on the sonotrode side.

Preliminary study on pressure brazing and diffusion welding of Nb-1Zr to Inconel 718

NASA Technical Reports Server (NTRS)

Moore, T. J.

1990-01-01

Future space power systems may include Nb-1Zr/Inconel 718 dissimilar metal joints for operation at 1000 K for 60,000 h. The serviceability of pressure-brazed and diffusion-welded joints was investigated. Ni-based metallic glass foil filler metals were used for brazing. Ni and Fe foils were used as diffusion welding inter-layers. Joint soundness was determined by metallographic examination in the as-brazed and as-welded condition, after aging at 1000 K, and after thermal cycling. Brazed joints thermally cycled in the as-brazed condition and diffusion-welded joints were unsatisfactory because of cracking problems. Brazed joints may meet the service requirements if the joints are aged at 1000 K prior to thermal cycling.

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

NASA Astrophysics Data System (ADS)

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

2012-06-01

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

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.

Double fillet lap of laser welding of thin sheet AZ31B Mg alloy

NASA Astrophysics Data System (ADS)

Ishak, Mahadzir; Salleh, M. N. M.

2018-05-01

In this paper, we describe the experimental laser welding of thin sheet AZ31B using double fillet lap joint method. Laser welding is capable of producing high quality weld seams especially for small weld bead on thin sheet product. In this experiment, both edges for upper and lower sheets were subjected to the laser beam from the pulse wave (PW) mode of fiber laser. Welded sample were tested their joint strength by tensile-shear strength method and the fracture loads were studied. Strength for all welded samples were investigated and the effect of laser parameters on the joint strength and appearances were studied. Pulsed energy (EP) from laser process give higher effect on joint strength compared to the welding speed (WS) and angle of irradiation (AOI). Highest joint strength was possessed by sample with high EP with the same value of WS and AOI. The strength was low due to the crack defect at the centre of weld region.

Fracture resistance of Nd:YAG laser-welded cast titanium joints with various clinical thicknesses and welding pulse energies.

PubMed

Lin, Mau-Chin; Lin, Sheng-Chieh; Wang, Yu-Tsai; Hu, Suh-Woan; Lee, Tzu-Hsin; Chen, Li-Kai; Huang, Her-Hsiung

2007-05-01

The purpose of this study was to evaluate the fracture resistance of Nd:YAG laser-welded cast titanium (Ti) joints with various clinical thicknesses and welding pulse energies. A four-point bending test was used to assess the effects of various specimen thicknesses (1-3 mm) and welding pulse energies (11-24 J) on the fracture resistance of Nd:YAG laser-welded Ti dental joints. Fracture resistance was evaluated in terms of the ratio of the number of fractured specimens to the number of tested specimens. As for the fracture frequencies, they were compared using the Cochran-Mantel-Haenszel test. Morphology of the fractured Ti joints was observed using a scanning electron microscope. Results showed that decreasing the specimen thickness and/or increasing the welding pulse energy, i.e., increasing the welded area percentage, resulted in an increase in the fracture resistance of the Ti joint. Where fracture occurred, the fracture site would be at the center of the weld metal.

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

NASA Astrophysics Data System (ADS)

Han, Bing; Tao, Wang; Chen, Yanbin

2017-06-01

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

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.

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

DOEpatents

Trent, Jett B.; Murphy, Jimmy L.

1981-01-01

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

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

DOEpatents

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

1980-01-03

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

Influence of PC-GTAW Parameters on the Microstructural and Mechanical Properties of Thin AISI 1008 Steel Joints

NASA Astrophysics Data System (ADS)

Kumar, Ravindra; Anant, Ramkishor; Ghosh, P. K.; Kumar, Ankit; Agrawal, B. P.

2016-09-01

Butt weld joints are prepared using pulse current gas tungsten arc welding out of thin sheets of AISI 1008 steel using various combinations of pulse parameters. During welding, the welding speed was kept high, but with the increase of welding speed the mean current was also increased to get the required weld joint at the constant heat input. The use of pulse current has led to improvement in mechanical and metallurgical properties of weld joints. It has resulted in less development of humping which is a common problem with high-speed welding. The undercut or dipped weld face is not observed severe. The tensile strength and hardness are enhanced by 12.5 and 12%. The increase of tensile strength and hardness is justified through TEM micrograph showing the presence of dislocation.

Effect of Tool Offset and Tool Rotational Speed on Enhancing Mechanical Property of Al/Mg Dissimilar FSW Joints

NASA Astrophysics Data System (ADS)

Liang, Zhiyuan; Chen, Ke; Wang, Xiaona; Yao, Junshan; Yang, Qi; Zhang, Lanting; Shan, Aidang

2013-08-01

Friction stir welding (FSW) is a promising solid-state joining technique for producing effective welds between Al alloy and Mg alloy. However, previously reported Al/Mg dissimilar FSW joints generally have limited strength or barely any ductility with relatively high strength, which was blamed on the brittle intermetallics formed during welding. In this study, effective joints with comparably high strength (163 MPa) and large elongation (~6 pct) were obtained. Three crucial/weak zones were identified in the welds: (1) Al/Mg bottom interface (BI) zone that resulted from the insufficient materials' intermixing and interdiffusion; (2) banded structure (BS) zone which contains intermetallic particles possibly formed by constitutional liquation; and (3) softened Al alloy to the retreating side (SAA-RS) zone due to the dissolution and coarsening of the strengthening precipitates. Three fracture modes observed in the tensile specimens perpendicular to the weld seam were found closely related to these zones. Their microstructure evolution with the change of tool rotational speed and tool offset was characterized and the consequent effect on the fracture mode alteration was studied. It turned out that enhancing the strengths of all these zones, but keeping the strength of the SAA lowest, is an effective way for enhancing ductility while keeping comparatively high strength in Al/Mg FSW joints. Also, suggestions for further improving the mechanical property of the Al/Mg dissimilar FSW joints were made accordingly for practical applications.

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

Forming Completely Penetrated Welded T-joints when Pulsed Arc Welding

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

49 CFR 195.216 - Welding: Miter joints.

Code of Federal Regulations, 2010 CFR

2010-10-01

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

49 CFR 195.216 - Welding: Miter joints.

Code of Federal Regulations, 2012 CFR

2012-10-01

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

49 CFR 195.216 - Welding: Miter joints.

Code of Federal Regulations, 2014 CFR

2014-10-01

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

49 CFR 195.216 - Welding: Miter joints.

Code of Federal Regulations, 2013 CFR

2013-10-01

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

49 CFR 195.216 - Welding: Miter joints.

Code of Federal Regulations, 2011 CFR

2011-10-01

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

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

PubMed

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

2015-05-01

Framework longevity is a key factor for the success of complete-arch prostheses and commonly depends on the welding methods. However, no consensus has been reached on the joint design and welding type for improving framework resistance. The purpose of this study was to assess the effect of different joint designs and welding methods with tungsten inert gas (TIG) or laser to join titanium alloy bars (Ti-6Al-4V). Seventy titanium alloy bar specimens were prepared (3.18 mm in diameter × 40.0 mm in length) and divided into 7 groups (n=10): the C-control group consisting of intact specimens without joints and the remaining 6 groups consisting of specimens sectioned perpendicular to the long-axis and rejoined using an I-, X30-, or X45-shaped joint design with TIG welding (TI, TX30, and TX45) or laser welding (LI, LX30, and LX45). The specimens were tested with 3-point bending. The fracture surfaces were first evaluated with stereomicroscopy to measure the weld penetration area and then analyzed with scanning electron microscopy (SEM). The data were statistically analyzed with 2-way ANOVA and the Tukey post hoc test, 1-way ANOVA and the Dunnett test, and the Pearson correlation test (α=.05). Specimens from the X30 and X45 groups showed higher flexural strength (P<.05) and welded area (P<.05) than specimens from the I groups, regardless of the welding type. TIG welded groups showed significantly higher flexural strength than the laser groups (P<.05), regardless of the joint design. TIG welding also resulted in higher welded areas than laser welding for the I-shaped specimens. No significant differences were found for the weld penetration area in the X45 group, either for laser or TIG welding. SEM analysis showed more pores at the fracture surfaces of the laser specimens. Fracture surfaces indicative of regions of increased ductility were detected for the TIG specimens. TIG welding resulted in higher flexural strength for the joined titanium specimens than laser welding. For both welding methods, X30- and X45-shaped joint designs resulted in higher flexural strength and welding penetration than the I-shaped joint design. Copyright © 2015 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Structure and mechanical properties of Cresco-Ti laser-welded joints and stress analyses using finite element models of fixed distal extension and fixed partial prosthetic designs.

PubMed

Uysal, Hakan; Kurtoglu, Cem; Gurbuz, Riza; Tutuncu, Naki

2005-03-01

The Cresco-Ti System uses a laser-welded process that provides an efficient technique to achieve passive fit frameworks. However, mechanical behavior of the laser-welded joint under biomechanical stress factors has not been demonstrated. This study describes the effect of Cresco-Ti laser-welding conditions on the material properties of the welded specimen and analyzes stresses on the weld joint through 3-dimensional finite element models (3-D FEM) of implant-supported fixed dentures with cantilever extensions and fixed partial denture designs. Twenty Grade III (ASTM B348) commercially pure titanium specimens were machine-milled to the dimensions described in the EN10002-1 tensile test standard and divided into test (n = 10) and control (n = 10) groups. The test specimens were sectioned and laser-welded. All specimens were subjected to tensile testing to determine yield strength (YS), ultimate tensile strength (UTS), and percent elongation (PE). The Knoop micro-indentation test was performed to determine the hardness of all specimens. On welded specimens, the hardness test was performed at the welded surface. Data were analyzed with the Mann-Whitney U test and Student's t test (alpha=.05). Fracture surfaces were examined by scanning electron microscopy to characterize the mode of fracture and identify defects due to welding. Three-dimensional FEMs were created that simulated a fixed denture with cantilever extensions supported by 5 implants (M1) and a fixed partial denture supported by 2 implants (M2), 1 of which was angled 30 degrees mesio-axially. An oblique load of 400 N with 15 degrees lingual-axial inclinations was applied to both models at various locations. Test specimens fractured between the weld and the parent material. No porosities were observed on the fractured surfaces. Mean values for YS, UTS, PE, and Knoop hardness were 428 +/- 88 MPa, 574 +/- 113 MPa, 11.2 +/- 0.4%, 270 +/- 17 KHN, respectively, for the control group and 642 +/- 2 MPa, 772 +/- 72 MPa, 4.8 +/- 0.7%, 353 +/- 23 KHN, respectively, for the test group. The differences between the groups were significant for all mechanical properties ( P <.05). For both models, the FEA revealed that maximum principal stresses were concentrated at the framework-weld junction but did not exceed the UTS of the weld joint. Within the constraints of the finite element models, mechanical failure of the welded joint between the support and the framework may not be expected under biomechanical conditions simulated in this study.

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.

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

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

Estimation of Vickers hardness uncertainty for a heterogeneous welded joint (S235JR+AR and X2CrNiMo17-12-2)

NASA Astrophysics Data System (ADS)

Dijmărescu, M. C.; Dijmărescu, M. R.

2017-08-01

When talking about tests that include measurements, the uncertainty of measurement is an essential element because it is important to know the limits within the obtained results may be assumed to lie and the influence the measurement technological system elements have on these results. The research presented in this paper focuses on the estimation of the Vickers hardness uncertainty of measurement for the heterogeneous welded joint between S235JR+AR and X2CrNiMo17-12-2 materials in order to establish the results relevance and the quality assessment of this joint. The paper contents are structured in three main parts. In the first part, the initial data necessary for the experiment is presented in terms of the welded joint and technological means characterisation. The second part presents the physical experiment development and its results and in the third part the uncertainty of the measurements is calculated and a results discussion is undertaken.

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.

49 CFR 571.221 - Standard No. 221; School bus body joint strength.

Code of Federal Regulations, 2011 CFR

2011-10-01

... and any structure forward of the passenger compartment. Maintenance access panel means a body panel... so that it does not bisect a spot weld or a discrete fastener. Support members which contribute to... structure attached to joint members, shall remain attached to the test specimen, except that material may be...

49 CFR 571.221 - Standard No. 221; School bus body joint strength.

Code of Federal Regulations, 2010 CFR

2010-10-01

... and any structure forward of the passenger compartment. Maintenance access panel means a body panel... so that it does not bisect a spot weld or a discrete fastener. Support members which contribute to... structure attached to joint members, shall remain attached to the test specimen, except that material may be...

49 CFR 571.221 - Standard No. 221; School bus body joint strength.

Code of Federal Regulations, 2013 CFR

2013-10-01

... and any structure forward of the passenger compartment. Maintenance access panel means a body panel... so that it does not bisect a spot weld or a discrete fastener. Support members which contribute to... structure attached to joint members, shall remain attached to the test specimen, except that material may be...

49 CFR 571.221 - Standard No. 221; School bus body joint strength.

Code of Federal Regulations, 2012 CFR

2012-10-01

... and any structure forward of the passenger compartment. Maintenance access panel means a body panel... so that it does not bisect a spot weld or a discrete fastener. Support members which contribute to... structure attached to joint members, shall remain attached to the test specimen, except that material may be...

49 CFR 571.221 - Standard No. 221; School bus body joint strength.

Code of Federal Regulations, 2014 CFR

2014-10-01

... and any structure forward of the passenger compartment. Maintenance access panel means a body panel... so that it does not bisect a spot weld or a discrete fastener. Support members which contribute to... structure attached to joint members, shall remain attached to the test specimen, except that material may be...

Friction Stir Welding of Magnesium Alloy Type AZ 31

NASA Astrophysics Data System (ADS)

Kupec, Tomáš; Behúlová, Mária; Turňa, Milan; Sahul, Miroslav

The paper deals with welding of Mg alloy of the type AZ 31 by Friction Stir Welding technology (FSW). The FSW technology is at present predominantly used for welding light metals and alloys, as aluminium, magnesium and their alloys. Experimental part consists of performing the simulation and fabrication of welded joints on a new-installed welding equipment available at the Welding Research Institute — Industrial Institute of SR Bratislava. Welding tools made of tool steel type H 13 were used for welding experiments. Geometry of welding tools was designed on the base of literature knowledge. Suitable welding parameters and conditions were determined using numerical simulation. Main emphasis was laid upon the tool revolutions, welding speed and tool bevel angle. The effect of welding parameters on the quality of welded joints was assessed. Assessment of welded joints was carried out by radiography, light microscopy, hardness measurement and EDX microanalysis. Static tensile test was employed for mechanical testing.

Fatigue limits of titanium-bar joints made with the laser and the electric resistance welding techniques: microstructural characterization and hardness properties.

PubMed

Degidi, Marco; Nardi, Diego; Morri, Alessandro; Sighinolfi, Gianluca; Tebbel, Florian; Marchetti, Claudio

2017-09-01

Fatigue behavior of the titanium bars is of utmost importance for the safe and reliable operation of dental implants and prosthetic constructions based on these implants. To date, however, only few data are available on the fatigue strength of dental prostheses made with electric resistance welding and laser welding techniques. This in-vitro study highlighted that although the joints made with the laser welding approach are credited of a superior tensile strength, joints made with electric resistance welding exhibited double the minimum fatigue strength with respect to the joints made with laser welding (120 vs 60 N).

Subminiature eddy-current transducers designed to study welded joints of titanium alloys

NASA Astrophysics Data System (ADS)

Malikov, V. N.; Dmitriev, S. F.; Katasonov, A. O.; Sagalakov, A. M.; Ishkov, A. V.

2017-12-01

Eddy current transducers (ECT) are used to construct a sensor for investigating titanium sheets connected by a welded joint. The paper provides key technical information about the eddy current transducer used and describes the procedure of measurements that makes it possible to control defects in welded joints of titanium alloys. It is capable of automatically changing the filtering cutoff frequency and operating frequency of the device. Experiments were conducted on welded VT1-0 titanium plates. The paper contains the results of these measurements. The dependence data facilitates the assessment of the quality of the welded joints and helps make an educated conclusion about welding quality.

Microstructural Aspects in FSW and TIG Welding of Cast ZE41A Magnesium Alloy

NASA Astrophysics Data System (ADS)

Carlone, Pierpaolo; Astarita, Antonello; Rubino, Felice; Pasquino, Nicola

2016-04-01

In this paper, magnesium ZE41A alloy plates were butt joined through friction stir welding (FSW) and Tungsten Inert Gas welding processes. Process-induced microstructures were investigated by optical and SEM observations, EDX microanalysis and microhardness measurements. The effect of a post-welded T5 heat treatment on FSW joints was also assessed. Sound joints were produced by means of both techniques. Different elemental distributions and grain sizes were found, whereas microhardness profiles reflect microstructural changes. Post-welding heat treatment did not induce significant alterations in elemental distribution. The FSW-treated joint showed a more homogeneous hardness profile than the as-welded FSW joint.

Experience of Application of EBW in Producing Welded VT41 Alloy Drums in the Design of an HPC in an Advanced Engine

NASA Astrophysics Data System (ADS)

Bykov, Yu. G.; Fomichev, E. O.; Kashapov, O. S.; Kyaramyan, K. A.

2017-12-01

The conditions of electron-beam welding (EBW) of ring samples made of a VT41 alloy are adjusted to produce large welded joints of this alloy for a high-pressure compressor (HPC) of an advanced engine. The problems of quality control of a welded joint, the level of residual stresses in the near-weld zone, the microstructure of the welded joint, and its properties are considered.

Fatigue Performance of Advanced High-Strength Steels (AHSS) GMAW Joints

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

Feng, Zhili; Sang, Yan; Jiang, Cindy

2009-01-01

The fatigue performance of gas metal arc welding (GMAW) joints of advanced high strength steels (AHSS) are compared and analyzed. The steel studied included a number of different grades of AHSS and baseline mild steels: DP600, DP780, DP980, M130, M220, solution annealed boron steel, fully hardened boron steels, HSLA690 and DR210 (a mild steel). Fatigue testing was conducted under a number of nominal stress ranges to obtain the S/N curves of the weld joints. A two-phase analytical model is developed to predict the fatigue performance of AHSS welds. It was found that there are appreciable differences in the fatigue S/Nmore » curves among different AHSS joints made using the same welding practices, suggesting that the local microstructure in the weld toe and root region plays non-negligible role in the fatigue performance of AHSS welds. Changes in weld parameters can influence the joint characteristics which in turn influence fatigue life of the weld joints, particularly of those of higher strength AHSS. The analytical model is capable of reasonably predicting the fatigue performance of welds made with various steel grades in this study.« less

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.

Improvement in Fatigue Performance of Aluminium Alloy Welded Joints by Laser Shock Peening in a Dynamic Strain Aging Temperature Regime.

PubMed

Su, Chun; Zhou, Jianzhong; Meng, Xiankai; Huang, Shu

2016-09-26

As a new treatment process after welding, the process parameters of laser shock peening (LSP) in dynamic strain aging (DSA) temperature regimes can be precisely controlled, and the process is a non-contact one. The effects of LSP at elevated temperatures on the distribution of the surface residual stress of AA6061-T6 welded joints were investigated by using X-ray diffraction technology with the sin² ϕ method and Abaqus software. The fatigue life of the welded joints was estimated by performing tensile fatigue tests. The microstructural evolution in surface and fatigue fractures of the welded joints was presented by means of surface integrity and fracture surface testing. In the DSA temperature regime of AA6061-T6 welded joints, the residual compressive stress was distributed more stably than that of LSP at room temperature. The thermal corrosion resistance and fatigue properties of the welded joints were also improved. The experimental results and numerical analysis were in mutual agreement.

Improvement in Fatigue Performance of Aluminium Alloy Welded Joints by Laser Shock Peening in a Dynamic Strain Aging Temperature Regime

PubMed Central

Su, Chun; Zhou, Jianzhong; Meng, Xiankai; Huang, Shu

2016-01-01

As a new treatment process after welding, the process parameters of laser shock peening (LSP) in dynamic strain aging (DSA) temperature regimes can be precisely controlled, and the process is a non-contact one. The effects of LSP at elevated temperatures on the distribution of the surface residual stress of AA6061-T6 welded joints were investigated by using X-ray diffraction technology with the sin2ϕ method and Abaqus software. The fatigue life of the welded joints was estimated by performing tensile fatigue tests. The microstructural evolution in surface and fatigue fractures of the welded joints was presented by means of surface integrity and fracture surface testing. In the DSA temperature regime of AA6061-T6 welded joints, the residual compressive stress was distributed more stably than that of LSP at room temperature. The thermal corrosion resistance and fatigue properties of the welded joints were also improved. The experimental results and numerical analysis were in mutual agreement. PMID:28773920

Effects of aging treatment and heat input on the microstructures and mechanical properties of TIG-welded 6061-T6 alloy joints

NASA Astrophysics Data System (ADS)

Peng, Dong; Shen, Jun; Tang, Qin; Wu, Cui-ping; Zhou, Yan-bing

2013-03-01

Aging treatment and various heat input conditions were adopted to investigate the microstructural evolution and mechanical properties of TIG welded 6061-T6 alloy joints by microstructural observations, microhardness tests, and tensile tests. With an increase in heat input, the width of the heat-affected zone (HAZ) increases and grains in the fusion zone (FZ) coarsen. Moreover, the hardness of the HAZ decreases, whereas that of the FZ decreases initially and then increases with an increase in heat input. Low heat input results in the low ultimate tensile strength of the welded joints due to the presence of partial penetrations and pores in the welded joints. After a simple artificial aging treatment at 175°C for 8 h, the microstructure of the welded joints changes slightly. The mechanical properties of the welded joints enhance significantly after the aging process as few precipitates distribute in the welded seam.

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

NASA Astrophysics Data System (ADS)

Taweejun, Nipon; Poapongsakorn, Piyamon; Kanchanomai, Chaosuan

2017-04-01

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

Microstructure and Mechanical Properties of Three-Layer TIG-Welded 2219 Aluminum Alloys with Dissimilar Heat Treatments

NASA Astrophysics Data System (ADS)

Zhang, Dengkui; Li, Quan; Zhao, Yue; Liu, Xianli; Song, Jianling; Wang, Guoqing; Wu, Aiping

2018-05-01

2219-C10S and 2219-CYS aluminum alloys are 2219 aluminum alloys with different heat treatment processes, and they have been widely used in the aerospace industry. In the present study, 2219-C10S and 2219-CYS aluminum alloys were butt-welded by three-layer tungsten inert gas arc welding (with the welding center of the third layer shifted toward the CYS side), and the microstructure characteristics and mechanical properties of the welded joint were investigated. The lamellar θ' phases, the bulk or rod θ phases, and the coarse rod-shaped or pancake-shaped Al-Cu-Fe-Mn phases coexisted in the two aluminum alloys. The Cu content of the α-Al matrix and the distribution of eutectic structures of different welding layers in the weld zone (WZ) were varied, implying that the segregation degrees of the Cu element were different due to the different welding thermal cycles in different welding layers. The microhardness values of the CYS side were much higher than those of the C10S side in each region on both sides of the joint. The tensile test deformation was concentrated mainly in the regions of WZ and the over aged zone (OAZ), where the microhardness values were relatively low. The main deformation concentrated region was transferred from the CYS side to the C10S side with the increase in the tensile load during the tensile test. The fracture behavior of the tensile test showed that the macroscopic crack initiated near the front weld toe had gone through the crack blunt region, the shear fracture region of the partially melted zone (PMZ), and the shear fracture region of OAZ. Meanwhile, the fracture characteristics gradually evolved from brittle to ductile. The concentrated stress and the dense eutectic structure in the region near the front weld toe of the C10S side contributed to the fracture of the joint. The shift of the welding center of the third layer to the CYS side resulted in two effects: (i) the microhardness values from the middle layer to the top layer in the PMZ of the CYS side were the most significantly increased and (ii) the distance between the front weld toe and the fusion line of the CYS side was significantly larger.

Models for selecting GMA Welding Parameters for Improving Mechanical Properties of Weld Joints

NASA Astrophysics Data System (ADS)

Srinivasa Rao, P.; Ramachandran, Pragash; Jebaraj, S.

2016-02-01

During the process of Gas Metal Arc (GMAW) welding, the weld joints mechanical properties are influenced by the welding parameters such as welding current and arc voltage. These parameters directly will influence the quality of the weld in terms of mechanical properties. Even small variation in any of the cited parameters may have an important effect on depth of penetration and on joint strength. In this study, S45C Constructional Steel is taken as the base metal to be tested using the parameters wire feed rate, voltage and type of shielding gas. Physical properties considered in the present study are tensile strength and hardness. The testing of weld specimen is carried out as per ASTM Standards. Mathematical models to predict the tensile strength and depth of penetration of weld joint have been developed by regression analysis using the experimental results.

Effect of process parameters on microstructure and mechanical properties of friction stir welded joints: A review

NASA Astrophysics Data System (ADS)

Wanare, S. P.; Kalyankar, V. D.

2018-04-01

Friction stir welding is emerging as a promising technique for joining of lighter metal alloys due to its several advantages over conventional fusion welding processes such as low thermal distortion, good mechanical properties, fine weld joint microstructure, etc. This review article mainly focuses on analysis of microstructure and mechanical properties of friction stir welded joints. Various microstructure characterization techniques used by previous researchers such as optical microscopes, x-ray diffraction, electron probe microscope, transmission electron microscope, scanning electron microscopes with electron back scattered diffraction, electron dispersive microscopy, etc. are thoroughly overviewed and their results are discussed. The effects of friction stir welding process parameters such as tool rotational speed, welding speed, tool plunge depth, axial force, tool shoulder diameter to tool pin diameter ratio, tool geometry etc. on microstructure and mechanical properties of welded joints are studied and critical observations are noted down. The microstructure examination carried out by previous researchers on various zones of welded joints such as weld zone, heat affected zone and base metal are studied and critical remarks have been presented. Mechanical performances of friction stir welded joints based on tensile test, micro-hardness test, etc. are discussed. This article includes exhaustive literature review of standard research articles which may become ready information for subsequent researchers to establish their line of action.

Microstructure and calorimetric behavior of laser welded open cell foams in CuZnAl shape memory alloy

NASA Astrophysics Data System (ADS)

Biffi, Carlo Alberto; Previtali, Barbara; Tuissi, Ausonio

Cellular shape memory alloys (SMAs) are very promising smart materials able to combine functional properties of the material with lightness, stiffness, and damping capacity of the cellular structure. Their processing with low modification of the material properties remains an open question. In this work, the laser weldability of CuZnAl SMA in the form of open cell foams was studied. The cellular structure was proved to be successfully welded in lap joint configuration by using a thin plate of the same alloy. Softening was seen in the welded bead in all the investigated ranges of process speed as well as a double stage heat affected zone was identified due to different microstructures; the martensitic transformation was shifted to higher temperatures and the corresponding peaks were sharper with respect to the base material due to the rapid solidification of the material. Anyways, no compositional variations were detected in the joints.

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.

Pulsed Laser Beam Welding of Pd43Cu27Ni10P20 Bulk Metallic Glass.

PubMed

Shao, Ling; Datye, Amit; Huang, Jiankang; Ketkaew, Jittisa; Woo Sohn, Sung; Zhao, Shaofan; Wu, Sujun; Zhang, Yuming; Schwarz, Udo D; Schroers, Jan

2017-08-11

We used pulsed laser beam welding method to join Pd 43 Cu 27 Ni 10 P 20 (at.%) bulk metallic glass and characterized the properties of the joint. Fusion zone and heat-affected zone in the weld joint can be maintained completely amorphous as confirmed by X-ray diffraction and differential scanning calorimetry. No visible defects were observed in the weld joint. Nanoindentation and bend tests were carried out to determine the mechanical properties of the weld joint. Fusion zone and heat-affected zone exhibit very similar elastic moduli and hardness when compared to the base material, and the weld joint shows high ductility in bending which is accomplished through the operation of multiple shear bands. Our results reveal that pulsed laser beam welding under appropriate processing parameters provides a practical viable method to join bulk metallic glasses.

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

DOEpatents

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

2005-09-27

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

Real weld geometry determining mechanical properties of high power laser welded medium plates

NASA Astrophysics Data System (ADS)

Liu, Sang; Mi, Gaoyang; Yan, Fei; Wang, Chunming; Li, Peigen

2018-06-01

Weld width is commonly used as one of main factors to assess joint performances in laser welding. However, it changes significantly through the thickness direction in conditions of medium or thick plates. In this study, high-power autogenous laser welding was conducted on 7 mm thickness 201 stainless steel to elucidate the factor of whole weld transverse shape critically affecting the mechanical properties with the aim of predicting the performance visually through the weld appearance. The results show that single variation of welding parameters could result in great changes of weld pool figures and subsequently weld transverse shapes. All the obtained welds are composed of austenite containing small amount of cellular dendritic δ-Ferrite. The 0.2% proof stresses of Nail- and Peanut-shaped joint reach 458 MPa and 454 MPa, 88.2% and 87.5% of the base material respectively, while that of Wedge-shaped joint only comes to 371 MPa, 71.5% of the base material. The deterioration effect is believed to be caused by the axial grain zone in the weld center. The fatigue strength of joint P is a bit lower than N, but much better than W. Significant deformation incompatibility through the whole thickness and microstructure resistance to crack initiation should be responsible for the poor performance of W-shaped joints.

Characterization of Mechanical Properties and Residual Stress in API 5L X80 Steel Welded Joints

NASA Astrophysics Data System (ADS)

de Sousa Lins, Amilton; de Souza, Luís Felipe Guimarães; Fonseca, Maria Cindra

2018-01-01

The use of high-strength and low-alloy steels, high design factors and increasingly stringent safety requirements have increased the operating pressure levels and, consequently, the need for further studies to avoid and prevent premature pipe failure. To evaluate the possibility of improving productivity in manual arc welding of this type of steel, this work characterizes the mechanical properties and residual stresses in API 5L X80 steel welded joints using the SMAW and FCAW processes. The residual stresses were analyzed using x-ray diffraction with the sin2 ψ method at the top and root of the welded joints in the longitudinal and transverse directions of the weld bead. The mechanical properties of the welded joints by both processes were characterized in terms of tensile strength, impact toughness and Vickers microhardness in the welded and shot peening conditions. A predominantly compressive residual stress was found, and shot peening increased the tensile strength and impact toughness in both welded joints.

Narrow gap laser welding

DOEpatents

Milewski, John O.; Sklar, Edward

1998-01-01

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

Narrow gap laser welding

DOEpatents

Milewski, J.O.; Sklar, E.

1998-06-02

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

Friction Stir Welding Development at NASA, Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

McGill, Preston; Gentz, Steve (Technical Monitor)

2001-01-01

Friction stir welding (FSW) is a solid state process that pan be used to join materials without melting. The process was invented by The Welding Institute (TWI), Cambridge, England. Friction stir welding exhibits several advantages over fusion welding in that it produces welds with fewer defects and higher joint efficiency and is capable of joining alloys that are generally considered non-weldable with a fusion weld process. In 1994, NASA-Marshall began collaborating with TWI to transform FSW from a laboratory curiosity to a viable metal joining process suitable for manufacturing hardware. While teamed with TWI, NASA-Marshall began its own FSW research and development effort to investigate possible aerospace applications for the FSW process. The work involved nearly all aspects of FSW development, including process modeling, scale-up issues, applications to advanced materials and development of tooling to use FSW on components of the Space Shuttle with particular emphasis on aluminum tanks. The friction stir welding process involves spinning a pin-tool at an appropriate speed, plunging it into the base metal pieces to be joined, and then translating it along the joint of the work pieces. In aluminum alloys the rotating speed typically ranges from 200 to 400 revolutions per minute and the translation speed is approximately two to five inches per minute. The pin-tool is inserted at a small lead angle from the axis normal to the work piece and requires significant loading along the axis of the tool. An anvil or reaction structure is required behind the welded material to react the load along the axis of the pin tool. The process requires no external heat input, filler material, protective shielding gas or inert atmosphere typical of fusion weld processes. The FSW solid-state weld process has resulted in aluminum welds with significantly higher strengths, higher joint efficiencies and fewer defects than fusion welds used to join similar alloys.

Dissimilar material joining using laser (aluminum to steel using zinc-based filler wire)

NASA Astrophysics Data System (ADS)

Mathieu, Alexandre; Shabadi, Rajashekar; Deschamps, Alexis; Suery, Michel; Matteï, Simone; Grevey, Dominique; Cicala, Eugen

2007-04-01

Joining steel with aluminum involving the fusion of one or both materials is possible by laser beam welding technique. This paper describes a method, called laser braze welding, which is a suitable process to realize this structure. The main problem with thermal joining of steel/aluminum assembly with processes such as TIG or MIG is the formation of fragile intermetallic phases, which are detrimental to the mechanical performances of such joints. Braze welding permits a localized fusion of the materials resulting in a limitation on the growth of fragile phases. This article presents the results of a statistical approach for an overlap assembly configuration using a filler wire composed of 85% Zn and 15% Al. Tensile tests carried on these assemblies demonstrate a good performance of the joints. The fracture mechanisms of the joints are analyzed by a detailed characterization of the seams.

Analysis on the Fracture of Al-Cu Dissimilar Materials Friction Stir Welding Lap Joint

NASA Astrophysics Data System (ADS)

Sun, Hongyu; Zhou, Qi; Zhu, Jun; Peng, Yong

2017-12-01

Friction stir welding (FWS) is regarded as a more plausible alternative to other welding methods for Al-Cu dissimilar joining. However, the structure of an FSW joint is different from others. In this study, lap joints of 6061 aluminum alloy and commercially pure copper were produced by FSW, and the effects of rotation rate on macromorphology, microstructure and mechanical properties were investigated. In addition, a fracture J integral model was used to analyze the effect of microstructure on the mechanical properties. The results revealed that the macrodefect-free joints were obtained at a feed rate of 150 mm/min and 1100 rpm and that the failure load of the joint reached as high as 4.57 kN and only reached 2.91 kN for the 900 rpm, where tunnel defects were identified. Particle-rich zones composed of Cu particles dispersed in an Al matrix, and "Flow tracks" were observed by the EDS. The J integral results showed that the microdefects on the advancing side cause serious stress concentration compared with the microdefects located on the Al-Cu interface, resulting in the fracture of the joints.

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

NASA Astrophysics Data System (ADS)

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

2015-07-01

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

Fatigue assessment for selected connections of structural steel bridge components using the finite elements method

NASA Astrophysics Data System (ADS)

Śledziewski, Krzysztof

2018-01-01

Material fatigue it is one of the most frequent causes of steel bridge failures, particularly the bridges already existing. Thus, the procedure of fatigue life assessment is one of the most relevant procedures in a comprehensive assessment of load-carrying capacity and service life of the structure. A reliable assessment of the fatigue life is predominantly decisive for estimation of the remaining service life. Hitherto, calculation methods of welded joints took into account only stresses occurring in cross sections of whole elements and did not take into account stress concentration occurring in the vicinity of the weld, caused by geometrical aspects of the detail. At present, use of the Finite Element Analysis, makes possible looking for more accurate approach to the fatigue design of steel structures. The method of geometrical stresses is just such approach which is based on definition of stresses which take into account geometry of the detail. The study presents fatigue assessment of a representative type of welded joint in welded bridge structures. The testing covered longitudinal attachments. The main analyses were carried out on the basis of FEM and the method of local stresses, so-called "hot-spot" stresses. The obtained values of stresses were compared with the values obtained in accordance with the method of nominal stress.

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

NASA Astrophysics Data System (ADS)

Yun, Seok-Chul; Kim, Jae-Woong

2010-12-01

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

The Load Distribution in Bolted or Riveted Joints in Light-Alloy Structures

NASA Technical Reports Server (NTRS)

Vogt, F.

1947-01-01

This report contains a theoretical discussion of the load distribution in bolted or riveted joints in light-alloy structures which is applicable not only for loads below the limit of proportionality but also for loads above this limit. The theory is developed for double and single shear joints. The methods given are illustrated by numerical examples and the values assumed for the bolt (or rivet) stiffnesses are based partly on theory and partly on known experimental values. It is shown that the load distribution does not vary greatly with the bolt (or rivet) stiffnesses and that for design purposes it is usually sufficient to know their order of magnitude. The theory may also be directly used for spot-welded structures and, with small modifications, for seam-welded structures, The computational work involved in the methods described is simple and may be completed in a reasonable time for most practical problems. A summary of earlier theoretical and experimental investigations on the subject is included in the report.

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.

Effect of tool offsetting on microstructure and mechanical properties dissimilar friction stir welded Mg-Al alloys

NASA Astrophysics Data System (ADS)

Baghdadi, Amir Hossein; Fazilah Mohamad Selamat, Nor; Sajuri, Zainuddin

2017-09-01

Automotive and aerospace industries are attempting to produce lightweight structure by using materials with low density such as aluminum and magnesium alloys to increase the fuel efficiency and consequently reduce the environmental pollution. It can be beneficial to join Mg to Al to acquire ideal performance in special applications. Friction stir welding (FSW) is solid state welding processes and relatively lower temperature of the process compared to fusion welding processes. This makes FSW a potential joining technique for joining of the dissimilar materials. In this study, Mg-Al butt joints were performed by FSW under different tool offset conditions, rotation rates (500-600 rpm) and traverse speeds (20 mm/min) with tool axis offset 1 mm shifted into AZ31B or Al6061 (T6), and without offset. During the welding process AZ31B was positioned at the advancing side (AS) and Al6061 (T6) was located at the retreating side (RS). Defect free AZ31B-Al6061 (T6) dissimilar metal FSW joints with good mechanical properties were obtained with the combination of intermediate rotation rate and low traverse speed pin is in the middle. When tool positioned in -1 mm or +1 mm offsetting, some defects were found in SZ of dissimilar FSWed joints such as cavity, tunnel, and crack. Furthermore, a thin layer of intermetallic compounds was observed in the stir zone at the interface between Mg-Al plates. The strength of the joint was influenced by FSW parameters. Good mechanical properties obtained with the combination of intermediate rotational speed of 600 rpm and low travelling speed of 20 mm/min by locating Mg on advancing side when pin is in the middle. Also, Joint efficiency of the welds prepared in the present study was between 29% and 68% for the different welding parameters.

Practical small-scale explosive seam welding

NASA Technical Reports Server (NTRS)

Bement, L. J.

1983-01-01

Joining principles and variables, types of joints, capabilities, and current and potential applications are described for an explosive seam welding process developed at NASA Langley Research Center. Variable small quantities of RDX explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long length, uniform, hermetrically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The first major all application of the process is the repair of four nuclear reactors in Canada. Potential applications include pipelines, sealing of vessels, and assembly of large space structures.

Mechanical and interfacial characterization of laser welded Co-Cr alloy with different joint configurations

PubMed Central

Kokolis, John; Chakmakchi, Makdad; Theocharopoulos, Antonios; Prombonas, Anthony

2015-01-01

PURPOSE The mechanical and interfacial characterization of laser welded Co-Cr alloy with two different joint designs. MATERIALS AND METHODS Dumbbell cast specimens (n=30) were divided into 3 groups (R, I, K, n=10). Group R consisted of intact specimens, group I of specimens sectioned with a straight cut, and group K of specimens with a 45° bevel made at the one welding edge. The microstructure and the elemental distributions of alloy and welding regions were examined by an SEM/EDX analysis and then specimens were loaded in tension up to fracture. The tensile strength (TS) and elongation (ε) were determined and statistically compared among groups employing 1-way ANOVA, SNK multiple comparison test (α=.05) and Weibull analysis where Weibull modulus m and characteristic strength σο were identified. Fractured surfaces were imaged by a SEM. RESULTS SEM/EDX analysis showed that cast alloy consists of two phases with differences in mean atomic number contrast, while no mean atomic number was identified for welded regions. EDX analysis revealed an increased Cr and Mo content at the alloy-joint interface. All mechanical properties of group I (TS, ε, m and σο) were found inferior to R while group K showed intermediated values without significant differences to R and I, apart from elongation with group R. The fractured surfaces of all groups showed extensive dendritic pattern although with a finer structure in the case of welded groups. CONCLUSION The K shape joint configuration should be preferred over the I, as it demonstrates improved mechanical strength and survival probability. PMID:25722836

An elastic-plastic fracture mechanics analysis of weld-toe surface cracks in fillet welded T-butt joint

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

Fu, B.

1994-12-31

This paper describes an elastic-plastic fracture mechanics (EPFM) study of shallow weld-toe cracks. Two limiting crack configurations, plane strain edge crack and semi-circular surface crack in fillet welded T-butt plate joint, were analyzed using the finite element method. Crack depth ranging from 2 to 40% of plate thickness were considered. The elastic-plastic analysis, assuming power-law hardening relationship and Mises yield criterion, was based on incremental plasticity theory. Tension and bending loads applied were monotonically increased to a level causing relatively large scale yielding at the crack tip. Effects of weld-notch geometry and ductile material modeling on prediction of fracture mechanicsmore » characterizing parameter were assessed. It was found that the weld-notch effect reduces and the effect of material modeling increases as crack depth increases. Material modeling is less important than geometric modeling in analysis of very shallow cracks but is more important for relatively deeper cracks, e.g. crack depth more than 20% of thickness. The effect of material modeling can be assessed using a simplified structural model. Weld magnification factors derived assuming linear elastic conditions can be applied to EPFM characterization.« less

Effect of adding powder on joint properties of laser penetration welding for dual phase steel and aluminum alloy

NASA Astrophysics Data System (ADS)

Zhou, D. W.; Liu, J. S.; Lu, Y. Z.; Xu, S. H.

2017-09-01

The experiments of laser penetration welding for dual phase steel and aluminum alloy were carried out, and the effect of adding Mn or Si powder on mechanical properties and microstructure of the weld was investigated. Some defects, such as spatter, inclusion, cracks and softening in heat affected zone (HAZ), can be avoided in welding joints, and the increased penetration depth is obtained by adding Mn or Si powder. The average tensile-shear strength of Si-added joint is 3.84% higher than that of Mn-added joint, and the strength of both joints exceeds that of no-added joint. In the case of adding Mn powder, small amount of liquid Al is mixed into steel molten pool, and the Al content increases in both sides of the weld, which leads to the increased weld width in aluminum molten pool. Thus, transverse area increases in jointing steel to aluminum, which is significant for the improved tensile-shear strength of joints. As far as adding Si powder is concerned, it is not the case, the enhancement of the joint properties benefits from improvement of metallurgical reaction.

Detection of damage in welded structure using experimental modal data

NASA Astrophysics Data System (ADS)

Abu Husain, N.; Ouyang, H.

2011-07-01

A typical automotive structure could contain thousands of spot weld joints that contribute significantly to the vehicle's structural stiffness and dynamic characteristics. However, some of these joints may be imperfect or even absent during the manufacturing process and they are also highly susceptible to damage due to operational and environmental conditions during the vehicle lifetime. Therefore, early detection and estimation of damage are important so necessary actions can be taken to avoid further problems. Changes in physical parameters due to existence of damage in a structure often leads to alteration of vibration modes; thus demonstrating the dependency between the vibration characteristics and the physical properties of structures. A sensitivity-based model updating method, performed using a combination of MATLAB and NASTRAN, has been selected for the purpose of this work. The updating procedure is regarded as parameter identification which aims to bring the numerical prediction to be as closely as possible to the measured natural frequencies and mode shapes data of the damaged structure in order to identify the damage parameters (characterised by the reductions in the Young's modulus of the weld patches to indicate the loss of material/stiffness at the damage region).

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 Effect of Tool Profiles on Mechanical Properties of Friction Stir Welded Al5052 T-Joints.

PubMed

Kim, Byeong-Jin; Bang, Hee-Seon; Bang, Han-Sur

2018-03-01

Al5052 T butt joints with two skins (5 mm) and one stringer (3 mm) has been successfully welded by friction stir welding (FSW). Notably, this paper has been investigated the effect of tool shape on welded formation mechanism and mechanical properties. The used shapes of tool pin are two types which are cylinder (type 1) and frustum (type 2). Dimension on two types of tool pin shape is respectively pin length of 4.7 mm and pin diameter of frustum type of top (5 mm) and bottom (3 mm). The results of experiment show that inner defects in FSWed T-joints increase significantly in accordance with traverse speed. The maximum tensile strength of welded joint fabricated using type 1 is equivalent to 85% that of the base metal, which is approximately 10% higher than that of type 2. Because welded joint of type 1 has more smoothly plastic flow in comparison with type 2. Consequently, the results show that type 1 is better appropriate for friction stir welded Al5052 T butt joints than type 2.

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

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

Shen, Z.; Chen, Y.; Haghshenas, M., E-mail: mhaghshe@uwaterloo.ca

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

Effects Of Welding On The Fatigue Behaviour Of Commercial Aluminum AA-1100 Joints

NASA Astrophysics Data System (ADS)

Uthayakumar, M.; Balasubramanian, V.; Rani, Ahmad Majdi Abdul; Hadzima, Branislav

2018-04-01

Friction Stir Welding (FSW) is an budding solid state welding process, which is frequently used for joining aluminum alloys where materials can be joined without melt and recast. Therefore, when welding alloys through FSW the phase transformations occurs will be in the solid state form. The present work is aimed in evaluating the fatigue life of friction stir welded commercial grade aluminum alloy joints. The commercial grade AA1100 aluminum alloy of 12mm thickness plate is welded and the specimens are tested using a rotary beam fatigue testing machine at different stress levels. The stress versus number of cycles (S-N) curves was plotted using the data points. The Fatigue life of tungsten inert gas (TIG) and metal inert gas (MIG) welded joints was compared. The fatigue life of the weld joints was interrelated with the tensile properties, microstructure and micro hardness properties. The effects of the notches and welding processes are evaluated and reported.

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.

Fracture strength of different soldered and welded orthodontic joining configurations with and without filling material.

PubMed

Bock, Jens Johannes; Bailly, Jacqueline; Gernhardt, Christian Ralf; Fuhrmann, Robert Andreas Werner

2008-01-01

The aim of this study was to compare the mechanical strength of different joints made by conventional brazing, TIG and laser welding with and without filling material. Five standardized joining configurations of orthodontic wire in spring hard quality were used: round, cross, 3 mm length, 9 mm length and 7 mm to orthodontic band. The joints were made by five different methods: brazing, tungsten inert gas (TIG) and laser welding with and without filling material. For the original orthodontic wire and for each kind of joint configuration or connecting method 10 specimens were carefully produced, totalizing 240. The fracture strengths were measured with a universal testing machine (Zwick 005). Data were analyzed by ANOVA (p=0.05) and Bonferroni post hoc test (p=0.05). In all cases, brazing joints were ruptured on a low level of fracture strength (186-407 N). Significant differences between brazing and TIG or laser welding (p<0.05, Bonferroni post hoc test) were found in each joint configuration. The highest fracture strength means were observed for laser welding with filling material and 3 mm joint length (998 N). Using filling materials, there was a clear tendency to higher mean values of fracture strength in TIG and laser welding. However, statistically significant differences were found only in the 9-mm long joints (p<0.05, Bonferroni post hoc test). In conclusion, the fracture strength of welded joints was positively influenced by the additional use of filling material. TIG welding was comparable to laser welding except for the impossibility of joining orthodontic wire with orthodontic band.

FRACTURE STRENGTH OF DIFFERENT SOLDERED AND WELDED ORTHODONTIC JOINING CONFIGURATIONS WITH AND WITHOUT FILLING MATERIAL

PubMed Central

Bock, Jens Johannes; Bailly, Jacqueline; Gernhardt, Christian Ralf; Fuhrmann, Robert Andreas Werner

2008-01-01

The aim of this study was to compare the mechanical strength of different joints made by conventional brazing, TIG and laser welding with and without filling material. Five standardized joining configurations of orthodontic wire in spring hard quality were used: round, cross, 3 mm length, 9 mm length and 7 mm to orthodontic band. The joints were made by five different methods: brazing, tungsten inert gas (TIG) and laser welding with and without filling material. For the original orthodontic wire and for each kind of joint configuration or connecting method 10 specimens were carefully produced, totalizing 240. The fracture strengths were measured with a universal testing machine (Zwick 005). Data were analyzed by ANOVA (p=0.05) and Bonferroni post hoc test (p=0.05). In all cases, brazing joints were ruptured on a low level of fracture strength (186-407 N). Significant differences between brazing and TIG or laser welding (p<0.05, Bonferroni post hoc test) were found in each joint configuration. The highest fracture strength means were observed for laser welding with filling material and 3 mm joint length (998 N). Using filling materials, there was a clear tendency to higher mean values of fracture strength in TIG and laser welding. However, statistically significant differences were found only in the 9-mm long joints (p<0.05, Bonferroni post hoc test). In conclusion, the fracture strength of welded joints was positively influenced by the additional use of filling material. TIG welding was comparable to laser welding except for the impossibility of joining orthodontic wire with orthodontic band. PMID:19089229

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

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

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

The Effect of Constant and Pulsed Current Gas Tungsten Arc Welding on Joint Properties of 2205 Duplex Stainless Steel to 316L Austenitic Stainless Steel

NASA Astrophysics Data System (ADS)

Neissi, R.; Shamanian, M.; Hajihashemi, M.

2016-05-01

In this study, dissimilar 316L austenitic stainless steel/2205 duplex stainless steel (DSS) joints were fabricated by constant and pulsed current gas tungsten arc welding process using ER2209 DSS as a filler metal. Microstructures and joint properties were characterized using optical and electron scanning microscopy, tensile, Charpy V-notch impact and micro-hardness tests, and cyclic polarization measurements. Microstructural observations confirmed the presence of chromium nitride and delta ferrite in the heat-affected zone of DSS and 316L, respectively. In addition, there was some deviation in the austenite/ferrite ratio of the surface welding pass in comparison to the root welding pass. Besides having lower pitting potential, welded joints produced by constant current gas tungsten arc welding process, consisted of some brittle sigma phase precipitates, which resulted in some impact energy reduction. The tensile tests showed high tensile strength for the weld joints in which all the specimens were broken in 316L base metal.

Effects of stress concentration on the fatigue strength of 7003-T5 aluminum alloy butt joints with weld reinforcement

NASA Astrophysics Data System (ADS)

Zhu, Zongtao; Li, Yuanxing; Zhang, Mingyue; Hui, Chen

2015-03-01

7003-T5 Aluminum (Al) alloy plates with a thickness of 5 mm are welded by gas metal arc welding (GMAW) method in this work. In order to investigate the influence of stress concentration introduced by weld reinforcement on fatigue strength, the stress concentration factor of the butt joint is calculated. Microscopic and X-ray techniques were utilized to make sure there are no weld defects with large size in butt weld, which can induce extra stress concentration. The cyclic stress - number of cycles to failure (S-N) curves of the joints with and without the welder were obtained by fatigue testing, and the results show that the fatigue strength of 7003-T5 Al alloy butt joints with the weld reinforcement is 50 MPa, which is only 45% of the joints without the weld reinforcement. Fracture surface observation indicated that the fatigue source and propagation are dissimilar for the specimens with and without the welder due to the stress concentration at the weld root. The stress concentration with a factor of 1.7 has great effect on the fatigue strength, but little influence on the tensile strength.

Review: magnetically assisted resistance spot welding

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

Li, Y. B.; Li, D. L.; Lin, Z. Q.

2016-02-25

Currently, the use of advanced high strength steels (AHSSs) is the most cost effective means of reducing vehicle body weight and maintaining structural integrity at the same time. However, AHSSs present a big challenge to the traditional resistance spot welding (RSW) widely applied in automotive industries because the rapid heating and cooling procedures during RSW produce hardened weld microstructures, which lower the ductility and fatigue properties of welded joints and raise the probability of interfacial failure under external loads. Changing process parameters or post-weld heat treatment may reduce the weld brittleness, but those traditional quality control methods also increase energymore » consumption and prolong cycle time. In recent years, a magnetically assisted RSW (MA-RSW) method was proposed, in which an externally applied magnetic field would interact with the conduction current to produce a Lorentz force that would affect weld nugget formation. This paper is a review of an experimental MA-RSW platform, the mode of the external magnetic field and the mechanism that controls nugget shape, weld microstructures and joint performance. In conclusion, the advantages of the MA-RSW method in improving the weldability of AHSSs are given, a recent application of the MA-RSW process to light metals is described and the outlook for the MA-RSW process is presented.« less

Camera Based Closed Loop Control for Partial Penetration Welding of Overlap Joints

NASA Astrophysics Data System (ADS)

Abt, F.; Heider, A.; Weber, R.; Graf, T.; Blug, A.; Carl, D.; Höfler, H.; Nicolosi, L.; Tetzlaff, R.

Welding of overlap joints with partial penetration in automotive applications is a challenging process, since the laser power must be set very precisely to achieve a proper connection between the two joining partners without damaging the backside of the sheet stack. Even minor changes in welding conditions can lead to bad results. To overcome this problem a camera based closed loop control for partial penetration welding of overlap joints was developed. With this closed loop control it is possible to weld such configurations with a stable process result even under changing welding conditions.

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).

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.

Effects of laser power density on static and dynamic mechanical properties of dissimilar stainless steel welded joints

NASA Astrophysics Data System (ADS)

Wei, Yan-Peng; Li, Mao-Hui; Yu, Gang; Wu, Xian-Qian; Huang, Chen-Guang; Duan, Zhu-Ping

2012-10-01

The mechanical properties of laser welded joints under impact loadings such as explosion and car crash etc. are critical for the engineering designs. The hardness, static and dynamic mechanical properties of AISI304 and AISI316 L dissimilar stainless steel welded joints by CO2 laser were experimentally studied. The dynamic strain-stress curves at the strain rate around 103 s-1 were obtained by the split Hopkinson tensile bar (SHTB). The static mechanical properties of the welded joints have little changes with the laser power density and all fracture occurs at 316 L side. However, the strain rate sensitivity has a strong dependence on laser power density. The value of strain rate factor decreases with the increase of laser power density. The welded joint which may be applied for the impact loading can be obtained by reducing the laser power density in the case of welding quality assurance.

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.)

The structure of Ti-Ta welded joint and microhardness distribution over the cross section

NASA Astrophysics Data System (ADS)

Fomin, Aleksandr A.; Koshuro, Vladimir A.; Egorov, Ivan S.; Shelkunov, Andrey Yu.; Zakharevich, Andrey M.; Steinhauer, Natalia N.; Rodionov, Igor V.

2018-04-01

In order to create highly efficient medical systems and measuring biosensors, an approach is frequently used, in which the constructive basis of the product is made of a high-strength biocompatible material (titanium, stainless steel), and the functional layer is made of a more expensive metal (Ta, Zr, Au, Pt, etc.) or ceramics (Ta2O5, ZrO2, CaTiO3, etc.). For a strong connection, e.g. titanium with tantalum, it is proposed to use diffusion butt welding. The heat generated by passing electric current (I is not less than 1.95-2.05 kA, P - not less than 9 kW, t = 250-1000 ms) and applied pressure (30-50 MPa) ensure an integral connection. To improve the quality of the joint, i.e. to exclude cracks and tightness, it is necessary to choose the right combination of the thickness of the welded parts. It was established that when titanium (2 mm thick) and tantalum (0.1-0.5 mm) are combined, a better Ti-Ta welded joint is formed when tantalum foil is used (0.5 mm). Here the distribution of hardness over the cross section of the sample, including the welding areas, is uniform and has no extremely high residual stresses of the tensile type.

Weld geometry strength effect in 2219-T87 aluminum

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Novak, H. L.; Mcilwain, M. C.

1981-01-01

A theory of the effect of geometry on the mechanical properties of a butt weld joint is worked out based upon the soft interlayer weld model. Tensile tests of 45 TIG butt welds and 6 EB beads-on-plate in 1/4-in. 2219-T87 aluminum plate made under a wide range of heat sink and power input conditions are analyzed using this theory. The analysis indicates that purely geometrical effects dominate in determining variations in weld joint strength with heat sink and power input. Variations in weld dimensions with cooling rate are significant as well as with power input. Weld size is suggested as a better indicator of the condition of a weld joint than energy input.

Mechanical Properties of Aluminum-Based Dissimilar Alloy Joints by Power Beams, Arc and FSW Processes

NASA Astrophysics Data System (ADS)

Okubo, Michinori; Kon, Tomokuni; Abe, Nobuyuki

Dissimilar smart joints are useful. In this research, welded quality of dissimilar aluminum alloys of 3 mm thickness by various welding processes and process parameters have been investigated by hardness and tensile tests, and observation of imperfection and microstructure. Base metals used in this study are A1050-H24, A2017-T3, A5083-O, A6061-T6 and A7075-T651. Welding processes used are YAG laser beam, electron beam, metal inert gas arc, tungsten inert gas arc and friction stir welding. The properties of weld zones are affected by welding processes, welding parameters and combination of base metals. Properties of high strength aluminum alloy joints are improved by friction stir welding.

Effects of conventional welding and laser welding on the tensile strength, ultimate tensile strength and surface characteristics of two cobalt-chromium alloys: a comparative study.

PubMed

Madhan Kumar, Seenivasan; Sethumadhava, Jayesh Raghavendra; Anand Kumar, Vaidyanathan; Manita, Grover

2012-06-01

The purpose of this study was to evaluate the efficacy of laser welding and conventional welding on the tensile strength and ultimate tensile strength of the cobalt-chromium alloy. Samples were prepared with two commercially available cobalt-chromium alloys (Wironium plus and Diadur alloy). The samples were sectioned and the broken fragments were joined using Conventional and Laser welding techniques. The welded joints were subjected to tensile and ultimate tensile strength testing; and scanning electron microscope to evaluate the surface characteristics at the welded site. Both on laser welding as well as on conventional welding technique, Diadur alloy samples showed lesser values when tested for tensile and ultimate tensile strength when compared to Wironium alloy samples. Under the scanning electron microscope, the laser welded joints show uniform welding and continuous molt pool all over the surface with less porosity than the conventionally welded joints. Laser welding is an advantageous method of connecting or repairing cast metal prosthetic frameworks.

Automatic hot wire GTA welding of pipe offers speed and increased deposition

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

Sykes, I.; Digiacomo, J.

1995-07-01

Heavy-wall pipe welding for the power and petrochemical industry must meet code requirements. Contractors strive to meet these requirements in the most productive way possible. The challenge put to orbital welding equipment manufacturers is to produce pipe welding equipment that cost-effectively produces code-quality welds. Orbital welding equipment using the GTA process has long produced outstanding quality results but has lacked the deposition rate to compete cost effectively with other manual and semiautomatic processes such as SMAW, FCAW and GMAW. In recent years, significant progress has been made with the use of narrow-groove weld joint designs to reduce weld joint volumemore » and improve welding times. Astro Arc Polysoude, an orbital welding equipment manufacturer based in Sun Valley, Calif., and Nantes, France, has combined the hot wire GTAW process with orbital welding equipment using a narrow-groove weld joint design. Field test results show this process and procedure is a good alternative for many heavy-wall-pipe welding applications.« less

Non-destructive three-dimensional evaluation of pores at different welded joints and their effects on joints strength.

PubMed

Nomoto, Rie; Takayama, Yasuko; Tsuchida, Fujio; Nakajima, Hiroyuki

2010-12-01

The purpose of this study was to measure the porosity in different laser welded cast alloys non-destructively using X-ray micro-focus computerized tomography (micro-CT) and to evaluate the effect of porosity on the tensile strength of the welded joints. The welding procedure was conducted in rectangular cast metals, CoCr, Ti and platinum added gold alloy (AuPt). The metal plates were butted CoCr to CoCr (CoCr/CoCr) or Ti to Ti (Ti/Ti) for welding of similar metals and Ti to AuPt (Ti/AuPt) for welding of dissimilar metals. Specimens were welded under several laser-welding conditions; with groove (normal), without groove (no groove), spatter, crack, or no overlapped welding (no overlap) (n=5). Porosity in the welded area was evaluated using a micro-CT. Tensile strength of the welded specimens was measured at a crosshead speed of 1mm/min. Multiple comparisons of the group means were performed using ANOVA and Fisher's multiple comparisons test (α=.05). The relationship between the porosity and the tensile strength was investigated with a regression analysis. Three-dimensional images of Ti/AuPt could not be obtained due to metal artifacts and the tensile specimens of Ti/AuPt were debonded prior to the tensile test. All other welded specimens had porosity in the welded area and the porosities ranged from 0.01% to 0.17%. The fractures of most of the CoCr/CoCr and Ti/Ti specimens occurred in the parent metals. Joint strength had no relationship with the porosity in the welded area (R(2)=0.148 for CoCr/CoCr, R(2)=0.088 for Ti/Ti, respectively). The small amount of porosity caused by the laser-welding procedures did not affect the joint strength. The joint strength of Ti/AuPt was too weak to be used clinically. Copyright © 2010 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

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.

Process modeling and parameter optimization using radial basis function neural network and genetic algorithm for laser welding of dissimilar materials

NASA Astrophysics Data System (ADS)

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

2015-11-01

The welded joints of dissimilar materials have been widely used in automotive, ship and space industries. The joint quality is often evaluated by weld seam geometry, microstructures and mechanical properties. To obtain the desired weld seam geometry and improve the quality of welded joints, this paper proposes a process modeling and parameter optimization method to obtain the weld seam with minimum width and desired depth of penetration for laser butt welding of dissimilar materials. During the process, Taguchi experiments are conducted on the laser welding of the low carbon steel (Q235) and stainless steel (SUS301L-HT). The experimental results are used to develop the radial basis function neural network model, and the process parameters are optimized by genetic algorithm. The proposed method is validated by a confirmation experiment. Simultaneously, the microstructures and mechanical properties of the weld seam generated from optimal process parameters are further studied by optical microscopy and tensile strength test. Compared with the unoptimized weld seam, the welding defects are eliminated in the optimized weld seam and the mechanical properties are improved. The results show that the proposed method is effective and reliable for improving the quality of welded joints in practical production.

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

PubMed

Villegas, Irene F; Palardy, Genevieve

2016-02-11

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

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

PubMed Central

Villegas, Irene F.; Palardy, Genevieve

2016-01-01

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints. PMID:26890931

Resistance welding graphite-fiber composites

NASA Technical Reports Server (NTRS)

Lamoureux, R. T.

1980-01-01

High-strength joints are welded in seconds in carbon-reinfored thermoplastic beams. Resistance-welding electrode applies heat and pressure to joint and is spring-loaded to follow softening material to maintain contact; it also holds parts together for cooling and hardening. Both transverse and longitudinal configurations can be welded. Adhesive bonding and encapsulation are more time consuming methods and introduce additional material into joint, while ultrasonic heating can damage graphite fibers in composite.

Prediction of Tensile Strength of Friction Stir Weld Joints with Adaptive Neuro-Fuzzy Inference System (ANFIS) and Neural Network

NASA Technical Reports Server (NTRS)

Dewan, Mohammad W.; Huggett, Daniel J.; Liao, T. Warren; Wahab, Muhammad A.; Okeil, Ayman M.

2015-01-01

Friction-stir-welding (FSW) is a solid-state joining process where joint properties are dependent on welding process parameters. In the current study three critical process parameters including spindle speed (??), plunge force (????), and welding speed (??) are considered key factors in the determination of ultimate tensile strength (UTS) of welded aluminum alloy joints. A total of 73 weld schedules were welded and tensile properties were subsequently obtained experimentally. It is observed that all three process parameters have direct influence on UTS of the welded joints. Utilizing experimental data, an optimized adaptive neuro-fuzzy inference system (ANFIS) model has been developed to predict UTS of FSW joints. A total of 1200 models were developed by varying the number of membership functions (MFs), type of MFs, and combination of four input variables (??,??,????,??????) utilizing a MATLAB platform. Note EFI denotes an empirical force index derived from the three process parameters. For comparison, optimized artificial neural network (ANN) models were also developed to predict UTS from FSW process parameters. By comparing ANFIS and ANN predicted results, it was found that optimized ANFIS models provide better results than ANN. This newly developed best ANFIS model could be utilized for prediction of UTS of FSW joints.

Enhancing Friction Stir Weldability of 6061-T6 Al and AZ31B Mg Alloys Assisted by External Non-rotational Shoulder

NASA Astrophysics Data System (ADS)

Ji, Shude; Huang, Ruofei; Meng, Xiangchen; Zhang, Liguo; Huang, Yongxian

2017-05-01

In order to increase cooling rate and then reduce the amounts of intermetallic compounds, external non-rotational shoulder tool system derived from traditional tool in friction stir welding was used to join dissimilar Al and Mg alloys. In this study, based on the external non-rotational shoulder, the weldability of Al and Mg alloys was significantly improved. The non-rotational shoulder tool is propitious to make more materials into weld, increase cooling rate and then reduce material adhesion of rotational pin, obtaining sound joint with smaller flashes and smooth surface. Importantly, the thickness of intermetallic compounds layer is reduced compared with traditional tool. Meanwhile, hardness values of dissimilar joint present uneven distribution, resulting from complex intercalated structures in nugget zone (NZ) featured by intermetallic compound layers and fine recrystallized Mg and Al grains. Compared with traditional tool, non-rotational shoulder is beneficial to higher tensile properties of joint. Due to the intermetallic compound layer formed in the interface of Al-Mg, the welding joint easily fractures at the NZ, presenting the typical brittle fracture mode.

Simulating the Structural Response of a Preloaded Bolted Joint

NASA Technical Reports Server (NTRS)

Knight, Norman F., Jr.; Phillips, Dawn R.; Raju, Ivatury S.

2008-01-01

The present paper describes the structural analyses performed on a preloaded bolted-joint configuration. The joint modeled was comprised of two L-shaped structures connected together using a single bolt. Each L-shaped structure involved a vertical flat segment (or shell wall) welded to a horizontal segment (or flange). Parametric studies were performed using elasto-plastic, large-deformation nonlinear finite element analyses to determine the influence of several factors on the bolted-joint response. The factors considered included bolt preload, washer-surface-bearing size, edge boundary conditions, joint segment length, and loading history. Joint response is reported in terms of displacements, gap opening, and surface strains. Most of the factors studied were determined to have minimal effect on the bolted-joint response; however, the washer-bearing-surface size affected the response significantly.

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

NASA Technical Reports Server (NTRS)

Prater, Tracie

2014-01-01

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Mechanical Properties and Microstructure of TIG and FSW Joints of a New Al-Mg-Mn-Sc-Zr Alloy

NASA Astrophysics Data System (ADS)

Xu, Guofu; Qian, Jian; Xiao, Dan; Deng, Ying; Lu, Liying; Yin, Zhimin

2016-04-01

A new Al-5.8%Mg-0.4%Mn-0.25%Sc-0.10%Zr (wt.%) alloy was successfully welded by tungsten inert gas (TIG) and friction stir welding (FSW) techniques, respectively. The mechanical properties and microstructure of the welded joints were investigated by microhardness measurements, tensile tests, and microscopy methods. The results show that the ultimate tensile strength, yield strength, and elongation to failure are 358, 234 MPa, and 27.6% for TIG welded joint, and 376, 245 MPa and 31.9% for FSW joint, respectively, showing high strength and superior ductility. The TIG welded joint fails in the heat-affected zone and the fracture of FSW joint is located in stirred zone. Al-Mg-Mn-Sc-Zr alloy is characterized by lots of dislocation tangles and secondary coherent Al3(Sc,Zr) particles. The superior mechanical properties of the TIG and FSW joints are mainly derived from the Orowan strengthening and grain boundary strengthening caused by secondary coherent Al3(Sc,Zr) nano-particles (20-40 nm). For new Al-Mg-Mn-Sc-Zr alloy, the positive effect from secondary Al3(Sc, Zr) particles in the base metal can be better preserved in FSW joint than in TIG welded joint.

Effect of Mechanical Heterogeneity on the Crack Driving Force of a Reactor Pressure Vessel Outlet Nozzle DMW Joint

NASA Astrophysics Data System (ADS)

Lingyan, Zhao; Yinghao, Cui; He, Xue

2017-12-01

The welding mechanical heterogeneity, load complexity, material and geometrical structure makes it very difficult to assess the structural integrity of dissimilar metal weld (DMW) joints. Based on a numerical simulated approach of the continuous change of material mechanical property in the buttering layer, a reactor pressure vessel (RPV) outlet nozzle DMW joint with service loads is studied, effect of mechanical heterogeneity on the stress-strain field and stress triaxiality at the semi-elliptical surface crack front are discussed. The analyses show that once the crack extends into the high hardness zone of Alloy 182 buttering, the strain decreases sharply, the strain gradient increases and the crack propagation slows down. The influence of strength mismatch on the stress triaxiality at the shallow crack front is greater than that at the deep crack front. The interaction between strength mismatch and crack depth directly affects the crack growth direction.

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.

Improving Mechanical Properties of PVPPA Welded Joints of 7075 Aluminum Alloy by PWHT

PubMed Central

Li, Guowei; Chen, Furong; Han, Yongquan; Liang, Yahong

2018-01-01

In this study, 7075 aluminum alloy with a thickness of 10 mm was successfully welded with no obvious defects by pulsed variable polarity plasma arc (PVPPA) welding. The mechanical properties of PVPPA welded joints have been researched by post weld heat treatment (PWHT). The results indicate that the heat treatment strongly affects the mechanical properties of the welded joints. The tensile strength and the microhardness of the welded joints gradually improved with the increase of the solution temperature. With the increase of the solution time, the tensile strength, and microhardness first dramatically increased and then decreased slightly. The best tensile strength of 537.5 MPa and the microhardness of 143.7 HV were obtained after 490 °C × 80 min + 120 °C × 24 h, and the strength was nearly 91.2% of that of the parent metal, and increased about 35% compared with as-welded. The improvement of strength and microhardness was mainly due to the precipitation of η′ phase. PMID:29510551

An optimization method for defects reduction in fiber laser keyhole welding

NASA Astrophysics Data System (ADS)

Ai, Yuewei; Jiang, Ping; Shao, Xinyu; Wang, Chunming; Li, Peigen; Mi, Gaoyang; Liu, Yang; Liu, Wei

2016-01-01

Laser welding has been widely used in automotive, power, chemical, nuclear and aerospace industries. The quality of welded joints is closely related to the existing defects which are primarily determined by the welding process parameters. This paper proposes a defects optimization method that takes the formation mechanism of welding defects and weld geometric features into consideration. The analysis of welding defects formation mechanism aims to investigate the relationship between welding defects and process parameters, and weld features are considered to identify the optimal process parameters for the desired welded joints with minimum defects. The improved back-propagation neural network possessing good modeling for nonlinear problems is adopted to establish the mathematical model and the obtained model is solved by genetic algorithm. The proposed method is validated by macroweld profile, microstructure and microhardness in the confirmation tests. The results show that the proposed method is effective at reducing welding defects and obtaining high-quality joints for fiber laser keyhole welding in practical production.

The Influence of the Heat-Affected Zone Mechanical Properties on the Behaviour of the Welding in Transverse Plate-to-Tube Joints.

PubMed

Lozano, Miguel; Serrano, Miguel A; López-Colina, Carlos; Gayarre, Fernando L; Suárez, Jesús

2018-02-09

Eurocode 3 establishes the component method to analytically characterize the structural joints between beam and columns. When one of the members involved in the joint is a hollow section (i.e., a tube) there is a lack of information for the specific components present in the joint. There are two different ways to bridge the gap: experimental testing on the actual beam column joints involving tubular sections; or numerical modelization, typically by means of finite element analysis. For this second option, it is necessary to know the actual mechanical properties of the material. As long as the joint implies a welding process, there is a concern related to how the mechanical properties in the heat-affected zone (HAZ) influence the behavior of the joint. In this work, some coupons were extracted from the HAZ of the beam-column joint. The coupons were tested and the results were implemented in the numerical model of the joint, in an attempt to bring it closer to the experimental results of the tested joints.

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.

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

NASA Astrophysics Data System (ADS)

Prater, Tracie

2014-01-01

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

Effect of post weld impact treatment (PWIT) on mechanical properties of spot-welded joint

NASA Astrophysics Data System (ADS)

Ghazali, F. A.; Salleh, Z.; Hyie, K. M.; Rozlin, N. M. Nik; Hamidi, S. H. Ahmad; Padzi, M. M.

2017-12-01

This paper focuses on the study of improvement for spot welding on the tensile shear and hardness by applying post weld impact treatment (PWIT) on the welded joint. The main objective of the research is to characterize and improve the mechanical properties of the joint. The method of PWIT used on the welded joint was Pneumatic Impact Treatment (PIT). The concept of PIT on spot welding is that it improves the mechanical properties of the welded zone. The working sample was undergoing a resistance spot welding of joining two similar in dimension and material of a steel plate before treated. The dimension of both plate are 110 mm × 45 mm × 1.2 mm and the material used were low carbon steel (LCS). All the welded samples were tested for its mechanical properties by performing the tensile-shear and hardness test. Tensile-shear test was conducted on the spot welded, both treated and as-welded samples using crosshead speed of 2 mm/min, while hardness test was performed using 1kgf load via Vickers hardness indenter. The effects of PIT on tensile-shear properties and hardness were evaluated and found that the implementation of PIT has increased tensile shear and hardness significantly.

Corrosion in artificial saliva of a Ni-Cr-based dental alloy joined by TIG welding and conventional brazing.

PubMed

Matos, Irma C; Bastos, Ivan N; Diniz, Marília G; de Miranda, Mauro S

2015-08-01

Fixed prosthesis and partial dental prosthesis frameworks are usually made from welded Ni-Cr-based alloys. These structures can corrode in saliva and have to be investigated to establish their safety. The purpose of this study was to evaluate the corrosion behavior of joints joined by tungsten inert gas (TIG) welding and conventional brazing in specimens made of commercial Ni-Cr alloy in Fusayama artificial saliva at 37°C (pH 2.5 and 5.5). Eighteen Ni-Cr base metal specimens were cast and welded by brazing or tungsten inert gas methods. The specimens were divided into 3 groups (base metal, 2 welded specimens), and the composition and microstructure were qualitatively evaluated. The results of potential corrosion and corrosion current density were analyzed with a 1-way analysis of variance and the Tukey test for pairwise comparisons (α=.05). Base metal and tungsten inert gas welded material showed equivalent results in electrochemical corrosion tests, while the air-torched specimens exhibited low corrosion resistance. The performance was worst at pH 2.5. These results suggest that tungsten inert gas is a suitable welding process for use in dentistry, because the final microstructure does not reduce the corrosion resistance in artificial saliva at 37°C, even in a corrosion-testing medium that facilitates galvanic corrosion processes. Moreover, the corrosion current density of brazed Ni-Cr alloy joints was significantly higher (P<.001) than the base metal and tungsten inert gas welded joints. Copyright © 2015 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

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.)

Special Features of Induction Annealing of Friction Stir Welded Joints of Medium-Alloy Steels

NASA Astrophysics Data System (ADS)

Priymak, E. Yu.; Stepanchukova, A. V.; Bashirova, E. V.; Fot, A. P.; Firsova, N. V.

2018-01-01

Welded joints of medium-alloy steels XJY750 and 40KhN2MA are studied in the initial condition and after different variants of annealing. Special features of the phase transformations occurring in the welded steels are determined. Optimum modes of annealing are recommended for the studied welded joints of drill pipes, which provide a high level of mechanical properties including the case of impact loading.

Failure of dissimilar material bonded joints

NASA Astrophysics Data System (ADS)

Konstantakopoulou, M.; Deligianni, A.; Kotsikos, G.

2016-03-01

Joining of materials in structural design has always been a challenge for engineers. Bolting and riveting has been used for many years, until the emergence of fusion welding which revolutionised construction in areas such as shipbuilding, automotive, infrastructure and consumer goods. Extensive research in the past 50 years has resulted in better understanding of the process and minimised the occurrence of failures associated with fusion welding such as, residual stress cracking, stress corrosion and corrosion fatigue cracking, localised reduction in mechanical properties due to microstructural changes (heat affected zone) etc. Bonding has been a technique that has been proposed as an alternative because it eliminates several of the problems associated with fusion welding. But, despite some applications it has not seen wide use. There is however a renewed interest in adhesively bonded joints, as designers look for ever more efficient structures which inevitably leads to the use and consequently joining of combinations of lightweight materials, often with fundamentally different mechanical and physical properties. This chapter provides a review of adhesively bonded joints and reports on improvements to bonded joint strength through the introduction of carbon nanotubes at the bond interface. Results from various workers in the field are reported as well as the findings of the authors in this area of research. It is obvious that there are several challenges that need to be addressed to further enhance the strength of bonded joints and worldwide research is currently underway to address those shortcomings and build confidence in the implementation of these new techniques.

Diffusion welding of MA 6000 and a conventional nickel-base superalloy

NASA Technical Reports Server (NTRS)

Moore, T. J.; Glasgow, T. K.

1985-01-01

A feasibility study of diffusion welding the oxide dispersion strengthened (ODS) alloy MA 6000 to itself and to conventional Ni-base superalloy Udimet 700 was conducted. Butt joints between MA 6000 pieces and lap joints between Udimet 700 and the ODS alloy were produced by hot pressing for 1.25 hr at temperatures ranging from 1000 to 1200 C (1832-2192 F) in vacuum. Following pressing, all weldments were heat treated and machined into mechanical property test specimens. While three different combinations of recrystallized and unrecrystallized MA 6000 butt joints were produced, the unrecrystallized to unrecrystallized joint was most successful as determined by mechanical properties and microstructural examination. Failure to weld the recrystallized material probably related to a lack of adequate deformation at the weld interface. While recrystallized MA 6000 could be diffusion welded to Udimet 700 in places, complete welding over the entire lap joint was not achieved, again due to the lack of sufficient deformation at the faying surfaces. Several methods are proposed to promote the intimate contact necessary for diffusion welding MA 6000 to itself and to superalloys.

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.

Corrosion resistance of a laser spot-welded joint of NiTi wire in simulated human body fluids.

PubMed

Yan, Xiao-Jun; Yang, Da-Zhi

2006-04-01

The purpose of this study was to investigate corrosion resistance of a laser spot-welded joint of NiTi alloy wires using potentiodynamic tests in Hank's solution at different PH values and the PH 7.4 NaCl solution for different Cl- concentrations. Scanning electron microscope observations were carried out before and after potentiodynamic tests. The composition of a laser spot-welded joint and base metal were characterized by using an electron probe microanalyzer. The results of potentiodynamic tests showed that corrosion resistance of a laser spot-welded joint of NiTi alloy wire was better than that of base metal, which exhibited a little higher breakdown potential and passive range, and a little lower passive current density. Corrosion resistances of a laser spot-welded joint and base metal decreased with increasing of the Cl- concentration and PH value. The improvement of corrosion resistance of the laser spot-welded joint was due to the decrease of the surface defects and the increase of the Ti/Ni ratio. (c) 2005 Wiley Periodicals, Inc.

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

PubMed

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

2013-01-01

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

Effect of Groove Design and Post-Weld Heat Treatment on Microstructure and Mechanical Properties of P91 Steel Weld

NASA Astrophysics Data System (ADS)

Pandey, C.; Mahapatra, M. M.

2016-07-01

The martensitic creep-resistant steel designated as ASTM A335 for plate and as P91 for pipe is primarily used for high-temperature and high-pressure applications in steam power plants due to its excellent high-temperature properties such as high creep strength, high thermal conductivity, low thermal expansion, and so on. However, in the case of welded joints of such steels, the presence of an inter-critical heat-affected zone (IC-HAZ) can cause the joint to have lower creep strength than the base metal. In the present study, the effect of post-welding heat treatment (PWHT) and weld groove designs on the overall microstructure and mechanical properties of P91 steel pipe welds produced by the gas tungsten arc welding process was studied. Various regions of welded joints were characterized in detail for hardness and metallographic and tensile properties. Sub-size tensile samples were also tested to evaluate the mechanical properties of the weld metal and heat-affected zone (HAZ) with respect to PWHT. After PWHT, a homogenous microstructure was observed in the HAZ and tensile test fracture samples revealed shifting of the fracture location from the IC-HAZ to the fine-grained heat-affected zone. Before PWHT, the conventional V-grooved welded joints exhibited higher tensile strength compared to the narrow-grooved joints. However, after PWHT, both narrow- and V-grooved joints exhibited similar strength. Fractography of the samples indicates the presence of carbide precipitates such as Cr23C6, VC, and NbC on the fracture surface.

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

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

Improving fatigue performance of rail thermite welds

NASA Astrophysics Data System (ADS)

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

2010-06-01

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

Effects of SO42- ions on the corrosion of GH3535 weld joint in FLiNaK molten salt

NASA Astrophysics Data System (ADS)

Zhu, Yasheng; Qiu, Jie; Hou, Juan; Liu, Wenguan; Chen, Huaican; Ai, Hua; Yu, Guojun; Wang, Jianqiang; Zhou, Xingtai

2017-08-01

The present work studied the impact of SO42- ions on the corrosion behaviors of GH3535 weld joint in FLiNaK molten salt. The concentration of SO42- ions in the FLiNaK molten salt was controlled by adjusting the quantity of Na2SO4 added into the salt. Results indicate that the SO42- ions in the FLiNaK salt speed up the corrosion rate remarkably by promoting the dissolution of Cr from the alloy matrix into the salt. With the concentration of SO42- ions in the FLiNaK salt increases from 100 ppm to 1000 ppm, the weight losses and the Cr depletion layer depths of the corroded specimens increase linearly. Even in the case of the heavy corrosion attack caused by the SO42- ions, the corrosion performance is similar between the base zone and fusion zone in the GH3535 weld joint. It is demonstrated that the structural diversity caused by the welding process has little impact on the corrosion performances of GH3535 alloy in FLiNaK molten salt.

The effect of axial external magnetic field on tungsten inert gas welding of magnesium alloy

NASA Astrophysics Data System (ADS)

Li, Caixia; Zhang, Xiaofeng; Wang, Jing

2018-04-01

The influences of axial external magnetic field on the microstructure and mechanical property of the AZ31 magnesium (Mg) alloy joints were studied. The microstructure of Mg alloy joint consisted of the weld seam, heat affected zone and base metal zone. The average grain size of weld seam welded with magnetic field is 39 μm, which is 38% smaller than that of the joint welded with absence of magnetic field. And the microhardness of weld seam increases with the help of magnetic field treatment, owing to the coarse grain refinement. With coil current of 2.0A, the maximum mechanical property of joint increases 6.7% to 255 MPa over the specimen without magnetic field treatment. Furthermore, fracture location is near heat affected area and the fracture surface is characterized with ductile fracture.

Capillary flow weld-bonding

NASA Technical Reports Server (NTRS)

Vaughan, R. W.; Jones, R. J. (Inventor)

1976-01-01

The invention of a weld-bonding technique for titanium plates was described. This involves fastening at least two plates of titanium together using spot-welding and applying a bead of adhesive along the edge of the resistance spot-welded joint which upon heating, flows and fills the separation between the joint components.

Fatigue strength of socket welded pipe joint

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

Higuchi, Makoto; Hayashi, Makoto; Yamauchi, Takayoshi

1995-12-01

Fully reversed four point bending fatigue tests were carried out on small diameter socket welded joints made of carbon steels. Experimental parameters were pipe diameter, thicknesses of pipe and socket wall, throat depth and shape of fillet welds, slip-on and diametral gaps in the socket welding, lack of penetration at the root of fillet welds, and peening of fillet welds. In most cases a fatigue crack started from the root of the fillet, but in the case of higher stress amplitude, it tended to start from the toe of fillet. The standard socket welded joint for a pipe with amore » 50 mm nominal diameter showed a relatively low fatigue strength of 46 MPa in stress amplitude at the 10{sup 7} cycles failure life. This value corresponds to about 1/5 of that for the smoothed base metal specimens in axial fatigue. The fatigue strength decreased with increasing pipe diameter, and increased with increasing thickness of the pipe and socket wall. The effects of throat depth and shape of fillet welds on fatigue strength were not significant. Contrary to expectation, the fatigue strength of a socket welded joint without slip-on gap is Higher than that of the joint with a normal gap. A lack of penetration at the root deleteriously reduced fatigue strength, showing 14 MPa in stress amplitude at the 10{sup 7} cycles failure life for the 50 mm diameter socket joint.« less

Fabrication and evaluation of superplastically formed/weld-brazed corrugated compression panels with beaded webs

NASA Technical Reports Server (NTRS)

Royster, D. M.; Davis, R. C.; Shinn, J. M., Jr.; Bales, T. T.; Wiant, H. R.

1985-01-01

A study was made to investigate the feasibility of superplastically forming corrugated panels with beaded webs and to demonstrate the structural integrity of these panels by testing. The test panels in the study consist of superplastically formed titanium alloy Ti-6Al-4V half-hat elements that are joined by weld-brazing to titanium alloy Ti-6Al-4V caps to form either single-corrugation compression panels or multiple-corrugation compression panels. Stretching and subsequent thinning of the titanium sheet during superplastic forming is reduced by approximately 35 percent with a shallow half-hat die concept instead of a deep die concept and results in a more uniform thickness across the beaded webs. The complete panels are tested in end compression at room temperature and the results compared with analysis. The heavily loaded panels failed at loads approaching the yield strength of the titanium material. At maximum load, the caps wrinkled locally accompanied with separation of the weld-braze joint in the wrinkle. None of the panels tested, however, failed catastrophically in the weld-braze joint. Experimental test results are in good agreement with structural analysis of the panels.

The effects of short pulse laser surface cleaning on porosity formation and reduction in laser welding of aluminium alloy for automotive component manufacture

NASA Astrophysics Data System (ADS)

AlShaer, A. W.; Li, L.; Mistry, A.

2014-12-01

Laser welding of aluminium alloys typically results in porosity in the fusion zones, leading to poor mechanical and corrosion performances. Mechanical and chemical cleaning of surfaces has been used previously to remove contaminants for weld joint preparations. However, these methods are slow, ineffective (e.g. due to hydrogen trapping) or lead to environmental hazards. This paper reports the effects of short pulsed laser surface cleaning on porosity formation and reduction in laser welding of AC-170PX (AA6014) aluminium sheets (coated with Ti/Zr and lubricated using a dry lubricant AlO70) with two types of joints: fillet edge and flange couch, using an AA4043 filler wire for automotive component assembly. The effect of laser cleaning on porosity reduction during laser welding using a filler wire has not been reported before. In this work, porosity and weld fusion zone geometry were examined prior to and after laser cleaning. The nanosecond pulsed Nd:YAG laser cleaning was found to reduce porosity significantly in the weld fusion zones. For the fillet edge welds, porosity was reduced to less than 0.5% compared with 10-80% without laser cleaning. For flange couch welds, porosity was reduced to 0.23-0.8% with laser cleaning from 0.7% to 4.3% without laser cleaning. This has been found to be due to the elimination of contaminations and oxide layers that contribute to the porosity formation. The laser cleaning is based on thermal ablation. This research focuses on porosity reduction in laser welding of aluminium alloy. Weld quality was investigated for two joints, fillet edge and flange couch joints. The effect of laser cleaning on porosity reduction after welding was investigated. It was found that laser cleaning reduced porosity less than 1% in both joints. Weld dimensions and strength were evaluated and discussed for both types of joints.

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.

Numerical Simulation of Tension Properties for Al-Cu Alloy Friction Stir-Welded Joints with GTN Damage Model

NASA Astrophysics Data System (ADS)

Sun, Guo-Qin; Sun, Feng-Yang; Cao, Fang-Li; Chen, Shu-Jun; Barkey, Mark E.

2015-11-01

The numerical simulation of tensile fracture behavior on Al-Cu alloy friction stir-welded joint was performed with the Gurson-Tvergaard-Needleman (GTN) damage model. The parameters of the GTN model were studied in each region of the friction stir-welded joint by means of inverse identification. Based on the obtained parameters, the finite element model of the welded joint was built to predict the fracture behavior and tension properties. Good agreement can be found between the numerical and experimental results in the location of the tensile fracture and the mechanical properties.

Strength of Welded Joints in Tubular Members for Aircraft

NASA Technical Reports Server (NTRS)

Whittemore, H L; Brueggeman, W C

1931-01-01

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

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.

Modeling of the fracture behavior of spot welds using advanced micro-mechanical damage models

NASA Astrophysics Data System (ADS)

Sommer, Silke

2010-06-01

This paper presents the modeling of deformation and fracture behavior of resistance spot welded joints in DP600 steel sheets. Spot welding is still the most commonly used joining technique in automotive engineering. In overloading situations like crash joints are often the weakest link in a structure. For those reasons, crash simulations need reliable and applicable tools to predict the load bearing capacity of spot welded components. Two series of component tests with different spot weld diameters have shown that the diameter of the weld nugget is the main influencing factor affecting fracture mode (interfacial or pull-out fracture), load bearing capacity and energy absorption. In order to find a correlation between nugget diameter, load bearing capacity and fracture mode, the spot welds are simulated with detailed finite element models containing base metal, heat affected zone and weld metal in lap-shear loading conditions. The change in fracture mode from interfacial to pull-out or peel-out fracture with growing nugget diameter under lap-shear loading was successfully modeled using the Gologanu-Leblond model in combination with the fracture criteria of Thomason and Embury. A small nugget diameter is identified to be the main cause for interfacial fracture. In good agreement with experimental observations, the calculated pull-out fracture initiates in the base metal at the boundary to the heat affected zone.

Effect of water-cooling treatment times on properties of friction stir welded joints of 7N01-T4 aluminum alloy

NASA Astrophysics Data System (ADS)

Zhang, T. H.; Wang, Y.; Fang, X. F.; Liang, P.; Zhao, Y.; Li, Y. H.; Liu, X. M.

2018-02-01

Due to the deformation caused by residual stress in the welding process, welded components need treatment to reduce welding distortion. In this paper, several different times of flame-heating and water-cooling treatment were subjected to the friction stir welding joints of 15mm thick 7N01P-T4 aluminum alloy sheets to study the microstructure variation of friction stir welding joints of 7N01P-T4 aluminum alloy, and to analyze the effect on micro-hardness, tensile and fracture mechanical properties. This investigation will be helpful to optimize treatment methods and provide instruction on industrial production.

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

NASA Technical Reports Server (NTRS)

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

1985-01-01

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

49 CFR 192.113 - Longitudinal joint factor (E) for steel pipe.

Code of Federal Regulations, 2010 CFR

2010-10-01

... class Longitudinal joint factor (E) ASTM A 53/A53M Seamless 1.00 Electric resistance welded 1.00 Furnace butt welded .60 ASTM A 106 Seamless 1.00 ASTM A 333/A 333M Seamless 1.00 Electric resistance welded 1.00 ASTM A 381 Double submerged arc welded 1.00 ASTM A 671 Electric-fusion-welded 1.00 ASTM A 672...

Infrared Thermography For Welding

NASA Technical Reports Server (NTRS)

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

1992-01-01

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

Laser welding of a cobalt-chromium removable partial denture alloy.

PubMed

NaBadalung, D P; Nicholls, J I

1998-03-01

The electric alloy brazed joints of removable partial denture alloys have failed frequently after routine usage. A technique providing higher joint strengths was investigated. This investigation compared the tensile strengths of electric-brazed and laser-welded joints for a cobalt-chromium removable partial denture alloy. Twenty-four cobalt-chromium standard tensile testing rods were prepared and divided into three groups of eight. All specimens in the control group (group 1) were left in the as-cast condition. Groups 2 and 3 were the test specimens, which were sectioned at the center of the rod. Eight specimens were joined by using electric brazing, and the remaining specimens were joined by using laser welding. After joining, each joint was ground to a uniform diameter, then tested to tensile failure on an Instron universal testing machine. Failure loads were recorded and fracture stress calculated. Statistical analysis was applied. The student-Newman-Keuls test showed a highly significant difference between the joint strengths of the as-cast control specimens, the electric-brazed and laser-welded joints. The tensile strengths of the as-cast joints were higher than those for the laser-welded joints, and both were higher than the electric-brazed joint strengths.

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.

Microstructure and Mechanical Properties of Fiber-Laser-Welded and Diode-Laser-Welded AZ31 Magnesium Alloy

NASA Astrophysics Data System (ADS)

Chowdhury, S. M.; Chen, D. L.; Bhole, S. D.; Powidajko, E.; Weckman, D. C.; Zhou, Y.

2011-07-01

The microstructures, tensile properties, strain hardening, and fatigue strength of fiber-laser-welded (FLW) and diode-laser-welded (DLW) AZ31B-H24 magnesium alloys were studied. Columnar dendrites near the fusion zone (FZ) boundary and equiaxed dendrites at the center of FZ, with divorced eutectic β-Mg17Al12 particles, were observed. The FLW joints had smaller dendrite cell sizes with a narrower FZ than the DLW joints. The heat-affected zone consisted of recrystallized grains. Although the DLW joints fractured at the center of FZ and exhibited lower yield strength (YS), ultimate tensile strength (UTS), and fatigue strength, the FLW joints failed at the fusion boundary and displayed only moderate reduction in the YS, UTS, and fatigue strength with a joint efficiency of ~91 pct. After welding, the strain rate sensitivity basically vanished, and the DLW joints exhibited higher strain-hardening capacity. Stage III hardening occurred after yielding in both base metal (BM) and welded samples. Dimple-like ductile fracture characteristics appeared in the BM, whereas some cleavage-like flat facets together with dimples and river marking were observed in the welded samples. Fatigue crack initiated from the specimen surface or near-surface defects, and crack propagation was characterized by the formation of fatigue striations along with secondary cracks.

Statistical Analysis of High-Cycle Fatigue Behavior of Friction Stir Welded AA5083-H321

DTIC Science & Technology

2011-01-01

durable structures are: (a) FSW is 111being used in a serial production of aluminum alloy -based 112ferryboat deck structures in Finland; (b) Al-Mg- Si -based...and strain-hardened/stabilized Al-Mg-Mn alloy ) are characterized by a relatively large statistical scatter. This scatter is closely related to the...associated with friction stir-welded (FSW) joints of AA5083-H321 (a solid-solution-strengthened and strain-hardened/stabilized Al-Mg-Mn alloy ) are

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

Optimization of laser butt welding parameters with multiple performance characteristics

NASA Astrophysics Data System (ADS)

Sathiya, P.; Abdul Jaleel, M. Y.; Katherasan, D.; Shanmugarajan, B.

2011-04-01

This paper presents a study carried out on 3.5 kW cooled slab laser welding of 904 L super austenitic stainless steel. The joints have butts welded with different shielding gases, namely argon, helium and nitrogen, at a constant flow rate. Super austenitic stainless steel (SASS) normally contains high amount of Mo, Cr, Ni, N and Mn. The mechanical properties are controlled to obtain good welded joints. The quality of the joint is evaluated by studying the features of weld bead geometry, such as bead width (BW) and depth of penetration (DOP). In this paper, the tensile strength and bead profiles (BW and DOP) of laser welded butt joints made of AISI 904 L SASS are investigated. The Taguchi approach is used as a statistical design of experiment (DOE) technique for optimizing the selected welding parameters. Grey relational analysis and the desirability approach are applied to optimize the input parameters by considering multiple output variables simultaneously. Confirmation experiments have also been conducted for both of the analyses to validate the optimized parameters.

Effects of post-weld heat treatment on microstructure and mechanical properties of laser welds in GH3535 superalloy

NASA Astrophysics Data System (ADS)

Yu, Kun; Jiang, Zhenguo; Leng, Bin; Li, Chaowen; Chen, Shuangjian; Tao, Wang; Zhou, Xingtai; Li, Zhijun

2016-07-01

In this study, the microstructure and mechanical properties of laser welds before and after post-weld heat treatment processes were studied. The results show that the tensile strength of the joints can be increased by 90 MPa by a post-weld heat treatment process at 871 °C for 6 h, exceeding the strength of the original state of the base metal. Besides, elongation of the joints are also increased to 43% by the process, whereas the elongation of as-welded joints are only 22%. In addition, the Charpy impact properties of laser welds almost do not change. Second phase precipitates, which were identified as Mo-Si rich M6C-type carbides by transmission electron diffraction and scanning electron microscope, were observed at solidification grain boundaries and solidification subgrain boundaries. These carbides can pin dislocations during the following tensile deformation, hence are responsible for the strengthening of tensile properties of the joints.

Mechanical Properties of Steel P92 Welded Joints Obtained By TIG Technology

NASA Astrophysics Data System (ADS)

Mohyla, P.; Havelka, L.; Schmidová, E.; Vontorová, J.

2017-11-01

Mechanical properties of P92 steel welded joints obtained using the TIG (141) technology have been studied upon post-welding heat treatment (PWHT). The microhardness, tensile strength, and impact toughness of metal in the weld and heat-affected zone are determined. The PWHT is shown to be obligatory.

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.

Electric arc welding gun

DOEpatents

Luttrell, Edward; Turner, Paul W.

1978-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Mechanical properties of friction stir welded butt joint of steel/aluminium alloys: effect of tool geometry

NASA Astrophysics Data System (ADS)

Syafiq, W. M.; Afendi, M.; Daud, R.; Mazlee, M. N.; Majid, M. S. Abdul; Lee, Y. S.

2017-10-01

This paper described the mechanical properties from hardness testing and tensile testing of Friction Stir Welded (FSW) materials. In this project, two materials of aluminium and steel are welded using conventional milling machine and tool designed with different profile and shoulder size. During welding the temperature along the weld line is collected using thermocouples. Threaded pins was found to produce stronger joints than cylindrical pins. 20 mm diameter shoulder tool welded a slightly stronger joint than 18 mm diameter one, as well as softer nugget zone due to higher heat input. Threaded pins also contributed to higher weld temperature than cylindrical pins due to increase in pin contact surface. Generally, higher temperatures were recorded in aluminium side due to pin offset away from steel.

Investigations on Microstructure and Corrosion behavior of Superalloy 686 weldments by Electrochemical Corrosion Technique

NASA Astrophysics Data System (ADS)

Arulmurugan, B.; Manikandan, M.

2018-02-01

In the present study, microstructure and the corrosion behavior of Nickel based superalloy 686 and its weld joints has been investigated by synthetic sea water environment. The weldments were fabricated by Gas Tungsten Arc Welding (GTAW) and Pulsed Current Gas Tungsten Arc Welding (PCGTAW) techniques with autogenous mode and three different filler wires (ERNiCrMo-4, ERNiCrMo-10 and ERNiCrMo-14). Microstructure and Scanning electron microscope examination was carried out to evaluate the structural changes in the fusion zones of different weldments. Energy Dispersive X-ray Spectroscopy (EDS) analysis was carried out to evaluate the microsegregation of alloying elements in the different weld joints. Potentiodynamic polarization study was experimented on the base metal and weld joints in the synthetic sea water environment to evaluate the corrosion rate. Tafel’s interpolation technique was used to obtain the corrosion rate. The microstructure examination revealed that the fine equiaxed dendrites were observed in the pulsed current mode. EDS analysis shows the absence of microsegregation in the current pulsing technique. The corrosion rates of weldments are compared with the base metal. The results show that the fine microstructure with the absence of microsegregation in the PCGTA weldments shows improved corrosion resistance compared to the GTAW. Autogenous PCGTAW shows higher corrosion resistance irrespective of all weldments employed in the present study.

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.

Initial Testing for the Recommendation of Improved Gas Metal Arc Welding Procedures for HY-80 Steel Plate Butt Joints at Norfolk Naval Shipyard

DTIC Science & Technology

2015-12-01

is unlimited 12b. DISTRIBUTION CODE 13. ABSTRACT (maximum 200 words) Hull cut welding proficiency is an essential skill maintained by personnel...at naval shipyards. This thesis explores arc weld theory to develop ideal submarine hull butt joint designs and recommends preliminary testing to...shipboard hull welding applications, theoretically. Butt joint samples were created using HY-80 steel plate so that the following comparisons could

An investigation on mechanical properties of steel fibre reinforced for underwater welded joint

NASA Astrophysics Data System (ADS)

Navin, K.; Zakaria, M. S.; Zairi, S.

2017-09-01

Underwater pipelines are always exposed to water and have a high tendency to have corrosion especially on the welded joint. This research is about using fiber glass as steel fiber to coat the welded joint to determine the effectiveness in corrosion prevention of the welded joint. Number of coating is varied to determine the better number coating to coat the pipeline. Few samples were left without immersion in salt water and few samples are immersed into salt water with same salinity as sea water. The material sample is prepared in dog bone shape to enable to be used in Universal Tensile Machine (UTM). The material prepared is left immersed for recommended time and tested in Universal Tensile Machine. Upon analyzing the result, the result is used to determine the breakage point whether broken on the welded joint or different place and also the suitable number of coating to be used.

Influence of Thermal Aging on Tensile and Low Cycle Fatigue Behavior of Type 316LN Austenitic Stainless Steel Weld Joint

NASA Astrophysics Data System (ADS)

Suresh Kumar, T.; Nagesha, A.; Ganesh Kumar, J.; Parameswaran, P.; Sandhya, R.

2018-05-01

Influence of short-term thermal aging on the low-cycle fatigue (LCF) behavior of 316LN austenitic stainless steel weld joint with 0.07 wt pct N has been investigated. Prior thermal exposure was found to improve the fatigue life compared with the as-welded condition. Besides, the treatment also imparted a softening effect on the weld metal, leading to an increase in the ductility of the weld joint which had a bearing on the cyclic stress response. The degree of cyclic hardening was seen to increase after aging. Automated ball-indentation (ABI) technique was employed toward understanding the mechanical properties of individual zones across the weld joint. It was observed that the base metal takes most of the applied cyclic strain during LCF deformation in the as-welded condition. In the aged condition, however, the weld also participates in the cyclic deformation. The beneficial effect of thermal aging on cyclic life is attributed to a reduction in the severity of the metallurgical notch leading to a restoration of ductility of the weld region. The transformation of δ-ferrite to σ-phase during the aging treatment was found to influence the location of crack initiation. Fatigue cracks were found to initiate in the base metal region of the joint in most of the testing conditions. However, embrittlement in the weld metal caused a shift in the point of crack initiation with increasing strain amplitude under LCF.

Effect of Local Post Weld Heat Treatment on Tensile Properties in Friction Stir Welded 2219-O Al Alloy

NASA Astrophysics Data System (ADS)

Chu, Guannan; Sun, Lei; Lin, Caiyuan; Lin, Yanli

2017-11-01

To improve the formability of the aluminum alloy welds and overcome the size limitation of the bulk post weld heat treatment (BPWHT) on large size friction stir welded joints, a local post weld heat treatment method (LPWHT) was proposed. In this method, the resistance heating as the moving heat source is adopted to only heat the weld seam. The temperature field of LPWHT and its influence on the mechanical properties and formability of FSW 2219-O Al alloy joints was investigated. The evaluation of the tensile properties of FSW samples was also examined by mapping the global and local strain distribution using the digital image correlation methodology. The results indicated that the formability was improved greatly after LPWHT, while the hardness distribution of the FSW joint was homogenized. The maximum elongation can reach 1.4 times that of as-welded joints with increase the strength and the strain of the nugget zone increased from 3 to 8% when annealing at 300 °C. The heterogeneity on the tensile deformation of the as-welded joints was improved by the nugget zone showing large local strain value and the reason was given according to the dimple fracture characteristics at different annealing temperatures. The tensile strength and elongation of LPWHT can reach 93.3 and 96.1% of the BPWHT, respectively. Thus, the LPWHT can be advantageous compared to the BPWHT for large size welds.

Earth boring apparatus with multiple welds

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

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

1981-06-16

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

Global and Local Mechanical Properties of Autogenously Laser Welded Ti-6Al-4V

NASA Astrophysics Data System (ADS)

Cao, Xinjin; Kabir, Abu Syed H.; Wanjara, Priti; Gholipour, Javad; Birur, Anand; Cuddy, Jonathan; Medraj, Mamoun

2014-03-01

Ti-6Al-4V sheets, 3.2-mm in thickness, were butt welded using a continuous wave 4 kW Nd:YAG laser welding system. The effect of two main process parameters, laser power and welding speed, on the joint integrity was characterized in terms of the joint geometry, defects, microstructure, hardness, and tensile properties. In particular, a digital image correlation technique was used to determine the local tensile properties of the welds. It was determined that a wide range of heat inputs can be used to fully penetrate the Ti-6Al-4V butt joints during laser welding. At high laser power levels, however, significant defects such as underfill and porosity, can occur and cause marked degradation in the joint integrity and performance. At low welding speeds, however, significant porosity occurs due to its growth and the potential collapse of instable keyholes. Intermediate to relatively high levels of heat input allow maximization of the joint integrity and performance by limiting the underfill and porosity defects. In considering the effect of the two main defects on the joint integrity, the underfill defect was found to be more damaging to the mechanical performance of the weldment than the porosity. Specifically, it was determined that the maximum tolerable underfill depth for Ti-6Al-4V is approximately 6 pct of the workpiece thickness, which is slightly stricter than the value of 7 pct specified in AWS D17.1 for fusion welding in aerospace applications. Hence, employing optimized laser process parameters allows the underfill depth to be maintained within the tolerable limit (6 pct), which in turn prevents degradation in both the weld strength and ductility. To this end, the ability to maintain weld ductility in Ti-6Al-4V by means of applying a high energy density laser welding process presents a significant advantage over conventional arc welding for the assembly of aerospace components.

In situ damage detection in frame structures through coupled response measurements

NASA Astrophysics Data System (ADS)

Liu, D.; Gurgenci, H.; Veidt, M.

2004-05-01

Due to the existence of global modes and local modes of the neighbouring members, damage detection on a structure is more challenging than damage on isolated beams. Detection of an artificial circumferential crack on a joint in a frame-like welded structure is studied in this paper using coupled response measurements. Similarity to real engineering structures is maintained in the fabrication of the test frame. Both the chords and the branch members have hollow sections and the branch members have smaller sizes. The crack is created by a hacksaw on a joint where a branch meets the chord. The methodology is first demonstrated on a single hollow section beam. The test results are then presented for the damaged and undamaged frame. The existence of the damage is clearly observable from the experimental results. It is suggested that this approach offers the potential to detect damage in welded structures such as cranes, mining equipment, steel-frame bridges, naval and offshore structures.

Effects of joint configuration for the arc welding of cast Ti-6Al-4V alloy rods in argon.

PubMed

Taylor, J C; Hondrum, S O; Prasad, A; Brodersen, C A

1998-03-01

Titanium and its alloys are more commonly used in prosthodontics and welding has become the most common modality for their joining. Studies on the welding of titanium and its alloys have not quantified this value, though its importance has been suggested. This study compared the strength and properties of the joint achieved at various butt joint gaps by the arc-welding of cast Ti-6Al-4V alloy tensile bars in an argon atmosphere. Forty of 50 specimens were sectioned and welded at four gaps. All specimens underwent tensile testing to determine ultimate tensile strength and percentage elongation, then oxygen analysis and scanning electron microscopy. As no more than 3 samples in any group of 10 actually fractured in the weld itself, a secondary analysis that involved fracture location was initiated. There were no differences in ultimate tensile strength or percentage elongation between specimens with weld gaps of 0.25, 0.50, 0.75, and 1.00 mm and the as-cast specimens. There were no differences in ultimate tensile strength between specimens fracturing in the weld and those fracturing in the gauge in welded specimens; however, as-cast specimens demonstrated a higher ultimate tensile strength than welded specimens that fractured in the weld. Specimens that fractured in the weld site demonstrated less ductility than those that fractured in the gauge in both welded and as-cast specimens, as confirmed by scanning electron microscopy examination. The weld wire showed an oxygen scavenging effect from the as-cast parent alloy. The effects of the joint gap were not significant, whereas the characteristics of the joint itself were, which displayed slightly lower strength and significantly lower ductility (and thus decreased toughness). The arc-welding of cast titanium alloy in argon atmosphere appears to be a reliable and efficient prosthodontic laboratory modality producing predictable results, although titanium casting and joining procedures must be closely controlled to minimize heat effects and oxygen contamination.

Microstructure and Mechanical Properties of Welds of Al - Mg - Si Alloys After Different Modes of Impulse Friction Stir Welding

NASA Astrophysics Data System (ADS)

Kondrat'ev, S. Yu.; Morozova, Yu. N.; Golubev, Yu. A.; Hantelmann, C.; Naumov, A. A.; Mikhailov, V. G.

2018-03-01

Welded joints of aluminum alloy 6082-T6 formed by the method of impulse friction stir welding are studied. The effect of the power and frequency of the pulses on the microstructure and mechanical properties of the welded joints is determined. Application of an additional pulse during the welding affects the surface quality and the shape of the weld, the distribution of the oxide layer and of particles of the hardening phase, and the grain size in the zone of dynamic recrystallization.

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.

Effects of welding technology on welding stress based on the finite element method

NASA Astrophysics Data System (ADS)

Fu, Jianke; Jin, Jun

2017-01-01

Finite element method is used to simulate the welding process under four different conditions of welding flat butt joints. Welding seams are simulated with birth and death elements. The size and distribution of welding residual stress is obtained in the four kinds of welding conditions by Q345 manganese steel plate butt joint of the work piece. The results shown that when using two-layers welding,the longitudinal and transverse residual stress were reduced;When welding from Middle to both sides,the residual stress distribution will change,and the residual stress in the middle of the work piece was reduced.

Dynamic analysis of I cross beam section dissimilar plate joined by TIG welding

NASA Astrophysics Data System (ADS)

Sani, M. S. M.; Nazri, N. A.; Rani, M. N. Abdul; Yunus, M. A.

2018-04-01

In this paper, finite element (FE) joint modelling technique for prediction of dynamic properties of sheet metal jointed by tungsten inert gas (TTG) will be presented. I cross section dissimilar flat plate with different series of aluminium alloy; AA7075 and AA6061 joined by TTG are used. In order to find the most optimum set of TTG welding dissimilar plate, the finite element model with three types of joint modelling were engaged in this study; bar element (CBAR), beam element and spot weld element connector (CWELD). Experimental modal analysis (EMA) was carried out by impact hammer excitation on the dissimilar plates that welding by TTG method. Modal properties of FE model with joints were compared and validated with model testing. CWELD element was chosen to represent weld model for TTG joints due to its accurate prediction of mode shapes and contains an updating parameter for weld modelling compare to other weld modelling. Model updating was performed to improve correlation between EMA and FEA and before proceeds to updating, sensitivity analysis was done to select the most sensitive updating parameter. After perform model updating, average percentage of error of the natural frequencies for CWELD model is improved significantly.

Pin Load Control Applied to Retractable Pin Tool Technology and its Characterization

NASA Technical Reports Server (NTRS)

Oelgoetz, Peter A.

2000-01-01

Until the development of retractable pin tool (RPT) technology, friction stir welding (FSW) was limited to constant thickness joining of aluminum materials and the choices of keyhole elimination focused on traditional fusion and plug weld repair techniques. An invention, US Patent Number 5,893,507, "Auto-Adjustable Pin Tool for Friction Stir Welding" assigned to NASA, demonstrated an approach to resolve these serious drawbacks. This approach brings forth a technique that allows the crater, or keyhole, to be closed out automatically at the end of the weld joint without adding any additional equipment or material. Also the probe length can be varied automatically in the weld joint to compensate for material thickness changes, such as, in a tapered joint. This paper reports the effects of pin extension and retraction rates in the weld joint and its correlation to weld quality. The investigation utilized a pin load-detecting device that was integrated in the Phase 2A RPT designed by Boeing for NASA/MSFC. The RPT modification provided pin load data that was accessed and used to eliminate root side indications and determine pin manipulation rates necessary to produce consistence homogeneous joints.

Pin Load Control Applied to Retractable Pin Tool Technology and its Characterization

NASA Technical Reports Server (NTRS)

Oelgoetz, Peter

2000-01-01

Until the development of retractable pin tool (RPT) technology, friction stir welding (FSW) was limited to constant thickness joining of aluminum materials and the choices of keyhole elimination focused on traditional fusion and plug weld repair techniques. An invention, US Patent Number 5,893.507, "Auto-Adjustable Pin Tool for Friction Stir Welding" assigned to NASA, demonstrated an approach to resolve these serious drawbacks. This approach brings forth a technique that allows the crater, or keyhole, to be closed out automatically at the end of the weld joint without adding any additional equipment or material. Also the probe length can be varied automatically in the weld joint to compensate for material thickness changes, such as, in a tapered joint. This paper reports the effects of pin extension and retraction rates in the weld joint and its correlation to weld quality. The investigation utilized a pin load-detecting device that was integrated in the Phase 2A RPT designed by Boeing for NASA/MSFC. The RPT modification provided pin load data that was accessed and used to eliminate root side indications and determine pin manipulation rates necessary to produce consistence homogeneous joints.

Pin Load Control Applied to Retractable Pin Tool Technology and Its Characterization

NASA Technical Reports Server (NTRS)

Olegoetz, P.

1999-01-01

Until the development of retractable pin tool (RPT) technology, friction stir welding (FSW) was limited to constant thickness joining of aluminum materials and the choices of keyhole elimination focused on traditional fusion and plug weld repair techniques. An invention, US Patent Number 5,893,507, "Auto-Adjustable Pin Tool for Friction Stir Welding" assigned to NASA, demonstrated an approach to resolve these serious drawbacks. This approach brings forth a technique that allows the crater, or keyhole, to be closed out automatically at the end of the weld joint without adding any additional equipment or material. Also the probe length can be varied automatically in the weld joint to compensate for material thickness changes, such as, in a tapered joint. This paper reports the effects of pin extension and retraction rates in the weld joint and its correlation to weld quality. The investigation utilized a pin load-detecting device that was integrated in the Phase IIA RPT designed by Boeing for NASA/MSFC. The RPT modification provided pin load data that was accessed and used to eliminate root side indications and determine pin manipulation rates necessary to produce consistence homogeneous joints.

Numerical analysis of the heat transfer and fluid flow in the butt-fusion welding process

NASA Astrophysics Data System (ADS)

Yoo, Jae Hyun; Choi, Sunwoong; Nam, Jaewook; Ahn, Kyung Hyun; Oh, Ju Seok

2017-02-01

Butt-fusion welding is an effective process for welding polymeric pipes. The process can be simplified into two stages. In heat soak stage, the pipe is heated using a hot plate contacted with one end of the pipe. In jointing stage, a pair of heated pipes is compressed against one another so that the melt regions become welded. In previous works, the jointing stage that is highly related to the welding quality was neglected. However, in this study, a finite element simulation is conducted including the jointing stage. The heat and momentum transfer are considered altogether. A new numerical scheme to describe the melt flow and pipe deformation for the butt-fusion welding process is introduced. High density polyethylene (HDPE) is used for the material. Flow via thermal expansion of the heat soak stage, and squeezing and fountain flow of the jointing stage are well reproduced. It is also observed that curling beads are formed and encounter the pipe body. The unique contribution of this study is its capability of directly observing the flow behaviors that occur during the jointing stage and relating them to welding quality.

Ultrasonic Welding of Hybrid Joints

NASA Astrophysics Data System (ADS)

Wagner, Guntram; Balle, Frank; Eifler, Dietmar

2012-03-01

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

Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel

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

Wang, Tianhao; Sidhar, Harpreet; Mishra, Rajiv S.

Friction stir scribe technology, a derivative of friction stir welding, was applied for the dissimilar lap welding of an aluminum alloy and galvanized mild steel sheets. During the process, the rotating tool with a cobalt steel scribe first penetrated the top material — aluminum — and then the scribe cut the bottom material — steel. The steel was displaced into the upper material to produce a characteristic hook feature. Lap welds were shear tested, and their fracture paths were studied. Welding parameters affected the welding features including hook height, which turned out to be highly related to fracture position. Therefore,more » in this paper, the relationships among welding parameters, hook height, joint strength and fracture position are presented. In addition, influence of zinc coating on joint strength was also studied. Keywords: friction stir scribe technology; dissimilar material welding; zinc coating; hook height; joint strength; fracture position« less

Residual-stress measurement in socket welded joints by neutron diffraction

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

Hayashi, M.; Ishiwata, M.; Minakawa, N.

1994-12-31

Neutron diffraction measurements of lattice strains provide spatial maps of residual stress near welds in ferritic steel socket joints. The highest tensile stresses in the welds are found in axial, radial and hoop direction at the weld root. However, the highest tensile stress in the axial direction is about 110MPa. Balancing compressive stresses are found near the surface of the socket weld fusion zone. Heat treatment at 600 C for 2 hours is sufficient to relieve residual stress in socket welds.

Microstructural Influence on Mechanical Properties in Plasma Microwelding of Ti6Al4V Alloy

NASA Astrophysics Data System (ADS)

Baruah, M.; Bag, S.

2016-11-01

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

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.

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

PubMed

Mroczka, K; Dutkiewicz, J; Pietras, A

2010-03-01

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

Effect of Initial Microstructure on the Microstructural Evolution and Joint Efficiency of a WE43 Alloy During Friction Stir Welding

DTIC Science & Technology

2013-04-01

to maximize joint efficiency. 15. SUBJECT TERMS friction stir welding, strain rate, dynamic recrystallization , joint efficiency, stir zone (SZ...stir welding, Strain rate, Dynamic recrystallization , Joint efficiency, Stir Zone (SZ) Abstract The initial microstructure plays an important role in... eutectic Mg17Al12 phase. Park et al. [7] demonstrated the importance of texture and related it to the mechanical properties of an AZ61 alloy

Study of the stability of electrode metal melting and transfer in the process of consumable electrode welding powered by supplies with differing dynamic characteristics

NASA Astrophysics Data System (ADS)

Saraev, Y. N.; Chinakhov, D. A.; Il'yashchenko, D. P.; Kiselev, A. S.; Gardiner, A. S.; Raev, I. V.

2016-11-01

In the paper we present the results of the study of the power supply characteristics effect upon the stability of electrode metal melting and transfer into the weld pool in the process of consumable electrode welding. It was shown that application of inverter type welding power supplies of the new generation results in changing the characteristics of the heat and mass transfer which has a decisive impact upon the heat content of the weld pool, reduction of residual stresses in the heat-affected zone (HAZ). The authors also substantiate the tendency to the reduction of the structural constituents in the area of the permanent joint.

Influence of the Strength Mismatch of a Narrow Gap Welded Joint of SA508 on the Plastic η Factor

NASA Astrophysics Data System (ADS)

Koo, J. M.; Huh, Y.; Seok, C. S.

2012-11-01

In this article, the influence of the strength mismatch of a narrow gap welded joint of SA508 on the η factor was evaluated. The η factor is the principal parameter that determines the plastic portion of the J-integral. The specimens for tensile and hardness tests were collected from piping with narrow gap welding and the stress-strain curve and hardness were obtained from those. From these results, the Ramberg-Osgood (R-O) constant was obtained. Also, the finite element analysis was performed with variations in the strength mismatch and the weld width. The η factor equation considering the strength mismatch and the weld width of a narrow gap welded joint was suggested.

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

NASA Astrophysics Data System (ADS)

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

2012-03-01

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

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

Microstructure and Strain Rate-Dependent Tensile Deformation Behavior of Fiber Laser-Welded Butt Joints of Dual-Phase Steels

NASA Astrophysics Data System (ADS)

Liu, Yang; Dong, Danyang; Han, Zhiqiang; Yang, Zhibin; Wang, Lu; Dong, Qingwei

2018-05-01

The microstructure and tensile deformation behavior of the fiber laser-welded similar and dissimilar dual-phase (DP) steel joints over a wide range of strain rates from 10-3 to 103 s-1 were investigated for the further applications on the lightweight design of vehicles. The high strain rate dynamic tensile deformation process and full-field strain distribution of the base metals and welded joints were examined using the digital image correlation method and high-speed photography. The strain rate effects on the stress-strain responses, tensile properties, deformation, and fracture behavior of the investigated materials were analyzed. The yield stress (YS) and ultimate tensile strength (UTS) of the dissimilar DP780/DP980 welded joints were lying in-between those of the DP780 and DP980 base metals, and all materials exhibited positive strain rate dependence on the YS and UTS. Owing to the microstructure heterogeneity, the welded joints showed relatively lower ductility in terms of total elongation (TE) than those of the corresponding base metals. The strain localization started before the maximum load was reached, and the strain localization occurred earlier during the whole deformation process with increasing strain rate. As for the dissimilar welded joint, the strain localization tended to occur in the vicinity of the lowest hardness value across the welded joint, which was in the subcritical HAZ at the DP780 side. As the strain rate increased, the typical ductile failure characteristic of the investigated materials did not change.

Microstructure and Strain Rate-Dependent Tensile Deformation Behavior of Fiber Laser-Welded Butt Joints of Dual-Phase Steels

NASA Astrophysics Data System (ADS)

Liu, Yang; Dong, Danyang; Han, Zhiqiang; Yang, Zhibin; Wang, Lu; Dong, Qingwei

2018-04-01

The microstructure and tensile deformation behavior of the fiber laser-welded similar and dissimilar dual-phase (DP) steel joints over a wide range of strain rates from 10-3 to 103 s-1 were investigated for the further applications on the lightweight design of vehicles. The high strain rate dynamic tensile deformation process and full-field strain distribution of the base metals and welded joints were examined using the digital image correlation method and high-speed photography. The strain rate effects on the stress-strain responses, tensile properties, deformation, and fracture behavior of the investigated materials were analyzed. The yield stress (YS) and ultimate tensile strength (UTS) of the dissimilar DP780/DP980 welded joints were lying in-between those of the DP780 and DP980 base metals, and all materials exhibited positive strain rate dependence on the YS and UTS. Owing to the microstructure heterogeneity, the welded joints showed relatively lower ductility in terms of total elongation (TE) than those of the corresponding base metals. The strain localization started before the maximum load was reached, and the strain localization occurred earlier during the whole deformation process with increasing strain rate. As for the dissimilar welded joint, the strain localization tended to occur in the vicinity of the lowest hardness value across the welded joint, which was in the subcritical HAZ at the DP780 side. As the strain rate increased, the typical ductile failure characteristic of the investigated materials did not change.

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

PubMed

Zupancic, Rok; Legat, Andraz; Funduk, Nenad

2006-10-01

The longevity of prosthodontic restorations is often limited due to the mechanical or corrosive failure occurring at the sites where segments of a metal framework are joined together. The purpose of this study was to determine which joining method offers the best properties to cobalt-chromium alloy frameworks. Brazed and 2 types of laser-welded joints were compared for their mechanical and corrosion characteristics. Sixty-eight cylindrical cobalt-chromium dental alloy specimens, 35 mm long and 2 mm in diameter, were cast. Sixteen specimens were selected for electrochemical measurements in an artificial saliva solution and divided into 4 groups (n=4). In the intact group, the specimens were left as cast. The specimens of the remaining 3 groups were sectioned at the center, perpendicular to the long-axis, and were subsequently rejoined by brazing (brazing group) or laser welding using an X- or I-shaped joint design (X laser and I laser groups, respectively). Another 16 specimens were selected for electrochemical measurements in a more acidic artificial saliva solution. These specimens were also divided into 4 groups (n=4) as described above. Electrochemical impedance spectroscopy and potentiodynamic polarization were used to assess corrosion potentials, breakdown potentials, corrosion current densities, total impedances at lowest frequency, and polarization charge-transfer resistances. The remaining 36 specimens were used for tensile testing. They were divided into 3 groups in which specimen pairs (n=6) were joined by brazing or laser welding to form 70-mm-long cylindrical rods. The tensile strength (MPa) was measured using a universal testing machine. Differences between groups were analyzed using 1-way analysis of variance (alpha=.05). The fracture surfaces and corrosion defects were examined with a scanning electron microscope. The average tensile strength of brazed joints was 792 MPa and was significantly greater (P<.05) than the tensile strength of both types of laser-welded joints (404 MPa and 405 MPa). When laser welding was used, successful joining was limited to the peripheral aspects of the weld. The welding technique did not significantly affect the joint tensile strength. Electrochemical measurements indicated that the corrosion resistance of the laser-welded joints was better than of the brazed ones, primarily due to differences in passivation ability. Laser welding provides excellent corrosion resistance to cobalt-chromium alloy joints, but strength is limited due to the shallow weld penetration. Brazed joints are less resistant to corrosion but have higher tensile strength than laser welds.

Influence of Laser Power on the Microstructure and Mechanical Properties of a Laser Welded-Brazed Mg Alloy/Ni-Coated Steel Dissimilar Joint

NASA Astrophysics Data System (ADS)

Tan, Caiwang; Xiao, Liyuan; Liu, Fuyun; Chen, Bo; Song, Xiaoguo; Li, Liqun; Feng, Jicai

2017-05-01

In this work, we describe a method to improve the bonding of an immiscible Mg/steel system using Ni as an interlayer by coating it on the steel surface. Laser welding-brazing of AZ31B Mg alloy to Ni-coated Q235 steel using Mg-based filler was performed in a lap configuration. The influence of laser power on the weld characteristics, including joint appearance, formation of interfacial reaction layers and mechanical properties was investigated. The results indicated that the presence of the Ni-coating promoted the wetting of the liquid filler metal on the steel surface. A thermal gradient along the interface led to the formation of heterogeneous interfacial reaction layers. When using a low laser power of 1600 W, the reaction products were an FeAl phase in the direct laser irradiation zone, an AlNi phase close to the intermediate zone and mixtures of AlNi phase and an (α-Mg + Mg2Ni) eutectic structure near the interface at the seam head zone. For high powers of more than 2000 W, the FeAl phase grew thicker in the direct laser irradiation zone and a new Fe(Ni) transition layer formed at the interface of the intermediate zone and the seam head zone. However, the AlNi phase and (α-Mg + Mg2Ni) eutectic structure were scattered at the Mg seam. All the joints fractured at the fusion zone, indicating that the improved interface was not the weakest joint region. The maximum tensile-shear strength of the Mg/Ni-coated steel joint reached 190 N/mm, and the joint efficiency was 70% with respect to the Mg alloy base metal.

Investigation on Microstructure and Mechanical Properties of Continuous and Pulsed Current Gas Tungsten Arc Welded alloy 600

NASA Astrophysics Data System (ADS)

Srikanth, A.; Manikandan, M.

2018-02-01

The present study investigates the microstructure and mechanical properties of joints fabricated by Continuous and pulsed current gas tungsten arc welded alloy 600. Welding was done by autogenous mode. The macro examination was carried out to evaluate the welding defects in the weld joints. Optical and Scanning Electron Microscope (SEM) were performed to assess the microstructural changes in the fusion zone. Energy Dispersive Spectroscopy (EDS) analysis was carried to evaluate the microsegregation of alloying elements in the fusion zone. The tensile test was conducted to assess the strength of the weld joints. The results show that no welding defects were observed in the fusion zones of Continuous and Pulsed current Gas Tungsten Arc Welding. The refined microstructure was found in the pulsed current compared to continuous current mode. Microsegregation was not noticed in the weld grain boundary of continuous and pulsed current mode. The pulsed current shows improved mechanical properties compared to the continuous current mode.

Microstructure and Porosity of Laser-welded Dissimilar Material Joints of HR-2 and J75

NASA Astrophysics Data System (ADS)

Shen, Xianfeng; Teng, Wenhua; Zhao, Shuming; He, Wenpei

Dissimilar laser welding of HR-2 and J75 has a wide range of applications in high-and low-temperature hydrogen storage. The porosity distributions of the welded joints were investigated at different line energies, penetration status, and welding positions (1G, 2G, and 3G). The effect of the welding position on the welding appearance was evident only at high line energies because of the essential effect of gravity of the larger and longer dwelling molten pool. The porosity of the welded joints between the solutionised and aged J75 and HR-2 at the 3G position and partial penetration was located at the weld centre line, while the porosity at the 2G position with full penetration was distributed at the weld edges, which is consistent with the distribution of floating slag. Full keyhole penetration resulted in minimum porosity, partial penetration resulted in moderate porosity, and periodic molten pool penetration resulted in maximum porosity.

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

NASA Technical Reports Server (NTRS)

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

2004-01-01

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

Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

DOE PAGES

Rabby, Reza; Tang, Wei; Reynolds, A. P.

2015-05-13

In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtainedmore » when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.« less

Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

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

Rabby, Reza; Tang, Wei; Reynolds, A. P.

In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtainedmore » when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.« less

The Mechanism of Ultrasonic Vibration on Grain Refining and Degassing in GTA Spot Welding of Copper Joints.

PubMed

Al-Ezzi, Salih; Quan, Gaofeng; Elrayah, Adil

2018-05-07

This paper examines the effect of ultrasonic vibration (USV) on grain size and interrupted porosity in Gas Tungsten Arc (GTA) spot-welded copper. Grain size was refined by perpendicularly attaching a transducer to the welded sheet and applying USV to the weld pool for a short time (0, 2, 4, and 6 s) in addition improvements to the degassing process. Results illustrate a significant reduction of grain size (57%). Notably, USV provided interaction between reformations (fragmentation) and provided nucleation points (detaching particles from the fusion line) for grains in the nugget zone and the elimination of porosity in the nugget zone. The GTA spot welding process, in conjunction with USV, demonstrated an improvement in the corrosion potential for a copper spot-welded joint in comparison to the joint welded without assistance of USV. Finally, welding of copper by GTA spot welding in conjunction with ultrasound for 2 s presented significant mechanical properties.

The Mechanism of Ultrasonic Vibration on Grain Refining and Degassing in GTA Spot Welding of Copper Joints

PubMed Central

Quan, Gaofeng

2018-01-01

This paper examines the effect of ultrasonic vibration (USV) on grain size and interrupted porosity in Gas Tungsten Arc (GTA) spot-welded copper. Grain size was refined by perpendicularly attaching a transducer to the welded sheet and applying USV to the weld pool for a short time (0, 2, 4, and 6 s) in addition improvements to the degassing process. Results illustrate a significant reduction of grain size (57%). Notably, USV provided interaction between reformations (fragmentation) and provided nucleation points (detaching particles from the fusion line) for grains in the nugget zone and the elimination of porosity in the nugget zone. The GTA spot welding process, in conjunction with USV, demonstrated an improvement in the corrosion potential for a copper spot-welded joint in comparison to the joint welded without assistance of USV. Finally, welding of copper by GTA spot welding in conjunction with ultrasound for 2 s presented significant mechanical properties. PMID:29735894

Effect of Stress Relief Annealing on Microstructure & Mechanical Properties of Welded Joints Between Low Alloy Carbon Steel and Stainless Steel

NASA Astrophysics Data System (ADS)

Nivas, R.; Das, G.; Das, S. K.; Mahato, B.; Kumar, S.; Sivaprasad, K.; Singh, P. K.; Ghosh, M.

2017-01-01

Two types of welded joints were prepared using low alloy carbon steel and austenitic stainless steel as base materials. In one variety, buttering material and weld metal were Inconel 82. In another type, buttering material and weld metal were Inconel 182. In case of Inconel 82, method of welding was GTAW. For Inconel 182, welding was done by SMAW technique. For one set of each joints after buttering, stress relief annealing was done at 923 K (650 °C) for 90 minutes before further joining with weld metal. Microstructural investigation and sub-size in situ tensile testing in scanning electron microscope were carried out for buttered-welded and buttered-stress relieved-welded specimens. Adjacent to fusion boundary, heat-affected zone of low alloy steel consisted of ferrite-pearlite phase combination. Immediately after fusion boundary in low alloy steel side, there was increase in matrix grain size. Same trend was observed in the region of austenitic stainless steel that was close to fusion boundary between weld metal-stainless steel. Close to interface between low alloy steel-buttering material, the region contained martensite, Type-I boundary and Type-II boundary. Peak hardness was obtained close to fusion boundary between low alloy steel and buttering material. In this respect, a minimum hardness was observed within buttering material. The peak hardness was shifted toward buttering material after stress relief annealing. During tensile testing no deformation occurred within low alloy steel and failure was completely through buttering material. Crack initiated near fusion boundary between low alloy steel-buttering material for welded specimens and the same shifted away from fusion boundary for stress relieved annealed specimens. This observation was at par with the characteristics of microhardness profile. In as welded condition, joints fabricated with Inconel 82 exhibited superior bond strength than the weld produced with Inconel 182. Stress relief annealing reduced the strength of transition joints and the reduction was maximum for specimen welded with Inconel 82.

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

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.

Investigation of welded joints of aluminium alloys using subminiature eddy-current transducers

NASA Astrophysics Data System (ADS)

Dmitriev, S. F.; Ishkov, A. V.; Katasonov, A. O.; Malikov, V. N.; Sagalakov, A. M.

2018-03-01

The authors developed a measuring system based on subminiaturized eddy-current transducers aimed at examining locally the defects of welded joints in aluminium-magnesium alloy plates connected by means of friction stir welding. The authors made a modification of the Delyann filter, which allowed them to increase considerably the signal-noise relations. The dependency of the eddy-current transducer response on defects was provided, i.e. concealed cuts and openings inside the welded joint, at the frequencies of 100-10000 Hz of the exciting winding.

NASA Astrophysics Data System (ADS)

Tube to tube-sheet joints in heat exchangers are currently welded by the orbital TIG process characterized by very high quality of the weld beads and good repeatability. However, due to high number of welds, a reduction in the welding cycle time would have an interesting impact on manufacturing costs and delays and laser welding technology is aimed to improve this factor. The main disadvantage is the positioning accuracy required by the laser welding process since beam deviations from real joint cause lack of penetration. It is expected that the Orbital laser welding head developed under the European project ORBITAL will avoid this drawback.

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.

Hybrid Laser-Arc Welding of the High-Strength Shipbuilding Steels: Equipment and Technology

NASA Astrophysics Data System (ADS)

Turichin, G.; Kuznetsov, M.; Tsibulskiy, I.; Firsova, A.

Hybrid laser-arc welding (HLAW) allows getting weld joints with thickness up to 35 mm for one pass, provide good quality formation of joints, minimal thermal deformations, the productivity in 10 times more in comparison with arc welding. In addition, replacement arc welding to the HLAW allows economizing filler materials, shielding gas and consumable electricity more than 4 times. Therefore, HLAW is actually technology for basic engineering branches and especially for shipbuilding. The Institute of Laser and Welding Technologies (ILWT) developed laser and hybrid laser-arc welding technologies for different type of steels and alloys including high-strength shipbuilding steels. Also ILWT produced portal and robotic systems for HLAW process realization. Portal system for hybrid laser-arc welding of panels with dimensions 6x6 m using at the manufacturing of flat curvilinear sections in the shipbuilding is depicted in the article. Results of experimental researches of the hybrid laser-arc welding parameters influence on the formation and mechanical properties of weld joint are described at the publication also. Experimental part was made with using of the portal system.

Mechanical strength and microstructure of laser-welded Ti-6Al-7Nb alloy castings.

PubMed

Srimaneepong, Viritpon; Yoneyama, Takayuki; Kobayashi, Equo; Doi, Hisashi; Hanawa, Takao

2005-12-01

Mechanical properties of laser-welded castings of Ti-6Al-7Nb alloy, CP Ti, and Co-Cr alloy were investigated and compared to the unwelded castings using a tensile test. Dumbbell-shaped specimens were cut at the center, and two halves of the specimens were welded with an Nd:YAG laser welding machine at 220 or 260 V of laser voltage. The mechanical strength of 260 V groups was higher than that of 220 V groups for Ti-6Al-7Nb and Co-Cr alloys except for CP Ti. All 260 V laser-welded castings of Ti-6Al-7Nb alloy and CP Ti, which fractured outside the welded joints, exhibited ductile characteristics, while all laser-welded Co-Cr alloy castings, which fractured within the welded joints, showed brittle characteristics. This study proved that the mechanical strength of laser-welded Ti-6Al-7Nb alloy and CP Ti castings was as high as that of unwelded castings, while the mechanical properties of laser-welded alloy joints were influenced by microstructural changes.

Hydrogen effects in duplex stainless steel welded joints - electrochemical studies

NASA Astrophysics Data System (ADS)

Michalska, J.; Łabanowski, J.; Ćwiek, J.

2012-05-01

In this work results on the influence of hydrogen on passivity and corrosion resistance of 2205 duplex stainless steel (DSS) welded joints are described. The results were discussed by taking into account three different areas on the welded joint: weld metal (WM), heat-affected zone (HAZ) and parent metal. The corrosion resistance was qualified with the polarization curves registered in a synthetic sea water. The conclusion is that, hydrogen may seriously deteriorate the passive film stability and corrosion resistance to pitting of 2205 DSS welded joints. The presence of hydrogen in passive films increases corrosion current density and decreases the potential of the film breakdown. It was also found that degree of susceptibility to hydrogen degradation was dependent on the hydrogen charging conditions. WM region has been revealed as the most sensitive to hydrogen action.

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

Microstructure and fatigue resistance of high strength dual phase steel welded with gas metal arc welding and plasma arc welding processes

NASA Astrophysics Data System (ADS)

Ahiale, Godwin Kwame; Oh, Yong-Jun; Choi, Won-Doo; Lee, Kwang-Bok; Jung, Jae-Gyu; Nam, Soo Woo

2013-09-01

This study presents the microstructure and high cycle fatigue performance of lap shear joints of dual phase steel (DP590) welded using gas metal arc welding (GMAW) and plasma arc welding (PAW) processes. High cycle fatigue tests were conducted on single and double lap joints under a load ratio of 0.1 and a frequency of 20 Hz. In order to establish a basis for comparison, both weldments were fabricated to have the same weld depth in the plate thickness. The PAW specimens exhibited a higher fatigue life, a gentle S-N slope, and a higher fatigue limit than the GMAW specimens. The improvement in the fatigue life of the PAW specimens was primarily attributed to the geometry effect that exhibited lower and wider beads resulting in a lower stress concentration at the weld toe where cracks initiate and propagate. Furthermore, the microstructural constituents in the heat-affected zone (HAZ) of the PAW specimens contributed to the improvement. The higher volume fraction of acicular ferrite in the HAZ beneath the weld toe enhanced the PAW specimen's resistance to fatigue crack growth. The double lap joints displayed a higher fatigue life than the single lap joints without changing the S-N slope.

High power laser welding of thick steel plates in a horizontal butt joint configuration

NASA Astrophysics Data System (ADS)

Atabaki, M. Mazar; Yazdian, N.; Ma, J.; Kovacevic, R.

2016-09-01

In this investigation, two laser-based welding techniques, autogenous laser welding (ALW) and laser welding assisted with a cold wire (LWACW), were applied to join thick plates of a structural steel (A36) in a horizontal narrow gap butt joint configuration. The main practical parameters including welding method and laser power were varied to get the sound weld with a requirement to achieve a full penetration with the reinforcement at the back side of weld in just one pass. The weld-bead shape, cross-section and mechanical properties were evaluated by profilometer, micro-hardness test and optical microscope. In order to investigate the stability of laser-induced plasma plume, the emitted optical spectra was detected and analyzed by the spectroscopy analysis. It was found that at the laser power of 7 kW a fully penetrated weld with a convex back side of weld could be obtained by the LWACW. The microstructural examinations showed that for the ALW the acicular ferrite and for the LWACW the pearlite were formed in the heat affected zone (HAZ). The prediction of microstructure based on continuous cooling transformation (CCT) diagram and cooling curves obtained by thermocouple measurement were in good agreement with each other. According to the plasma ionization values obtained from the spectroscopy analysis the plume for both processes was recognized as dominated weakly ionized plasma including the main vaporized elemental composition. At the optimum welding condition (LWACW at the laser power of 7 kW) the fluctuation of the electron temperature was reduced. The spectroscopy analysis demonstrated that at the higher laser power more of the elemental compositions such as Mn and Fe were evaporated.

Microstructure Evolution and Mechanical Properties of High-Speed Friction Stir Welded Aluminum Alloy Thin Plate Joints

NASA Astrophysics Data System (ADS)

Liu, Fenjun; Fu, Li; Chen, Haiyan

2018-06-01

Sound friction stir welded (FSW) joints of 6061-T6 aluminum alloy sheets with an 0.8 mm thickness were obtained at conventional speed (2000 rpm, 300 mm/min) and high speed (11,000 rpm, 1500 mm/min). The recrystallization mechanism, precipitate evolution, mechanical properties and fracture behavior were investigated in detail. Microstructure analyses revealed that the grain structure evolution in the nugget zone (NZ) was dominated by continuous dynamic recrystallization. In the process of FSW, high speed facilitates the formation of finer equiaxed recrystallized grains, higher density of dislocations and substructures, and a larger number of precipitates in the NZ compared to the conventional speed, which further significantly improves the hardness and tensile strength of the joints. The maximum tensile strength was obtained with 292.6 MPa, 83.2% for the 6061-T6 aluminum alloy and 122.6% for the conventional-speed FSW joints. This work provides an effective method for preparing FSW aluminum alloy thin plate joints with excellent mechanical properties.

Deconvoluting the Friction Stir Weld Process for Optimizing Welds

NASA Technical Reports Server (NTRS)

Schneider, Judy; Nunes, Arthur C.

2008-01-01

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

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

PubMed

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

2018-02-07

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

Improved Abutting Edges For Welding In Keyhole Mode

NASA Technical Reports Server (NTRS)

Harwing, Dennis D.; Sanders, John M.

1994-01-01

Welds of better quality made, and/or heat input reduced. Improved shapes devised for abutting edges of metal pieces to be joined by plasma arc welding in keyhole mode, in which gas jet maintains molten hole ("keyhole") completely through thickness of weld joint. Edges of metal pieces to be welded together machined to provide required combination gap and shaped, thin sections. Shapes and dimensions chosen to optimize weld in various respects; e.g., to enhance penetration of keyhole or reduce heat input to produce joint of given thickness.

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.

Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel

DOE PAGES

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

2014-01-01

A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductilemore » fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.« less

Microstructure and Properties of Lap Joint Between Aluminum Alloy and Galvanized Steel by CMT

NASA Astrophysics Data System (ADS)

Niu, Song; Chen, Su; Dong, Honggang; Zhao, Dongsheng; Zhang, Xiaosheng; Guo, Xin; Wang, Guoqiang

2016-05-01

Lap joining of 1-mm-thick Novelist AC 170 PX aluminum alloy to 1.2-mm-thick ST06 Z galvanized steel sheets for automotive applications was conducted by cold metal transfer advanced welding process with ER4043 and ER4047 filler wires. Under the optimized welding parameters with ER4043 filler wire, the tensile shear strength of joint was 189 MPa, reaching 89% of the aluminum alloy base metal. Microstructure and elemental distribution were characterized by optical metalloscope and electron probe microanalysis. The lap joints with ER4043 filler wire had smaller wetting angle and longer bonded line length with better wettability than with ER4047 filler wire during welding with same parameters. The needle-like Al-Fe-Si intermetallic compounds (IMCs) were spalled into the weld and brought negative effect to the tensile strength of joints. With increasing welding current, the needle-like IMCs grew longer and spread further into the weld, which would deteriorate the tensile shear strength.

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

NASA Astrophysics Data System (ADS)

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

2014-12-01

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

INERT GAS SHIELD FOR WELDING

DOEpatents

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

1958-10-14

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

Design and technology parameters influence on durability for heat exchangers tube to tubesheet joints

NASA Astrophysics Data System (ADS)

Ripeanu, R. G.

2017-02-01

The main failures of heat exchangers are: corrosion of tubes and jacket, tubes blockage and failures of tube to tubesheet joints also by corrosion. The most critical zone is tube to tubesheet joints. Depending on types of tube to tubesheet joints, in order to better respect conditions of tension and compression, this paper analyses the tubesheet holes shapes, smooth and with a grove, on corrosion behavior. In the case of welding tubes with tubesheet, welding parameters modify corrosion behavior. Were realized welded joints by three welding regimes and tested at corrosion in two media, tap water and industrial water. Were tested also samples made of smooth tubes, finned tubes and tubes coated with a passive product as applied by a heat exchanger manufacturer. For all samples, the roughness parameters were measured, before and after the corrosion tests. The obtained corrosion rates show that stress values and their distribution along the joint modify the corrosion behavior. The optimum welding parameters were established in order to increase the joint durability. The paper has shown that passive product used is not proper chosen and the technology of obtaining rolled thread pipes diminishes tubes’ durability by increasing the corrosion rate.

Mehanical Properties of Electron Beam Welded Joints in Thick Gage CA6NM Stainless Steel

NASA Astrophysics Data System (ADS)

Sarafan, Sheida; Wanjara, Priti; Gholipour, Javad; Champliaud, Henri; Mathieu, Louis

2017-10-01

Design of hydroelectric turbine components requires high integrity welds (without detectable volumetric defects) in heavy gage sections of stainless steel materials, such as ASTM A743 grade CA6NM—a low carbon 13% Cr-4% Ni martensitic stainless steel that is manufactured in cast form. In this work, 90-mm-thick plates of CA6NM were joined using a single-pass autogenous electron beam (EB) welding process and the mechanical properties were evaluated in the as-welded condition to characterize the performance of the joints. The static tensile properties that were evaluated in two directions—transverse and longitudinal to the EB weld seam—demonstrated conformance of the joints with the requirements of the ASME Section IX standard. The Charpy impact energies of the EB welds—measured at -18 °C on samples with V-notch roots located in the fusion and heat-affected zones—met the minimum requirements of 27 J specified in ASME Section VIII standard. In addition, bend tests that were conducted on the entire weld cross section displayed no discontinuities on the tension side of the bent joints. Hence, the developed EB welding process was demonstrated to render high-performance joints and promises key advantages for industrialization, such as cost savings through reductions in consumable material, production time and labor intensity.

Effects of Different Filler Metals on the Mechanical Behaviors of GTA Welded AA7A52(T6)

NASA Astrophysics Data System (ADS)

Shu, Fengyuan; Lv, Yaohui; Liu, Yuxin; Lin, Jianjun; Sun, Zhe; Xu, Binshi; He, Peng

2014-06-01

ER4043, ER5356, and AA7A52 on behalf of the Al-Si, Al-Mg, and Al-Zn-Mg-based welding material, respectively, were chosen as the filler metal to weld AA7A52(T6) plates by GTAW. The variance in mechanical performances of the joints caused by the various filler materials was investigated with reference to the SEM and EDS test results for the weld seam and the fracture surface. Failure was found in the seam for all the welded joints. With regard to the joint obtained with ER4043 welding wire, the total elongation was limited by the brittle intergranular compound Mg2Si of which Mg was introduced by convection mass transfer. As for the other two welds, the content ratio of Zn and Mg was found to play the dominant role in deciding the mechanical properties of the intergranular Mg-Zn compounds which were responsible for the tensile behavior of the joints. The content ratio (wt.%) of beyond 2:1 gave birth to the strengthening phase MgZn2 leading to a ductile fracture. Cr in the seam obtained with AA7A52 filler metal was found to enhance the strength of the joint through isolated particles.

Microstructural Evolution of HSLA ISO 3183 X80M (API 5L X80) Friction Stir Welded Joints

NASA Astrophysics Data System (ADS)

Hermenegildo, Tahiana F. C.; Santos, Tiago F. A.; Torres, Edwar A.; Afonso, Conrado R. M.; Ramirez, Antonio J.

2018-03-01

Evaluation was made of friction stir welded joints, identifying conditions that resulted in satisfactory welded joints free from defects and with microstructural characteristics that provided good mechanical properties. Microstructural characterization and cooling curve analysis of the joints with lower and higher heat inputs evidenced deformation below and above the non-recrystallization temperature (Tnr) and dynamic recrystallization during microstructural evolution. Microscopy analyses showed acicular ferrite, bainitic ferrite, and coalesced bainite microstructures in the stir zone of the cold weld (lower heat input), while the stir zone of the hot weld (higher heat input) contained bainitic ferrite, acicular ferrite, coalesced bainite, martensite, and dispersed carbides. Granular bainite and dispersed carbides were observed in all the heat affected zones. Analysis of the microstructural transformations, together with the thermal history of the joints, showed that the variable that had the greatest influence on the morphology of the bainite (granular bainite/bainitic ferrite) was the deformation temperature.

The effects of alloying elements on microstructures and mechanical properties of tungsten inert gas welded AZ80 magnesium alloys joint

NASA Astrophysics Data System (ADS)

Li, Hui; Zhang, Jiansheng; Ding, Rongrong

2017-11-01

The effects of alloying elements on the macrostructures, microstructures and tensile strength of AZ80 Mg alloy weldments were studied in the present study. The results indicate that with the decrease of Al element content of filler wire, the welding defects of seam are gradually eliminated and the β-Mg17Al12 phases at α-Mg boundaries are refined and become discontinuous, which are beneficial to the improvement of tensile strength. With AZ31 Mg alloy filler wire, the maximum tensile strength of AZ80 weldment is 220 MPa and fracture occurs at the welding seam of joint. It is experimentally proved that robust AZ80 Mg alloy joints can be obtained by tungsten inert gas (TIG) welding process with AZ31 Mg alloy filler wire. However, further study is required to improve the microstructures and reduce welding defects of joint in order to further improve the joining strength of AZ80 Mg alloy joint.

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

NASA Astrophysics Data System (ADS)

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

2016-12-01

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

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

PubMed Central

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

2015-01-01

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

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

PubMed

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

2015-06-11

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

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

NASA Astrophysics Data System (ADS)

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

2015-06-01

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

Evaluation of the Possibility of Obtaining Tube-to-Tube Sheet Welded Joints of 15Cr5Mo Steel by Alternative Technological Process

NASA Astrophysics Data System (ADS)

Rizvanov, R. G.; Mulikov, D. Sh.; Karetnikov, D. V.; Fairushin, A. M.; Tokarev, A. S.

2018-03-01

This paper presents the results of the tests of joints of chrome-molybdenum steel, obtained by rotary friction welding. On their basis, conclusions were drawn about the weldability of this type of steel by friction welding, and also the applicability of this welding technology in the manufacture of heat exchange equipment.

Plating To Reinforce Welded Joints

NASA Technical Reports Server (NTRS)

Otousa, J. E.

1982-01-01

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

On the microstructure analysis of FSW joints of aluminium components made via direct metal laser sintering

NASA Astrophysics Data System (ADS)

Scherillo, Fabio; Astarita, Antonello; di Martino, Daniela; Contaldi, Vincenzo; di Matteo, Luca; di Petta, Paolo; Casarin, Renzo; Squillace, Antonino; Langella, Antonio

2017-10-01

Additive Manufacturing (AM), applied to metal industry, is a family of processes that allow complex shape components to be realized from raw materials in the form of powders. The compaction of the powders can be achieved by local melting of the powder bed or by solid state sintering. Direct Metal Laser Sintering (DMLS) is an additive manufacturing process in which a focalized laser beam is the heat source that allows the powders to be compacted. By DMLS it is possible to realize complex shape components. One of the limits of DMLS, as for every additive layer manufacturing techniques, is the unfeasibility to realize large dimension parts. Due to this limit the study of joining process of parts made via ALM is of great interest. One of the most promising options is the Friction Stir Welding (FSW), a solid state welding technique that has been proven to be very effective in the welding of metals difficult to weld, above all aluminium alloys. Since FSW is a solid-state technique, the microstructure of the various zone of the weld bead depends not only by the process itself but also by the parent microstruct ure of the parts to be welded. Furthermore, parts made of aluminium alloy via DMLS have a particular microstructure that is the result of repeated severe thermal cycles. In the present work the authors, starting from the description of the parent microstructure of parts made of AlSi10Mg aluminium alloy, study the microstructure evolution occurred within the joint made by Friction Stir Welding, analysing in details the microstructure of the main well recognized zone of the weld bead. The structure of the parent material is characterized by the presence of melting pools with a very fine microstructure. In the joint the recrystallization, the grain refinement and, above all, the redistribution of intermetallic phases occurs, resulting in an homogenization of the microstructure and in an increase of micro hardness.

Fatigue Crack Growth Behavior of Gas Metal Arc Welded AISI 409 Grade Ferritic Stainless Steel Joints

NASA Astrophysics Data System (ADS)

Lakshminarayanan, A. K.; Shanmugam, K.; Balasubramanian, V.

2009-10-01

The effect of filler metals such as austenitic stainless steel, ferritic stainless steel, and duplex stainless steel on fatigue crack growth behavior of the gas metal arc welded ferritic stainless steel joints was investigated. Rolled plates of 4 mm thickness were used as the base material for preparing single ‘V’ butt welded joints. Center cracked tensile specimens were prepared to evaluate fatigue crack growth behavior. Servo hydraulic controlled fatigue testing machine with a capacity of 100 kN was used to evaluate the fatigue crack growth behavior of the welded joints. From this investigation, it was found that the joints fabricated by duplex stainless steel filler metal showed superior fatigue crack growth resistance compared to the joints fabricated by austenitic and ferritic stainless steel filler metals. Higher yield strength and relatively higher toughness may be the reasons for superior fatigue performance of the joints fabricated by duplex stainless steel filler metal.

Effects of the Heterogeneity in the Electron Beam Welded Joint on Mechanical Properties of Ti6Al4V Alloy

NASA Astrophysics Data System (ADS)

Liu, Jing; Gao, Xiao-Long; Zhang, Lin-Jie; Zhang, Jian-Xun

2015-01-01

The aim of this investigation was to evaluate the effect of microstructure heterogeneity on the tensile and low cycle fatigue properties of electron beam welded (EBW) Ti6Al4V sheets. To achieve this goal, the tensile and low cycle fatigue property in the EBW joints and base metal (BM) specimens is compared. During the tensile testing, digital image correlation technology was used to measure the plastic strain field evolution within the specimens. The experimental results showed that the tensile ductility and low cycle fatigue strength of EBW joints are lower than that of BM specimens, mainly because of the effect of microstructure heterogeneity of the welded joint. Moreover, the EBW joints exhibit the cyclic hardening behavior during low fatigue process, while BM specimens exhibit the cyclic softening behavior. Compared with the BM specimens with uniform microstructure, the heterogeneity of microstructure in the EBW joint is found to decrease the mechanical properties of welded joint.

Hardness analysis of welded joints of austenitic and duplex stainless steels

NASA Astrophysics Data System (ADS)

Topolska, S.

2016-08-01

Stainless steels are widely used in the modern world. The continuous increase in the use of stainless steels is caused by getting greater requirements relating the corrosion resistance of all types of devices. The main property of these steels is the ability to overlap a passive layer of an oxide on their surface. This layer causes that they become resistant to oxidation. One of types of corrosion-resistant steels is ferritic-austenitic steel of the duplex type, which has good strength properties. It is easily formable and weldable as well as resistant to erosion and abrasive wear. It has a low susceptibility to stress-corrosion cracking, to stress corrosion, to intercrystalline one, to pitting one and to crevice one. For these reasons they are used, among others, in the construction of devices and facilities designed for chemicals transportation and for petroleum and natural gas extraction. The paper presents the results which shows that the particular specimens of the ][joint representing both heat affected zones (from the side of the 2205 steel and the 316L one) and the weld are characterized by higher hardness values than in the case of the same specimens for the 2Y joint. Probably this is caused by machining of edges of the sections of metal sheets before the welding process, which came to better mixing of native materials and the filler metal. After submerged arc welding the 2205 steel still retains the diphase, austenitic-ferritic structure and the 316L steel retains the austenitic structure with sparse bands of ferrite σ.

Optimization of Aluminium-to-Magnesium Ultrasonic Spot Welding

NASA Astrophysics Data System (ADS)

Panteli, A.; Chen, Y.-C.; Strong, D.; Zhang, Xiaoyun; Prangnell, P. B.

2012-03-01

The ability to join dissimilar materials in the automotive industry will result in more efficient multimaterial structures. However, welding of aluminium (Al) to magnesium (Mg) alloys is problematic because of the rapid formation of brittle intermetallic phases at the weld interface. Ultrasonic welding (USW) is a solid-state joining technology that may offer a potential solution, but USW of Al to Mg is currently not well understood. Here, we have investigated the effect of process variables and energy input on joint formation between Al-6111 and Mg-AZ31 alloys, and we report on the optimum welding conditions, heat generation, and the formation of a significant intermetallic reaction layer. Furthermore, the factors influencing the interface reaction rate and the advantages of precoating the Mg with Al are discussed.

Influence of different brazing and welding methods on tensile strength and microhardness of orthodontic stainless steel wire.

PubMed

Bock, Jens Johannes; Fraenzel, Wolfgang; Bailly, Jacqueline; Gernhardt, Christian Ralf; Fuhrmann, Robert Andreas Werner

2008-08-01

The aim of this study was to compare the mechanical strength and microhardness of joints made by conventional brazing and tungsten inert gas (TIG) and laser welding. A standardized end-to-end joint configuration of the orthodontic wire material in spring hard quality was used. The joints were made using five different methods: brazing (soldering > 450 degrees C) with universal silver solder, two TIG, and two laser welders. Laser parameters and welding conditions were used according to the manufacturers' guidance. The tensile strengths were measured with a universal testing machine (Zwick 005). The microhardness measurements were carried out with a hardness tester (Zwick 3202). Data were analysed using one-way analysis of variance and Bonferroni's post hoc correction (P < 0.05). In all cases, brazing joints ruptured at low levels of tensile strength (198 +/- 146 MPa). Significant differences (P < 0.001) between brazing and TIG or laser welding were found. The highest means were observed for TIG welding (699-754 MPa). Laser welding showed a significantly lower mean tensile strength (369-520 MPa) compared with TIG welding. Significant differences (P < 0.001) were found between the original orthodontic wire and the mean microhardness at the centre of the welded area. The mean microhardness differed significantly between brazing (1.99 GPa), TIG (2.22-2.39 GPa) and laser welding (2.21-2.68 GPa). For orthodontic purposes, laser and TIG welding are solder-free alternatives to joining metal. TIG welding with a lower investment cost is comparable with laser welding. However, while expensive, the laser technique is a sophisticated and simple method.

Design, Construction, Demonstration and Delivery of an Automated Narrow Gap Welding System.

DTIC Science & Technology

1982-06-29

DESIGN, CONSTRUCTION, DEMONSTRATION AND DELIVERY OF WE DA4I &NARROW GAP CONTRACT NO. NOOGOO-81-C-E923 TO DAVID TAYLOR NAVAL RESEARCH AND DEVELOPMENT...the automated * Narrow Gap welding process, is the narrow (3/8 - inch), square-butt joint *design. This narrow joint greatly reduces the volume of weld...AD-i45 495 DESIGN CONSTRUCTION DEMONSTRATION AiND DELIVERY OF RN 1/j AUrOMATED NARROW GAP WELDING SYSTEMI() CRC AUTOMATIC WELDING CO HOUSTON TX 29

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.

Studies on Creep Deformation and Rupture Behavior of 316LN SS Multi-Pass Weld Joints Fabricated with Two Different Electrode Sizes

NASA Astrophysics Data System (ADS)

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

2017-02-01

Effect of electrode size on creep deformation and rupture behavior has been assessed by carrying out creep tests at 923 K (650 °C) over the stress range 140 to 225 MPa on 316LN stainless steel weld joints fabricated employing 2.5 and 4 mm diameter electrodes. The multi-pass welding technique not only changes the morphology of delta ferrite from vermicular to globular in the previous weld bead region near to the weld bead interface, but also subjects the region to thermo-mechanical heat treatment to generate appreciable strength gradient. Electron backscatter diffraction analysis revealed significant localized strain gradients in regions adjoining the weld pass interface for the joint fabricated with large electrode size. Larger electrode diameter joint exhibited higher creep rupture strength than the smaller diameter electrode joint. However, both the joints had lower creep rupture strength than the base metal. Failure in the joints was associated with microstructural instability in the fusion zone, and the vermicular delta ferrite zone was more prone to creep cavitation. Larger electrode diameter joint was found to be more resistant to failure caused by creep cavitation than the smaller diameter electrode joint. This has been attributed to the larger strength gradient between the beads and significant separation between the cavity prone vermicular delta ferrite zones which hindered the cavity growth. Close proximity of cavitated zones in smaller electrode joint facilitated their faster coalescence leading to more reduction in creep rupture strength. Failure location in the joints was found to depend on the electrode size and applied stress. The change in failure location has been assessed on performing finite element analysis of stress distribution across the joint on incorporating tensile and creep strengths of different constituents of joints, estimated by ball indentation and impression creep testing techniques.

Mechanical strength of laser-welded cobalt-chromium alloy.

PubMed

Baba, N; Watanabe, I; Liu, J; Atsuta, M

2004-05-15

The purpose of this study was to investigate the effect of the output energy of laser welding and welding methods on the joint strength of cobalt-chromium (Co-Cr) alloy. Two types of cast Co-Cr plates were prepared, and transverse sections were made at the center of the plate. The cut surfaces were butted against one another, and the joints welded with a laser-welding machine at several levels of output energy with the use of two methods. The fracture force required to break specimens was determined by means of tensile testing. For the 0.5-mm-thick specimens, the force required to break the 0.5-mm laser-welded specimens at currents of 270 and 300 A was not statistically different (p > 0.05) from the results for the nonwelded control specimens. The force required to break the 1.0-mm specimens double-welded at a current of 270 A was the highest value among the 1.0-mm laser-welded specimens. The results suggested that laser welding under the appropriate conditions improved the joint strength of cobalt- chromium alloy. Copyright 2004 Wiley Periodicals, Inc.

Use of photostress and strain gages to analyze behavior of weldments and use of photostress and strain gages to analyze behavior of an aft skirt test specimen

NASA Technical Reports Server (NTRS)

Gambrell, S. C.; Karr, Gerald R.

1993-01-01

Previous work using Photostress on TIG welded, heat treated specimens of 2219-T87 parent material and 2319 weld material indicated that behavior of the joint can be highly irregular and non-uniform. Welded joints 1.40 inches thick exhibited a totally non-uniform behavior through the weld thickness with the 'wide' side of the weld being much more ductile than the 'narrow' side. It is believed that this difference in behavior through the weld is, in part, caused by procedures used when laying the weld bead. Joints similar to weldments in references 1 and 2 are an integral part of the aft skirt of the SRB of the shuttle. Since the ultimate safety factor for the lower portion of the weld is below the minimum required safety factor, a photostress analysis of this lower portion will be conducted in the vicinity of the weld. A test program using photostress will be conducted in accordance with the project planning document entitled 'Photostress Evaluation Requirements for AFT Skirt Test Article No. 4'.

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.

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

NASA Technical Reports Server (NTRS)

Hordon, M. J.

1970-01-01

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

Friction stir welding of Zr-based bulk metallic glass

NASA Astrophysics Data System (ADS)

Ji, Y. S.; Fujii, H.; Maeda, M.; Nakata, K.; Kimura, H.; Inoue, A.; Nogi, K.

2009-05-01

A Zr55Cu30Al10Ni5 bulk metallic glass plate was successfully welded below its crystallization temperature by friction stir welding. The flash formation and heat concentration at the shoulder edge was minimized using a wider tool and the angle of the recessed shoulder surface was 3°. To analyze the crystallization of the base material and stir zone, the microstructure and mechanical properties were analyzed using DSC, XRD, TEM, and micro-hardness. As a result, it was found that the amorphous structure and original mechanical properties were maintained in the whole joints.

Experimental studies of diffusion welding of YBCO to copper using solder layers

NASA Astrophysics Data System (ADS)

Xie, Y.; Ouyang, Z.; Shi, L.; Kuang, Z.; Meng, M.

2017-02-01

The welding technology is of great importance in YBCO application. To make better joints, the diffusion welding of YBCO tape to copper has been carried out in a vacuum environment. In consideration of high welding temperature (above 200°C) could do damage to the material performance, a new kind of diffusion welding method with temperature below 200 °C has been developed recently. A new welding appliance which can offer pressure over 35Kg/mm2 and controlled temperature has been designed and built; several YBCO coated conductors joints soldered with different melting points of tins has been tested. The results showed that the diffusion can perfectly connect YBCO to copper as well as stainless steel and resistance of the joint was low, and the YBCO tape could bear 217°C for at least 15mins.

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.

Inspection of thick welded joints using laser-ultrasonic SAFT.

PubMed

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

2016-07-01

The detection of defects in thick butt joints in the early phase of multi-pass arc welding would be very valuable to reduce cost and time in the necessity of reworking. As a non-contact method, the laser-ultrasonic technique (LUT) has the potential for the automated inspection of welds, ultimately online during manufacturing. In this study, testing has been carried out using LUT combined with the synthetic aperture focusing technique (SAFT) on 25 and 50mm thick butt welded joints of steel both completed and partially welded. EDM slits of 2 or 3mm height were inserted at different depths in the multi-pass welding process to simulate a lack of fusion. Line scans transverse to the weld are performed with the generation and detection laser spots superimposed directly on the surface of the weld bead. A CCD line camera is used to simultaneously acquire the surface profile for correction in the SAFT processing. All artificial defects but also real defects are visualized in the investigated thick butt weld specimens, either completed or partially welded after a given number of passes. The results obtained clearly show the potential of using the LUT with SAFT for the automated inspection of arc welds or hybrid laser-arc welds during manufacturing. Crown Copyright © 2016. Published by Elsevier B.V. All rights reserved.

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

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

Mukherjee, Manidipto; Saha, Saptarshi; Pal, Tapan Kumar, E-mail: tkpal.ju@gmail.com

2015-04-15

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

Low activation steels welding with PWHT and coating for ITER test blanket modules and DEMO

NASA Astrophysics Data System (ADS)

Aubert, P.; Tavassoli, F.; Rieth, M.; Diegele, E.; Poitevin, Y.

2011-02-01

EUROFER weldability is investigated in support of the European material properties database and TBM manufacturing. Electron Beam, Hybrid, laser and narrow gap TIG processes have been carried out on the EUROFER-97 steel (thickness up to 40 mm), a reduced activation ferritic-martensitic steel developed in Europe. These welding processes produce similar welding results with high joint coefficients and are well adapted for minimizing residual distortions. The fusion zones are typically composed of martensite laths, with small grain sizes. In the heat-affected zones, martensite grains contain carbide precipitates. High hardness values are measured in all these zones that if not tempered would degrade toughness and creep resistance. PWHT developments have driven to a one-step PWHT (750 °C/3 h), successfully applied to joints restoring good material performances. It will produce less distortion levels than a full austenitization PWHT process, not really applicable to a complex welded structure such as the TBM. Different tungsten coatings have been successfully processed on EUROFER material. It has shown no really effect on the EUROFER base material microstructure.

Numerical Simulation and Experimental Validation of MIG Welding of T-Joints of Thin Aluminum Plates for Top Class Vehicles

NASA Astrophysics Data System (ADS)

Bonazzi, Enrico; Colombini, Elena; Panari, Davide; Vergnano, Alberto; Leali, Francesco; Veronesi, Paolo

2017-01-01

The integration of experiments with numerical simulations can efficiently support a quick evaluation of the welded joint. In this work, the MIG welding operation on aluminum T-joint thin plate has been studied by the integration of both simulation and experiments. The aim of the paper is to enlarge the global database, to promote the use of thin aluminum sheets in automotive body industries and to provide new data. Since the welding of aluminum thin plates is difficult to control due to high speed of the heat source and high heat flows during heating and cooling, a simulation model could be considered an effective design tool to predict the real phenomena. This integrated approach enables new evaluation possibilities on MIG-welded thin aluminum T-joints, as correspondence between the extension of the microstructural zones and the simulation parameters, material hardness, transient 3D temperature distribution on the surface and inside the material, stresses, strains, and deformations. The results of the mechanical simulations are comparable with the experimental measurements along the welding path, especially considering the variability of the process. The results could well predict the welding-induced distortion, which together with local heating during welding must be anticipated and subsequently minimized and counterbalance.

Microstructure and corrosion behavior of shielded metal arc-welded dissimilar joints comprising duplex stainless steel and low alloy steel

NASA Astrophysics Data System (ADS)

Srinivasan, P. Bala; Muthupandi, V.; Sivan, V.; Srinivasan, P. Bala; Dietzel, W.

2006-12-01

This work describes the results of an investigation on a dissimilar weld joint comprising a boiler-grade low alloy steel and duplex stainless steel (DSS). Welds produced by shielded metal arc-welding with two different electrodes (an austenitic and a duplex grade) were examined for their microstructural features and properties. The welds were found to have overmatching mechanical properties. Although the general corrosion resistance of the weld metals was good, their pitting resistance was found to be inferior when compared with the DSS base material.

Creep-Fatigue Cracking Near the Welded Interface in Friction Welding Dissimilar Superalloys INCONEL 718 and MAR-M247

NASA Astrophysics Data System (ADS)

Tra, Tran Hung; Okazaki, Masakazu

2017-08-01

A forged INCONEL 718 and a cast MAR-M247 alloy were joined by a friction welding process. The creep-fatigue strength of this joint was investigated. The life of the joint was significantly shorter than that of the base alloys. The joint failed near the interface of the INCONEL 718 side, although the life of INCONEL 718 was longer than that of MAR-M247. To understand this behavior, the stress field in the welding was numerically analyzed using a visco-elastic model. The results suggested that triaxiality in the stress state could be promoted near the welded interface and lead to an acceleration of creep-fatigue crack nucleation.

Studying the Issues in Laser Joining of Lightweight Materials in a Coach-Peel Joint Configuration

NASA Astrophysics Data System (ADS)

Yang, Guang

In the automotive industry, aluminum alloys have been widely used and partially replaced the conventional steel structures in order to decrease the weight of a car and improve its fuel efficiency. This Thesis focuses on the development of laser joining of light-weight materials, such as aluminum alloys and high-strength galvanized steels. Among different joint types, the coach-peel configuration is of a specific design that requires a heat source capable of heating up a large surface area of the joint. Coach-peel joints applied on the visible exterior of a car require a smooth transition from the weld surface to the panel surface and low surface roughness without any need for post-processing. Although these joints are used as non-load-bearing components, a desirable strength of the weld is also needed. A fusion-brazing process using a dual-beam laser allows the automotive components such as the roof and side member panels to be joined in a coach-peel configuration with a high surface quality as well as an acceptable strength of the weld. To improve the weld surface quality, processing parameters such as laser beam configuration, laser-wire position, and shielding gas parameters were optimized for joining of aluminum alloy to aluminum alloy. Laser power was optimized for dual-beam laser joining of aluminum alloy to galvanized steel at high speed. The feasibility of joining as-received panels with lubricant was also explored. The identification of strain hardening models of aluminum alloys was conducted for the mechanical finite element analysis of the joint. Control of the molten pool solidification through the selection of laser beam configuration is one approach to improve joint quality. Laser joining of aluminum alloy AA 6111-T4 coach peel panels with the addition of AA 4047 filler wire was investigated using three configurations of laser beam: a single beam, dual beams in-line with the weld bead, and dual beams aligned perpendicular to the weld bead (herein referred to as cross-beam). To compare the three joining processes, the transient heat distribution, cooling rates, and solidification rates were analyzed by three-dimensional finite element models using ANSYS. Microstructure evolution, tensile strength, fracture mechanisms, and surface roughness of joints were investigated accordingly. To improve the weld surface quality of aluminum joints, the laser-wire position and the gas parameters were optimized. Visualization of the gas flow by a CCD camera revealed the effects of nozzle shape, flow rate, inclination angle of the gas tube, nozzle position, and gas compositions (argon and helium) on the weld surface quality. The suppression of plasma plume and the effects of oxidation on the molten pool were illustrated in detail. With an optimized set of processing parameters, the weld surface roughness (Ra) of approximately 1 microm can be achieved. The feasibility of fabricating the aluminum alloy panel joint in the as-received condition, i.e., with stamping lubricant, by using the cross-beam laser was investigated. Two commercial mineral oils, Bonderite L-FM MP-404 and Ferrocote 61 MAL HCL, were applied onto clean panels prior to joining in order to simulate the conditions of the production environment. The formation and growth of hydrogen bubbles inside the molten pool, the stability of welding process, and the possible energy absorption capability of the porous weld were explained. Besides joining of similar materials, cross-beam laser was applied to join aluminum alloy 6111 to hot-dip galvanized steel in the coach-peel configuration. The filler material was not only brazed onto the galvanized steel but also partially fusion-welded with the aluminum panel. Through adjusting the laser power to 3.4 kW, a desirable wetting and spreading of filler wire on both panel surfaces could be achieved, and the thickness of intermetallic layer in the middle section of the interface between the weld bead and steel was less than 2 microm. To better understand the solid/liquid interfacial reaction at the brazing interface, two rotary Gaussian heat source models were introduced to simulate the temperature distribution in the molten pool by using the finite element method. Joint properties were examined in terms of microstructure and mechanical properties. Simulation of the mechanical response of a coach-peel joint is instructive for improvement of the joining process. The effective true stress-strain curve of fusion-brazed AA 4047 was difficult to obtain experimentally. Therefore, the von Mises isotropic flow function of the weld bead was inversely derived by image-based finite element analysis. Through iterative correction, the predicted tensile response of the coach-peel joint matched well with the experiment. The von Mises fracture stresses at the fusion zone boundary and the brazing interface were identified, respectively.

Real-time monitoring of laser welding of galvanized high strength steel in lap joint configuration

NASA Astrophysics Data System (ADS)

Kong, Fanrong; Ma, Junjie; Carlson, Blair; Kovacevic, Radovan

2012-10-01

Two different cases regarding the zinc coating at the lap joint faying surface are selected for studying the influence of zinc vapor on the keyhole dynamics of the weld pool and the final welding quality. One case has the zinc coating fully removed at the faying surface; while the other case retains the zinc coating on the faying surface. It is found that removal of the zinc coating at the faying surface produces a significantly better weld quality as exemplified by a lack of spatters whereas intense spatters are present when the zinc coating is present at the faying surface. Spectroscopy is used to detect the optical spectra emitted from a laser generated plasma plume during the laser welding of galvanized high strength DP980 steel in a lap-joint configuration. A correlation between the electron temperature and defects within the weld bead is identified by using the Boltzmann plot method. The laser weld pool keyhole dynamic behavior affected by a high-pressure zinc vapor generated at the faying surface of galvanized steel lap-joint is monitored in real-time by a high speed charge-coupled device (CCD) camera assisted with a green laser as an illumination source.

Microstructure, Tensile Properties and Work Hardening Behavior of GTA-Welded Dual-Phase Steels

NASA Astrophysics Data System (ADS)

Ashrafi, H.; Shamanian, M.; Emadi, R.; Saeidi, N.

2017-03-01

In the present study, microstructure, tensile properties and work hardening behavior of a DP700 steel after gas tungsten arc welding were investigated. Formation of bainite in the fusion zone resulted in a hardness increase compared to that for the base metal (BM), whereas tempering of the pre-existing martensite in the subcritical heat-affected zone (HAZ) led to softening. The GTA-welded joint exhibited a continuous yielding behavior and a yield strength close to that for the BM, while its ultimate tensile strength and total elongation were lower than those for the BM owing to the formation of soft zone in the HAZ. A joint efficiency of about 81% was obtained for the GTA-welded joint, and it failed in the softened HAZ. Analysis of work hardening based on the Kocks-Mecking approach showed one stage of hardening behavior corresponding to the stage III for both the DP700 BM and welded sample. It was also revealed that the DP700 BM has larger values of work hardening exponent and magnitude of work hardening compared with the welded sample. Analysis of fractured surfaces showed that the dominant fracture mode for both the DP700 BM and welded joint was ductile.

Effect of Repair Welding on Electrochemical Corrosion and Stress Corrosion Cracking Behavior of TIG Welded AA2219 Aluminum Alloy in 3.5 Wt Pct NaCl Solution

NASA Astrophysics Data System (ADS)

Venugopal, A.; Sreekumar, K.; Raja, V. S.

2010-12-01

The stress corrosion cracking (SCC) behavior of AA2219 aluminum alloy in the as-welded (AW) and repair-welded (RW) conditions was examined and compared with that of the base metal (BM) in 3.5 wt pct NaCl solution using the slow strain rate technique (SSRT). The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of both BM and welded joints. The results show that the ductility ratio ( ɛ NaCl/( ɛ air)) of the BM was close to one (0.97) and reduced to 0.9 for the AW joint. This value further reduced to 0.77 after carrying out one repair welding operation. However, the RW specimen exhibited higher ductility than the single-weld specimens even in 3.5 wt pct NaCl solution. SSRT results obtained using pre-exposed samples followed by post-test metallographic observations clearly showed localized pitting corrosion along the partially melted zone (PMZ), signifying that the reduction in ductility ratio of both the AW and RW joints was more due to mechanical overload failure, caused by the localized corrosion and a consequent reduction in specimen thickness, than due to SCC. Also, the RW joint exhibited higher ductility than the AW joint both in air and the environment, although SCC index (SI) for the former is lower than that of the latter. Fractographic examination of the failed samples, in general, revealed a typical ductile cracking morphology for all the base and welded joints, indicating the good environmental cracking resistance of this alloy. Microstructural examination and polarization tests further demonstrate grain boundary melting along the PMZ, and that provided the necessary electrochemical condition for the preferential cracking on that zone of the weldment.

Detection of defects in laser welding of AZ31B magnesium alloy in zero-gap lap joint configuration by a real-time spectroscopic analysis

NASA Astrophysics Data System (ADS)

Harooni, Masoud; Carlson, Blair; Kovacevic, Radovan

2014-05-01

The effect of surface oxide layer existing at the lap-joint faying surface of magnesium sheets is investigated on the keyhole dynamics of the weld pool and weld bead qualities. It is observed that by removing the oxide layer from the faying surface of the lap joint, a high quality weld can be achieved in the laser welding process. However, the presence of an oxide layer deteriorates the quality of the weld by forming pores at the interface of the two overlapped sheets. The purpose of this paper is to identify the correlation between the integrity of the weld and the interaction between the laser and material. A spectroscopy sensor was applied to detect the spectra emitted from a plasma plume during the laser welding of AZ31B magnesium alloy in a zero-gap lap joint configuration. The electron temperature was calculated by applying a Boltzmann plot method based on the detected spectra, and the correlation between the pore formation and the spectral signals was studied. The laser molten pool and the keyhole condition were monitored in real-time by a high speed charge-coupled device (CCD) camera. A green laser was used as an illumination source in order to detect the influence of the oxide layer on the dynamic behavior of the molten pool. Results revealed that the detected spectrum and weld defects had a meaningful correlation for real-time monitoring of the weld quality during laser welding of magnesium alloys.

Corrosion Properties of Cryorolled AA2219 Friction Stir Welded Joints Using Different Tool Pin Profiles

NASA Astrophysics Data System (ADS)

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

The purpose of this paper is to present the corrosion behavior of the Cryorolled (CR) material and its Friction Stir Welded joints. Due to the thermal cycles of Friction Stir Welding (FSW) process, the corrosion behavior of the material gets affected. Here, the cryorolling process was carried out on AA2219 alloy and CR material was joined by FSW process using four different pin tool profiles such as cylindrical, threaded cylindrical, square and hexagonal pin. The FSW joints were analyzed by corrosion resistance with the help of potentiodynamic polarization test with 3.5% NaCl solution. From the analysis, it is found that CR AA2219 material exhibits good corrosion resistance compared to the base AA2219 material, and also a hexagonal pin profile FSW joint exhibits high corrosion resistance. Among the weld joints created by four different tools, the lowest corrosion resistance was found in the cylindrical pin tool FSW welds. Further, the corroded samples were investigated through metallurgical investigations like OM, Transmission Electron Microscopy (TEM), Energy-Dispersive X-ray Spectroscopy (EDX) and X-Ray Diffraction (XRD). It was found that the amount of dissolution of Al2Cu precipitate was present in the weld nugget. The amount of dissolution of Al2Cu precipitate is higher in the weld nugget produced by hexagonal pin tool. This is due to the enhancement of the corrosion resistance.

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

NASA Technical Reports Server (NTRS)

Seshadri, Banavara R.; Smith, Stephen W.; Newman, John A.

2013-01-01

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Influence of groove size and reinforcements addition on mechanical properties and microstructure of friction stir welded joints

NASA Astrophysics Data System (ADS)

Reddy Baridula, Ravinder; Ibrahim, Abdullah Bin; Yahya, Che Ku Mohammad Faizal Bin Che Ku; Kulkarni, Ratnakar; Varma Ramaraju, Ramgopal

2018-03-01

The butt joints fabricated by friction stir welding were found to have more strength than the joints obtained by conventional joining process. The important outcome of this process is the successful fabrication of surface composites with improved properties. Thus in order to further enhance the strength of the dissimilar alloy joints the reinforcements can be deposited in to the aluminium matrix during the process of friction stir welding. In the present study the multi-walled carbon nanotubes were embedded in to the groove by varying the width during joining of dissimilar alloys AA2024 and AA7075. Four widths were selected with constant depth and optimum process parameters were selected to fabricate the sound welded joints. The results show that the mechanical properties of the fabricated butt joints were influenced by the size of the groove, due to variation in the deposition of reinforcement in the stir zone. The microstructural study and identification of the elements of the welded joints show that the reinforcements deposition is influenced by the size of the groove. It has also been observed that the groove with minimum width is more effective than higher width. The mechanical properties are found to be improved due to the pinning of grain boundaries.

Automatic control of positioning along the joint during EBW in conditions of action of magnetic fields

NASA Astrophysics Data System (ADS)

Druzhinina, A. A.; Laptenok, V. D.; Murygin, A. V.; Laptenok, P. V.

2016-11-01

Positioning along the joint during the electron beam welding is a difficult scientific and technical problem to achieve the high quality of welds. The final solution of this problem is not found. This is caused by weak interference protection of sensors of the joint position directly in the welding process. Frequently during the electron beam welding magnetic fields deflect the electron beam from the optical axis of the electron beam gun. The collimated X-ray sensor is used to monitor the beam deflection caused by the action of magnetic fields. Signal of X-ray sensor is processed by the method of synchronous detection. Analysis of spectral characteristics of the X-ray sensor showed that the displacement of the joint from the optical axis of the gun affects on the output signal of sensor. The authors propose dual-circuit system for automatic positioning of the electron beam on the joint during the electron beam welding in conditions of action of magnetic interference. This system includes a contour of joint tracking and contour of compensation of magnetic fields. The proposed system is stable. Calculation of dynamic error of system showed that error of positioning does not exceed permissible deviation of the electron beam from the joint plane.

Effect of current and speed on porosity in autogenous Tungsten Inert Gas (TIG) welding of aluminum alloys A1100 butt joint

NASA Astrophysics Data System (ADS)

Milyardi, Indra; Sunar Baskoro, Ario

2018-04-01

Autogenous Tungsten Inert Gas (TIG) welding has been conducted on aluminum alloy A1100. The purpose of this research is to determine the proper current and speed of autogenous TIG welding with butt joint pattern. Variations on welding current are 150 A, 155 A, and 160 A with the variations on welding speed are 1 mm/seconds, 1.1 mm/seconds, 1.2 mm/seconds. The welded results were tested using non-destructive test (NDT) method using X-Ray radiography. After the test, it is found that the appropriate current for the best result without porosity can be achieved using the welding parameter of welding current of 160 A and the welding speed of 1.1 mm seconds.

Automated Variable-Polarity Plasma-Arc Welding

NASA Technical Reports Server (NTRS)

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

1984-01-01

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

Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

NASA Astrophysics Data System (ADS)

Ji, Shude; Yang, Zhanpeng; Wen, Quan; Yue, Yumei; Zhang, Liguo

2018-04-01

Trailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

Weldability of high toughness Fe-12% Ni alloys containing Ti, Al or Nb

NASA Technical Reports Server (NTRS)

Devletian, J. H.; Stephens, J. R.; Witzke, W. R.

1977-01-01

Three exceptionally high-toughness Fe-12%Ni alloys designed for cryogenic service were welded using the GTA welding process. Evaluation of weldability included equivalent energy (KIed) fracture toughness tests, transverse-weld tensile tests at -196 and 25 C and weld crack sensitivity tests. The Fe-12%Ni-0.25%Ti alloy proved extremely weldable for cryogenic applications, having weld and HAZ properties comparable with those of the wrought base alloy. The Fe-12%Ni-0.5%Al had good weld properties only after the weld joint was heat treated. The Fe-12%Ni-0.25%Nb alloy was not considered weldable for cryogenic use because of its poor weld joint properties at -196 C and its susceptibility to hot cracking.

Characterization of Nitinol Laser-Weld Joints by Nondestructive Testing

NASA Astrophysics Data System (ADS)

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

2015-12-01

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

Effect of Exchanging Advancing and Retreating Side Materials on Mechanical Properties and Electrochemical Corrosion Resistance of Dissimilar 6013-T4 and 7003 Aluminum Alloys FSW Joints

NASA Astrophysics Data System (ADS)

Zhao, Zhixia; Liang, Haimei; Zhao, Yong; Yan, Keng

2018-03-01

Friction stir welding (FSW) was used to weld dissimilar joints between Al 6013-T4 and Al7003 alloys in this work. The effect of exchanging advancing (AS) and retreating (RS) side material on microstructure, mechanical behaviors and electrochemical corrosion resistance was discussed. Results showed that different joint cross sections were obtained when exchanging AS and RS materials. The material on the AS would be more deformed during the welding process. When the Al6013 placed on the AS, the plastic flow of weld is more sufficient. Whether on the AS or RS, the Al6013-T4 side is the weak region for both tensile specimens and hardness samples. The fracture position corresponds to the minimum hardness position. Also, more strengthening phase can be retained in the joint, and the joint of A6R7 has better corrosion resistance.

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

ERIC Educational Resources Information Center

Espy, John

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

Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint

NASA Astrophysics Data System (ADS)

Das, H.; Kumar, A.; Rajkumar, K. V.; Saravanan, T.; Jayakumar, T.; Pal, Tapan Kumar

2015-11-01

Dissimilar lap joints of aluminum sheet (AA 6061) of 2 mm thickness and zinc-coated steel sheet of 1 mm thickness were produced by friction stir welding with different combinations of rotational speed and travel speed. Ultrasonic C- and B-scanning, and radiography have been used in a complementary manner for detection of volumetric (cavity and flash) and planar (de bond) defects as the defects are in micron level. Advanced ultrasonic C-scanning did not provide any idea about the defects, whereas B-scanning cross-sectional image showed an exclusive overview of the micron-level defects. A digital x-ray radiography methodology is proposed for quality assessment of the dissimilar welds which provide three-fold increase in signal-to-noise ratio with improved defect detection sensitivity. The present study clearly shows that the weld tool rotational speed and travel speed have a decisive role on the quality of the joints obtained by the friction stir welding process. The suitability of the proposed NDE techniques to evaluate the joint integrity of dissimilar FSW joints is thus established.

Microstructure, texture, and mechanical properties of friction stir welded commercial brass alloy

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

Heidarzadeh, A., E-mail: ak.hz62@gmail.com

Microstructural evolution during friction stir welding of single-phase brass and corresponding mechanical properties were investigated. For this purpose, 2 mm thick brass plate was friction stir welded at a rotational speed of 450 rpm and traverse speed of 100 mm/min. The microstructure of the joint was studied using optical microscopy, scanning electron microscopy equipped with electron back scattered diffraction system, and scanning transmission electron microscopy. The mechanical properties were measured using hardness and tensile tests. The formation of subgrains and their transformation into new grains in conjunction with existence of A{sub 1}{sup ⁎}, A{sub 2}{sup ⁎} and C texture componentsmore » revealed that the continuous dynamic recrystallization plays a dominant role in the microstructural evolution. However, grain boundary bulging, along with the formation of twin boundaries, and presence of the G texture component showed that the discontinues dynamic recrystallization may participate in the new grain formation. Furthermore, the different strengthening mechanisms, which caused the higher strength of the joint, were discussed. - Highlights: •Microstructural evolution during FSW of a single phase brass was investigated. •CDRX and DDRX were the main mechanisms of the grain structure formation during FSW. •GDRX and SRX were not contributed in grain structure formation. •The lamellas TBs were formed in the SZ of the joints. •Grain boundary, dislocation, and texture effects resulted in higher strength.« less

Evaluation of Laser Braze-welded Dissimilar Al-Cu Joints

NASA Astrophysics Data System (ADS)

Schmalen, Pascal; Plapper, Peter

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

Electron beam weld development on a Filter Pack Assembly

NASA Astrophysics Data System (ADS)

Dereskiewicz, J. P.

1994-06-01

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

Reduced heat input keyhole welding through improved joint design

NASA Technical Reports Server (NTRS)

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

1993-01-01

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

Solid State Joining of Magnesium to Steel

NASA Astrophysics Data System (ADS)

Jana, Saumyadeep; Hovanski, Yuri; Pilli, Siva P.; Field, David P.; Yu, Hao; Pan, Tsung-Yu; Santella, M. L.

Friction stir welding and ultrasonic welding techniques were applied to join automotive magnesium alloys to steel sheet. The effect of tooling and process parameters on the post-weld microstructure, texture and mechanical properties was investigated. Static and dynamic loading were utilized to investigate the joint strength of both cast and wrought magnesium alloys including their susceptibility and degradation under corrosive media. The conditions required to produce joint strengths in excess of 75% of the base metal strength were determined, and the effects of surface coatings, tooling and weld parameters on weld properties are presented.

Laser based spot weld characterization

NASA Astrophysics Data System (ADS)

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

2016-02-01

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

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

NASA Astrophysics Data System (ADS)

Kumar, Nikhil; Mukherjee, Manidipto; Bandyopadhyay, Asish

2017-09-01

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

Investigation of the structure and properties of titanium-stainless steel permanent joints obtained by laser welding with the use of intermediate inserts and nanopowders

NASA Astrophysics Data System (ADS)

Cherepanov, A. N.; Orishich, A. M.; Pugacheva, N. B.; Shapeev, V. P.

2015-03-01

Results of an experimental study of the structure, the phase composition, and the mechanical properties of laser-welded joints of 3-mm thick titanium and 12Kh18N10T steel sheets obtained with the use of intermediate inserts and nanopowdered modifying additives are reported. It is shown that that such parameters as the speed of welding, the radiation power, and the laser-beam focal spot position all exert a substantial influence on the welding-bath process and on the seam structure formed. In terms of chemical composition, most uniform seams with the best mechanical strength are formed at a 1-m/min traverse speed of laser and 2.35-kW laser power, with the focus having been positioned at the lower surface of the sheets. Under all other conditions being identical, uplift of the focus to workpiece surface or to a higher position results in unsteady steel melting, in a decreased depth and reduced degree of the diffusion-induced mixing of elements, and in an interpolate connection formed according to the soldering mechanism in the root portion of the seam. The seam material is an over-saturated copper-based solid solution of alloying elements with homogeneously distributed intermetallic disperse particles (Ti(Fe, Cr)2 and TiCu3) contained in this alloy. Brittle fracture areas exhibiting cleavage and quasi-cleavage facets correspond to coarse Ti(Fe, Cr)2 intermetallic particles or to diffusion zones primarily occurring at the interface with the titanium alloy. The reported data and the conclusions drawn from the numerical calculations of the thermophysical processes of welding of 3-mm thick titanium and steel sheets through an intermediate copper insert are in qualitative agreement with the experimental data. The latter agreement points to adequacy of the numerical description of the melting processes of contacting materials versus welding conditions and focal-spot position in the system.

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.

Statistical Analysis of Stress Signals from Bridge Monitoring by FBG System

PubMed Central

Ye, Xiao-Wei; Xi, Pei-Sen

2018-01-01

In this paper, a fiber Bragg grating (FBG)-based stress monitoring system instrumented on an orthotropic steel deck arch bridge is demonstrated. The FBG sensors are installed at two types of critical fatigue-prone welded joints to measure the strain and temperature signals. A total of 64 FBG sensors are deployed around the rib-to-deck and rib-to-diagram areas at the mid-span and quarter-span of the investigated orthotropic steel bridge. The local stress behaviors caused by the highway loading and temperature effect during the construction and operation periods are presented with the aid of a wavelet multi-resolution analysis approach. In addition, the multi-modal characteristic of the rainflow counted stress spectrum is modeled by the method of finite mixture distribution together with a genetic algorithm (GA)-based parameter estimation approach. The optimal probability distribution of the stress spectrum is determined by use of Bayesian information criterion (BIC). Furthermore, the hot spot stress of the welded joint is calculated by an extrapolation method recommended in the specification of International Institute of Welding (IIW). The stochastic characteristic of stress concentration factor (SCF) of the concerned welded joint is addressed. The proposed FBG-based stress monitoring system and probabilistic stress evaluation methods can provide an effective tool for structural monitoring and condition assessment of orthotropic steel bridges. PMID:29414850

Effect of different filler wires on weld formation for fiber laser welding 6A02 Aluminum alloy

NASA Astrophysics Data System (ADS)

Xu, F.; Chen, L.; Lu, W.; He, E. G.

2017-12-01

6A02 aluminum alloy was welded by fibre laser welding with two different filler wires (ER4043 and ER5356). The weld apperance, microstructure and mechanical properties were analysed. The results show the welding course with ER4043 is more stable than that with ER5356, and the welding spatters of the former are smaller than that of the latter. The microsturtrue of the weld zone, including columnar-grains near the fusion zone and mixed microstructures (columnar grains and equiaxed grains) in the weld center zone, is finer with ER5356 than that with ER4043. So the average microhardness value of the former is higher than the latter. A great number of low melting point eutectic phases disperse in grains boundary. Due to the eutectic phases distributing more in two zones (overheat zone near the fusion zone and the weld center zone) than other zones, the welded joints have these two low hardness and weak strength zones. The ultimate strength and the elongations after fracture of the welded joints with ER4043 are lower than that with ER5356 slihgtly. However, the former are improved obviously and higher than the latter after heat treatment. The tensile properties of all joints can reach to the base material level. And the tensile fractures always occur near the fusion zone.

Metallurgical and mechanical properties of laser welded high strength low alloy steel

PubMed Central

Oyyaravelu, Ramachandran; Kuppan, Palaniyandi; Arivazhagan, Natarajan

2016-01-01

The study aimed at investigating the microstructure and mechanical properties of Neodymium-Doped Yttrium Aluminum Garnet (Nd:YAG) laser welded high strength low alloy (HSLA) SA516 grade 70 boiler steel. The weld joint for a 4 mm thick plate was successfully produced using minimum laser power of 2 kW by employing a single pass without any weld preheat treatment. The micrographs revealed the presence of martensite phase in the weld fusion zone which could be due to faster cooling rate of the laser weldment. A good correlation was found between the microstructural features of the weld joints and their mechanical properties. The highest hardness was found to be in the fusion zone of cap region due to formation of martensite and also enrichment of carbon. The hardness results also showed a narrow soft zone at the heat affected zone (HAZ) adjacent to the weld interface, which has no effect on the weld tensile strength. The yield strength and ultimate tensile strength of the welded joints were 338 MPa and 549 MPa, respectively, which were higher than the candidate metal. These tensile results suggested that the laser welding process had improved the weld strength even without any weld preheat treatment and also the fractography of the tensile fractured samples showed the ductile mode of failure. PMID:27222751

Study of gas tungsten arc welding procedures for tantalum alloy T-111 (Ta-8 W-2Hf) plate

NASA Technical Reports Server (NTRS)

Gold, R. E.; Kesterson, R. L.

1973-01-01

Methods of eliminating or reducing underbread cracking in multipass GTA welds in thick T-111 plate were studied. Single V butt welds prepared using experimental filler metal compositions and standard weld procedures resulted in only moderate success in reducing underbread cracking. Subsequent procedural changes incorporating manual welding, slower weld speeds, and three or fewer fill passes resulted in crack-free single V welds only when the filler metal was free of hafnium. The double V joint design with successive fill passes on opposite sides of the joint produced excellent welds. The quality of each weld was determined metallographically since the cracking, when present, was very slight and undetectable using standard NDT techniques. Tensile and bend tests were performed on selected weldments. The inherent filler metal strength and the joint geometry determined the strength of the weldment. Hardness and electron beam microprobe traverses were made on selected specimens with the result that significant filler metal-base metal dilution as well as hafnium segregation was detected. A tentative explanation of T-111 plate underbread cracking is presented based on the intrinsic effects of hafnium in the weldment.

Characterisation of weld zone reactions in dissimilar glass-to-aluminium pulsed picosecond laser welds

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

Ciuca, Octav P., E-mail: octav.ciuca@manchester.ac

Precision welded joints, produced between fused silica glass and aluminium by a newly-developed picosecond-pulse laser technique, have been analysed for the first time using a full range of electron microscopy methods. The welds were produced as lap joints by focusing a 1.2 μm diameter laser beam through the transparent glass top sheet, slightly below the surface of the metal bottom sheet. Despite the extremely short interaction time, extensive reaction was observed in the weld zone, which involved the formation of nanocrystalline silicon and at least two transitional alumina phases, γ- and δ-Al{sub 2}O{sub 3}. The weld formation process was foundmore » to be complex and involved: the formation of a constrained plasma cavity at the joint interface, non-linear absorption in the glass, and the creation of multiple secondary keyholes in the metal substrate by beam scattering. The joint area was found to expand outside of the main interaction volume, as the energy absorbed into the low conductivity and higher melting point silica glass sheet melted the aluminium surface across a wider contact area. The reasons for the appearance of nanocrystalline Si and transitional alumina reaction products within the welds are discussed. - Highlights: •Pulsed laser welding of dissimilar materials causes extensive chemical reactivity. •Metastable Al{sub 2}O{sub 3} phases form due to laser-induced highly-transient thermal regime. •Fused silica is reduced by Al to form nanocrystalline Si. •Mechanism of joint formation is discussed.« less

Improved Assembly for Gas Shielding During Welding or Brazing

NASA Technical Reports Server (NTRS)

Gradl, Paul; Baker, Kevin; Weeks, Jack

2009-01-01

An improved assembly for inert-gas shielding of a metallic joint is designed to be useable during any of a variety of both laser-based and traditional welding and brazing processes. The basic purpose of this assembly or of a typical prior related assembly is to channel the flow of a chemically inert gas to a joint to prevent environmental contamination of the joint during the welding or brazing process and, if required, to accelerate cooling upon completion of the process.

Nd:YAG laser welding of coated sheet steel

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

Graham, M.P.; Kerr, H.W.; Weckman, D.C.

1994-12-31

Coated sheet steels are used extensively in the automotive industry for the fabrication of automobile body components; however, their reduced weldability by the traditional welding processes has led to numerous studies into the use of alternate process such as laser welding. In this paper, we present a modified joint geometry which allows high quality lap welds of coated sheet steels to be made by laser welding processes. Hot-dipped galvanized sheet (16 gauge), with a 60 g/m zinc coating was used in this study. A groove was created in the top sheet of a specimen pair by pressing piano wires ofmore » various diameters into the sheet. The specimens were clamped together in a lag-joint configuration such that they were in contacted only along the grove projection. A parametric study was conducted using the variables of welding speed, laser mean power (685 W, 1000 W and 1350 W), and grove size. Weld quality and weld pool dimensions were assessed using metallurgical cross-sections and image analysis techniques. Acceptable quality seam welds were produced in the galvanized sheet steel with both grove sizes when using 1000 W and 1350 W laser mean powers and a range of welding speeds. Results of the shear-tensile tests showed that high loads to failure, with failure occurring in the parent material, were predominately found in welds produced at speeds over 1.2 m/min and when using the high mean laser powers: 1000 W and 1350 W. A modified lap joint geometry, in which a groove is pre-placed in the top sheet of the lap-joint configuration, has been developed which permits laser welding of coated sheet steels. Good quality seam welds have been produced in 16 gauge galvanized sheet steels at speeds up to 2.7 m/min using a 2 kW CW Nd:YAG laser operating at 1350 W laser mean power. Weld quality was not affected by changes in groove size.« less

State-of-technology for joining TD-NiCr sheet

NASA Technical Reports Server (NTRS)

Holko, K. H.; Moore, T. J.; Gyorgak, C. A.

1972-01-01

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding, gas-tungsten arc welding, diffusion welding, resistance spot welding, resistance seam welding, and brazing. The strengths of the welds made by the various processes show considerable variation, especially at elevated temperatures. Most of the fusion welding processes tend to give weak welds at elevated temperatures (with the exception of fusion-type resistance spotwelds). However, solid-state welds have been made with parent metal properties. The process used for a specific application will be dictated by the specific joint requirements. In highly stressed joints at elevated temperatures, one of the solid-state processes, such as DFW, RSW (solid-state or fusion), and RSEW, offer the most promise.

Formation of porous inner architecture at the interface of magnetic pulse welded Al/Cu joints

NASA Astrophysics Data System (ADS)

Sapanathan, T.; Raoelison, R. N.; Yang, K.; Buiron, N.; Rachik, M.

2016-10-01

Porous inner architecture has been revealed at the interface of magnetic pulse welded aluminum/copper (Al/Cu) joints. These materials could serve the purpose of heterogeneous architectured materials, while their makeup of inner architecture of porous interface with the pore sizes of sub-micron to a few microns, could offer potential attributes in energy storage application. Two welding cases with various impact intensities are compared. An input voltage of 6.5 kV with an initial air gap of 1.5 mm and a higher voltage of 7.5 kV with a large initial air gap of 5 mm are respectively considered as two cases with low and high velocity impacts. Overall morphology of the porous medium was revealed at the interface either in layered or pocketed structures. The allocation of the porous zone and pore sizes vary with the impact condition. The low velocity impact welding conditions also produces smaller pores compared to the high velocity impact case, where the pore sizes varies in submicron to a few microns (<10μm). By investigating the potential mechanism of the porous zone formation, it was identified that a combined phenomena of cavitation and coalescence play a major role in nucleation and growth of the pores where a rapid cooling that eventually freezes the porous structure at the interface.

Geometry and Material Constraint Effects on Creep Crack Growth Behavior in Welded Joints

NASA Astrophysics Data System (ADS)

Li, Y.; Wang, G. Z.; Xuan, F. Z.; Tu, S. T.

2017-02-01

In this work, the geometry and material constraint effects on creep crack growth (CCG) and behavior in welded joints were investigated. The CCG paths and rates of two kinds of specimen geometry (C(T) and M(T)) with initial cracks located at soft HAZ (heat-affected zone with lower creep strength) and different material mismatches were simulated. The effect of constraint on creep crack initiation (CCI) time was discussed. The results show that there exists interaction between geometry and material constraints in terms of their effects on CCG rate and CCI time of welded joints. Under the condition of low geometry constraint, the effect of material constraint on CCG rate and CCI time becomes more obvious. Higher material constraint can promote CCG due to the formation of higher stress triaxiality around crack tip. Higher geometry constraint can increase CCG rate and reduce CCI time of welded joints. Both geometry and material constraints should be considered in creep life assessment and design for high-temperature welded components.

Optimization and Characterization of the Friction Stir Welded Sheets of AA 5754-H111: Monitoring of the Quality of Joints with Thermographic Techniques.

PubMed

De Filippis, Luigi Alberto Ciro; Serio, Livia Maria; Palumbo, Davide; De Finis, Rosa; Galietti, Umberto

2017-10-11

Friction Stir Welding (FSW) is a solid-state welding process, based on frictional and stirring phenomena, that offers many advantages with respect to the traditional welding methods. However, several parameters can affect the quality of the produced joints. In this work, an experimental approach has been used for studying and optimizing the FSW process, applied on 5754-H111 aluminum plates. In particular, the thermal behavior of the material during the process has been investigated and two thermal indexes, the maximum temperature and the heating rate of the material, correlated to the frictional power input, were investigated for different process parameters (the travel and rotation tool speeds) configurations. Moreover, other techniques (micrographs, macrographs and destructive tensile tests) were carried out for supporting in a quantitative way the analysis of the quality of welded joints. The potential of thermographic technique has been demonstrated both for monitoring the FSW process and for predicting the quality of joints in terms of tensile strength.

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.

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.

An Evaluation of Global and Local Tensile Properties of Friction-Stir Welded DP980 Dual-Phase Steel Joints Using a Digital Image Correlation Method

PubMed Central

Lee, Hyoungwook; Kim, Cheolhee; Song, Jung Han

2015-01-01

The effect of the microstructure heterogeneity on the tensile plastic deformation characteristic of friction-stir-welded (FSW) dual-phase (DP) steel was investigated for the potential applications on the lightweight design of vehicles. Friction-stir-welded specimens with a butt joint configuration were prepared, and quasi-static tensile tests were conducted, to evaluate the tensile properties of DP980 dual-phase steels. The friction-stir welding led to the formation of martensite and a significant hardness rise in the stir zone (SZ), but the presence of a soft zone in the heat-affected zone (HAZ) was caused by tempering of the pre-existing martensite. Owing to the appearance of severe soft zone, DP980 FSW joint showed almost 93% joint efficiency with the view-point of ultimate tensile strength and relatively low ductility than the base metal (BM). The local tensile deformation characteristic of the FSW joints was also examined using the digital image correlation (DIC) methodology by mapping the global and local strain distribution, and was subsequently analyzed by mechanics calculation. It is found that the tensile deformation of the FSW joints is highly heterogeneous, leading to a significant decrease in global ductility. The HAZ of the joints is the weakest region where the strain localizes early, and this localization extends until fracture with a strain near 30%, while the strain in the SZ and BM is only 1% and 4%, respectively. Local constitutive properties in different heterogeneous regions through the friction-stir-welded joint was also briefly evaluated by assuming iso-stress conditions. The local stress-strain curves of individual weld zones provide a clear indication of the heterogeneity of the local mechanical properties. PMID:28793720

An Evaluation of Global and Local Tensile Properties of Friction-Stir Welded DP980 Dual-Phase Steel Joints Using a Digital Image Correlation Method.

PubMed

Lee, Hyoungwook; Kim, Cheolhee; Song, Jung Han

2015-12-04

The effect of the microstructure heterogeneity on the tensile plastic deformation characteristic of friction-stir-welded (FSW) dual-phase (DP) steel was investigated for the potential applications on the lightweight design of vehicles. Friction-stir-welded specimens with a butt joint configuration were prepared, and quasi-static tensile tests were conducted, to evaluate the tensile properties of DP980 dual-phase steels. The friction-stir welding led to the formation of martensite and a significant hardness rise in the stir zone (SZ), but the presence of a soft zone in the heat-affected zone (HAZ) was caused by tempering of the pre-existing martensite. Owing to the appearance of severe soft zone, DP980 FSW joint showed almost 93% joint efficiency with the view-point of ultimate tensile strength and relatively low ductility than the base metal (BM). The local tensile deformation characteristic of the FSW joints was also examined using the digital image correlation (DIC) methodology by mapping the global and local strain distribution, and was subsequently analyzed by mechanics calculation. It is found that the tensile deformation of the FSW joints is highly heterogeneous, leading to a significant decrease in global ductility. The HAZ of the joints is the weakest region where the strain localizes early, and this localization extends until fracture with a strain near 30%, while the strain in the SZ and BM is only 1% and 4%, respectively. Local constitutive properties in different heterogeneous regions through the friction-stir-welded joint was also briefly evaluated by assuming iso-stress conditions. The local stress-strain curves of individual weld zones provide a clear indication of the heterogeneity of the local mechanical properties.

Effects of different brazing and welding methods on the fracture load of various orthodontic joining configurations.

PubMed

Bock, Jens J; Bailly, Jacqueline; Fuhrmann, Robert A

2009-06-01

The aim of this study was to compare the fracture load of different joints made by conventional brazing, tungston inert gas (TIG) and laser welding. Six standardized joining configurations of spring hard quality orthodontic wire were investigated: end-to-end, round, cross, 3 mm length, 9 mm length and 6.5 mm to orthodontic band. The joints were made by five different methods: brazing with universal silver solder, two TIG and two laser welding devices. The fracture loads were measured with a universal testing machine (Zwick 005). Data were analysed with the Mann-Whitney-Wilcoxon and Kruskal-Wallis tests. The significance level was set at P<0.05). In all cases brazed joints were ruptured at a low level of fracture load (186-407 N). Significant differences between brazing and TIG or laser welding (P<0.05) were found. The highest mean fracture loads were observed for laser welding (826 N). No differences between the various TIG or laser welding devices were demonstrated, although it was not possible to join an orthodontic wire to an orthodontic band using TIG welding. For orthodontic purposes laser and TIG welding are solder free alternatives. TIG welding and laser welding showed similar results. The laser technique is an expensive, but sophisticated and simple method.

Effect of rotation speed and welding speed on Friction Stir Welding of AA1100 Aluminium alloy

NASA Astrophysics Data System (ADS)

Raja, P.; Bojanampati, S.; Karthikeyan, R.; Ganithi, R.

2018-04-01

Aluminum AA1100 is the most widely used grade of Aluminium due to its excellent corrosion resistance, high ductility and reflective finish, the selected material was welded with Friction Stir Welding (FSW) process on a CNC machine, using a combination of different tool rotation speed (1500 rpm, 2500 rpm, 3500 rpm) and welding speed (10 mm/min, 30 mm/min, 50 mm/min) as welding parameters. The effect of FSW using this welding parameter was studied by measuring the ultimate tensile strength of the welded joints. A high-speed steel tool was prepared for welding the Aluminium AA1100 alloy having an 8mm shoulder diameter and pin dimension of 4mm diameter and 2.8 mm length. The welded joints were tested using the universal testing machine. It was found that Ultimate Tensile Strength of FSW specimen was highest with a value of 98.08 MPa when the weld was performed at rotation speed of 1500 RPM and welding speed of 50 mm/min.