On-Site Evaluation of Large Components Using Saft and Tofd Ultrasonic Imaging

NASA Astrophysics Data System (ADS)

Spies, M.; Rieder, H.; Dillhöfer, A.

2011-06-01

This contribution addresses ultrasonic inspection and evaluation of welds in large components. An approach has been developed in order to enhance the reliability of welded ship propellers. The Synthetic Aperture Focusing Technique (SAFT) has been modified with regard to the curved surfaces and the sound attenuation of cast Ni-Al bronzes. For weld inspection in steels the Time-of-Flight Diffraction technique (TOFD) can provide additional information for specific defect orientations. Both techniques have been combined in view of the determination of defect sizes and shapes in longitudinal welds of pipes with diameters of up to 48 inches. Details on the inspection and evaluation concepts as well as experimental results are presented.

Evaluation of microstructure stability at the interfaces of Al-6061 welds fabricated using ultrasonic additive manufacturing

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

Sridharan, Niyanth S.; Gussev, Maxim N.; Parish, Chad M.

Here, ultrasonic additive manufacturing (UAM) is a solid-state additive manufacturing process that uses fundamental principles of ultrasonic welding and sequential layering of tapes to fabricate complex three-dimensional (3-D) components. One of the factors limiting the use of this technology is the poor tensile strength along the z-axis. Recent work has demonstrated the improvement of the z-axis properties after post-processing treatments. The abnormally high stability of the grains at the interface during post-weld heat treatments is, however, not yet well understood. In this work we use multiscale characterization to understand the stability of the grains during post-weld heat treatments. Aluminum alloymore » (6061) builds, fabricated using ultrasonic additive manufacturing, were post-weld heat treated at 180, 330 and 580 °C. The grains close to the tape interfaces are stable during post-weld heat treatments at high temperatures (i.e., 580 °C). This is in contrast to rapid grain growth that takes place in the bulk. Transmission electron microscopy and atom-probe tomography display a significant enrichment of oxygen and magnesium near the stable interfaces. Based on the detailed characterization, two mechanisms are proposed and evaluated: nonequilibrium nano-dispersed oxides impeding the grain growth due to grain boundary pinning, or grain boundary segregation of magnesium and oxygen reducing the grain boundary energy.« less

Evaluation of microstructure stability at the interfaces of Al-6061 welds fabricated using ultrasonic additive manufacturing

DOE PAGES

Sridharan, Niyanth S.; Gussev, Maxim N.; Parish, Chad M.; ...

2018-03-06

Here, ultrasonic additive manufacturing (UAM) is a solid-state additive manufacturing process that uses fundamental principles of ultrasonic welding and sequential layering of tapes to fabricate complex three-dimensional (3-D) components. One of the factors limiting the use of this technology is the poor tensile strength along the z-axis. Recent work has demonstrated the improvement of the z-axis properties after post-processing treatments. The abnormally high stability of the grains at the interface during post-weld heat treatments is, however, not yet well understood. In this work we use multiscale characterization to understand the stability of the grains during post-weld heat treatments. Aluminum alloymore » (6061) builds, fabricated using ultrasonic additive manufacturing, were post-weld heat treated at 180, 330 and 580 °C. The grains close to the tape interfaces are stable during post-weld heat treatments at high temperatures (i.e., 580 °C). This is in contrast to rapid grain growth that takes place in the bulk. Transmission electron microscopy and atom-probe tomography display a significant enrichment of oxygen and magnesium near the stable interfaces. Based on the detailed characterization, two mechanisms are proposed and evaluated: nonequilibrium nano-dispersed oxides impeding the grain growth due to grain boundary pinning, or grain boundary segregation of magnesium and oxygen reducing the grain boundary energy.« less

A support vector machine approach for classification of welding defects from ultrasonic signals

NASA Astrophysics Data System (ADS)

Chen, Yuan; Ma, Hong-Wei; Zhang, Guang-Ming

2014-07-01

Defect classification is an important issue in ultrasonic non-destructive evaluation. A layered multi-class support vector machine (LMSVM) classification system, which combines multiple SVM classifiers through a layered architecture, is proposed in this paper. The proposed LMSVM classification system is applied to the classification of welding defects from ultrasonic test signals. The measured ultrasonic defect echo signals are first decomposed into wavelet coefficients by the wavelet packet transform. The energy of the wavelet coefficients at different frequency channels are used to construct the feature vectors. The bees algorithm (BA) is then used for feature selection and SVM parameter optimisation for the LMSVM classification system. The BA-based feature selection optimises the energy feature vectors. The optimised feature vectors are input to the LMSVM classification system for training and testing. Experimental results of classifying welding defects demonstrate that the proposed technique is highly robust, precise and reliable for ultrasonic defect classification.

Method for the concurrent ultrasonic inspection of partially completed welds

DOEpatents

Johnson, John A.; Larsen, Eric D.; Miller, Karen S.; Smartt, Herschel B.; McJunkin, Timothy R.

2002-01-01

A method for the concurrent ultrasonic inspection of partially completed welds is disclosed and which includes providing a pair of transducers which are individually positioned on the opposite sides of a partially completed weld to be inspected; moving the transducers along the length of and laterally inwardly and outwardly relative to the partially completed weld; pulsing the respective transducers to produce an ultrasonic signal which passes through or is reflected from the partially completed weld; receiving from the respective transducers ultrasonic signals which pass through or are reflected from the partially completed welds; and analyzing the ultrasonic signal which has passed through or is reflected from the partially completed weld to determine the presence of any weld defects.

Process Stability of Ultrasonic-Wave-Assisted Gas Metal Arc Welding

NASA Astrophysics Data System (ADS)

Fan, Chenglei; Xie, Weifeng; Yang, Chunli; Lin, Sanbao; Fan, Yangyang

2017-10-01

As a newly developed arc welding method, ultrasonic-wave-assisted arc welding successfully introduced power ultrasound into the arc and weld pool, during which the ultrasonic acts on the top of the arc in the coaxial alignment direction. The advanced process for molten metals can be realized by using an additional ultrasonic field. Compared with the conventional gas metal arc welding (GMAW), the welding arc is compressed, the droplet size is decreased, and the droplet transfer frequency is increased significantly in ultrasonic-wave-assisted GMAW (U-GMAW). However, the stability of the metal transfer has deep influence on the welding quality equally, and the ultrasonic wave effect on the stability of the metal transfer is a phenomenon that is not completely understood. In this article, the stabilities of the short-circuiting transfer process and globular transfer process are studied systematically, and the effect of ultrasonic wave on the metal transfer is analyzed further. The transfer frequency and process stability of the U-GMAW process are much higher than those of the conventional GMAW. Analytical results show that the additional ultrasonic wave is helpful for improving welding stability.

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

NASA Technical Reports Server (NTRS)

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

2017-01-01

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

Grain fragmentation in ultrasonic-assisted TIG weld of pure aluminum.

PubMed

Chen, Qihao; Lin, Sanbao; Yang, Chunli; Fan, Chenglei; Ge, Hongliang

2017-11-01

Under the action of acoustic waves during an ultrasonic-assisted tungsten inert gas (TIG) welding process, a grain of a TIG weld of aluminum alloy is refined by nucleation and grain fragmentation. Herein, effects of ultrasound on grain fragmentation in the TIG weld of aluminum alloy are investigated via systematic welding experiments of pure aluminum. First, experiments involving continuous and fixed-position welding are performed, which demonstrate that ultrasound can break the grain of the TIG weld of pure aluminum. The microstructural characteristics of an ultrasonic-assisted TIG weld fabricated by fixed-position welding are analyzed. The microstructure is found to transform from plane crystal, columnar crystal, and uniform equiaxed crystal into plane crystal, deformed columnar crystal, and nonuniform equiaxed crystal after application of ultrasound. Second, factors influencing ultrasonic grain fragmentation are investigated. The ultrasonic amplitude and welding current are found to have a considerable effect on grain fragmentation. The degree of fragmentation first increases and then decreases with an increase in ultrasonic amplitude, and it increases with an increase in welding current. Measurement results of the vibration of the weld pool show that the degree of grain fragmentation is related to the intensity of acoustic nonlinearity in the weld pool. The greater the intensity of acoustic nonlinearity, the greater is the degree of grain fragmentation. Finally, the mechanism of ultrasonic grain fragmentation in the TIG weld of pure aluminum is discussed. A finite element simulation is used to simulate the acoustic pressure and flow in the weld pool. The acoustic pressure in the weld pool exceeds the cavitation threshold, and cavitation bubbles are generated. The flow velocity in the weld pool does not change noticeably after application of ultrasound. It is concluded that the high-pressure conditions induced during the occurrence of cavitation, lead to grain fragmentation in a pure aluminum TIG weld during an ultrasonic-assisted TIG welding process. Copyright © 2017 Elsevier B.V. All rights reserved.

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.

Pulsed ultrasonic stir welding system

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2013-01-01

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

Pulsed ultrasonic stir welding method

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2013-01-01

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

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.

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.

Evaluation of ultrasonics and optimized radiography for 2219-T87 aluminum weldments

NASA Technical Reports Server (NTRS)

Clotfelter, W. N.; Hoop, J. M.; Duren, P. C.

1975-01-01

Ultrasonic studies are described which are specifically directed toward the quantitative measurement of randomly located defects previously found in aluminum welds with radiography or with dye penetrants. Experimental radiographic studies were also made to optimize techniques for welds of the thickness range to be used in fabricating the External Tank of the Space Shuttle. Conventional and innovative ultrasonic techniques were applied to the flaw size measurement problem. Advantages and disadvantages of each method are discussed. Flaw size data obtained ultrasonically were compared to radiographic data and to real flaw sizes determined by destructive measurements. Considerable success was achieved with pulse echo techniques and with 'pitch and catch' techniques. The radiographic work described demonstrates that careful selection of film exposure parameters for a particular application must be made to obtain optimized flaw detectability. Thus, film exposure techniques can be improved even though radiography is an old weld inspection method.

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

Decomposition of cellulose by ultrasonic welding in water

NASA Astrophysics Data System (ADS)

Nomura, Shinfuku; Miyagawa, Seiya; Mukasa, Shinobu; Toyota, Hiromichi

2016-07-01

The use of ultrasonic welding in water to decompose cellulose placed in water was examined experimentally. Filter paper was used as the decomposition material with a horn-type transducer 19.5 kHz adopted as the ultrasonic welding power source. The frictional heat at the point where the surface of the tip of the ultrasonic horn contacts the filter paper decomposes the cellulose in the filter paper into 5-hydroxymethylfurfural (5-HMF), furfural, and oligosaccharide through hydrolysis and thermolysis that occurs in the welding process.

Ultrasonic stir welding process and apparatus

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2009-01-01

An ultrasonic stir welding device provides a method and apparatus for elevating the temperature of a work piece utilizing at least one ultrasonic heater. Instead of relying on a rotating shoulder to provide heat to a workpiece an ultrasonic heater is utilized to provide ultrasonic energy to the workpiece. A rotating pin driven by a motor assembly performs the weld on the workpiece. A handheld version can be constructed as well as a fixedly mounted embodiment.

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.

Ultrasonic Welding of Thin Alumina and Aluminum Using Inserts

NASA Astrophysics Data System (ADS)

Ishikuro, Tomoaki; Matsuoka, Shin-Ichi

This paper describes an experimental study of ultrasonic welding of thin ceramics and metals using inserts. Ultrasonic welding has enable the joining of various thick ceramics, such as Al2O3 and ZrO2, to aluminum at room temperature quickly and easily as compared to other welding methods. However, for thin ceramics, which are brittle, welding is difficult to perform without causing damage. In this study, aluminum anodized oxide with different anodizing time was used as thin alumina ceramic. Vapor deposition of aluminum alloys was used to create an effective binder layer for welding at a low pressure and within a short duration in order to prevent damage to the anodic oxide film formed with a short anodizing time. For example, ultrasonic welding of thin Al2O3/Al was accomplished under the following conditions: ultrasonic horn tip amplitude of 30µm, welding pressure of 5MPa, and required duration of 0.1s. However, since the vapor deposition film tends to exfoliate as observed in the anodic oxide film formed with a long anodizing time, welding was difficult.

Catalytic effect on ultrasonic decomposition of cellulose

NASA Astrophysics Data System (ADS)

Nomura, Shinfuku; Wakida, Kousuke; Mukasa, Shinobu; Toyota, Hiromichi

2018-07-01

Cellulase used as a catalyst is introduced into the ultrasonic welding method for cellulose decomposition in order to obtain glucose. By adding cellulase in the welding process, filter paper decomposes cellulose into glucose, 5-hydroxymethylfurfural (5-HMF), furfural, and oligosaccharides. The amount of glucose from hydrolysis was increased by ultrasonic welding in filter paper immersed in water. Most glucose was obtained by 100 W ultrasonic irradiation; however, when was applied 200 W, the dehydration of the glucose itself occurred, and was converted into 5-HMF owing to the thermolysis of ultrasonics. Therefore, there is an optimum welding power for the production of glucose from cellulose decomposition.

Experimental Investigation on Acoustic Control Droplet Transfer in Ultrasonic-Wave-Assisted Gas Metal Arc Welding

NASA Astrophysics Data System (ADS)

Weifeng, Xie; Chenglei, Fan; Chunli, Yang; Sanbao, Lin

2018-02-01

Ultrasonic-wave-assisted gas metal arc welding (U-GMAW) is a new, advanced arc welding method that uses an ultrasonic wave emitted from an ultrasonic radiator above the arc. However, it remains unclear how the ultrasonic wave affects the metal droplet, hindering further application of U-GMAW. In this paper, an improved U-GMAW system was used and its superiority was experimentally demonstrated. Then a series of experiments were designed and performed to study how the ultrasonic wave affects droplet transfer, including droplet size, velocity, and motion trajectory. The behavior of droplet transfer was observed in high-speed images. The droplet transfer is closely related to the distribution of the acoustic field, determined by the ultrasonic current. Moreover, by analyzing the variably accelerated motion of the droplet, the acoustic control of the droplet transfer was intuitively demonstrated. Finally, U-GMAW was successfully used in vertical-up and overhead welding experiments, showing that U-GMAW is promising for use in welding in all positions.

Development Of Ultrasonic Testing Based On Delphi Program As A Learning Media In The Welding Material Study Of Detection And Welding Disables In The Environment Of Vocational Education

NASA Astrophysics Data System (ADS)

Dwi Cahyono, Bagus; Ainur, Chandra

2018-04-01

The development of science and technology has a direct impact on the preparation of qualified workers, including the preparation of vocational high school graduates. Law Number 20 the Year 2003 on National Education System explains that the purpose of vocational education is to prepare learners to be ready to work in certain fields. One of the learning materials in Vocational High School is welding and detecting welding defects. Introduction of welding and detecting welding defects, one way that can be done is by ultrasonic testing will be very difficult if only capitalize the book only. Therefore this study aims to adopt ultrasonic testing in a computer system. This system is called Delphi Program-based Ultrasonic Testing Expert System. This system is used to determine the classification and type of welding defects of the welded defect indicator knew. In addition to the system, there is a brief explanation of the notion of ultrasonic testing, calibration procedures and inspection procedures ultrasonic testing. In this system, ultrasonic input data testing that shows defects entered into the computer manually. This system is built using Delphi 7 software and Into Set Up Compiler as an installer. The method used in this research is Research and Development (R & D), with the following stages: (1) preliminary research; (2) manufacture of software design; (3) materials collection; (4) early product development; (5) validation of instructional media experts; (6) product analysis and revision; (8) media trials in learning; And (9) result of end product of instructional media. The result of the research shows that: (1) the result of feasibility test according to ultrasonic material testing expert that the system is feasible to be used as instructional media in welding material subject and welding defect detection in vocational education environment, because it contains an explanation about detection method of welding defect using method Ultrasonic testing in detail; (2) feasibility test results according to media experts, that this system has a very attractive visual, user friendly, compatible with windows and Linux and media size that is not too large; And (3) result of test by using data of indication of welding defect in PT PAL Surabaya, obtained classification data of welding defect in accordance with calculation of welding defect classification.

Ultrasonic Stir Welding

NASA Technical Reports Server (NTRS)

Nabors, Sammy

2015-01-01

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

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

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

None

1969-07-01

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

Detection and assessment of flaws in friction stir welded metallic plates

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

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.

Process control of GMAW by detection of discontinuities in the molten weld pool

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

Carlson, N.M.; Kunerth, D.C.; Johnson, J.A.

1988-01-01

The use of ultrasonic sensors to detect discontinuities associated with the molten pool is one phase of a project to automate the welding process. In this work, ultrasonic sensors were used to interrogate the region around the molten/solid interface during gas metal arc welding (GMAW). The ultrasonic echoes from the interface and the molten pool provide information about the quality of the fusion zone and the molten pool. This information can be sent to a controller that can vary the welding parameters to correct the process. Previously ultrasonic shear waves were used to determine if the geometry of the molten/solidmore » interface was indicative of an acceptable weld. In this work, longitudinal waves were used to interrogate the molten weld pool for discontinuities. Unacceptable welding conditions that can result in porosity, incomplete penetration, or undercut were detected. 8 refs., 4 figs.« less

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.

The ultrasonic characteristics of high frequency modulated arc and its application in material processing.

PubMed

He, Longbiao; Yang, Ping; Li, Luming; Wu, Minsheng

2014-12-01

To solve the difficulty of introducing traditional ultrasonic transducers to welding molten pool, high frequency current is used to modulate plasma arc and ultrasonic wave is excited successfully. The characteristics of the excited ultrasonic field are studied. The results show that the amplitude-frequency response of the ultrasonic emission is flat. The modulating current is the main factor influencing the ultrasonic power and the sound pressure depends on the variation of arc plasma stream force. Experimental study of the welding structure indicates grain refinement by the ultrasonic emission of the modulated arc and the test results showed there should be an energy region for the arc ultrasonic to get best welding joints. Copyright © 2014 Elsevier B.V. All rights reserved.

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

PubMed

Manjula, K; Vijayarekha, K; Venkatraman, B

2018-03-01

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

Experiment and numerical simulation for laser ultrasonic measurement of residual stress.

PubMed

Zhan, Yu; Liu, Changsheng; Kong, Xiangwei; Lin, Zhongya

2017-01-01

Laser ultrasonic is a most promising method for non-destructive evaluation of residual stress. The residual stress of thin steel plate is measured by laser ultrasonic technique. The pre-stress loading device is designed which can easily realize the condition of the specimen being laser ultrasonic tested at the same time in the known stress state. By the method of pre-stress loading, the acoustoelastic constants are obtained and the effect of different test directions on the results of surface wave velocity measurement is discussed. On the basis of known acoustoelastic constants, the longitudinal and transverse welding residual stresses are measured by the laser ultrasonic technique. The finite element method is used to simulate the process of surface wave detection of welding residual stress. The pulsed laser is equivalent to the surface load and the relationship between the physical parameters of the laser and the load is established by the correction coefficient. The welding residual stress of the specimen is realized by the ABAQUS function module of predefined field. The results of finite element analysis are in good agreement with the experimental method. The simple and effective numerical and experimental methods for laser ultrasonic measurement of residual stress are demonstrated. Copyright © 2016. Published by Elsevier B.V.

Evaluation of near-surface stress distributions in dissimilar welded joint by scanning acoustic microscopy.

PubMed

Kwak, Dong Ryul; Yoshida, Sanichiro; Sasaki, Tomohiro; Todd, Judith A; Park, Ik Keun

2016-04-01

This paper presents the results from a set of experiments designed to ultrasonically measure the near surface stresses distributed within a dissimilar metal welded plate. A scanning acoustic microscope (SAM), with a tone-burst ultrasonic wave frequency of 200 MHz, was used for the measurement of near surface stresses in the dissimilar welded plate between 304 stainless steel and low carbon steel. For quantitative data acquisition such as leaky surface acoustic wave (leaky SAW) velocity measurement, a point focus acoustic lens of frequency 200 MHz was used and the leaky SAW velocities within the specimen were precisely measured. The distributions of the surface acoustic wave velocities change according to the near-surface stresses within the joint. A three dimensional (3D) finite element simulation was carried out to predict numerically the stress distributions and compare with the experimental results. The experiment and FE simulation results for the dissimilar welded plate showed good agreement. This research demonstrates that a combination of FE simulation and ultrasonic stress measurements using SAW velocity distributions appear promising for determining welding residual stresses in dissimilar material joints. Copyright © 2016 Elsevier B.V. All rights reserved.

Weld quality inspection using laser-EMAT ultrasonic system and C-scan method

NASA Astrophysics Data System (ADS)

Yang, Lei; Ume, I. Charles

2014-02-01

Laser/EMAT ultrasonic technique has attracted more and more interests in weld quality inspection because of its non-destructive and non-contact characteristics. When ultrasonic techniques are used to detect welds joining relative thin plates, the dominant ultrasonic waves present in the plates are Lamb waves, which propagate all through the thickness. Traditional Time of Flight(ToF) method loses its power. The broadband nature of laser excited ultrasound plus dispersive and multi-modal characteristic of Lamb waves make the EMAT acquired signals very complicated in this situation. Challenge rises in interpreting the received signals and establishing relationship between signal feature and weld quality. In this paper, the laser/EMAT ultrasonic technique was applied in a C-scan manner to record full wave propagation field over an area close to the weld. Then the effect of weld defect on the propagation field of Lamb waves was studied visually by watching an movie resulted from the recorded signals. This method was proved to be effective to detect the presence of hidden defect in the weld. Discrete wavelet transform(DWT) was applied to characterize the acquired ultrasonic signals and ideal band-pass filter was used to isolate wave components most sensitive to the weld defect. Different interactions with the weld defect were observed for different wave components. Thus this C-Scan method, combined with DWT and ideal band-pass filter, proved to be an effective methodology to experimentally study interactions of various laser excited Lamb Wave components with weld defect. In this work, the method was demonstrated by inspecting a hidden local incomplete penetration in weld. In fact, this method can be applied to study Lamb Wave interactions with any type of structural inconsistency. This work also proposed a ideal filtered based method to effectively reduce the total experimental time.

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.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Navy ManTech 2010 Project Book

DTIC Science & Technology

2010-01-01

31 S2253 Ultrasonic Testing as an Alternative to Radiography for the Inspection of Naval Piping, Pressure Vessel and Machinery Welds...for Inspection S2253 — Ultrasonic Testing as an Alternative to Radiography for the Inspection of Naval Piping, Pressure Vessel and Machinery Welds...Ultrasonic Testing as an Alternative to Radiography for the Inspection of Naval Piping, Pressure Vessel and Machinery Welds

Ultrasonic Phased Array Inspection Simulations of Welded Components at NASA

NASA Technical Reports Server (NTRS)

Roth, D. J.; Tokars, R. P.; Martin, R. E.; Rauser, R. W.; Aldrin, J. C.; Schumacher, E. J.

2009-01-01

Comprehensive and accurate inspections of welded components have become of increasing importance as NASA develops new hardware such as Ares rocket segments for future exploration missions. Simulation and modeling will play an increased role in the future for nondestructive evaluation in order to better understand the physics of the inspection process and help explain the experimental results. It will also help to prove or disprove the feasibility for an inspection method or inspection scenario, help optimize inspections, and allow to a first approximation limits of detectability. This study presents simulation and experimental results for an ultrasonic phased array inspection of a critical welded structure important for NASA future exploration vehicles.

Comparison of ultrasonic suture welding and traditional knot tying in a rabbit rotator cuff repair model.

PubMed

Nho, Shane J; Cole, Brian J; Mazzocca, Augustus D; Williams, James M; Romeo, Anthony A; Bush-Joseph, Charles A; Bach, Bernard R; Hallab, Nadim J

2006-01-01

The purpose of this study is to evaluate ultrasonic suture welding of monofilament suture in an animal model of rotator cuff repair with biomechanical and histologic analyses. We randomly assigned 46 shoulders in 23 rabbits to 1 of 3 treatment groups: sham-operated (n = 15), knotted (n = 15), and welded (n = 16). Supraspinatus defects were surgically created and acutely repaired with suture anchors loaded with either No. 2-0 Ethibond for knotted group or No. 2-0 nylon for welded shoulders. Eighteen weeks postoperatively, all animals were killed, and the shoulders underwent either biomechanical testing or histologic analysis. The maximum stress of the sham-operated group (20.6 N/mm2) was significantly greater than that of both the knotted (10.2 N/mm2) and welded (8.3 N/mm2) groups (P < .05), but no differences were observed between the knotted and welded groups. Although some histologic changes were noted, none was considered to be significant to distinguish either group.

The Detection of Burn-Through Weld Defects Using Noncontact Ultrasonics

PubMed Central

Abbasi, Zeynab; Yuhas, Donald; Zhang, Lu; Basantes, Alexandra-Del-Carmen; Tehrani, Niloofar Nabili; Ozevin, Didem; Indacochea, Ernesto

2018-01-01

Nearly all manufactured products in the metal industry involve welding. The detection and correction of defects during welding improve the product reliability and quality, and prevent unexpected failures. Nonintrusive process control is critical for avoiding these defects. This paper investigates the detection of burn-through damage using noncontact, air-coupled ultrasonics, which can be adapted to the immediate and in-situ inspection of welded samples. The burn-through leads to a larger volume of degraded weld zone, providing a resistance path for the wave to travel which results in lower velocity, energy ratio, and amplitude. Wave energy dispersion occurs due to the increase of weld burn-through resulting in higher wave attenuation. Weld sample micrographs are used to validate the ultrasonic results. PMID:29342875

Ultrasonic sensing of GMAW: Laser/EMAT defect detection system

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

Carlson, N.M.; Johnson, J.A.; Larsen, E.D.

1992-08-01

In-process ultrasonic sensing of welding allows detection of weld defects in real time. A noncontacting ultrasonic system is being developed to operate in a production environment. The principal components are a pulsed laser for ultrasound generation and an electromagnetic acoustic transducer (EMAT) for ultrasound reception. A PC-based data acquisition system determines the quality of the weld on a pass-by-pass basis. The laser/EMAT system interrogates the area in the weld volume where defects are most likely to occur. This area of interest is identified by computer calculations on a pass-by-pass basis using weld planning information provided by the off-line programmer. Themore » absence of a signal above the threshold level in the computer-calculated time interval indicates a disruption of the sound path by a defect. The ultrasonic sensor system then provides an input signal to the weld controller about the defect condition. 8 refs.« less

Defense Waste Processing Facility Canister Closure Weld Current Validation Testing

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

Korinko, P. S.; Maxwell, D. N.

Two closure welds on filled Defense Waste Processing Facility (DWPF) canisters failed to be within the acceptance criteria in the DWPF operating procedure SW4-15.80-2.3 (1). In one case, the weld heat setting was inadvertently provided to the canister at the value used for test welds (i.e., 72%) and this oversight produced a weld at a current of nominally 210 kA compared to the operating procedure range (i.e., 82%) of 240 kA to 263 kA. The second weld appeared to experience an instrumentation and data acquisition upset. The current for this weld was reported as 191 kA. Review of the datamore » from the Data Acquisition System (DAS) indicated that three of the four current legs were reading the expected values, approximately 62 kA each, and the fourth leg read zero current. Since there is no feasible way by further examination of the process data to ascertain if this weld was actually welded at either the target current or the lower current, a test plan was executed to provide assurance that these Nonconforming Welds (NCWs) meet the requirements for strength and leak tightness. Acceptance of the welds is based on evaluation of Test Nozzle Welds (TNW) made specifically for comparison. The TNW were nondestructively and destructively evaluated for plug height, heat tint, ultrasonic testing (UT) for bond length and ultrasonic volumetric examination for weld defects, burst pressure, fractography, and metallography. The testing was conducted in agreement with a Task Technical and Quality Assurance Plan (TTQAP) (2) and applicable procedures.« less

Ultrasonic sensing of GMAW: Laser/EMAT defect detection system. [Gas Metal Arc Welding (GMAW), Electromagnetic acoustic transducer (EMAT)

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

Carlson, N.M.; Johnson, J.A.; Larsen, E.D.

1992-01-01

In-process ultrasonic sensing of welding allows detection of weld defects in real time. A noncontacting ultrasonic system is being developed to operate in a production environment. The principal components are a pulsed laser for ultrasound generation and an electromagnetic acoustic transducer (EMAT) for ultrasound reception. A PC-based data acquisition system determines the quality of the weld on a pass-by-pass basis. The laser/EMAT system interrogates the area in the weld volume where defects are most likely to occur. This area of interest is identified by computer calculations on a pass-by-pass basis using weld planning information provided by the off-line programmer. Themore » absence of a signal above the threshold level in the computer-calculated time interval indicates a disruption of the sound path by a defect. The ultrasonic sensor system then provides an input signal to the weld controller about the defect condition. 8 refs.« less

Real-time nondestructive monitoring of the gas tungsten arc welding (GTAW) process by combined airborne acoustic emission and non-contact ultrasonics

NASA Astrophysics Data System (ADS)

Zhang, Lu; Basantes-Defaz, Alexandra-Del-Carmen; Abbasi, Zeynab; Yuhas, Donald; Ozevin, Didem; Indacochea, Ernesto

2018-03-01

Welding is a key manufacturing process for many industries and may introduce defects into the welded parts causing significant negative impacts, potentially ruining high-cost pieces. Therefore, a real-time process monitoring method is important to implement for avoiding producing a low-quality weld. Due to high surface temperature and possible contamination of surface by contact transducers, the welding process should be monitored via non-contact transducers. In this paper, airborne acoustic emission (AE) transducers tuned at 60 kHz and non-contact ultrasonic testing (UT) transducers tuned at 500 kHz are implemented for real time weld monitoring. AE is a passive nondestructive evaluation method that listens for the process noise, and provides information about the uniformity of manufacturing process. UT provides more quantitative information about weld defects. One of the most common weld defects as burn-through is investigated. The influences of weld defects on AE signatures (time-driven data) and UT signals (received signal energy, change in peak frequency) are presented. The level of burn-through damage is defined by using single method or combine AE/UT methods.

Using Phased Array Ultrasonic Testing in Lieu of Radiography for Acceptance of Carbon Steel Piping Welds

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

Moran, Traci L.; Anderson, Michael T.; Cinson, Anthony D.

2014-08-01

The Pacific Northwest National Laboratory (PNNL) is conducting studies for the U.S. Nuclear Regulatory Commission (NRC) to assess the capability, effectiveness, and reliability of ultrasonic testing (UT) as a replacement method for radiographic testing (RT) for volumetric examination of nuclear power plant (NPP) components. This particular study focused on evaluating the use of UT on carbon steel plate welds. Welding fabrication flaws included a combination of planar and volumetric types, e.g., incomplete fusion, lack of penetration, cracks, porosity, and slag inclusions. The examinations were conducted using phased-array (PA) UT techniques applied primarily for detection and flaw type characterization. This papermore » will discuss the results of using UT in lieu of RT for detection and classification of fabrication flaws in carbon steel plate welds.« 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.

Spatially resolved ultrasonic attenuation in resistance spot welds: implications for nondestructive testing.

PubMed

Mozurkewich, George; Ghaffari, Bita; Potter, Timothy J

2008-09-01

Spatial variation of ultrasonic attenuation and velocity has been measured in plane parallel specimens extracted from resistance spot welds. In a strong weld, attenuation is larger in the nugget than in the parent material, and the region of increased attenuation is surrounded by a ring of decreased attenuation. In the center of a stick weld, attenuation is even larger than in a strong weld, and the low-attenuation ring is absent. These spatial variations are interpreted in terms of differences in grain size and martensite formation. Measured frequency dependences indicate the presence of an additional attenuation mechanism besides grain scattering. The observed attenuations do not vary as commonly presumed with weld quality, suggesting that the common practice of using ultrasonic attenuation to indicate weld quality is not a reliable methodology.

NonDestructive Evaluation for Industrial & Development Applications

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

Hunter, James F.

2016-10-12

Provide overview of weld inspection for Non-Destructive Testing at LANL. This includes radiography (RT/DR/CR/CT for x-ray & neutron sources), ultrasonic testing (UT/PAUT), dye penetrant inspection (PT), eddy current inspection (ET) and magnetic particle testing (MT). Facilities and capabilities for weld inspection will be summarized with examples.

Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

NASA Astrophysics Data System (ADS)

Perez Regalado, Waldo Josue

The real-time ultrasonic spot weld monitoring system, introduced by our research group, has been designed for the unsupervised quality characterization of the spot welding process. It comprises the ultrasonic transducer (probe) built into one of the welding electrodes and an electronics hardware unit which gathers information from the transducer, performs real-time weld quality characterization and communicates with the robot programmable logic controller (PLC). The system has been fully developed for the inspection of spot welds manufactured in steel alloys, and has been mainly applied in the automotive industry. In recent years, a variety of materials have been introduced to the automotive industry. These include high strength steels, magnesium alloys, and aluminum alloys. Aluminum alloys have been of particular interest due to their high strength-to-weight ratio. Resistance spot welding requirements for aluminum vary greatly from those of steel. Additionally, the oxide film formed on the aluminum surface increases the heat generation between the copper electrodes and the aluminum plates leading to accelerated electrode deterioration. Preliminary studies showed that the real-time quality inspection system was not able to monitor spot welds manufactured with aluminum. The extensive experimental research, finite element modelling of the aluminum welding process and finite difference modeling of the acoustic wave propagation through the aluminum spot welds presented in this dissertation, revealed that the thermodynamics and hence the acoustic wave propagation through an aluminum and a steel spot weld differ significantly. For this reason, the hardware requirements and the algorithms developed to determine the welds quality from the ultrasonic data used on steel, no longer apply on aluminum spot welds. After updating the system and designing the required algorithms, parameters such as liquid nugget penetration and nugget diameter were available in the ultrasonic data acquired during the aluminum welding process. Finally, a fuzzy system was designed to receive these parameters and determine the weld quality.

Welding characteristics of 27, 40 and 67 kHz ultrasonic plastic welding systems using fundamental- and higher-resonance frequencies.

PubMed

Tsujino, Jiromaru; Hongoh, Misugi; Yoshikuni, Masafumi; Hashii, Hidekazu; Ueoka, Tetsugi

2004-04-01

The welding characteristics of 27, 40 and 67 kHz ultrasonic plastic welding systems that are driven at only the fundamental-resonance frequency vibration were compared, and also those of the welding systems that were driven at the fundamental and several higher resonance frequencies simultaneously were studied. At high frequency, welding characteristics can be improved due to the larger vibration loss of plastic materials. For welding of rather thin or small specimens, as the fundamental frequency of these welding systems is higher and the numbers of driven higher frequencies are driven simultaneously, larger welded area and weld strength were obtained.

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

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Gleeson, Sean T.

2014-03-01

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

Ultrasonically-assisted Thermal Stir Welding System

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2014-01-01

A welding head assembly has a work piece disposed between its containment plates' opposing surfaces with the work piece being maintained in a plastic state thereof at least in a vicinity of the welding head assembly's stir rod as the rod is rotated about its longitudinal axis. The welding head assembly and the work piece experience relative movement there between in a direction perpendicular to the rod's longitudinal axis as the work piece is subjected to a compressive force applied by the containment plates. A first source coupled to the first containment plate applies a first ultrasonic wave thereto such that the first ultrasonic wave propagates parallel to the direction of relative movement. A second source coupled to the second containment plate applies a second ultrasonic wave thereto such that the second ultrasonic wave propagates parallel to the direction of relative movement.propagates parallel to the direction of relative movement.

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.

Product development using process monitoring and NDE data fusion

NASA Astrophysics Data System (ADS)

Peterson, Todd; Bossi, Richard H.

1998-03-01

Composite process/product development relies on both process monitoring information and nondestructive evaluation measurements for determining application suitability. In the past these activities have been performed and analyzed independently. Our present approach is to present the process monitoring and NDE data together in a data fusion workstation. This methodology leads to final product acceptance based on a combined process monitoring and NDE criteria. The data fusion work station combines process parameter and NDE data in a single workspace enabling all the data to be used in the acceptance/rejection decision process. An example application is the induction welding process, a unique joining method for assembling primary composite structure, that offers significant cost and weight advantages over traditional fasted structure. The determination of the required time, temperature and pressure conditions used in the process to achieve a complete weld is being aided by the use of ultrasonic inspection techniques. Full waveform ultrasonic inspection data is employed to evaluate the quality of spar cap to skin fit, an essential element of the welding process, and is processed to find a parameter that can be used for weld acceptance. Certification of the completed weld incorporates the data fusion methodology.

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.

Ultrasonic Welding of Graphite/Thermoplastic Composite

NASA Technical Reports Server (NTRS)

Hardy, S. S.; Page, D. B.

1982-01-01

Ultrasonic welding of graphite/thermoplastic composite materials eliminates need for fasteners (which require drilling or punching, add weight, and degrade stiffness) and can be totally automated in beam fabrication and assembly jigs. Feasibility of technique has been demonstrated in laboratory tests which show that neither angular orientation nor vacuum affect weld quality.

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

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

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

2014-03-24

PNNL conducted a technical assessment of the NDE issues and protocols that led to missed detections of several axially oriented flaws in a steam generator primary inlet dissimilar metal weld at North Anna Power Station, Unit 1 (NAPS-1). This particular component design exhibits a significant outside-diameter (OD) taper that is not included as a blind performance demonstration mock-up within the industry’s Performance Demonstration Initiative, administered by EPRI. For this reason, the licensee engaged EPRI to assist in the development of a technical justification to support the basis for a site-specific qualification. The service-induced flaws at NAPS-1 were eventually detected asmore » a result of OD surface machining in preparation for a full structural weld overlay. The machining operation uncovered the existence of two through-wall flaws, based on the observance of primary water leaking from the dissimilar metal weld. A total of five axially oriented flaws were detected in varied locations around the weld circumference. The field volumetric examination that was conducted at NAPS-1 was a non-encoded, real-time manual ultrasonic examination. PNNL conducted both an initial assessment, and subsequently, a more rigorous technical evaluation (reported here), which has identified an array of NDE issues that may have led to the subject missed detections. These evaluations were performed through technical reviews and discussions with NRC staff, EPRI NDE Center personnel, industry and ISI vendor personnel, and ultrasonic transducer manufacturers, and laboratory tests, to better understand the underlying issues at North Anna.« less

Development of a beam builder for automatic fabrication of large composite space structures

NASA Technical Reports Server (NTRS)

Bodle, J. G.

1979-01-01

The composite material beam builder which will produce triangular beams from pre-consolidated graphite/glass/thermoplastic composite material through automated mechanical processes is presented, side member storage, feed and positioning, ultrasonic welding, and beam cutoff are formed. Each process lends itself to modular subsystem development. Initial development is concentrated on the key processes for roll forming and ultrasonic welding composite thermoplastic materials. The construction and test of an experimental roll forming machine and ultrasonic welding process control techniques are described.

Effect of acoustic field parameters on arc acoustic binding during ultrasonic wave-assisted arc welding.

PubMed

Xie, Weifeng; Fan, Chenglei; Yang, Chunli; Lin, Sanbao

2016-03-01

As a newly developed arc welding method, power ultrasound has been successfully introduced into arc and weld pool during ultrasonic wave-assisted arc welding process. The advanced process for molten metals can be realized by utilizing additional ultrasonic field. Under the action of the acoustic wave, the plasma arc as weld heat source is regulated and its characteristics make an obvious change. Compared with the conventional arc, the ultrasonic wave-assisted arc plasma is bound significantly and becomes brighter. To reveal the dependence of the acoustic binding force on acoustic field parameters, a two-dimensional acoustic field model for ultrasonic wave-assisted arc welding device is established. The influences of the radiator height, the central pore radius, the radiator radius, and curvature radius or depth of concave radiator surface are discussed using the boundary element method. Then the authors analyze the resonant mode by this relationship curve between acoustic radiation power and radiator height. Furthermore, the best acoustic binding ability is obtained by optimizing the geometric parameters of acoustic radiator. In addition, three concave radiator surfaces including spherical cap surface, paraboloid of revolution, and rotating single curved surface are investigated systematically. Finally, both the calculation and experiment suggest that, to obtain the best acoustic binding ability, the ultrasonic wave-assisted arc welding setup should be operated under the first resonant mode using a radiator with a spherical cap surface, a small central pore, a large section radius and an appropriate curvature radius. Copyright © 2015 Elsevier B.V. All rights reserved.

Pulsed infrared thermography for assessment of ultrasonic welds

NASA Astrophysics Data System (ADS)

McGovern, Megan E.; Rinker, Teresa J.; Sekol, Ryan C.

2018-03-01

Battery packs are a critical component in electric vehicles. During pack assembly, the battery cell tab and busbar are ultrasonically welded. The properties of the welds ultimately affect battery pack durability. Quality inspection of these welds is important to ensure durable battery packs. Pack failure is detrimental economically and could also pose a safety hazard, such as thermal runaway. Ultrasonic welds are commonly checked by measuring electrical resistance or auditing using destructive mechanical testing. Resistance measurements are quick, but sensitive to set-up changes. Destructive testing cannot represent the entire weld set. It is possible for a weak weld to satisfy the electrical requirement check, because only sufficient contact between the tabs and busbar is required to yield a low resistance measurement. Laboratory techniques are often not suitable for inline inspection, as they may be time-consuming, use couplant, or are only suitable for coupons. The complex surface geometry also poses difficulties for conventional nondestructive techniques. A method for inspection of ultrasonic welds is proposed using pulsed infrared thermography to identify discrepant welds in a manufacturing environment. Thermal measurements of welds were compared to electrical and mechanical measurements. The heat source distribution was calculated to obtain thermal images with high temporal and spatial resolution. All discrepant welds were readily identifiable using two thermographic techniques: pixel counting and the gradient image. A positive relationship between pixel count and mechanical strength was observed. The results demonstrate the potential of pulsed thermography for inline inspection, which can complement, or even replace, conventional electrical resistance measurements.

Investigation the Amplitude Uniformity on the Surface of the Wide-Blade Ultrasonic Plastic Welding Horn

NASA Astrophysics Data System (ADS)

Hai Nguyen, Thanh; Thanh Quang, Quang; Luat Tran, Cong; Loc Nguyen, Huu

2017-10-01

Ultrasonic welding has been applied for joining thermoplastic components due to their advantages such as clean, fast and reliable. The basic principle is to use the mechanical energy of ultrasonic frequency vibration to produce the molten pool at the interface of the joined components under high pressure to create solid-state welding joints. Depending on the specific application, the ultrasonic horn is designed to generate suitable amplitudes on the surface of the welding zone. Uniformity of the amplitudes can be a challenge as the welding area increases. Therefore, design a welding horn in order to obtain the uniform amplitudes at the large area is significant difficult. This work presents a method for obtaining the uniform amplitudes at the working surface of the stepped wide-blade horn. Finite element method is used to analyze the amplitude distribution at the horn surface of 250 × 34 mm2 with working frequency of 15 kHz and aluminum alloy 7075. The uniformity of amplitude is obtained by changing the shape of the horn.

Computational modeling and experimental studies of the dynamic performance of ultrasonic horn profiles used in plastic welding.

PubMed

Roopa Rani, M; Rudramoorthy, R

2013-03-01

Ultrasonic horns are tuned components designed to vibrate in a longitudinal mode at ultrasonic frequencies. Reliable performance of such horns is normally decided by the uniformity of vibration amplitude at the working surface and the stress developed during loading condition. The horn design engineer must pay particular attention to designing a tool that will produce the desired amplitude without fracturing. The present work discusses horn configurations which satisfy these criteria and investigates the design requirements of horns in ultrasonic system. Different horn profiles for ultrasonic welding of thermoplastics have been characterized in terms of displacement amplitude and von-Mises stresses using modal and harmonic analysis. To validate the simulated results, five different horns are fabricated from Aluminum, tested and tuned to the operating frequency. Standard ABS plastic parts are welded using these horns. Temperature developed during the welding of ABS test parts using different horns is recorded using sensors and National Instruments (NIs) data acquisition system. The recorded values are compared with the predicted values. Experimental results show that welding using a Bezier horn has a high interface temperature and the welded joints had higher strength as compared to the other horn profiles. Copyright © 2012 Elsevier B.V. All rights reserved.

Advanced Welding Concepts

NASA Technical Reports Server (NTRS)

Ding, Robert J.

2010-01-01

Four advanced welding techniques and their use in NASA are briefly reviewed in this poster presentation. The welding techniques reviewed are: Solid State Welding, Friction Stir Welding (FSW), Thermal Stir Welding (TSW) and Ultrasonic Stir Welding.

Towards Real Time Diagnostics of Hybrid Welding Laser/GMAW

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

Timothy Mcjunkin; Dennis C. Kunerth; Corrie Nichol

2013-07-01

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

Towards real time diagnostics of Hybrid Welding Laser/GMAW

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

McJunkin, T. R.; Kunerth, D. C.; Nichol, C. I.

2014-02-18

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

Towards real time diagnostics of Hybrid Welding Laser/GMAW

NASA Astrophysics Data System (ADS)

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

2014-02-01

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

Ultrasonic Phased Array Evaluation of Control Rod Drive Mechanism (CRDM) Nozzle Interference Fit and Weld Region

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

Cinson, Anthony D.; Crawford, Susan L.; MacFarlan, Paul J.

2011-07-31

Ultrasonic phased array data were collected on a removed-from-service CRDM nozzle specimen to assess a previously reported leak path. First a mock-up CRDM specimen was evaluated that contained two 0.076-mm (3.0-mil) interference fit regions formed from an actual Inconel CRDM tube and two 152.4-mm (6.0-in.) thick carbon steel blocks. One interference fit region has a series of precision crafted electric discharge machining (EDM) notches at various lengths, widths, depths, and spatial separations for establishing probe sensitivity, resolution and calibration. The other interference fit has zones of boric acid (crystal form) spaced periodically between the tube and block to represent anmore » actively leaking CRDM nozzle assembly in the field. Ultrasonic phased-array evaluations were conducted using an immersion 8-element annular 5.0-MHz probe from the tube inner diameter (ID). A variety of focal laws were employed to evaluate the interference fit regions and J grove weld, where applicable. Responses from the mock-up specimen were evaluated to determine detection limits and characterization ability as well as contrast the ultrasonic response differences with the presence of boric acid in the fit region. Nozzle 63, from the North Anna Unit-2 nuclear power plant, was evaluated to assess leakage path(s) and was destructively dismantled to allow a visual verification of the leak path(s).« less

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

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

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

2014-02-18

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

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

NASA Astrophysics Data System (ADS)

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

2014-02-01

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

Ultrasonic Spot Welding of a Rare-Earth Containing ZEK100 Magnesium Alloy: Effect of Welding Energy

NASA Astrophysics Data System (ADS)

Macwan, A.; Chen, D. L.

2016-04-01

Ultrasonic spot welding was used to join a low rare-earth containing ZEK100 Mg alloy at different levels of welding energy, and tensile lap shear tests were conducted to evaluate the failure strength in relation to the microstructural changes. It was observed that dynamic recrystallization occurred in the nugget zone; the grain size increased and microhardness decreased with increasing welding energy arising from the increasing interface temperature and strain rate. The weld interface experienced severe plastic deformation at a high strain rate from ~500 to ~2100 s-1 with increasing welding energy from 500 to 2000 J. A relationship between grain size and Zener-Hollomon parameter, and a Hall-Petch-type relationship between microhardness and grain size were established. The tensile lap shear strength and failure energy were observed to first increase with increasing welding energy, reach the maximum values at 1500 J, and then decrease with a further increase in the welding energy. The samples welded at a welding energy ≤1500 J exhibited an interfacial failure mode, while nugget pull-out occurred in the samples welded at a welding energy above 1500 J. The fracture surfaces showed typical shear failure. Low-temperature tests at 233 K (-40 °C) showed no significant effect on the strength and failure mode of joints welded at the optimal welding energy of 1500 J. Elevated temperature tests at 453 K (180 °C) revealed a lower failure load but a higher failure energy due to the increased deformability, and showed a mixed mode of partial interfacial failure and partial nugget pull-out.

Literature Review: Theory and Application of In-Line Inspection Technologies for Oil and Gas Pipeline Girth Weld Defection

PubMed Central

Feng, Qingshan; Li, Rui; Nie, Baohua; Liu, Shucong; Zhao, Lianyu; Zhang, Hong

2016-01-01

Girth weld cracking is one of the main failure modes in oil and gas pipelines; girth weld cracking inspection has great economic and social significance for the intrinsic safety of pipelines. This paper introduces the typical girth weld defects of oil and gas pipelines and the common nondestructive testing methods, and systematically generalizes the progress in the studies on technical principles, signal analysis, defect sizing method and inspection reliability, etc., of magnetic flux leakage (MFL) inspection, liquid ultrasonic inspection, electromagnetic acoustic transducer (EMAT) inspection and remote field eddy current (RFDC) inspection for oil and gas pipeline girth weld defects. Additionally, it introduces the new technologies for composite ultrasonic, laser ultrasonic, and magnetostriction inspection, and provides reference for development and application of oil and gas pipeline girth weld defect in-line inspection technology. PMID:28036016

Comparative testing of radiographic testing, ultrasonic testing and phased array advanced ultrasonic testing non destructive testing techniques in accordance with the AWS D1.5 bridge welding code.

DOT National Transportation Integrated Search

2014-02-01

A comprehensive body of non-destructive testing data was collected from steel bridge welds under real-world conditions in a fabricators shop. Three different non-destructive testing (NDT) techniques were used on each weld inspection, these being R...

Novel Round Energy Director for Use with Servo-driven Ultrasonic Welder

NASA Astrophysics Data System (ADS)

Savitski, Alex; Klinstein, Leo; Holt, Kenneth

Increasingly stringent process repeatability and precision of assembly requirements are common for high-volume manufacturing for electronic, automotive and especially medical device industries, in which components for disposable medication delivery devices are produced in hundreds of millions annually. Ultrasonic welding, one of the most efficient of plastic welding processes often joins these small plastic parts together, and quite possibly, the one most broadly adopted for high volume assembly. The very fundamental factor in ultrasonic welding process performance is a proper joint design, the most common of which is a design utilizing an energy director. Keeping the energy director size and shape consistent on a part-to-part basis in high volume, multi-cavity operations presents a constant challenge to molded part vendors, as dimensional variations from cavity to cavity and variations in the molding process are always present. A newly developed concept of energy director design, when the tip of the energy director is round, addresses these problems, as the round energy director is significantly easier to mold and maintain its dimensional consistency. It also eliminates a major source of process variability for assembly operations. Materializing the benefits of new type of joint design became possible with the introduction of servo-driven ultrasonic welders, which allow an unprecedented control of material flow during the welding cycle and results in significantly improved process repeatability. This article summarizes results of recent studies focused on evaluating performance of round energy director and investigating the main factors responsible for the joint quality.

Determination of Flaw Type and Location Using an Expert Module in Ultrasonic Nondestructive Testing for Weld Inspection

NASA Astrophysics Data System (ADS)

Shahriari, D.; Zolfaghari, A.; Masoumi, F.

2011-01-01

Nondestructive evaluation is explained as nondestructive testing, nondestructive inspection, and nondestructive examination. It is a desire to determine some characteristic of the object or to determine whether the object contains irregularities, discontinuities, or flaws. Ultrasound based inspection techniques are used extensively throughout industry for detection of flaws in engineering materials. The range and variety of imperfections encountered is large, and critical assessment of location, size, orientation and type is often difficult. In addition, increasing quality requirements of new standards and codes of practice relating to fitness for purpose are placing higher demands on operators. Applying of an expert knowledge-based analysis in ultrasonic examination is a powerful tool that can help assure safety, quality, and reliability; increase productivity; decrease liability; and save money. In this research, an expert module system is coupled with ultrasonic examination (A-Scan Procedure) to determine and evaluate type and location of flaws that embedded during welding parts. The processing module of this expert system is implemented based on EN standard to classify welding defects, acceptance condition and measuring of their location via echo static pattern and image processing. The designed module introduces new system that can automate evaluating of the results of A-scan method according to EN standard. It can simultaneously recognize the number and type of defects, and determine flaw position during each scan.

Characterization of inhomogeneous and anisotropic steel welds by ultrasonic array measurements

NASA Astrophysics Data System (ADS)

Fan, Z.; Lowe, M. J. S.

2013-01-01

Austenitic welds are difficult to inspect non-destructively by ultrasound due to the anisotropic and inhomogeneous material in the weld, which causes spatial deviation of ultrasonic beams. A common way to describe such material is to consider it as transversely isotropic, in which the plane perpendicular to the direction of the grain growth is considered to be isotropic. Therefore a weld performance map which indicates the orientation of the grain growth can be used to describe the material properties in the weld. In our work, we have chosen a weld map based on the parameters of the MINA model which uses the information of the welding procedure and rules for crystalline growth to predict the orientations, and thus has a good physical foundation. We have compared the measured grain orientations for a realistic weld with the predictions from the model. With this model, only a small number of parameters are used to describe the weld properties, therefore enabling the possibility of a well conditioned refining process to determine the weld map from ultrasonic measurements. We have demonstrated the feasibility of doing this, using a ray tracing model, and both simulated and experimental measurements.

Non Destructive Test Dye Penetrant and Ultrasonic on Welding SMAW Butt Joint with Acceptance Criteria ASME Standard

NASA Astrophysics Data System (ADS)

Endramawan, T.; Sifa, A.

2018-02-01

The purpose of this research is to know the type of discontinuity of SMAW welding result and to determine acceptance criteria based on American Society of Mechanical Engineer (ASME) standard. Material used is mild steel 98,71% Fe and 0,212% C with hardness 230 VHN with specimen diameter 20 cm and thickness 1.2 cm which is welded use SMAW butt joint with electrode for rooting LB 52U diameter 2.6 mm, current 70 Ampere and voltage 380 volt, filler used LB 5218 electrode diameter 3.2 mm with current 80 Ampere and 380 volt. The method used to analyze the welded with non destructive test dye penetrant (PT) method to see indication on the surface of the object and Ultrasonic (UT) to see indication on the sub and inner the surface of the object, the result is discontinuity recorded and analyzed and then the discontinuity is determine acceptance criteria based on the American Society of Mechanical Engineer (ASME) standards. The result show the discontinuity of porosity on the surface of the welded and inclusion on sub material used ultrasonic test, all indication on dye penetrant or ultrasonic test if there were rejected of result of welded that there must be gouging on part which rejected and then re-welding.

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.

Characteristics of coated copper wire specimens using high frequency ultrasonic complex vibration welding equipments.

PubMed

Tsujino, J; Ihara, S; Harada, Y; Kasahara, K; Sakamaki, N

2004-04-01

Welding characteristic of thin coated copper wires were studied using 40, 60, 100 kHz ultrasonic complex vibration welding equipments with elliptical to circular vibration locus. The complex vibration systems consisted of a longitudinal-torsional vibration converter and a driving longitudinal vibration system. Polyurethane coated copper wires of 0.036 mm outer diameter and copper plates of 0.3 mm thickness and the other dimension wires were used as welding specimens. The copper wire part is completely welded on the copper substrate and the insulated coating material is driven from welded area to outsides of the wire specimens by high frequency complex vibration.

Multi-mode ultrasonic welding control and optimization

DOEpatents

Tang, Jason C.H.; Cai, Wayne W

2013-05-28

A system and method for providing multi-mode control of an ultrasonic welding system. In one embodiment, the control modes include the energy of the weld, the time of the welding process and the compression displacement of the parts being welded during the welding process. The method includes providing thresholds for each of the modes, and terminating the welding process after the threshold for each mode has been reached, the threshold for more than one mode has been reached or the threshold for one of the modes has been reached. The welding control can be either open-loop or closed-loop, where the open-loop process provides the mode thresholds and once one or more of those thresholds is reached the welding process is terminated. The closed-loop control provides feedback of the weld energy and/or the compression displacement so that the weld power and/or weld pressure can be increased or decreased accordingly.

Apparatus and process for ultrasonic seam welding stainless steel foils

DOEpatents

Leigh, Richard W.

1992-01-01

An ultrasonic seam welding apparatus having a head which is rotated to form contact, preferably rolling contact, between a metallurgically inert coated surface of the head and an outside foil of a plurality of layered foils or work materials. The head is vibrated at an ultrasonic frequency, preferably along a longitudinal axis of the head. The head is constructed to transmit vibration through a contacting surface of the head into each of the layered foils. The contacting surface of the head is preferably coated with aluminum oxide to prevent the head from becoming welded to layered stainless steel foils.

Performance Improvement of Friction Stir Welds by Better Surface Finish

NASA Technical Reports Server (NTRS)

Russell, Sam; Nettles, Mindy

2015-01-01

The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

The evolution of microstructures, corrosion resistance and mechanical properties of AZ80 joints using ultrasonic vibration assisted welding process

NASA Astrophysics Data System (ADS)

Li, Hui; Zhang, Jiansheng

2017-12-01

The evolution of microstructures, corrosion resistance and mechanical properties of AZ80 joints using an ultrasonic vibration assisted welding process is investigated. The results show that, with ultrasonic vibration treatment, a reliable AZ80 joint without defects is obtained. The coarsening α-Mg grains are refined to about 83.5  ±  3.3 µm and the continuous β-Mg17Al12 phases are broken to granular morphology, owing to the acoustic streaming effect and the cavitation effect evoked by ultrasonic vibration. Both immersion and electrochemical test results indicate that the corrosion resistance of the AZ80 joint welded with ultrasonic vibration is improved, attributed to microstructure evolution. With ultrasonic power of 900 W, the maximum tensile strength of an AZ80 specimen is 261  ±  7.5 MPa and fracture occurs near the heat affected zone of the joint.

Modelling welded material for ultrasonic testing using MINA: Theory and applications

NASA Astrophysics Data System (ADS)

Moysan, J.; Corneloup, G.; Chassignole, B.; Gueudré, C.; Ploix, M. A.

2012-05-01

Austenitic steel multi-pass welds exhibit a heterogeneous and anisotropic structure that causes difficulties in the ultrasonic testing. Increasing the material knowledge is a long term research field for LCND laboratory and EDF Les Renardières in France. A specific model has been developed: the MINA model (Modelling an Isotropy from Notebook of Arc welding). Welded material is described in 2D for flat position arc welding with shielded electrode (SMAW) at a functional scale for UT modeling. The grain growth is the result of three physical phenomena: epitaxial growth, influence of temperature gradient, and competition between the grains. The model uses phenomenological rules to combine these three phenomena. A limited number of parameters is used to make the modelling possible from the information written down in a notebook of arc welding. We present all these principles with 10 years' hindsight. To illustrate the model's use, we present conclusions obtained with two recent applications. In conclusion we give also insights on other research topics around this model : inverse problem using a F.E.M. code simulating the ultrasonic propagation, in position welding, 3D prospects, GTAW.

Insights Gained from Ultrasonic Testing of Piping Welds Subjected to the Mechanical Stress Improvement Process

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

Anderson, Michael T.; Cinson, Anthony D.; Crawford, Susan L.

2010-12-01

Pacific Northwest National Laboratory (PNNL) is assisting the United States Nuclear Regulatory Commission (NRC) in developing a position on the management of primary water stress corrosion cracking (PWSCC) in leak-before-break piping systems. Part of this involves determining whether inspections alone, or inspections plus mitigation, are needed. This work addresses the reliability of ultrasonic testing (UT) of cracks that have been mitigated by the mechanical stress improvement process (MSIP). The MSIP has been approved by the NRC (NUREG-0313) since 1986 and modifies residual stresses remaining after welding with compressive, or neutral, stresses near the inner diameter surface of the pipe. Thismore » compressive stress is thought to arrest existing cracks and inhibit new crack formation. To evaluate the effectiveness of the MSIP and the reliability of ultrasonic inspections, flaws were evaluated both before and after MSIP application. An initial investigation was based on data acquired from cracked areas in 325-mm-diameter piping at the Ignalina Nuclear Power Plant (INPP) in Lithuania. In a follow-on exercise, PNNL acquired and evaluated similar UT data from a dissimilar metal weld (DMW) specimen containing implanted thermal fatigue cracks. The DMW specimen is a carbon steel nozzle-to-safe end-to-stainless steel pipe section that simulates a pressurizer surge nozzle. The flaws were implanted in the nozzle-to-safe end Alloy 82/182 butter region. Results are presented on the effects of MSIP on specimen surfaces, and on UT flaw responses.« less

Interfacial Healing and Transport Phenomena Modeling ff Biopolymers

NASA Astrophysics Data System (ADS)

Lebron, Karla

This research focuses on the characterization of bioplastics joined using ultrasonic welding and modeling of temperature distributions and interfacial healing. Polylactic acid (PLA), which is typically derived from starch-rich crops such as corn, was studied. While the measurement of activation energy for interfacial healing at weld interfaces of PLA films has been reported, here, this information is used to predict the weld strength of rigid PLA samples welded by ultrasonics. A characterization of the mechanical properties was completed with a tensile test to determine the effects of amplitude, melt velocity and collapse distance on weld strength. From previous interfacial healing activation energy measurements based on an impulse welding method, it was also possible to predict weld strength. It was found that the most influential parameters were weld time, collapse distance and weld velocity. In general, the model predicted weld strength reasonably well with r2 values between 0.77 and 0.78.

Parametric Investigation on Microstructure and Mechanical Properties of Ultrasonic spot welded Aluminium to Copper sheets

NASA Astrophysics Data System (ADS)

Prasad Satpathy, Mantra; Das Mohapatra, Kasinath; Sahoo, Ananda Kumar; Sahoo, Susanta Kumar

2018-03-01

Ultrasonic welding is one of the promising solid state welding methods which have been widely used to join highly conductive materials like aluminum and copper. Despite these applications in the automotive field, other industries also have a strong interest to adopt this process for joining of various advanced alloys. In some of its applications, poor weld strength and sticking of the workpiece to the tool are issues. Thus, an attempt has been taken in the present study to overcome these issues by performing experiments with a suitable range of weld parameters. The major objectives of this study are to obtain a good joint strength with a reduced sticking phenomenon and microstructure of Al-Cu weld coupons. The results uncovered the mechanical strength of the joint increased up to 0.34 sec of weld time and afterward, it gradually decreased. Meantime, the plastic deformation in the weld zone enhanced the formation of an intermetallic layer of 1.5 μm thick, and it is composed of mainly Al2Cu compound. The temperature evolved during the welding process is also measured by thermocouples to show its relationship with the plastic deformation. The present work exemplifies a finer understanding of the failure behavior of joints and provides an insight of ultrasonic welding towards the improvement in the quality of weld.

Identification of the Quality Spot Welding used Non Destructive Test-Ultrasonic Testing: (Effect of Welding Time)

NASA Astrophysics Data System (ADS)

Sifa, A.; Endramawan, T.; Badruzzaman

2017-03-01

Resistance Spot Welding (RSW) is frequently used as one way of welding is used in the manufacturing process, especially in the automotive industry [4][5][6][7]. Several parameters influence the process of welding points. To determine the quality of a welding job needs to be tested, either by damaging or testing without damage, in this study conducted experimental testing the quality of welding or identify quality of the nugget by using Non-Destructive Test (NDT) -Ultrasonic Testing (UT), in which the identification of the quality of the welding is done with parameter thickness of worksheet after welding using NDT-UT with use same material worksheet and have more thickness of worksheet, the thickness of the worksheet single plate 1mm, with the capability of propagation Ultrasonic Testing (UT) standard limited> 3 mm [1], welding process parameters such as the time difference between 1-10s and the welding current of 8 KV, visually Heat Affected Zone ( HAZ ) have different results due to the length of time of welding. UT uses a probe that is used with a frequency of 4 MHz, diameter 10 mm, range 100 and the couplant used is oil. Identification techniques using drop 6dB, with sound velocity 2267 m / s of Fe, with the result that the effect of the Welding time affect the size of the HAZ, identification with the lowest time 1s show results capable identified joined through NDT - UT.

The detection of tightly closed flaws by nondestructive testing (NDT) methods. [fatigue crack formation in aluminum alloy test specimens

NASA Technical Reports Server (NTRS)

Rummel, W. D.; Rathke, R. A.; Todd, P. H., Jr.; Mullen, S. J.

1975-01-01

Liquid penetrant, ultrasonic, eddy current and X-radiographic techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens in integrally stiffened panel, and weld panel configurations. Fatigue cracks in integrally stiffened panels, lack-of-fusion in weld panels, and fatigue cracks in weld panels were the flaw types used for evaluation. A 2319 aluminum alloy weld filler rod was used for all welding to produce the test specimens. Forty seven integrally stiffened panels containing a total of 146 fatigue cracks, ninety three lack-of-penetration (LOP) specimens containing a total of 239 LOP flaws, and one-hundred seventeen welded specimens containing a total of 293 fatigue cracks were evaluated. Nondestructive test detection reliability enhancement was evaluated during separate inspection sequences in the specimens in the 'as-machined or as-welded', post etched and post proof loaded conditions. Results of the nondestructive test evaluations were compared to the actual flaw size obtained by measurement of the fracture specimens after completing all inspection sequences. Inspection data were then analyzed to provide a statistical basis for determining the flaw detection reliability.

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

PubMed

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

2009-12-01

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

Ultrasonic Sensor Signals and Optimum Path Forest Classifier for the Microstructural Characterization of Thermally-Aged Inconel 625 Alloy

PubMed Central

de Albuquerque, Victor Hugo C.; Barbosa, Cleisson V.; Silva, Cleiton C.; Moura, Elineudo P.; Rebouças Filho, Pedro P.; Papa, João P.; Tavares, João Manuel R. S.

2015-01-01

Secondary phases, such as laves and carbides, are formed during the final solidification stages of nickel-based superalloy coatings deposited during the gas tungsten arc welding cold wire process. However, when aged at high temperatures, other phases can precipitate in the microstructure, like the γ” and δ phases. This work presents an evaluation of the powerful optimum path forest (OPF) classifier configured with six distance functions to classify background echo and backscattered ultrasonic signals from samples of the inconel 625 superalloy thermally aged at 650 and 950 °C for 10, 100 and 200 h. The background echo and backscattered ultrasonic signals were acquired using transducers with frequencies of 4 and 5 MHz. The potentiality of ultrasonic sensor signals combined with the OPF to characterize the microstructures of an inconel 625 thermally aged and in the as-welded condition were confirmed by the results. The experimental results revealed that the OPF classifier is sufficiently fast (classification total time of 0.316 ms) and accurate (accuracy of 88.75% and harmonic mean of 89.52) for the application proposed. PMID:26024416

Ultrasonic sensor signals and optimum path forest classifier for the microstructural characterization of thermally-aged inconel 625 alloy.

PubMed

de Albuquerque, Victor Hugo C; Barbosa, Cleisson V; Silva, Cleiton C; Moura, Elineudo P; Filho, Pedro P Rebouças; Papa, João P; Tavares, João Manuel R S

2015-05-27

Secondary phases, such as laves and carbides, are formed during the final solidification stages of nickel-based superalloy coatings deposited during the gas tungsten arc welding cold wire process. However, when aged at high temperatures, other phases can precipitate in the microstructure, like the γ'' and δ phases. This work presents an evaluation of the powerful optimum path forest (OPF) classifier configured with six distance functions to classify background echo and backscattered ultrasonic signals from samples of the inconel 625 superalloy thermally aged at 650 and 950 °C for 10, 100 and 200 h. The background echo and backscattered ultrasonic signals were acquired using transducers with frequencies of 4 and 5 MHz. The potentiality of ultrasonic sensor signals combined with the OPF to characterize the microstructures of an inconel 625 thermally aged and in the as-welded condition were confirmed by the results. The experimental results revealed that the OPF classifier is sufficiently fast (classification total time of 0.316 ms) and accurate (accuracy of 88.75%" and harmonic mean of 89.52) for the application proposed.

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

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

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

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

Immersion probe arrays for rapid pipeline weld inspection

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

Lebsack, S.; Heckhauser, H.

In 1992, F.H. Gottfeld, Herne, Germany, a member of the SGA Group (Societe Generale de Surveillance) and Krautkramer Branson, Koin, undertook production of a rapid automated ultrasonic testing (UT) system to inspect manually and machine welded pipeline girth welds. The result of the project is a system called MIPA, or multiple immersion probe array. The advantages of using UT to detect certain weld defects have been realized for many years, however for some applications the time required for UT has been a limiting factor. Where time has not been a factor, automated ultrasonic technology has advanced a reliable solution tomore » many inspection problems across a broad industrial base. The recent past has seen the entrance of automated ultrasonic technology into the harsh and demanding environment of pipelay operations, However, the use of these systems has been focused on automated welding processes. Their effectiveness for manual pipeline welding inspection is contested. This is due to the infinite variability of the joint alignment and shape that is unavoidable even when highly skilled welders are used.« less

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

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

Artificial Intelligence Assists Ultrasonic Inspection

NASA Technical Reports Server (NTRS)

Schaefer, Lloyd A.; Willenberg, James D.

1992-01-01

Subtle indications of flaws extracted from ultrasonic waveforms. Ultrasonic-inspection system uses artificial intelligence to help in identification of hidden flaws in electron-beam-welded castings. System involves application of flaw-classification logic to analysis of ultrasonic waveforms.

Determination of the Order of Passes of AN Austenitic Weld by Optimization of AN Inversion Process of Ultrasound Data

NASA Astrophysics Data System (ADS)

Gueudré, C.; Marrec, L. Le; Chekroun, M.; Moysan, J.; Chassignole, B.; Corneloup, G.

2011-06-01

Multipass welds made in austenitic stainless steel, in the primary circuit of nuclear power plants with pressurized water reactors, are characterized by an anisotropic and heterogeneous structure that disturbs the ultrasonic propagation and challenge the ultrasonic non-destructive testing. The simulation in this type of structure is now possible thanks to the MINA code which allows the grain orientation modeling taking into account the welding process, and the ATHENA code to exactly simulate the ultrasonic propagation. We propose studying the case where the order of the passes is unknown to estimate the possibility of reconstructing this important parameter by ultrasound measures. The first results are presented.

Accelerated Post-Weld Natural Ageing in Ultrasonic Welding Aluminium 6111-T4 Automotive Sheet

NASA Astrophysics Data System (ADS)

Chen, Ying-Chun; Prangnell, Phil

In contrast to previously published reports, it is shown that there is an observable HAZ when ultrasonic spot welding (USW) automotive alloys, like AA6111-T4, the severity of which depends on the welding energy. Immediately after welding, softening is seen relative to the T4 condition, but this is rapidly recovered by natural ageing, which masks the presence of a HAZ, and the weld strength eventually exceeds that of the parent material. This behaviour is caused by dissolution of the solute clusters/GPZs in the T4 sheet, due to the high weld temperatures (> 400 °C), combined with accelerated post-weld natural ageing to a more advanced state than in the parent material. Modelling has demonstrated that this accelerated natural ageing behaviour can be attributed to an excess vacancy concentration generated by the USW process.

Ultrasonic probe system for the bore-side inspection of tubes and welds therein

DOEpatents

Cook, K. Von; Koerner, Dan W.; Cunningham, Jr., Robert A.; Murrin, Jr., Horace T.

1977-07-26

A probe system is provided for the bore-side inspection of tube-to-header welds and the like for small diameter tubes. The probe head of the system includes an ultrasonic transmitter-receiver transducer, a separate ultrasonic receiver, a reflector associated with the transducer to properly orient the ultrasonic signal with respect to a tube wall, a baffle to isolate the receiver from the transducer, and means for maintaining the probe head against the tube wall under investigation. Since the probe head must rotate to inspect along a helical path, special ultrasonic signal connections are employed. Through the use of the probe, flaws at either the inner or outer surfaces may be detected.

Ultrasonic seam welding on thin silicon solar cells

NASA Technical Reports Server (NTRS)

Stofel, E. J.

1982-01-01

The ultrathin silicon solar cell has progressed to where it is a serious candidate for future light weight or radiation tolerant spacecraft. The ultrasonic method of producing welds was found to be satisfactory. These ultrathin cells could be handled without breakage in a semiautomated welding machine. This is a prototype of a machine capable of production rates sufficiently large to support spacecraft array assembly needs. For comparative purposes, this project also welded a variety of cells with thicknesses up to 0.23 mm as well as the 0.07 mm ultrathin cells. There was no electrical degradation in any cells. The mechanical pull strength of welds on the thick cells was excellent when using a large welding force. The mechanical strength of welds on thin cells was less since only a small welding force could be used without cracking these cells. Even so, the strength of welds on thin cells appears adequate for array application. The ability of such welds to survive multiyear, near Earth orbit thermal cycles needs to be demonstrated.

Microstructure and Fatigue Properties of Ultrasonic Spot Welded Joints of Aluminum 5754 Alloy

NASA Astrophysics Data System (ADS)

Mirza, F. A.; Macwan, A.; Bhole, S. D.; Chen, D. L.

2016-05-01

The purpose of this investigation was to evaluate the microstructural change, lap shear tensile load, and fatigue resistance of ultrasonic spot welded joints of aluminum 5754 alloy for automotive applications. A unique "necklace"-type structure with very fine equiaxed grains was observed to form along the weld line due to the mechanical interlocking coupled with the occurrence of dynamic recrystallization. The maximum lap shear tensile strength of 85 MPa and the fatigue limit of about 0.5 kN (at 1 × 107 cycles) were achieved. The tensile fracture occurred at the Al/Al interface in the case of lower energy inputs, and at the edge of nugget zone in the case of higher energy inputs. The maximum cyclic stress for the transition of fatigue fracture mode from the transverse through-thickness crack growth to the interfacial failure increased with increasing energy input. Fatigue crack propagation was mainly characterized by the formation of fatigue striations, which usually appeared perpendicular to the fatigue crack propagation.

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 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.

Metallic-packaging fiber Bragg grating sensor based on ultrasonic welding for strain-insensitive temperature measurement

NASA Astrophysics Data System (ADS)

Zhu, Lianqing; Yang, Runtao; Zhang, Yumin; Dong, Mingli; Lou, Xiaoping

2018-04-01

In this paper, a metallic-packaging fiber Bragg grating temperature sensor characterized by a strain insensitive design is demonstrated. The sensor is fabricated by the one-step ultrasonic welding technique using type-II fiber Bragg grating combined with an aluminum alloy substrate. Finite element analysis is used to perform theoretical evaluation. The result of the experiment illustrates that the metallic-packaging temperature sensor is insensitive to longitudinal strain. The sensor's temperature sensitivity is 36 pm/°C over the range of 50-110 °C, with the correlation coefficient (R2) being 0.999. The sensor's temporal response is 40 s at a sudden temperature change from 21 °C to 100 °C. The proposed sensor can be applied on reliable and precise temperature measurement.

Finite element analysis simulations for ultrasonic array NDE inspections

NASA Astrophysics Data System (ADS)

Dobson, Jeff; Tweedie, Andrew; Harvey, Gerald; O'Leary, Richard; Mulholland, Anthony; Tant, Katherine; Gachagan, Anthony

2016-02-01

Advances in manufacturing techniques and materials have led to an increase in the demand for reliable and robust inspection techniques to maintain safety critical features. The application of modelling methods to develop and evaluate inspections is becoming an essential tool for the NDE community. Current analytical methods are inadequate for simulation of arbitrary components and heterogeneous materials, such as anisotropic welds or composite structures. Finite element analysis software (FEA), such as PZFlex, can provide the ability to simulate the inspection of these arrangements, providing the ability to economically prototype and evaluate improved NDE methods. FEA is often seen as computationally expensive for ultrasound problems however, advances in computing power have made it a more viable tool. This paper aims to illustrate the capability of appropriate FEA to produce accurate simulations of ultrasonic array inspections - minimizing the requirement for expensive test-piece fabrication. Validation is afforded via corroboration of the FE derived and experimentally generated data sets for a test-block comprising 1D and 2D defects. The modelling approach is extended to consider the more troublesome aspects of heterogeneous materials where defect dimensions can be of the same length scale as the grain structure. The model is used to facilitate the implementation of new ultrasonic array inspection methods for such materials. This is exemplified by considering the simulation of ultrasonic NDE in a weld structure in order to assess new approaches to imaging such structures.

Ultrasonic Welded Resorbable Mesh (SonicWeld Rx System) in Reconstruction of Segmental Mandibular Defects: Technical Note and Report of 2 Cases.

PubMed

Shanti, Rabie M; Yampolsky, Andrew; Milles, Maano; Braidy, Hani

2015-11-01

The present report describes 2 patients who underwent mandibular reconstruction after segmental mandibulectomy for benign pathology. The potential of an ultrasonic-aided biodegradable system for containment of a nonvascularized bone graft is discussed. Copyright © 2015 American Association of Oral and Maxillofacial Surgeons. Published by Elsevier Inc. All rights reserved.

Comparative testing of radiographic testing, ultrasonic testing and phased array advanced ultrasonic testing non destructive testing techniques in accordance with the AWS D1.5 bridge welding code : [summary].

DOT National Transportation Integrated Search

2014-02-01

To ensure that Florida bridges remain safe and structurally secure for their 50-year-plus service life, they are inspected regularly. For steel bridges, welds critical to the bridges integrity do not even leave the workshop unless they meet rigoro...

Effects of Ultrasonic Nanocrystal Surface Modification on the Residual Stress, Microstructure, and Corrosion Resistance of 304 Stainless Steel Welds

NASA Astrophysics Data System (ADS)

Ye, Chang; Telang, Abhishek; Gill, Amrinder; Wen, Xingshuo; Mannava, Seetha R.; Qian, Dong; Vasudevan, Vijay K.

2018-03-01

In this study, ultrasonic nanocrystal surface modification (UNSM) of 304 stainless steel welds was carried out. UNSM effectively eliminates the tensile stress generated during welding and imparts beneficial compressive residual stresses. In addition, UNSM can effectively refine the grains and increase hardness in the near-surface region. Corrosion tests in boiling MgCl2 solution demonstrate that UNSM can significantly improve the corrosion resistance due to the compressive residual stresses and changes in the near-surface microstructure.

Ultrasonic Stir Welding Development for Ground-Based and In Situ Fabrication and Repair for In-Space Propulsion Systems/Commercial Space Sector

NASA Technical Reports Server (NTRS)

Ding, Jeff

2015-01-01

The completed Center Innovation Fund (CIF) project used the upgraded Ultrasonic Stir Weld (USW) Prototype System (built in 2013/2014) to begin characterizing the weld process using 2219 aluminum (fig. 1). This work is being done in Bldg. 4755 at NASA Marshall Space Flight Center (MSFC). The capabilities of the USW system provides the means to precisely control and document individual welding parameters. The current upgraded system has the following capabilities: (1) Ability to 'pulse' ultrasonic (US) energy on and off and adjust parameters real-time (travel speed, spindle rpm, US amplitude, X and Z axis positions, and plunge and pin axis force; (2) Means to measure draw force; (3) Ability to record US power versus time; (4) Increasing stiffness of Z axis drive and reduce head deflection using laser technology; (5) Adding linear encoder to better control tool penetration setting; (6) Ultrasonic energy integrated into stir rod and containment plate; (7) Maximum 600 rpm; (8) Maximum Z force 15,000 lb; (9) Real-time data acquisition and logging capabilities at a minimum frequency of 10 Hz; and (10) Two separate transducer power supplies operating at 4.5 kW power.

Thin Wall Pipe Ultrasonic Inspection through Paint Coating

NASA Astrophysics Data System (ADS)

Predoi, Mihai Valentin; Petre, Cristian Cătălin

Classical ultrasonic inspection of welds is currently done for plates thicker than 8 mm. The inspection of but welds in thin walled pipes has considerable implementation difficulties, due to guided waves dominating ultrasonic pulses propagation. Generation of purely symmetric modes, either torsional or longitudinal, requires a circumferential uniform distribution of transducers and dedicated inspection equipment, which are increasing the inspection costs. Moreover, if the surface is paint coated, the received signals are close to the detection level. The present work implies a single transducer, coupled to the painted surface. The proper choice of the guided mode and frequency range, allows the detection of a standard, small diameter through thickness hole. In this way, the inspection of pipe welds can use the same equipment as for thick materials, with only wedge adaptation.

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.

Phased Array Ultrasonic Examination of Reactor Coolant System (Carbon Steel-to-CASS) Dissimilar Metal Weld Mockup Specimen

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

Crawford, S. L.; Cinson, A. D.; Diaz, A. A.

2015-11-23

In the summer of 2009, Pacific Northwest National Laboratory (PNNL) staff traveled to the Electric Power Research Institute (EPRI) NDE Center in Charlotte, North Carolina, to conduct phased-array ultrasonic testing on a large bore, reactor coolant pump nozzle-to-safe-end mockup. This mockup was fabricated by FlawTech, Inc. and the configuration originated from the Port St. Lucie nuclear power plant. These plants are Combustion Engineering-designed reactors. This mockup consists of a carbon steel elbow with stainless steel cladding joined to a cast austenitic stainless steel (CASS) safe-end with a dissimilar metal weld and is owned by Florida Power & Light. The objectivemore » of this study, and the data acquisition exercise held at the EPRI NDE Center, were focused on evaluating the capabilities of advanced, low-frequency phased-array ultrasonic testing (PA-UT) examination techniques for detection and characterization of implanted circumferential flaws and machined reflectors in a thick-section CASS dissimilar metal weld component. This work was limited to PA-UT assessments using 500 kHz and 800 kHz probes on circumferential flaws only, and evaluated detection and characterization of these flaws and machined reflectors from the CASS safe-end side only. All data were obtained using spatially encoded, manual scanning techniques. The effects of such factors as line-scan versus raster-scan examination approaches were evaluated, and PA-UT detection and characterization performance as a function of inspection frequency/wavelength, were also assessed. A comparative assessment of the data is provided, using length-sizing root-mean-square-error and position/localization results (flaw start/stop information) as the key criteria for flaw characterization performance. In addition, flaw signal-to-noise ratio was identified as the key criterion for detection performance.« less

Hermetic edge sealing of photovoltaic modules

NASA Astrophysics Data System (ADS)

Nowlan, M. J.

1983-07-01

The feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules was investigated. The fabrication sequence is to attach an aluminum foil "gasket' to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 400 sq cm (8 x 8 s64 sq in) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process.

Hermetic edge sealing of photovoltaic modules

NASA Technical Reports Server (NTRS)

Nowlan, M. J.

1983-01-01

The feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules was investigated. The fabrication sequence is to attach an aluminum foil "gasket' to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 400 sq cm (8 x 8 s64 sq in) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process.

Automated flaw detection scheme for cast austenitic stainless steel weld specimens using Hilbert-Huang transform of ultrasonic phased array data

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

Khan, Tariq; Majumdar, Shantanu; Udpa, Lalita

2012-05-17

The objective of this work is to develop processing algorithms to detect and localize flaws using ultrasonic phased-array data. Data was collected on cast austenitic stainless stell (CASS) weld specimens onloan from the U.S. nuclear power industry' Pressurized Walter Reactor Owners Group (PWROG) traveling specimen set. Each specimen consists of a centrifugally cast stainless stell (CCSS) pipe section welded to a statically cst(SCSS) or wrought (WRSS) section. The paper presents a novel automated flaw detection and localization scheme using low frequency ultrasonic phased array inspection singals from the weld and heat affected zone of the based materials. The major stepsmore » of the overall scheme are preprocessing and region of interest (ROI) detection followed by the Hilbert-Huang transform (HHT) of A-scans in the detected ROIs. HHT offers time-frequency-energy distribution for each ROI. The Accumulation of energy in a particular frequency band is used as a classification feature for the particular ROI.« less

Welds in thermoplastic composite materials

NASA Astrophysics Data System (ADS)

Taylor, N. S.

Welding methods are reviewed that can be effectively used for joining of thermoplastic composites and continuous-fiber thermoplastics. Attention is given to the use of ultrasonic, vibration, hot-plate, resistance, and induction welding techniques. The welding techniques are shown to provide complementary weld qualities for the range of thermoplastic materials that are of interest to industrial and technological applications.

Robotic Welding and Inspection System

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

H. B. Smartt; D. P. Pace; E. D. Larsen

2008-06-01

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

Ultrasonic technique for inspection of GPHS capsule girth weld integrity

NASA Astrophysics Data System (ADS)

Placr, Arnost

1993-05-01

An innovative nondestructive examination (NDE) technique for the inspection of integrity of General Purpose Heat Source (GPHS) capsule girth welds was developed employing a Lamb wave as the mode of the sound propagation. Reliability of the Lamb wave technique was tested on GPHS capsules using plutonium pallet simulators. All ten capsules, which were previously rejected, passed ultrasonic (UT) inspection using the Lamb wave technique.

Dynamics of ultrasonic additive manufacturing.

PubMed

Hehr, Adam; Dapino, Marcelo J

2017-01-01

Ultrasonic additive manufacturing (UAM) is a solid-state technology for joining similar and dissimilar metal foils near room temperature by scrubbing them together with ultrasonic vibrations under pressure. Structural dynamics of the welding assembly and work piece influence how energy is transferred during the process and ultimately, part quality. To understand the effect of structural dynamics during UAM, a linear time-invariant model is proposed to relate the inputs of shear force and electric current to resultant welder velocity and voltage. Measured frequency response and operating performance of the welder under no load is used to identify model parameters. Using this model and in-situ measurements, shear force and welder efficiency are estimated to be near 2000N and 80% when welding Al 6061-H18 weld foil, respectively. Shear force and welder efficiency have never been estimated before in UAM. The influence of processing conditions, i.e., welder amplitude, normal force, and weld speed, on shear force and welder efficiency are investigated. Welder velocity was found to strongly influence the shear force magnitude and efficiency while normal force and weld speed showed little to no influence. The proposed model is used to describe high frequency harmonic content in the velocity response of the welder during welding operations and coupling of the UAM build with the welder. Copyright © 2016 Elsevier B.V. All rights reserved.

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

NASA Astrophysics Data System (ADS)

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

2012-05-01

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

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.

The Effectiveness of Surface Coatings on Preventing Interfacial Reaction During Ultrasonic Welding of Aluminum to Magnesium

NASA Astrophysics Data System (ADS)

Panteli, Alexandria; Robson, Joseph D.; Chen, Ying-Chun; Prangnell, Philip B.

2013-12-01

High power ultrasonic spot welding (USW) is a solid-state joining process that is advantageous for welding difficult dissimilar material couples, like magnesium to aluminum. USW is also a useful technique for testing methods of controlling interfacial reaction in welding as the interface is not greatly displaced by the process. However, the high strain rate deformation in USW has been found to accelerate intermetallic compound (IMC) formation and a thick Al12Mg17 and Al3Mg2 reaction layer forms after relatively short welding times. In this work, we have investigated the potential of two approaches for reducing the IMC reaction rate in dissimilar Al-Mg ultrasonic welds, both involving coatings on the Mg sheet surface to (i) separate the join line from the weld interface, using a 100- μm-thick Al cold spray coating, and (ii) provide a diffusion barrier layer, using a thin manganese physical vapor deposition (PVD) coating. Both methods were found to reduce the level of reaction and increase the failure energy of the welds, but their effectiveness was limited due to issues with coating attachment and survivability during the welding cycle. The effect of the coatings on the joint's interface microstructure, and the fracture behavior have been investigated in detail. Kinetic modeling has been used to show that the benefit of the cold spray coating can be attributed to the reaction rate reverting to that expected under static conditions. This reduces the IMC growth rate by over 50 pct because at the weld line, the high strain rate dynamic deformation in USW normally enhances diffusion through the IMC layer. In comparison, the thin PVD barrier coating was found to rapidly break up early in USW and become dispersed throughout the deformation layer reducing its effectiveness.

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

NASA Astrophysics Data System (ADS)

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

2016-06-01

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

77 FR 57596 - Government-Owned Inventions, Available for Licensing

Federal Register 2010, 2011, 2012, 2013, 2014

2012-09-18

...; NASA Case No.: MFS-32940-1: Weld Nugget Temperature Control in Thermal Stir Welding; NASA Case No.: MFS-31559-2-DIV: Thermal Stir Welding Process; NASA Case No.: MFS-32611-1: Mass Gauging Demonstrator for Any....: MFS-32859-1: Pulsed Ultrasonic Stir Welding System; NASA Case No.: MFS-32655-1: Aerospace Laser...

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.

Automated Laser Ultrasonic Testing (ALUT) of Hybrid Arc Welds for Pipeline Construction, #272

DOT National Transportation Integrated Search

2009-12-22

One challenge in developing new gas reserves is the high cost of pipeline construction. Welding costs are a major component of overall construction costs. Industry continues to seek advanced pipeline welding technologies to improve productivity and s...

Development of a pseudo phased array technique using EMATs for DM weld testing

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

Cobb, Adam C., E-mail: adam.cobb@swri.org; Fisher, Jay L., E-mail: adam.cobb@swri.org; Shiokawa, Nobuyuki

2015-03-31

Ultrasonic inspection of dissimilar metal (DM) welds in piping with cast austenitic stainless steel (CASS) has been an area ongoing research for many years given its prevalence in the petrochemical and nuclear industries. A typical inspection strategy for pipe welds is to use an ultrasonic phased array system to scan the weld from a sensor located on the outer surface of the pipe. These inspection systems generally refract either longitudinal or shear vertical (SV) waves at varying angles to inspect the weld radially. In DM welds, however, the welding process can produce a columnar grain structure in the CASS materialmore » in a specific orientation. This columnar grain structure can skew ultrasonic waves away from their intended path, especially for SV and longitudinal wave modes. Studies have shown that inspection using the shear horizontal (SH) wave mode significantly reduces the effect of skewing. Electromagnetic acoustic transducers (EMATs) are known to be effective for producing SH waves in field settings. This paper presents an inspection strategy that seeks to reproduce the scanning and imaging capabilities of a commercial phase array system using EMATs. A custom-built EMAT was used to collect data at multiple propagation angles, and a processing strategy known as the synthetic aperture focusing technique (SAFT) was used to combine the data to produce an image. Results are shown using this pseudo phased array technique to inspect samples with a DM weld and artificial defects, demonstrating the potential of this approach in a laboratory setting. Recommendations for future work to transition the technique to the field are also provided.« less

Langley Research Center Standard for the Evaluation of Socket Welds

NASA Technical Reports Server (NTRS)

Berry, R. F., Jr.

1985-01-01

A specification utilized for the nondestructive evaluation of socket type pipe joints at Langley Research Center (LaRC) is discussed. The scope of hardware shall include, but is not limited to, all common pipe fittings: tees, elbows, couplings, caps, and so forth, socket type flanges, unions, and valves. In addition, the exterior weld of slip on flanges shall be inspected using this specification. At the discretion of the design engineer, standard practice engineer, Fracture Mechanics Engineering Section, Pressure Systems Committee, or other authority, four nondestructive evaluation techniques may be utilized exclusively, or in combination, to inspect socket type welds. These techniques are visual, radiographic, magnetic particle, and dye penetrant. Under special circumstances, other techniques (such as eddy current or ultrasonics) may be required and their application shall be guided by the appropriate sections of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (B&PVC).

Flight-vehicle materials, structures, and dynamics - Assessment and future directions. Vol. 4 - Tribological materials and NDE

NASA Technical Reports Server (NTRS)

Fusaro, Robert L. (Editor); Achenbach, J. D. (Editor)

1993-01-01

The present volume on tribological materials and NDE discusses liquid lubricants for advanced aircraft engines, a liquid lubricant for space applications, solid lubricants for aeronautics, and thin solid-lubricant films in space. Attention is given to the science and technology of NDE, tools for an NDE engineering base, experimental techniques in ultrasonics for NDE and material characterization, and laser ultrasonics. Topics addressed include thermal methods of NDE and quality control, digital radiography in the aerospace industry, materials characterization by ultrasonic methods, and NDE of ceramics and ceramic composites. Also discussed are smart materials and structures, intelligent processing of materials, implementation of NDE technology on flight structures, and solid-state weld evaluation.

Method and system having ultrasonic sensor movable by translation device for ultrasonic profiling of weld samples

DOEpatents

Panyard, James; Potter, Timothy; Charron, William; Hopkins, Deborah; Reverdy, Frederic

2010-04-06

A system for ultrasonic profiling of a weld sample includes a carriage movable in opposite first and second directions. An ultrasonic sensor is coupled to the carriage to move over the sample as the carriage moves. An encoder determines the position of the carriage to determine the position of the sensor. A spring is connected at one end of the carriage. Upon the carriage being moved in the first direction toward the spring such that the carriage and the sensor are at a beginning position and the spring is compressed the spring decompresses to push the carriage back along the second direction to move the carriage and the sensor from the beginning position to an ending position. The encoder triggers the sensor to take the ultrasonic measurements of the sample when the sensor is at predetermined positions while the sensor moves over the sample between the beginning and positions.

Apparatus for the concurrent inspection of partially completed welds

DOEpatents

Smartt, Herschel B.; Johnson, John A.; Larsen, Eric D.; Bitsoi, Rodney J.; Perrenoud, Ben C.; Miller, Karen S.; Pace, David P.

2002-01-01

An apparatus for the concurrent inspection of partially completed welds is described in which is utilized in combination with a moveable welder for forming a partially completed weld, and an ultrasonic generator mounted on a moveable welder in which is reciprocally moveable along a path of travel which is laterally disposed relative to the partially completed weld.

Applying a nonlinear, pitch-catch, ultrasonic technique for the detection of kissing bonds in friction stir welds.

PubMed

Delrue, Steven; Tabatabaeipour, Morteza; Hettler, Jan; Van Den Abeele, Koen

2016-05-01

Friction stir welding (FSW) is a promising technology for the joining of aluminum alloys and other metallic admixtures that are hard to weld by conventional fusion welding. Although FSW generally provides better fatigue properties than traditional fusion welding methods, fatigue properties are still significantly lower than for the base material. Apart from voids, kissing bonds for instance, in the form of closed cracks propagating along the interface of the stirred and heat affected zone, are inherent features of the weld and can be considered as one of the main causes of a reduced fatigue life of FSW in comparison to the base material. The main problem with kissing bond defects in FSW, is that they currently are very difficult to detect using existing NDT methods. Besides, in most cases, the defects are not directly accessible from the exposed surface. Therefore, new techniques capable of detecting small kissing bond flaws need to be introduced. In the present paper, a novel and practical approach is introduced based on a nonlinear, single-sided, ultrasonic technique. The proposed inspection technique uses two single element transducers, with the first transducer transmitting an ultrasonic signal that focuses the ultrasonic waves at the bottom side of the sample where cracks are most likely to occur. The large amount of energy at the focus activates the kissing bond, resulting in the generation of nonlinear features in the wave propagation. These nonlinear features are then captured by the second transducer operating in pitch-catch mode, and are analyzed, using pulse inversion, to reveal the presence of a defect. The performance of the proposed nonlinear, pitch-catch technique, is first illustrated using a numerical study of an aluminum sample containing simple, vertically oriented, incipient cracks. Later, the proposed technique is also applied experimentally on a real-life friction stir welded butt joint containing a kissing bond flaw. Copyright © 2016 Elsevier B.V. All rights reserved.

Accurate modelling of anisotropic effects in austenitic stainless steel welds

NASA Astrophysics Data System (ADS)

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

2014-02-01

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

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.

Fatigue behavior of welded connections enhanced with ultrasonic impact treatment (UIT) and bolting.

DOT National Transportation Integrated Search

2008-11-01

A common problem in bridges employing welded steel girders is development of fatigue cracks at the ends of girder coverplates. Fatigue cracks tend to form at the toes of the transverse welds connecting a coverplate to a girder flange since this detai...

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

DTIC Science & Technology

2012-06-01

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

Effect of Interfacial Reaction on the Mechanical Performance of Steel to Aluminum Dissimilar Ultrasonic Spot Welds

NASA Astrophysics Data System (ADS)

Xu, Lei; Wang, Li; Chen, Ying-Chun; Robson, Joe D.; Prangnell, Philip B.

2016-01-01

The early stages of formation of intermetallic compounds (IMC) have been investigated in dissimilar aluminum to steel welds, manufactured by high power (2.5 kW) ultrasonic spot welding (USW). To better understand the influence of alloy composition, welds were produced between a low-carbon steel (DC04) and two different aluminum alloys (6111 and 7055). The joint strengths were measured in lap shear tests and the formation and growth behavior of IMCs at the weld interface were characterized by electron microscopy, for welding times from 0.2 to 2.4 seconds. With the material combinations studied, the η (Fe2Al5) intermetallic phase was found to form first, very rapidly in the initial stage of welding, with a discontinuous island morphology. Continuous layers of η and then θ (FeAl3) phase were subsequently seen to develop on extending the welding time to greater than 0.7 second. The IMC layer formed in the DC04-AA7055 combination grew thicker than for the DC04-AA6111 welds, despite both weld sets having near identical thermal histories. Zinc was also found to be dissolved in the IMC phases when welding with the AA7055 alloy. After post-weld aging of the aluminum alloy, fracture in the lap shear tests always occurred along the joint interface; however, the DC04-AA6111 welds had higher fracture energy than the DC04-AA7055 combination.

Toward practical 3D radiography of pipeline girth welds

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

Wassink, Casper, E-mail: casper.wassink@applusrtd.com; Hol, Martijn, E-mail: martijn.hol@applusrtd.com; Flikweert, Arjan, E-mail: martijn.hol@applusrtd.com

2015-03-31

Digital radiography has made its way into in-the-field girth weld testing. With recent generations of detectors and x-ray tubes it is possible to reach the image quality desired in standards as well as the speed of inspection desired to be competitive with film radiography and automated ultrasonic testing. This paper will show the application of these technologies in the RTD Rayscan system. The method for achieving an image quality that complies with or even exceeds prevailing industrial standards will be presented, as well as the application on pipeline girth welds with CRA layers. A next step in development will bemore » to also achieve a measurement of weld flaw height to allow for performing an Engineering Critical Assessment on the weld. This will allow for similar acceptance limits as currently used with Automated Ultrasonic Testing of pipeline girth welds. Although a sufficient sizing accuracy was already demonstrated and qualified in the TomoCAR system, testing in some applications is restricted to time limits. The paper will present some experiments that were performed to achieve flaw height approximation within these time limits.« less

Accurate modelling of anisotropic effects in austenitic stainless steel welds

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

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

2014-02-18

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

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.

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.

Ultrasonic Inspection and Fatigue Evaluation of Critical Pore Size in Welds.

DTIC Science & Technology

1981-09-01

Boiler and Pressure Vessel Code ) 20...Five porosity levels were produced that parallelled ASME boiler and pressure vessel code specification (Section VIII). Appendix IV of the pressure...Figure 2 shows porosity charts (ASME Boiler and Pressure Vessel Code ) which classify and designate the number and size of pores in any six inch length

Ultrasonic weld testing.

DOT National Transportation Integrated Search

1970-12-01

The study was broken down into two phases. Phase I consisted of a laboratory investigation of test specimens to determine the reliability of the ultrasonic equipment and testing procedure. Phase II was a field study where the knowledge, skills and ab...

Decrease of contact resistance at the interface of carbon nanotube/electrode by nanowelding

NASA Astrophysics Data System (ADS)

Zhao, Bo; Wang, Yanfang; Zhang, Yafei

2017-03-01

Reliable interconnection between carbon nanotubes (CNTs) and external circuit is one of the prerequisite in CNT electronics. In this work, ultrasonic nanowelding was used to bond CNTs with metal electrodes. By exerting ultrasonic energy at the interface of CNT/electrode, a reliable joint with negligible contact resistance was obtained between CNTs and electrodes. The performance of welding is susceptible to the ultrasonic parameters such as ultrasonic power and clamping force, as well as the metal type. It is found that the metals with good ductility or low melting point are easier to achieve effective joints. Moreover, interfacial compounds are formed at the welded surface of metal Al and Fe, which is resulted from the interacting and chemical bonding of carbon and metal atoms. After nanowelding, the contact resistance between CNTs and electrode is decreased dramatically, and the two-terminal resistance of the sample approximates to the intrinsic resistance of the CNT itself.

High-frequency ultrasonic wire bonding systems

PubMed

Tsujino; Yoshihara; Sano; Ihara

2000-03-01

The vibration characteristics of longitudinal-complex transverse vibration systems with multiple resonance frequencies of 350-980 kHz for ultrasonic wire bonding of IC, LSI or electronic devices were studied. The complex vibration systems can be applied for direct welding of semiconductor tips (face-down bonding, flip-chip bonding) and packaging of electronic devices. A longitudinal-complex transverse vibration bonding system consists of a complex transverse vibration rod, two driving longitudinal transducers 7.0 mm in diameter and a transverse vibration welding tip. The vibration distributions along ceramic and stainless-steel welding tips were measured at up to 980 kHz. A high-frequency vibration system with a height of 20.7 mm and a weight of less than 15 g was obtained.

Flow accelerated corrosion of carbon steel feeder pipes from pressurized heavy water reactors

NASA Astrophysics Data System (ADS)

Singh, J. L.; Kumar, Umesh; Kumawat, N.; Kumar, Sunil; Kain, Vivekanand; Anantharaman, S.; Sinha, A. K.

2012-10-01

Detailed investigation of a number of feeder pipes received from Rajasthan Atomic Power Station Unit 2 (RAPS#2) after en-masse feeder pipe replacement after 15.67 Effective Full Power Years (EFPYs) was carried out. Investigations included ultrasonic thickness measurement by ultrasonic testing, optical microscopy, scanning electron microscopy, chemical analysis and X-ray Diffraction (XRD). Results showed that maximum thickness reduction of the feeder had occurred downstream and close to the weld in 32 NB (1.25″/32.75 mm ID) elbows. Rate of Flow Accelerated Corrosion (FAC) was measured to be higher in the lower diameter feeder pipes due to high flow velocity and turbulence. Weld regions had thinned to a lower extent than the parent material due to higher chromium content in the weld. A weld protrusion has been shown to add to the thinning due to FAC and lead to faster thinning rate at localized regions. Surface morphology of inner surface of feeder had shown different size scallop pattern over the weld and parent material. Inter-granular cracks were also observed along the weld fusion line and in the parent material in 32 NB outlet feeder elbow.

Studies on thermo-elastic heating of horns used in ultrasonic plastic welding.

PubMed

Roopa Rani, M; Prakasan, K; Rudramoorthy, R

2015-01-01

Ultrasonic welding horn is half wavelength section or tool used to focus the ultrasonic vibrations to the components being welded. The horn is designed in such a way that it maximizes the amplitude of the sound wave passing through it. The ends of the horn represent the displacement anti-nodes and the center the 'node' of the wave. As the horns perform 20,000 cycles of expansion and contraction per second, they are highly stressed at the nodes and are heated owing to thermo-elastic effects. Considerable temperature rise may be observed in the horn, at the nodal region when working at high amplitudes indicating high stress levels leading to failure of horns due to cyclic loading. The limits for amplitude must therefore be evaluated for the safe working of the horn. Horns made of different materials have different thermo-elastic behaviors and hence different temperatures at the nodes and antinodes. This temperature field can be used as a control mechanism for setting the amplitude/weld parameters. Safe stress levels can be predicted using modal and harmonic analyses followed by a stress analysis to study the effect of cyclic loads. These are achieved using 'Ansys'. The maximum amplitude level obtained from the stress analysis is used as input for 'Comsol' to predict the temperature field. The actual temperature developed in the horn during operation is measured using infrared camera and compared with the simulated temperature. From experiments, it is observed that horn made of titanium had the lowest temperature rise at the critical region and can be expected to operate at amplitudes up to 77 μm without suffering failure due to cyclic loading. The method of predicting thermo-elastic stresses and temperature may be adopted by the industry for operating the horn within the safe stress limits thereby extending the life of the horn. Copyright © 2014 Elsevier B.V. All rights reserved.

Ultrasonic fingerprinting by phased array transducer

NASA Astrophysics Data System (ADS)

Sednev, D.; Kataeva, O.; Abramets, V.; Pushenko, P.; Tverdokhlebova, T.

2016-06-01

Increasing quantity of spent nuclear fuel that must be under national and international control requires a novel approach to safeguard techniques and equipment. One of the proposed approaches is utilize intrinsic features of casks with spent fuel. In this article an application of a phased array ultrasonic method is considered. This study describes an experimental results on ultrasonic fingerprinting of austenitic steel seam weld.

Electromagnetic Acoustic Transducers for Robotic Nondestructive Inspection in Harsh Environments.

PubMed

Choi, Sungho; Cho, Hwanjeong; Lindsey, Matthew S; Lissenden, Cliff J

2018-01-11

Elevated temperature, gamma radiation, and geometric constraints inside dry storage casks for spent nuclear fuel represent a harsh environment for nondestructive inspection of the cask and require that the inspection be conducted with a robotic system. Electromagnetic acoustic transducers (EMATs) using non-contact ultrasonic transduction based on the Lorentz force to excite/receive ultrasonic waves are suited for use in the robotic inspection. Periodic permanent magnet EMATs that actuate/receive shear horizontal guided waves are developed for application to robotic nondestructive inspection of stress corrosion cracks in the heat affected zone of welds in stainless steel dry storage canisters. The EMAT's components are carefully selected in consideration of the inspection environment, and tested under elevated temperature and gamma radiation doses up to 177 °C and 5920 krad, respectively, to evaluate the performance of the EMATs under realistic environmental conditions. The effect of gamma radiation is minimal, but the EMAT's performance is affected by temperatures above 121 °C due to the low Curie temperature of the magnets. Different magnets are needed to operate at 177 °C. The EMAT's capability to detect notches is also evaluated from B-scan measurements on 304 stainless steel welded plate containing surface-breaking notches.

Advances in ultrasonic testing of austenitic stainless steel welds. Towards a 3D description of the material including attenuation and optimisation by inversion

NASA Astrophysics Data System (ADS)

Moysan, J.; Gueudré, C.; Ploix, M.-A.; Corneloup, G.; Guy, Ph.; Guerjouma, R. El; Chassignole, B.

In the case of multi-pass welds, the material is very difficult to describe due to its anisotropic and heterogeneous properties. Anisotropy results from the metal solidification and is correlated with the grain orientation. A precise description of the material is one of the key points to obtain reliable results with wave propagation codes. A first advance is the model MINA which predicts the grain orientations in multi-pass 316-L steel welds. For flat position welding, good predictions of the grains orientations were obtained using 2D modelling. In case of welding in position the resulting grain structure may be 3D oriented. We indicate how the MINA model can be improved for 3D description. A second advance is a good quantification of the attenuation. Precise measurements are obtained using plane waves angular spectrum method together with the computation of the transmission coefficients for triclinic material. With these two first advances, the third one is now possible: developing an inverse method to obtain the material description through ultrasonic measurements at different positions.

Computer automation of ultrasonic testing. [inspection of ultrasonic welding

NASA Technical Reports Server (NTRS)

Yee, B. G. W.; Kerlin, E. E.; Gardner, A. H.; Dunmyer, D.; Wells, T. G.; Robinson, A. R.; Kunselman, J. S.; Walker, T. C.

1974-01-01

Report describes a prototype computer-automated ultrasonic system developed for the inspection of weldments. This system can be operated in three modes: manual, automatic, and computer-controlled. In the computer-controlled mode, the system will automatically acquire, process, analyze, store, and display ultrasonic inspection data in real-time. Flaw size (in cross-section), location (depth), and type (porosity-like or crack-like) can be automatically discerned and displayed. The results and pertinent parameters are recorded.

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.

Development of Phased-Array Ultrasonic Testing Acceptability Criteria : (Phase I)

DOT National Transportation Integrated Search

2014-10-01

Phase I of this research effort involved a review of the current state of the art of weld inspection using PAUT, development of the preliminary technical approach to inspecting CJP butt welds with and without transitions, fabrication of suitable test...

Detection and evaluation of weld defects in stainless steel using alternating current field measurement

NASA Astrophysics Data System (ADS)

Wei-Li, Ma, Weiping; Pan-Qi, Wen-jiao, Dou; Yuan, Xin'an; Yin, Xiaokang

2018-04-01

Stainless steel is widely used in nuclear power plants, such as various high-radioactive pool, tools storage and fuel transportation channel, and serves as an important barrier to stop the leakage of high-radioactive material. NonDestructive Evaluation (NDE) methods, eddy current testing (ET), ultrasonic examination (UT), penetration testing (PT) and hybrid detection method, etc., have been introduced into the inspection of a nuclear plant. In this paper, the Alternating Current Field Measurement (ACFM) was fully applied to detect and evaluate the defects in the welds of the stainless steel. Simulations were carried out on different defect types, crack lengths, and orientation to reveal the relationship between the signals and dimensions to determine whether methods could be validated by the experiment. A 3-axis ACFM probe was developed and three plates including 16 defects, which served in nuclear plant before, were examined by automatic detection equipment. The result shows that the minimum detectable crack length on the surface is 2mm and ACFM shows excellent inspection results for a weld in stainless steel and gives an encouraging prospect of broader application.

Pearson's Functions to Describe FSW Weld Geometry

NASA Astrophysics Data System (ADS)

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

2011-01-01

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

Welding of Aluminum Alloys to Steels: An Overview

DTIC Science & Technology

2013-08-01

and deformations are a few examples of the unwanted consequences which somehow would lead to brittle fracture, fatigue fracture, shape instability...was made under the copper tips of the spot welding machine. The fatigue results showed higher fatigue strength of the joints with transition layer...kHz ultrasonic butt welding system with a vibration source applying eight bolt-clamped Langevin type PZT transducers and a 50 kW static induction

Use of Ultrasound in Reconditioning by Welding of Tools Used in the Process of Regenerating Rubber.

PubMed

Dobrotă, Dan; Petrescu, Valentin

2018-02-10

Addressing the problem of reconditioning large parts is of particular importance, due to their value and to the fact that the technologies for their reconditioning are very complex. The tools used to refine regenerated rubber which measure 660 mm in diameter and 2130 mm in length suffer from a rather fast dimensional wear. Within this research, the authors looked for a welding reconditioning procedure that would allow a very good adhesion between the deposited material layer and the base material. In this regard, the MAG (Metal Active Gas) welding process was used, but the ultrasonic activation of the welding process was also considered. Thus, the wire used for welding was activated considering a variation of the frequency of ultrasounds in the range f = 18-22 kHz respectively of the oscillation amplitude A = 30-60 μm. Under these conditions it was found that the presence of ultrasonic waves during the welding cladding process results in uniform deposition of hard carbons at the grain boundary and in the elimination of any existing oxides on the deposition surface, but at the same time increases the adhesion between the base material and the additional material, all of which positively influence the wear and corrosion resistance of the tools used to refine the regenerated rubber.

Sensing the gas metal arc welding process

NASA Technical Reports Server (NTRS)

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

1994-01-01

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

Sensing the gas metal arc welding process

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

Carlson, N.M.; Johnson, J.A.; Smartt, H.B.

1992-01-01

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

Sensing the gas metal arc welding process

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

Carlson, N.M.; Johnson, J.A.; Smartt, H.B.

1992-10-01

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

Ultrasonic Low-Friction Containment Plate for Thermal and Ultrasonic Stir Weld Processes

NASA Technical Reports Server (NTRS)

Graff, Karl; Short, Matt

2013-01-01

The thermal stir welding (TSW) process is finding applications in fabrication of space vehicles. In this process, workpieces to be joined by TSW are drawn, by heavy forces, between "containment plates," past the TSW tool that then causes joining of the separate plates. It is believed that the TSW process would be significantly improved by reducing the draw force, and that this could be achieved by reducing the friction forces between the workpieces and containment plates. Based on use of high-power ultrasonics in metal forming processes, where friction reduction in drawing dies has been achieved, it is believed that ultrasonic vibrations of the containment plates could achieve similar friction reduction in the TSW process. By applying ultrasonic vibrations to the containment plates in a longitudinal vibration mode, as well as by mounting and holding the containment plates in a specific manner such as to permit the plates to acoustically float, friction between the metal parts and the containment plates is greatly reduced, and so is the drawing force. The concept was to bring in the ultrasonics from the sides of the plates, permitting the ultrasonic hardware to be placed to the side, away from the equipment that contains the thermal stir tooling and that applies clamping forces to the plates. Tests demonstrated that one of the major objectives of applying ultrasonics to the thermal stir system, that of reducing draw force friction, should be achievable on a scaled-up system.

Generation of sonic power during welding

NASA Technical Reports Server (NTRS)

Mc Campbell, W. M.

1969-01-01

Generation of intense sonic and ultrasonic power in the weld zone, close to the puddle, reduces the porosity and refinement of the grain. The ac induction brazing power supply is modified with long cables for deliberate addition of resistance to that circuit. The concept is extensible to the molding of metals and plastics.

Quality status display for a vibration welding process

DOEpatents

Spicer, John Patrick; Abell, Jeffrey A.; Wincek, Michael Anthony; Chakraborty, Debejyo; Bracey, Jennifer; Wang, Hui; Tavora, Peter W.; Davis, Jeffrey S.; Hutchinson, Daniel C.; Reardon, Ronald L.; Utz, Shawn

2017-03-28

A system includes a host machine and a status projector. The host machine is in electrical communication with a collection of sensors and with a welding controller that generates control signals for controlling the welding horn. The host machine is configured to execute a method to thereby process the sensory and control signals, as well as predict a quality status of a weld that is formed using the welding horn, including identifying any suspect welds. The host machine then activates the status projector to illuminate the suspect welds. This may occur directly on the welds using a laser projector, or on a surface of the work piece in proximity to the welds. The system and method may be used in the ultrasonic welding of battery tabs of a multi-cell battery pack in a particular embodiment. The welding horn and welding controller may also be part of the system.

Development of Inspection for Friction Stir Welds for Rocket Fuel Tanks

NASA Technical Reports Server (NTRS)

Russell, Samuel S.

2012-01-01

During development of the Ares I weld processes nondestructive and destructive testing were used to identify and characterize defects that occurred. These defects were named and character noted. This catalogue of defects and characteristics was then used to develop inspection methods for Self Reacting Friction Stir Welds (SR ]FSW) and Conventional Friction Stir Welds (C ]FSW). Dye penetrant, eddy current, x ]radiography, single element ultrasonic, and phased array ultrasonic (PAUT) inspection procedures were developed to target the expected defects. Once the method procedure was developed a comparison was performed to allow for selection of the best inspection method. Tests of the effectiveness of the inspection were performed on purposely fabricated flawed specimens and electrodischarge machined notches. The initial test results prompted a revisit of the PAUT procedure and a redesign of the inspection. Subsequent testing showed that a multi ]angle PAUT inspection resulted in better detection capability. A discussion of the most effective orientations of the PAUT transducer will be presented. Also, the implementation of the inspection on production hardware will be presented. In some cases the weld tool is used as the transducer manipulator and in some cases a portable scanner is used

Design of advanced ultrasonic transducers for welding devices.

PubMed

Parrini, L

2001-11-01

A new high frequency ultrasonic transducer has been conceived, designed, prototyped, and tested. In the design phase, an advanced approach was used and established. The method is based on an initial design estimate obtained with finite element method (FEM) simulations. The simulated ultrasonic transducers and resonators are then built and characterized experimentally through laser interferometry and electrical resonance spectra. The comparison of simulation results with experimental data allows the parameters of FEM models to be adjusted and optimized. The achieved FEM simulations exhibit a remarkably high predictive potential and allow full control of the vibration behavior of the transducer. The new transducer is mounted on a wire bonder with a flange whose special geometry was calculated by means of FEM simulations. This flange allows the transducer to be attached on the wire bonder, not only in longitudinal nodes, but also in radial nodes of the ultrasonic field excited in the horn. This leads to a total decoupling of the transducer to the wire bonder, which has not been achieved so far. The new approach to mount ultrasonic transducers on a welding device is of major importance, not only for wire bonding, but also for all high power ultrasound applications and has been patented.

Three-dimensional welding residual stresses evaluation based on the eigenstrain methodology via X-ray measurements at the surface

NASA Astrophysics Data System (ADS)

Ogawa, Masaru

2014-12-01

In order to assure structural integrity for operating welded structures, it is necessary to evaluate crack growth rate and crack propagation direction for each observed crack non-destructively. Here, three dimensional (3D) welding residual stresses must be evaluated to predict crack propagation. Today, X-ray diffraction is used and the ultrasonic method has been proposed as non-destructive method to measure residual stresses. However, it is impossible to determine residual stress distributions in the thickness direction. Although residual stresses through a depth of several tens of millimeters can be evaluated non-destructively by neutron diffraction, it cannot be used as an on-site measurement technique. This is because neutron diffraction is only available in special irradiation facilities. Author pays attention to the bead flush method based on the eigenstrain methodology. In this method, 3D welding residual stresses are calculated by an elastic Finite Element Method (FEM) analysis from eigenstrains which are evaluated by an inverse analysis from released strains by strain gauges in the removal of the reinforcement of the weld. Here, the removal of the excess metal can be regarded as non-destructive treatment because toe of weld which may become crack starters can be eliminated. The effectiveness of the method has been proven for welded plates and pipes even with relatively lower bead height. In actual measurements, stress evaluation accuracy becomes poorer because measured values of strain gauges are affected by processing strains on the machined surface. In the previous studies, the author has developed the bead flush method that is free from the influence of the affecting strains by using residual strains on surface by X-ray diffraction. However, stress evaluation accuracy is not good enough because of relatively poor measurement accuracy of X-ray diffraction. In this study, a method to improve the estimation accuracy of residual stresses in this method is formulated, and it is shown numerically that inner welding residual stresses can be estimated accurately from the residual strains measured by X-ray diffraction.

Progress in composite structure and space construction systems technology

NASA Technical Reports Server (NTRS)

Bodle, J. B.; Jenkins, L. M.

1981-01-01

The development of deployable and fabricated composite trusses for large space structures by NASA and private industry is reviewed. Composite materials technology is discussed with a view toward fabrication processes and the characteristics of finished truss beams. Advances in roll-forming open section caps from graphite-composite strip material and new ultrasonic welding techniques are outlined. Vacuum- and gravity-effect test results show that the ultrasonic welding of graphite-thermoplastic materials in space is feasible. The structural characteristics of a prototype truss segment are presented. A new deployable graphite-composite truss with high packaging density for broad application to large space platforms is described.

Quasi-Rayleigh waves in butt-welded thick steel plate

NASA Astrophysics Data System (ADS)

Kamas, Tuncay; Giurgiutiu, Victor; Lin, Bin

2015-03-01

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

Electromagnetic Acoustic Transducers for Robotic Nondestructive Inspection in Harsh Environments

PubMed Central

Choi, Sungho; Cho, Hwanjeong; Lindsey, Matthew S.; Lissenden, Cliff J.

2018-01-01

Elevated temperature, gamma radiation, and geometric constraints inside dry storage casks for spent nuclear fuel represent a harsh environment for nondestructive inspection of the cask and require that the inspection be conducted with a robotic system. Electromagnetic acoustic transducers (EMATs) using non-contact ultrasonic transduction based on the Lorentz force to excite/receive ultrasonic waves are suited for use in the robotic inspection. Periodic permanent magnet EMATs that actuate/receive shear horizontal guided waves are developed for application to robotic nondestructive inspection of stress corrosion cracks in the heat affected zone of welds in stainless steel dry storage canisters. The EMAT’s components are carefully selected in consideration of the inspection environment, and tested under elevated temperature and gamma radiation doses up to 177 °C and 5920 krad, respectively, to evaluate the performance of the EMATs under realistic environmental conditions. The effect of gamma radiation is minimal, but the EMAT’s performance is affected by temperatures above 121 °C due to the low Curie temperature of the magnets. Different magnets are needed to operate at 177 °C. The EMAT’s capability to detect notches is also evaluated from B-scan measurements on 304 stainless steel welded plate containing surface-breaking notches. PMID:29324721

The effect of advanced ultrasonic forging on fatigue fracture mechanisms of welded Ti-6A1-4V alloy

NASA Astrophysics Data System (ADS)

Smirnova, A.; Pochivalov, Yu.; Panin, V.; Panin, S.; Eremin, A.; Gorbunov, A.

2017-12-01

The current study is devoted to application of advanced postwelding ultrasonic forging to joints formed by laser welding of Ti-6A1-4V alloy in order to enhance their mechanical properties and fatigue durability. Low cycle fatigue tests were performed via digital image correlation technique used to obtain strain fields and in situ characterization of deformation, crack growth and fracture. Fracture surfaces were studied by SEM analysis accompanied with calculation of fracture patterns percentage. The fatigue tests demonstrate the high increase in the number of cycles until fracture (from 17 000 to 32 000 cycles) which could be explained by high ductility of welded material after treatment. This leads to lower fatigue crack growth rate due to higher energy dissipation. The obtained effect is attributable only for small cracks on micro-/mesoscales and fails to play a significant role for macro cracks.

Electroacoustics modeling of piezoelectric welders for ultrasonic additive manufacturing processes

NASA Astrophysics Data System (ADS)

Hehr, Adam; Dapino, Marcelo J.

2016-04-01

Ultrasonic additive manufacturing (UAM) is a recent 3D metal printing technology which utilizes ultrasonic vibrations from high power piezoelectric transducers to additively weld similar and dissimilar metal foils. CNC machining is used intermittent of welding to create internal channels, embed temperature sensitive components, sensors, and materials, and for net shaping parts. Structural dynamics of the welder and work piece influence the performance of the welder and part quality. To understand the impact of structural dynamics on UAM, a linear time-invariant model is used to relate system shear force and electric current inputs to the system outputs of welder velocity and voltage. Frequency response measurements are combined with in-situ operating measurements of the welder to identify model parameters and to verify model assumptions. The proposed LTI model can enhance process consistency, performance, and guide the development of improved quality monitoring and control strategies.

Seam-weld quality of modern ERW/HFI line pipe

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

Groeneveld, T.P.; Barnes, C.R.

1991-09-01

This study was undertaken to determine whether the seam-weld quality of modern ERW (electric resistance-welded)/HFI (high-frequency induction) welded pipe has been improved and justifies more widespread use of this type of pipe in critical applications. Wider use of ERW/HFI line pipe in gas-transmission lines would be expected to reduce construction costs. Five recently produced, heavy wall pipes fabricated using high-frequency electric-resistance welding (ERW) processes to make the seam weld and one pipe fabricated using the high-frequency induction (HFI) welding process to make the seam weld were studied. Four of the pipes were Grade X-60, one was Grade X-65, and onemore » was Grade X-70. All of the pipes were produced from microalloyed, controlled-rolled steels, and the weld zones were post-weld normalized. Ultrasonic inspection of the seam welds in the six pipe sections evaluated revealed no indications of defects. The tensile properties of all of the weld zones exceeded the minimum specified yield strengths for the respective grades of pipe and all of the pipes exhibited ductile failures either in the weld zone or in the base metal. Five of the six pipes exhibited ductile failures either in the weld zone or in the base metal. Five of the six pipes exhibited relatively low 85% shear area transition temperatures and relatively high upper-shelf energy absorptions as determined with Charpy V-notch specimens. In addition, for two of the three joints of pipe for which the properties were determined at both ends of the pipe, the tensile and impact properties showed little variation from end-to-end. However, for the other joint of pipe, the impact properties varied substantially from one end to the other.« less

Ultrasonic Non-destructive Prediction of Spot Welding Shear Strength

NASA Astrophysics Data System (ADS)

Himawan, R.; Haryanto, M.; Subekti, R. M.; Sunaryo, G. R.

2018-02-01

To enhance a corrosion resistant of ferritic steel in reactor pressure vessel, stainless steel was used as a cladding. Bonding process between these two steels may result a inhomogenity either sub-clad crack or un-joined part. To ensure the integrity, effective inspection method is needed for this purpose. Therefore, in this study, an experiment of ultrasonic test for inspection of two bonding plate was performed. The objective of this study is to develop an effective method in predicting the shear fracture load of the join. For simplicity, these joined was modelled with two plate of stainless steel with spot welding. Ultrasonic tests were performed using contact method with 5 MHz in frequency and 10 mm in diameter of transducer. Amplitude of reflected wave from intermediate layer was used as a quantitative parameter. A set of experiment results show that shear fracture load has a linear correlation with amplitude of reflected wave. Besides, amplitude of reflected wave also has relation with nugget diameter. It could be concluded that ultrasonic contact method could be applied in predicting a shear fracture load.

SAFT-assisted sound beam focusing using phased arrays (PA-SAFT) for non-destructive evaluation

NASA Astrophysics Data System (ADS)

Nanekar, Paritosh; Kumar, Anish; Jayakumar, T.

2015-04-01

Focusing of sound has always been a subject of interest in ultrasonic non-destructive evaluation. An integrated approach to sound beam focusing using phased array and synthetic aperture focusing technique (PA-SAFT) has been developed in the authors' laboratory. The approach involves SAFT processing on ultrasonic B-scan image collected by a linear array transducer using a divergent sound beam. The objective is to achieve sound beam focusing using fewer elements than the ones required using conventional phased array. The effectiveness of the approach is demonstrated on aluminium blocks with artificial flaws and steel plate samples with embedded volumetric weld flaws, such as slag and clustered porosities. The results obtained by the PA-SAFT approach are found to be comparable to those obtained by conventional phased array and full matrix capture - total focusing method approaches.

Use of Ultrasound in Reconditioning by Welding of Tools Used in the Process of Regenerating Rubber

PubMed Central

Dobrotă, Dan; Petrescu, Valentin

2018-01-01

Addressing the problem of reconditioning large parts is of particular importance, due to their value and to the fact that the technologies for their reconditioning are very complex. The tools used to refine regenerated rubber which measure 660 mm in diameter and 2130 mm in length suffer from a rather fast dimensional wear. Within this research, the authors looked for a welding reconditioning procedure that would allow a very good adhesion between the deposited material layer and the base material. In this regard, the MAG (Metal Active Gas) welding process was used, but the ultrasonic activation of the welding process was also considered. Thus, the wire used for welding was activated considering a variation of the frequency of ultrasounds in the range f = 18–22 kHz respectively of the oscillation amplitude A = 30–60 μm. Under these conditions it was found that the presence of ultrasonic waves during the welding cladding process results in uniform deposition of hard carbons at the grain boundary and in the elimination of any existing oxides on the deposition surface, but at the same time increases the adhesion between the base material and the additional material, all of which positively influence the wear and corrosion resistance of the tools used to refine the regenerated rubber. PMID:29439400

Passively damped vibration welding system and method

DOEpatents

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

2013-04-02

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

Metallurgical evaluation of a feedwater nozzle to safe-end weld

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

Bowerman, B.S.; Czajkowski, C.J.; Roberts, T.C.

1999-11-01

Weld cracks in safety class systems are a serious concern, because these systems are part of the primary barrier providing containment of radioactive coolant. Loss of weld integrity yields leaks, or, under catastrophic failure, can be the basis for a severe loss of coolant accident. A circumferential indication was found by ultrasonic examination (UT) in the N4A-2 inlet feedwater nozzle to safe-end weld during the second refueling outage of River Bend Station Unit 1 in March 1989. The indication, approximately 15cm (6in) long with a reported maximum depth of 0.5cm (0.1in), was located in the Alloy 182 weld butter onmore » the safe-end side of the weld. (The safe-end base metal was ASME SA 508 Class 1 carbon steel.) The reported characteristics of the UT indication were indicative of intergranular stress corrosion cracking. This indication was reexamined during the second and third fuel cycles in March 1990 and September 1991, respectively, and during the third refuel outage in November 1990. Crack growth was reported during each examination. The safe-end was replaced during the fourth refueling outage in the summer of 1992. The US Nuclear Regulatory Commission (NRC) subsequently contracted with Brookhaven National laboratory (BNL) to conduct a confirmatory investigation to establish the failure mode and determine the root causes of cracking in the safe-end weld.« less

Alternative acceptance criteria of girth weld defects in cross country pipelines. Final report

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

Denys, R.M.; Lefevre, T.

1997-06-01

The failure behaviour of defective girth welds in large diameter pipe lines was assessed using radiographic and mechanised ultrasonic inspection, small scale (tensile, hardness, Charpy and CTOD) and wide plate tests. The specimens were taken from girth welds in API 5LX70 pipe of 1219 mm (48 inches) in diameter by 8,0 mm (0,323 inch) and 13,3 mm (0,524 inch) wall. The test welds were made with the SMAW (8 welds) and GMAW (9 welds) welding processes. Upon completion of the non-destructive tests, 96 curved wide plate specimens were tested to destruction under tensile load. Testing was performed at low temperaturemore » (-50{degrees}C/-58{degrees}F). Defect type, defect position and size were determined from photographs of the fracture face and macro sections (defect characterisation and sizing). In total, 290 typical surface breaking and embedded defects in SMAW or GMAW girth welds have been evaluated. The vast majority of these defects were grossly out of tolerance with respect to current weld quality (workmanship) acceptance levels. To allow the defect tolerance to be determined, the failure strains and stresses were correlated with a defect length determined for an equivalent 3 mm (0, 118 inch) deep defect. This target depth was chosen to represent the average height of one weld pass. The results of this approach have been compared to wall thickness, current workmanship and the EPRG Tier 2 defect limit for planar defects. The defect lengths were derived for rectangular, parabolic and elliptical defect representations.« less

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

NASA Astrophysics Data System (ADS)

Oliveira, N.; Pontes, A. J.

2015-12-01

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

Cold Spray Repair of Martensitic Stainless Steel Components

NASA Astrophysics Data System (ADS)

Faccoli, M.; Cornacchia, G.; Maestrini, D.; Marconi, G. P.; Roberti, R.

2014-12-01

The possibility of using cold spray as repair technique of martensitic stainless steel components was evaluated through laboratory investigations. An austenitic stainless steel feedstock powder was chosen, instead of soft metals powders like nickel, copper, or aluminum, used for repairing components made in light alloy or cast iron. The present study directly compares the microstructure, the residual stresses, and the micro-hardness of repairs obtained by cold spray and by TIG welding, that is commonly used as repair technique in large steel components. XRD and optical metallographic analysis of the repairs showed that cold spray offers some advantages, inducing compressive residual stresses in the repair and avoiding alterations of the interface between repair and base material. For these reasons, a heat treatment after the cold spray repair is not required to restore the base material properties, whereas a post-weld heat treatment is needed after the welding repair. Cold spray repair also exhibits a higher micro-hardness than the welding repair. In addition, the cavitation erosion resistance of a cold spray coating was investigated through ultrasonic cavitation tests, and the samples worn surfaces were observed by scanning electron microscopy.

46 CFR 52.05-20 - Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1).

Code of Federal Regulations, 2010 CFR

2010-10-01

... 46 Shipping 2 2010-10-01 2010-10-01 false Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1). 52.05-20 Section 52.05-20 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING POWER BOILERS Requirements for Boilers Fabricated by Welding § 52.05-20...

46 CFR 52.05-20 - Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1).

Code of Federal Regulations, 2014 CFR

2014-10-01

... 46 Shipping 2 2014-10-01 2014-10-01 false Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1). 52.05-20 Section 52.05-20 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING POWER BOILERS Requirements for Boilers Fabricated by Welding § 52.05-20...

46 CFR 52.05-20 - Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1).

Code of Federal Regulations, 2011 CFR

2011-10-01

... 46 Shipping 2 2011-10-01 2011-10-01 false Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1). 52.05-20 Section 52.05-20 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING POWER BOILERS Requirements for Boilers Fabricated by Welding § 52.05-20...

46 CFR 52.05-20 - Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1).

Code of Federal Regulations, 2012 CFR

2012-10-01

... 46 Shipping 2 2012-10-01 2012-10-01 false Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1). 52.05-20 Section 52.05-20 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING POWER BOILERS Requirements for Boilers Fabricated by Welding § 52.05-20...

46 CFR 52.05-20 - Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1).

Code of Federal Regulations, 2013 CFR

2013-10-01

... 46 Shipping 2 2013-10-01 2013-10-01 false Radiographic and ultrasonic examination (modifies PW-11 and PW-41.1). 52.05-20 Section 52.05-20 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) MARINE ENGINEERING POWER BOILERS Requirements for Boilers Fabricated by Welding § 52.05-20...

NDE of copper canisters for long-term storage of spent nuclear fuel from the Swedish nuclear power plants

NASA Astrophysics Data System (ADS)

Stepinski, Tadeusz

2003-07-01

Sweden has been intensively developing methods for long term storage of spent fuel from the nuclear power plants for twenty-five years. A dedicated research program has been initiated and conducted by the Swedish company SKB (Swedish Nuclear Fuels and Waste Management Co.). After the interim storage SKB plans to encapsulate spent nuclear fuel in copper canisters that will be placed at a deep repository located in bedrock. The canisters filled with fuel rods will be sealed by an electron beam weld. This paper presents three complementary NDE techniques used for assessing the sealing weld in copper canisters, radiography, ultrasound, and eddy current. A powerful X-ray source and a digital detector are used for the radiography. An ultrasonic array system consisting of a phased ultrasonic array and a multi-channel electronics is used for the ultrasonic examination. The array system enables electronic focusing and rapid electronic scanning eliminating the use of a complicated mechanical scanner. A specially designed eddy current probe capable of detecting small voids at the depth up to 4 mm in copper is used for the eddy current inspection. Presently, all the NDE techniques are verified in SKB's Canister Laboratory where full scale canisters are welded and examined.

Quasi-Rayleigh waves in butt-welded thick steel plate

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

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

2015-03-31

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

46 CFR 160.035-6 - Construction of aluminum oar-, hand-, and motor-propelled lifeboats.

Code of Federal Regulations, 2010 CFR

2010-10-01

... is to be heat-treated and checked by X-ray to assure a satisfactory weld. When using 5086-H 112 aluminum, the welded area is to be checked by a nondestructive test method such as X-ray, ultrasonic waves...) Dissimilar metals. (1) Where in the construction of aluminum lifeboats the use of dissimilar metals are...

46 CFR 160.035-6 - Construction of aluminum oar-, hand-, and motor-propelled lifeboats.

Code of Federal Regulations, 2011 CFR

2011-10-01

... is to be heat-treated and checked by X-ray to assure a satisfactory weld. When using 5086-H 112 aluminum, the welded area is to be checked by a nondestructive test method such as X-ray, ultrasonic waves...) Dissimilar metals. (1) Where in the construction of aluminum lifeboats the use of dissimilar metals are...

Propagation characteristics of ultrasonic guided waves in continuously welded rail

NASA Astrophysics Data System (ADS)

Yao, Wenqing; Sheng, Fuwei; Wei, Xiaoyuan; Zhang, Lei; Yang, Yuan

2017-07-01

Rail defects cause numerous railway accidents. Trains are derailed and serious consequences often occur. Compared to traditional bulk wave testing, ultrasonic guided waves (UGWs) can provide larger monitoring ranges and complete coverage of the waveguide cross-section. These advantages are of significant importance for the non-destructive testing (NDT) of the continuously welded rail, and the technique is therefore widely used in high-speed railways. UGWs in continuous welded rail (CWR) and their propagation characteristics have been discussed in this paper. Finite element methods (FEMs) were used to accomplish a vibration modal analysis, which is extended by a subsequent dispersion analysis. Wave structure features were illustrated by displacement profiles. It was concluded that guided waves have the ability to detect defects in the rail via choice of proper mode and frequency. Additionally, thermal conduction that is caused by temperature variation in the rail is added into modeling and simulation. The results indicated that unbalanced thermal distribution may lead to the attenuation of UGWs in the rail.

Laser ablated micropillar energy directors for ultrasonic welding of microfluidic systems

NASA Astrophysics Data System (ADS)

Esben Poulsen, Carl; Kistrup, Kasper; Korsgaard Andersen, Nis; Taboryski, Rafael; Fougt Hansen, Mikkel; Wolff, Anders

2016-06-01

We present a new type of energy director (ED) for ultrasonic welding of microfluidic systems. These micropillar EDs are based on the replication of cone like protrusion structures introduced using a pico-second laser and may therefore be added to any mould surface accessible to a pico-second laser beam. The technology is demonstrated on an injection moulded microfluidic device featuring high-aspect ratio (h  ×  w  =  2000 μm  ×  550 μm) and free-standing channel walls, where bonding is achieved with no detectable channel deformation. The bonding strength is similar to conventional EDs and the fabricated system can withstand pressures of over 9.5 bar.

A study on pseudo interface wave technique for CRDM weld defects in nuclear power plants

NASA Astrophysics Data System (ADS)

Lee, Jaesun; Park, Junpil; Cho, Younho; Huh, Hyung; Park, Keun-Bae; Kim, Dong-Ok

2015-03-01

The nuclear power plant inspection is very important for the safety issue. However due to some radiation and geometric problems, the detection of CRDM(Control Rod Drive Mechanism) can be very difficult by using conventional Ultrasonic Testing method. Also the shrink fit boundary condition can also be an obstacle for the inspection in this paper, instead of conventional Ultrasonic Testing, guided wave was used for the detection of some complicated structures. The CRDM nozzle was installed in reactor head with perfect shrink fit condition by using stainless steel. The wave amplitude distribution on the circumferential direction was calculated with various boundary conditions and the experimental result shows a possibility of the defect detection on J-groove weld.

Configurations of high-frequency ultrasonics complex vibration systems for packaging in microelectronics.

PubMed

Tsujino, Jiromaru; Harada, Yoshiki; Ihara, Shigeru; Kasahara, Kohei; Shimizu, Masanori; Ueoka, Tetsugi

2004-04-01

Ultrasonic high-frequency complex vibrations are effective for various ultrasonic high-power applications. Three types of ultrasonic complex vibration system with a welding tip vibrating elliptical to circular locus for packaging in microelectronics were studied. The complex vibration sources are using (1) a longitudinal-torsional vibration converter with diagonal slits that is driven only by a longitudinal vibration source, (2) a complex transverse vibration rod with several stepped parts that is driven by two longitudinal vibration source crossed at a right angle and (3) a longitudinal vibration circular disk and three longitudinal transducers that are installed at the circumference of the disk.

Assessment of NDE Methods to Detect Lack of Fusion in HDPE Butt Fusion Joints

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

Crawford, Susan L.; Doctor, Steven R.; Cinson, Anthony D.

2011-07-31

Studies at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington, were conducted to evaluate nondestructive examinations (NDE) coupled with mechanical testing of butt fusion joints in high-density polyethylene (HDPE) pipe for assessing lack of fusion. The work provided information to the United States Nuclear Regulatory Commission (NRC) on the effectiveness of volumetric inspection techniques of HDPE butt fusion joints in Section III, Division 1, Class 3, buried piping systems in nuclear power plants. This paper describes results from assessments using ultrasonic and microwave nondestructive techniques and mechanical testing with the high-speed tensile impact test and the side-bend test formore » determining joint integrity. A series of butt joints were fabricated in 3408, 12-inch (30.5-cm) IPS DR-11 HDPE material by varying the fusion parameters to create good joints and joints containing a range of lack-of-fusion conditions. Six of these butt joints were volumetrically examined with time-of-flight diffraction (TOFD), phased-array (PA) ultrasound, and the Evisive microwave system. The outer diameter (OD) weld beads were removed for microwave evaluation and the pipes ultrasonically re-evaluated. In two of the six pipes, both the outer and inner diameter (ID) weld beads were removed and the pipe joints re-evaluated. Some of the pipes were sectioned and the joints destructively evaluated with the high-speed tensile test and the side-bend test. The fusion parameters, nondestructive and destructive evaluation results have been correlated to validate the effectiveness of what each NDE technology detects and what each does not detect. There was no single NDE method that detected all of the lack-of-fusion flaws but a combination of NDE methods did detect most of the flaws.« less

Improvement of bonding properties of laser transmission welded, dissimilar thermoplastics by plasma surface treatment

NASA Astrophysics Data System (ADS)

Hopmann, Ch.; Weber, M.; Schöngart, M.; Sooriyapiragasam, S.; Behm, H.; Dahlmann, R.

2015-05-01

Compared to different welding methods such as ultrasonic welding, laser transmission welding is a relatively new technology to join thermoplastic parts. The most significant advantages over other methods are the contactless energy input which can be controlled very precisely and the low mechanical loads on the welded parts. Therefore, laser transmission welding is used in various areas of application, for example in medical technology or for assembling headlights in the automotive sector. However, there are several challenges in welding dissimilar thermoplastics. This may be due to different melting points on the one hand and different polarities on the other hand. So far these problems are faced with the intermediate layer technique. In this process a layer bonding together the two components is placed between the components. This means that an additional step in the production is needed to apply the extra layer. To avoid this additional step, different ways of joining dissimilar thermoplastics are investigated. In this regard, the improvement in the weldability of the dissimilar thermoplastics polyamide 6 (PA 6) and polypropylene (PP) by means of plasma surface modification and contour welding is examined. To evaluate the influence of the plasma surface modification process on the subsequent welding process of the two dissimilar materials, the treatment time as well as the storage time between treatment and welding are varied. The treatment time in pulsed micro wave excited oxygen plasmas with an electron density of about 1x1017 m-3 is varied from 0.5 s to 120 s and the time between treatment and welding is varied from a few minutes up to a week. As reference, parts being made of the same polymer (PP and PA 6) are welded and tested. For the evaluation of the results of the welding experiments, short-time tensile tests are used to determine the bond strength. Without plasma treatment the described combination of PA 6/PP cannot be welded with sufficient bond strength to withstand handling of the samples. In contrast, the tear-out force of previously plasma treated samples can be determined to up to 1400 N. The achieved bond strengths are higher than of untreated PP/PP welded parts (about 1000 N).

Improvement of bonding properties of laser transmission welded, dissimilar thermoplastics by plasma surface treatment

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

Hopmann, Ch.; Weber, M.; Schöngart, M.

2015-05-22

Compared to different welding methods such as ultrasonic welding, laser transmission welding is a relatively new technology to join thermoplastic parts. The most significant advantages over other methods are the contactless energy input which can be controlled very precisely and the low mechanical loads on the welded parts. Therefore, laser transmission welding is used in various areas of application, for example in medical technology or for assembling headlights in the automotive sector. However, there are several challenges in welding dissimilar thermoplastics. This may be due to different melting points on the one hand and different polarities on the other hand.more » So far these problems are faced with the intermediate layer technique. In this process a layer bonding together the two components is placed between the components. This means that an additional step in the production is needed to apply the extra layer. To avoid this additional step, different ways of joining dissimilar thermoplastics are investigated. In this regard, the improvement in the weldability of the dissimilar thermoplastics polyamide 6 (PA 6) and polypropylene (PP) by means of plasma surface modification and contour welding is examined. To evaluate the influence of the plasma surface modification process on the subsequent welding process of the two dissimilar materials, the treatment time as well as the storage time between treatment and welding are varied. The treatment time in pulsed micro wave excited oxygen plasmas with an electron density of about 1x10{sup 17} m{sup −3} is varied from 0.5 s to 120 s and the time between treatment and welding is varied from a few minutes up to a week. As reference, parts being made of the same polymer (PP and PA 6) are welded and tested. For the evaluation of the results of the welding experiments, short-time tensile tests are used to determine the bond strength. Without plasma treatment the described combination of PA 6/PP cannot be welded with sufficient bond strength to withstand handling of the samples. In contrast, the tear-out force of previously plasma treated samples can be determined to up to 1400 N. The achieved bond strengths are higher than of untreated PP/PP welded parts (about 1000 N)« less

Semiconductor measurement technology: Microelectronic ultrasonic bonding

NASA Technical Reports Server (NTRS)

Harman, G. G. (Editor)

1974-01-01

Information for making high quality ultrasonic wire bonds is presented as well as data to provide a basic understanding of the ultrasonic systems used. The work emphasizes problems and methods of solving them. The required measurement equipment is first introduced. This is followed by procedures and techniques used in setting up a bonding machine, and then various machine- or operator-induced reliability problems are discussed. The characterization of the ultrasonic system and its problems are followed by in-process bonding studies and work on the ultrasonic bonding (welding) mechanism. The report concludes with a discussion of various effects of bond geometry and wire metallurgical characteristics. Where appropriate, the latest, most accurate value of a particular measurement has been substituted for an earlier reported one.

Solid State Welding Development at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Ding, Robert J.; Walker, Bryant

2012-01-01

What is TSW and USW? TSW is a solid state weld process consisting of an induction coil heating source, a stir rod, and non-rotating containment plates Independent heating, stirring and forging controls Decouples the heating, stirring and forging process elements of FSW. USW is a solid state weld process consisting of an induction coil heating source, a stir rod, and a non-rotating containment plate; Ultrasonic energy integrated into non-rotating containment plate and stir rod; Independent heating, stirring and forging controls; Decouples the heating, stirring and forging process elements of FSW.

Detection and Sizing of Fatigue Cracks in Steel Welds with Advanced Eddy Current Techniques

NASA Astrophysics Data System (ADS)

Todorov, E. I.; Mohr, W. C.; Lozev, M. G.

2008-02-01

Butt-welded specimens were fatigued to produce cracks in the weld heat-affected zone. Advanced eddy current (AEC) techniques were used to detect and size the cracks through a coating. AEC results were compared with magnetic particle and phased-array ultrasonic techniques. Validation through destructive crack measurements was also conducted. Factors such as geometry, surface treatment, and crack tightness interfered with depth sizing. AEC inspection techniques have the potential of providing more accurate and complete sizing flaw data for manufacturing and in-service inspections.

Modelling and control for laser based welding processes: modern methods of process control to improve quality of laser-based joining methods

NASA Astrophysics Data System (ADS)

Zäh, Ralf-Kilian; Mosbach, Benedikt; Hollwich, Jan; Faupel, Benedikt

2017-02-01

To ensure the competitiveness of manufacturing companies it is indispensable to optimize their manufacturing processes. Slight variations of process parameters and machine settings have only marginally effects on the product quality. Therefore, the largest possible editing window is required. Such parameters are, for example, the movement of the laser beam across the component for the laser keyhole welding. That`s why it is necessary to keep the formation of welding seams within specified limits. Therefore, the quality of laser welding processes is ensured, by using post-process methods, like ultrasonic inspection, or special in-process methods. These in-process systems only achieve a simple evaluation which shows whether the weld seam is acceptable or not. Furthermore, in-process systems use no feedback for changing the control variables such as speed of the laser or adjustment of laser power. In this paper the research group presents current results of the research field of Online Monitoring, Online Controlling and Model predictive controlling in laser welding processes to increase the product quality. To record the characteristics of the welding process, tested online methods are used during the process. Based on the measurement data, a state space model is ascertained, which includes all the control variables of the system. Depending on simulation tools the model predictive controller (MPC) is designed for the model and integrated into an NI-Real-Time-System.

Plastic deformation and wave formation on the interface of metals welded by ultrasound-assisted explosive welding

NASA Astrophysics Data System (ADS)

Kuz'min, E. V.; Kuz'min, S. V.; Lysak, V. I.; Lata, A. N.

2017-10-01

This paper presents the influence of the effect of ultrasound on the wave formation and plastic deformation in the metals welded by ultrasound-assisted explosive welding. It has been established that the influence of high-frequency acoustic waves on the metal leads to a reduction of the dynamic yield stress, which in turn leads to changes in the properties of the surface layers of metal and in the conditions of bonding between the collided plates upon 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 is 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 behind the point of contact.

Improvement of carbon nanotube field emission properties by ultrasonic nanowelding

NASA Astrophysics Data System (ADS)

Zhao, Bo; Yadian, Boluo; Chen, Da; Xu, Dong; Zhang, Yafei

2008-12-01

Ultrasonic nanowelding was used to improve the field emission properties of carbon nanotube (CNT) cathodes. The CNTs were deposited on the Ti-coated glass substrate by electrophoretic deposition. By pressing CNTs against metal (Ti) substrate under a vibrating force at ultrasonic frequency, a reliable and low resistance contact was obtained between CNTs and Ti. The scanning electron microscopy results show that CNTs are embedded into the metal substrate and act as stable field emitters. The welded cathode demonstrates an excellent field emission with high emission current density and good current stability.

Development of an ultrasonic weld inspection system based on image processing and neural networks

NASA Astrophysics Data System (ADS)

Roca Barceló, Fernando; Jaén del Hierro, Pedro; Ribes Llario, Fran; Real Herráiz, Julia

2018-04-01

Several types of discontinuities and defects may be present on a weld, thus leading to a considerable reduction of its resistance. Therefore, ensuring a high welding quality and reliability has become a matter of key importance for many construction and industrial activities. Among the non-destructive weld testing and inspection techniques, the time-of-flight diffraction (TOFD) arises as a very safe (no ionising radiation), precise, reliable and versatile practice. However, this technique presents a relevant drawback, associated to the appearance of speckle noise that should be addressed. In this regard, this paper presents a new, intelligent and automatic method for weld inspection and analysis, based on TOFD, image processing and neural networks. The developed system is capable of detecting weld defects and imperfections with accuracy, and classify them into different categories.

Fatigue flaw growth and NDI evaluation for preventing through cracks in spacecraft tankage structures

NASA Technical Reports Server (NTRS)

Pettit, D. E.; Hoeppner, D. W.

1972-01-01

A program was conducted to determine the fatigue-crack propagation behavior of parent and welded 2219-T87 aluminum alloy sheet under controlled cyclic stress conditions in room temperature air and 300 F air. Specimens possessing an initial surface defect of controlled dimensions were cycled under constant load amplitude until the propagating fatigue crack penetrated the back surface of the specimen. A series of precracked specimens were prepared to determine optimum penetrant, X-ray, ultrasonic, and eddy current nondestructive inspection procedures.

Processing ultrasonic inspection data from multiple scan patterns for turbine rotor weld build-up evaluations

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

Guan, Xuefei; Zhou, S. Kevin; Rasselkorde, El Mahjoub

The study presents a data processing methodology for weld build-up using multiple scan patterns. To achieve an overall high probability of detection for flaws with different orientations, an inspection procedure with three different scan patterns is proposed. The three scan patterns are radial-tangential longitude wave pattern, axial-radial longitude wave pattern, and tangential shear wave pattern. Scientific fusion of the inspection data is implemented using volume reconstruction techniques. The idea is to perform spatial domain forward data mapping for all sampling points. A conservative scheme is employed to handle the case that multiple sampling points are mapped to one grid location.more » The scheme assigns the maximum value for the grid location to retain the largest equivalent reflector size for the location. The methodology is demonstrated and validated using a realistic ring of weld build-up. Tungsten balls and bars are embedded to the weld build-up during manufacturing process to represent natural flaws. Flat bottomed holes and side drilled holes are installed as artificial flaws. Automatic flaw identification and extraction are demonstrated. Results indicate the inspection procedure with multiple scan patterns can identify all the artificial and natural flaws.« less

Processing ultrasonic inspection data from multiple scan patterns for turbine rotor weld build-up evaluations

NASA Astrophysics Data System (ADS)

Guan, Xuefei; Rasselkorde, El Mahjoub; Abbasi, Waheed; Zhou, S. Kevin

2015-03-01

The study presents a data processing methodology for weld build-up using multiple scan patterns. To achieve an overall high probability of detection for flaws with different orientations, an inspection procedure with three different scan patterns is proposed. The three scan patterns are radial-tangential longitude wave pattern, axial-radial longitude wave pattern, and tangential shear wave pattern. Scientific fusion of the inspection data is implemented using volume reconstruction techniques. The idea is to perform spatial domain forward data mapping for all sampling points. A conservative scheme is employed to handle the case that multiple sampling points are mapped to one grid location. The scheme assigns the maximum value for the grid location to retain the largest equivalent reflector size for the location. The methodology is demonstrated and validated using a realistic ring of weld build-up. Tungsten balls and bars are embedded to the weld build-up during manufacturing process to represent natural flaws. Flat bottomed holes and side drilled holes are installed as artificial flaws. Automatic flaw identification and extraction are demonstrated. Results indicate the inspection procedure with multiple scan patterns can identify all the artificial and natural flaws.

Ultrasonic Processing of Materials

NASA Astrophysics Data System (ADS)

Han, Qingyou

2015-08-01

Irradiation of high-energy ultrasonic vibration in metals and alloys generates oscillating strain and stress fields in solids, and introduces nonlinear effects such as cavitation, acoustic streaming, and radiation pressure in molten materials. These nonlinear effects can be utilized to assist conventional material processing processes. This article describes recent research at Oak Ridge National Labs and Purdue University on using high-intensity ultrasonic vibrations for degassing molten aluminum, processing particulate-reinforced metal matrix composites, refining metals and alloys during solidification process and welding, and producing bulk nanostructures in solid metals and alloys. Research results suggest that high-intensity ultrasonic vibration is capable of degassing and dispersing small particles in molten alloys, reducing grain size during alloy solidification, and inducing nanostructures in solid metals.

Development of low-cost welding procedures for thick sections of HY-150 steel

NASA Technical Reports Server (NTRS)

Schmidt, P. M.; Snow, R. S.

1972-01-01

Low cost welding procedures were developed for welding 6-inch thick HY-150 steel to be used in the manufacture of large diameter motor case Y rings and nozzle attachment flanges. An extensive investigation was made of the mechanical and metallurgical properties and fracture toughness of HY-150 base plate and welds made with manual shielded metal arc process and semi-automatic gas metal arc process in the flat position. Transverse tensiles, all-weld metal tensiles, Charpy V-notch specimens and edge notched bend specimens were tested in the course of the program. In addition metallographic studies and hardness tests were performed on the weld, weld HAZ and base metal. The results of the work performed indicate that both the shielded metal arc and gas metal arc processes are capable of producing consistently sound welds as determined by radiographic and ultrasonic inspection. In addition, the weld metal, deposited by each process was found to exhibit a good combination of strength and toughness such that the selection of a rolled and welded procedure for fabricating rocket motor case components would appear to be technically feasible.

Correlation analysis of the variation of weld seam and tensile strength in laser welding of galvanized steel

NASA Astrophysics Data System (ADS)

Sinha, Amit Kumar; Kim, Duck Young; Ceglarek, Darek

2013-10-01

Many advantages of laser welding technology such as high speed and non-contact welding make the use of the technology more attractive in the automotive industry. Many studies have been conducted to search the optimal welding condition experimentally that ensure the joining quality of laser welding that relies both on welding system configuration and welding parameter specification. Both non-destructive and destructive techniques, for example, ultrasonic inspection and tensile test are widely used in practice for estimating the joining quality. Non-destructive techniques are attractive as a rapid quality testing method despite relatively low accuracy. In this paper, we examine the relationship between the variation of weld seam and tensile shear strength in the laser welding of galvanized steel in a lap joint configuration in order to investigate the potential of the variation of weld seam as a joining quality estimator. From the experimental analysis, we identify a trend in between maximum tensile shear strength and the variation of weld seam that clearly supports the fact that laser welded parts having larger variation in the weld seam usually have lower tensile strength. The discovered relationship leads us to conclude that the variation of weld seam can be used as an indirect non-destructive testing method for estimating the tensile strength of the welded parts.

Development of Real Time Ultrasonic Imaging

DTIC Science & Technology

1999-01-01

piezoelectric material known as poly vinyl difluoride ( PVDF ) which enables the conversion of mechanical energy to charge the CCD chip. The system...geometries such as curved (wing) surfaces. Other future applications might include heavy gauge welds in plate, corrosion in piping, welds in piping...Harrison, G. "A Novel High Speed, High Resolution Ultrasound Imaging System", QNDE Review of Progress In Quantitative NDE, Plenum Press, Volume 17B, pp

Quality improvement of polymer parts by laser welding

NASA Astrophysics Data System (ADS)

Puetz, Heidrun; Treusch, Hans-Georg; Welz, M.; Petring, Dirk; Beyer, Eckhard; Herziger, Gerd

1994-09-01

The growing significance of laser technology in industrial manufacturing is also observed in case of plastic industry. Laser cutting and marking are established processes. Laser beam welding is successfully practiced in processes like joining foils or winding reinforced prepregs. Laser radiation and its significant advantages of contactless and local heating could even be an alternative to conventional welding processes using heating elements, vibration or ultrasonic waves as energy sources. Developments in the field of laser diodes increase the interest in laser technology for material processing because in the near future they will represent an inexpensive energy source.

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

NASA Technical Reports Server (NTRS)

1980-01-01

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

NASA welding assessment program

NASA Technical Reports Server (NTRS)

Stofel, E. J.

1984-01-01

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

Contributions to study of the stability of the electric welding arc under the action of acoustic pressure

NASA Technical Reports Server (NTRS)

Petru, S.

1974-01-01

During the treatment of an electric welding arc with ultrasonic oscillations, an improvement was found in overall source-arc stability. Theoretical explanations are provided for this phenomenon and formulas of equivalence between the classical arc and the treated arc are derived, taking stability as their criterion. A knowledge of this phenomenon can be useful in extending the applications of ultrasounds to different forms of electric arcs.

Design and some practical applications of ultrasonic transducers with axicon lenses

NASA Astrophysics Data System (ADS)

Katchadjian, P.; Desimone, C.; Garcia, A.

2013-01-01

In this paper the applications, detailed in previous papers, referred to ultrasonic transducers with the addition of axicon lenses are extended. Axicon lenses, both contact and immersion, for normal and angular incidence were manufactured, in order to study defectology in welds and other components. For immersion transducers, as had already been made for contact transducers, signal amplitude in function of the depth of the reflector and transverse acoustic pressure at the focus were measured. For this purpose a small metallic sphere submerged in different fluids was used. Several practical applications are shown where it is possible to exploit the advantages that these transducers offer: high resolution measurements for corrosion, laminations and thickness reduction. Discrimination between a weld root and a defect very close to it, etc. Measurements in anisotropic materials (composites) in order to achieve an SNR improvement.

A review of recent developments in joining high-performance thermoplastic composites

NASA Astrophysics Data System (ADS)

Cole, K. C.

1991-06-01

There is currently a great deal of interest in the use of thermoplastic polymers as matrices in fiber reinforced composites for high performance applications, such as those encountered in the aerospace industry. These materials include polyether ether ketone (PEEK), polyphenylene sulphide (PPS), polyetherimide (PEI), polyamideimide (PAI), polyamides, polyimides, and polysulphones. A literature review is provided on the different ways of joining high performance thermoplastic composites by adhesive and fusion bonding. The discussion on adhesive bonding includes examination of the performance of specific adhesive/thermoplastic combinations and of techniques for the preparation of composite surfaces: abrasion, etching, flame, and plasma treatments. Thermoplastic composite welding techniques discussed in depth include the following: heated press welding, resistance welding, induction welding, and ultrasonic welding. Works which examine or compare applications for these bonding techniques are also reviewed.

The algorithm of verification of welding process for plastic pipes

NASA Astrophysics Data System (ADS)

Rzasinski, R.

2017-08-01

The study analyzes the process of butt welding of PE pipes in terms of proper selection of connector parameters. The process was oriented to the elements performed as a series of types of pipes. Polymeric materials commonly referred to as polymers or plastics, synthetic materials are produced from oil products in the polyreaction compounds of low molecular weight, called monomers. During the polyreactions monomers combine to build a macromolecule material monomer named with the prefix poly polypropylene, polyethylene or polyurethane, creating particles in solid state on the order of 0,2 to 0,4 mm. Finished products from polymers of virtually any shape and size are obtained by compression molding, injection molding, extrusion, laminating, centrifugal casting, etc. Weld can only be a thermoplastic that softens at an elevated temperature, and thus can be connected via a clamp. Depending on the source and method of supplying heat include the following welding processes: welding contact, radiant welding, friction welding, dielectric welding, ultrasonic welding. The analysis will be welding contact. In connection with the development of new generation of polyethylene, and the production of pipes with increasing dimensions (diameter, wall thickness) is important to select the correct process.

Diffractive beam shaping for enhanced laser polymer welding

NASA Astrophysics Data System (ADS)

Rauschenberger, J.; Vogler, D.; Raab, C.; Gubler, U.

2015-03-01

Laser welding of polymers increasingly finds application in a large number of industries such as medical technology, automotive, consumer electronics, textiles or packaging. More and more, it replaces other welding technologies for polymers, e. g. hot-plate, vibration or ultrasonic welding. At the same rate, demands on the quality of the weld, the flexibility of the production system and on processing speed have increased. Traditionally, diode lasers were employed for plastic welding with flat-top beam profiles. With the advent of fiber lasers with excellent beam quality, the possibility to modify and optimize the beam profile by beam-shaping elements has opened. Diffractive optical elements (DOE) can play a crucial role in optimizing the laser intensity profile towards the optimal M-shape beam for enhanced weld seam quality. We present results on significantly improved weld seam width constancy and enlarged process windows compared to Gaussian or flat-top beam profiles. Configurations in which the laser beam diameter and shape can be adapted and optimized without changing or aligning the laser, fiber-optic cable or optical head are shown.

Role of Friction on the Thermal Development in Ultrasonically Consolidated Aluminum Foils and Composites

DTIC Science & Technology

2011-01-01

amplitude, . The third input parameter, weld speed, s, is inversely proportional to N, the num- ber of cycles as shown in Eq. (3). In summary, F is...though, an extensive body of work on mechanical testing of ultrasonically consolidated thin foils has been performed at Loughborough University. In...comprehensive textbook on tribology presents a preliminary derivation for plastic contact of ductile metals which suggests ≤ 1/5; this is much lower

Nondestructive Testing Residual Stress Using Ultrasonic Critical Refracted Longitudinal Wave

NASA Astrophysics Data System (ADS)

Xu, Chunguang; Song, Wentao; Pan, Qinxue; Li, Huanxin; Liu, Shuai

Residual stress has significant impacts on the performance of the mechanical components, especially on its strength, fatigue life and corrosion resistance and dimensional stability. Based on theory of acoustoelasticity, the testing principle of ultrasonic LCR wave method is analyzed. The testing system of residual stress is build. The method of calibration of stress coefficient is proposed in order to improve the detection precision. At last, through experiments and applications on residual stress testing of oil pipeline weld joint, vehicle's torsion shaft, glass and ceramics, gear tooth root, and so on, the result show that it deserved to be studied deeply on application and popularization of ultrasonic LCR wave method.

NASA welding assessment program

NASA Technical Reports Server (NTRS)

Stofel, E. J.

1984-01-01

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

Identification of the Thickness of Nugget on Worksheet Spot Welding Using Non Destructive Test (NDT) - Effect of Pressure

NASA Astrophysics Data System (ADS)

Sifa, A.; Baskoro, A. S.; Sugeng, S.; Badruzzaman, B.; Endramawan, T.

2018-02-01

Resistance Spot Welding (RSW) is a process of connecting between two worksheet with thermomechanical loading process, RSW is widely used in automotive industry, the quality of splicing spot welding is influenced by several factors. One of the factors at the time of the welding process is pressure. The quality of welding on the nuggets can be determined by undertaking non-destructive testing by using Non Destructive Test (NDT) - Ultrasonic Test. In the NDT test is done by detecting the thickness of the nugget area, the purpose of research conducted to determine the effect of pressure to welding quality with Nugget thickness gauge measurement with Non Destructive Test method and manual measurement with micrometer, Experimental welding process by entering the welding parameters that have been specified and pressure variables 1 -5 bars on the worksheet thickness of 1 mm. The results of testing with NDT show there is addition of thickness in nugget superiority after compare with measurement result of thickness of nugget with micrometer which slightly experience thickness in nugget area, this indicates that the welding results have a connection between worksheet 1 and worksheet 2.

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

PubMed

Lee, Jaesun; Park, Junpil; Cho, Younho

2016-05-01

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

Confined Tube Crimp Using Portable Hand Tools

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

Reynolds, Joseph James; Pereyra, R. A.; Archuleta, Jeffrey Christopher

2016-04-04

The Lawrence Radiation Laboratory developed handheld tools that crimp a 1/16 inch OD tube, forming a leak tight seal1 (see Figure 1). The leak tight seal forms by confining the 1/16 inch OD tubing inside a die while applying crimp pressure. Under confined pressure, the tube walls weld at the crimp. The purpose of this study was to determine conditions for fabricating a leak tight tube weld. The equipment was used on a trial-and-error basis, changing the conditions after each attempt until successful welds were fabricated. To better confine the tube, the die faces were polished. Polishing removed a fewmore » thousandths of an inch from the die face, resulting in a tighter grip on the tubing wall. Using detergent in an ultrasonic bath, the tubing was cleaned. Also, the time under crimp pressure was increased to 30 seconds. With these modifications, acceptable cold welds were fabricated. After setting the conditions for an acceptable cold weld, the tube was TIG welded across the crimped face.« less

Determination of toughness and embrittlement for reactor pressure vessel steels using ultrasonic measurements

NASA Astrophysics Data System (ADS)

Hiser, Allen Lee, Jr.

Neutron irradiation embrittlement of nuclear reactor pressure vessel (RPV) steels results in a loss of fracture toughness (e.g., reduction in load carrying capacity of the steel). For the setting of operational limits and assuring the continued safe operation of the plant, current procedures estimate the effects of neutron embrittlement using empirical relations or the results of small samples irradiated in the plant. These procedures account for uncertainties in the estimates through the use of margin terms to ensure the conservatism of the resultant estimate vis-a-vis the "real" material toughness. Therefore, the ability to develop non destructive measurements that can estimate the actual RPV steel fracture toughness in situ would provide more accurate evaluations of operating limits for plants. This study was undertaken to evaluate the suitability of ultrasonic attenuation measurements for estimating the fracture toughness of RPV steels. Ultrasonic measurements were made on samples in three distinct phases: (1) a heat treated RPV steel to induce changes in its fracture toughness; (2) several irradiated RPV steels to assess actual neutron embrittlement changes in fracture toughness; and (3) a matrix of unirradiated RPV steels with a range of as fabricated toughness levels. The results indicate that ultrasonic attenuation is generally able to identify differences in responses for samples with different toughness levels, although in some cases the differences in ultrasonic responses are small. The results from the three phases are not consistent, as in some cases reduced toughness results in higher attenuation and in other cases lower attenuation. This trend is not surprising given the different types of microstructural changes that result in the toughness changes for each phase of this work. In addition, different trends were identified for plate and weld materials.

Formation of Nanostructures in Severely Deformed High-Strength Steel Induced by High-Frequency Ultrasonic Impact Treatment

NASA Astrophysics Data System (ADS)

Dutta, R. K.; Malet, L.; Gao, H.; Hermans, M. J. M.; Godet, S.; Richardson, I. M.

2015-02-01

Surface modification by the generation of a nanostructured surface layer induced via ultrasonic impact treatment was performed at the weld toe of a welded high-strength quenched and tempered structural steel, S690QL1 (Fe-0.16C-0.2Si-0.87Mn-0.33Cr-0.21Mo (wt pct)). Such high-frequency peening techniques are known to improve the fatigue life of welded components. The nanocrystallized structure as a function of depth from the top-treated surface was characterized via a recently developed automated crystal orientation mapping in transmission electron microscopy. Based on the experimental observations, a grain refinement mechanism induced by plastic deformation during the ultrasonic impact treatment is proposed. It involves the formation of low-angle misoriented lamellae displaying a high density of dislocations followed by the subdivision of microbands into blocks and the resulting formation of polygonal submicronic grains. These submicronic grains further breakdown into nano grains. The results show the presence of retained austenite even after severe surface plastic deformation. The average grain size of the retained austenite and martensite is 17 and 35 nm, respectively. The in-grain deformation mechanisms are different in larger and smaller grains. Larger grains show long-range lattice rotations, while smaller grains show plastic deformation through grain rotation. Also the smaller nano grains exhibit the presence of short-range disorder. Surface nanocrystallization also leads to an increased fraction of low angle and low energy coincident site lattice boundaries especially in the smaller grains ( nm).

In situ laser-induced breakdown spectroscopy measurements of chemical compositions in stainless steels during tungsten inert gas welding

NASA Astrophysics Data System (ADS)

Taparli, Ugur Alp; Jacobsen, Lars; Griesche, Axel; Michalik, Katarzyna; Mory, David; Kannengiesser, Thomas

2018-01-01

A laser-induced breakdown spectroscopy (LIBS) system was combined with a bead-on-plate Tungsten Inert Gas (TIG) welding process for the in situ measurement of chemical compositions in austenitic stainless steels during welding. Monitoring the weld pool's chemical composition allows governing the weld pool solidification behavior, and thus enables the reduction of susceptibility to weld defects. Conventional inspection methods for weld seams (e.g. ultrasonic inspection) cannot be performed during the welding process. The analysis system also allows in situ study of the correlation between the occurrence of weld defects and changes in the chemical composition in the weld pool or in the two-phase region where solid and liquid phase coexist. First experiments showed that both the shielding Ar gas and the welding arc plasma have a significant effect on the selected Cr II, Ni II and Mn II characteristic emissions, namely an artificial increase of intensity values via unspecific emission in the spectra. In situ investigations showed that this artificial intensity increase reached a maximum in presence of weld plume. Moreover, an explicit decay has been observed with the termination of the welding plume due to infrared radiation during sample cooling. Furthermore, LIBS can be used after welding to map element distribution. For austenitic stainless steels, Mn accumulations on both sides of the weld could be detected between the heat affected zone (HAZ) and the base material.

Interfacial Reaction During Dissimilar Joining of Aluminum Alloy to Magnesium and Titanium Alloys

NASA Astrophysics Data System (ADS)

Robson, J. D.; Panteli, A.; Zhang, C. Q.; Baptiste, D.; Cai, E.; Prangnell, P. B.

Ultrasonic welding (USW), a solid state joining process, has been used to produce welds between AA6111 aluminum alloy and AZ31 magnesium alloys or titanium alloy Ti-6Al-4V. The mechanical properties of the welds have been assessed and it has been shown that it is the nature and thickness of the intermetallic compounds (IMCs) at the joint line that are critical in determining joint strength and particularly fracture energy. Al-Mg welds suffer from a very low fracture energy, even when strength is comparable with that of similar metal Mg-Mg welds, due to a thick IMC layer always being formed. It is demonstrated that in USW of Al-Ti alloy the slow interdiffusion kinetics means that an IMC layer does not form during welding, and fracture energy is greater. A model has been developed to predict IMC formation during welding and provide an understanding of the critical factors that determine the IMC thickness. It is predicted that in Al-Mg welds, most of the lMC thickening occurs whilst the IMC regions grow as separate islands, prior to the formation of a continuous layer.

Folded Resonant Horns for Power Ultrasonic Applications

NASA Technical Reports Server (NTRS)

Sherrit, Stewart; Askins, Stephen; Gradziel, Michael; Bao, Xiaoqi; Chang, Zensheu; Dolgin, Benjamin; Bar-Cohen, Yoseph; Peterson, Tom

2003-01-01

Folded horns have been conceived as alternatives to straight horns used as resonators and strain amplifiers in power ultrasonic systems. Such systems are used for cleaning, welding, soldering, cutting, and drilling in a variety of industries. In addition, several previous NASA Tech Briefs articles have described instrumented drilling, coring, and burrowing machines that utilize combinations of sonic and ultrasonic vibrational actuation. The main advantage of a folded horn, relative to a straight horn of the same resonance frequency, is that the folded horn can be made shorter (that is, its greatest linear dimension measured from the outside can be made smaller). Alternatively, for a given length, the resonance frequency can be reduced. Hence, the folded-horn concept affords an additional degree of design freedom for reducing the length of an ultrasonic power system that includes a horn.

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.

Advancements in NDE for utilities and the petrochemical industry through electromagnetic acoustic transducers (EMATs)

NASA Astrophysics Data System (ADS)

Robertson, M. O.; Stevens, Donald M.; Schlader, Daniel M.; Tilley, Richard M.

1998-03-01

The ultrasonic testing (UT) method continues to broaden in its effectiveness and capabilities for nondestructive evaluation (NDE). Much of this expansion can be attributed to advancements in specific techniques of the method. The utilization of electromagnetic acoustic transducers (EMATs) in dedicated ultrasonic systems has provided McDermott Technology, Inc. (MTI), formerly Babcock & Wilcox, with significant advantages over conventional ultrasonics. In recent years, through significant R&D, MTI has been instrumental in bringing about considerable advancements in the maturing EMAT technology. Progress in electronic design, magnet configurations, and sensor concepts has greatly improved system capabilities while reducing cost and equipment size. These improvements, coupled with the inherent advantages of utilizing the non-contact EMAT technique, have combined to make this technology a viable option for many commercial system inspection applications. MTI has recently completed the development and commercialization of an EMAT-based UT scanner for boiler tube thickness measurements. MTI is currently developing an automated EMAT scanner, based on phased array technology, for complete volumetric inspection of circumferential girth welds associated with pipelines (intended primarily for offshore applications). Additional benefits of phased array technology for providing materials characterization are currently being researched.

Development of Phased-Array Ultrasonic Testing Acceptability Criteria : (Phase II)

DOT National Transportation Integrated Search

2014-10-01

The preliminary technical approach and scan plans developed during phase I of this research was implemented on testing four butt-weld specimens. The ray path analysis carried out to develop the scan plans and the preliminary data analysis indicated t...

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.

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

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Gleeson, Sean T.

2014-02-01

A three-dimensional MPA probe has been incorporated with a high speed phased array electronic board to visualize nugget images of resistance spot welds. The primary application area of this battery operated portable MPA ultrasonic imaging system is in the automotive industry which a conventional destructive testing process is commonly adopted to check the quality of resistance spot welds in auto bodies. Considering an average of five-thousand spot welds in a medium size passenger vehicle, the amount of time and effort given to popping the welds and measuring nugget size are immeasurable in addition to the millions of dollars' worth of scrap metals recycled per plant per year. This wasteful labor intensive destructive testing process has become less reliable as auto body sheet metal has transitioned from thick and heavy mild steels to thin and light high strength steels. Consequently, the necessity of developing a non-destructive inspection methodology has become inevitable. In this paper, the fundamental aspects of the current 3-D probe design, data acquisition algorithms, and weld nugget imaging process are discussed.

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

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

Na, Jeong K.; Gleeson, Sean T.

2014-02-18

A three-dimensional MPA probe has been incorporated with a high speed phased array electronic board to visualize nugget images of resistance spot welds. The primary application area of this battery operated portable MPA ultrasonic imaging system is in the automotive industry which a conventional destructive testing process is commonly adopted to check the quality of resistance spot welds in auto bodies. Considering an average of five-thousand spot welds in a medium size passenger vehicle, the amount of time and effort given to popping the welds and measuring nugget size are immeasurable in addition to the millions of dollars' worth ofmore » scrap metals recycled per plant per year. This wasteful labor intensive destructive testing process has become less reliable as auto body sheet metal has transitioned from thick and heavy mild steels to thin and light high strength steels. Consequently, the necessity of developing a non-destructive inspection methodology has become inevitable. In this paper, the fundamental aspects of the current 3-D probe design, data acquisition algorithms, and weld nugget imaging process are discussed.« less

Combined Performance of Polypropylene Fibre and Weld Slag in High Performance Concrete

NASA Astrophysics Data System (ADS)

Ananthi, A.; Karthikeyan, J.

2017-12-01

The effect of polypropylene fibre and weld slag on the mechanical properties of High Performance Concrete (HPC) containing silica fume as the mineral admixtures was experimentally verified in this study. Sixteen series of HPC mixtures(70 MPa) were designed with varying fibre fractions and Weld Slag (WS). Fibre added at different proportion (0, 0.1, 0.3 and 0.6%) to the weight of cement. Weld slag was substituted to the fine aggregate (0, 10, 20 and 30%) at volume. The addition of fibre decreases the slump at 5, 9 and 14%, whereas the substitution of weld slag decreases by about 3, 11 and 21% with respect to the control mixture. Mechanical properties like compressive strength, split tensile strength, flexural strength, Ultrasonic Pulse Velocity test (UPV) and bond strength were tested. Durability studies such as Water absorption and Sorptivity test were conducted to check the absorption of water in HPC. Weld slag of 10% and fibre dosage of 0.3% in HPC, attains the maximum strength and hence this combination is most favourable for the structural applications.

Signal quality enhancement using higher order wavelets for ultrasonic TOFD signals from austenitic stainless steel welds.

PubMed

Praveen, Angam; Vijayarekha, K; Abraham, Saju T; Venkatraman, B

2013-09-01

Time of flight diffraction (TOFD) technique is a well-developed ultrasonic non-destructive testing (NDT) method and has been applied successfully for accurate sizing of defects in metallic materials. This technique was developed in early 1970s as a means for accurate sizing and positioning of cracks in nuclear components became very popular in the late 1990s and is today being widely used in various industries for weld inspection. One of the main advantages of TOFD is that, apart from fast technique, it provides higher probability of detection for linear defects. Since TOFD is based on diffraction of sound waves from the extremities of the defect compared to reflection from planar faces as in pulse echo and phased array, the resultant signal would be quite weak and signal to noise ratio (SNR) low. In many cases the defect signal is submerged in this noise making it difficult for detection, positioning and sizing. Several signal processing methods such as digital filtering, Split Spectrum Processing (SSP), Hilbert Transform and Correlation techniques have been developed in order to suppress unwanted noise and enhance the quality of the defect signal which can thus be used for characterization of defects and the material. Wavelet Transform based thresholding techniques have been applied largely for de-noising of ultrasonic signals. However in this paper, higher order wavelets are used for analyzing the de-noising performance for TOFD signals obtained from Austenitic Stainless Steel welds. It is observed that higher order wavelets give greater SNR improvement compared to the lower order wavelets. Copyright © 2013 Elsevier B.V. All rights reserved.

Systematic Review of Ultrasonic Impact Treatment Parameters on Residual Stresses of Welded Non-Sensitized Versus Sensitized Aluminum-Magnesium

DTIC Science & Technology

2015-03-01

during the treatment. The images of the toe region were taken in the same location, approximately 4 to 6 mm from the toe of the weld. The heat effected...Available: http://en.wikipedia.org/wiki/USS_Chosin_%28CG-65%29. Accessed Mar. 11, 2015. [ 6 ] HSV-2 Swift. (2003, Nov. 4 ). Wikipedia. Available: http...Leave blank) I 2. REPORT DATE I 3. REPORT TYPE AND DATES COVERED March 2015 Master ’s Thesis 4 . TITLE AND SUBTITLE 5. FUNDING NUMBERS SYSTEMATIC REVIEW

Space fabrication: Graphite composite truss welding and cap forming subsystems

NASA Technical Reports Server (NTRS)

Jenkins, L. M.; Browning, D. L.

1980-01-01

An automated beam builder for the fabrication of space structures is described. The beam builder forms a triangular truss 1.3 meters on a side. Flat strips of preconsolidated graphite fiber fabric in a polysulfone matrix are coiled in a storage canister. Heaters raise the material to forming temperature then the structural cap section is formed by a series of rollers. After cooling, cross members and diagonal tension cords are ultrasonically welded in place to complete the truss. The stability of fabricated structures and composite materials is also examined.

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

Eric Larsen; Art Watkins; Timothy R. McJunkin

The U.S. Department of Energy (DOE) created the National Spent Nuclear Fuel Program (NSNFP) to manage DOE’s spent nuclear fuel (SNF). One of the NSNFP’s tasks is to prepare spent nuclear fuel for storage, transportation, and disposal at the national repository. As part of this effort, the NSNFP developed a standardized canister for interim storage and transportation of SNF. These canisters will be built and sealed to American Society of Mechanical Engineers (ASME) Section III, Division 3 requirements. Packaging SNF usually is a three-step process: canister loading, closure welding, and closure weld verification. After loading SNF into the canisters, themore » canisters must be seal welded and the welds verified using a combination of visual, surface eddy current, and ultrasonic inspection or examination techniques. If unacceptable defects in the weld are detected, the defective sections of weld must be removed, re-welded, and re-inspected. Due to the high contamination and/or radiation fields involved with this process, all of these functions must be performed remotely in a hot cell. The prototype apparatus to perform these functions is a floor-mounted carousel that encircles the loaded canister; three stations perform the functions of welding, inspecting, and repairing the seal welds. A welding operator monitors and controls these functions remotely via a workstation located outside the hot cell. The discussion describes the hardware and software that have been developed and the results of testing that has been done to date.« less

Simulation assisted pod of a phased array ultrasonic inspection in manufacturing

NASA Astrophysics Data System (ADS)

Dominguez, N.; Feuillard, V.; Jenson, F.; Willaume, P.

2012-05-01

The concept of Probability of Detection (POD) is generally used to quantitatively assess performances and reliability of NDT operations for in-service operations related to damage tolerant designs. Application of the POD approach as a metric for manufacturing NDT assessment would also be relevant but the very expensive cost of such campaigns generally prevents us from doing so. However the increase in NDT simulation capability and maturity opens the field for POD demonstrations for manufacturing NDT with the help of simulation. This paper presents the example of an automated phased array ultrasonic testing procedure of Electron Beam Welding on rotative parts, as part of the PICASSO European project. POD is calculated by using the uncertainty propagation approach in CIVA. The peculiarity of uncertainties in automated NDT compared to in-service manual operations is discussed and raises questions on appropriate statistics to be used for this kind of data. Alternative estimation techniques like Box-Cox transform or quantile regression are proposed and evaluated.

U.S. pipeline industry enters new era

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

Johnsen, M.R.

1999-11-01

The largest construction project in North America this year and next--the Alliance Pipeline--marks some advances for the US pipeline industry. With the Alliance Pipeline system (Alliance), mechanized welding and ultrasonic testing are making their debuts in the US as primary mainline construction techniques. Particularly in Canada and Europe, mechanized welding technology has been used for both onshore and offshore pipeline construction for at least 15 years. However, it has never before been used to build a cross-country pipeline in the US, although it has been tested on short segments. This time, however, an accelerated construction schedule, among other reasons, necessitatedmore » the use of mechanized gas metal arc welding (GMAW). The $3-billion pipeline will delivery natural gas from northwestern British Columbia and northeastern Alberta in Canada to a hub near Chicago, Ill., where it will connect to the North American pipeline grid. Once the pipeline is completed and buried, crews will return the topsoil. Corn and other crops will reclaim the land. While the casual passerby probably won't know the Alliance pipeline is there, it may have a far-reaching effect on the way mainline pipelines are built in the US. For even though mechanized welding and ultrasonic testing are being used for the first time in the United States on this project, some US workers had already gained experience with the technology on projects elsewhere. And work on this pipeline has certainly developed a much larger pool of experienced workers for industry to draw from. The Alliance project could well signal the start of a new era in US pipeline construction.« less

Practical applications of nondestructive materials characterization

NASA Astrophysics Data System (ADS)

Green, Robert E., Jr.

1992-10-01

Nondestructive evaluation (NDE) techniques are reviewed for applications to the industrial production of materials including microstructural, physical, and chemical analyses. NDE techniques addressed include: (1) double-pulse holographic interferometry for sealed-package leak testing; (2) process controls for noncontact metals fabrication; (3) ultrasonic detections of oxygen contamination in titanium welds; and (4) scanning acoustic microscopy for the evaluation of solder bonds. The use of embedded sensors and emerging NDE concepts provides the means for controlling the manufacturing and quality of quartz crystal resonators, nickel single-crystal turbine blades, and integrated circuits. Advances in sensor technology and artificial intelligence algorithms and the use of embedded sensors combine to make NDE technology highly effective in controlling industrial materials manufacturing and the quality of the products.

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

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

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

2015-03-31

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

Thermo-mechanical process for treatment of welds

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

Malik, R K

1980-03-01

Benefits from thermo-mechanical processing (TMP) of austenitic stainless steel weldments, analogous to hot isostatic pressing (HIP) of castings, most likely result from compressive plastic deformation, enhanced diffusion, and/or increased dislocation density. TMP improves ultrasonic inspectability of austenitic stainless steel welds owing to: conversion of cast dendrites into equiaxed austenitic grains, reduction in size and number of stringers and inclusions, and reduction of delta ferrite content. TMP induces structural homogenization and healing of void-type defects and thus contributes to an increase in elongation, impact strength, and fracture toughness as well as a significant reduction in data scatter for these properties. Anmore » optimum temperature for TMP or HIP of welds is one which causes negligible grain growth and an acceptable reduction in yield strength, and permits healing of porosity.« less

Ultrasonic-assisted soldering of Cu/Ti joints

NASA Astrophysics Data System (ADS)

Cui, Wei; Wang, Chunyu; Li, Yuhang; Zhong, Tongtong; Yang, Jianguo; Bao, Yefeng

2018-03-01

Cu/Ti joints are expected to be used in various applications, while reliable joining method is still to be developed. It is commonly not possible to solder Ti alloys using Sn-based solder alloys because of their poor wettability. In this study, Sn-Ag-Cu soldering filler metal was used to joining TC4 titanium alloy and pure copper using ultrasonic-assisted soldering. The influence of different temperature and different ultrasonic time on the welded joint is studied and explored. Microstructure of the joints was investigated. Shear strength of the joints reached the maximum value, i.e. 38.2MPa. Relationship between the sonication parameters and the microstructure and strength of the joints was discussed. Thus, it is verified that dissimilar metal brazing of TC4 and copper is suitable for low temperature soldering.

FMC/TFM experimental comparisons

NASA Astrophysics Data System (ADS)

Spencer, Roger; Sunderman, Ruth; Todorov, Evgueni

2018-04-01

Ultrasonic full matrix capture/total focusing method (FMC/TFM) technology has progressed significantly over the past few years and has seen increased use in industry. The technology has the potential to provide better detection and measurement capabilities for weld flaws, as well as, many other applications including additive manufacturing. This project looked at the effectiveness of FMC/TFM for detection and sizing of both planar and volumetric flaw types. FMC/TFM experimental data was collected and processed using multiple combinations of probe types and wave propagation modes. The data was then compared to typical ultrasonic phased-array results, as well as FMC/TFM inspection simulations.

Ultrasonic cavitation erosion of 316L steel weld joint in liquid Pb-Bi eutectic alloy at 550°C.

PubMed

Lei, Yucheng; Chang, Hongxia; Guo, Xiaokai; Li, Tianqing; Xiao, Longren

2017-11-01

Liquid lead-bismuth eutectic alloy (LBE) is applied in the Accelerator Driven transmutation System (ADS) as the high-power spallation neutron targets and coolant. A 19.2kHz ultrasonic device was deployed in liquid LBE at 550°C to induce short and long period cavitation erosion damage on the surface of weld joint, SEM and Atomic force microscopy (AFM) were used to map out the surface properties, and Energy Dispersive Spectrometer (EDS) was applied to the qualitative and quantitative analysis of elements in the micro region of the surface. The erosion mechanism for how the cavitation erosion evolved by studying the element changes, their morphology evolution, the surface hardness and the roughness evolution, was proposed. The results showed that the pits, caters and cracks appeared gradually on the erode surface after a period of cavitation. The surface roughness increased along with exposure time. Work hardening by the bubbles impact in the incubation stage strengthened the cavitation resistance efficiently. The dissolution and oxidation corrosion and cavitation erosion that simultaneously happened in liquid LBE accelerated corrosion-erosion process, and these two processes combined to cause more serious damage on the material surface. Contrast to the performance of weld metal, base metal exhibited a much better cavitation resistance. Copyright © 2017. Published by Elsevier B.V.

NDE and DE of PWSCC Found in the J-Groove Weld of a Removed-From-Service Control Rod Drive Mechanism

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

Cumblidge, Stephen E.; Doctor, Steven R.; Schuster, George J.

2008-01-01

Studies conducted at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington focused on assessing the effectiveness of nondestructive examination (NDE) techniques for inspecting control rod drive mechanism (CRDM) nozzles and J-groove weldments. The primary objective of this work is to provide information to the United States Nuclear Regulatory Commission (US NRC) on the effectiveness of NDE methods as related to the in-service inspection of CRDM nozzles and J-groove weldments, and to enhance the knowledge base of primary water stress corrosion cracking (PWSCC) through destructive characterization of the CRDM assemblies. Two CRDM assemblies were removed from service, decontaminated, and thenmore » used in a series of laboratory NDE and DE measurements; this report addresses the following questions: 1) What did each NDE technique detect?, 2) What did each NDE technique miss?, 3) How accurately did each NDE technique characterize the detected flaws?, and finally 4) What were the basis for the NDE techniques performance? Two CRDM assemblies including the CRDM nozzle, the J-groove weld, buttering, and a portion of the ferritic head material were selected for this study. This paper focuses on a CRDM assembly that contained suspected PWSCC, based on in-service inspection data and through-wall leakage. The laboratory NDE measurements used to examine the CRDM assembly followed standard industry techniques for conducting in-service inspections of CRDM nozzles and the crown of the J-groove welds and buttering. These techniques included eddy current testing, time of flight diffraction ultrasound, and penetrant testing. In addition, other laboratory-based NDE methods were employed to conduct inspections of the CRDM assembly with particular emphasis on inspecting the J-groove weld and buttering. These techniques included volumetric ultrasonic inspection of the J-groove weld metal, visual testing via replicant material of the J-groove weld and high resolution photography of the J-groove weld crown and buttering. The results from these NDE studies were used to guide the development of the destructive characterization plan. The NDE studies found several crack-like indications. The NDE and DE studies determined that one of these was a through-weld radially-oriented PWSCC crack in the wetted surface of the J-groove weld, located at the transition point between the weld and the buttering. The crack was 6 mm long on the surface and quickly grew to 25 mm long at a depth of 8 mm, covering the length of the weld between the penetration tube and the carbon steel. The NDE studies found that only ET was able to detect the through-weld crack. The crack was oriented poorly for the ultrasonic testing, and was too tight for accurate PT or VT. The ET voltage response of the flaw was 30% that of a deep EDM notch. The DE performed on the crack consisted of slicing the crack into thin sections, polishing the sections, and then using optical and scanning electron microscopy (SEM) to characterize the crack. DE shows the crack was PWSCC and that it initiated on the wetted surface, grew and expanded through the weld metal, and exited into the annulus. The SEM examinations showed the crack followed the weld grain boundaries as it progressed through the weld. The crack was branched and discontinuous along its length.« less

Explosive Tube-to-fitting Joining of Small-diameter Tubes

NASA Technical Reports Server (NTRS)

Bement, L. J.

1985-01-01

An effort is currently under way by NASA Marshall Space Flight Center to upgrade the space shuttle main engine through the use of improved materials and processes. Under consideration is the use of the Langley Research Center explosive seam welding process. The objective is to demonstrate the feasibility of joining space shuttle main engine tube to fitting components in an oxygen heat exchanger, using the NASA LaRC explosive seam welding process. It was concluded that LaRC explosive joining is viable for this application; that there is no incompatability of materials; that ultrasonic inspection is the best nondestructive testing method; and that the .500 DIA joint experiences interface problems.

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.

Definition of mutually optimum NDI and proof test criteria for 2219 aluminum pressure vessels. Volume 1: Methods

NASA Technical Reports Server (NTRS)

Schwartzberg, F. R.; King, R. G.; Todd, P. H., Jr.

1979-01-01

The requirements for proof testing and nondestructive inspection of aluminum pressure vessels were discussed. The following conclusions are (1) lack-of-fusion weld defects are sufficiently tight in the as-welded condition to be considered undetectable; (2) proof-level loads are required to fully open lack-of-fusion weld defects; (3) significant crack opening occurs at subproof levels so that an inspection enhancement loading treatment designed to avoid catastrophic failure is feasible; (4) currently used proof levels for 2219 pressure vessels are adequate for postproof inspection; (5) quantification of defect size and location using collimated ultrasonic pitch-catch techniques appears sufficiently feasible for tankage to warrant developmental work; (6) for short-time single-cycle pressure-vessel applications, postproof inspection is desirable; and (7) for long-term multiple-cycle pressure-vessel applications, postproof inspection is essential for life assurance.

Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers

NASA Astrophysics Data System (ADS)

Hehr, Adam J.

Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientific understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.

Rapid bonding enhancement by auxiliary ultrasonic actuation for the fabrication of cyclic olefin copolymer (COC) microfluidic devices

NASA Astrophysics Data System (ADS)

Yu, H.; Tor, S. B.; Loh, N. H.

2014-11-01

Thermal compression bonding is a straightforward, inexpensive and widely used method for enclosing open microchannels in thermoplastic microfluidic devices. It is advantageous over adhesive, solvent and grafting bonding methods in retaining material homogeneity. However, the trade-off between high bond strength and low microchannel deformation is always a crucial consideration in thermal compression bonding. In this study, an effective method for improving bond strength while retaining the microchannel integrity with negligible distortion is proposed and analyzed. Longitudinal ultrasonic actuation was applied to the preheated cyclic olefin copolymer (COC) substrates to achieve accelerated and enhanced bonding with an ultrasonic welding system. Intimate contact between the bonding surfaces before the ultrasonic actuation was found to be an important prior condition. With improper contact, several bonding defects would occur, such as voids, localized spot melting and edge melting. Under auxiliary ultrasonic vibration, within 10 s, the bond strength developed at the bonding interface could be dramatically improved compared with those achieved without ultrasonic actuation. The enhanced bond strength obtained at a preheating temperature of 20 °C lower than its Tg could be comparable to the strength for pure thermal compression at 5 °C higher than its Tg. It is believed that the ultrasonic energy introduced could elevate the interfacial temperature and facilitate the interdiffusion of molecular chain segments at the interface, consequently resulting in rapidly enhanced bonding. Also, the microchannel distortion after ultrasonic actuation was found to be satisfactory—another important requirement. From dynamic mechanical analysis, the glass transition temperature of COC was found to increase with increasing frequency, and the temperature of the bulk polymer under ultrasonic actuation was still well under Tg; therefore the deformation is minor under ultrasonic actuation.

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

PubMed

Dale Marcy, A; Drake, Pamela L

2007-11-01

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

Flaw depth sizing using guided waves

NASA Astrophysics Data System (ADS)

Cobb, Adam C.; Fisher, Jay L.

2016-02-01

Guided wave inspection technology is most often applied as a survey tool for pipeline inspection, where relatively low frequency ultrasonic waves, compared to those used in conventional ultrasonic nondestructive evaluation (NDE) methods, propagate along the structure; discontinuities cause a reflection of the sound back to the sensor for flaw detection. Although the technology can be used to accurately locate a flaw over long distances, the flaw sizing performance, especially for flaw depth estimation, is much poorer than other, local NDE approaches. Estimating flaw depth, as opposed to other parameters, is of particular interest for failure analysis of many structures. At present, most guided wave technologies estimate the size of the flaw based on the reflected signal amplitude from the flaw compared to a known geometry reflection, such as a circumferential weld in a pipeline. This process, however, requires many assumptions to be made, such as weld geometry and flaw shape. Furthermore, it is highly dependent on the amplitude of the flaw reflection, which can vary based on many factors, such as attenuation and sensor installation. To improve sizing performance, especially depth estimation, and do so in a way that is not strictly amplitude dependent, this paper describes an approach to estimate the depth of a flaw based on a multimodal analysis. This approach eliminates the need of using geometric reflections for calibration and can be used for both pipeline and plate inspection applications. To verify the approach, a test set was manufactured on plate specimens with flaws of different widths and depths ranging from 5% to 100% of total wall thickness; 90% of these flaws were sized to within 15% of their true value. A description of the initial multimodal sizing strategy and results will be discussed.

Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

Five-axis ultrasonic additive manufacturing for nuclear component manufacture

DOE PAGES

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

2016-01-01

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

[Biodegradable fixation systems in pediatric craniofacial surgery: 10-year experience with 324 patients].

PubMed

Yasonov, S A; Lopatin, A V; Bel'chenko, V A; Vasil'ev, I G

Over the past 15 years, resorbable materials have been successfully used for osteosynthesis, but their high cost prevents widespread application. However, the use of resorbable systems could be a method of choice, especially in treatment of children in the active growth period. Obviously, biodegradable materials not only are highly competitive with known metal constructs in terms of fixation rigidity, biocompatibility, and a low risk of infection but also have an undeniable advantage, such as gradual resorption allowing quick return of damaged bones to the physiological conditions of functioning. A special feature of bioresorbable systems is that they can be assembled using ultrasonic welding, which greatly facilitates the fixation process and also provides necessary rigidity, even in cases of joining very thin bones when reliable fixation with screws is impossible. Over the past 10 years, we have used biodegradable systems in 324 patients. In 244 of them, we used traditional (plate/screw) systems; in 80 cases, an ultrasonic welding system was chosen for osteosynthesis. In the present work, we discuss, based on clinical evidence, the advantages and disadvantages of both fixation systems for reconstructive craniofacial surgery in children.

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

Lee, Jaesun, E-mail: jaesun@pusan.ac.kr, E-mail: jpp@pusan.ac.kr; Park, Junpil, E-mail: jaesun@pusan.ac.kr, E-mail: jpp@pusan.ac.kr; Cho, Younho, E-mail: mechcyh@pusan.ac.kr

The nuclear power plant inspection is very important for the safety issue. However due to some radiation and geometric problems, the detection of CRDM(Control Rod Drive Mechanism) can be very difficult by using conventional Ultrasonic Testing method. Also the shrink fit boundary condition can also be an obstacle for the inspection in this paper, instead of conventional Ultrasonic Testing, guided wave was used for the detection of some complicated structures. The CRDM nozzle was installed in reactor head with perfect shrink fit condition by using stainless steel. The wave amplitude distribution on the circumferential direction was calculated with various boundarymore » conditions and the experimental result shows a possibility of the defect detection on J-groove weld.« less

Remote Acoustic Emission Monitoring of Metal Ware and Welded Joints

NASA Astrophysics Data System (ADS)

Kapranov, Boris I.; Sutorikhin, Vladimir A.

2017-10-01

An unusual phenomenon was revealed in the metal-ultrasound interaction. Microwave sensor generates surface electric conductivity oscillations from exposure to elastic ultrasonic vibrations on regions of defects embracing micro-defects termed as “crack mouth.” They are known as the region of “acoustic activity,” method of Acoustic Emission (AE) method. It was established that the high phase-modulation coefficient of reflected field generates intentional Doppler radar signal with the following parameters: amplitude-1-5 nm, 6-30 dB adjusted to 70- 180 mm. This phenomenon is termed as “Gorbunov effect,” which is applied as a remote non-destructive testing method replacing ultrasonic flaw detection and acoustic emission methods.

Nondestructive and Destructive Examination Studies on Removed-from-Service Control Rod Drive Mechanism Penetrations

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

Cumblidge, Stephen E.; Crawford, Susan L.; Doctor, Steven R.

2007-06-07

Studies conducted at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington, focused on assessing the effectiveness of nondestructive examination (NDE) techniques for inspecting control rod drive mechanism (CRDM) nozzles and J-groove weldments. The primary objectives of this work are to provide information to the U.S. Nuclear Regulatory Commission (NRC) on the effectiveness of NDE methods as related to the in-service inspection of CRDM nozzles and J-groove weldments and to enhance the knowledge base of primary water stress corrosion cracking (PWSCC) through destructive characterization of the CRDM assemblies. Two CRDM assemblies were removed from service, decontaminated, and then used inmore » a series of NDE and destructive examination (DE) measurements; this report addresses the following questions: 1) What did each NDE technique detect? 2) What did each NDE technique miss? 3) How accurately did each NDE technique characterize the detected flaws? 4) Why did the NDE techniques perform or not perform? Two CRDM assemblies including the CRDM nozzle, the J-groove weld, buttering, and a portion of the ferritic head material were selected for this study. This report focuses on a CRDM assembly that contained suspected PWSCC, based on in-service inspection data and through-wall leakage. The NDE measurements used to examine the CRDM assembly followed standard industry techniques for conducting in-service inspections of CRDM nozzles and the crown of the J-groove welds and buttering. These techniques included eddy current testing (ET), time-of-flight diffraction ultrasound, and penetrant testing. In addition, laboratory-based NDE methods were employed to conduct inspections of the CRDM assembly with particular emphasis on inspecting the J-groove weld and buttering. These techniques included volumetric ultrasonic inspection of the J-groove weld metal and visual testing via replicant material of the J-groove weld. The results from these NDE studies were used to guide the development of the destructive characterization plan. The NDE studies found several crack-like indications. The NDE and DE studies determined that one of these was a through-weld, radially oriented PWSCC crack in the wetted surface of the J-groove weld, located at the transition point between the weld and the buttering. The crack was 6 mm long on the surface and quickly grew to 25 mm long at a depth of 8 mm, covering the length of the weld between the penetration tube and the carbon steel. The NDE studies found that only ET was able to detect the through-weld crack. The crack was oriented poorly for the ultrasonic testing and was too tight for accurate dye penetrant testing or visual testing. The ET voltage response of the through-wall crack was 30% of the response from a deep electrical discharge machined notch. Destructive examination showed the crack is PWSCC and that it initiated on the wetted surface, grew and expanded through the weld metal, and exited into the annulus. The crack was branched and discontinuous along its length.« less

Small Business Innovations (Robotic Wrist)

NASA Technical Reports Server (NTRS)

1991-01-01

Under a Langley Research Center Small Business Innovation Research (SBIR) contract, Ross-Hime Designs, Inc. Minneapolis, MN, developed the Omni-Wrist actuator, which has a 25-pound capacity, 180 degrees of pitch/yaw, and 360 degrees of roll. Company literature calls it "the first successful singularity-free high-precision (robotic) wrist." Applications include spray painting, sealing, ultrasonic testing, welding and a variety of nuclear industry, aerospace and military uses.

Metallography of Battery Resistance Spot Welds

NASA Technical Reports Server (NTRS)

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

2015-01-01

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

PFC Decontamination of a Metal Surface and the Recycling of a Spent PFC Solution

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

Jung, C.H.; Won, H.J.; Oh, W.Z.

2006-07-01

PFC (per-fluorocarbon) ultrasonic decontamination behavior of loosely contaminated metal specimens such as a plate, pipe, welding and a crevice specimen in a mixed solution of PFC and an anionic surfactant was investigated. Perfluoroheptane (C{sub 7}F{sub 16}) was used as a PFC ultrasonic media. The contaminants were completely removed for almost all of the tested specimens except for the longest pipe length specimen. For the 6-cm long specimen, 98.5 % of the contaminants were removed. For the recycling of the PFC solution, a distillation test for the spent PFC solution was also performed. The results show that 97.5 % of themore » PFC was recycled without a loss of the decontamination efficiency. (authors)« less

Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding)

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

Carlson, N.M.; Johnson, J.A.; Smartt, H.B.

1989-01-01

One of the requirements of a sensing system for feedback control of gas metal arc welding (GMAW) is the capability to determine the metal-transfer mode. Because the operating boundary for the desired transfer mode, expressed as a function of mass input and heat input, may vary due to conditions beyond the control of the system, a means of detecting the transfer mode during welding is necessary. A series of sensing experiments was performed during which the ultrasonic emissions, audio emissions, welding current fluctuations and welding voltage fluctuations were recorded as a function of the transfer mode. In addition, high speedmore » movies (5000 frames/s) of the droplet formation and detachment were taken synchronously with the sensing data. An LED mounted in the camera was used to mark the film at the beginning and end of the data acquisition period. A second LED was pulsed at a 1 kHz rate and the pulses recorded on film and with the sensor data. Thus events recorded on the film can be correlated with the sensor data. Data acquired during globular transfer, spray transfer, and stiff spray or streaming transfer were observed to correlate with droplet detachment and arc shorting. The audio, current, and voltage data can be used to discriminate among these different transfer modes. However, the current and voltage data are also dependent on the characteristic of the welding power supply. 5 refs., 3 figs., 1 tab.« less

Non-destructive Magnetic Evaluation of Laser Weld Quality in Hot Rolled Coils

NASA Astrophysics Data System (ADS)

Mohapatra, J. N.; Chakradhar, I.; Rao, K. R. C.; Rao, V. V. L.; Kaza, Marutiram

2015-06-01

Weld quality evaluation was conducted on laser welded thin sectsions (2 mm) of hot-rolled (HR) low-carbon steel coils during cold rolling process. The analysis revealed that the poor welds consisting of the weld defects like incomplete fusion, cluster of porosity, and large difference in hardness between the weld zone and base metal were responsible for the weld failures. Experiments were conducted by varying the welding parameters; laser power and welding speed to optimize the parameters for minimizing the weld defects. The optimized weld process parameters have helped elimination of weld defects and the results are verified with microscopy and microhardness measurements. As destructive evaluation techniques are time consuming and not always permitted in industrial applications, attempts have been made in the present investigation for the utilization of suitable non-destructive techniques for the evaluation of weld quality. Non-destructive magnetic techniques of magnetic hysteresis loop and magnetic Barkhausen emissions were used in the present investigation to establish possible correlations of magnetic properties across the weld seam with the mechanical property (microhardness) for evaluation of weld quality. It is inferred that the magnetic properties of coercivity and inverse of root mean square voltage can be effectively utilized to determine weld quality in HR steel coils.

Industrial laser welding evaluation study

NASA Technical Reports Server (NTRS)

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

1974-01-01

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

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

NASA Technical Reports Server (NTRS)

Russell, C.

2001-01-01

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

Conference Video for Booth at SAE World Congress Experience Conference

NASA Technical Reports Server (NTRS)

Harkey, Ann Marie

2017-01-01

Contents: Publicly released videos on technology transfer items available for licensing from NASA. Includes; Powder Handling Device for Analytical Instruments (Ames); 2. Fiber Optic Shape Sensing (FOSS) (Armstrong); 3. Robo-Glove (Johnson); 4. Modular Robotic Vehicle (Johnson); 5. Battery Management System (Johnson); 6. Active Response Gravity Offload System (ARGOS) (Johnson); 7. Contaminant Resistant Coatings for Extreme Environments (Langley); 8. Molecular Adsorber Coating (MAC) (Goddard); 9. Ultrasonic Stir Welding (Marshall). Also includes scenes from the International Space Station.

Design and development of high frequency matrix phased-array ultrasonic probes

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Spencer, Roger L.

2012-05-01

High frequency matrix phased-array (MPA) probes have been designed and developed for more accurate and repeatable assessment of weld conditions of thin sheet metals commonly used in the auto industry. Unlike the line focused ultrasonic beam generated by a linear phased-array (LPA) probe, a MPA probe can form a circular shaped focused beam in addition to the typical beam steering capabilities of phased-array probes. A CIVA based modeling and simulation method has been used to design the probes in terms of various probe parameters such as number of elements, element size, overall dimensions, frequency etc. Challenges associated with the thicknesses of thin sheet metals have been resolved by optimizing these probe design parameters. A further improvement made on the design of the MPA probe proved that a three-dimensionally shaped matrix element can provide a better performing probe at a much lower probe manufacturing cost by reducing the total number of elements and lowering the operational frequency. This three dimensional probe naturally matches to the indentation shape of the weld on the thin sheet metals and hence a wider inspection area with the same level of spatial resolution obtained by a twodimensional flat MPA probe operating at a higher frequency. The two aspects, a wider inspection area and a lower probe manufacturing cost, make this three-dimensional MPA sensor more attractive to auto manufacturers demanding a quantitative nondestructive inspection method.

Residual Stress Measurement and Calibration for A7N01 Aluminum Alloy Welded Joints by Using Longitudinal Critically Refracted ( LCR) Wave Transmission Method

NASA Astrophysics Data System (ADS)

Zhu, Qimeng; Chen, Jia; Gou, Guoqing; Chen, Hui; Li, Peng; Gao, W.

2016-10-01

Residual stress measurement and control are highly important for the safety of structures of high-speed trains, which is critical for the structure design. The longitudinal critically refracted wave technology is the most widely used method in measuring residual stress with ultrasonic method, but its accuracy is strongly related to the test parameters, namely the flight time at the free-stress condition ( t 0), stress coefficient ( K), and initial stress (σ0) of the measured materials. The difference of microstructure in the weld zone, heat affected zone, and base metal (BM) results in the divergence of experimental parameters. However, the majority of researchers use the BM parameters to determine the residual stress in other zones and ignore the initial stress (σ0) in calibration samples. Therefore, the measured residual stress in different zones is often high in errors and may result in the miscalculation of the safe design of important structures. A serious problem in the ultrasonic estimation of residual stresses requires separation between the microstructure and the acoustoelastic effects. In this paper, the effects of initial stress and microstructure on stress coefficient K and flight time t 0 at free-stress conditions have been studied. The residual stress with or without different corrections was investigated. The results indicated that the residual stresses obtained with correction are more accurate for structure design.

Effect of ultrasonic capillary dynamics on the mechanics of thermosonic ball bonding.

PubMed

Huang, Yan; Shah, Aashish; Mayer, Michael; Zhou, Norman Y; Persic, John

2010-01-01

Microelectronic wire bonding is an essential step in today's microchip production. It is used to weld (bond) microwires to metallized pads of integrated circuits using ultrasound with hundreds of thousands of vibration cycles. Thermosonic ball bonding is the most popular variant of the wire bonding process and frequently investigated using finite element (FE) models that simplify the ultrasonic dynamics of the process with static or quasistatic boundary conditions. In this study, the ultrasonic dynamics of the bonding tool (capillary), made from Al(2)O(3), is included in a FE model. For more accuracy of the FE model, the main material parameters are measured. The density of the capillary was measured to be rho(cap) = 3552 +/- 100 kg/m(3). The elastic modulus of the capillary, E(cap) = 389 +/- 11 GPa, is found by comparing an auxiliary FE model of the free vibrating capillary with measured values. A capillary "nodding effect" is identified and found to be essential when describing the ultrasonic vibration shape. A main FE model builds on these results and adds bonded ball, pad, chip, and die attach components. There is excellent agreement between the main model and the ultrasonic force measured at the interface on a test chip with stress microsensors. Bonded ball and underpad stress results are reported. When adjusted to the same ultrasonic force, a simplified model without ultrasonic dynamics and with an infinitely stiff capillary tip is substantially off target by -40% for the maximum underpad stress. The compliance of the capillary causes a substantial inclination effect at the bonding interface between wire and pad. This oscillating inclination effect massively influences the stress fields under the pad and is studied in more detail. For more accurate results, it is therefore recommended to include ultrasonic dynamics of the bonding tool in mechanical FE models of wire bonding.

Detection of metal-transfer mode in GMAW

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

Johnson, J.A.; Carlson, N.M.; Smartt, H.B.

1989-01-01

One of the requirements of a sensing system for feedback control of gas metal arc welding (GMAW) is the capability to detect information about the metal-transfer mode. Because the operating boundary for the desired transfer mode, expressed as a function of mass input and heat input, may vary due to conditions beyond the control of the system, a means of determining the transfer mode during welding is necessary. A series of sensing experiments is performed during which the ultrasonic emissions, audio emissions, welding current fluctuations, and welding voltage fluctuations are recorded as a function of the transfer mode. In addition,more » high speed movies (5000 frame/s) of the droplet formation and detachment are taken synchronously with the sensing data. An LED mounted in the camera is used to work the film at the beginning and end of the data acquisition period. A second LED is pulsed at a 1 kHz rate and the pulses are recorded on film and with the sensor data. Thus events observed on the film can be correlated with the sensor data. Data acquired during globular transfer, spray transfer, and stiff spray or streaming transfer are observed to correlate with droplet detachment and arc shorting. The audio, current, and voltage data can be used to discriminate among these different transfer modes. However, the current and voltage data are also dependent on the characteristics of the welding power supply. 4 refs., 5 figs.« less

Nondestructive Evaluation Methods for the Ares I Common Bulkhead

NASA Technical Reports Server (NTRS)

Walker, James

2010-01-01

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

In-service Inspection Ultrasonic Testing of Reactor Pressure Vessel Welds for Assessing Flaw Density and Size Distribution per 10 CFR 50.61a, Alternate Fracture Toughness Requirements

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

Sullivan, Edmund J.; Anderson, Michael T.; Norris, Wallace

2012-09-17

Pressurized thermal shock (PTS) events are system transients in a pressurized water reactor (PWR) in which there is a rapid operating temperature cool-down that results in cold vessel temperatures with or without repressurization of the vessel. The rapid cooling of the inside surface of the reactor pressure vessel (RPV) causes thermal stresses that can combine with stresses caused by high pressure. The aggregate effect of these stresses is an increase in the potential for fracture if a pre-existing flaw is present in a material susceptible to brittle failure. The ferritic, low alloy steel of the reactor vessel beltline adjacent tomore » the core, where neutron radiation gradually embrittles the material over the lifetime of the plant, can be susceptible to brittle fracture. The PTS rule, described in the Code of Federal Regulations, Title 10, Section 50.61 (§50.61), “Fracture Toughness Requirements for Protection against Pressurized Thermal Shock Events,” adopted on July 23, 1985, establishes screening criteria to ensure that the potential for a reactor vessel to fail due to a PTS event is deemed to be acceptably low. The U.S. Nuclear Regulatory Commission (NRC) completed a research program that concluded that the risk of through-wall cracking due to a PTS event is much lower than previously estimated. The NRC subsequently developed a rule, §50.61a, published on January 4, 2010, entitled “Alternate Fracture Toughness Requirements for Protection Against Pressurized Thermal Shock Events” (75 FR 13). Use of the new rule by licensees is optional. The §50.61a rule differs from §50.61 in that it requires licensees who choose to follow this alternate method to analyze the results from periodic volumetric examinations required by the ASME Code, Section XI, Rules for Inservice Inspection (ISI) of Nuclear Power Plants. These analyses are intended to determine if the actual flaw density and size distribution in the licensee’s reactor vessel beltline welds are bounded by the flaw density and size distribution values used in the PTS technical basis. Under a contract with the NRC, Pacific Northwest National Laboratory (PNNL) has been working on a program to assess the ability of current inservice inspection (ISI)-ultrasonic testing (UT) techniques, as qualified through ASME Code, Appendix VIII, Supplements 4 and 6, to detect small fabrication or inservice-induced flaws located in RPV welds and adjacent base materials. As part of this effort, the investigators have pursued an evaluation, based on the available information, of the capability of UT to provide flaw density/distribution inputs for making RPV weld assessments in accordance with §50.61a. This paper presents the results of an evaluation of data from the 1993 Browns Ferry Nuclear Plant, Unit 3, Spirit of Appendix VIII reactor vessel examination, a comparison of the flaw density/distribution from this data with the distribution in §50.61a, possible reasons for differences, and plans and recommendations for further work in this area.« less

Recent Developments for Ultrasonic-Assisted Friction Stir Welding: Joining, Testing, Corrosion - an Overview

NASA Astrophysics Data System (ADS)

Thomä, M.; Wagner, G.; Straß, B.; Conrad, C.; Wolter, B.; Benfer, S.; Fürbeth, W.

2016-03-01

Due to the steadily increasing demand on innovative manufacturing processes, modern lightweight construction concepts become more and more important. Especially joints of dissimilar metals offer a variety of advantages due to their high potential for lightweight construction. The focus of the investigations was Al/Mg-joints. Friction Stir Welding (FSW) is an efficient process to realize high strength joints between these materials in ductile condition. Furthermore, for a simultaneous transmission of power ultrasound during the FSW-process (US-FSW) a positive effect on the achievable tensile strength of the Al/Mg-joints was proven. In the present work the industrial used die cast alloys EN AC-48000 (AlSi12CuNiMg) and AZ80 (MgAl8Zn) were joined by a machining center modified especially for Ultrasound Supported Friction Stir Welding. The appearing welding zone and the formation of intermetallic phases under the influence of power ultrasound were examined in particular. In order to identify optimal process parameters extensive preliminary process analyzes have been carried out. Following this, an ultrasound-induced more intensive stirring of the joining zone and as a result of this a considerably modified intermetallic zone was detected. At the same time an increase of the tensile strength of about 25% for US-FSW-joints and for fatigue an up to three times higher number of cycles to failure in comparison to a conventional welding process was observed. Moreover, detailed corrosion analyzes have shown that especially the welding zone was influenced by the corrosive attack. To expand and deepen the knowledge of the US-FSW-process further material combinations such as Ti/Steel and Al/Steel will be considered in future.

A Non-Intrusive GMA Welding Process Quality Monitoring System Using Acoustic Sensing.

PubMed

Cayo, Eber Huanca; Alfaro, Sadek Crisostomo Absi

2009-01-01

Most of the inspection methods used for detection and localization of welding disturbances are based on the evaluation of some direct measurements of welding parameters. This direct measurement requires an insertion of sensors during the welding process which could somehow alter the behavior of the metallic transference. An inspection method that evaluates the GMA welding process evolution using a non-intrusive process sensing would allow not only the identification of disturbances during welding runs and thus reduce inspection time, but would also reduce the interference on the process caused by the direct sensing. In this paper a nonintrusive method for weld disturbance detection and localization for weld quality evaluation is demonstrated. The system is based on the acoustic sensing of the welding electrical arc. During repetitive tests in welds without disturbances, the stability acoustic parameters were calculated and used as comparison references for the detection and location of disturbances during the weld runs.

A Non-Intrusive GMA Welding Process Quality Monitoring System Using Acoustic Sensing

PubMed Central

Cayo, Eber Huanca; Alfaro, Sadek Crisostomo Absi

2009-01-01

Most of the inspection methods used for detection and localization of welding disturbances are based on the evaluation of some direct measurements of welding parameters. This direct measurement requires an insertion of sensors during the welding process which could somehow alter the behavior of the metallic transference. An inspection method that evaluates the GMA welding process evolution using a non-intrusive process sensing would allow not only the identification of disturbances during welding runs and thus reduce inspection time, but would also reduce the interference on the process caused by the direct sensing. In this paper a nonintrusive method for weld disturbance detection and localization for weld quality evaluation is demonstrated. The system is based on the acoustic sensing of the welding electrical arc. During repetitive tests in welds without disturbances, the stability acoustic parameters were calculated and used as comparison references for the detection and location of disturbances during the weld runs. PMID:22399990

Nondestructive testing and characterization of residual stress field using an ultrasonic method

NASA Astrophysics Data System (ADS)

Song, Wentao; Xu, Chunguang; Pan, Qinxue; Song, Jianfeng

2016-03-01

To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel(12%C) as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave (LCR wave) is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.

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.

Seal Integrity of Selected Fuzes as Measured by Three Leak Test Methods

DTIC Science & Technology

1976-09-01

the worst fuze from the seal standpoint. The M503A-2 fuze body is made from a cast aluminum alloy . The casting process leaves voids which, after...leak resistance of the joint. WDU4A/A The design of this fuze depends upon ultrasonic welding to seal lid to case. The specified leak test merely...test is probably one of the better leakage tests from an effectiveness standpoint. However, from lot quantities of 690 and 480, reject rates of 20% were

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Flexible, FEP-Teflon covered solar cell module development

NASA Technical Reports Server (NTRS)

Rauschenbach, H. S.; Cannady, M. D.

1976-01-01

Techniques and equipment were developed for the large scale, low-cost fabrication of lightweight, roll-up and fold-up, FEP-Teflon encapsulated solar cell modules. Modules were fabricated by interconnecting solderless single-crystal silicon solar cells and heat laminating them at approximately 300 C between layers of optically clear FEP and to a loadbearing Kapton substrate sheet. Modules were fabricated from both conventional and wraparound contact solar cells. A heat seal technique was developed for mechanically interconnecting modules into an array. The electrical interconnections for both roll-up and fold-up arrays were also developed. The use of parallel-gap resistance welding, ultrasonic bonding, and thermocompression bonding processes for attaching interconnects to solar cells were investigated. Parallel-gap welding was found to be best suited for interconnecting the solderless solar cells into modules. Details of the fabrication equipment, fabrication processes, module and interconnect designs, environmental test equipment, and test results are presented.

Development of an ultrasonic inspection robot using an electromagnetic acoustic transducer for a Lamb wave and an SH-plate wave.

PubMed

Murayama, Riichi; Makiyama, Shunnichi; Kodama, Mitutoshi; Taniguchi, Yasutoshi

2004-04-01

For inspection of a storage tank and pipeline in service, the application of an automatic inspection system (nondestructive inspection robot) is desirable, because manual inspection is difficult to perfectly and exactly perform due to the enormous amount of inspection needed. However, an ultrasonic nondestructive inspection robot with a piezoelectric oscillator needs to touch only the material surface to be directly inspected using a coupling medium. That is, the material surface and the sensor must always be held by constant pressure in the vertical direction on the material side. Actually, it is difficult to overcome these problems; thus an ultrasonic inspection robot could not be widely applied. We then tried to develop an ultrasonic inspection robot with an electromagnetic acoustic transducer (EMAT) which did not require a coupling medium to inspect the circumferential pipe parts. We developed a special EMAT that could transmit and receive alternately a Lamb wave with high sensitivity and a SH-plate wave without influence by the welded part. The method by which the inspection robot turned around the direction of the steel pipe surroundings was executed by observing the tape pasted in the direction of the steel pipe surroundings with an installed CCD camera. In this report, the basic mechanism of this inspection robot and an examination of results are described.

Anchoring submersible ultrasonic receivers in river channels with stable substrate

USGS Publications Warehouse

Bettoli, Phillip William; Scholten, G.D.; Hubbs, D.

2010-01-01

We developed an anchoring system for submersible ultrasonic receivers (SURs) that we placed on the bottom of the riverine reaches of three main-stem reservoirs in the upper Tennessee River. Each anchor consisted of a steel tube (8.9 x 35.6 cm) welded vertically to a round plate of steel (5.1 x 40.6 cm). All seven SURs and their 57-kg anchors were successfully deployed and retrieved three times over 547 d by a dive team employing surface air-breathing equipment and a davit-equipped boat. All of the anchors and their SURs remained stationary over two consecutive winters on the hard-bottom, thalweg sites where they were deployed. The SUR and its anchor at the most downriver site experienced flows that exceeded 2,100 m(3)/s and mean water column velocities of about 0.9 m/s.

Structural health monitoring of plates with surface features using guided ultrasonic waves

NASA Astrophysics Data System (ADS)

Fromme, P.

2009-03-01

Distributed array systems for guided ultrasonic waves offer an efficient way for the long-term monitoring of the structural integrity of large plate-like structures. The measurement concept involving baseline subtraction has been demonstrated under laboratory conditions. For the application to real technical structures it needs to be shown that the methodology works equally well in the presence of structural and surface features. Problems employing this structural health monitoring concept can occur due to the presence of additional changes in the signal reflected at undamaged parts of the structure. The influence of the signal processing parameters and transducer placement on the damage detection and localization accuracy is discussed. The use of permanently attached, distributed sensors for the A0 Lamb wave mode has been investigated. Results are presented using experimental data obtained from laboratory measurements and Finite Element simulated signals for a large steel plate with a welded stiffener.

Acousto-ultrasonic nondestructive evaluation of materials using laser beam generation and detection

NASA Technical Reports Server (NTRS)

Huber, Robert D.; Green, Robert E., Jr.; Vary, Alex; Kautz, Harold

1990-01-01

Presented in viewgraph format, the possibility of using laser generation and detection of ultrasound to replace piezoelectric transducers for the acousto-ultrasonic technique is advanced. The advantages and disadvantages of laser acousto-ultrasonics are outlined. Laser acousto-ultrasonics complements standard piezoelectric acousto-ultrasonics and offers non-contact nondestructive evaluation.

Wide Panel Testing Technique for Evaluating Repair Weld Strengths

NASA Technical Reports Server (NTRS)

Rogers, Patrick R.; Bynum, Julian E.; Shah, Sandeep R.

1998-01-01

This paper describes a new tensile testing technique for evaluating the overall effect of a repair weld on the strength of a welded joint. Previously, repair weld strengths have been evaluated using one-inch width tensile specimens, but this technique does not capture all of the effects that result from a repair. The new technique involves testing of "wide panel" tensile specimens which contain the full length of a repair weld within a longer initial weld, allowing the specimen to capture the combined effects of residual stresses, local strength degradation, and load redistribution around a repair. The development of strains in the repair area of standard aluminum alloy specimens and new high-performance aluminum-lithium alloy specimens was observed and evaluated using photoelastic material. The results of this evaluation show an increased sensitivity to repair welding residual stresses in the aluminum-lithium alloy specimens.

Progress In Developing Laser Based Post Irradiation Examination Infrastructure

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

Smith, James A.; Scott, Clark L.; Benefiel, Brad C.

To be able to understand the performance of reactor fuels and materials, irradiated materials must be characterized effectively and efficiently in a high rad environment. The characterization work must be performed remotely and in an environment hostile to instrumentation. Laser based characterization techniques provide the ability to be remote and robust in a hot-cell environment. Laser based instrumentation also can provide high spatial resolution suitable for scanning and imaging large areas. The INL is currently developing three laser based Post Irradiation Examination (PIE) stations for the Hot Fuel Examination Facility at the INL. These laser based systems will characterize irradiatedmore » materials and fuels. The characterization systems are the following: Laser Shock Laser based ultrasonic C-scan system Gas Assay, Sample, and Recharge system (GASR, up-grade to an existing system). The laser shock technique will characterize material properties and failure loads/mechanisms in various materials such as LWR fuel, plate fuel, and next generation fuel forms, for PIE in high radiation areas. The laser shock-technique induces large amplitude shock waves to mechanically characterize interfaces such as the fuel-clad bond. The shock wave travels as a compression wave through the material to the free (unconfined) back surface and reflects back through the material under test as a rarefaction (tensile) wave. This rarefaction wave is the physical mechanism that produces internal de-lamination failure. As part of the laser shock system, a laser-based ultrasonic C-scan system will be used to detect and characterize debonding caused by the laser shock technique. The laser ultrasonic system will be fully capable of performing classical non-destructive evaluation testing and imaging functions such as microstructure characterization, flaw detection and dimensional metrology in complex components. The purpose of the GASR is to measure the pressure/volume of the plenum of an irradiated fuel element and obtain fission gas samples for analysis. The study of pressure and volume in the plenum of an irradiated fuel element and the analysis of fission gases released from the fuel is important to understanding the performance of reactor fuels and materials. This system may also be used to measure the pressure/volume of other components (such as control blades) and obtain gas samples from these components for analysis. The main function of the laser in this application is to puncture the fuel element to allow the fission gas to escape and if necessary to weld the spot close. The GASR station will have the inherent capability to perform cutting welding and joining functions within a hot-cell.« less

MEMS ultrasonic transducer for monitoring of steel structures

NASA Astrophysics Data System (ADS)

Jain, Akash; Greve, David W.; Oppenheim, Irving J.

2002-06-01

Ultrasonic methods can be used to monitor crack propagation, weld failure, or section loss at critical locations in steel structures. However, ultrasonic inspection requires a skilled technician, and most commonly the signal obtained at any inspection is not preserved for later use. A preferred technology would use a MEMS device permanently installed at a critical location, polled remotely, and capable of on-chip signal processing using a signal history. We review questions related to wave geometry, signal levels, flaw localization, and electromechanical design issues for microscale transducers, and then describe the design, characterization, and initial testing of a MEMS transducer to function as a detector array. The device is approximately 1-cm square and was fabricated by the MUMPS process. The chip has 23 sensor elements to function in a phased array geometry, each element containing 180 hexagonal polysilicon diaphragms with a typical leg length of 49 microns and an unloaded natural frequency near 3.5 MHz. We first report characterization studies including capacitance-voltage measurements and admittance measurements, and then report initial experiments using a conventional piezoelectric transducer for excitation, with successful detection of signals in an on-axis transmission experiment and successful source localization from phased array performance in an off-axis transmission experiment.

Time-localized frequency analysis of ultrasonic guided waves for nondestructive testing

NASA Astrophysics Data System (ADS)

Shin, Hyeon Jae; Song, Sung-Jin

2000-05-01

A time-localized frequency (TLF) analysis is employed for the guided wave mode identification and improved guided wave applications. For the analysis of time-localized frequency contents of digitized ultrasonic signals, TLF analysis consists of splitting the time domain signal into overlapping segments, weighting each with the hanning window, and forming the columns of discrete Fourier transforms. The result is presented by a frequency versus time domain diagram showing frequency variation along the signal arrival time. For the demonstration of the utility of TLF analysis, an experimental group velocity dispersion pattern obtained by TLF analysis is compared with the dispersion diagram obtained by theory of elasticity. Sample piping is carbon steel piping that is used for the transportation of natural gas underground. Guided wave propagation characteristic on the piping is considered with TLF analysis and wave structure concepts. TLF analysis is used for the detection of simulated corrosion defects and the assessment of weld joint using ultrasonic guided waves. TLF analysis has revealed that the difficulty of mode identification in multi-mode propagation could be overcome. Group velocity dispersion pattern obtained by TLF analysis agrees well with theoretical results.

Comparative study on the welded structure fatigue strength assessment method

NASA Astrophysics Data System (ADS)

Hu, Tao

2018-04-01

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

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

NASA Technical Reports Server (NTRS)

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

1991-01-01

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

Mechanical Properties and Microstructural Characterization of Aged Nickel-based Alloy 625 Weld Metal

NASA Astrophysics Data System (ADS)

Silva, Cleiton Carvalho; de Albuquerque, Victor Hugo C.; Miná, Emerson Mendonça; Moura, Elineudo P.; Tavares, João Manuel R. S.

2018-03-01

The aim of this work was to evaluate the different phases formed during solidification and after thermal aging of the as-welded 625 nickel-based alloy, as well as the influence of microstructural changes on the mechanical properties. The experiments addressed aging temperatures of 650 and 950 °C for 10, 100, and 200 hours. The samples were analyzed by electron microscopy, microanalysis, and X-ray diffraction in order to identify the secondary phases. Mechanical tests such as hardness, microhardness, and Charpy-V impact test were performed. Nondestructive ultrasonic inspection was also conducted to correlate the acquired signals with mechanical and microstructural properties. The results show that the alloy under study experienced microstructural changes when aged at 650 °C. The aging was responsible by the dissolution of the Laves phase formed during the solidification and the appearance of γ″ phase within interdendritic region and fine carbides along the solidification grain boundaries. However, when it was aged at 950 °C, the Laves phase was continuously dissolved and the excess Nb caused the precipitation of the δ-phase (Ni3Nb), which was intensified at 10 hours of aging, with subsequent dissolution for longer periods such as 200 hours. Even when subjected to significant microstructural changes, the mechanical properties, especially toughness, were not sensitive to the dissolution and/or precipitation of the secondary phases.

Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

Welding quality evaluation of resistance spot welding using the time-varying inductive reactance signal

NASA Astrophysics Data System (ADS)

Zhang, Hongjie; Hou, Yanyan; Yang, Tao; Zhang, Qian; Zhao, Jian

2018-05-01

In the spot welding process, a high alternating current is applied, resulting in a time-varying electromagnetic field surrounding the welder. When measuring the welding voltage signal, the impedance of the measuring circuit consists of two parts: dynamic resistance relating to weld nugget nucleation event and inductive reactance caused by mutual inductance. The aim of this study is to develop a method to acquire the dynamic reactance signal and to discuss the possibility of using this signal to evaluate the weld quality. For this purpose, a series of experiments were carried out. The reactance signals under different welding conditions were compared and the results showed that the morphological feature of the reactance signal was closely related to the welding current and it was also significantly influenced by some abnormal welding conditions. Some features were extracted from the reactance signal and combined to construct weld nugget strength and diameter prediction models based on the radial basis function (RBF) neural network. In addition, several features were also used to monitor the expulsion in the welding process by using Fisher linear discriminant analysis. The results indicated that using the dynamic reactance signal to evaluate weld quality is possible and feasible.

Test and Evaluation of Ultrasonic Additive Manufacturing (UAM) for a Large Aircraft Maintenance Shelter (LAMS) Baseplate

DTIC Science & Technology

2015-03-26

TEST AND EVALUATION OF ULTRASONIC ADDITIVE MANUFACTURING (UAM) FOR A LARGE AREA MAINTENANCE...States Government. AFIT-ENV-MS-15-M-158 TEST AND EVALUATION OF ULTRASONIC ADDITIVE MANUFACTURING FOR A LARGE AREA MAINTENANCE SHELTER...Civil Engineer (CE) operations. This research replicates a Large Area Maintenance Shelter (LAMS) baseplate design for ultrasonic additive

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.

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.

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.

Semiconductor power devices for chopper applications at frequencies of 20 kHz and higher, and for 5 to 20 kVA power output

NASA Astrophysics Data System (ADS)

Grube, R.; Tursky, W.; Gerzovskovits, S.; Schierz, W.

1982-12-01

An asymmetrical gate assisted turn-off thyristor and two types of rectifier diodes were developed. These devices are suitable for self-commutated convertors working at frequencies between 15 and 30 kHz for direct connection to 380 V and 500 V lines and for power outputs up to 20 kVA. Such convertors allow economic and easily controllable power supplies to be realized for applications such as welding, inductive heating, ultrasonic generators, and radar modulators.

Fatigue evaluation of socket welded piping in nuclear power plant

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

Vecchio, R.S.

1996-12-01

Fatigue failures in piping systems occur, almost without exception, at the welded connections. In nuclear power plant systems, such failures occur predominantly at the socket welds of small diameter piping ad fillet attachment welds under high-cycle vibratory conditions. Nearly all socket weld fatigue failures are identified by leaks which, though not high in volume, generally are costly due to attendant radiological contamination. Such fatigue cracking was recently identified in the 3/4 in. diameter recirculation and relief piping socket welds from the reactor coolant system (RCS) charging pumps at a nuclear power plant. Consequently, a fatigue evaluation was performed to determinemore » the cause of cracking and provide an acceptable repair. Socket weld fatigue life was evaluated using S-N type fatigue life curves for welded structures developed by AASHTO and the assessment of an effective cyclic stress range adjacent to each socket weld. Based on the calculated effective tress ranges and assignment of the socket weld details to the appropriate AASHTO S-N curves, the socket weld fatigue lives were calculated and found to be in excellent agreement with the accumulated cyclic life to-date.« less

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.

Computational simulation of weld microstructure and distortion by considering process mechanics

NASA Astrophysics Data System (ADS)

Mochizuki, M.; Mikami, Y.; Okano, S.; Itoh, S.

2009-05-01

Highly precise fabrication of welded materials is in great demand, and so microstructure and distortion controls are essential. Furthermore, consideration of process mechanics is important for intelligent fabrication. In this study, the microstructure and hardness distribution in multi-pass weld metal are evaluated by computational simulations under the conditions of multiple heat cycles and phase transformation. Because conventional CCT diagrams of weld metal are not available even for single-pass weld metal, new diagrams for multi-pass weld metals are created. The weld microstructure and hardness distribution are precisely predicted when using the created CCT diagram for multi-pass weld metal and calculating the weld thermal cycle. Weld distortion is also investigated by using numerical simulation with a thermal elastic-plastic analysis. In conventional evaluations of weld distortion, the average heat input has been used as the dominant parameter; however, it is difficult to consider the effect of molten pool configurations on weld distortion based only on the heat input. Thus, the effect of welding process conditions on weld distortion is studied by considering molten pool configurations, determined by temperature distribution and history.

Ultrasonic Nondestructive Evaluation of Damage in Continuous Fiber Composites

DTIC Science & Technology

1989-01-01

Security Classification) Ultrasonic Nondestructive Evalustion of Damage in Continuous Fiber Composites 12. PERSONAL AUTHOR(S) Vikram K. Kinra 13a...Attenuatiorn Composites , Damage / " UltrasonicNondestructive Evaluation. \\ ’k 19. ABSTRACT (Continue on reverse if necessary and identify by block n,,ber) A...n SIrIE -~ 2 4IiCUi’.ZIEfEi Ultrasonic nondestructive evaluation of fibre-reinforced composite materials - a review VIKRAM K KINRA and VINAY DAYAL

International Symposium on Interfacial Joining and Surface Technology (IJST2013)

NASA Astrophysics Data System (ADS)

Takahashi, Yasuo

2014-08-01

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

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.

Development of evaluation technique of GMAW welding quality based on statistical analysis

NASA Astrophysics Data System (ADS)

Feng, Shengqiang; Terasaki, Hidenri; Komizo, Yuichi; Hu, Shengsun; Chen, Donggao; Ma, Zhihua

2014-11-01

Nondestructive techniques for appraising gas metal arc welding(GMAW) faults plays a very important role in on-line quality controllability and prediction of the GMAW process. On-line welding quality controllability and prediction have several disadvantages such as high cost, low efficiency, complication and greatly being affected by the environment. An enhanced, efficient evaluation technique for evaluating welding faults based on Mahalanobis distance(MD) and normal distribution is presented. In addition, a new piece of equipment, designated the weld quality tester(WQT), is developed based on the proposed evaluation technique. MD is superior to other multidimensional distances such as Euclidean distance because the covariance matrix used for calculating MD takes into account correlations in the data and scaling. The values of MD obtained from welding current and arc voltage are assumed to follow a normal distribution. The normal distribution has two parameters: the mean µ and standard deviation σ of the data. In the proposed evaluation technique used by the WQT, values of MD located in the range from zero to µ+3 σ are regarded as "good". Two experiments which involve changing the flow of shielding gas and smearing paint on the surface of the substrate are conducted in order to verify the sensitivity of the proposed evaluation technique and the feasibility of using WQT. The experimental results demonstrate the usefulness of the WQT for evaluating welding quality. The proposed technique can be applied to implement the on-line welding quality controllability and prediction, which is of great importance to design some novel equipment for weld quality detection.

Application of Various NDT Methods for the Evaluation of Building Steel Structures for Reuse

PubMed Central

Fujita, Masanori; Masuda, Tomoya

2014-01-01

The reuse system proposed by the authors is an overall business system for realizing a cyclic reuse flow through the processes of design, fabrication, construction, maintenance, demolition and storage. The reuse system is one of the methods to reduce the environmental burden in the field of building steel structures. These buildings are assumed to be demolished within approximately 30 years or more for physical, architectural, economic and social reasons in Japan. In this paper, focusing on building steel structures used for plants, warehouses and offices without fire protection, the performance of steel structural members for reuse is evaluated by a non-destructive test. First, performance evaluation procedures for a non-destructive test, such as mechanical properties, chemical compositions, dimension and degradation, are shown. Tensile strengths are estimated using Vickers hardness measured by a portable ultrasonic hardness tester, and chemical compositions are measured by a portable optical emission spectrometer. The weldability of steel structural members is estimated by carbon equivalent and weld crack sensitivity composition using chemical compositions. Finally, the material grade of structural members of the building steel structure for reuse is estimated based on the proposed procedures. PMID:28788237

Application of Various NDT Methods for the Evaluation of Building Steel Structures for Reuse.

PubMed

Fujita, Masanori; Masuda, Tomoya

2014-10-22

The reuse system proposed by the authors is an overall business system for realizing a cyclic reuse flow through the processes of design, fabrication, construction, maintenance, demolition and storage. The reuse system is one of the methods to reduce the environmental burden in the field of building steel structures. These buildings are assumed to be demolished within approximately 30 years or more for physical, architectural, economic and social reasons in Japan. In this paper, focusing on building steel structures used for plants, warehouses and offices without fire protection, the performance of steel structural members for reuse is evaluated by a non-destructive test. First, performance evaluation procedures for a non-destructive test, such as mechanical properties, chemical compositions, dimension and degradation, are shown. Tensile strengths are estimated using Vickers hardness measured by a portable ultrasonic hardness tester, and chemical compositions are measured by a portable optical emission spectrometer. The weldability of steel structural members is estimated by carbon equivalent and weld crack sensitivity composition using chemical compositions. Finally, the material grade of structural members of the building steel structure for reuse is estimated based on the proposed procedures.

Heavy-section welding with very high power laser beams: the challenge

NASA Astrophysics Data System (ADS)

Goussain, Jean-Claude; Becker, Ahim; Chehaibou, A.; Leca, P.

1997-08-01

The 45 kW CO2 laser system of Institut de Soudure was used to evaluate and explore the possibilities offered by the high power laser beams for welding different materials in various thickness and in different welding positions. Stainless steels, low carbon steels, aluminum and titanium alloys were studied. Butt joints in 10 to 35 mm thick plates were achieved and evaluated by radiographic, metallurgical and mechanical tests. Gaps and alignment tolerances were determined with and without filler wire in order to obtain acceptable welds concerning the weld geometry, the aspect on front and end root sides. The main problem raised by heavy section welding concerns weld porosity in the weld which increases drastically with the thickness of the weld. Indications are given on their origin and the way to proceed in order to better control them. Lastly some large parts, recently welded on the system, are presented and discussed before drawing some conclusions on the prospects of very high power laser welding.

Identification and prioritization of rail squat defects in the field using rail magnetisation technology

NASA Astrophysics Data System (ADS)

Kaewunruen, Sakdirat

2015-04-01

Inevitably, rail squats and studs are continuing to be a serious problem for railway organisations around the world in the 21st century. They are typically classified as the growth of any cracks that have grown longitudinally through the subsurface and some of the cracks propagating to the bottom of rails transversely, and have branched from initial longitudinal cracks with a depression of rail surface. The horizontal crack, which results in a depression of rail surface, induces increased maintenance level, more frequent monitoring, compromised rail testing (as the crack shields the signal echoes), and possible broken rails. This paper presents field investigations using a magnetised-rail testing device developed by MRX Technologies to identify and prioritise the rail squats. Most of the in situ squats were found on the high rail of the transition (variable-radius curved track), which is associated with rolling contact fatigue (RCF). This investigation highlights the field performance of the MRX's surface crack detection technology in comparison with the traditional ultrasonic method and detailed walking inspection. Visually, it was found in the field that the size of the RCF squats varies from very small to moderate. The predicted crack data were obtained by scanning the magnitised rails. The comparison of the actual crack depths (ultrasonic) and the predicted crack depths (MRX device) shows: • A possible correlation for small RCF/ squat cracks. • Poor interpretation of larger defects and welds. The field assessment also suggests some practical issues required for further development, including the detection of rail spalling, deep transverse crack, welding, and so on.

Enabling high speed friction stir welding of aluminum tailor welded blanks

NASA Astrophysics Data System (ADS)

Hovanski, Yuri

Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding (FSW) has traditionally been applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translate to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum FSW components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability using a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.

Friction Stir Spot Welding of Advanced High Strength Steels

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

Hovanski, Yuri; Grant, Glenn J.; Santella, M. L.

Friction stir spot welding techniques were developed to successfully join several advanced high strength steels. Two distinct tool materials were evaluated to determine the effect of tool materials on the process parameters and joint properties. Welds were characterized primarily via lap shear, microhardness, and optical microscopy. Friction stir spot welds were compared to the resistance spot welds in similar strength alloys by using the AWS standard for resistance spot welding high strength steels. As further comparison, a primitive cost comparison between the two joining processes was developed, which included an evaluation of the future cost prospects of friction stir spotmore » welding in advanced high strength steels.« less

Emissions of fluorides from welding processes.

PubMed

Szewczyńska, Małgorzata; Pągowska, Emilia; Pyrzyńska, Krystyna

2015-11-01

The levels of fluoride airborne particulates emitted from welding processes were investigated. They were sampled with the patented IOM Sampler, developed by J. H. Vincent and D. Mark at the Institute of Occupational Medicine (IOM), personal inhalable sampler for simultaneous collection of the inhalable and respirable size fractions. Ion chromatography with conductometric detection was used for quantitative analysis. The efficiency of fluoride extraction from the cellulose filter of the IOM sampler was examined using the standard sample of urban air particle matter SRM-1648a. The best results for extraction were obtained when water and the anionic surfactant N-Cetyl-N-N-N-trimethylammonium bromide (CTAB) were used in an ultrasonic bath. The limits of detection and quantification for the whole procedure were 8μg/L and 24μg/L, respectively. The linear range of calibration was 0.01-10mg/L, which corresponds to 0.0001-0.1mg of fluorides per m(3) in collection of a 20L air sample. The concentration of fluorides in the respirable fraction of collected air samples was in the range of 0.20-1.82mg/m(3), while the inhalable fraction contained 0.23-1.96mg/m(3) of fluorides during an eight-hour working day in the welding room. Copyright © 2015. Published by Elsevier B.V.

Nonlinear ultrasonic assessment of stress corrosion cracking damage in sensitized 304 stainless steel

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

Morlock, Florian, E-mail: fmorlock3@gatech.edu; Jacobs, Laurence J., E-mail: fmorlock3@gatech.edu; Kim, Jin-Yeon, E-mail: fmorlock3@gatech.edu

2015-03-31

This research uses nonlinear Rayleigh surface waves to characterize stress corrosion cracking (SCC) damage in welded 304 Stainless Steel (304 SS). 304 SS is widely used in reactor pressure vessels, where a corrosive environment in combination with applied stress due to high internal pressures can cause SCC. Welds and the nearby heat affected zones (HAZ) in the vessel material are especially sensitive to SCC damage. SCC damage results in microstructural changes such as dislocation formation and microcrack initiation that in the long term lead to reduced structural integrity and material failure. Therefore, the early detection of SCC is crucial tomore » ensure safe operation. It has been shown that the microstructural changes caused by SCC can generate higher harmonic waves when excited harmonically. This research considers different levels of SCC damage induced in samples of welded 304 SS by applying stress to a specimen held in a corrosive medium (Sodium Thiosulfate). A nonlinear Rayleigh surface wave is introduced in the material and the fundamental and the second harmonic waves are measured using wedge detection. The nonlinearity parameter that relates the fundamental and the second harmonic amplitudes, is computed to quantify the SCC damage in each sample. These results are used to demonstrate the feasibility of using nonlinear Rayleigh waves to characterize SCC damage.« less

Study of guided wave transmission through complex junction in sodium cooled reactor

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

Elie, Q.; Le Bourdais, F.; Jezzine, K.

2015-07-01

Ultrasonic guided wave techniques are seen as suitable candidates for the inspection of welded structures within sodium cooled fast reactors (SFR), as the long range propagation of guided waves without amplitude attenuation can overcome the accessibility problem due to the liquid sodium. In the context of the development of the Advanced Sodium Test Reactor for Industrial Demonstration (ASTRID), the French Atomic Commission (CEA) investigates non-destructive testing techniques based on guided wave propagation. In this work, guided wave NDT methods are applied to control the integrity of welds located in a junction-type structure welded to the main vessel. The method presentedmore » in this paper is based on the analysis of scattering matrices peculiar to each expected defect, and takes advantage of the multi-modal and dispersive characteristics of guided wave generation. In a simulation study, an algorithm developed using the CIVA software is presented. It permits selecting appropriate incident modes to optimize detection and identification of expected flawed configurations. In the second part of this paper, experimental results corresponding to a first validation step of the simulation results are presented. The goal of the experiments is to estimate the effectiveness of the incident mode selection in plates. The results show good agreement between experience and simulation. (authors)« less

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

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

Hovanski, Yuri; Carsley, John; Carlson, Blair

2014-01-15

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

Performance of PIN-PMN-PT Single Crystal Piezoelectric versus PZT8 Piezoceramic Materials in Ultrasonic Transducers

NASA Astrophysics Data System (ADS)

DeAngelis, D. A.; Schulze, G. W.

The recent advancements in the manufacturing of single crystal PIN-PMN-PT piezoelectric materials now make them a cost-competitive alternative to PZT4 and PZT8 (Navy Types I and III) piezoceramic materials, which have been the workhorse of power ultrasonic applications (e.g., welding, cutting, sonar, etc.) for over 50 years. Although there are great benefits to the use of single crystal materials with respect to high output, as well as added actuating and sensing abilities, many transducer designers are still reluctant to explore these materials due to inadequate design guidelines for substituting the familiar PZT materials; for example, what are the implications of the higher capacitance, sensitivity to chipping/cracks, aging effects, frequency shifts, or how much preload can be used are all common questions. This research is a case study on the performance of identical ultrasonic transducer bodies, used for semiconductor wire bonding, assembled with either PZT8 or PIN-PMN-PT piezo material. The main purpose of the study is to establish rule-of-thumb design guidelines for direct substitution of single crystal materials in existing PZT8 transducer designs, along with a side-by-side performance comparison to highlight benefits. Several metrics are investigated such as impedance, frequency, displacement gain, quality factor and electromechanical coupling factor.

Performance of PZT8 Versus PZT4 Piezoceramic Materials in Ultrasonic Transducers

NASA Astrophysics Data System (ADS)

DeAngelis, Dominick A.; Schulze, Gary W.

PZT8 and PZT4 are the common "hard" piezoceramic materials used in power ultrasonic transducers (e.g., welding, cutting, sonar, etc.). PZT8 is perceived as the better choice for resonant devices, primarily due to its higher mechanical quality factor Qm. PZT8 is also considered a "harder" material compared to PZT4, since it has better stability at higher preloads and drive levels. Many transducer designers never consider PZT4 for their applications, even though it has clear advantages such as higher output (i.e., higher d33). Even the perceived advantage of PZT8 regarding Qm may not be significant for most Langevin, bolted stack type transducers if the mechanical joint losses dominate. This research is a case study on the performance of identical ultrasonic transducers used for semiconductor wire bonding, assembled with either PZT8 or PZT4 materials. The main purpose of the study is to establish rule-of-thumb transducer design guidelines for the selection of PZT8 versus PZT4 materials. Several metrics are investigated such as impedance, frequency, capacitance, dielectric loss, Qm, heating, displacement gain, and electro-mechanical coupling factor. The experimental and theoretical research methods include Bode plots, thermal IR camera imaging, scanning laser vibrometry and coupled-field finite element analysis.

Advanced Bode Plot Techniques for Ultrasonic Transducers

NASA Astrophysics Data System (ADS)

DeAngelis, D. A.; Schulze, G. W.

The Bode plot, displayed as either impedance or admittance versus frequency, is the most basic test used by ultrasonic transducer designers. With simplicity and ease-of-use, Bode plots are ideal for baseline comparisons such as spacing of parasitic modes or impedance, but quite often the subtleties that manifest as poor process control are hard to interpret or are nonexistence. In-process testing of transducers is time consuming for quantifying statistical aberrations, and assessments made indirectly via the workpiece are difficult. This research investigates the use of advanced Bode plot techniques to compare ultrasonic transducers with known "good" and known "bad" process performance, with the goal of a-priori process assessment. These advanced techniques expand from the basic constant voltage versus frequency sweep to include constant current and constant velocity interrogated locally on transducer or tool; they also include up and down directional frequency sweeps to quantify hysteresis effects like jumping and dropping phenomena. The investigation focuses solely on the common PZT8 piezoelectric material used with welding transducers for semiconductor wire bonding. Several metrics are investigated such as impedance, displacement/current gain, velocity/current gain, displacement/voltage gain and velocity/voltage gain. The experimental and theoretical research methods include Bode plots, admittance loops, laser vibrometry and coupled-field finite element analysis.

A drift chamber with a new type of straws for operation in vacuum

NASA Astrophysics Data System (ADS)

Azorskiy, N.; Glonti, L.; Gusakov, Yu.; Elsha, V.; Enik, T.; Kakurin, S.; Kekelidze, V.; Kislov, E.; Kolesnikov, A.; Madigozhin, D.; Movchan, S.; Polenkevich, I.; Potrebenikov, Yu.; Samsonov, V.; Shkarovskiy, S.; Sotnikov, S.; Zinchenko, A.; Danielsson, H.; Bendotti, J.; Degrange, J.; Dixon, N.; Lichard, P.; Morant, J.; Palladino, V.; Gomez, F. Perez; Ruggiero, G.; Vergain, M.

2016-07-01

A 2150×2150 mm2 registration area drift chamber capable of working in vacuum is presented. Thin-wall tubes (straws) of a new type are used in the chamber. A large share of these 9.80 mm diameter drift tubes are made in Dubna from metalized 36 μm Mylar film welded along the generatrix using an ultrasonic welding machine created at JINR. The main features of the chamber and some characteristics of the drift tubes are described. Four such chambers with the X, Y, U, V coordinates each, containing 7168 straws in total, are designed and produced at JINR and CERN. They are installed in the vacuum volume of the NA62 setup in order to study the ultra-rare decay K+ →π+ vv bar and to search for and study rare meson decays. In autumn 2014 the chambers were used for the first time for the data taking in the experimental run of the NA62 at CERN's SPS.

Status of FAA Studies in Thermal Acoustics

NASA Astrophysics Data System (ADS)

Lively, John; Ouyang, Zhong; Brasche, Lisa; Holland, Steve; Eisenmann, David; Bantel, Tom; Hassan, Waled

2008-02-01

As with many aerospace applications, commercial jet engine components are operated in demanding environments, often at extreme temperature and stress conditions. The predominant used surface inspection method used on these components is fluorescent penetrant inspection. Research has been ongoing for a number of years on a new technology using a short burst of low frequency (˜20 KHz) ultrasound to "heat up" cracks and make them visible in the infrared range. The basic premise of the Thermal Acoustic method is to use an energy source with recent efforts using an ultrasonic horn originally intended for use in ultrasonic welding to excite the component. The energy source causes an increase in local heating, which is detectable with infrared cameras typically used in Thermographic inspection. While considerable research is underway, additional information on the sensitivity and applicability of this technique to engine components and alloys is needed prior to widespread use in the aviation industry. The purpose of this program is to provide additional data to determine applicability of this method to engine components.

High-Speed Friction-Stir Welding To Enable Aluminum Tailor-Welded Blanks

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

Hovanski, Yuri; Upadhyay, Piyush; Carsley, John

Current joining technologies for automotive aluminum alloys are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding has been traditionally applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translatemore » to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum welded components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability utilizing a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.« less

Parameter optimization of flux-aided backing-submerged arc welding by using Taguchi method

NASA Astrophysics Data System (ADS)

Pu, Juan; Yu, Shengfu; Li, Yuanyuan

2017-07-01

Flux-aided backing-submerged arc welding has been conducted on D36 steel with thickness of 20 mm. The effects of processing parameters such as welding current, voltage, welding speed and groove angle on welding quality were investigated by Taguchi method. The optimal welding parameters were predicted and the individual importance of each parameter on welding quality was evaluated by examining the signal-to-noise ratio and analysis of variance (ANOVA) results. The importance order of the welding parameters for the welding quality of weld bead was: welding current > welding speed > groove angle > welding voltage. The welding quality of weld bead increased gradually with increasing welding current and welding speed and decreasing groove angle. The optimum values of the welding current, welding speed, groove angle and welding voltage were found to be 1050 A, 27 cm/min, 40∘ and 34 V, respectively.

[Evaluation of measurement uncertainty of welding fume in welding workplace of a shipyard].

PubMed

Ren, Jie; Wang, Yanrang

2015-12-01

To evaluate the measurement uncertainty of welding fume in the air of the welding workplace of a shipyard, and to provide quality assurance for measurement. According to GBZ/T 192.1-2007 "Determination of dust in the air of workplace-Part 1: Total dust concentration" and JJF 1059-1999 "Evaluation and expression of measurement uncertainty", the uncertainty for determination of welding fume was evaluated and the measurement results were completely described. The concentration of welding fume was 3.3 mg/m(3), and the expanded uncertainty was 0.24 mg/m(3). The repeatability for determination of dust concentration introduced an uncertainty of 1.9%, the measurement using electronic balance introduced a standard uncertainty of 0.3%, and the measurement of sample quality introduced a standard uncertainty of 3.2%. During the determination of welding fume, the standard uncertainty introduced by the measurement of sample quality is the dominant uncertainty. In the process of sampling and measurement, quality control should be focused on the collection efficiency of dust, air humidity, sample volume, and measuring instruments.

VPPA weld model evaluation

NASA Technical Reports Server (NTRS)

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

1992-01-01

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

Hermetic edge sealing of photovoltaic modules

NASA Astrophysics Data System (ADS)

1983-02-01

The edge sealing technique is accomplished by a combination of a chemical bond between glass and aluminum, formed by electrostatic bonding, and a metallurgical bond between aluminum and aluminum, formed by ultrasonic welding. Such a glass to metal seal promises to provide a low cost, long lifetime, highly effective hermetic seal which can protect module components from severe environments. Development of the sealing techniques and demonstration of their effectiveness by fabricating a small number of dummy modules, up to eight inches square in size, and testing them for hermeticity using helium leak testing methods are reviewed. Non-destructive test methods are investigated.

Intraocular lens fabrication

DOEpatents

Salazar, M.A.; Foreman, L.R.

1997-07-08

This invention describes a method for fabricating an intraocular lens made from clear Teflon{trademark}, Mylar{trademark}, or other thermoplastic material having a thickness of about 0.025 millimeters. These plastic materials are thermoformable and biocompatable with the human eye. The two shaped lenses are bonded together with a variety of procedures which may include thermosetting and solvent based adhesives, laser and impulse welding, and ultrasonic bonding. The fill tube, which is used to inject a refractive filling material is formed with the lens so as not to damage the lens shape. A hypodermic tube may be included inside the fill tube. 13 figs.

Intraocular lens fabrication

DOEpatents

Salazar, Mike A.; Foreman, Larry R.

1997-01-01

This invention describes a method for fabricating an intraocular lens made rom clear Teflon.TM., Mylar.TM., or other thermoplastic material having a thickness of about 0.025 millimeters. These plastic materials are thermoformable and biocompatable with the human eye. The two shaped lenses are bonded together with a variety of procedures which may include thermosetting and solvent based adhesives, laser and impulse welding, and ultrasonic bonding. The fill tube, which is used to inject a refractive filling material is formed with the lens so as not to damage the lens shape. A hypodermic tube may be included inside the fill tube.

Study to develop improved methods to detect leakage in fluid systems, phase 2

NASA Technical Reports Server (NTRS)

Janus, J. C.; Cimerman, I.

1971-01-01

An ultrasonic contact sensor engineering prototype leak detection system was developed and its capabilities under cryogenic operations demonstrated. The results from tests indicate that the transducer performed well on liquid hydrogen plumbing, that flow and valve actuation could be monitored, and that the phase change from gaseous to liquid hydrogen could be detected by the externally mounted transducers. Tests also demonstrate the ability of the system to detect internal leaks past valve seats and to function as a flow meter. Such a system demonstrates that it is not necessary to break into welded systems to locate internal leaks.

Hermetic edge sealing of photovoltaic modules

NASA Technical Reports Server (NTRS)

1983-01-01

The edge sealing technique is accomplished by a combination of a chemical bond between glass and aluminum, formed by electrostatic bonding, and a metallurgical bond between aluminum and aluminum, formed by ultrasonic welding. Such a glass to metal seal promises to provide a low cost, long lifetime, highly effective hermetic seal which can protect module components from severe environments. Development of the sealing techniques and demonstration of their effectiveness by fabricating a small number of dummy modules, up to eight inches square in size, and testing them for hermeticity using helium leak testing methods are reviewed. Non-destructive test methods are investigated.

SLAM examination of solar cells and solar cell welds. [Scanning Laser Acoustic Microscope

NASA Technical Reports Server (NTRS)

Stella, P. M.; Vorres, C. L.; Yuhas, D. E.

1981-01-01

The scanning laser acoustic microscope (SLAM) has been evaluated for non-destructive examination of solar cells and interconnector bonds. Using this technique, it is possible to view through materials in order to reveal regions of discontinuity such as microcracks and voids. Of particular interest is the ability to evaluate, in a unique manner, the bonds produced by parallel gap welding. It is possible to not only determine the area and geometry of the bond between the tab and cell, but also to reveal any microcracks incurred during the welding. By correlating the SLAM results with conventional techniques of weld evaluation a more confident weld parameter optimization can be obtained.

In-field Welding and Coating Protocols

DOT National Transportation Integrated Search

2009-05-12

Gas Technology Institute (GTI) and Edison Welding Institute (EWI) created both laboratory and infield girth weld samples to evaluate the effects of weld geometry and hydrogen off-gassing on the performance of protective coatings. Laboratory made plat...

Ultrasonic stress wave characterization of composite materials

NASA Technical Reports Server (NTRS)

Duke, J. C., Jr.; Henneke, E. G., II; Stinchcomb, W. W.

1986-01-01

The work reported covers three simultaneous projects. The first project was concerned with: (1) establishing the sensitivity of the acousto-ultrasonic method for evaluating subtle forms of damage development in cyclically loaded composite materials, (2) establishing the ability of the acousto-ultrasonic method for detecting initial material imperfections that lead to localized damage growth and final specimen failure, and (3) characteristics of the NBS/Proctor sensor/receiver for acousto-ultrasonic evaluation of laminated composite materials. The second project was concerned with examining the nature of the wave propagation that occurs during acoustic-ultrasonic evaluation of composite laminates and demonstrating the role of Lamb or plate wave modes and their utilization for characterizing composite laminates. The third project was concerned with the replacement of contact-type receiving piezotransducers with noncontacting laser-optical sensors for acousto-ultrasonic signal acquisition.

Status analysis of keyhole bottom in laser-MAG hybrid welding process.

PubMed

Wang, Lin; Gao, Xiangdong; Chen, Ziqin

2018-01-08

The keyhole status is a determining factor of weld quality in laser-metal active gas arc (MAG) hybrid welding process. For a better evaluation of the hybrid welding process, three different penetration welding experiments: partial penetration, normal penetration (or full penetration), and excessive penetration were conducted in this work. The instantaneous visual phenomena including metallic vapor, spatters and keyhole of bottom surface were used to evaluate the keyhole status by a double high-speed camera system. The Fourier transform was applied on the bottom weld pool image for removing the image noise around the keyhole, and then the bottom weld pool image was reconstructed through the inverse Fourier transform. Lastly, the keyhole bottom was extracted from the de-noised bottom weld pool image. By analyzing the visual features of the laser-MAG hybrid welding process, mechanism of the closed and opened keyhole bottom were revealed. The results show that the stable opened or closed status of keyhole bottom is directly affected by the MAG droplet transition in the normal penetration welding process, and the unstable opened or closed status of keyhole bottom would appear in excessive penetration welding and partial penetration welding. The analysis method proposed in this paper could be used to monitor the keyhole stability in laser-MAG hybrid welding process.

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

NASA Technical Reports Server (NTRS)

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

1999-01-01

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

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.

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.

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.

Repair welding of gamma titanium aluminide castings

NASA Astrophysics Data System (ADS)

Kelly, T. J.

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

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.

An Evaluation of Former Soviet Union Welding Processes on Commercially Pure Titanium

DTIC Science & Technology

2001-12-01

welding (GTAW), gas metal arc welding ( GMAW ), and plasma arc welding (PAW) being the most widely used techniques. Of these, the GTAW process is much...quality welds, is free of the spatter that may occur with GMAW , and can be used with or without filler material, depending on the specific application

Ultrasonic and radiographic evaluation of advanced aerospace materials: Ceramic composites

NASA Technical Reports Server (NTRS)

Generazio, Edward R.

1990-01-01

Two conventional nondestructive evaluation techniques were used to evaluate advanced ceramic composite materials. It was shown that neither ultrasonic C-scan nor radiographic imaging can individually provide sufficient data for an accurate nondestructive evaluation. Both ultrasonic C-scan and conventional radiographic imaging are required for preliminary evaluation of these complex systems. The material variations that were identified by these two techniques are porosity, delaminations, bond quality between laminae, fiber alignment, fiber registration, fiber parallelism, and processing density flaws. The degree of bonding between fiber and matrix cannot be determined by either of these methods. An alternative ultrasonic technique, angular power spectrum scanning (APSS) is recommended for quantification of this interfacial bond.

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.

Evaluation of Distortion in Welding Unions of 304 Stainless Steel with Elliptic Trajectory Using a Welding Robot

NASA Astrophysics Data System (ADS)

Carrasco-González, L. A.; Hurtado-Delgado, E.; Reyes-Valdés, F. A.

The aim of this investigation is to evaluate the distortions generated in welding unions of stainless steel 304 by effect of the welding temperature and the microestructural changes. The joint design is a 100 × 100 mm steel plate of 3 mm thickness. The plate was joined to a tube of 50 mm diameter and 2 mm thickness, which has a defined angular cut; therefore, the trajectory followed by the seam has an elliptic form. Temperature data acquisition was developed by type K thermocouples, placed in pairs at 0°, 90°, 180° and 270° along the welding trajectory and connected to a data acquisition device yo obtain the measures to generate time-temperature plots. The welding process was executed by a KUKA ®; KR16 welding robot with an integrated GMAW (Gas metal arc welding) process where the input parameters of voltage, wire feed and travel speed are set to constant. The distortion of the work piece was measured using a laser scanning technique that generates a point cloud with the VXelements TM software for comparison between the pre and post-weld condition. Microstructural evaluation was performed on transversal sections of the seam, at the mentioned angles for correlation.

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.

High-Speed Friction-Stir Welding to Enable Aluminum Tailor-Welded Blanks

NASA Astrophysics Data System (ADS)

Hovanski, Yuri; Upadhyay, Piyush; Carsley, John; Luzanski, Tom; Carlson, Blair; Eisenmenger, Mark; Soulami, Ayoub; Marshall, Dustin; Landino, Brandon; Hartfield-Wunsch, Susan

2015-05-01

Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and they have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high volumes. While friction-stir welding (FSW) has been traditionally applied at linear velocities less than 1 m/min, high-volume production applications demand the process be extended to higher velocities more amenable to cost-sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low-to-moderate welding velocities do not directly translate to high-speed linear FSW. Therefore, to facilitate production of high-volume aluminum FSW components, parameters were developed with a minimum welding velocity of 3 m/min. With an emphasis on weld quality, welded blanks were evaluated for postweld formability using a combination of numerical and experimental methods. An evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum TWBs, which provided validation of the numerical and experimental analysis of laboratory-scale tests.

Implementation of an Outer Can Welding System for Savannah River Site FB-Line

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

Howard, S.R.

2003-03-27

This paper details three phases of testing to confirm use of a Gas Tungsten Arc (GTA) system for closure welding the 3013 outer container used for stabilization/storage of plutonium metals and oxides. The outer container/lid closure joint was originally designed for laser welding, but for this application, the gas tungsten arc (GTA) welding process has been adapted. The testing progressed in three phases: (1) system checkout to evaluate system components for operational readiness, (2) troubleshooting to evaluate high weld failure rates and develop corrective techniques, and (3) pre-installation acceptance testing.

Evaluation of Hydrogen Cracking in Weld Metal Deposited Using Cellulosic Electrodes

DOT National Transportation Integrated Search

2005-11-01

Cellulosic-coated electrodes (primarily AWS EXX10-type) are traditionally used for "stovepipe" welding of pipelines because they are well suited for deposition of pipeline girth welds and are capable of high deposition rates when welding downhill. Ex...

Mechanical Properties of Friction Stir Welds in A12195-T8

NASA Technical Reports Server (NTRS)

Kinchen, David G.; Li, Zhixian; Adams, Glynn P.

1999-01-01

An extensive study of the mechanical properties of friction stir welded Al-Li 2195 has been conducted by Lockheed Martin Michoud Space Systems under contract to NASA. The study was part of a development program in which weld parameters were defined for using FSW to assemble large-scale aluminum cryogenic tanks. In excess of 300 feet of 0.320 in. gage plate material was welded and tested. The tests include room temperature and cryogenic temperature tensile tests and surface crack tension (SCT) tests, nondestructive evaluation, metallurgical studies, and photostress analysis. The results of the testing demonstrated improved mechanical properties with FSW as compared to typical fusion welding processes. Increases in ultimate tensile strength, cryogenic enhancement and elongation were observed with the tensile test results. Increased fracture toughness was observed with the SCT results. Nondestructive evaluations were conducted on all welded Joints. No volumetric defects were indicated. Surface indications on the root side of the welds did not significantly affect weld strength. The results of the nondestructive evaluations were confirmed via metallurgical studies. Photostress analysis revealed strain concentrations in multi-pass and heat-repaired FSW's. Details of the tests and results are presented.

Experimental investigation on sandwich structure ring-type ultrasonic motor.

PubMed

Peng, Taijiang; Shi, Hongyan; Liang, Xiong; Luo, Feng; Wu, Xiaoyu

2015-02-01

This paper presents a manufacture method for a sandwich structure Ultrasonic Motor (USM) and experiment. Two pieces of rotor clamped on a stator, and a stainless steel disk-spring is bonded on the hollow rotor disk to provide the press by a nut assembled on the shaft. The stator is made of a double-side Printed-Circuit Board (PCB) which is sawed out the ring in the center and connected on the board with three legs. On each side of the ring surface, there are electrodes connected at the same position via through hole. The three layer drive circuit for sine, cosine, and ground signal is connected on the board through each leg. There are many piezoelectric components (PZT) bonded between two electrodes and fill soldering tin on each electrode. Then PZT is welded on PCB by reflow soldering. Finally, rub the gibbous soldering tin down to the position of PZT surface makes sure the surface contacts with rotor evenly. The welding process can also be completed by Surface Mounted Technology (SMT). A prototype motor is manufactured by this method. Two B03 model shapes of the stator are obtained by the finite element analysis and the optimal frequency of the motor is 56.375 kHz measured by impedance instrument. The theoretical analysis is conducted for the relationship between the revolving speed of the USM and thickness of stator ring, number of the travelling waves, PZT amplitude, frequency and the other parameters. The experiment result shows that the maximum revolving speed is 116 RPM and the maximum torque is 25 N mm, when the actuate voltage is 200 VAC. Copyright © 2014 Elsevier B.V. All rights reserved.

Evaluation of Hydrogen Cracking in Weld Metal Deposited using Cellulosic-Coated Electrodes

DOT National Transportation Integrated Search

2009-06-16

Cellulosic-coated electrodes (primarily AWS EXX10-type) are traditionally used for "stovepipe" welding of pipelines because they are well suited for deposition of pipeline girth welds and are capable of high deposition rates when welding downhill. De...

Aircraft Propeller Hub Repair

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

Muth, Thomas R.; Peter, William H.

The team performed a literature review, conducted residual stress measurements, performed failure analysis, and demonstrated a solid state additive manufacturing repair technique on samples removed from a scrapped propeller hub. The team evaluated multiple options for hub repair that included existing metal buildup technologies that the Federal Aviation Administration (FAA) has already embraced, such as cold spray, high velocity oxy-fuel deposition (HVOF), and plasma spray. In addition the team helped Piedmont Propulsion Systems, LLC (PPS) evaluate three potential solutions that could be deployed at different stages in the life cycle of aluminum alloy hubs, in addition to the conventional spraymore » coating method for repair. For new hubs, a machining practice to prevent fretting with the steel drive shaft was recommended. For hubs that were refurbished with some material remaining above the minimal material condition (MMC), a silver interface applied by an electromagnetic pulse additive manufacturing method was recommended. For hubs that were at or below the MMC, a solid state additive manufacturing technique using ultrasonic welding (UW) of thin layers of 7075 aluminum to the hub interface was recommended. A cladding demonstration using the UW technique achieved mechanical bonding of the layers showing promise as a viable repair method.« less

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach

PubMed Central

Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

2016-01-01

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design. PMID:28773800

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach.

PubMed

Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

2016-08-09

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design.

Underwater laser weld bowing distortion behavior and mechanism of thin 304 stainless steel plates

NASA Astrophysics Data System (ADS)

Huang, ZunYue; Luo, Zhen; Ao, Sansan; Cai, YangChuan

2018-10-01

Underwater laser weld bowing distortion behavior and mechanism of thin 304 stainless steel plates are studied in the paper. The influence of underwater laser welding parameters (such as laser power, welding speed, defocusing distance and gas flow rate) on weld bowing distortion was investigated through central composite rotatable design and an orthogonal test. A quadratic response model was established to evaluate the underwater laser weld bowing distortion by central composite rotatable design and the order of the impacts of the welding parameters on weld bowing distortion was studied by an orthogonal test. The weld bowing distortion after welding was determined by the digital image correlation technique. The weld bowing distortion of in-air laser welding and underwater laser welding were compared and it revealed that the shape of the in-air and underwater laser welded specimens are the same, but the weld bowing distortion amount of in-air welding is larger than that of underwater welding. Weld bowing distortion mechanism was studied by the digital image correlation technique, and it was demonstrated that weld bowing distortion is associated with the welding plate temperature gradient during laser welding. The wider weld width also resulted in larger weld bowing distortion.

Description and Preliminary Training Evaluation of an Arc Welding Simulator. Research Report SRR 73-23.

ERIC Educational Resources Information Center

Abrams, Macy L.; And Others

A prototype arc welding training simulator was designed to provide immediate, discriminative feedback and the capacity for concentrated practice. Two randomly selected groups of welding trainees were compared to evaluate the simulator, one group being trained using the simulator and the other using conventional practice. Preliminary data indicated…

[Clinical analysis of laser welding on porcelain bonded metal surface].

PubMed

Weng, Jia-wei; Dai, Wen-an; Wu, Xue-ying

2011-02-01

To evaluate the clinical effect of laser-welded crowns and bridges. Two hundred defective crowns and bridges were welded by using Heraplus laser welding machine, and then restored by porcelain. After being welded ,those defective crowns and bridges of different materials fit well and their marginal areas were also satisfactory. During the follow up period of one year, no fractured porcelain and crack were found at welding spots. The technology of laser welding has no direct effect on welding spots between metal and porcelain and could be used to deal with the usual problems of the crowns and bridges.

Evaluation of the AISI 904L Alloy Weld Overlays Obtained by GMAW and Electro-Slag Welding Processes

NASA Astrophysics Data System (ADS)

Jorge, Jorge C. F.; Meira, O. G.; Madalena, F. C. A.; de Souza, L. F. G.; Araujo, L. S.; Mendes, M. C.

2017-05-01

The use of superaustenitic stainless steels (SASS) as an overlay replacement for nickel-based alloys can be an interesting alternative for the oil and gas industries, due to its lower cost, when compared to superalloys. Usually, the deposition is made with several welding passes by using conventional arc welding processes, such as gas tungsten arc welding (GTAW) or gas metal arc welding (GMAW) processes. In this respect, electro-slag welding (ESW), which promotes high heat inputs and low dilution of the welds, can also be attractive for this application, as it provides a higher productivity, once only one layer is needed for the deposition of the minimum thickness required. The present work evaluates the behavior of an AISI 904L SASS weld overlay deposited on a carbon steel ASTM A516 Grade 70 by ESW and GMAW processes. Both as-welded and heat-treated conditions were evaluated and compared. A multipass welding by GMAW process with three layers and 48 passes was performed on 12.5 × 200 × 250 mm steel plates with average welding energy of 1.0 kJ/mm. For ESW process, only one layer was deposited on 50 × 400 × 400 mm steel plates with average welding energy of 11.7 kJ/mm. After welding, a post-weld heat treatment (PWHT) at 620 °C for 10 h was performed in half of the steel plate, in order to allow the comparison between this condition and the as-welded one. For both processes, the austenitic microstructure of the weld deposits was characterized by optical microscopy and scanning electron microscopy with electron backscatter diffraction. A low proportion of secondary phases were observed in all conditions, and the PWHT did not promote significant changes on the hardness profile. Martensite for GMAW process and bainite for ESW process were the microstructural constituents observed at the coarse grain heat-affected zone, due to the different cooling rates. For ESW process, no evidences of partially diluted zones were found. As a consequence of the microstructural findings, the hardness results for ESW were lower than those usually observed for other electric arc welding processes. In addition, specimens subject to bending tests performed in accordance with the current standards used for qualification of welding procedures were approved. These evidences allow the conclusion that the ESW process can provide deposits with high quality despite the high welding energy levels, in order to achieve the desired productivity, being an interesting alternative for AISI 904L weld overlays.

The applicability of a material-treatment laser pulse in non-destructive evaluations.

PubMed

Hrovatin, R; Petkovsek, R; Diaci, J; Mozina, J

2006-12-22

A practical optodynamic study was performed to determine the usability of different lengths of laser pulses for the generation of ultrasonic transients in a solid material. The aim of the study was to evaluate the possibility of a dual use for a laser pulse-for laser material processing, on the one hand, and for the ultrasonic wave generation on the other-with both processes being combined on the same production line. The propagation of the laser-generated ultrasonic waves is evaluated by detecting and measuring with a PID-controlled stabilized interferometer. Thus, both systems provided the basic tools, the generation and detection of ultrasonic waves, for an ultrasonic, laser-based, non-destructive material evaluation. The ultrasonic transients generated by 'classical' nanosecond laser pulses were compared with the transients generated by industrial laser pulses with a duration of a few tenths of a microsecond. The experimental results are compared with the results of a time-of-flight analysis that also involved part of a mode-conversion analysis for both regimes in a layered material structure. The differences between the two waveforms were assessed in terms of their visibility, wavelength and resolution. The limit values were calculated and estimated for the laser-pulse parameters, when such pulses are intended for use in an ultrasonic, laser-based, non-destructive evaluation. The possibility of using an industrial marking laser for laser ultrasound generation is thus demonstrated.

Nondestructive evaluation/characterization of composite materials and structures using the acousto-ultrasonic techniques

NASA Technical Reports Server (NTRS)

Dos Reis, H. L. M.; Vary, A.

1988-01-01

This paper introduces the nature and the underlying rational of the acousto-ultrasonic stress wave factor technique and some of its applications to composite materials and structures. Furthermore, two examples of successful application of the acousto-ultrasonic technique are presented in detail. In the first example, the acousto-ultrasonic technique is used to evaluate the adhesive bond strength between rubber layers and steel plates, and in the seocnd example the tehcnique is used to monitor progressive damage in wire rope.

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.

An Evaluation of a Welding Fumes Exhaust System. Agricultural Experiment Station Research Report 284.

ERIC Educational Resources Information Center

Jacobs, C. O.

A study evaluated the feasibility of introducing unheated outside air into the airstream of a cross-flow welding exhaust system to reduce heating energy costs of a school welding laboratory. The physical facility used was the agricultural mechanics laboratory at the University of Arizona, which is similar to facilities in which instruction in…

The Influence of Grain Structure on Intermetallic Compound Layer Growth Rates in Fe-Al Dissimilar Welds

NASA Astrophysics Data System (ADS)

Xu, Lei; Robson, Joseph D.; Wang, Li; Prangnell, Philip B.

2018-02-01

The thickness of the intermetallic compound (IMC) layer that forms when aluminum is welded to steel is critical in determining the properties of the dissimilar joints. The IMC reaction layer typically consists of two phases ( η and θ) and many attempts have been made to determine the apparent activation energy for its growth, an essential parameter in developing any predictive model for layer thickness. However, even with alloys of similar composition, there is no agreement of the correct value of this activation energy. In the present work, the IMC layer growth has been characterized in detail for AA6111 aluminum to DC04 steel couples under isothermal annealing conditions. The samples were initially lightly ultrasonically welded to produce a metallic bond, and the structure and thickness of the layer were then characterized in detail, including tracking the evolution of composition and grain size in the IMC phases. A model developed previously for Al-Mg dissimilar welds was adapted to predict the coupled growth of the two phases in the layer, whilst accounting explicitly for grain boundary and lattice diffusion, and considering the influence of grain growth. It has been shown that the intermetallic layer has a submicron grain size, and grain boundary diffusion as well as grain growth plays a critical role in determining the thickening rate for both phases. The model was used to demonstrate how this explains the wide scatter in the apparent activation energies previously reported. From this, process maps were developed that show the relative importance of each diffusion path to layer growth as a function of temperature and time.

[Comprehensive evaluation of protective measures in electric welding].

PubMed

Ye, K; Zhao, Z

1995-03-01

Protective effects of safety masks, eyewear, work clothes, gloves, periodically physical examination system, and ventilation and barriers at workplace, were evaluated by one-way analysis for handtorch welding, carbon dioxide gas-protective welding, and argon-arc welding operations, etc. in township and village enterprises and state-owned enterprises by interviewing managers in the departments of technology and work safety and field investigating. Based on the results of one-way analysis of protective measures, comprehensive evaluations of various enterprises were made with a fussy mathematical model. Both enterprises in township and village level and of state-owned were graded as A on a basis of the evaluation, which will be helpful to the better management of occupational health in the future.

Fabrication of seamless calandria tubes by cold pilgering route using 3-pass and 2-pass schedules

NASA Astrophysics Data System (ADS)

Saibaba, N.

2008-12-01

Calandria tube is a large diameter, extremely thin walled zirconium alloy tube which has diameter to wall thickness ratio as high as 90-95. Such tubes are conventionally produced by the 'welded route', which involves extrusion of slabs followed by a series of hot and cold rolling passes, intermediate anneals, press forming of sheets into circular shape and closing the gap by TIG welding. Though pilgering is a well established process for the fabrication of seamless tubes, production of extremely thin walled tubes offers several challenges during pilgering. Nuclear fuel complex (NFC), Hyderabad, has successfully developed a process for the production of Zircaloy-4 calandria tubes by adopting the 'seamless route' which involves hot extrusion of mother blanks followed by three-pass pilgering or two-pass pilgering schedules. This paper deals with standardization of the seamless route processes for fabrication of calandria tubes, comparison between the tubes produced by 2-pass and 3-pass pilgering schedules, role of ultrasonic test charts for control of process parameters, development of new testing methods for burst testing and other properties.

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

NASA Technical Reports Server (NTRS)

Russell, Carolyn; Bjorkman, Gerry; McCool, Carolyn (Technical Monitor)

2000-01-01

A viewgraph presentation outlines NASA Marshall Space Flight Center, Lockheed Martin Michoud Space Systems, and McCook Metals' development an aluminum-copper weld filler wire for fusion welding 2195 aluminum lithium. The aluminum-copper based weld filler wire has been identified as B218, which is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The Super Lightweight External Tank for the NASA Space Shuttle Program consists of 2195 welded with 4043 aluminum-silicon weld filler wire. The B218 filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties. An initial characterization of the B218 weld filler wire was performed consisting of initial weld and repair weld evaluation comparing B218 and 4043. The testing involved room temperature and cryogenic tensile testing along with fracture toughness testing. B218 weld filler wire proved to produce enhanced initial and repair weld tensile and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding 2195 and other aluminum lithium alloys over 4043.

Ultrasonic impact peening for the surface properties’ management

NASA Astrophysics Data System (ADS)

Mordyuk, Bohdan N.; Prokopenko, Georgiy I.

2007-12-01

It is demonstrated that the ultrasonic impact peening (UIP) technique is a beneficial method for essential increase in the fatigue durability of metallic materials due to the surface nanocrystallization and hardening process provided for severe plastic deformation of surface via multiple impacts of high velocity impact pins. Nano-scale grain structures were obtained in the surface layers of stainless steel, low carbon steel weld and different titanium alloys using developed equipment for the UIP. Both the surface nanostructure and compressive residual stresses are shown to attribute to the essential hardness increase. It is revealed experimentally using profilometry that new modification of the UIP apparatus providing high velocity "sliding" impacts leads to marked diminution of the surface roughness, which is another important factor affecting to the fatigue cracks initiation process. The two-dimensional finite element model is used to simulate the indent formation process during single impaction. The solid steel pin and the Al alloy plate are modeled as a rigid material and an elasto-plastic material, respectively. It is shown that the surface roughness magnitude depends on the correlation of the vertical and lateral load components.

Ultrasonic-Based Nondestructive Evaluation Methods for Wood: A Primer and Historical Review

Treesearch

Adam C. Senalik; Greg Schueneman; Robert J. Ross

2014-01-01

The authors conducted a review of ultrasonic testing and evaluation of wood and wood products, starting with a description of basic ultrasonic inspection setups and commonly used equations. The literature review primarily covered wood research presented between 1965 and 2013 in the Proceedings of the Nondestructive Testing of Wood Symposiums. A table that lists the...

Research on Characterization of Damage States in Continuous Fiber Composites Using Ultrasonic Nondestructive Evaluation.

DTIC Science & Technology

1986-05-01

Composites Using Ultrasonic Nondestructive Evaluation Annual Technical Report I by Vikrai K. Kinra Depdrtment of Aerospace Engineering r and Mechanics...and identify by b ko number) 7It is well known that composite materials suffer complex damage when they are.-ub- jected to either monotonic or...Characterization of Damage States in Continuous Fiber Composites Using Ultrasonic Nondestructive Evaluation Annual Technical Report by Vikram K. Kinra Department

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.

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

NASA Astrophysics Data System (ADS)

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

2010-11-01

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

Welded tie plate feasibility study for ITER central solenoid structure

NASA Astrophysics Data System (ADS)

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

2014-01-01

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

Evaluation of anodic behavior of commercially pure titanium in tungsten inert gas and laser welds.

PubMed

Orsi, Iara Augusta; Raimundo, Larica B; Bezzon, Osvaldo Luiz; Nóbilo, Mauro Antonio de Arruda; Kuri, Sebastião E; Rovere, Carlos Alberto D; Pagnano, Valeria Oliveira

2011-12-01

This study evaluated the resistance to corrosion in welds made with Tungsten Inert Gas (TIG) in specimens made of commercially pure titanium (cp Ti) in comparison with laser welds. A total of 15 circular specimens (10-mm diameter, 2-mm thick) were fabricated and divided into two groups: control group-cp Ti specimens (n = 5); experimental group-cp Ti specimens welded with TIG (n = 5) and with laser (n = 5). They were polished mechanically, washed with isopropyl alcohol, and dried with a drier. In the anodic potentiodynamic polarization assay, measurements were taken using a potentiostat/galvanostat in addition to CorrWare software for data acquisition and CorrView for data visualization and treatment. Three curves were made for each working electrode. Corrosion potential values were statistically analyzed by the Student's t-test. Statistical analysis showed that corrosion potentials and passive current densities of specimens welded with TIG are similar to those of the control group, and had lower values than laser welding. TIG welding provided higher resistance to corrosion than laser welding. Control specimens welded with TIG were more resistant to local corrosion initiation and propagation than those with laser welding, indicating a higher rate of formation and growth of passive film thickness on the surfaces of these alloys than on specimens welded with laser, making it more difficult for corrosion to occur. © 2011 by the American College of Prosthodontists.

Study of Gravity Effects on Titanium Laser Welding in the Vertical Position

PubMed Central

Yuan, Zhang; Pu, Haitao; Li, Haigang; Cheng, Hao; Du, Dong; Shan, Jiguo

2017-01-01

To obtain satisfactory welds in positional laser beam welding, it is necessary to know how process parameters will influence the quality of welds in different welding positions. In this study, the titanium alloy Ti6Al4V sheets were laser welded in two vertical welding positions (vertical up and vertical down), and the appearance, porosity, strength, and ductility of the laser joints were evaluated. Results show that undercuts of the vertical up welds were greater than that of vertical down welds, while the porosity contents were much higher in vertical down welds than that in vertical up welds. When welding with a higher heat input, the vertical up welding position resulted in poor weld profiles (undercuts and burn-through holes), whereas the vertical down welding position led to excessive porosity contents in welds. Both severe undercut and excessive porosity were detrimental to the tensile properties of the welds. Weld appearance was improved and porosity contents were reduced by using a lower heat input, achieving better weld quality. Therefore, it is suggested that process parameter settings with relatively high laser powers and welding speeds, which can result in lower heat inputs, are used when laser welding the Ti6Al4V titanium alloys vertically. PMID:28885573

Study of Gravity Effects on Titanium Laser Welding in the Vertical Position.

PubMed

Chang, Baohua; Yuan, Zhang; Pu, Haitao; Li, Haigang; Cheng, Hao; Du, Dong; Shan, Jiguo

2017-09-08

To obtain satisfactory welds in positional laser beam welding, it is necessary to know how process parameters will influence the quality of welds in different welding positions. In this study, the titanium alloy Ti6Al4V sheets were laser welded in two vertical welding positions (vertical up and vertical down), and the appearance, porosity, strength, and ductility of the laser joints were evaluated. Results show that undercuts of the vertical up welds were greater than that of vertical down welds, while the porosity contents were much higher in vertical down welds than that in vertical up welds. When welding with a higher heat input, the vertical up welding position resulted in poor weld profiles (undercuts and burn-through holes), whereas the vertical down welding position led to excessive porosity contents in welds. Both severe undercut and excessive porosity were detrimental to the tensile properties of the welds. Weld appearance was improved and porosity contents were reduced by using a lower heat input, achieving better weld quality. Therefore, it is suggested that process parameter settings with relatively high laser powers and welding speeds, which can result in lower heat inputs, are used when laser welding the Ti6Al4V titanium alloys vertically.

Competencies in Welding Needed for Agricultural Machinery Maintenance.

ERIC Educational Resources Information Center

Hansen, Herbert Eugene

To determine needed competencies in welding for agricultural maintenance, questionnaires from 185 farmers familar with welding and 96 job-shop welders representing 40 percent of the Iowa vocational agriculture departments were rated and evaluated. The ten most needed competencies in arc welding were found to be: (1) understanding of the effect of…

Quantitative ultrasonic evaluation of engineering properties in metals, composites and ceramics

NASA Technical Reports Server (NTRS)

Vary, A.

1980-01-01

Ultrasonic technology from the perspective of nondestructive evaluation approaches to material strength prediction and property verification is reviewed. Emergent advanced technology involving quantitative ultrasonic techniques for materials characterization is described. Ultrasonic methods are particularly useful in this area because they involve mechanical elastic waves that are strongly modulated by the same morphological factors that govern mechanical strength and dynamic failure processes. It is emphasized that the technology is in its infancy and that much effort is still required before all the available techniques can be transferred from laboratory to industrial environments.

Modeling of Ultrasonic and Terahertz Radiations in Defective Tiles for Condition Monitoring of Thermal Protection Systems

DTIC Science & Technology

2013-04-01

different ultrasonic and electromagnetic field modeling problems for NDE (nondestructive evaluation) applications [5- 14]. 2d . Use of the...transient ultrasonic wave propagation using the Distributed Point Source Method”, IEEE Transactions on Ultrasonics, Ferroelectric and Frequency Control...Cavity”, IEEE Transactions on Ultrasonics, Ferroelectric and Frequency Control, Vol. 57(6), pp. 1396-1404, 2010. [10] A. Shelke, S. Das and T. Kundu

High resolution ultrasonic spectroscopy system for nondestructive evaluation

NASA Technical Reports Server (NTRS)

Chen, C. H.

1991-01-01

With increased demand for high resolution ultrasonic evaluation, computer based systems or work stations become essential. The ultrasonic spectroscopy method of nondestructive evaluation (NDE) was used to develop a high resolution ultrasonic inspection system supported by modern signal processing, pattern recognition, and neural network technologies. The basic system which was completed consists of a 386/20 MHz PC (IBM AT compatible), a pulser/receiver, a digital oscilloscope with serial and parallel communications to the computer, an immersion tank with motor control of X-Y axis movement, and the supporting software package, IUNDE, for interactive ultrasonic evaluation. Although the hardware components are commercially available, the software development is entirely original. By integrating signal processing, pattern recognition, maximum entropy spectral analysis, and artificial neural network functions into the system, many NDE tasks can be performed. The high resolution graphics capability provides visualization of complex NDE problems. The phase 3 efforts involve intensive marketing of the software package and collaborative work with industrial sectors.

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.

A fitness-for-purpose evaluation of fracture critical electro-slag welds.

DOT National Transportation Integrated Search

2009-03-01

A fitness-for-purpose evaluation was performed on the electro-slag flange welds of the West Fremont bridge approach : superstructures, per the request of FHWA. This evaluation required gathering knowledge of the material properties, fabrication : def...

Development of a chromium-free consumable for joining stainless steels

NASA Astrophysics Data System (ADS)

Sowards, Jeffrey William

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

Thermo-Mechanical Calculations of Hybrid Rotary Friction Welding at Equal Diameter Copper Bars and Effects of Essential Parameters on Dependent Special Variables

NASA Astrophysics Data System (ADS)

Parsa, M. H.; Davari, H.; Hadian, A. M.; Ahmadabadi, M. Nili

2007-05-01

Hybrid Rotary Friction Welding is a modified type of common rotary friction welding processes. In this welding method parameters such as pressure, angular velocity and time of welding control temperature, stress, strain and their variations. These dependent factors play an important rule in defining optimum process parameters combinations in order to improve the design and manufacturing of welding machines and quality of welded parts. Thermo-mechanical simulation of friction welding has been carried out and it has been shown that, simulation is an important tool for prediction of generated heat and strain at the weld interface and can be used for prediction of microstructure and evaluation of quality of welds. For simulation of Hybrid Rotary Friction Welding, a commercial finite element program has been used and the effects of pressure and rotary velocity of rotary part on temperature and strain variations have been investigated.

B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Russell, Carolyn

2000-01-01

NASA Marshall Space Flight Center, Lockheed Martin Space Systems- Michoud Operations, and McCook Metals have developed an aluminum-copper weld filler wire for fusion welding aluminum lithium alloy 2195. The aluminum-copper based weld filler wire has been identified as B218, a McCook Metals designation. B218 is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties over the 4043 aluminum-silicon weld filler wire, which is currently used to weld 2195 on the Super Lightweight External Tank for the NASA Space Shuttle Program. An initial characterization was performed consisting of a repair weld evaluation using B218 and 4043 weld filler wires. The testing involved room temperature and cryogenic repair weld tensile testing along with fracture toughness testing. From the testing, B218 weld filler wire produce enhanced repair weld tensile strength, ductility, and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding aluminum lithium alloy 2195 over 4043.

The National Shipbuilding Research Program: Evaluation of the Cincinnati Milacron T-3 Robot for Shipbuilding Welding

DTIC Science & Technology

1984-01-01

acknowledgement is extended to the members of Welding Panel SP-7 of the SNAME Ship Production Committee, who served as technical advisors in the preparation...Binzel Robo 450. . . . . . 4.4.4.1.3 Hobart WCG 600 . . . . . . 4.4.4.2 Maintenance and Service . . . . . . . 4.4.4.3 Recommendation...Machine Specialties D & F - Welding . . . Torch Binzel Robo 450 - Welding Torch. Hobart WCG - 600 - Welding Torch. Binzel Nozzle Cleaner

Residual Stresses and Critical Initial Flaw Size Analyses of Welds

NASA Technical Reports Server (NTRS)

Brust, Frederick W.; Raju, Ivatury, S.; Dawocke, David S.; Cheston, Derrick

2009-01-01

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). A series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on the fatigue life. The purpose of the weld analyses was to model the weld process using a variety of sequences to determine the 'best' sequence in terms of weld residual stresses and distortions. The many factors examined in this study include weld design (single-V, double-V groove), weld sequence, boundary conditions, and material properties, among others. The results of this weld analysis are included with service loads to perform a fatigue and critical initial flaw size evaluation.

Inspecting Pipe Radiographically Through Asbestos Insulation

NASA Technical Reports Server (NTRS)

Gianettino, David P.

1994-01-01

Welds between sections of insulated steampipe located and inspected radiographically. Unless need to repair defective weld, one avoids cost, time, and hazard of removing asbestos insulation. Enables inspectors to locate and evaluate nondestructively any weld in pipe system, without shutting down steam. Hidden weld joints first located by use of low-power fluoroscope, moved along pipe while technician observes fluoroscopic image. Low-energy x rays from fluoroscope penetrate insulation but not pipe. Weld bead appears in silhouette on fluoroscope screen. Technician then accurately marks weld sites on insulation for later inspection.

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.

Proceedings of the Second Annual Symposium for Nondestructive Evaluation of Bond Strength

NASA Technical Reports Server (NTRS)

Roberts, Mark J. (Compiler)

1999-01-01

Ultrasonics, microwaves, optically stimulated electron emission (OSEE), and computational chemistry approaches have shown relevance to bond strength determination. Nonlinear ultrasonic nondestructive evaluation methods, however, have shown the most effectiveness over other methods on adhesive bond analysis. Correlation to changes in higher order material properties due to microstructural changes using nonlinear ultrasonics has been shown related to bond strength. Nonlinear ultrasonic energy is an order of magnitude more sensitive than linear ultrasound to these material parameter changes and to acoustic velocity changes caused by the acoustoelastic effect when a bond is prestressed. Signal correlations between non-linear ultrasonic measurements and initialization of bond failures have been measured. This paper reviews bond strength research efforts presented by university and industry experts at the Second Annual Symposium for Nondestructive Evaluation of Bond Strength organized by the NDE Sciences Branch at NASA Langley in November 1998.

Acousto-ultrasonic nondestructive evaluation of materials using laser beam generation and detection. M.S. Thesis

NASA Technical Reports Server (NTRS)

Huber, Robert D.; Green, Robert E., Jr.

1990-01-01

The acousto-ultrasonic method has proven to be a most interesting technique for nondestructive evaluation of the mechanical properties of a variety of materials. Use of the technique or a modification thereof, has led to correlation of the associated stress wave factor with mechanical properties of both metals and composite materials. The method is applied to the nondestructive evaluation of selected fiber reinforced structural composites. For the first time, conventional piezoelectric transducers were replaced with laser beam ultrasonic generators and detectors. This modification permitted true non-contact acousto-ultrasonic measurements to be made, which yielded new information about the basic mechanisms involved as well as proved the feasibility of making such non-contact measurements on terrestrial and space structures and heat engine components. A state-of-the-art laser based acousto-ultrasonic system, incorporating a compact pulsed laser and a fiber-optic heterodyne interferometer, was delivered to the NASA Lewis Research Center.

Prediction of Building Limestone Physical and Mechanical Properties by Means of Ultrasonic P-Wave Velocity

PubMed Central

Concu, Giovanna; De Nicolo, Barbara; Valdes, Monica

2014-01-01

The aim of this study was to evaluate ultrasonic P-wave velocity as a feature for predicting some physical and mechanical properties that describe the behavior of local building limestone. To this end, both ultrasonic testing and compressive tests were carried out on several limestone specimens and statistical correlation between ultrasonic velocity and density, compressive strength, and modulus of elasticity was studied. The effectiveness of ultrasonic velocity was evaluated by regression, with the aim of observing the coefficient of determination r 2 between ultrasonic velocity and the aforementioned parameters, and the mathematical expressions of the correlations were found and discussed. The strong relations that were established between ultrasonic velocity and limestone properties indicate that these parameters can be reasonably estimated by means of this nondestructive parameter. This may be of great value in a preliminary phase of the diagnosis and inspection of stone masonry conditions, especially when the possibility of sampling material cores is reduced. PMID:24511286

Prediction of building limestone physical and mechanical properties by means of ultrasonic P-wave velocity.

PubMed

Concu, Giovanna; De Nicolo, Barbara; Valdes, Monica

2014-01-01

The aim of this study was to evaluate ultrasonic P-wave velocity as a feature for predicting some physical and mechanical properties that describe the behavior of local building limestone. To this end, both ultrasonic testing and compressive tests were carried out on several limestone specimens and statistical correlation between ultrasonic velocity and density, compressive strength, and modulus of elasticity was studied. The effectiveness of ultrasonic velocity was evaluated by regression, with the aim of observing the coefficient of determination r(2) between ultrasonic velocity and the aforementioned parameters, and the mathematical expressions of the correlations were found and discussed. The strong relations that were established between ultrasonic velocity and limestone properties indicate that these parameters can be reasonably estimated by means of this nondestructive parameter. This may be of great value in a preliminary phase of the diagnosis and inspection of stone masonry conditions, especially when the possibility of sampling material cores is reduced.

Evaluation of correlation between physical properties and ultrasonic pulse velocity of fired clay samples.

PubMed

Özkan, İlker; Yayla, Zeliha

2016-03-01

The aim of this study is to establish a correlation between physical properties and ultrasonic pulse velocity of clay samples fired at elevated temperatures. Brick-making clay and pottery clay were studied for this purpose. The physical properties of clay samples were assessed after firing pressed clay samples separately at temperatures of 850, 900, 950, 1000, 1050 and 1100 °C. A commercial ultrasonic testing instrument (Proceq Pundit Lab) was used to evaluate the ultrasonic pulse velocity measurements for each fired clay sample as a function of temperature. It was observed that there became a relationship between physical properties and ultrasonic pulse velocities of the samples. The results showed that in consequence of increasing densification of the samples, the differences between the ultrasonic pulse velocities were higher with increasing temperature. These findings may facilitate the use of ultrasonic pulse velocity for the estimation of physical properties of fired clay samples. Copyright © 2015 Elsevier B.V. All rights reserved.

Evaluation of AISI 4140 Steel Repair Without Post-Weld Heat Treatment

NASA Astrophysics Data System (ADS)

Silva, Cleiton C.; de Albuquerque, Victor H. C.; Moura, Cícero R. O.; Aguiar, Willys M.; Farias, Jesualdo P.

2009-04-01

The present work evaluates the two-layer technique on the heat affected zone (HAZ) of AISI 4140 steel welded with different heat input levels between the first and second layer. The weld heat input levels selected by the Higuchi test were 5/5, 5/10, and 15/5 kJ/cm. The evaluation of the refining and/or tempering of the coarsened grain HAZ of the first layer was carried out using metallographic tests, microhardness measurements, and the Charpy-V impact test. The tempering of the first layer was only reached when the weld heat input ratio was 5/5 kJ/cm. The results of the Charpy-V impact test showed that the two-layer technique was efficient, from the point of view of toughness, since the toughness values reached were greater than the base metal for all weld heat input ratios applied. The results obtained indicate that the best performance of the two-layer deposition technique was for the weld heat input ratio 5/5 kJ/cm employing low heat input.

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

NASA Technical Reports Server (NTRS)

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

1997-01-01

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

Methodology for Estimating Thermal and Neutron Embrittlement of Austenitic Stainless Steel Welds During Service in Light Water Reactors

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

Chopra, O. K.; Rao, A. S.

The effect of thermal aging on the degradation of fracture toughness and Charpy-impact properties of austenitic stainless steel (SS) welds has been characterized at reactor temperatures. The solidification behavior and the distribution and morphology of the ferrite phase in SS welds are described. Thermal aging of the welds results in moderate decreases in Charpy-impact strength and fracture toughness. The upper-shelf Charpy-impact energy of aged welds decreases by 50–80 J/cm2. The decrease in fracture toughness J-R curve, or JIc is relatively small. Thermal aging has minimal effect on the tensile strength. The fracture properties of SS welds are insensitive to fillermore » metal; the welding process has a significant effect. The large variability in the data makes it difficult to establish the effect of the welding process on fracture properties of SS welds. Consequently, the approach used for evaluating thermal and neutron embrittlement of austenitic SS welds relies on establishing a lower-bound fracture toughness J-R curve for unaged and aged, and non-irradiated and irradiated, SS welds. The existing fracture toughness J-R curve data for SS welds have been reviewed and evaluated to define lower-bound J-R curve for submerged arc (SA)/shielded metal arc (SMA)/manual metal arc (MMA) welds and gas tungsten arc (GTA)/tungsten inert gas (TIG) welds in the unaged and aged conditions. At reactor temperatures, the fracture toughness of GTA/TIG welds is a factor of about 2.3 higher than that of SA/SMA/MMA welds. Thermal aging decreases the fracture toughness by about 20%. The potential combined effects of thermal and neutron embrittlement of austenitic SS welds are also described. Lower-bound curves are presented that define the change in coefficient C and exponent n of the power-law J-R curve and the JIc value for SS welds as a function of neutron dose. The potential effects of reactor coolant environment on the fracture toughness of austenitic SS welds are also discussed.« less

Evaluation of a method to shield a welding electron beam from magnetic interference

NASA Technical Reports Server (NTRS)

Wall, W. A.

1976-01-01

It is known that electron beams are easily deflected by magnetic and electrostatic fields. Therefore, to prevent weld defects, stray electromagnetic fields are avoided in electron beam welding chambers if at all possible. The successful results of tests conducted at MSFC to evaluate a simple magnetic shield made from steel tubing are reported. Tests indicate that this shield was up to 85 percent effective in reducing magnetic effects on the electron beam of a welding machine. In addition, residual magnetic fields within the shield were so nearly uniform that the net effect on the beam alignment was negligible. It is concluded that the shield, with the addition of a tungsten liner, could be used in production welding.

Floating Ultrasonic Transducer Inspection System and Method for Nondestructive Evaluation

NASA Technical Reports Server (NTRS)

Johnston, Patrick H. (Inventor); Zalameda, Joseph N. (Inventor)

2016-01-01

A method for inspecting a structural sample using ultrasonic energy includes positioning an ultrasonic transducer adjacent to a surface of the sample, and then transmitting ultrasonic energy into the sample. Force pulses are applied to the transducer concurrently with transmission of the ultrasonic energy. A host machine processes ultrasonic return pulses from an ultrasonic pulser/receiver to quantify attenuation of the ultrasonic energy within the sample. The host machine detects a defect in the sample using the quantified level of attenuation. The method may include positioning a dry couplant between an ultrasonic transducer and the surface. A system includes an actuator, an ultrasonic transducer, a dry couplant between the transducer the sample, a scanning device that moves the actuator and transducer, and a measurement system having a pulsed actuator power supply, an ultrasonic pulser/receiver, and a host machine that executes the above method.

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.

Cleaning without chlorinated solvents

NASA Technical Reports Server (NTRS)

Thompson, L. M.; Simandl, R. F.

1995-01-01

Because of health and environmental concerns, many regulations have been passed in recent years regarding the use of chlorinated solvents. The Oak Ridge Y-12 Plant has had an active program to find alternatives for these solvents used in cleaning applications for the past 7 years. During this time frame, the quantity of solvents purchased has been reduced by 92 percent. The program has been a twofold effort. Vapor degreasers used in batch cleaning operations have been replaced by ultrasonic cleaning with aqueous detergent, and other organic solvents have been identified for use in hand-wiping or specialty operations. In order to qualify these alternatives for use, experimentation was conducted on cleaning ability as well as effects on subsequent operations such as welding, painting, and bonding. Cleaning ability was determined using techniques such as x-ray photoelectron spectroscopy (XPS) and Fourier transform infrared spectroscopy (FTIR) which are capable of examining monolayer levels of contamination on a surface. Solvents have been identified for removal of rust preventative oils, lapping oils, machining coolants, lubricants, greases, and mold releases. Solvents have also been evaluated for cleaning urethane foam spray guns, swelling of urethanes, and swelling of epoxies.

Ultrasonic guided wave bondline evaluation of thick metallic structures with viscoelastic coatings and the demonstration of a novel mode sweep technique

NASA Astrophysics Data System (ADS)

Bostron, Jason

Ultrasonic guided waves are becoming more widely used in nondestructive evaluation applications due to their efficiency in defect detection, ability to inspect hidden areas, and other reasons. This dissertation addresses two main topics: ultrasonic guided wave bond evaluation of thin and thick coatings on thick metallic structures, and the use of a novel phased array technique for optimal guided wave mode and frequency selection. (Abstract shortened by UMI.).

Effects of Flux Precoating and Process Parameter on Welding Performance of Inconel 718 Alloy TIG Welds

NASA Astrophysics Data System (ADS)

Lin, Hsuan-Liang; Wu, Tong-Min; Cheng, Ching-Min

2014-01-01

The purpose of this study is to investigate the effect of activating flux on the depth-to-width ratio (DWR) and hot cracking susceptibility of Inconel 718 alloy tungsten inert gas (TIG) welds. The Taguchi method is employed to investigate the welding parameters that affect the DWR of weld bead and to achieve optimal conditions in the TIG welds that are coated with activating flux in TIG (A-TIG) process. There are eight single-component fluxes used in the initial experiment to evaluate the penetration capability of A-TIG welds. The experimental results show that the Inconel 718 alloy welds precoated with 50% SiO2 and 50% MoO3 flux were provided with better welding performance such as DWR and hot cracking susceptibility. The experimental procedure of TIG welding process using mixed-component flux and optimal conditions not only produces a significant increase in DWR of weld bead, but also decreases the hot cracking susceptibility of Inconel 718 alloy welds.

Prediction of ultrasonic properties from grain angle

Treesearch

M.F. Kabir

2001-01-01

The ultrasonic properties of rubber wood were evaluated in three main symmetry axes – longitudinal (L), radial (R) and tangential direction and also at an angle rotating from the symmetry axes at different moisture content. The ultrasonic velocity were determined with a commercial ultrasonic tester of 45 kHz pulsed longitudinal waves. The experimental results were...

Optimization of operator and physical parameters for laser welding of dental materials.

PubMed

Bertrand, C; le Petitcorps, Y; Albingre, L; Dupuis, V

2004-04-10

Interactions between lasers and materials are very complex phenomena. The success of laser welding procedures in dental metals depends on the operator's control of many parameters. The aims of this study were to evaluate factors relating to the operator's dexterity and the choice of the welding parameters (power, pulse duration and therefore energy), which are recognized determinants of weld quality. In vitro laboratory study. FeNiCr dental drawn wires were chosen for these experiments because their properties are well known. Different diameters of wires were laser welded, then tested in tension and compared to the control material as extruded, in order to evaluate the quality of the welding. Scanning electron microscopy of the fractured zone and micrograph observations perpendicular and parallel to the wire axis were also conducted in order to analyse the depth penetration and the quality of the microstructure. Additionally, the micro-hardness (Vickers type) was measured both in the welded and the heat-affected zones and then compared to the non-welded alloy. Adequate combination of energy and pulse duration with the power set in the range between 0.8 to 1 kW appears to improve penetration depth of the laser beam and success of the welding procedure. Operator skill is also an important variable. The variation in laser weld quality in dental FeNiCr wires attributable to operator skill can be minimized by optimization of the physical welding parameters.

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

DTIC Science & Technology

1980-08-01

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

Risk assessment of turbine rotor failure using probabilistic ultrasonic non-destructive evaluations

NASA Astrophysics Data System (ADS)

Guan, Xuefei; Zhang, Jingdan; Zhou, S. Kevin; Rasselkorde, El Mahjoub; Abbasi, Waheed A.

2014-02-01

The study presents a method and application of risk assessment methodology for turbine rotor fatigue failure using probabilistic ultrasonic nondestructive evaluations. A rigorous probabilistic modeling for ultrasonic flaw sizing is developed by incorporating the model-assisted probability of detection, and the probability density function (PDF) of the actual flaw size is derived. Two general scenarios, namely the ultrasonic inspection with an identified flaw indication and the ultrasonic inspection without flaw indication, are considered in the derivation. To perform estimations for fatigue reliability and remaining useful life, uncertainties from ultrasonic flaw sizing and fatigue model parameters are systematically included and quantified. The model parameter PDF is estimated using Bayesian parameter estimation and actual fatigue testing data. The overall method is demonstrated using a realistic application of steam turbine rotor, and the risk analysis under given safety criteria is provided to support maintenance planning.

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

Korinko, P.; Howard, S.; Maxwell, D.

During final preparations for start of the PDCF Inner Can (IC) qualification effort, welding was performed on an automated weld system known as the PICN. During the initial weld, using a pedigree canister and plug, a weld defect was observed. The defect resulted in a hole in the sidewall of the canister, and it was observed that the plug sidewall had not been consumed. This was a new type of failure not seen during development and production of legacy Bagless Transfer Cans (FB-Line/Hanford). Therefore, a team was assembled to determine the root cause and to determine if the process couldmore » be improved. After several brain storming sessions (MS and T, R and D Engineering, PDC Project), an evaluation matrix was established to direct this effort. The matrix identified numerous activities that could be taken and then prioritized those activities. This effort was limited by both time and resources (the number of canisters and plugs available for testing was limited). A discovery process was initiated to evaluate the Vendor's IC fabrication process relative to legacy processes. There were no significant findings, however, some information regarding forging/anneal processes could not be obtained. Evaluations were conducted to compare mechanical properties of the PDC canisters relative to the legacy canisters. Some differences were identified, but mechanical properties were determined to be consistent with legacy materials. A number of process changes were also evaluated. A heat treatment procedure was established that could reduce the magnetic characteristics to levels similar to the legacy materials. An in-situ arc annealing process was developed that resulted in improved weld characteristics for test articles. Also several tack welds configurations were addressed, it was found that increasing the number of tack welds (and changing the sequence) resulted in decreased can to plug gaps and a more stable weld for test articles. Incorporating all of the process improvements for the actual can welding process, however, did not result in an improved weld geometry. Several possibilities for the lack of positive response exist, some of which are that (1) an insufficient number of test articles were welded under prototypic conditions, (2) the process was not optimized so that significant improvements were observable over the 'noise', and (3) the in-situ arc anneal closed the gap down too much so the can was unable to exhaust pressure ahead of the weld. Several operational and mechanical improvements were identified. The weld clamps were changed to a design consistent with those used in the legacy operations. A helium puff operation was eliminated; it is believed that this operation was the cause of the original weld defect. Also, timing of plug mast movement was found to correspond with weld irregularities. The timing of the movement was changed to occur during weld head travel between tacks. In the end a three sequential tack weld process followed by a pulse weld at the same current and travel speed as was used for the legacy processes was suggested for use during the IC qualification effort. Relative to legacy welds, the PDC IC weld demonstrates greater fluctuation in the region of the weld located between tack welds. However, canister weld response (canister to canister) is consistent and with the aid of the optical mapping system (for targeting the cut position) is considered adequate. DR measurements and METs show the PDC IC welds to have sufficient ligament length to ensure adequate canister pressure/impact capacity and to ensure adequate stub function. The PDC welding process has not been optimized as a result of this effort. Differences remain between the legacy BTC welds and the PDC IC weld, but these differences are not sufficient to prevent resumption of the current PDC IC qualification effort. During the PDC IC qualification effort, a total of 17 cans will be welded and a variety of tests/inspections will be performed. The extensive data collected during that qualification effort should be of a sufficient population to determine if additional weld process optimization is necessary prior to production release.« less

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.

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.)

Progress and achievements of R&D activities for the ITER vacuum vessel

NASA Astrophysics Data System (ADS)

Nakahira, M.; Takahashi, H.; Koizumi, K.; Onozuka, M.; Ioki, K.

2001-04-01

The Full Scale Sector Model Project, which was initiated in 1995 as one of the Seven Large Projects for ITER R&D, has been continued with the joint effort of the ITER Joint Central Team and the Japanese, Russian Federation and United States Home Teams. The fabrication of a full scale 18° toroidal sector, which is composed of two 9° sectors spliced at the port centre, was successfully completed in September 1997 with a dimensional accuracy of +/-3 mm for the total height and total width. Both sectors were shipped to the test site at the Japan Atomic Energy Research Institute and the integration test of the sectors was begun in October 1997. The integration test involves the adjustment of field joints, automatic narrow gap tungsten inert gas welding of field joints with splice plates and inspection of the joints by ultrasonic testing, as required for the initial assembly of the ITER vacuum vessel. This first demonstration of field joint welding and the performance test of the mechanical characteristics were completed in May 1998, and all the results obtained have satisfied the ITER design. In addition to these tests, integration with the midplane port extension fabricated by the Russian Home Team by using a fully remotized welding and cutting system developed by the US Home Team was completed in March 2000. The article describes the progress, achievements and latest status of the R&D activities for the ITER vacuum vessel.

Physical Principles Pertaining to Ultrasonic and Mechanical Properties of Anisotropic Media and Their Application to Nondestructive Evaluation of Fiber-Reinforced Composite Materials

NASA Astrophysics Data System (ADS)

Handley, Scott Michael

The central theme of this thesis is to contribute to the physics underlying the mechanical properties of highly anisotropic materials. Our hypothesis is that a fundamental understanding of the physics involved in the interaction of interrogating ultrasonic waves with anisotropic media will provide useful information applicable to quantitative ultrasonic measurement techniques employed for the determination of material properties. Fiber-reinforced plastics represent a class of advanced composite materials that exhibit substantial anisotropy. The desired characteristics of practical fiber -reinforced composites depend on average mechanical properties achieved by placing fibers at specific angles relative to the external surfaces of the finished part. We examine the physics underlying the use of ultrasound as an interrogation probe for determination of ultrasonic and mechanical properties of anisotropic materials such as fiber-reinforced composites. Fundamental constituent parameters, such as elastic stiffness coefficients (c_{rm IJ}), are experimentally determined from ultrasonic time-of-flight measurements. Mechanical moduli (Poisson's ratio, Young's and shear modulus) descriptive of the anisotropic mechanical properties of unidirectional graphite/epoxy composites are obtained from the ultrasonically determined stiffness coefficients. Three-dimensional visualizations of the anisotropic ultrasonic and mechanical properties of unidirectional graphite/epoxy composites are generated. A related goal of the research is to strengthen the connection-between practical ultrasonic nondestructive evaluation methods and the physics underlying quantitative ultrasonic measurements for the assessment of manufactured fiber-reinforced composites. Production defects such as porosity have proven to be of substantial concern in the manufacturing of composites. We investigate the applicability of ultrasonic interrogation techniques for the detection and characterization of porosity in graphite/epoxy laminates. Complementary ultrasonic parameters based on the frequency dependence of ultrasonic attenuation and integrated polar backscatter are investigated. In summary, the approach taken in this thesis is to examine the physical mechanisms in terms of a continuum mechanics framework and a linear elastic description of ultrasonic wave propagation in anisotropic media with specific application to the nondestructive evaluation of advanced composite materials.

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

NASA Technical Reports Server (NTRS)

Malone, Tina W.; Graham, Benny F.; Gentz, Steven J. (Technical Monitor)

2001-01-01

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

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

PubMed

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

2017-09-15

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

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

PubMed Central

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

2017-01-01

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

Theory and experimental technique for nondestructive evaluation of ceramic composites

NASA Technical Reports Server (NTRS)

Generazio, Edward R.

1990-01-01

The important ultrasonic scattering mechanisms for SiC and Si3N4 ceramic composites were identified by examining the interaction of ultrasound with individual fibers, pores, and grains. The dominant scattering mechanisms were identified as asymmetric refractive scattering due to porosity gradients in the matrix material, and symmetric diffractive scattering at the fiber-to-matrix interface and at individual pores. The effect of the ultrasonic reflection coefficient and surface roughness in the ultrasonic evaluation was highlighted. A new nonintrusive ultrasonic evaluation technique, angular power spectrum scanning (APSS), was presented that is sensitive to microstructural variations in composites. Preliminary results indicate that APSS will yield information on the composite microstructure that is not available by any other nondestructive technique.

Evaluation of iron aluminide weld overlays for erosion - corrosion resistant boiler tube coatings in low NO{sub x} boilers

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

DuPont, J.N.; Banovic, S.W.; Marder, A.R.

1996-08-01

Low NOx burners are being installed in many fossil fired power plants in order to comply with new Clean Air Regulations. Due to the operating characteristics of these burners, boiler tube sulfidation corrosion is often enhanced and premature tube failures can occur. Failures due to oxidation and solid particle erosion are also a concern. A program was initiated in early 1996 to evaluate the use of iron aluminide weld overlays for erosion/corrosion protection of boiler tubes in Low NOx boilers. Composite iron/aluminum wires will be used with the Gas Metal Arc Welding (GMAW) process to prepare overlays on boiler tubesmore » steels with aluminum contents from 8 to 16wt%. The weldability of the composite wires will be evaluated as a function of chemical composition and welding parameters. The effect of overlay composition on corrosion (oxidation and sulfidation) and solid particle erosion will also be evaluated. The laboratory studies will be complemented by field exposures of both iron aluminide weld overlays and co-extruded tubing under actual boiler conditions.« less

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

DTIC Science & Technology

1983-03-31

evaluated on the Narrow Gap welding system. By using the combinational qas shielding assembly, it is now possible to reduce the gas flow rates to a value...AD-A145 496 DESIGN CONSTRUCTION DEMONSTRATION AND DE IVER OF AN AUTOMATED NARROW GAP WELDING SYSTEM(U) CRC AUTOMATIC WELDING CO HODSTON SX 31 MAR 83...STANDARDS-963 - A CRC REPORT NO. NAV A/W 7 0PHASE 3 REPORT ON SDESIGN, CONSTRUCTION, DEMONSTRATION AND DELIVERY OF AN AUTOMATED NARROW GAP WELDING

Stress evaluation of metallic material under steady state based on nonlinear critically refracted longitudinal wave

NASA Astrophysics Data System (ADS)

Mao, Hanling; Zhang, Yuhua; Mao, Hanying; Li, Xinxin; Huang, Zhenfeng

2018-06-01

This paper presents the study of applying the nonlinear ultrasonic wave to evaluate the stress state of metallic materials under steady state. The pre-stress loading method is applied to guarantee components with steady stress. Three kinds of nonlinear ultrasonic experiments based on critically refracted longitudinal wave are conducted on components which the critically refracted longitudinal wave propagates along x, x1 and x2 direction. Experimental results indicate the second and third order relative nonlinear coefficients monotonically increase with stress, and the normalized relationship is consistent with simplified dislocation models, which indicates the experimental result is logical. The combined ultrasonic nonlinear parameter is proposed, and three stress evaluation models at x direction are established based on three ultrasonic nonlinear parameters, which the estimation error is below 5%. Then two stress detection models at x1 and x2 direction are built based on combined ultrasonic nonlinear parameter, the stress synthesis method is applied to calculate the magnitude and direction of principal stress. The results show the prediction error is within 5% and the angle deviation is within 1.5°. Therefore the nonlinear ultrasonic technique based on LCR wave could be applied to nondestructively evaluate the stress of metallic materials under steady state which the magnitude and direction are included.

Welding Penetration Control of Fixed Pipe in TIG Welding Using Fuzzy Inference System

NASA Astrophysics Data System (ADS)

Baskoro, Ario Sunar; Kabutomori, Masashi; Suga, Yasuo

This paper presents a study on welding penetration control of fixed pipe in Tungsten Inert Gas (TIG) welding using fuzzy inference system. The welding penetration control is essential to the production quality welds with a specified geometry. For pipe welding using constant arc current and welding speed, the bead width becomes wider as the circumferential welding of small diameter pipes progresses. Having welded pipe in fixed position, obviously, the excessive arc current yields burn through of metals; in contrary, insufficient arc current produces imperfect welding. In order to avoid these errors and to obtain the uniform weld bead over the entire circumference of the pipe, the welding conditions should be controlled as the welding proceeds. This research studies the intelligent welding process of aluminum alloy pipe 6063S-T5 in fixed position using the AC welding machine. The monitoring system used a charge-coupled device (CCD) camera to monitor backside image of molten pool. The captured image was processed to recognize the edge of molten pool by image processing algorithm. Simulation of welding control using fuzzy inference system was constructed to simulate the welding control process. The simulation result shows that fuzzy controller was suitable for controlling the welding speed and appropriate to be implemented into the welding system. A series of experiments was conducted to evaluate the performance of the fuzzy controller. The experimental results show the effectiveness of the control system that is confirmed by sound welds.

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.

Effect of Weld Tool Geometry on Friction Stir Welded AA2219-T87 Properties

NASA Technical Reports Server (NTRS)

Querin, Joseph A.; Schneider, Judy A.

2008-01-01

In this study, flat panels of AA2219-T87 were friction stir welded (FSWed) using weld tools with tapered pins The three pin geometries of the weld tools included: 0 (straight cylinder), 30 , and 60 angles on the frustum. For each weld tool geometry, the FSW process parameters were optimized to eliminate defects. A constant heat input was maintained while varying the process parameters of spindle rpm and travel speed. This provided a constant heat input for each FSW weld panel while altering the hot working conditions imparted to the workpiece. The resulting mechanical properties were evaluated from tensile test results of the FSW joint.

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

PubMed

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

2018-03-21

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

Restoration of Worn Movable Bridge Props with Use of Bronze Claddings

PubMed Central

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

2018-01-01

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

Mechanical properties of weldments in experimental Fe-12Mn-0.2Ti and Fe-12Mn-1Mo-0.2Ti alloys for cryogenic service

NASA Technical Reports Server (NTRS)

Stephens, J. R.; Witzke, W. R.; Devletian, J. H.

1981-01-01

Mechanical properties of weldments in two Fe-12Mn experimental alloys designed for cryogenic service were evaluated. Weldments were made using the GTA welding process. Tests to evaluate the weldments were conducted at -196 C and included: equivalent energy fracture toughness tests; autogenous transverse weld, notched transverse weld, and longitudinal weld tensile tests; and all-weld-metal tensile tests. The Fe-12Mn-0.2Ti and Fe-12Mn-1Mo-0.2Ti alloys proved weldable for cryogenic service, with weld metal and heat-affected zone properties comparable with those of the base metal. Optimum properties were achieved in the base alloys, weld metals, and heat-affected zones after a two-step heat treatment consisting of austenitizing at 900 C followed by tempering at 500 C. The Mo-containing alloy offered a marked improvement in cryogenic properties over those of the Mo-free alloy. Molybdenum increased the amount of retained austenite and reduced the amount of epsilon martensite observed in the microstructure of the two alloys.

1301253

NASA Image and Video Library

2013-12-12

JASON ELDRIDGE, AN ERC INCORPORATED EMPLOYEE SUPPORTING THE MATERIALS & PROCESSES LABORATORY AT NASA'S MARSHALL SPACE FLIGHT CENTER, SIGNS HIS NAME ON THE INTERIOR OF THE ADAPTER THAT WILL CONNECT THE ORION SPACECRAFT TO A UNITED LAUNCH ALLIANCE DELTA IV ROCKET FOR EXPLORATION FLIGHT TEST (EFT)-1. MARSHALL CENTER TEAM MEMBERS WHO WERE INVOLVED IN THE DESIGN, CONSTRUCTION AND TESTING OF THE ADAPTER HAD THE OPPORTUNITY TO AUTOGRAPH IT BEFORE THE HARDWARE IS SHIPPED TO NASA'S KENNEDY SPACE CENTER IN FEBRUARY. ELDRIDGE WAS ON A TEAM THAT PERFORMED ULTRASONIC INSPECTIONS ON THE ADAPTER'S WELDS -- ENSURING THEY ARE STRUCTURALLY SOUND. EFT-1, SCHEDULED FOR 2014, WILL PROVIDE EARLY EXPERIENCE FOR NASA SPACE LAUNCH SYSTEM (SLS) HARDWARE AHEAD OF THE ROCKET'S FIRST FLIGHT IN 2017.

Development of crawler type device using new measuring system

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

Maruyama, T.; Sasaki, T.; Yagi, T.

1995-08-01

This paper reports the development and field application of a new device which examine shell to shell weld joints of RPV. In a BWR type nuclear power plant, there is narrow space around the Reactor Pressure Vessel (RPV) because RPV is enclosed by the Reactor Shield Wall (RSW) and thermal insulations. The developed device is characterized by a new position measuring system and magnet wheels for driving. The new position measuring system uses laser beam and ultrasonic wave. The magnet wheels make the device travel freely in the narrow space between RPV and insulation. This device is tested on mock-upsmore » and applied examination of RPVs to verify field applicability.« less

Ultrasonically bonded value assembly

NASA Technical Reports Server (NTRS)

Salvinski, R. J. (Inventor)

1975-01-01

A valve apparatus capable of maintaining a fluid-tight seal over a relatively long period of time by releasably bonding a valve member to its seat is described. The valve member is bonded or welded to the seat and then released by the application of the same energy to the bond joint. The valve member is held in place during the bonding by a clamping device. An appropriate force device can activate the opening and closing of the valve member. Various combinations of material for the valve member and valve seat can be utilized to provide an adequate sealing bond. Aluminum oxide, stainless steel, inconel, tungsten carbide as hard materials and copper, aluminum, titanium, silver, and gold as soft materials are suggested.

Which cartilage is regenerated, hyaline cartilage or fibrocartilage? Non-invasive ultrasonic evaluation of tissue-engineered cartilage.

PubMed

Hattori, K; Takakura, Y; Ohgushi, H; Habata, T; Uematsu, K; Takenaka, M; Ikeuchi, K

2004-09-01

To investigate ultrasonic evaluation methods for detecting whether the repair tissue is hyaline cartilage or fibrocartilage in new cartilage regeneration therapy. We examined four experimental rabbit models: a spontaneous repair model (group S), a large cartilage defect model (group L), a periosteal graft model (group P) and a tissue-engineered cartilage regeneration model (group T). From the resulting ultrasonic evaluation, we used %MM (the maximum magnitude of the measurement area divided by that of the intact cartilage) as a quantitative index of cartilage regeneration. The results of the ultrasonic evaluation were compared with the histological findings and histological score. The %MM values were 61.1 +/- 16.5% in group S, 29.8 +/- 15.1% in group L, 36.3 +/- 18.3% in group P and 76.5 +/- 18.7% in group T. The results showed a strong similarity to the histological scoring. The ultrasonic examination showed that all the hyaline-like cartilage in groups S and T had a high %MM (more than 60%). Therefore, we could define the borderline between the two types of regenerated cartilage by the %MM.

Ultrasonic assessment of additive manufactured Ti-6Al-4V

NASA Astrophysics Data System (ADS)

Schehl, Norman; Kramb, Vicki; Dierken, Josiah; Aldrin, John; Schwalbach, Edwin; John, Reji

2018-04-01

Additive Manufacturing (AM) processes offer the potential for manufacturing cost savings and rapid insertion into service through production of near net shape components for complicated structures. Use of these parts in high reliability applications such as those in the aerospace industry will require nondestructive characterization methods to ensure post-process material quality in as-built condition. Ultrasonic methods can be used for this quality verification. Depending on the application, the service life of AM components can be sensitive to the part surface condition. The surface roughness and layered structure inherent to the electron-beam powder-bed fusion process necessitates new approaches to evaluate subsurface material integrity in its presence. Experimental methods and data analytics may improve the evaluation of as-built additively manufactured materials. This paper discusses the assessment of additively manufactured EBM Ti-6Al-4V panels using ultrasonic methods and the data analytics applied to evaluate material integrity. The assessment was done as an exploratory study as the discontinuities of interest in these test samples were not known when the measurements were performed. Water immersion ultrasonic techniques, including pulse-echo and through transmission with 10 MHz focused transducers, were used to explore the material integrity of as-built plates. Subsequent destructive mechanical tests of specimens extracted from the plates provided fracture locations indicating critical flaws. To further understand the effect of surface-roughness, an evaluation of ultrasonic response in the presence of as-built surfaces and with the surface removed was performed. The assessment of additive manufactured EBM Ti-6Al-4V panels with ultrasonic techniques indicated that ultrasonic energy was attenuated by the as-built surface roughness. In addition, feature detection was shown to be sensitive to experimental ultrasonic parameters and flaw morphology.

Ultrasonic nondestructive evaluation, microstructure, and mechanical property interrelations

NASA Technical Reports Server (NTRS)

Vary, A.

1984-01-01

Ultrasonic techniques for mechanical property characterizations are reviewed and conceptual models are advanced for explaining and interpreting the empirically based results. At present, the technology is generally empirically based and is emerging from the research laboratory. Advancement of the technology will require establishment of theoretical foundations for the experimentally observed interrelations among ultrasonic measurements, mechanical properties, and microstructure. Conceptual models are applied to ultrasonic assessment of fracture toughness to illustrate an approach for predicting correlations found among ultrasonic measurements, microstructure, and mechanical properties.

Welding, V-TECS Guide.

ERIC Educational Resources Information Center

Moore, Charles G.; And Others

This guide provides job-related tasks, performance objectives, performance guides, resources, teaching activities, evaluation standards, and criterion-referenced measures in three units of a welding course. Through the curriculum content of the welding course, the guide helps teachers lead students through the learning process, including the…

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.

Optimization of ultrasonication period for better dispersion and stability of TiO2-water nanofluid.

PubMed

Mahbubul, I M; Elcioglu, Elif Begum; Saidur, R; Amalina, M A

2017-07-01

Nanofluids are promising in many fields, including engineering and medicine. Stability deterioration may be a critical constraint for potential applications of nanofluids. Proper ultrasonication can improve the stability, and possibility of the safe use of nanofluids in different applications. In this study, stability properties of TiO 2 -H 2 O nanofluid for varying ultrasonication durations were tested. The nanofluids were prepared through two-step method; and electron microscopies, with particle size distribution and zeta potential analyses were conducted for the evaluation of their stability. Results showed the positive impact of ultrasonication on nanofluid dispersion properties up to some extent. Ultrasonication longer than 150min resulted in re-agglomeration of nanoparticles. Therefore, ultrasonication for 150min was the optimum period yielding highest stability. A regression analysis was also done in order to relate the average cluster size and ultrasonication time to zeta potential. It can be concluded that performing analytical imaging and colloidal property evaluation during and after the sample preparation leads to reliable insights. Copyright © 2017 Elsevier B.V. All rights reserved.

Evaluation in vitro of the tensile strength of crimpable hooks used for stabilization in orthognathic surgery.

PubMed

Andrade Gomes, Nascimento Leonard Euller; Melo, Pithon Matheus; Lacerda, Santos Rogério; D'Albuquerque, Medeiros Paulo Jose

2012-03-01

The aim of this study was to evaluate the tensile strength of crimpable hooks used for arch stabilization in orthognatic surgery. Ninety stainless steel wire (0.019" × 0.026") segments, each measuring 6 cm long, were used and attached to crimpable hooks of different commercial brands. Six groups were formed (n = 10) denominated as follows: control, in which the wire segments were perpendicularly welded by spot welding machine; and the hooks groups M (Morelli), MS (Morelli with weld), TP (TP Ortho), TPS (TP with weld), TPTg (TP-tungsten), TPTgS (TP-tungsten with weld), AO (American Orthodontics), and AOS (American Orthodontics with weld). The test specimen topography was evaluated by scanning electron microscopy before and after the tensile strength tests. After obtaining the results, the analysis of variance and Kruskal-Wallis multiple-comparison tests were applied. Compared with the control group, the AOS ball hooks and those from TPS required a greater amount of force to be displaced along the rectangular arch. The hooks in group M were significantly easier to displace, followed by those from AO. The best ball hooks for clinical application are those from AOS and TPS. Copyright © 2012 Elsevier Inc. All rights reserved.

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.

Vaccum Gas Tungsten Arc Welding, phase 1

NASA Astrophysics Data System (ADS)

Weeks, J. L.; Krotz, P. D.; Todd, D. T.; Liaw, Y. K.

1995-03-01

This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

Vaccum Gas Tungsten Arc Welding, phase 1

NASA Technical Reports Server (NTRS)

Weeks, J. L.; Krotz, P. D.; Todd, D. T.; Liaw, Y. K.

1995-01-01

This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

Novel Repair Technique for Life-Extension of Hydraulic Turbine Components in Hydroelectric Power Stations

NASA Astrophysics Data System (ADS)

Hiramatsu, Yoichi; Ishii, Jun; Funato, Kazuhiro

A significant number of hydraulic turbines operated in Japan were installed in the first half of the 20th century. Today, aging degradation and flaws are observed in these turbine equipments. So far, Japanese engineers have applied NDI technology of Ultrasonic Testing (UT) to detect the flaws, and after empirical evaluation of the remaining life they decided an adequate moment to replace the equipments. Since the replacement requires a large-scale field site works and high-cost, one of the solutions for life-extension of the equipments is introduction of repair services. We have been working in order to enhance the accuracy of results during the detection of flaws and flaws dimensioning, in particular focusing on the techniques of Tip-echo, TOFD and Phased-Array UT, accompanied by the conventional UT. These NDI methods made possible to recognize the entire image of surface and embedded flaws with complicated geometry. Then, we have developed an evaluation system of these flaws based on the theory of crack propagation, of the logic of crack growth driven by the stress-intensity factor of the crack tip front. The sophisticated evaluation system is constituted by a hand-made software and database of stress-intensity factor. Based on these elemental technologies, we propose a technique of repair welding to provide a life-extension of hydraulic turbine components.

Weldability of Advanced High Strength Steels using Ytterbium:Yttrium Aluminium Garnet high power laser for Tailor-Welded Blank applications

NASA Astrophysics Data System (ADS)

Sharma, Rajashekhar Shivaram

Use of a high power Yb:YAG laser is investigated for joining advanced high strength steel materials for use in tailor-welded blank (TWB) applications. TWB's are materials of different chemistry, coating or thicknesses that are joined before metal forming and other operations such as trimming, assembly and painting are carried out. TWB is becoming an important design tool in the automotive industry for reducing weight, improving fuel economy and passenger safety, while reducing the overall costs for the customer. Three advanced high strength steels, TRIP780, DP980 and USIBOR, which have many unique properties that are conducive to achieving these objectives, along with mild steel, are used in this work. The objective of this work is to ensure that high quality welds can be obtained using Yb:YAG lasers which are also becoming popular for metal joining operations, since they produce high quality laser beams that suffer minimal distortion when transported via fiber optic cables. Various power levels and speeds for the laser beam were used during the investigation. Argon gas was consistently used for shielding purposes during the welding process. After the samples were welded, metallographic examination of the fusion and heat-affected zones using optical and scanning electron microscopes were carried out to determine the microstructures as well as weld defects. Optical and scanning electron microscopes were also used to examine the top of welds as well as fracture surfaces. Additionally, cross-weld microhardness evaluations, tensile tests using Instron tester, limited fatigue tests as well as formability evaluations using OSU plane strain evaluation were carried out. The examinations included a 2-factor full factorial design of experiments to determine the impact of coatings on the surface roughness on the top of the welds. Tensile strengths of DP980, TRIP780 and mild steel materials as well as DP980 welded to TRIP780 and mild steel in the rolling direction as well as transverse direction were evaluated. Metallographic examinations determined that most of the fusion zone is martensitic with small regions of bainite and ferrite. High microhardness values of the order of 550--600 Hv were noted in most joints, which are attributed to high alloy content of the fusion zone as well as high rates of cooling typical of laser welds. During tensile, fatigue and formability tests, no fractures in the fusion or heat affected zones were observed. Geometric variability evaluations indicated that coatings such as aluminum (in the case of USIBOR) and galvanized zinc (TRIP780) can affect the variability of the weld zone and the surface roughness on the top of the weld. Excessive variability in the form of weld concavity in the weld zones can lead to fractures in the weld region, even though higher hardness can, to some extent, compensate for these surface irregularities. The 2-factor design of experiments further confirmed that coatings adversely affect the surface roughness on the top of the welds. Although thickness differentials alone do not make a significant impact on surface roughness, together with coatings, they can have an adverse effect on roughness. Tensile tests in the direction of rolling as well as in the transverse direction indicate that TRIP780 seems weaker in the direction of rolling when compared to transverse direction while mild steel is stronger in the direction of rolling. Weldability analyses revealed that the typical melting efficiency is on the order of 50--70% for full penetration welding. Formability tests showed that TR/MS joints fractured in a direction parallel to the weld line when tested with the loads perpendicular to the weld line. Tests have also confirmed that weld speed and power have no impact on the outcome of formability results. Overall, this work conclusively proves that high power Yb:YAG lasers can effectively join high strength materials such as DP980, TRIP780, USIBOR, as well as mild steel, for use in tailor-welded blank applications, contributing to lighter, more fuel-efficient and safer vehicles.

Effect of electrical spot welding on load deflection rate of orthodontic wires.

PubMed

Alavi, Shiva; Abrishami, Arezoo

2015-01-01

One of the methods used for joining metals together is welding, which can be carried out using different techniques such as electric spot welding. This study evaluated the effect of electric spot welding on the load deflection rate of stainless steel and chromium-cobalt orthodontic wires. In this experimental-laboratory study, load deflection rate of 0.016 × 0.022 inch stainless steel and chromium cobalt wires were evaluated in five groups (n =18): group one: Stainless steel wires, group two: chromium-cobalt wires, group three: stainless steel wires welded to stainless steel wires, group four: Stainless steel wires welded to chromium-cobalt wires, group five: chromium-cobalt wire welded to chromium-cobalt wires. Afterward, the forces induced by the samples in 0.5 mm, 1 mm, 1.5 mm deflection were measured using a universal testing machine. Then mean force measured for each group was compared with other groups. The data were analyzed using repeated measure analysis of variance (ANOVA), one-way ANOVA, and paired t-test by the SPSS software. The significance level was set as 0.05. The Tukey test showed that there were significant differences between the load deflection rates of welded groups compared to control ones (P < 0.001). Considering the limitation of this study, the electric spot welding process performed on stainless steel and chromium-cobalt wires increased their load deflection rates.

Influence of M-TIG and A-TIG Welding Process on Microstructure and Mechanical Behavior of 409 Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Vidyarthy, R. S.; Dwivedi, D. K.; Vasudevan, M.

2017-03-01

The current study investigates the effects of activating flux tungsten inert gas welding (A-TIG) and multipass tungsten inert gas welding (M-TIG) on the weld morphology, angular distortion, microstructures and mechanical properties when welding 8-mm-thick 409 ferritic stainless steel (FSS). SiO2 was used as activating flux for A-TIG welding, while SUPERTIG ER309L was used as filler for M-TIG welding. Bead-on-plate weld trials were carried out to obtain the full penetration by using different combinations of flux coating density, welding speed and welding current. An optical microscope, field emission scanning microscope (FESEM), and x-ray diffractometer were used for the metallurgical characterizations. Vickers hardness, tensile test, Charpy toughness test, and creep behavior test were carried out to evaluate the mechanical properties of the base and weld metals. Experimental results indicate that the A-TIG process can increase the joint penetration and tends to reduce the angular distortion of the 409 FSS weldment. The A-TIG welded joint also exhibited greater mechanical strength. However, a critically low Charpy toughness was measured for the A-TIG weld fusion zone, which was later sufficiently improved after post weld heat treatment (PWHT). It was concluded that PWHT is mandatory for A-TIG welded 409 FSS.

Adhesion of Salmonella Enteritidis and Listeria monocytogenes on stainless steel welds.

PubMed

Casarin, Letícia Sopeña; Brandelli, Adriano; de Oliveira Casarin, Fabrício; Soave, Paulo Azevedo; Wanke, Cesar Henrique; Tondo, Eduardo Cesar

2014-11-17

Pathogenic microorganisms are able to adhere on equipment surfaces, being possible to contaminate food during processing. Salmonella spp. and Listeria monocytogenes are important pathogens that can be transmitted by food, causing severe foodborne diseases. Most surfaces of food processing industry are made of stainless steel joined by welds. However currently, there are few studies evaluating the influence of welds in the microorganism's adhesion. Therefore the purpose of the present study was to investigate the adhesion of Salmonella Enteritidis and L. monocytogenes on surface of metal inert gas (MIG), and tungsten inert gas (TIG) welding, as well as to evaluate the cell and surface hydrophobicities. Results demonstrated that both bacteria adhered to the surface of welds and stainless steel at same levels. Despite this, bacteria and surfaces demonstrated different levels of hydrophobicity/hydrophilicity, results indicated that there was no correlation between adhesion to welds and stainless steel and the hydrophobicity. Copyright © 2014 Elsevier B.V. All rights reserved.

Physical interpretation and development of ultrasonic nondestructive evaluation techniques applied to the quantitative characterization of textile composite materials

NASA Technical Reports Server (NTRS)

Miller, James G.

1993-01-01

In this Progress Report, we describe our current research activities concerning the development and implementation of advanced ultrasonic nondestructive evaluation methods applied to the characterization of stitched composite materials and bonded aluminum plate specimens. One purpose of this investigation is to identify and characterize specific features of polar backscatter interrogation which enhance the ability of ultrasound to detect flaws in a stitched composite laminate. Another focus is to explore the feasibility of implementing medical linear array imaging technology as a viable ultrasonic-based nondestructive evaluation method to inspect and characterize bonded aluminum lap joints. As an approach to implementing quantitative ultrasonic inspection methods to both of these materials, we focus on the physics that underlies the detection of flaws in such materials.

[Hygienic evaluation of new welding processes and welding materials].

PubMed

Gorban', L N

1990-01-01

The possibility of contaminating the breathing air zone with hazardous substances in manual and semi-automated welding increases with the intensity of their formation in the arc zone. This necessitates more comprehensive data on both the specific excreta and the formation intensity of the most hazardous substances, such as hard and gaseous compounds of welding aerosols, with due account of the welding regimen used and electrode diameter, wires, etc. When calculating the effectiveness of both local and general ventilation systems in welding shops, a possibility of a specific one-way hazardous action of some chemical substances (e.g. chromium, fluorine, etc.) should be taken into account.

Stability evaluation of short-circuiting gas metal arc welding based on ensemble empirical mode decomposition

NASA Astrophysics Data System (ADS)

Huang, Yong; Wang, Kehong; Zhou, Zhilan; Zhou, Xiaoxiao; Fang, Jimi

2017-03-01

The arc of gas metal arc welding (GMAW) contains abundant information about its stability and droplet transition, which can be effectively characterized by extracting the arc electrical signals. In this study, ensemble empirical mode decomposition (EEMD) was used to evaluate the stability of electrical current signals. The welding electrical signals were first decomposed by EEMD, and then transformed to a Hilbert-Huang spectrum and a marginal spectrum. The marginal spectrum is an approximate distribution of amplitude with frequency of signals, and can be described by a marginal index. Analysis of various welding process parameters showed that the marginal index of current signals increased when the welding process was more stable, and vice versa. Thus EEMD combined with the marginal index can effectively uncover the stability and droplet transition of GMAW.

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.

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

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

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

1995-12-31

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

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

NASA Astrophysics Data System (ADS)

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

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

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.

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.

Pulsed Magnetic Welding for Advanced Core and Cladding Steel

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

Cao, Guoping; Yang, Yong

2013-12-19

To investigate a solid-state joining method, pulsed magnetic welding (PMW), for welding the advanced core and cladding steels to be used in Generation IV systems, with a specific application for fuel pin end-plug welding. As another alternative solid state welding technique, pulsed magnetic welding (PMW) has not been extensively explored on the advanced steels. The resultant weld can be free from microstructure defects (pores, non-metallic inclusions, segregation of alloying elements). More specifically, the following objectives are to be achieved: 1. To design a suitable welding apparatus fixture, and optimize welding parameters for repeatable and acceptable joining of the fuel pinmore » end-plug. The welding will be evaluated using tensile tests for lap joint weldments and helium leak tests for the fuel pin end-plug; 2 Investigate the microstructural and mechanical properties changes in PMW weldments of proposed advanced core and cladding alloys; 3. Simulate the irradiation effects on the PWM weldments using ion irradiation.« less

Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

Pan, Yi; Lados, Diana A.

2017-04-01

Friction stir welding (FSW) is a solid-state process widely used for joining similar and dissimilar materials for critical applications in the transportation sector. Understanding the effects of the process on microstructure and mechanical properties is critical in design for structural integrity. In this study, four aluminum alloy systems (wrought 6061-T651 and cast A356, 319, and A390) were processed in both as-fabricated and pre-weld heat-treated (T6) conditions using various processing parameters. The effects of processing and heat treatment on the resulting microstructures, macro-/micro-hardness, and tensile properties were systematically investigated and mechanistically correlated to changes in grain size, characteristic phases, and strengthening precipitates. Tensile tests were performed at room temperature both along and across the welding zones. A new method able to evaluate weld quality (using a weld quality index) was developed based on the stress concentration calculated under tensile loading. Optimum processing parameter domains that provide both defect-free welds and good mechanical properties were determined for each alloy and associated with the thermal history of the process. These results were further related to characteristic microstructural features, which can be used for component design and materials/process optimization.

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

NASA Astrophysics Data System (ADS)

Kourdani, Ahmad; Derakhshandeh-Haghighi, Reza

2018-04-01

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

Aging Degradation of Austenitic Stainless Steel Weld Probed by Electrochemical Method and Impact Toughness Evaluation

NASA Astrophysics Data System (ADS)

Singh, Raghuvir; Das, Goutam; Mahato, B.; Singh, P. K.

2017-03-01

The present study discriminates the spinodal decomposition and G-phase precipitation in stainless steel welds by double loop electrochemical potentio-kinetic reactivation method and correlates it with the degradation in toughness property. The welds produced with different heat inputs were aged up to 10,000 hours at 673 K to 723 K (400 to 450 °C) and evaluated subsequently for the degree of sensitization (DOS) and impact toughness. The DOS values obtained were attributed to the spinodal decomposition and precipitation of G-phase. Study shows that the DOS correlates well with the impact toughness of the 304LN weld. Prolonged aging at 673 K and 723 K (400 °C and 450 °C) increased the DOS values while the impact toughness was decreased. The weld fabricated at 1 kJ/mm of heat input, produced higher DOS, compared to that at 3 kJ/mm. The geometrical location along the weld is shown to influence the DOS; higher values were obtained at the root than at the topside of the weld. Vermicular and columnar microstructure, in addition to the spinodal decomposition and G-phase precipitation, observed in the root side of the weld appear risky for the impact toughness.

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.

2014/2219 Tri-Point Crack Analysis

NASA Technical Reports Server (NTRS)

Horton, Karla Renee

2011-01-01

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. The objective of this study was to evaluate the deformation response at the tips of cracks located in the heat affected zone of friction plug welds and to study the fracture behavior of welds with defects in the form of fatigue cracks. The study used existing 2014-T6 to 2219-T87 self-reacting friction stir weld panels with 2219-T87 friction plug welds. Electro-discharge machined (EDM) notches were machined into the heat affected zone of the plug at the plug-to-base metal interface. Samples were then cycled to generate a fatigue crack emanating from the notch. After the fatigue crack reached a pre-defined length, a speckle pattern was applied and the ARAMIS system (a three dimensional imaging correlation system) was used to measure the deformations at the crack tip under a sequence of loads. Testing was conducted at ambient laboratory conditions. Fracture data from the testing was analyzed to evaluate residual strength capability of the panel as a function of flaw size. ARAMIS strain data was evaluated to examine strain and deformation patterns that develop around the crack tip and at the plug/weld interfaces. Four samples were used in this study, with three samples in a post-weld heat treated condition. Three samples contained large diameter plugs (M5) and one sample contained a small diameter plug (M3). Two samples were 4 inches in width and two samples were 8.5 inches in width. All samples failed through the precrack with residual strengths ranging from 37 ksi to 42 ksi.

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.

Weldability of high-toughness iron - 12 percent-nickel alloys with reactive metal additions of titanium, aluminum, or niobium

NASA Technical Reports Server (NTRS)

Delvetian, J. H.; Stephens, J. R.; Witzke, W. R.

1977-01-01

Three exceptionally high toughness Fe-12Ni alloys designed for cryogenic service were welded by using the gas tungsten arc welding process. Evaluation of their weldability included equivalent energy fracture toughness tests, transverse weld tensile tests at -196 and 25 C, and weld crack sensitivity tests. The Fe-12Ni-0.25Ti alloy proved extremely weldable for cryogenic applications, having weld and heat affected zone properties comparable to those of the wrought base alloy. The Fe-12Ni-0.5Al alloy had good weld properties only after the weld joint was heat treated. The Fe-12Ni-0.25Nb alloy was not considered weldable for cryogenic use because of its poor weld joint properties at -196 C and its susceptibility to hot cracking.

Strengthening of Aluminum Wires Treated with A206/Alumina Nanocomposites.

PubMed

Florián-Algarín, David; Marrero, Raúl; Li, Xiaochun; Choi, Hongseok; Suárez, Oscar Marcelo

2018-03-10

This study sought to characterize aluminum nanocomposite wires that were fabricated through a cold-rolling process, having potential applications in TIG (tungsten inert gas) welding of aluminum. A206 (Al-4.5Cu-0.25Mg) master nanocomposites with 5 wt % γAl₂O₃ nanoparticles were first manufactured through a hybrid process combining semi-solid mixing and ultrasonic processing. A206/1 wt % γAl₂O₃ nanocomposites were fabricated by diluting the prepared master nanocomposites with a monolithic A206 alloy, which was then added to a pure aluminum melt. The fabricated Al-γAl₂O₃ nanocomposite billet was cold-rolled to produce an Al nanocomposite wire with a 1 mm diameter and a transverse area reduction of 96%. Containing different levels of nanocomposites, the fabricated samples were mechanically and electrically characterized. The results demonstrate a significantly higher strength of the aluminum wires with the nanocomposite addition. Further, the addition of alumina nanoparticles affected the wires' electrical conductivity compared with that of pure aluminum and aluminum-copper alloys. The overall properties of the new material demonstrate that these wires could be an appealing alternative for fillers intended for aluminum welding.

Strengthening of Aluminum Wires Treated with A206/Alumina Nanocomposites

PubMed Central

Marrero, Raúl; Li, Xiaochun; Choi, Hongseok

2018-01-01

This study sought to characterize aluminum nanocomposite wires that were fabricated through a cold-rolling process, having potential applications in TIG (tungsten inert gas) welding of aluminum. A206 (Al-4.5Cu-0.25Mg) master nanocomposites with 5 wt % γAl2O3 nanoparticles were first manufactured through a hybrid process combining semi-solid mixing and ultrasonic processing. A206/1 wt % γAl2O3 nanocomposites were fabricated by diluting the prepared master nanocomposites with a monolithic A206 alloy, which was then added to a pure aluminum melt. The fabricated Al–γAl2O3 nanocomposite billet was cold-rolled to produce an Al nanocomposite wire with a 1 mm diameter and a transverse area reduction of 96%. Containing different levels of nanocomposites, the fabricated samples were mechanically and electrically characterized. The results demonstrate a significantly higher strength of the aluminum wires with the nanocomposite addition. Further, the addition of alumina nanoparticles affected the wires’ electrical conductivity compared with that of pure aluminum and aluminum–copper alloys. The overall properties of the new material demonstrate that these wires could be an appealing alternative for fillers intended for aluminum welding. PMID:29534441

Defect Detectability Improvement for Conventional Friction Stir Welds

NASA Technical Reports Server (NTRS)

Hill, Chris

2013-01-01

This research was conducted to evaluate the effects of defect detectability via phased array ultrasound technology in conventional friction stir welds by comparing conventionally prepped post weld surfaces to a machined surface finish. A machined surface is hypothesized to improve defect detectability and increase material strength.

Evaluating the SCC resistance of underwater welds in sodium tetrathionate

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

White, R.A.; Angeliu, T.M.

1997-12-01

The susceptibility of welds to stress corrosion cracking (SCC) is enhanced by the surface residual tensile stresses generated by the typical welding process. However, underwater plasma transferred arc (PTA) welding has been shown to produce compressive surface residual stresses, an encouraging result if repairs of cracked boiling water reactor (BWR) components are to be made without further endangering them to SCC. This program was designed to verify that underwater PTA welds are resistant to SCC and to determine if underwater PTA welding could mitigate SCC in potentially susceptible welds. This was achieved by exposing various welds on solution annealed (SA)more » and SA + thermally sensitized 304 stainless steel at 25 C in a solution of 1.5 gm/liter of sodium sulfide added to 0.05M sodium tetrathionate, titrated to a pH of 1.25 with H{sub 2}SO{sub 4}. The autogeneous welds were produced using gas tungsten arc (GTA) and plasma transferred arc (PTA) welding under atmospheric conditions, and PTA welding underwater. After 1 hour of sodium tetrathionate exposure, GTA and air PTA welds exhibited SCC while the underwater PTA weld heat affected zones were more resistant. Underwater PTA welds bisecting a GTA weld eliminated the cracking in the GTA weld heat affected zone under certain conditions. The lack of IG cracking in the region influenced by the underwater PTA weld is consistent with the measurement of compressive surface residual stresses inherent to the underwater welding process.« less

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.

Transferable and flexible thin film devices for engineering applications

NASA Astrophysics Data System (ADS)

Mutyala, Madhu Santosh K.; Zhou, Jingzhou; Li, Xiaochun

2014-05-01

Thin film devices can be of significance for manufacturing, energy conversion systems, solid state electronics, wireless applications, etc. However, these thin film sensors/devices are normally fabricated on rigid silicon substrates, thus neither flexible nor transferrable for engineering applications. This paper reports an innovative approach to transfer polyimide (PI) embedded thin film devices, which were fabricated on glass, to thin metal foils. Thin film thermocouples (TFTCs) were fabricated on a thin PI film, which was spin coated and cured on a glass substrate. Another layer of PI film was then spin coated again on TFTC/PI and cured to obtain the embedded TFTCs. Assisted by oxygen plasma surface coarsening of the PI film on the glass substrate, the PI embedded TFTC was successfully transferred from the glass substrate to a flexible copper foil. To demonstrate the functionality of the flexible embedded thin film sensors, they were transferred to the sonotrode tip of an ultrasonic metal welding machine for in situ process monitoring. The dynamic temperatures near the sonotrode tip were effectively measured under various ultrasonic vibration amplitudes. This technique of transferring polymer embedded electronic devices onto metal foils yield great potentials for numerous engineering applications.

Effect of Bainitic Microstructure on Ballistic Performance of Armour Steel Weld Metal Using Developed High Ni-Coated Electrode

NASA Astrophysics Data System (ADS)

Pramanick, A. K.; Das, H.; Reddy, G. M.; Ghosh, M.; Nandy, S.; Pal, T. K.

2018-05-01

Welding of armour steel has gained significant importance during the past few years as recent civilian and military requirements demand weld metal properties matching with base metal having good ballistic performance along with high strength and toughness at - 40 °C as per specification. The challenge of armour steel welding therefore lies in controlling the weld metal composition which is strongly dependent on welding electrode/consumables, resulting in desired weld microstructure consisting of lower bainite along with retained austenite. The performance of butt-welded armour steel joints produced by the developed electrodes was evaluated using tensile testing, ballistic testing, impact toughness at room temperature and subzero temperature. Microstructures of weld metals are exclusively characterized by x-ray diffraction technique, scanning electron microscope and transmission electron microscopy with selected area diffraction pattern. Experimental results show that weld metal with relatively lower carbon, higher manganese and lower nickel content was attributed to lower bainite with film type of retained austenite may be considered as a most covetable microstructure for armour steel weld metal.

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy

PubMed Central

Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

2013-01-01

Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force. PMID:28788430

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

Effect of Bainitic Microstructure on Ballistic Performance of Armour Steel Weld Metal Using Developed High Ni-Coated Electrode

NASA Astrophysics Data System (ADS)

Pramanick, A. K.; Das, H.; Reddy, G. M.; Ghosh, M.; Nandy, S.; Pal, T. K.

2018-04-01

Welding of armour steel has gained significant importance during the past few years as recent civilian and military requirements demand weld metal properties matching with base metal having good ballistic performance along with high strength and toughness at - 40 °C as per specification. The challenge of armour steel welding therefore lies in controlling the weld metal composition which is strongly dependent on welding electrode/consumables, resulting in desired weld microstructure consisting of lower bainite along with retained austenite. The performance of butt-welded armour steel joints produced by the developed electrodes was evaluated using tensile testing, ballistic testing, impact toughness at room temperature and subzero temperature. Microstructures of weld metals are exclusively characterized by x-ray diffraction technique, scanning electron microscope and transmission electron microscopy with selected area diffraction pattern. Experimental results show that weld metal with relatively lower carbon, higher manganese and lower nickel content was attributed to lower bainite with film type of retained austenite may be considered as a most covetable microstructure for armour steel weld metal.

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.

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy.

PubMed

Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

2013-12-18

Friction Stir Welding (FSW) is a solid-state joining process; i.e. , no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force.

Ultrasonic Monitoring of the Progress of Lactic Acid Fermentation

NASA Astrophysics Data System (ADS)

Masuzawa, Nobuyoshi; Kimura, Akihiro; Ohdaira, Etsuzo

2003-05-01

Promotion of lactic acid fermentation by ultrasonic irradiation has been attempted. It is possible to determine the progress of fermentation and production of a curd, i.e., yoghurt and or kefir, by measuring acidity using a pH meter. However, this method is inconvenient and indirect for the evaluation of the progress of lactic acid fermentation under anaerobic condition. In this study, an ultrasonic monitoring method for evaluating the progress of lactic acid fermentation was examined.

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

PubMed

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

2013-01-01

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

Automated generation of weld path trajectories.

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

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

2003-06-01

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

Electron beam, laser beam and plasma arc welding studies

NASA Technical Reports Server (NTRS)

Banas, C. M.

1974-01-01

This program was undertaken as an initial step in establishing an evaluation framework which would permit a priori selection of advanced welding processes for specific applications. To this end, a direct comparison of laser beam, electron beam and arc welding of Ti-6Al-4V alloy was undertaken. Ti-6Al-4V was selected for use in view of its established welding characteristics and its importance in aerospace applications.