weld bead width: Topics by Science.gov

Sample records for weld bead width

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

NASA Astrophysics Data System (ADS)

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

2011-04-01

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

NASA Astrophysics Data System (ADS)

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

2014-05-01

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

NASA Astrophysics Data System (ADS)

Subashini, L.; Vasudevan, M.

2012-02-01

Type 316 LN stainless steel is the major structural material used in the construction of nuclear reactors. Activated flux tungsten inert gas (A-TIG) welding has been developed to increase the depth of penetration because the depth of penetration achievable in single-pass TIG welding is limited. Real-time monitoring and control of weld processes is gaining importance because of the requirement of remoter welding process technologies. Hence, it is essential to develop computational methodologies based on an adaptive neuro fuzzy inference system (ANFIS) or artificial neural network (ANN) for predicting and controlling the depth of penetration and weld bead width during A-TIG welding of type 316 LN stainless steel. In the current work, A-TIG welding experiments have been carried out on 6-mm-thick plates of 316 LN stainless steel by varying the welding current. During welding, infrared (IR) thermal images of the weld pool have been acquired in real time, and the features have been extracted from the IR thermal images of the weld pool. The welding current values, along with the extracted features such as length, width of the hot spot, thermal area determined from the Gaussian fit, and thermal bead width computed from the first derivative curve were used as inputs, whereas the measured depth of penetration and weld bead width were used as output of the respective models. Accurate ANFIS models have been developed for predicting the depth of penetration and the weld bead width during TIG welding of 6-mm-thick 316 LN stainless steel plates. A good correlation between the measured and predicted values of weld bead width and depth of penetration were observed in the developed models. The performance of the ANFIS models are compared with that of the ANN models.
Selection of optimal welding condition for GTA pulse welding in root-pass of V-groove butt joint

NASA Astrophysics Data System (ADS)

Yun, Seok-Chul; Kim, Jae-Woong

2010-12-01

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

NASA Astrophysics Data System (ADS)

Yang, Tao; Xiong, Jun; Chen, Hui; Chen, Yong

2015-03-01

Weld-based rapid prototyping (RP) has shown great promises for fabricating 3D complex parts. During the layered deposition of forming metallic parts with robotic gas metal arc welding, the geometry of a single weld bead has an important influence on surface finish quality, layer thickness and dimensional accuracy of the deposited layer. In order to obtain accurate, predictable and controllable bead geometry, it is essential to understand the relationships between the process variables with the bead geometry (bead width, bead height and ratio of bead width to bead height). This paper highlights an experimental study carried out to develop mathematical models to predict deposited bead geometry through the quadratic general rotary unitized design. The adequacy and significance of the models were verified via the analysis of variance. Complicated cause-effect relationships between the process parameters and the bead geometry were revealed. Results show that the developed models can be applied to predict the desired bead geometry with great accuracy in layered deposition with accordance to the slicing process of RP.
Weld bead profile of laser welding dissimilar joints stainless steel

NASA Astrophysics Data System (ADS)

Mohammed, Ghusoon R.; Ishak, M.; Aqida, S. N.; Abdulhadi, Hassan A.

2017-10-01

During the process of laser welding, the material consecutively melts and solidifies by a laser beam with a peak high power. Several parameters such as the laser energy, pulse frequency, pulse duration, welding power and welding speed govern the mode of the welding process. The aim of this paper is to investigate the effect of peak power, incident angle, and welding speed on the weld bead geometry. The first investigation in this context was conducted using 2205-316L stainless steel plates through the varying of the welding speed from 1.3 mm/s to 2.1 mm/s. The second investigation was conducted by varying the peak power from 1100 W to 1500 W. From the results of the experiments, the welding speed and laser power had a significant effect on the geometry of the weld bead, and the variation in the diameter of the bead pulse-size. Due to the decrease in the heat input, welding speed affected penetration depth more than bead width, and a narrow width of heat affected zone was achieved ranging from 0.2 to 0.5 mm. Conclusively, weld bead geometry dimensions increase as a function of peak power; at over 1350 W peak power, the dimensions lie within 30 μm.
Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes.

PubMed

Pinto-Lopera, Jesús Emilio; S T Motta, José Mauricio; Absi Alfaro, Sadek Crisostomo

2016-09-15

Associated to the weld quality, the weld bead geometry is one of the most important parameters in welding processes. It is a significant requirement in a welding project, especially in automatic welding systems where a specific width, height, or penetration of weld bead is needed. This paper presents a novel technique for real-time measuring of the width and height of weld beads in gas metal arc welding (GMAW) using a single high-speed camera and a long-pass optical filter in a passive vision system. The measuring method is based on digital image processing techniques and the image calibration process is based on projective transformations. The measurement process takes less than 3 milliseconds per image, which allows a transfer rate of more than 300 frames per second. The proposed methodology can be used in any metal transfer mode of a gas metal arc welding process and does not have occlusion problems. The responses of the measurement system, presented here, are in a good agreement with off-line data collected by a common laser-based 3D scanner. Each measurement is compare using a statistical Welch's t-test of the null hypothesis, which, in any case, does not exceed the threshold of significance level α = 0.01, validating the results and the performance of the proposed vision system.
Effect of Heat Input on Geometry of Austenitic Stainless Steel Weld Bead on Low Carbon Steel

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

PubMed Central

Sampaio, Renato Coral; Vargas, José A. R.

2018-01-01

The arc welding process is widely used in industry but its automatic control is limited by the difficulty in measuring the weld bead geometry and closing the control loop on the arc, which has adverse environmental conditions. To address this problem, this work proposes a system to capture the welding variables and send stimuli to the Gas Metal Arc Welding (GMAW) conventional process with a constant voltage power source, which allows weld bead geometry estimation with an open-loop control. Dynamic models of depth and width estimators of the weld bead are implemented based on the fusion of thermographic data, welding current and welding voltage in a multilayer perceptron neural network. The estimators were trained and validated off-line with data from a novel algorithm developed to extract the features of the infrared image, a laser profilometer was implemented to measure the bead dimensions and an image processing algorithm that measures depth by making a longitudinal cut in the weld bead. These estimators are optimized for embedded devices and real-time processing and were implemented on a Field-Programmable Gate Array (FPGA) device. Experiments to collect data, train and validate the estimators are presented and discussed. The results show that the proposed method is useful in industrial and research environments. PMID:29570698
Sensor Fusion to Estimate the Depth and Width of the Weld Bead in Real Time in GMAW Processes.

PubMed

Bestard, Guillermo Alvarez; Sampaio, Renato Coral; Vargas, José A R; Alfaro, Sadek C Absi

2018-03-23

The arc welding process is widely used in industry but its automatic control is limited by the difficulty in measuring the weld bead geometry and closing the control loop on the arc, which has adverse environmental conditions. To address this problem, this work proposes a system to capture the welding variables and send stimuli to the Gas Metal Arc Welding (GMAW) conventional process with a constant voltage power source, which allows weld bead geometry estimation with an open-loop control. Dynamic models of depth and width estimators of the weld bead are implemented based on the fusion of thermographic data, welding current and welding voltage in a multilayer perceptron neural network. The estimators were trained and validated off-line with data from a novel algorithm developed to extract the features of the infrared image, a laser profilometer was implemented to measure the bead dimensions and an image processing algorithm that measures depth by making a longitudinal cut in the weld bead. These estimators are optimized for embedded devices and real-time processing and were implemented on a Field-Programmable Gate Array (FPGA) device. Experiments to collect data, train and validate the estimators are presented and discussed. The results show that the proposed method is useful in industrial and research environments.
Elucidation of Metallic Plume and Spatter Characteristics Based on SVM During High-Power Disk Laser Welding

NASA Astrophysics Data System (ADS)

Gao, Xiangdong; Liu, Guiqian

2015-01-01

During deep penetration laser welding, there exist plume (weak plasma) and spatters, which are the results of weld material ejection due to strong laser heating. The characteristics of plume and spatters are related to welding stability and quality. Characteristics of metallic plume and spatters were investigated during high-power disk laser bead-on-plate welding of Type 304 austenitic stainless steel plates at a continuous wave laser power of 10 kW. An ultraviolet and visible sensitive high-speed camera was used to capture the metallic plume and spatter images. Plume area, laser beam path through the plume, swing angle, distance between laser beam focus and plume image centroid, abscissa of plume centroid and spatter numbers are defined as eigenvalues, and the weld bead width was used as a characteristic parameter that reflected welding stability. Welding status was distinguished by SVM (support vector machine) after data normalization and characteristic analysis. Also, PCA (principal components analysis) feature extraction was used to reduce the dimensions of feature space, and PSO (particle swarm optimization) was used to optimize the parameters of SVM. Finally a classification model based on SVM was established to estimate the weld bead width and welding stability. Experimental results show that the established algorithm based on SVM could effectively distinguish the variation of weld bead width, thus providing an experimental example of monitoring high-power disk laser welding quality.
Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes

PubMed Central

Pinto-Lopera, Jesús Emilio; S. T. Motta, José Mauricio; Absi Alfaro, Sadek Crisostomo

2016-01-01

Associated to the weld quality, the weld bead geometry is one of the most important parameters in welding processes. It is a significant requirement in a welding project, especially in automatic welding systems where a specific width, height, or penetration of weld bead is needed. This paper presents a novel technique for real-time measuring of the width and height of weld beads in gas metal arc welding (GMAW) using a single high-speed camera and a long-pass optical filter in a passive vision system. The measuring method is based on digital image processing techniques and the image calibration process is based on projective transformations. The measurement process takes less than 3 milliseconds per image, which allows a transfer rate of more than 300 frames per second. The proposed methodology can be used in any metal transfer mode of a gas metal arc welding process and does not have occlusion problems. The responses of the measurement system, presented here, are in a good agreement with off-line data collected by a common laser-based 3D scanner. Each measurement is compare using a statistical Welch’s t-test of the null hypothesis, which, in any case, does not exceed the threshold of significance level α = 0.01, validating the results and the performance of the proposed vision system. PMID:27649198
Welding polarity effects on weld spatters and bead geometry of hyperbaric dry GMAW

NASA Astrophysics Data System (ADS)

Xue, Long; Wu, Jinming; Huang, Junfen; Huang, Jiqiang; Zou, Yong; Liu, Jian

2016-03-01

Welding polarity has influence on welding stability to some extent, but the specific relationship between welding polarity and weld quality has not been found, especially under the hyperbaric environment. Based on a hyperbaric dry welding experiment system, gas metal arc welding(GMAW) experiments with direct current electrode positive(DCEP) and direct current electrode negative(DCEN) operations are carried out under the ambient pressures of 0.1 MPa, 0.4 MPa, 0.7 MPa and 1.0 MPa to find the influence rule of different welding polarities on welding spatters and weld bead geometry. The effects of welding polarities on the weld bead geometry such as the reinforcement, the weld width and the penetration are discussed. The experimental results show that the welding spatters gradually grow in quantity and size for GMAW with DCEP, while GMAW with DCEN can produce fewer spatters comparatively with the increase of the ambient pressure. Compared with DCEP, the welding current and arc voltage waveforms for DCEN is more stable and the distribution of welding current probability density for DCEN is more concentrated under the hyperbaric environment. When the ambient pressure is increased from 0.1 MPa to 1.0 MPa, the effects of welding polarities on the reinforcement, the weld width and the penetration are as follows: an increase of 0.8 mm for the weld reinforcement is produced by GMAW with DCEN and 1.3 mm by GMAW with DCEP, a decrease of 7.2 mm for the weld width is produced by DCEN and 6.1 mm by DCEP; and an increase of 3.9 mm for the penetration is produced by DCEN and 1.9 mm by DCEP. The proposed research indicates that the desirable stability in the welding procedure can be achieved by GMAW with DCEN operation under the hyperbaric environment.
The variable polarity plasma arc welding process: Characteristics and performance

NASA Technical Reports Server (NTRS)

Hung, R. J.; Zhu, G. J.

1991-01-01

Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. The power distribution was analyzed for an argon plasma gas flow constituting the fluid in the VPPA Welding Process. The major heat loss at the torch nozzle is convective heat transfer; in the space between the outlet of the nozzle and the workpiece; radiative heat transfer; and in the keyhole in the workpiece, convective heat transfer. The power absorbed at the workpiece produces the molten puddle that solidifies into the weld bead. Crown and root widths, and crown and root heights of the weld bead are predicted. The basis is provided for an algorithm for automatic control of VPPA welding machine parameters to obtain desired weld bead dimensions.
Studies on the Parametric Effects of Plasma Arc Welding of 2205 Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Selva Bharathi, R.; Siva Shanmugam, N.; Murali Kannan, R.; Arungalai Vendan, S.

2018-03-01

This research study attempts to create an optimized parametric window by employing Taguchi algorithm for Plasma Arc Welding (PAW) of 2 mm thick 2205 duplex stainless steel. The parameters considered for experimentation and optimization are the welding current, welding speed and pilot arc length respectively. The experimentation involves the parameters variation and subsequently recording the depth of penetration and bead width. Welding current of 60-70 A, welding speed of 250-300 mm/min and pilot arc length of 1-2 mm are the range between which the parameters are varied. Design of experiments is used for the experimental trials. Back propagation neural network, Genetic algorithm and Taguchi techniques are used for predicting the bead width, depth of penetration and validated with experimentally achieved results which were in good agreement. Additionally, micro-structural characterizations are carried out to examine the weld quality. The extrapolation of these optimized parametric values yield enhanced weld strength with cost and time reduction.
Nanosecond pulsed laser welding of high carbon steels

NASA Astrophysics Data System (ADS)

Ascari, Alessandro; Fortunato, Alessandro

2014-03-01

The present paper deals with the possibility to exploit low-cost, near infra-red, nanosecond pulsed laser sources in welding of high carbon content thin sheets. The exploitation of these very common sources allows to achieve sound weld beads with a good depth-to-width ratio and very small heat affected zones when the proper process parameters are involved. In particular the role of pulse frequency, pulse duration, peak power and welding speed on the characteristics of the weld beads is studied and the advantage of the application of short-pulse laser sources over traditional long-pulse or continuous wave one is assessed.
Optimization of hybrid laser - TIG welding of 316LN steel using response surface methodology (RSM)

NASA Astrophysics Data System (ADS)

Ragavendran, M.; Chandrasekhar, N.; Ravikumar, R.; Saxena, Rajesh; Vasudevan, M.; Bhaduri, A. K.

2017-07-01

In the present study, the hybrid laser - TIG welding parameters for welding of 316LN austenitic stainless steel have been investigated by combining a pulsed laser beam with a TIG welding heat source at the weld pool. Laser power, pulse frequency, pulse duration, TIG current were presumed as the welding process parameters whereas weld bead width, weld cross-sectional area and depth of penetration (DOP) were considered as the process responses. Central composite design was used to complete the design matrix and welding experiments were conducted based on the design matrix. Weld bead measurements were then carried out to generate the dataset. Multiple regression models correlating the process parameters with the responses have been developed. The accuracy of the models were found to be good. Then, the desirability approach optimization technique was employed for determining the optimum process parameters to obtain the desired weld bead profile. Validation experiments were then carried out from the determined optimum process parameters. There was good agreement between the predicted and measured values.
The effect of laser pulse tailored welding of Inconel 718

NASA Technical Reports Server (NTRS)

Mccay, T. Dwayne; Mccay, Mary Helen; Sharp, C. Michael; Womack, Michael G.

1990-01-01

Pulse tailored laser welding has been applied to wrought, wrought grain grown, and cast Inconel 718 using a CO2 laser. Prior to welding, the material was characterized metallographically and the solid state transformation regions were identified using Differential Scanning Calorimetry and high temperature x-ray diffraction. Bead on plate welds (restrained and unrestrained) were then produced using a matrix of pulse duty cycles and pulsed average power. Subsequent characterization included heat affected zone width, penetration and underbead width, the presence of cracks, microfissures and porosity, fusion zone curvature, and precipitation and liquated region width. Pedigree welding on three selected processing conditions was shown by microstructural and dye penetrant analysis to produce no microfissures, a result which strongly indicates the viability of pulse tailored welding for microfissure free IN 718.
Optimization of laser butt welding parameters with multiple performance characteristics

NASA Astrophysics Data System (ADS)

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

2011-04-01

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

NASA Astrophysics Data System (ADS)

Rong, Youmin; Zhang, Zhen; Zhang, Guojun; Yue, Chen; Gu, Yafei; Huang, Yu; Wang, Chunming; Shao, Xinyu

2015-04-01

The laser brazing (LB) is widely used in the automotive industry due to the advantages of high speed, small heat affected zone, high quality of welding seam, and low heat input. Welding parameters play a significant role in determining the bead geometry and hence quality of the weld joint. This paper addresses the optimization of the seam shape in LB process with welding crimping butt of 0.8 mm thickness using back propagation neural network (BPNN) and genetic algorithm (GA). A 3-factor, 5-level welding experiment is conducted by Taguchi L25 orthogonal array through the statistical design method. Then, the input parameters are considered here including welding speed, wire speed rate, and gap with 5 levels. The output results are efficient connection length of left side and right side, top width (WT) and bottom width (WB) of the weld bead. The experiment results are embed into the BPNN network to establish relationship between the input and output variables. The predicted results of the BPNN are fed to GA algorithm that optimizes the process parameters subjected to the objectives. Then, the effects of welding speed (WS), wire feed rate (WF), and gap (GAP) on the sum values of bead geometry is discussed. Eventually, the confirmation experiments are carried out to demonstrate the optimal values were effective and reliable. On the whole, the proposed hybrid method, BPNN-GA, can be used to guide the actual work and improve the efficiency and stability of LB process.

Mixing weld gases offers advantages

NASA Technical Reports Server (NTRS)

May, J. L.; Mendenhall, M. M.

1969-01-01

Argon added to helium during gas tungsten arc cover-pass welding in the horizontal position results in a better controlled wider bead width, increased arc stability, and reduction in heat input. Adequate filler material wetness and penetration pass coverage is possible with only one pass.
Integrated optical sensor

DOEpatents

Watkins, Arthur D.; Smartt, Herschel B.; Taylor, Paul L.

1994-01-01

An integrated optical sensor for arc welding having multifunction feedback control. The sensor, comprising generally a CCD camera and diode laser, is positioned behind the arc torch for measuring weld pool position and width, standoff distance, and post-weld centerline cooling rate. Computer process information from this sensor is passed to a controlling computer for use in feedback control loops to aid in the control of the welding process. Weld pool position and width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint. Sensor standoff distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to determine the final metallurgical state of the weld bead and heat affected zone, thereby controlling post-weld mechanical properties.
Integrated optical sensor

DOEpatents

Watkins, A.D.; Smartt, H.B.; Taylor, P.L.

1994-01-04

An integrated optical sensor for arc welding having multifunction feedback control is described. The sensor, comprising generally a CCD camera and diode laser, is positioned behind the arc torch for measuring weld pool position and width, standoff distance, and post-weld centerline cooling rate. Computer process information from this sensor is passed to a controlling computer for use in feedback control loops to aid in the control of the welding process. Weld pool position and width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint. Sensor standoff distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to determine the final metallurgical state of the weld bead and heat affected zone, thereby controlling post-weld mechanical properties. 6 figures.
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.
Optimization of cladding parameters for resisting corrosion on low carbon steels using simulated annealing algorithm

NASA Astrophysics Data System (ADS)

Balan, A. V.; Shivasankaran, N.; Magibalan, S.

2018-04-01

Low carbon steels used in chemical industries are frequently affected by corrosion. Cladding is a surfacing process used for depositing a thick layer of filler metal in a highly corrosive materials to achieve corrosion resistance. Flux cored arc welding (FCAW) is preferred in cladding process due to its augmented efficiency and higher deposition rate. In this cladding process, the effect of corrosion can be minimized by controlling the output responses such as minimizing dilution, penetration and maximizing bead width, reinforcement and ferrite number. This paper deals with the multi-objective optimization of flux cored arc welding responses by controlling the process parameters such as wire feed rate, welding speed, Nozzle to plate distance, welding gun angle for super duplex stainless steel material using simulated annealing technique. Regression equation has been developed and validated using ANOVA technique. The multi-objective optimization of weld bead parameters was carried out using simulated annealing to obtain optimum bead geometry for reducing corrosion. The potentiodynamic polarization test reveals the balanced formation of fine particles of ferrite and autenite content with desensitized nature of the microstructure in the optimized clad bead.
Optimization of laser welding thin-gage galvanized steel via response surface methodology

NASA Astrophysics Data System (ADS)

Zhao, Yangyang; Zhang, Yansong; Hu, Wei; Lai, Xinmin

2012-09-01

The increasing demand of light weight and durability makes thin-gage galvanized steels (<0.6 mm) attractive for future automotive applications. Laser welding, well known for its deep penetration, high speed and small heat affected zone, provides a potential solution for welding thin-gage galvanized steels in automotive industry. In this study, the effect of the laser welding parameters (i.e. laser power, welding speed, gap and focal position) on the weld bead geometry (i.e. weld depth, weld width and surface concave) of 0.4 mm-thick galvanized SAE1004 steel in a lap joint configuration has been investigated by experiments. The process windows of the concerned process parameters were therefore determined. Then, response surface methodology (RSM) was used to develop models to predict the relationship between the processing parameters and the laser weld bead profile and identify the correct and optimal combination of the laser welding input variables to obtain superior weld joint. Under the optimal welding parameters, defect-free weld were produced, and the average aspect ratio increased about 30%, from 0.62 to 0.83.
Optimization of Gas Metal Arc Welding Process Parameters

NASA Astrophysics Data System (ADS)

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

2016-09-01

This study presents the application of Taguchi method combined with grey relational analysis to optimize the process parameters of gas metal arc welding (GMAW) of AISI 1020 carbon steels for multiple quality characteristics (bead width, bead height, weld penetration and heat affected zone). An orthogonal array of L9 has been implemented to fabrication of joints. The experiments have been conducted according to the combination of voltage (V), current (A) and welding speed (Ws). The results revealed that the welding speed is most significant process parameter. By analyzing the grey relational grades, optimal parameters are obtained and significant factors are known using ANOVA analysis. The welding parameters such as speed, welding current and voltage have been optimized for material AISI 1020 using GMAW process. To fortify the robustness of experimental design, a confirmation test was performed at selected optimal process parameter setting. Observations from this method may be useful for automotive sub-assemblies, shipbuilding and vessel fabricators and operators to obtain optimal welding conditions.
An Approach to Maximize Weld Penetration During TIG Welding of P91 Steel Plates by Utilizing Image Processing and Taguchi Orthogonal Array

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

NASA Astrophysics Data System (ADS)

Patschger, Andreas; Bliedtner, Jens

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

NASA Astrophysics Data System (ADS)

Kügler, H.; Mittelstädt, C.; Vollertsen, F.

Presshardened steel is used in nowadays automotive production. Due to its high strength, sheet thicknesses can be reduced which results in decreasing weight of car body components. However, because of microstructure softening and coating agglomerations in the seam, welding is still a challenge. In this paper laser beam welding of 22MnB5 with varying energy input per irradiated area is presented. It is found that increasing energy input per seam length reduces tensile strength. Using a small spot size of 200 μm, tensile strength of 1434 N/mm2 can be reached in bead on plate welds. In lap welds tensile strength is limited because of coating particles agglomerating at the melt pool border line. However, the resulting strength is higher when using several small weld seams than using one seam with the same total seam width. With three weld seams, each 0.5mm in width, tensile strength of 911N/mm2 is reached in lap welding.
Study of the Performance of Stainless Steel A-TIG Welds

NASA Astrophysics Data System (ADS)

Shyu, S. W.; Huang, H. Y.; Tseng, K. H.; Chou, C. P.

2008-04-01

The purpose of the present work was to investigate the effect of oxide fluxes on weld morphology, arc voltage, mechanical properties, angular distortion and hot cracking susceptibility obtained with TIG welding, which applied to the welding of 5 mm thick austenitic stainless steel plates. A novel variant of the autogenous TIG welding process, oxide powders (Al2O3, Cr2O3, TiO2, SiO2 and CaO) was applied on a type 304 stainless steel through a thin layer of the flux to produce a bead on plate welds. The experimental results indicated that the increase in the penetration is significant with the use of Cr2O3, TiO2, and SiO2. A-TIG welding can increase the weld depth to bead-width ratio, and tends to reduce the angular distortion of the weldment. It was also found that A-TIG welding can increase the retained delta-ferrite content of stainless steel 304 welds and, in consequence, the hot-cracking susceptibility of as-welded is reduced. Physically constricting the plasma column and reducing the anode spot are the possible mechanism for the effect of certain flux on A-TIG penetration.
An integrated optical sensor for GMAW feedback control

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

Taylor, P.L.; Watkins, A.D.; Larsen, E.D.

1992-08-01

The integrated optical sensor (IOS) is a multifunction feedback control sensor for arc welding, that is computer automated and independent of significant operator interaction. It is based on three major ``off-the-shelf`` components: a charged coupled device (CCD) camera, a diode laser, and a processing computer. The sensor head is compact and lightweight to avoid interference with weld head mobility, hardened to survive the harsh operating environment, and free of specialized cooling and power requirements. The sensor is positioned behind the GMAW torch and measures weld pool position and width, standoff distance, and postweld centerline cooling rate. Weld pool position andmore » width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint, thus allowing compensation for such phenomena as arc blow. Sensor stand off distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to infer the final metallurgical state of the weld bead and heat affected zone, thereby providing a means of controlling post weld mechanical properties.« less
An integrated optical sensor for GMAW feedback control

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

Taylor, P.L.; Watkins, A.D.; Larsen, E.D.

1992-01-01

The integrated optical sensor (IOS) is a multifunction feedback control sensor for arc welding, that is computer automated and independent of significant operator interaction. It is based on three major off-the-shelf'' components: a charged coupled device (CCD) camera, a diode laser, and a processing computer. The sensor head is compact and lightweight to avoid interference with weld head mobility, hardened to survive the harsh operating environment, and free of specialized cooling and power requirements. The sensor is positioned behind the GMAW torch and measures weld pool position and width, standoff distance, and postweld centerline cooling rate. Weld pool position andmore » width are used in a feedback loop, by the weld controller, to track the weld pool relative to the weld joint, thus allowing compensation for such phenomena as arc blow. Sensor stand off distance is used in a feedback loop to control the contact tip to base metal distance during the welding process. Cooling rate information is used to infer the final metallurgical state of the weld bead and heat affected zone, thereby providing a means of controlling post weld mechanical properties.« less
Effects of SO/sub 2/ torch gas additions on GTA weld shape

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

Heiple, C.R.; Burgardt, P.

1984-01-01

Small additions of sulfur or oxygen to the GTA weld pool in steels with low weld d/w (depth/width) ratios substantially increases the weld d/w ratio and furthermore the improved weld d/w ratio is largely independent of reasonable variations in base metal sulfur and oxygen content. The addition of small concentrations of SO/sub 2/ to the normal argon shielding gas is a simple and effective way to add sulfur to the weld pool and increase weld d/w ratio. Autogenous bead-on-plate welds under otherwise identical welding conditions were made on stainless steel plate with SO/sub 2/ concentrations in the torch gas rangingmore » between 0 and 2000 ppM.« less
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.
Microstructure and Solidification Crack Susceptibility of Al 6014 Molten Alloy Subjected to a Spatially Oscillated Laser Beam.

PubMed

Kang, Minjung; Han, Heung Nam; Kim, Cheolhee

2018-04-23

Oscillating laser beam welding for Al 6014 alloy was performed using a single mode fiber laser and two-axis scanner system. Its effect on the microstructural evolution of the fusion zone was investigated. To evaluate the influence of oscillation parameters, self-restraint test specimens were fabricated with different beam patterns, widths, and frequencies. The behavior of hot cracking propagation was analyzed by high-speed camera and electron backscatter diffraction. The behavior of crack propagation was observed to be highly correlated with the microstructural evolution of the fusion zone. For most oscillation conditions, the microstructure resembled that of linear welds. A columnar structure was formed near the fusion line and an equiaxed structure was generated at its center. The wide equiaxed zone of oscillation welding increased solidification crack susceptibility. For an oscillation with an infinite-shaped scanning pattern at 100 Hz and 3.5 m/min welding speed, the bead width, solidification microstructure, and the width of the equiaxed zone at the center of fusion fluctuated. Furthermore, the equiaxed and columnar regions alternated periodically, which could reduce solidification cracking susceptibility.
Microstructure and Solidification Crack Susceptibility of Al 6014 Molten Alloy Subjected to a Spatially Oscillated Laser Beam

PubMed Central

Kang, Minjung; Han, Heung Nam

2018-01-01

Oscillating laser beam welding for Al 6014 alloy was performed using a single mode fiber laser and two-axis scanner system. Its effect on the microstructural evolution of the fusion zone was investigated. To evaluate the influence of oscillation parameters, self-restraint test specimens were fabricated with different beam patterns, widths, and frequencies. The behavior of hot cracking propagation was analyzed by high-speed camera and electron backscatter diffraction. The behavior of crack propagation was observed to be highly correlated with the microstructural evolution of the fusion zone. For most oscillation conditions, the microstructure resembled that of linear welds. A columnar structure was formed near the fusion line and an equiaxed structure was generated at its center. The wide equiaxed zone of oscillation welding increased solidification crack susceptibility. For an oscillation with an infinite-shaped scanning pattern at 100 Hz and 3.5 m/min welding speed, the bead width, solidification microstructure, and the width of the equiaxed zone at the center of fusion fluctuated. Furthermore, the equiaxed and columnar regions alternated periodically, which could reduce solidification cracking susceptibility. PMID:29690630
Interaction of trace elements and welding parameters on GTA weld shape. [Variation with penetration and tip angle

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

Burgardt, P.; Heiple, C.R.

1985-01-01

Good penetration and poor penetration steels have different responses to changes in temperature distribution on the weld pool surface. Penetration of 304 SS was varied using S and Se dopants. The weld parameter investigated was the electrode tip angle. Results of bead-on-plate GTA welds show that there is a difference in response of weld pool shape to tip angle depending on penetration: Low penetration base metal showed no dependence, intermediate penetration steel showed a small linear decrease of weld depth-to-width ratio (d/w) with tip angle, while high penetration steel showed an increase of d/w up to a maximum at aboutmore » 50/sup 0/, followed by a decrease in d/w. (DLC)« less
Weld analysis and control system

NASA Technical Reports Server (NTRS)

Kennedy, Larry Z. (Inventor); Rodgers, Michael H. (Inventor); Powell, Bradley W. (Inventor); Burroughs, Ivan A. (Inventor); Goode, K. Wayne (Inventor)

1994-01-01

The invention is a Weld Analysis and Control System developed for active weld system control through real time weld data acquisition. Closed-loop control is based on analysis of weld system parameters and weld geometry. The system is adapted for use with automated welding apparatus having a weld controller which is capable of active electronic control of all aspects of a welding operation. Enhanced graphics and data displays are provided for post-weld analysis. The system provides parameter acquisition, including seam location which is acquired for active torch cross-seam positioning. Torch stand-off is also monitored for control. Weld bead and parent surface geometrical parameters are acquired as an indication of weld quality. These parameters include mismatch, peaking, undercut, underfill, crown height, weld width, puddle diameter, and other measurable information about the weld puddle regions, such as puddle symmetry, etc. These parameters provide a basis for active control as well as post-weld quality analysis and verification. Weld system parameters, such as voltage, current and wire feed rate, are also monitored and archived for correlation with quality parameters.
Optimization of process parameters of pulsed TIG welded maraging steel C300

NASA Astrophysics Data System (ADS)

Deepak, P.; Jualeash, M. J.; Jishnu, J.; Srinivasan, P.; Arivarasu, M.; Padmanaban, R.; Thirumalini, S.

2016-09-01

Pulsed TIG welding technology provides excellent welding performance on thin sections which helps to increase productivity, enhance weld quality, minimize weld costs, and boost operator efficiency and this has drawn the attention of the welding society. Maraging C300 steel is extensively used in defence and aerospace industry and thus its welding becomes an area of paramount importance. In pulsed TIG welding, weld quality depends on the process parameters used. In this work, Pulsed TIG bead-on-plate welding is performed on a 5mm thick maraging C300 plate at different combinations of input parameters: peak current (Ip), base current (Ib) and pulsing frequency (HZ) as per box behnken design with three-levels for each factor. Response surface methodology is utilized for establishing a mathematical model for predicting the weld bead depth. The effect of Ip, Ib and HZ on the weld bead depth is investigated using the developed model. The weld bead depth is found to be affected by all the three parameters. Surface and contour plots developed from regression equation are used to optimize the processing parameters for maximizing the weld bead depth. Optimum values of Ip, Ib and HZ are obtained as 259 A, 120 A and 8 Hz respectively. Using this optimum condition, maximum bead depth of the weld is predicted to be 4.325 mm.

Numerical simulation of humping phenomenon in high speed gas metal arc welding

NASA Astrophysics Data System (ADS)

Chen, Ji; Wu, Chuan-Song

2011-06-01

It is of great significance to obtain a thorough understanding of the physical mechanisms responsible for humping bead phenomenon in high speed gas metal arc welding (GMAW) in order to raise welding efficiency. Experiments were conducted to observe the weld pool behaviors in high speed GMAW, and it was found that both the severely deformed weld pool surface and strong backward flowing play a dominant role in humping bead formation. In this study, a mathematical model is developed to quantitatively analyze the forming mechanism of humping beads for high speed GMAW through considering both the momentum and heat content distribution of the backward flowing molten metal inside the weld pool. The transient development of temperature profiles in the weld pool with severe deformation demonstrates the humping bead forming process under some welding conditions. The predicted and measured humping bead dimensions are in agreement.
Trailing Shield For Welding On Pipes

NASA Technical Reports Server (NTRS)

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

1991-01-01

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

NASA Astrophysics Data System (ADS)

Xiong, Jun; Zhang, Guangjun

2013-11-01

Additive manufacturing based on gas metal arc welding is an advanced technique for depositing fully dense components with low cost. Despite this fact, techniques to achieve accurate control and automation of the process have not yet been perfectly developed. The online measurement of the deposited bead geometry is a key problem for reliable control. In this work a passive vision-sensing system, comprising two cameras and composite filtering techniques, was proposed for real-time detection of the bead height and width through deposition of thin walls. The nozzle to the top surface distance was monitored for eliminating accumulated height errors during the multi-layer deposition process. Various image processing algorithms were applied and discussed for extracting feature parameters. A calibration procedure was presented for the monitoring system. Validation experiments confirmed the effectiveness of the online measurement system for bead geometry in layered additive manufacturing.
Effects of SO/sub 2/ shielding gas additions on GTA weld shape

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

Heiple, C.R.; Burgardt, P.

1985-06-01

Substantial increases in GTA weld depth/width ratio resulted from small additions of sulfur dioxide (SO/sub 2/) to the torch shielding gas when welding two stainless steels. The improvement was demonstrated on both Types 304 and 21-6-9 austenitic stainless steels, but would be expected for iron-base alloys generally. The weld pool shape achieved was essentially independent of variations in both SO/sub 2/ content of the torch gas and base metal composition when SO/sub 2/ in the shielding gas was in the range of 500 to 1400 ppm. With 700 ppm SO/sub 2/ in the torch gas, less than 30 ppm sulfurmore » was added to an autogenous weld bead. For alloys where this additional sulfur can be tolerated and appropriate measures can be taken to handle the toxic SO/sub 2/, this technique offers a promising way to improve GTA weld joint penetration while suppressing variable penetration.« less
Molten Pool Behavior and Mechanical Properties of Pulsed Current Double-Sided Synchronization GTA Welded Fe-18Cr-17Mn-Ni-N

NASA Astrophysics Data System (ADS)

Qiang, Wei; Wang, Kehong; Feng, Yuehai; Chen, Jiahe

2017-02-01

Double-sided synchronization vertical gas tungsten arc welding (DSSVW) procedure was used to weld high-nitrogen low-nickel stainless steel Fe-18Cr-17Mn-Ni-N without groove and filler wire. First, the molten pool behaviors and appearances of pulsed current DSSVW (PC-DSSVW) and constant current DSSVW (CC-DSSVW) were comparatively analyzed. The periodic variation occurs in the width of both the anode region of the arc and the molten pool tail during PC-DSSVW, while the contact angle first increases and then decreases, and both the width of the anode region and the length of arc plume increase progressively in CC-DSSVW. It is found that the weld appearance of PC-DSSVW is superior to that of CC-DSSVW. Second, the forces of the DSSVW molten pool were analyzed. The result indicates that the molten pool of the DSSVW procedure is in a state of unstable equilibrium, and it will easily lose balance after being disturbed, resulting in the asymmetrical weld or hump bead. Third, the PC-DSSVW experiments at various welding speeds were conducted to study the influence of welding speed on the weld profile, microstructure, tensile strength and impact toughness. Furthermore, the solidification mode of Fe-18Cr-17Mn-Ni-N was predicted to help determine the microstructure of the welded joint. Results indicate that the weld width, weld reinforcement and melting area all increase with decreasing welding speed, and Fe-18Cr-17Mn-Ni-N solidifies as A mode. The microstructure of the base metal (BM) and heat-affected zone (HAZ) is equiaxed austenite and that of the fusion zone (FZ) is austenite dendrite with some chromium carbides dispersed in the grain boundary; with decreasing welding speed, grains become coarse. The maximum tensile strength (UTS) and elongation of PC-DSSVW joint are 860 MPa and 8.1%, and the elongation decreases dramatically with decreasing welding speed. The impact toughness decreases substantially compared to the BM, achieving 48.2% of the BM.
Influence of Oxides on Microstructures and Mechanical Properties of High-Strength Steel Weld Joint

NASA Astrophysics Data System (ADS)

Cai, Yangchuan; Luo, Zhen; Huang, Zunyue; Zeng, Yida

2016-11-01

A comprehensive investigation was conducted into the effect of oxides on penetrations, microstructures and mechanical properties of BS700MC super steel weld bead. Boron oxide changed the penetration of weld bead by changing the Marangoni convection in the weld pool and contracting the welding arc. Chromium oxide only changed the Marangoni convection in the weld pool to increase the penetration of super steel. Thus, the super steel weld bead has higher penetration coated with flux boron oxide than that coated with chromium oxide. In other words, the activating flux TIG (A-TIG) welding with flux boron oxide has less welding heat input than the A-TIG welding with flux chromium oxide. As a result, on the one hand, there existed more fine and homogeneous acicular ferrites in the microstructure of welding heat-affected zone when the super steel was welded by A-TIG with flux boron oxide. Thus, the weld beads have higher value of low-temperature impact toughness. On the other hand, the softening degree of welding heat-affected zone, welded by A-TIG with flux boron oxide, will be decreased for the minimum value of welding heat input.
Weld bead reinforcement removal: A method of improving the strength and ductility of peaked welds in 2219-T87 aluminum alloy plate

NASA Technical Reports Server (NTRS)

Lovoy, C. V.

1979-01-01

The results of a study to determine the degree to which the ductility and tensile properties of peaked welds could be enhanced by removing the reinforcing bead and fairing the weld nugget into the adjacent parent metal are presented. The study employed 2219-T87 aluminum alloy plate, tungsten inert gas (TIG) welding, and 2319 filler wire. The study concluded that significant improvements in peak weld, ultimate strength, and ductility can be obtained through removal and fairing of the weld reinforcing bead. The specimens so treated and tested in this program exhibited ultimate strength improvements of 2 to 3 percent for peak angles of 5.8 to 10 degrees and 10 to 22 percent for welds with peak angles of 11.7 to 16.9 degrees. It was also determined that removal of the weld bead enhanced the ability of peaked welds to straighten when exposed to cyclic loading at stress levels above the yield strength.
Investigation on edge joints of Inconel 625 sheets processed with laser welding

NASA Astrophysics Data System (ADS)

Caiazzo, F.; Alfieri, V.; Cardaropoli, F.; Sergi, V.

2017-08-01

Laser welding of Inconel 625 edge joint beads in square groove configuration was investigated. The use of different weld geometries in new aerospace solutions explains research on edge joints. A structured plan was carried out in order to characterize the process defining the influence of laser power and welding speed and to study possible interactions among the governing factors. As weld pool protection is crucial in order to obtain sound joints when processing superalloys, a special glove box for gas supply was designed to upgrade the welding head. Welded joints were characterized referring to bead profile, microstructure and X-rays. It was found that heat input plays an important role as it affects welding stability, porosity content and bead shape. Results suggest operating with low values of heat input to reduce porosity and guarantee stable bead conformation. Furthermore, a decrease in the grain size has been observed as a consequence of decreasing heat input.
Analysis of droplet transfer mode and forming process of weld bead in CO 2 laser-MAG hybrid welding process

NASA Astrophysics Data System (ADS)

Liu, Shuangyu; Liu, Fengde; Zhang, Hong; Shi, Yan

2012-06-01

In this paper, CO 2 laser-metal active gas (MAG) hybrid welding technique is used to weld high strength steel and the optimized process parameters are obtained. Using LD Pumped laser with an emission wavelength of 532 nm to overcome the strong interference from the welding arc, a computer-based system is developed to collect and visualize the waveforms of the electrical welding parameters and metal transfer processes in laser-MAG. The welding electric signals of hybrid welding processes are quantitatively described and analyzed using the ANALYSATOR HANNOVER. The effect of distance between laser and arc ( DLA) on weld bead geometry, forming process of weld shape, electric signals, arc characteristic and droplet transfer behavior is investigated. It is found that arc characteristic, droplet transfer mode and final weld bead geometry are strongly affected by the distance between laser and arc. The weld bead geometry is changed from "cocktail cup" to "cone-shaped" with the increasing DLA. The droplet transfer mode is changed from globular transfer to projected transfer with the increasing DLA. Projected transfer mode is an advantage for the stability of hybrid welding processes.
Weld-Bead Shaver

NASA Technical Reports Server (NTRS)

Guirguis, Kamal; Price, Daniel S.

1990-01-01

Hand-held power tool shaves excess metal from inside circumference of welded duct. Removes excess metal deposited by penetration of tungsten/inert-gas weld or by spatter from electron-beam weld. Produces smooth transition across joint. Easier to use and not prone to overshaving. Also cuts faster, removing 35 in. (89 cm) of weld bead per hour.
Hot Forging of a Cladded Component by Automated GMAW Process

NASA Astrophysics Data System (ADS)

Rafiq, Muhammad; Langlois, Laurent; Bigot, Régis

2011-01-01

Weld cladding is employed to improve the service life of engineering components by increasing corrosion and wear resistance and reducing the cost. The acceptable multi-bead cladding layer depends on single bead geometry. Hence, in first step, the relationship between input process parameters and the single bead geometry is studied and in second step a comprehensive study on multi bead clad layer deposition is carried out. This paper highlights an experimental study carried out to get single layer cladding deposited by automated Gas Metal Arc Welding (GMAW) process and to find the possibility of hot forming of the cladded work piece to get the final hot formed improved structure. GMAW is an arc welding process that uses an arc between a consumable electrode and the welding pool with an external shielding gas and the cladding is done by alongside deposition of weld beads. The experiments for single bead were conducted by varying the three main process parameters wire feed rate, arc voltage and welding speed while keeping other parameters like nozzle to work distance, shielding gas and its flow rate and torch angle constant. The effect of bead spacing and torch orientation on the cladding quality of single layer from the results of single bead deposition was studied. Effect of the dilution rate and nominal energy on the cladded layer hot bending quality was also performed at different temperatures.
Evaluation Of Four Welding Arc Processes Applied To 6061 Aluminium Alloy

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

Benoit, A.; Laboratoire de Genie des Materiaux et Procedes Associes; Paillard, P.

At a time when greenhouse gas emissions must be reduced, the use of the aluminium alloys is expanding, in particular in the transportation industry. In order to extend the possibilities of aluminium assembly design, new Metal Inert Gas (MIG) welding processes have been conceived. They work at lower temperatures than usual arc processes (classic MIG or Tungsten Inert Gas). This study compares four arc welding processes, applied to the 6061 aluminium alloy. These four weld processes have been studied through the metallurgical analysis of the weld beads. Metallography, micro-hardness testings, X Ray radiography have been carried out on the producedmore » weld beads. The processes are classified according to the quality of the beads like geometry of beads, size of the heat affected zone and presence of defects.« less
Shielding gas selection for increased weld penetration and productivity in GTA welding

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

Leinonen, J.I.

1996-12-31

The effects of hydrogen and helium additions to the argon shielding gas on GTA weld pool profiles in the case of two austenitic stainless steel sheets 3 mm thick are investigated here in detail. One of the test steels shows good weldability, with a relatively deep, narrow weld pool profile, but the other is poorly weldable, with a shallow, wide weld pool when argon shielding gas is used. Bead-on-plate test welds were produced with arc shields of argon, argon with hydrogen additions of 2 to 18.2% and argon with helium additions of 20 to 80%. The hydrogen additions increases themore » depth of weld penetration in both test steels, but productivity with respect to maximum welding speed can be improved to an accepted level only with steel sheets of good weldability in terms of a relatively high depth/width (D/W) ratio. The depth of penetration in the test steel of good weldability increased somewhat with helium additions and the D/W ratio remained unchanged, while these parameters increased markedly in the poorly weldable steel when a He-20% Ar shielding gas was used and resembled those of the more weldable steel.« less
Heat flow in variable polarity plasma arc welds

NASA Technical Reports Server (NTRS)

Abdelmessih, Amanie N.

1992-01-01

The space shuttle external tank and the space station Freedom are fabricated by the variable polarity plasma arc (VPPA) welding. Heat sink effects (taper) are observed when there are irregularities in the work-piece configuration especially if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, and in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of the previous, present, and consecutive research studies is to investigate the effect of irregularities in the work-piece configuration and fixture differences on the weld bead geometry with the ultimate objective to compensate automatically for the heat sink effects and achieve a perfect weld.
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.
Coating Layer Characterization of Laser Deposited AlSi Coating over Laser Weld Bead

NASA Astrophysics Data System (ADS)

Gu, Hongping; Van Gelder, Aldo

Corrosion protection of steel components is an important topic in automotive industry. Laser beam welding makes a narrow weld bead, thus minimizing the damage to the original coating on the steel material. However, the weld bead loses its original coating and is vulnerable to corrosive attack. It was demonstrated in this study that laser beam generated AlSi coating is an effective way to apply a protective coating on the weld bead. Coatings with different thickness and topography have been deposited under different laser power and processing speed. The microstructure of the as-deposited coating and its evolution after heat treatment has been studied. EDS was employed to analyze the distribution of chemical compositions of the laser generated coatings. Several metallic compounds of Al and iron have been identified. It was found that the type of metallic compounds can be influenced by the laser processing parameters.
Development of an intelligent system for cooling rate and fill control in GMAW. [Gas Metal Arc Welding (GMAW)

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

Einerson, C.J.; Smartt, H.B.; Johnson, J.A.

1992-01-01

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

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

Einerson, C.J.; Smartt, H.B.; Johnson, J.A.

1992-09-01

A control strategy for gas metal arc welding (GMAW) is developed in which the welding system detects certain existing conditions and adjusts the process in accordance to pre-specified rules. This strategy is used to control the reinforcement and weld bead centerline cooling rate during welding. Relationships between heat and mass transfer rates to the base metal and the required electrode speed and welding speed for specific open circuit voltages are taught to a artificial neural network. Control rules are programmed into a fuzzy logic system. TRADITOINAL CONTROL OF THE GMAW PROCESS is based on the use of explicit welding proceduresmore » detailing allowable parameter ranges on a pass by pass basis for a given weld. The present work is an exploration of a completely different approach to welding control. In this work the objectives are to produce welds having desired weld bead reinforcements while maintaining the weld bead centerline cooling rate at preselected values. The need for this specific control is related to fabrication requirements for specific types of pressure vessels. The control strategy involves measuring weld joint transverse cross-sectional area ahead of the welding torch and the weld bead centerline cooling rate behind the weld pool, both by means of video (2), calculating the required process parameters necessary to obtain the needed heat and mass transfer rates (in appropriate dimensions) by means of an artificial neural network, and controlling the heat transfer rate by means of a fuzzy logic controller (3). The result is a welding machine that senses the welding conditions and responds to those conditions on the basis of logical rules, as opposed to producing a weld based on a specific procedure.« less
Microstructures and mechanical properties of bonding layers between low carbon steel and alloy 625 processed by gas tungsten arc welding

NASA Astrophysics Data System (ADS)

Lou, Shuai; Lee, Seul Bi; Nam, Dae-Geun; Choi, Yoon Suk

2017-11-01

A filler metal wire, Alloy 625, was cladded on a plate of a low carbon streel, SS400, by gas tungsten arc welding, and the morphology of the weld bead and resulting dilution ratio were investigated under different welding parameter values (the input current, weld speed and wire feed speed). The wire feed speed was found to be most influential in controlling the dilution ratio of the weld bead, and seemed to limit the influence of other welding parameters. Two extreme welding conditions (with the minimum and maximum dilution ratios) were identified, and the corresponding microstructures, hardness and tensile properties near the bond line were compared between the two cases. The weld bead with the minimum dilution ratio showed superior hardness and tensile properties, while the formation lath martensite (due to relatively fast cooling) affected mechanical properties in the heat affected zone of the base metal with the maximum dilution ratio.

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

NASA Astrophysics Data System (ADS)

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

2011-05-01

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

PubMed Central

Cocota, José Alberto Naves; Garcia, Gabriel Carvalho; da Costa, Adilson Rodrigues; de Lima, Milton Sérgio Fernandes; Rocha, Filipe Augusto Santos; Freitas, Gustavo Medeiros

2017-01-01

This work proposes a new methodology for the detection of discontinuities in the weld bead applied in Shielded Metal Arc Welding (SMAW) processes. The detection system is based on two sensors—a microphone and piezoelectric—that acquire acoustic emissions generated during the welding. The feature vectors extracted from the sensor dataset are used to construct classifier models. The approaches based on Artificial Neural Network (ANN) and Support Vector Machine (SVM) classifiers are able to identify with a high accuracy the three proposed weld bead classes: desirable weld bead, shrinkage cavity and burn through discontinuities. Experimental results illustrate the system’s high accuracy, greater than 90% for each class. A novel Hierarchical Support Vector Machine (HSVM) structure is proposed to make feasible the use of this system in industrial environments. This approach presented 96.6% overall accuracy. Given the simplicity of the equipment involved, this system can be applied in the metal transformation industries. PMID:28489045
Discontinuity Detection in the Shield Metal Arc Welding Process.

PubMed

Cocota, José Alberto Naves; Garcia, Gabriel Carvalho; da Costa, Adilson Rodrigues; de Lima, Milton Sérgio Fernandes; Rocha, Filipe Augusto Santos; Freitas, Gustavo Medeiros

2017-05-10

This work proposes a new methodology for the detection of discontinuities in the weld bead applied in Shielded Metal Arc Welding (SMAW) processes. The detection system is based on two sensors-a microphone and piezoelectric-that acquire acoustic emissions generated during the welding. The feature vectors extracted from the sensor dataset are used to construct classifier models. The approaches based on Artificial Neural Network (ANN) and Support Vector Machine (SVM) classifiers are able to identify with a high accuracy the three proposed weld bead classes: desirable weld bead, shrinkage cavity and burn through discontinuities. Experimental results illustrate the system's high accuracy, greater than 90% for each class. A novel Hierarchical Support Vector Machine (HSVM) structure is proposed to make feasible the use of this system in industrial environments. This approach presented 96.6% overall accuracy. Given the simplicity of the equipment involved, this system can be applied in the metal transformation industries.
A Study to Increase Weld Penetration in P91 Steel During TIG Welding by using Activating Fluxes

NASA Astrophysics Data System (ADS)

Singh, Akhilesh Kumar; Kumar, Mayank; Dey, Vidyut; Naresh Rai, Ram

2017-08-01

Activated Flux TIG (ATIG) welding is a unique joining process, invented at Paton Institute of electric welding in 1960. ATIG welding process is also known as flux zoned TIG (FZTIG). In this process, a thin layer of activating flux is applied along the line on the surface of the material where the welding is to be carries out. The ATIG process aids to increase the weld penetration in thick materials. Activating fluxes used in the literature show the use of oxides like TiO2, SiO2, Cr2O3, ZnO, CaO, Fe2O3, and MnO2 during welding of steels. In the present study, ATIG was carried out on P-91 steel. Though, Tungsten Inert Gas welding gives excellent quality welds, but the penetration obtained in such welding is still demanding. P91 steel which is ferritic steel is used in high temperature applications. As this steel is, generally, used in thick sections, fabrication of such structures with TIG welding is limited, due to its low depth of penetration. To increase the depth of penetration in P91while welding with ATIG, the role of various oxides were investigated. Apart from the oxides mentioned above, in the present study the role of B2O3, V2O5 and MgO, during ATIG welding of P91 was investigated. It was seen that, compared to TIG welding, there was phenomenal increase in weld penetration during ATIG welding. Amongst all the oxides used in this study, maximum penetration was achieved in case of B2O3. The measurements of weld penetration, bead width and heat affected zone of the weldings were carried out using an image analysis technique.
Performance of repair welds on aged Cr-Mo piping girth welds

NASA Astrophysics Data System (ADS)

Viswanathan, R.; Gandy, D. W.

1999-10-01

This article documents the results of an industry survey of weld repair practices and describes the results of experimental evaluations performed on service-aged 21/4 Cr-1Mo steel piping using SMAW with both conventional postweld heat treatments and temper bead repair techniques. The overall results of this program provide substantial evidence that service-aged piping systems can be successfully weld repaired with and without postweld heat treatments and that life extension by several decades is achievable under the right design and repair conditions. Weld repairs performed on degraded exservice welds resulted in restoration or improvement of tensile and creep properties. Microhardness test results within the heat-affected zone of each weldment indicated that the temper bead weld repairs produced only slightly higher peak hardness values than those measured for the fully postweld heat treated repairs. Finally, in terms of toughness, temper bead weld repairs consistently produced higher impact properties than those measured for the postweld heat treated weldments. Gas tungsten arc weld repairs with postweld heat treatment resulted in the best combination of tensile strength, uniform microhardness distribution across the weld, Charpy toughness, and creep rupture life.
More About Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

Oelgoetz, Peter A.; Davis, William M.

1996-01-01

Report describes modification and testing of proposed tool discussed in "Cutting Tool For Shaving Weld Beads" (MFS-30056). Modified version of commercial pneumatically driven rotary cutting tool removes such hard metals as nickel alloys, titanium, and stainless steels.
Experimental characterization of fatigue strength in butt welded joint considering the geometry and the effect of cooling rate of the weld

NASA Astrophysics Data System (ADS)

Arzola, Nelson; Hernández, Edgar

2017-05-01

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

NASA Astrophysics Data System (ADS)

Ascari, A.; Fortunato, A.; Liverani, E.; Gamberoni, A.; Tomesani, L.

The application of laser technology to welding of dissimilar AISI316 stainless steel components manufactured with selective laser melting (SLM) and traditional methods has been investigated. The role of laser parameters on weld bead formation has been studied experimentally, with particular attention placed on effects occurring at the interface between the two parts. In order to assess weld bead characteristics, standardised tensile tests were carried out on suitable specimens and the fracture zone was analysed. The results highlighted the possibility of exploiting suitable process parameters to appropriately shape the heat affected and fusion zones in order to maximise the mechanical performance of the component and minimise interactions between the two parent metals in the weld bead.
Modeling of plasma and thermo-fluid transport in hybrid welding

NASA Astrophysics Data System (ADS)

Ribic, Brandon D.

Hybrid welding combines a laser beam and electrical arc in order to join metals within a single pass at welding speeds on the order of 1 m min -1. Neither autonomous laser nor arc welding can achieve the weld geometry obtained from hybrid welding for the same process parameters. Depending upon the process parameters, hybrid weld depth and width can each be on the order of 5 mm. The ability to produce a wide weld bead increases gap tolerance for square joints which can reduce machining costs and joint fitting difficulty. The weld geometry and fast welding speed of hybrid welding make it a good choice for application in ship, pipeline, and aerospace welding. Heat transfer and fluid flow influence weld metal mixing, cooling rates, and weld bead geometry. Cooling rate affects weld microstructure and subsequent weld mechanical properties. Fluid flow and heat transfer in the liquid weld pool are affected by laser and arc energy absorption. The laser and arc generate plasmas which can influence arc and laser energy absorption. Metal vapors introduced from the keyhole, a vapor filled cavity formed near the laser focal point, influence arc plasma light emission and energy absorption. However, hybrid welding plasma properties near the opening of the keyhole are not known nor is the influence of arc power and heat source separation understood. A sound understanding of these processes is important to consistently achieving sound weldments. By varying process parameters during welding, it is possible to better understand their influence on temperature profiles, weld metal mixing, cooling rates, and plasma properties. The current literature has shown that important process parameters for hybrid welding include: arc power, laser power, and heat source separation distance. However, their influence on weld temperatures, fluid flow, cooling rates, and plasma properties are not well understood. Modeling has shown to be a successful means of better understanding the influence of processes parameters on heat transfer, fluid flow, and plasma characteristics for arc and laser welding. However, numerical modeling of laser/GTA hybrid welding is just beginning. Arc and laser welding plasmas have been previously analyzed successfully using optical emission spectroscopy in order to better understand arc and laser plasma properties as a function of plasma radius. Variation of hybrid welding plasma properties with radial distance is not known. Since plasma properties can affect arc and laser energy absorption and weld integrity, a better understanding of the change in hybrid welding plasma properties as a function of plasma radius is important and necessary. Material composition influences welding plasma properties, arc and laser energy absorption, heat transfer, and fluid flow. The presence of surface active elements such as oxygen and sulfur can affect weld pool fluid flow and bead geometry depending upon the significance of heat transfer by convection. Easily vaporized and ionized alloying elements can influence arc plasma characteristics and arc energy absorption. The effects of surface active elements on heat transfer and fluid flow are well understood in the case of arc and conduction mode laser welding. However, the influence of surface active elements on heat transfer and fluid flow during keyhole mode laser welding and laser/arc hybrid welding are not well known. Modeling has been used to successfully analyze the influence of surface active elements during arc and conduction mode laser welding in the past and offers promise in the case of laser/arc hybrid welding. A critical review of the literature revealed several important areas for further research and unanswered questions. (1) The understanding of heat transfer and fluid flow during hybrid welding is still beginning and further research is necessary. (2) Why hybrid welding weld bead width is greater than that of laser or arc welding is not well understood. (3) The influence of arc power and heat source separation distance on cooling rates during hybrid welding are not known. (4) Convection during hybrid welding is not well understood despite its importance to weld integrity. (5) The influence of surface active elements on weld geometry, weld pool temperatures, and fluid flow during high power density laser and laser/arc hybrid welding are not known. (6) Although the arc power and heat source separation distance have been experimentally shown to influence arc stability and plasma light emission during hybrid welding, the influence of these parameters on plasma properties is unknown. (7) The electrical conductivity of hybrid welding plasmas is not known, despite its importance to arc stability and weld integrity. In this study, heat transfer and fluid flow are analyzed for laser, gas tungsten arc (GTA), and laser/GTA hybrid welding using an experimentally validated three dimensional phenomenological model. By evaluating arc and laser welding using similar process parameters, a better understanding of the hybrid welding process is expected. The role of arc power and heat source separation distance on weld depth, weld pool centerline cooling rates, and fluid flow profiles during CO2 laser/GTA hybrid welding of 321 stainless steel are analyzed. Laser power is varied for a constant heat source separation distance to evaluate its influence on weld temperatures, weld geometry, and fluid flow during Nd:YAG laser/GTA hybrid welding of A131 structural steel. The influence of oxygen and sulfur on keyhole and weld bead geometry, weld temperatures, and fluid flow are analyzed for high power density Yb doped fiber laser welding of (0.16 %C, 1.46 %Mn) mild steel. Optical emission spectroscopy was performed on GTA, Nd:YAG laser, and Nd:YAG laser/GTA hybrid welding plasmas for welding of 304L stainless steel. Emission spectroscopy provides a means of determining plasma temperatures and species densities using deconvoluted measured spectral intensities, which can then be used to calculate plasma electrical conductivity. In this study, hybrid welding plasma temperatures, species densities, and electrical conductivities were determined using various heat source separation distances and arc currents using an analytical method coupled calculated plasma compositions. As a result of these studies heat transfer by convection was determined to be dominant during hybrid welding of steels. The primary driving forces affecting hybrid welding fluid flow are the surface tension gradient and electromagnetic force. Fiber laser weld depth showed a negligible change when increasing the (0.16 %C, 1.46 %Mn) mild steel sulfur concentration from 0.006 wt% to 0.15 wt%. Increasing the dissolved oxygen content in weld pool from 0.0038 wt% to 0.0257 wt% increased the experimental weld depth from 9.3 mm to 10.8 mm. Calculated partial pressure of carbon monoxide increased from 0.1 atm to 0.75 atm with the 0.0219 wt% increase in dissolved oxygen in the weld metal and may explain the increase in weld depth. Nd:YAG laser/GTA hybrid welding plasma temperatures were calculated to be approximately between 7927 K and 9357 K. Increasing the Nd:YAG laser/GTA hybrid welding heat source separation distance from 4 mm to 6 mm reduced plasma temperatures between 500 K and 900 K. Hybrid welding plasma total electron densities and electrical conductivities were on the order of 1 x 1022 m-3 and 3000 S m-1, respectively.
Characterization and Optimization of Ni-WC Composite Weld Matrix Deposited by Plasma-Transferred Arc Process

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

NASA Technical Reports Server (NTRS)

Haryung, J.; Wroth, R. S.

1967-01-01

Program investigates the effects of varied welding positions on weld qualities. Progressive changes in bead geometry occur as the weld plane angle is varied from upslope to downslope. The gravitational effect on the weld puddle varies greatly with welding position.
Studies of localized corrosion in welded aluminum alloys by the scanning reference electrode technique

NASA Technical Reports Server (NTRS)

Danford, M. D.; Nunes, A. C.

1995-01-01

Localized corrosion in welded samples of 2219-T87 Al alloy (2319 filler), 2090 Al-Li alloy (4043 and 2319 fillers), and 2195 Al-Li alloy (4043 and 2319 fillers) has been investigated using the relatively new scanning reference electrode technique. The weld beads are cathodic in all cases, leading to reduced anode/cathode ratios. A reduction in anode/cathode ratio leads to an increase in the corrosion rates of the welded metals, in agreement with results obtained in previous electrochemical and stress corrosion studies involving the overall corrosion rates of welded samples. The cathodic weld beads are bordered on both sides by strong anodic regions, with high propensity for corrosion.
Fatigue properties of dissimilar metal laser welded lap joints

NASA Astrophysics Data System (ADS)

Dinsley, Christopher Paul

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

NASA Astrophysics Data System (ADS)

Masubuchi, Koichi; Nayama, Michisuke

A series of gas tungsten arc welding experiments under low-gravity conditions created using parabolic flight of aircraft were performed. The materials used were aluminum and 2219 aluminum alloy. Welding was conducted in a small chamber filled with 100 percent argon gas, and the power source was a set of storage batteries. While welding was conducted, CCD image of welding phenomena, welding current, voltage, and the gravity level of the welding table were recorded continuously. It was found that sound welds can be obtained under low-gravity conditions. The bead appearance of the weld bead made under low-gravity conditions was very smooth and flat with no ripple lines which normally exist in welds made on the earth. The observed shape of the arc plasma under low-gravity conditions was larger than that made under normal gravity condition, but the difference was not so significant. Welds made under low-gravity conditions tend to contain more porosity compared with welds made under the earth conditions.
Simultaneous laser cutting and welding of metal foil to edge of a plate

DOEpatents

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

1996-01-01

A method of welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads.
Gas metal arc weldability of 1.5 GPa grade martensitic steels

NASA Astrophysics Data System (ADS)

Hwang, Insung; Yun, Hyeonsang; Kim, Dongcheol; Kang, Munjin; Kim, Young-Min

2018-01-01

The gas metal arc weldability of 1.5 GPa grade martensitic (MART) steel was evaluated using both inverter direct current (DC) and DC pulse power type welders, under conditions of different welding currents, welding speeds, and shielding gasses. By investigating the bead appearance, tensile strength, and arc stability, it was determined that DC pulse power is better than inverter DC power for arc welding of 1.3 mm thick 1.5 GPa grade MART steel. Further, from the results of the weldability for various shielding gases, it was determined that mixed shielding gas is more effective for welding 1.5 GPa grade MART steel than is pure inert gas (Ar) or active (CO2) gas. In the case of pure shielding gas, no sound bead was formed under any conditions. However, when the mixed shielding gas was used, sound and fine beads were obtained.
Cutting Tool For Shaving Weld Beads

NASA Technical Reports Server (NTRS)

Hoffman, David S.; Mcferrin, David C.; Daniel, Ronald L., Jr.; Coby, John B., Jr.; Dawson, Sidney G.

1995-01-01

Cutting tool proposed for use in shaving weld beads flush with adjacent surfaces of weldments. Modified version of commercial pneumatically driven rotary cutting tool, cutting wheel of which turns at speeds sufficient for machining nickel alloys, titanium, and stainless steels. Equipped with forward-mounted handle and rear-mounted skid plate to maximize control and reduce dependence on skill of technician.
Dual-beam laser welding of AZ31B magnesium alloy in zero-gap lap joint configuration

NASA Astrophysics Data System (ADS)

Harooni, Masoud; Carlson, Blair; Kovacevic, Radovan

2014-03-01

Porosity within laser welds of magnesium alloys is one of the main roadblocks to achieving high quality joints. One of the causes of pore formation is the presence of pre-existing coatings on the surface of magnesium alloy such as oxide or chromate layers. In this study, single-beam and dual-beam laser heat sources are investigated in relation to mitigation of pores resulting from the presence of the as-received oxide layer on the surface of AZ31B-H24 magnesium alloy during the laser welding process. A fiber laser with a power of up to 4 kW is used to weld samples in a zero-gap lap joint configuration. The effect of dual-beam laser welding with different beam energy ratios is studied on the quality of the weld bead. The purpose of this paper is to identify the beam ratio that best mitigates pore formation in the weld bead. The laser molten pool and the keyhole condition, as well as laser-induced plasma plume are monitored in real-time by use of a high speed charge-coupled device (CCD) camera assisted with a green laser as an illumination source. Tensile and microhardness tests were used to measure the mechanical properties of the laser welded samples. Results showed that a dual-beam laser configuration can effectively mitigate pore formation in the weld bead by a preheating-welding mechanism.
Automated Welding System

NASA Technical Reports Server (NTRS)

Bayless, E. O.; Lawless, K. G.; Kurgan, C.; Nunes, A. C.; Graham, B. F.; Hoffman, D.; Jones, C. S.; Shepard, R.

1993-01-01

Fully automated variable-polarity plasma arc VPPA welding system developed at Marshall Space Flight Center. System eliminates defects caused by human error. Integrates many sensors with mathematical model of the weld and computer-controlled welding equipment. Sensors provide real-time information on geometry of weld bead, location of weld joint, and wire-feed entry. Mathematical model relates geometry of weld to critical parameters of welding process.

Vision-based weld pool boundary extraction and width measurement during keyhole fiber laser welding

NASA Astrophysics Data System (ADS)

Luo, Masiyang; Shin, Yung C.

2015-01-01

In keyhole fiber laser welding processes, the weld pool behavior is essential to determining welding quality. To better observe and control the welding process, the accurate extraction of the weld pool boundary as well as the width is required. This work presents a weld pool edge detection technique based on an off axial green illumination laser and a coaxial image capturing system that consists of a CMOS camera and optic filters. According to the difference of image quality, a complete developed edge detection algorithm is proposed based on the local maximum gradient of greyness searching approach and linear interpolation. The extracted weld pool geometry and the width are validated by the actual welding width measurement and predictions by a numerical multi-phase model.
Visualization of hump formation in high-speed gas metal arc welding

NASA Astrophysics Data System (ADS)

Wu, C. S.; Zhong, L. M.; Gao, J. Q.

2009-11-01

The hump bead is a typical weld defect observed in high-speed welding. Its occurrence limits the improvement of welding productivity. Visualization of hump formation during high-speed gas metal arc welding (GMAW) is helpful in the better understanding of the humping phenomena so that effective measures can be taken to suppress or decrease the tendency of hump formation and achieve higher productivity welding. In this study, an experimental system was developed to implement vision-based observation of the weld pool behavior during high-speed GMAW. Considering the weld pool characteristics in high-speed welding, a narrow band-pass and neutral density filter was equipped for the CCD camera, the suitable exposure time was selected and side view orientation of the CCD camera was employed. The events that took place at the rear portion of the weld pools were imaged during the welding processes with and without hump bead formation, respectively. It was found that the variation of the weld pool surface height and the solid-liquid interface at the pool trailing with time shows some useful information to judge whether the humping phenomenon occurs or not.
Influence of the Gap Width on the Geometry of the Welded Joint in Hybrid Laser-Arc Welding

NASA Astrophysics Data System (ADS)

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

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

PubMed

Caiazzo, Fabrizia; Caggiano, Alessandra

2018-04-20

Laser welding of titanium alloys is attracting increasing interest as an alternative to traditional joining techniques for industrial applications, with particular reference to the aerospace sector, where welded assemblies allow for the reduction of the buy-to-fly ratio, compared to other traditional mechanical joining techniques. In this research work, an investigation on laser welding of Ti⁻6Al⁻4V alloy plates is carried out through an experimental testing campaign, under different process conditions, in order to perform a characterization of the produced weld bead geometry, with the final aim of developing a cognitive methodology able to support decision-making about the selection of the suitable laser welding process parameters. The methodology is based on the employment of artificial neural networks able to identify correlations between the laser welding process parameters, with particular reference to the laser power, welding speed and defocusing distance, and the weld bead geometric features, on the basis of the collected experimental data.
Investigation of Laser Welding of Ti Alloys for Cognitive Process Parameters Selection

PubMed Central

2018-01-01

Laser welding of titanium alloys is attracting increasing interest as an alternative to traditional joining techniques for industrial applications, with particular reference to the aerospace sector, where welded assemblies allow for the reduction of the buy-to-fly ratio, compared to other traditional mechanical joining techniques. In this research work, an investigation on laser welding of Ti–6Al–4V alloy plates is carried out through an experimental testing campaign, under different process conditions, in order to perform a characterization of the produced weld bead geometry, with the final aim of developing a cognitive methodology able to support decision-making about the selection of the suitable laser welding process parameters. The methodology is based on the employment of artificial neural networks able to identify correlations between the laser welding process parameters, with particular reference to the laser power, welding speed and defocusing distance, and the weld bead geometric features, on the basis of the collected experimental data. PMID:29677114
Simultaneous laser cutting and welding of metal foil to edge of a plate

DOEpatents

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

1996-03-19

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

NASA Technical Reports Server (NTRS)

Abdelmessih, Amanie N.

1991-01-01

The Space Shuttle External Tank is fabricated by the variable polarity plasma arc (VPPA) welding process. In VPPA welding, a noble gas, usually argon, is directed through an arc to emerge from the torch as a hot plasma jet. This jet is surrounded by a shielding gas, usually helium, to protect the weld from contamination with air. The high velocity, hot plasma jet completely penetrates the workpiece (resembling a line heat source) when operated in the 'keyhole' mode. The metal melts on touching the side of the jet, as the torch travels in the perpendicular direction to the direction of the jet, and melted metal moves around the plasma jet in the keyhole forming a puddle which solidifies behind the jet. Heat sink effects are observed when there are irregularities in the workpiece configuration, especially, if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, i.e., in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of this research is to study the effect of irregularities in workpiece configuration and fixture differences (heat sink effects) on the weld bead geometry with the ultimate objective to compensate for the heat sink effects and achieve a perfect weld. Experiments were performed on different workpiece geometries and compared to approximate models.
Fluid Flow Phenomena during Welding

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

Zhang, Wei

2011-01-01

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

DOEpatents

Benson, David K.; Tracy, C. Edwin

1987-01-01

A laser sealed evacuated window panel is comprised of two glass panes held spaced apart in relation to each other by a plurality of spherical glass beads and glass welded around the edges to provide an evacuated space between the glass panes that is completely glass sealed from the exterior. The glass welded edge seal is obtained by welding the edges of the glass panes together with a laser beam while the glass panes and bead spacers are positioned in a vacuum furnace and heated to the annealing point of the glass to avoid stress fracture in the area of the glass weld. The laser welding in the furnace can be directed around the perimeter of the glass panel by a combination of rotating the glass panel and linearly translating or aiming the laser with a relay mirror.
Laser sealed vacuum insulating window

DOEpatents

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

1985-08-19

A laser sealed evacuated window panel is comprised of two glass panes held spaced apart in relation to each other by a plurality of spherical glass beads and glass welded around the edges to provide an evacuated space between the glass panes that is completely glass sealed from the exterior. The glass welded edge seal is obtained by welding the edges of the glass panes together with a laser beam while the glass panes and bead spacers are positioned in a vacuum furnace and heated to the annealing point of the glass to avoid stress fracture in the area of the glass weld. The laser welding in the furnace can be directed around the perimeter of the galss panel by a combination of rotating the glass panel and linearly translating or aiming the laser with a relay mirror.
Capillary flow weld-bonding

NASA Technical Reports Server (NTRS)

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

1976-01-01

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

DOEpatents

McKelvey, T.E.; Guarnieri, J.J.

1984-03-13

A thermocouple arrangement is provided for mounting in a blind hole of a specimen. The thermocouple arrangement includes a cup-like holder member, which receives an elongated thermal insulator, one end of which is seated at an end wall of the holder. A pair of thermocouple wires, threaded through passageways in the insulator, extend beyond the insulator member, terminating in free ends which are joined together in a spherical weld bead. A spring, held captive within the holder, applies a bias force to the weld bead, through the insulator member. The outside surface of the holder is threaded for engagement with the blind hole of the specimen. When the thermocouple is installed in the specimen, the spherical contact surface of the weld bead is held in contact with the end wall of the blind hole, with a predetermined bias force.
Spring loaded thermocouple module

DOEpatents

McKelvey, Thomas E.; Guarnieri, Joseph J.

1985-01-01

A thermocouple arrangement is provided for mounting in a blind hole of a specimen. The thermocouple arrangement includes a cup-like holder member, which receives an elongated thermal insulator, one end of which is seated at an end wall of the holder. A pair of thermocouple wires, threaded through passageways in the insulator, extend beyond the insulator member, terminating in free ends which are joined together in a spherical weld bead. A spring, held captive within the holder, applies a bias force to the weld bead, through the insulator member. The outside surface of the holder is threaded for engagement with the blind hole of the specimen. When the thermocouple is installed in the specimen, the spherical contact surface of the weld bead is held in contact with the end wall of the blind hole, with a predetermined bias force.
Isothermal Calorimetric Observations of the Affect of Welding on Compatibility of Stainless Steels with High-Test Hydrogen Peroxide Propellant

NASA Technical Reports Server (NTRS)

Gostowski, Rudy C.

2002-01-01

Compatibility is determined by the surface area, the chemical constituency and the surface finish of a material. In this investigation exposed area is obviously not a factor as the welded samples had a slightly smaller surface than the unwelded, but were more reactive. The chemical makeup of welded CRES 316L and welded CRES 304L have been observed in the literature to change from the parent material as chromium and iron are segregated in zones. In particular, the ratio of chromium to iron in CRES 316L increased from 0.260 to 0.79 in the heat affected zone (HAZ) of the weld and to 1.52 in the weld bead itself. In CRES 304L the ratio of chromium to iron increased from 0.280 to 0.44 in the HAZ and to 0.33 in the weld bead. It is possible that the increased reactivity of the welded samples and of those welded without purge gas is due to this segregation phenomenon. Likewise the reactivity increased in keeping with the greater roughness of the welded and welded without purge gas samples. Therefore enhanced roughness may also be responsible for the increased reactivity.
Inert-Gas Diffuser For Plasma Or Arc Welding

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.; Spencer, Carl N.; Hosking, Timothy J.

1994-01-01

Inert-gas diffuser provides protective gas cover for weld bead as it cools. Follows welding torch, maintaining continuous flow of argon over newly formed joint and prevents it from oxidizing. Helps to ensure welds of consistently high quality. Devised for plasma arc keyhole welding of plates of 0.25-in. or greater thickness, also used in tungsten/inert-gas and other plasma or arc welding processes.
Fusion Welding Research.

DTIC Science & Technology

1984-04-30

ratios of iron to chromium and manganese to chromium (Cr content does not change significantly) for three different steels. As can be seen Mn...weld defects such as humping and undercutting of the weld bead. Humping and undercutting are common in high travel speed and high current GTAW
Evaluation of Surface Roughness by Image Processing of a Shot-Peened, TIG-Welded Aluminum 6061-T6 Alloy: An Experimental Case Study

PubMed Central

Rawashdeh, Nathir A.

2018-01-01

Visual inspection through image processing of welding and shot-peened surfaces is necessary to overcome equipment limitations, avoid measurement errors, and accelerate processing to gain certain surface properties such as surface roughness. Therefore, it is important to design an algorithm to quantify surface properties, which enables us to overcome the aforementioned limitations. In this study, a proposed systematic algorithm is utilized to generate and compare the surface roughness of Tungsten Inert Gas (TIG) welded aluminum 6061-T6 alloy treated by two levels of shot-peening, high-intensity and low-intensity. This project is industrial in nature, and the proposed solution was originally requested by local industry to overcome equipment capabilities and limitations. In particular, surface roughness measurements are usually only possible on flat surfaces but not on other areas treated by shot-peening after welding, as in the heat-affected zone and weld beads. Therefore, those critical areas are outside of the measurement limitations. Using the proposed technique, the surface roughness measurements were possible to obtain for weld beads, high-intensity and low-intensity shot-peened surfaces. In addition, a 3D surface topography was generated and dimple size distributions were calculated for the three tested scenarios: control sample (TIG-welded only), high-intensity shot-peened, and low-intensity shot-peened TIG-welded Al6065-T6 samples. Finally, cross-sectional hardness profiles were measured for the three scenarios; in all scenarios, lower hardness measurements were obtained compared to the base metal alloy in the heat-affected zone and in the weld beads even after shot-peening treatments. PMID:29748520
Evaluation of Surface Roughness by Image Processing of a Shot-Peened, TIG-Welded Aluminum 6061-T6 Alloy: An Experimental Case Study.

PubMed

Atieh, Anas M; Rawashdeh, Nathir A; AlHazaa, Abdulaziz N

2018-05-10

Visual inspection through image processing of welding and shot-peened surfaces is necessary to overcome equipment limitations, avoid measurement errors, and accelerate processing to gain certain surface properties such as surface roughness. Therefore, it is important to design an algorithm to quantify surface properties, which enables us to overcome the aforementioned limitations. In this study, a proposed systematic algorithm is utilized to generate and compare the surface roughness of Tungsten Inert Gas (TIG) welded aluminum 6061-T6 alloy treated by two levels of shot-peening, high-intensity and low-intensity. This project is industrial in nature, and the proposed solution was originally requested by local industry to overcome equipment capabilities and limitations. In particular, surface roughness measurements are usually only possible on flat surfaces but not on other areas treated by shot-peening after welding, as in the heat-affected zone and weld beads. Therefore, those critical areas are outside of the measurement limitations. Using the proposed technique, the surface roughness measurements were possible to obtain for weld beads, high-intensity and low-intensity shot-peened surfaces. In addition, a 3D surface topography was generated and dimple size distributions were calculated for the three tested scenarios: control sample (TIG-welded only), high-intensity shot-peened, and low-intensity shot-peened TIG-welded Al6065-T6 samples. Finally, cross-sectional hardness profiles were measured for the three scenarios; in all scenarios, lower hardness measurements were obtained compared to the base metal alloy in the heat-affected zone and in the weld beads even after shot-peening treatments.
Grinding Parts For Automatic Welding

NASA Technical Reports Server (NTRS)

Burley, Richard K.; Hoult, William S.

1989-01-01

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

The use of electromagnetic body forces to enhance the quality of laser welds

NASA Astrophysics Data System (ADS)

Ambrosy, Guenter; Berger, P.; Huegel, H.; Lindenau, D.

2003-11-01

The use of electromagnetic body forces in laser beam welding of aluminum alloys is a new method to shape the geometry and to enhance the quality of the weld seams. In this new approach, electromagnetic volume forces are utilized by applying magnetic fields and electric currents of various origins. Acting in the liquid metal, they directly affect the flow field and can lead to favourable conditions for the melt dynamics and energy coupling. Numerous welds with full and partial penetration using both CO2 and Nd:YAG lasers demonstrate that this method directly influences the seam geometry and top-bead topography as well as the penetration depth and the evolution of pores and cracks. In the case of full penetration, it is also possible to lift or to lower the weld pool. The method, therefore, can be used to shape the geometry and to enhance the quality of the weld seam. Depending on the orientation of an external magnetic field, significant impacts are achieved in CO2 welding, even without an external current: the shape of the cross-sectional area can be increased of up to 50% and also the seam width is changed. Whereas for such conditions with Nd:YAG lasers no significant effect could be observed, it turned out that, when an external electric current is applied, similar effects are present with both wavelengths. In further investigations, the effect of electromagnetic body forces resulting from the interaction of an external current and its self-induced magnetic field was studied. Hereby, the current was fed into the workpiece via a tungsten electrode or a filler wire. The resulting phenomena are the same independent from wavelength and means of current feed.
Analysis of thermal stresses and metal movement during welding

NASA Technical Reports Server (NTRS)

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

1974-01-01

Finite element computer programs were developed to determine thermal stresses and metal movement during butt welding of flat plates and bead-on-plate welding along the girth of a cylindrical shell. Circular cylindrical shells of 6061 aluminum alloy were used for the tests. Measurements were made of changes in temperature and thermal strains during the welding process.
Weld Bead Geometry of Ni-Based Alloy Deposited by PTA Process for Pipe Conduction of Shale Gas

NASA Astrophysics Data System (ADS)

Echavarria-Figueroa, C.; García-Vázquez, F.; Ruiz-Mondragón, J.; Hernández-García, H. M.; González-González, D.; Vargas, A.

The transportation of shale gas has the problem that the piping used for the extraction does not resist the erosion generated by the amount of solids causing cracks over the surface and it is necessary to extend the life of the pipelines. Plasma transferred arc (PTA) welded coatings are used to improve the surface properties of mechanical parts. Therefore, in this paper is studied the use of Ni-based filler metal as weld bead deposits on A36 steel substrates by PTA. In order to determine the suitable conditions to ensure coating quality on the substrate a design of experiments (DOE) was determined. Welding current, feed rate, and travel speed were used as input parameters and the dilution percentage as the response variable. The composition and properties of hardfacing or overlay deposited are strongly influenced by the dilution obtained. Control of dilution is important, where typically low dilution is desirable. When the dilution is low, the final deposit composition will be closer to that of the filler metal, and the wear and corrosion resistance of the hardfacing will also be maintained. To evaluate the features on the weld beads/substrate interface a microstructural characterization was performed by using scanning electron microscopy and to evaluate the mechanical properties was carried out hardness test.
Real-time monitoring of the laser hot-wire welding process

NASA Astrophysics Data System (ADS)

Liu, Wei; Liu, Shuang; Ma, Junjie; Kovacevic, Radovan

2014-04-01

The laser hot-wire welding process was investigated in this work. The dynamics of the molten pool during welding was visualized by using a high-speed charge-coupled device (CCD) camera assisted by a green laser as an illumination source. It was found that the molten pool is formed by the irradiation of the laser beam on the filler wire. The effect of the hot-wire voltage on the stability of the welding process was monitored by using a spectrometer that captured the emission spectrum of the laser-induced plasma plume. The spectroscopic study showed that when the hot-wire voltage is above 9 V a great deal of spatters occur, resulting in the instability of the plasma plume and the welding process. The effect of spatters on the plasma plume was shown by the identified spectral lines of the element Mn I. The correlation between the Fe I electron temperature and the weld-bead shape was studied. It was noted that the electron temperature of the plasma plume can be used to real-time monitor the variation of the weld-bead features and the formation of the weld defects.
Welding technology transfer task/laser based weld joint tracking system for compressor girth welds

NASA Technical Reports Server (NTRS)

Looney, Alan

1991-01-01

Sensors to control and monitor welding operations are currently being developed at Marshall Space Flight Center. The laser based weld bead profiler/torch rotation sensor was modified to provide a weld joint tracking system for compressor girth welds. The tracking system features a precision laser based vision sensor, automated two-axis machine motion, and an industrial PC controller. The system benefits are elimination of weld repairs caused by joint tracking errors which reduces manufacturing costs and increases production output, simplification of tooling, and free costly manufacturing floor space.
A quantitative evaluation of the L.B.W. efficiency on AISI 304 bead on plates welded under different focusing and tilted laser beam conditions

NASA Astrophysics Data System (ADS)

Daurelio, Giuseppe; Ludovico, Antonio D.; Lugara, M. P.; De Filippis, L. A. C.; Spera, A. M.; Rocco, S.

2005-03-01

The aim of this search is to evaluate the WE (Welding Efficiency) of each beads versus the different positions of the laser beam optical focus (positive or negative or zero values) respect to the work-piece surface and also versus different laser beam incidence angles (80° and 70°) by using two laser power levels (2 and 2.5 KW) and two welding speeds (3 and 6 m/min). The WE values have been reported on two DA.LU. method plots and the relate evaluations regarding the same ones as well as the recorded best parameters have been evidenced.
Fabrication and evaluation of superplastically formed/weld-brazed corrugated compression panels with beaded webs

NASA Technical Reports Server (NTRS)

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

1985-01-01

A study was made to investigate the feasibility of superplastically forming corrugated panels with beaded webs and to demonstrate the structural integrity of these panels by testing. The test panels in the study consist of superplastically formed titanium alloy Ti-6Al-4V half-hat elements that are joined by weld-brazing to titanium alloy Ti-6Al-4V caps to form either single-corrugation compression panels or multiple-corrugation compression panels. Stretching and subsequent thinning of the titanium sheet during superplastic forming is reduced by approximately 35 percent with a shallow half-hat die concept instead of a deep die concept and results in a more uniform thickness across the beaded webs. The complete panels are tested in end compression at room temperature and the results compared with analysis. The heavily loaded panels failed at loads approaching the yield strength of the titanium material. At maximum load, the caps wrinkled locally accompanied with separation of the weld-braze joint in the wrinkle. None of the panels tested, however, failed catastrophically in the weld-braze joint. Experimental test results are in good agreement with structural analysis of the panels.
Maintenance Welding in Nuclear Power Plants/III, Conference Proceedings Held at Knoxville, Tennessee on 6-8 November 1985

DTIC Science & Technology

1985-11-06

Mongiat, S. Kumar and K.K. Subbayya ALTERNATXVES TO ONE-HALF BEAD REPAIR TECHNIQUE ( GTAW ); ................................... 153 By P. J. Alberry...3.5.1 Welding Procedure The welding procedure used for mechanized welding of permanently installed pipes is the pulsed GTAW welding procedure with a cold...be adapted . to this system to an -’verall height of 130 mm. Because of the considerably shorter welding times, the GTAW narrow opening welling
Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

NASA Astrophysics Data System (ADS)

Bhatt, R. B.; Kamat, H. S.; Ghosal, S. K.; de, P. K.

1999-10-01

The influence of nitrogen in shielding gas on the corrosion resistance of welds of a duplex stainless steel (grade U-50), obtained by gas tungsten arc (GTA) with filler wire, autogenous GTA (bead-on-plate), electron beam welding (EBW), and microplasma techniques, has been evaluated in chloride solutions at 30 °C. Pitting attack has been observed in GTA, electron beam welding, and microplasma welds when welding has been carried out using pure argon as the shielding gas. Gas tungsten arc welding with 5 to 10% nitrogen and 90 to 95% argon, as the shielding gas, has been found to result in an improved pitting corrosion resistance of the weldments of this steel. However, the resistance to pitting of autogenous welds (bead-on-plate) obtained in pure argon as the shielding gas has been observed to remain unaffected. Microscopic examination, electron probe microanalysis (EPMA), and x-ray diffraction studies have revealed that the presence of nitrogen in the shielding gas in the GTA welds not only modifies the microstructure and the austenite to ferrite ratio but also results in a nearly uniform distribution of the various alloying elements, for example, chromium, nickel, and molybdenum among the constitutent phases, which are responsible for improved resistance to pitting corrosion.
Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

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

Bhatt, R.B.; Kamat, H.S.; Ghosal, S.K.

1999-10-01

The influence of nitrogen in shielding gas on the corrosion resistance of welds of a duplex stainless steel (grade U-50), obtained by gas tungsten arc (GTA) with filler wire, autogenous GTA (bead-on-plate), electron beam welding (EBW), and microplasma techniques, has been evaluated in chloride solutions at 30 C. Pitting attack has been observed in GTA, electron beam welding, and microplasma welds when welding has been carried out using pure argon as the shielding gas. Gas tungsten arc welding with 5 to 10% nitrogen and 90 to 95% argon, as the shielding gas, has been found to result in an improvedmore » pitting corrosion resistance of the weldments of this steel. However, the resistance of pitting of autogenous welds (bead-on-plate) obtained in pure argon as the shielding gas has been observed to remain unaffected. Microscopic examination, electron probe microanalysis (EPMA), and x-ray diffraction studies have revealed that the presence of nitrogen in the shielding gas in the GTA welds not only modifies the microstructure and the austenite to ferrite ratio but also results in a nearly uniform distribution of the various alloying elements, for example, chromium, nickel, and molybdenum among the constituent phases, which are responsible for improved resistance to pitting corrosion.« less
Specifics of Pulsed Arc Welding Power Supply Performance Based On A Transistor Switch

NASA Astrophysics Data System (ADS)

Krampit, N. Yu; Kust, T. S.; Krampit, M. A.

2016-08-01

Specifics of designing a pulsed arc welding power supply device are presented in the paper. Electronic components for managing large current was analyzed. Strengths and shortcomings of power supply circuits based on thyristor, bipolar transistor and MOSFET are outlined. As a base unit for pulsed arc welding was chosen MOSFET transistor, which is easy to manage. Measures to protect a transistor are given. As for the transistor control device is a microcontroller Arduino which has a low cost and adequate performance of the work. Bead transfer principle is to change the voltage on the arc in the formation of beads on the wire end. Microcontroller controls transistor when the arc voltage reaches the threshold voltage. Thus there is a separation and transfer of beads without splashing. Control strategies tested on a real device and presented. The error in the operation of the device is less than 25 us, it can be used controlling drop transfer at high frequencies (up to 1300 Hz).
ME8373 Spring 2015 ICME Proposal ICME Analysis of Fatigue Crack Growth Through a Weld in SA-516 Grade 70 Plate

NASA Technical Reports Server (NTRS)

Woods, Jody L.

2015-01-01

This paper describes work accomplished to predict the service life of a flexure joint design which is a component of a diffuser duct in the A3 Test Stand, an altitude simulation rocket engine test facility at NASA's Stennis Space Center. The duct has two pressure shells separated by cooling water passages and connected by stiffening ribs and flexure joints. Rocket exhaust flows within the duct and heats the inner pressure shell while the outer pressure shell remains at ambient temperature. The flexure joints allow for differential thermal expansion of the inner and outer pressure shells and are subject to in-service loading by this thermal expansion along with water pressure in the cooling water passage, atmospheric pressure outside the duct, near vacuum conditions within the duct, and vibrational loads from operation of the facility and rocket engine. Figure 1 shows a schematic axisymmetric cross section of the diffuser pressure shells and flexure joints with a zoomed in view of the flexure joint. The flexure joints are expected to eventually fail by fatigue cracking leading to leaks from the cooling water passages to the outside. The zoomed in view in Figure 1 indicates where cracking is expected to occur, namely through a weld bead between two plates of SA-516 Grade 70 steel. This weld bead acts as the fulcrum of the flexure joint and it is clear from inspection of the geometry and loading represented in the zoomed in portion of Figure 1 that inherent in the design there is a severe notch formed between the flexure plate, weld bead, and stiffening ring that will be the site of crack initiation and location from which the crack grows to the outer surface of the weld bead.
Metal transfer and V-I transients in GMAW of aluminium

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

Pandey, S.; Rao, U.R.K.; Aghakhani, M.

1996-12-31

The mode of metal transfer in arc welding significantly affects the positional weldability; particularly the overhead welding, the chemical composition and properties of weld metal, metallurgy of weld metal, weld pool stability, arc stability, spatter losses, and weld bead geometry. The mode of metal transfer is affected mainly by the type of the arc, welding current, electrode polarity, arc voltage, contact tube to plate distance (CTPD)/Stand-off, type and flow rate of the shielding gas, torch angle and alloying elements in GMAW of aluminium and its alloys.
Influence of shielding gas on the mechanical and metallurgical properties of DP-GMA-welded 5083-H321 aluminum alloy

NASA Astrophysics Data System (ADS)

Koushki, Amin Reza; Goodarzi, Massoud; Paidar, Moslem

2016-12-01

In the present research, 6-mm-thick 5083-H321 aluminum alloy was joined by the double-pulsed gas metal arc welding (DP-GMAW) process. The objective was to investigate the influence of the shielding gas composition on the microstructure and properties of GMA welds. A macrostructural study indicated that the addition of nitrogen and oxygen to the argon shielding gas resulted in better weld penetration. Furthermore, the tensile strength and bending strength of the welds were improved when oxygen and nitrogen (at concentrations as high as approximately 0.1vol%) were added to the shielding gas; however, these properties were adversely affected when the oxygen and nitrogen contents were increased further. This behavior was attributed to the formation of excessive brown and black oxide films on the bead surface, the formation of intermetallic compounds in the weld metal, and the formation of thicker oxide layers on the bead surface with increasing nitrogen and oxygen contents in the argon-based shielding gas. Analysis by energy-dispersive X-ray spectroscopy revealed that most of these compounds are nitrides or oxides.
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.
Microstructural Characterization of the Heat-Affected Zones in Grade 92 Steel Welds: Double-Pass and Multipass Welds

NASA Astrophysics Data System (ADS)

Xu, X.; West, G. D.; Siefert, J. A.; Parker, J. D.; Thomson, R. C.

2018-04-01

The microstructure in the heat-affected zone (HAZ) of multipass welds typical of those used in power plants and made from 9 wt pct chromium martensitic Grade 92 steel is complex. Therefore, there is a need for systematic microstructural investigations to define the different regions of the microstructure across the HAZ of Grade 92 steel welds manufactured using the traditional arc welding processes in order to understand possible failure mechanisms after long-term service. In this study, the microstructure in the HAZ of an as-fabricated two-pass bead-on-plate weld on a parent metal of Grade 92 steel has been systematically investigated and compared to a complex, multipass thick section weldment using an extensive range of electron and ion-microscopy-based techniques. A dilatometer has been used to apply controlled thermal cycles to simulate the microstructures in distinctly different regions in a multipass HAZ using sequential thermal cycles. A wide range of microstructural properties in the simulated materials were characterized and compared with the experimental observations from the weld HAZ. It has been found that the microstructure in the HAZ can be categorized by a combination of sequential thermal cycles experienced by the different zones within the complex weld metal, using the terminology developed for these regions based on a simpler, single-pass bead-on-plate weld, categorized as complete transformation, partial transformation, and overtempered.
NASA Astrophysics Data System (ADS)

Tube to tube-sheet joints in heat exchangers are currently welded by the orbital TIG process characterized by very high quality of the weld beads and good repeatability. However, due to high number of welds, a reduction in the welding cycle time would have an interesting impact on manufacturing costs and delays and laser welding technology is aimed to improve this factor. The main disadvantage is the positioning accuracy required by the laser welding process since beam deviations from real joint cause lack of penetration. It is expected that the Orbital laser welding head developed under the European project ORBITAL will avoid this drawback.
Characterization of lap joints laser beam welding of thin AA 2024 sheets with Yb:YAG disk-laser

NASA Astrophysics Data System (ADS)

Caiazzo, Fabrizia; Alfieri, Vittorio; Cardaropoli, Francesco; Sergi, Vincenzo

2012-06-01

Lap joints obtained by overlapping two plates are widely diffused in aerospace industry. Nevertheless, because of natural aging, adhesively bonded and riveted aircraft lap joints may be affected by cracks from rivets, voids or corrosion. Friction stir welding has been proposed as a valid alternative, although large heat affected zones are produced both in the top and the bottom plate due to the pin diameter. Interest has therefore been shown in studying laser lap welding as the laser beam has been proved to be competitive since it allows to concentrate the thermal input and increases productivity and quality. Some challenges arise as a consequence of aluminum low absorptance and high thermal conductivity; furthermore, issues are due to metallurgical challenges such as both micro and macro porosity formation and softening in the fused zone. Welding of AA 2024 thin sheets in a lap joint configuration is discussed in this paper: tests are carried out using a recently developed Trumpf TruDisk 2002 Yb:YAG disk-laser with high beam quality which allows to produce beads with low plates distortion and better penetration. The influence of the processing parameters is discussed considering the fused zone extent and the bead shape. The porosity content as well as the morphological features of the beads have been examined.
Modeling, simulation and control of pulsed DE-GMA welding process for joining of aluminum to steel

NASA Astrophysics Data System (ADS)

Zhang, Gang; Shi, Yu; Li, Jie; Huang, Jiankang; Fan, Ding

2014-09-01

Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme's feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme further. The beautiful and smooth weld beads are also obtained by this method. Pulsed DE-GMAW can thus be considered as an alternative method for low cost, high efficiency joining of aluminum to steel.
Analytical Modeling of Weld Bead Shape in Dry Hyperbaric GMAW Using Ar-He Chamber Gas Mixtures

NASA Astrophysics Data System (ADS)

Azar, Amin S.; Ås, Sigmund K.; Akselsen, Odd M.

2013-03-01

Hyperbaric arc welding is a special application of joining the pipeline steels under seawater. In order to analyze the behavior of the arc under ambient pressure, a model is required to estimate the arc efficiency. A distributed point heat source model was employed. The simulated isotherms were calibrated iteratively to fit the actual bead cross section. Basic gas mixture rules and models were used to calculate the thermal properties of the low-temperature shielding gas under the ambient pressure of 10 bar. Nine bead-on-plate welds were deposited each of which under different Ar-He chamber gas compositions. The well-known correlation between arc efficiency (delivered heat) and the thermal conductivity was established for different gas mixtures. The arc efficiency was considered separately for the transverse and perpendicular heat sources. It was found that assigning single heat efficiency factor for the entire arc, which is usually below unity, causes a noticeable underestimation for the heat transfer in the perpendicular direction and a little overestimation in the transverse direction.

Automatic welding systems for large ship hulls

NASA Astrophysics Data System (ADS)

Arregi, B.; Granados, S.; Hascoet, JY.; Hamilton, K.; Alonso, M.; Ares, E.

2012-04-01

Welding processes represents about 40% of the total production time in shipbuilding. Although most of the indoor welding work is automated, outdoor operations still require the involvement of numerous operators. To automate hull welding operations is a priority in large shipyards. The objective of the present work is to develop a comprehensive welding system capable of working with several welding layers in an automated way. There are several difficulties for the seam tracking automation of the welding process. The proposed solution is the development of a welding machine capable of moving autonomously along the welding seam, controlling both the position of the torch and the welding parameters to adjust the thickness of the weld bead to the actual gap between the hull plates.
Parametric study in weld mismatch of longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

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

1991-01-01

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

DTIC Science & Technology

2008-01-01

and slag formed on the upper weld surface by the FSW process and the remnant laser weld bead on the underside of the FSW surface were removed from...using 3M brand ‘Super 77’ spray adhesive and then hand sanding against a mechanically flat ceramic backing surface using silicon 32 carbide...weld surface using Loctite brand “5-minute Epoxy” and allowing to cure. Following the required cure period, the aluminum grating glass backing was
Energy Losses Estimation During Pulsed-Laser Seam Welding

NASA Astrophysics Data System (ADS)

Sebestova, Hana; Havelkova, Martina; Chmelickova, Hana

2014-06-01

The finite-element tool SYSWELD (ESI Group, Paris, France) was adapted to simulate pulsed-laser seam welding. Besides temperature field distribution, one of the possible outputs of the welding simulation is the amount of absorbed power necessary to melt the required material volume including energy losses. Comparing absorbed or melting energy with applied laser energy, welding efficiencies can be calculated. This article presents achieved results of welding efficiency estimation based on the assimilation both experimental and simulation output data of the pulsed Nd:YAG laser bead on plate welding of 0.6-mm-thick AISI 304 stainless steel sheets using different beam powers.
Development of an innovative method to predict and to characterize the performances of Ti-6Al-4V LBW joints

NASA Astrophysics Data System (ADS)

Liberini, Mariacira; Esposito, Sara; Reshad, Kambitz; Previtali, Barbara; Viola, Marco; Squillace, Antonino

2016-10-01

Every manufacturing process leaves on the surface of the piece a typical "technology signature". In particular, the laser welding leaves a feature at the edge of the weld bead called "undercut". In this work an experimental campaign has been conducted on Ti6Al4V butt joints. In particular a Central Composite Design (CCD) with the central point repeated three times has been investigated. In the CCD there are two factors (power and speed of the fiber laser) and five levels for each factor. This paper deals with the investigation about the correlation between the severity of the undercut and the process parameters of the laser welding. In particular, through the confocal microscopy, the original geometry of the joint was accurately acquired and rebuilt in order to make a FEM model and simulate the mechanical behavior using Ansys14.5. Moreover, response surfaces and level curves were carried out to understand and predict the depth and the width of the undercut starting from the power and the speed of the laser. At last a mathematic and geometry regression was performed in order to find a unique conical curve that interpolates all the different undercuts and that varies its parameters according to the process parameters. It is established that the process with higher speed minimizes and optimizes the undercut in the joints.
Comparison on welding mode characteristics of arc heat source for heat input control in hybrid welding of aluminum alloy

NASA Astrophysics Data System (ADS)

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

2015-03-01

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

NASA Technical Reports Server (NTRS)

Iceland, W. F.

1986-01-01

Circuit maintains arc length on irregularly shaped workpieces. Length of plasma arc continuously adjusted by control circuit to maintain commanded value. After pilot arc is established, contactor closed and transfers arc to workpiece. Control circuit then half-wave rectifies ac arc voltage to produce dc control signal proportional to arc length. Circuit added to plasma arc welding machines with few wiring changes. Welds made with circuit cleaner and require less rework than welds made without it. Beads smooth and free of inclusions.
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.
Study of weld offset in longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

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

1992-01-01

Welded joints are an essential part of rocket engine structures such as the Space Shuttle Main Engine (SSME) turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet X-rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered in this report. Using the FEM and beamlike plate approximations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thicknesses on both sides of the joint. Following the study, some conclusions are derived for the weld offsets.
Influence of the post-weld surface treatment on the corrosion resistance of the duplex stainless steel 1.4062

NASA Astrophysics Data System (ADS)

Rosemann, P.; Müller, C.; Baumann, O.; Modersohn, W.; Halle, T.

2017-03-01

The duplex stainless steel 1.4062 (X2CrNiN22-2) is used as alternative material to austenitic stainless steels in the construction industry. The corrosion resistance of welded seams is influenced by the base material, the weld filler material, the welding process and also by the final surface treatment. The scale layer next to the weld seam can be removed by grinding, pickling, electro-polished or blasting depending on the application and the requested corrosion resistance. Blasted surfaces are often used in industrial practice due to the easier and cheaper manufacturing process compared to pickled or electro-polished surfaces. Furthermore blasting with corundum-grain is more effective than blasting with glass-beads which also lower the process costs. In recent years, stainless steel surfaces showed an unusually high susceptibility to pitting corrosion after grinding with corundum. For this reason, it is now also questioned critically whether the corrosion resistance is influenced by the applied blasting agent. This question was specifically investigated by comparing grinded, pickled, corundum-grain- and glass-bead-blasted welding seams. Results of the SEM analyses of the blasting agents and the blasted surfaces will be presented and correlated with the different performed corrosion tests (potential measurement, KorroPad-test and pitting potential) on welding seams with different surface treatments.
The effects of laser welding parameters on the microstructure of ferritic and duplex stainless steels welds

NASA Astrophysics Data System (ADS)

Pekkarinen, J.; Kujanpää, V.

This study is focused to determine empirically, which microstructural changes occur in ferritic and duplex stainless steels when heat input is controlled by welding parameters. Test welds were done autogenously bead-on-plate without shielding gas using 5 kW fiber laser. For comparison, some gas tungsten arc welds were made. Used test material were 1.4016 (AISI 430) and 1.4003 (low-carbon ferritic) type steels in ferritic steels group and 1.4162 (low-alloyed duplex, LDX2101) and 1.4462 (AISI 2205) type steels in duplex steels group. Microstructural changes in welds were identified and examined using optical metallographic methods.
The effect of weld porosity on the cryogenic fatigue strength of ELI grade Ti-5Al-2.5Sn

NASA Technical Reports Server (NTRS)

Rogers, P. R.; Lambdin, R. C.; Fox, D. E.

1992-01-01

The effect of weld porosity on the fatigue strength of ELI grade Ti-5Al-2.5Sn at cryogenic temperature was determined. A series of high cycle fatigue (HCF) and tensile tests were performed at -320 F on specimens made from welded sheets of the material. All specimens were tested with weld beads intact and some amount of weld offset. Specimens containing porosity and control specimens containing no porosity were tested. Results indicate that for the weld configuration tested, the fatigue life of the material is not affected by the presence of spherical embedded pores.
Laser Powder Welding of a Ti52Al46.8Cr1Si0.2Titanium Aluminide Alloy at Elevated Temperature

NASA Astrophysics Data System (ADS)

Smal, C. A.; Meacock, C. G.; Rossouw, H. J.

2011-04-01

A method for the joining of a Ti52Al46.8Cr1Si0.2Titanium Aluminide alloy by laser powder welding is presented. The technique acts to join materials by consolidating powder with focused laser beam to form weld beads that fill a V joint. In order to avoid the occurrence of residual thermal stresses and hence cracking of the brittle material, the weld plates were heated to a temperature of 1173 K (= 900 °C) by an ohmic heating device, welded and then slowly cooled to produce pore and crack free welds.
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.
Weld geometry strength effect in 2219-T87 aluminum

NASA Technical Reports Server (NTRS)

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

1981-01-01

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

DOEpatents

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

1996-03-26

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

Method for laser welding ultra-thin metal foils

DOEpatents

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

1996-01-01

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

NASA Astrophysics Data System (ADS)

Pal, Kamal; Pal, Surjya K.

2011-08-01

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

NASA Astrophysics Data System (ADS)

Song, Chaoqun; Dong, Shiyun; Yan, Shixing; He, Jiawu; Xu, Binshi; He, Peng

2017-10-01

Ultra-narrow gap laser welding is a novel method for thick high strength aluminum alloy plate for its lower heat input, less deformation and higher efficiency. To obtain a perfect welding quality, it is vital to control the more complex droplet transfer behavior under the influence of ultra-narrow gap groove. This paper reports the effects of gap width of groove on droplet transfer behavior in ultra-narrow gap laser welding of 7A52 aluminum alloy plates by a high speed camera, using an ER 5356 filler wire. The results showed that the gap width had directly effects on droplet transfer mode and droplet shape. The droplet transfer modes were, in order, both-sidewall transfer, single-sidewall transfer, globular droplet transfer and bridging transfer, with different droplet shape and transition period, as the gap width increased from 2 mm to 3.5mm. The effect of gap width on lack of fusion was also studied to analyze the cause for lack of fusion at the bottom and on the sidewall of groove. Finally, with a 2.5 mm U-type parallel groove, a single-pass joint with no lack of fusion and other macro welding defects was successfully obtained in a single-sidewall transfer mode.
Investigation of Hot Cracking Behavior in Transverse Mechanically Arc Oscillated Autogenous AA2014 T6 TIG Welds

NASA Astrophysics Data System (ADS)

Biradar, N. S.; Raman, R.

2012-09-01

Hot cracking studies on autogenous AA2014 T6 TIG welds were carried out. Significant cracking was observed during linear and circular welding test (CWT) on 4-mm-thick plates. Weld metal grain structure and amount of liquid distribution during the terminal stages of solidification were the key cause for hot cracking in aluminum welds. Square-wave AC TIG welding with transverse mechanical arc oscillation (TMAO) was employed to study the cracking behavior during linear and CWT. TMAO welds with amplitude = 0.9 mm and frequency = 0.5 Hz showed significant reduction in cracking tendency. The increase in cracking resistance in the arc-oscillated weld was attributed to grain refinement and improved weld bead morphology, which improved the weld metal ductility and uniformity, respectively, of residual tensile stresses that developed during welding. The obtained results were comparable to those of reported favorable results of electromagnetic arc oscillation.
Studies on Creep Deformation and Rupture Behavior of 316LN SS Multi-Pass Weld Joints Fabricated with Two Different Electrode Sizes

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

NASA Astrophysics Data System (ADS)

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

2012-03-01

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

NASA Technical Reports Server (NTRS)

Norris, Jeff; Fairley, Mike

1989-01-01

Tool aids in alignment of oscillator probe on variable-polarity plasma-arc welding torch. Probe magnetically pulls arc from side to side as it moves along joint. Tensile strength of joint depends on alignment of weld bead and on alignment of probe. Operator installs new tool on front of torch body, levels it with built-in bubble glass, inserts probe in slot on tool, and locks probe in place. Procedure faster and easier and resulting alignment more accurate and repeatable.
Influence of the Strength Mismatch of a Narrow Gap Welded Joint of SA508 on the Plastic η Factor

NASA Astrophysics Data System (ADS)

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

2012-11-01

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

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

Burgardt, Paul; Pierce, Stanley W.; Dvornak, Matthew John

It is useful to characterize the dimensions of the electron beam during process development for electron beam welding applications. Analysis of the behavior of electron beam welds is simplest when a single number can be assigned to the beam properties that describes the size of the beam spot; this value we generically call the “beam diameter”. This approach has worked well for most applications and electron beam welding machines with the weld dimensions (width and depth) correlating well with the beam diameter. However, in recent weld development for a refractory alloy, Ta-10W, welded with a low voltage electron beam machinemore » (LVEB), it was found that the weld dimensions (weld penetration and weld width) did not correlate well with the beam diameter and especially with the experimentally determined sharp focus point. These data suggest that the presently used definition of beam diameter may not be optimal for all applications. The possible reasons for this discrepancy and a suggested possible alternative diameter definition is the subject of this paper.« less
Weld pool oscillation during GTA welding of mild steel

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

Xiao, Y.H.; Ouden, G. den

1993-08-01

In this paper the results are reported of a study dealing with the oscillation behavior of weld pools in the case of GTA bead-on-plate welding of mild steel, Fe 360. During welding, the weld pool was brought into oscillation by applying short current pulses, and the oscillation frequency and amplitude were measured by monitoring the arc voltage. It was found that the oscillation of the partially penetrated weld pool is dominated by one of two different oscillation modes (Mode 1 and Mode 2) depending on the welding conditions, whereas the oscillation of the fully penetrated weld pool is characterized bymore » a third oscillation mode (Mode 3). It is possible to maintain partially penetrated weld pool oscillation in Mode 1 by choosing appropriate welding conditions. Under these conditions, an abrupt decrease in oscillation frequency occurs when the weld pool transfers from partial penetration to full penetration. Thus, weld penetration can be in-process controlled by monitoring the oscillation frequency during welding.« less
Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

NASA Technical Reports Server (NTRS)

Walsh, Daniel W.

1987-01-01

The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. This study examined the effects of oxide, halide, and sulfate additions to the weld plate on the keyhole and the weld pool. Changes in both the arc plasma character and the bead morphology were correlated to the chemical environment of the weld. Pool behavior was observed by adding flow markers to actual VPPA welds. A low temperature analog to the welding process was developed. The results of the study indicate that oxygen, even at low partial pressures, can disrupt the stable keyhole and weld pool. The results also indicate that the Marangoni surface tension driven flows dominate the weld pool over the range of welding currents studied.
Sensoring fusion data from the optic and acoustic emissions of electric arcs in the GMAW-S process for welding quality assessment.

PubMed

Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

2012-01-01

The present study shows the relationship between welding quality and optical-acoustic emissions from electric arcs, during welding runs, in the GMAW-S process. Bead on plate welding tests was carried out with pre-set parameters chosen from manufacturing standards. During the welding runs interferences were induced on the welding path using paint, grease or gas faults. In each welding run arc voltage, welding current, infrared and acoustic emission values were acquired and parameters such as arc power, acoustic peaks rate and infrared radiation rate computed. Data fusion algorithms were developed by assessing known welding quality parameters from arc emissions. These algorithms have showed better responses when they are based on more than just one sensor. Finally, it was concluded that there is a close relation between arc emissions and quality in welding and it can be measured from arc emissions sensing and data fusion algorithms.
Welding of Thin Steel Plates by Hybrid Welding Process Combined TIG Arc with YAG Laser

NASA Astrophysics Data System (ADS)

Kim, Taewon; Suga, Yasuo; Koike, Takashi

TIG arc welding and laser welding are used widely in the world. However, these welding processes have some advantages and problems respectively. In order to improve problems and make use of advantages of the arc welding and the laser welding processes, hybrid welding process combined the TIG arc with the YAG laser was studied. Especially, the suitable welding conditions for thin steel plate welding were investigated to obtain sound weld with beautiful surface and back beads but without weld defects. As a result, it was confirmed that the shot position of the laser beam is very important to obtain sound welds in hybrid welding. Therefore, a new intelligent system to monitor the welding area using vision sensor is constructed. Furthermore, control system to shot the laser beam to a selected position in molten pool, which is formed by TIG arc, is constructed. As a result of welding experiments using these systems, it is confirmed that the hybrid welding process and the control system are effective on the stable welding of thin stainless steel plates.
Effect of heat input on the microstructure, residual stresses and corrosion resistance of 304L austenitic stainless steel weldments

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

Unnikrishnan, Rahul, E-mail: rahulunnikrishnannair@gmail.com; Idury, K.S.N. Satish, E-mail: satishidury@gmail.com; Ismail, T.P., E-mail: tpisma@gmail.com

Austenitic stainless steels are widely used in high performance pressure vessels, nuclear, chemical, process and medical industry due to their very good corrosion resistance and superior mechanical properties. However, austenitic stainless steels are prone to sensitization when subjected to higher temperatures (673 K to 1173 K) during the manufacturing process (e.g. welding) and/or certain applications (e.g. pressure vessels). During sensitization, chromium in the matrix precipitates out as carbides and intermetallic compounds (sigma, chi and Laves phases) decreasing the corrosion resistance and mechanical properties. In the present investigation, 304L austenitic stainless steel was subjected to different heat inputs by shielded metalmore » arc welding process using a standard 308L electrode. The microstructural developments were characterized by using optical microscopy and electron backscattered diffraction, while the residual stresses were measured by X-ray diffraction using the sin{sup 2}ψ method. It was observed that even at the highest heat input, shielded metal arc welding process does not result in significant precipitation of carbides or intermetallic phases. The ferrite content and grain size increased with increase in heat input. The grain size variation in the fusion zone/heat affected zone was not effectively captured by optical microscopy. This study shows that electron backscattered diffraction is necessary to bring out changes in the grain size quantitatively in the fusion zone/heat affected zone as it can consider twin boundaries as a part of grain in the calculation of grain size. The residual stresses were compressive in nature for the lowest heat input, while they were tensile at the highest heat input near the weld bead. The significant feature of the welded region and the base metal was the presence of a very strong texture. The texture in the heat affected zone was almost random. - Highlights: • Effect of heat input on microstructure, residual stresses and corrosion is studied. • HAZ and width of dendrite in the welded region increase with heat input. • Residual stresses are tensile near the welded region after the highest heat input. • Welded region has the highest pit density after highest heat input. • Dendrites and δ-ferrite were highly oriented in the welded region.« less
Effect of linear energy on the properties of an AL alloy in DPMIG welding

NASA Astrophysics Data System (ADS)

Liao, Tianfa; Jin, Li; Xue, Jiaxiang

2018-01-01

The effect of different linear energy parameters on the DPMIG welding performance of AA1060 aluminium alloy is studied in this paper. The stability of the welding process is verified with a Labview electrical signal acquisition system, and the microstructure and tensile properties of the welded joint are studied via optical microscopy, scanning electron microscopy and electrical tensile tests. The test results show that the welding process for the DPMIG methods stable and that the weld beads appear as scales. Tensile strength results indicate that, with increasing linear energy, the tensile strength first increases and then decreases. The tensile strength of the joint is maximized when the linear energy is 120.5 J / mm-1.
The potential of a GAS can with payload G-169

NASA Technical Reports Server (NTRS)

Tamir, David

1988-01-01

The feasibility of using welding for the construction, expansion and emergency repair of space based structures is discussed and the advantages of gas tungsten arc welding (GTAW) over other welding techniques are briefly examined. The objective and design concept for the G-169 Get Away Special payload are described. The G-169 experiment will allow the comparison of a space GTA welded joint with a terrestrial GTA welded joint with all parameters held constant except for gravitational forces. Specifically, a bead-on-plate weld around the perimeter of a 2 inch diameter stainless steel pipe section will be performed. The use of Learjet microgravity simulation for the G-169 and other Get Away Special experiments is also addressed.
Micro-Welding of Copper Plate by Frequency Doubled Diode Pumped Pulsed Nd:YAG Laser

NASA Astrophysics Data System (ADS)

Nakashiba, Shin-Ichi; Okamoto, Yasuhiro; Sakagawa, Tomokazu; Takai, Sunao; Okada, Akira

A pulsed laser of 532 nm wavelength with ms range pulse duration was newly developed by second harmonic generation of diode pumped pulsed Nd:YAG laser. High electro-optical conversion efficiency more than 13% could be achieved, and 1.5 kW peak power green laser pulse was put in optical fiber of 100 μm in diameter. In micro- welding of 1.0 mm thickness copper plate, a keyhole welding was successfully performed by 1.0 kW peak power at spot diameter less than 200 μm. The frequency doubled pulsed laser improved the processing efficiency of copper welding, and narrow and deep weld bead was stably obtained.
Investigation on microstructure and properties of narrow-gap laser welding on reduced activation ferritic/martensitic steel CLF-1 with a thickness of 35 mm

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

NASA Astrophysics Data System (ADS)

Gao, Ming; Chen, Cong; Wang, Lei; Wang, Zemin; Zeng, Xiaoyan

2015-05-01

Laser-arc hybrid welding with Cu3Si filler wire was employed to join dissimilar Ti6Al4V titanium alloy and AISI316 stainless steel (316SS). The effects of welding parameters on bead shape, microstructure, mechanical properties, and fracture behavior were investigated in detail. The results show that cross-weld tensile strength of the joints is up to 212 MPa. In the joint, obvious nonuniformity of the microstructure is found in the fusion zone (FZ) and at the interfaces from the top to the bottom, which could be improved by increasing heat input. For the homogeneous joint, the FZ is characterized by Fe67- x Si x Ti33 dendrites spreading on α-Cu matrix, and the two interfaces of 316SS/FZ and FZ/Ti6Al4V are characterized by a bamboo-like 316SS layer and a CuTi2 layer, respectively. All the tensile samples fractured in the hardest CuTi2 layer at Ti6Al4V side of the joints. The fracture surface is characterized by river pattern revealing brittle cleavage fracture. The bead formation mechanisms were discussed according to the melt flow and the thermodynamic calculation.

Method for enhanced control of welding processes

DOEpatents

Sheaffer, Donald A.; Renzi, Ronald F.; Tung, David M.; Schroder, Kevin

2000-01-01

Method and system for producing high quality welds in welding processes, in general, and gas tungsten arc (GTA) welding, in particular by controlling weld penetration. Light emitted from a weld pool is collected from the backside of a workpiece by optical means during welding and transmitted to a digital video camera for further processing, after the emitted light is first passed through a short wavelength pass filter to remove infrared radiation. By filtering out the infrared component of the light emitted from the backside weld pool image, the present invention provides for the accurate determination of the weld pool boundary. Data from the digital camera is fed to an imaging board which focuses on a 100.times.100 pixel portion of the image. The board performs a thresholding operation and provides this information to a digital signal processor to compute the backside weld pool dimensions and area. This information is used by a control system, in a dynamic feedback mode, to automatically adjust appropriate parameters of a welding system, such as the welding current, to control weld penetration and thus, create a uniform weld bead and high quality weld.
Characterization of disk-laser dissimilar welding of titanium alloy Ti-6Al-4V to aluminum alloy 2024

NASA Astrophysics Data System (ADS)

Caiazzo, Fabrizia; Alfieri, Vittorio; Cardaropoli, Francesco; Corrado, Gaetano; Sergi, Vincenzo

2013-02-01

Both technical and economic reasons suggest to join dissimilar metals, benefiting from the specific properties of each material in order to perform flexible design. Adhesive bonding and mechanical joining have been traditionally used although adhesives fail to be effective in high-temperature environments and mechanical joining are not adequate for leak-tight joints. Friction stir welding is a valid alternative, even being difficult to perform for specific joint geometries and thin plates. The attention has therefore been shifted to laser welding. Interest has been shown in welding titanium to aluminum, especially in the aviation industry, in order to benefit from both corrosive resistance and strength properties of the former, and low weight and cost of the latter. Titanium alloy Ti-6Al-4V and aluminum alloy 2024 are considered in this work, being them among the most common ones in aerospace and automotive industries. Laser welding is thought to be particularly useful in reducing the heat affected zones and providing deep penetrative beads. Nevertheless, many challenges arise in welding dissimilar metals and the aim is further complicated considering the specific features of the alloys in exam, being them susceptible to oxidation on the upper surface and porosity formation in the fused zone. As many variables are involved, a systematic approach is used to perform the process and to characterize the beads referring to their shape and mechanical features, since a mixture of phases and structures is formed in the fused zone after recrystallization.
Welding of 316L Austenitic Stainless Steel with Activated Tungsten Inert Gas Process

NASA Astrophysics Data System (ADS)

Ahmadi, E.; Ebrahimi, A. R.

2015-02-01

The use of activating flux in TIG welding process is one of the most notable techniques which are developed recently. This technique, known as A-TIG welding, increases the penetration depth and improves the productivity of the TIG welding. In the present study, four oxide fluxes (SiO2, TiO2, Cr2O3, and CaO) were used to investigate the effect of activating flux on the depth/width ratio and mechanical property of 316L austenitic stainless steel. The effect of coating density of activating flux on the weld pool shape and oxygen content in the weld after the welding process was studied systematically. Experimental results indicated that the maximum depth/width ratio of stainless steel activated TIG weld was obtained when the coating density was 2.6, 1.3, 2, and 7.8 mg/cm2 for SiO2, TiO2, Cr2O3, and CaO, respectively. The certain range of oxygen content dissolved in the weld, led to a significant increase in the penetration capability of TIG welds. TIG welding with active fluxes can increase the delta-ferrite content and improves the mechanical strength of the welded joint.
Reinforcement with alumina particles at the interface region of AA6101-T6 and AA1350 alloys during friction stir welding

NASA Astrophysics Data System (ADS)

Ashok Kumar, R.; Thansekhar, M. R.

2018-04-01

This paper deals the combinational effect of friction stir welding and friction stir processing on dissimilar AA6101-T6 and AA1350 aluminium alloys. For that, alumina particles are reinforced at interface region of AA6101-T6 and AA1350 aluminium alloys. Friction Stir Welding and Friction Stir Processing are done simultaneously for various sizes of groove. To analyze the welding quality and surface modifications, mechanical, wear and microstructural tests are carried out. Among these, smallest groove of 0.5 mm width and 1 mm depth reveals highest tensile and bending strengths and largest groove of 2 mm width and 3 mm depth gives maximum hardness and wear resistance. Taguchi technique shows that groove width is most influencing parameter. Developed second order models with interaction predict the responses with minimum error.
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
Influence of groove size and reinforcements addition on mechanical properties and microstructure of friction stir welded joints

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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

Barnett, R.J.; Cook, G.E.; Strauss, A.M.

1996-12-31

Inspection of the appearance of weld beads is an integral part of the overall welding process. Lack of satisfactory appearance in itself may be sufficient grounds for part rejection or the lack of satisfactory appearance may be used as an indirect indicator of more substantive problems such as poor fusion or subsurface cracks. In all cases the inspection process tends to be both time and labor intensive. The present research uses a video system and appropriate image capture and processing to determine the quality of the weld based upon surface appearance. This relative quality rating was compared to similar ratingsmore » performed by human inspectors and was found to give very good correlation. The system was implemented for the Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW) processes.« less
Sensoring Fusion Data from the Optic and Acoustic Emissions of Electric Arcs in the GMAW-S Process for Welding Quality Assessment

PubMed Central

Alfaro, Sadek Crisóstomo Absi; Cayo, Eber Huanca

2012-01-01

The present study shows the relationship between welding quality and optical-acoustic emissions from electric arcs, during welding runs, in the GMAW-S process. Bead on plate welding tests was carried out with pre-set parameters chosen from manufacturing standards. During the welding runs interferences were induced on the welding path using paint, grease or gas faults. In each welding run arc voltage, welding current, infrared and acoustic emission values were acquired and parameters such as arc power, acoustic peaks rate and infrared radiation rate computed. Data fusion algorithms were developed by assessing known welding quality parameters from arc emissions. These algorithms have showed better responses when they are based on more than just one sensor. Finally, it was concluded that there is a close relation between arc emissions and quality in welding and it can be measured from arc emissions sensing and data fusion algorithms. PMID:22969330
Interaction of both plasmas in CO2 laser-MAG hybrid welding of carbon steel

NASA Astrophysics Data System (ADS)

Kutsuna, Muneharu; Chen, Liang

2003-03-01

Researches and developments of laser and arc hybrid welding has been curried out since in 1978. Especially, CO2 laser and TIG hybrid welding has been studied for increasing the penetration depth and welding speed. Recently laser and MIG/MAG/Plasma hybrid welding processes have been developed and applied to industries. It was recognized as a new welding process that promote the flexibility of the process for increasing the penetration depth, welding speed and allowable joint gap and improving the quality of the welds. In the present work, CO2 Laser-MAG hybrid welding of carbon steel (SM490) was investigated to make clear the phenomenon and characteristics of hybrid welding process comparing with laser welding and MAG process. The effects of many process parameters such as welding current, arc voltage, welding speed, defocusing distance, laser-to-arc distance on penetration depth, bead shape, spatter, arc stability and plasma formation were investigated in the present work. Especially, the interaction of laser plasma and MAG arc plasma was considered by changing the laser to arc distance (=DLA).
Characterization of the structural details of residual austenite in the weld metal of a 9Cr1MoNbV welded rotor

NASA Astrophysics Data System (ADS)

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

2014-06-01

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

DOEpatents

Heiple, C.R.; Burgardt, P.

1984-03-13

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

NASA Technical Reports Server (NTRS)

Walsh, Daniel W.; Nunes, Arthur C., Jr.

1990-01-01

Report describes experimental study of some of the physical and chemical effects that occur during variable-polarity plasma arc (VPPA) keyhole welding of 2219 aluminum alloy. Comprised three major programs: (1) determination of effects of chemical additions (i.e., impurities) on structure and shape of bead and keyhole; (2) determination of flow in regions surrounding keyhole; (3) development of analog used easily to study flow in keyhole region.
Keyhole behavior and liquid flow in molten pool during laser-arc hybrid welding

NASA Astrophysics Data System (ADS)

Naito, Yasuaki; Katayama, Seiji; Matsunawa, Akira

2003-03-01

Hybrid welding was carried out on Type 304 stainless steel plate under various conditions using YAG laser combined with TIG arc. During arc and laser-arc hybrid welding, arc voltage variation was measured, and arc plasma, laser-induced plume and evaporation spots as well as keyhole behavior and liquid flow in the molten pool were observed through CCD camera and X-ray real-time transmission apparatus. It was consequently found that hybrid welding possessed many features in comparison with YAG laser welding. The deepest weld bead could be produced when the YAG laser beam of high power density was shot on the molten pool made beforehand stably with TIG arc. A keyhole was long and narrow, and its behavior was rather stable inside the molten pool. It was also confirmed that porosity was reduced by the suppression of bubble formation in hybrid welding utilizing a laser of a moderate power density.
Double fillet lap of laser welding of thin sheet AZ31B Mg alloy

NASA Astrophysics Data System (ADS)

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

2018-05-01

In this paper, we describe the experimental laser welding of thin sheet AZ31B using double fillet lap joint method. Laser welding is capable of producing high quality weld seams especially for small weld bead on thin sheet product. In this experiment, both edges for upper and lower sheets were subjected to the laser beam from the pulse wave (PW) mode of fiber laser. Welded sample were tested their joint strength by tensile-shear strength method and the fracture loads were studied. Strength for all welded samples were investigated and the effect of laser parameters on the joint strength and appearances were studied. Pulsed energy (EP) from laser process give higher effect on joint strength compared to the welding speed (WS) and angle of irradiation (AOI). Highest joint strength was possessed by sample with high EP with the same value of WS and AOI. The strength was low due to the crack defect at the centre of weld region.
Radiation and annealing response of WWER 440 beltline welding seams

NASA Astrophysics Data System (ADS)

Viehrig, Hans-Werner; Houska, Mario; Altstadt, Eberhard

2015-01-01

The focus of this paper is on the irradiation response and the effect of thermal annealing in weld materials extracted from decommissioned WWER 440 reactor pressure vessels of the nuclear power plant Greifswald. The characterisation is based on the measurement of the hardness, the yield stress, the Master Curve reference temperature, T0, and the Charpy-V transition temperature through the thickness of multi-layer beltline welding seams in the irradiated and the thermally annealed condition. Additionally, the weld bead structure was characterised by light microscopic studies. We observed a large variation in the through thickness T0 values in the irradiated as well as in thermally annealed condition. The T0 values measured with the T-S-oriented Charpy size SE(B) specimens cut from different thickness locations of the multilayer welding seams strongly depend on the intrinsic weld bead structure along the crack tip. The Master Curve, T0, and Charpy-V, TT47J, based ductile-to-brittle transition temperature progressions through the thickness of the multi-layer welding seam do not correspond to the forecast according to the Russian code. In general, the fracture toughness values at cleavage failure, KJc, measured on SE(B) specimens from the irradiated and large-scale thermally annealed beltline welding seams follow the Master Curve description, but more than the expected number lie outside the curves for 2% and 98% fracture probability. In this case the test standard ASTM E1921 indicates the investigated multi-layer weld metal as not uniform. The multi modal Master Curve based approach describes the temperature dependence of the specimen size adjusted KJc-1T values well. Thermal annealing at 475 °C for 152 h results in the expected decrease of the hardness and tensile strength and the shift of Master Curve and Charpy-V based ductile-to-brittle transition temperatures to lower values.
Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

NASA Astrophysics Data System (ADS)

Vasantharaja, P.; Vasudevan, M.

2012-02-01

Low Activation Ferritic-Martensitic steels (LAFM) are chosen as the candidate material for structural components in fusion reactors. The structural components are generally fabricated by welding processes. Activated Tungsten Inert Gas (A-TIG) welding is an emerging process for welding of thicker components. In the present work, attempt was made to develop A-TIG welding technology for LAFM steel plates of 10 mm thick. Activated flux was developed for LAFM steel by carrying out various bead-on-plate TIG welds without flux and with flux. The optimum flux was identified as one which gave maximum depth of penetration at minimum heat input values. With the optimized flux composition, LAFM steel plate of 10 mm thickness was welded in square butt weld joint configuration using double side welding technique. Optical and Scanning Electron Microscopy was used for characterizing the microstructures. Microhardness measurements were made across the weld cross section for as welded and post weld heat treated samples. Tensile and impact toughness properties were determined. The mechanical properties values obtained in A-TIG weld joint were comparable to that obtained in weld joints of LAFM steel made by Electron beam welding process.
A simple 2-d thermal model for GMA welds

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

Matteson, M.A.; Franke, G.L.; Vassilaros, M.G.

1996-12-31

The Rosenthal model of heat distribution from a moving source has been used in many applications to predict the temperature distribution during welding. The equation has performed well in its original form or as modified. The expression has a significant limitation for application to gas metal arc welds (GMAW) that have a papilla extending from the root of the weld bead. The shape of the fusion line between the papilla and the plate surface has a concave shape rather than the expected convex shape. However, at some distance from the fusion line the heat affected zone (HAZ) made visible bymore » etching has the expected convex shape predicted by the Rosenthal expression. This anomaly creates a limitation to the use of the Rosenthal expression for predicting GMAW bead shapes or HAZ temperature histories. Current research at the Naval Surface Warfare Center--Carderock Division (NSWC--CD) to develop a computer based model to predict the microstructure of multi-pass GMAW requires a simple expression to predict the fusion line and temperature history of the HAZ for each weld pass. The solution employed for the NSWC--CD research is a modified Rosenthal expression that has a dual heat source. One heat source is a disk source above the plate surface supplying the majority of the heat. The second heat source is smaller and below the surface of the plate. This second heat source helps simulate the penetration power of many GMAW welds that produces the papilla. The assumptions, strengths and limitations of the model are presented along with some applications.« less
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.
Research on the microstructure and properties of laser-MIG hybrid welded joint of Invar alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Zhang, Dan; Wei, Yanhong; Wang, Yuhua

2017-12-01

In order to solve the problem of large deformation, low production efficiency and high tendency of hot cracking in welding 19.05 mm thick plates of Fe36Ni Invar alloy, laser-MIG hybrid multi-layer welding technique (LMHMW) has been developed. To investigate the influence of different welding parameters on the joint properties, optical microscope observation, SEM, EDS and microhardness measurement were conducted. Experimental results illustrated that different matching of welding parameters significantly affected the depth-to-width ratio, formation of defects and HAZ width. Besides, weld zone were consisted of two regions according to the different grain shape. The region near center of weld seam (region 1) was columnar dendrite induced by laser, while the region far away from weld seam center (region 2) was cellular dendrite which was mainly caused by MIG arc. The peak value of microhardness appeared at the center of weld seam since the grains in region 1 were relatively fine, and the lowest hardness value was obtained in HAZ. In addition, results showed that the sheets can be welded at optimum process parameters, with few defects such as, surface oxidation, porosity, cracks and lack of penetration in the welding seam: laser power of backing weld P = 5500 W, welding current I = 240 A, welding speed v = 1 m/min. laser power of filling weld P = 2000 W, welding current I = 220 A, welding speed v = 0.35 m/min. laser power of cosmetic weld P = 2000 W, welding current I = 300 A, welding speed v = 0.35 m/min.
Effect of pressure and shielding gas on the microstructure of hyperbaric metal cored GMAW welds down to 111 bar

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

Jorge, J.C.F.; Santos, V.R. dos; Santos, J.F. dos

1995-12-31

The microstructural evolution of hyperbaric C-Mn weld metals was studied by means of bead-on-plate welds deposit with GMAW process using a commercial metal cored wire. The welding was carried out in the flat position in the range of 51 bar to 111 bar with He+ CO{sub 2} as shielding gas, which CO{sub 2} content varied from 0.1% to 0.8 %. The microstructures were quantitatively analyzed by optical microscopy to evaluate the amount of constituents according to the IIW/IIS terminology. The results showed that all weld metals presented great amounts of acicular ferrite and a stronger influence of pressure on microstructuremore » compared to the influence of the shielding gas.« less

Effects of active flux on plasma behavior and weld shape in laser welding of X5CrNi189 stainless steel

NASA Astrophysics Data System (ADS)

Dai, Hongbin; Peng, Jun

2016-11-01

In this paper, stainless steel was welded by active flux-aided laser welding method. The effects of single active flux (Cr2O3, SiO2 and TiO2) and composite active flux on laser welding were studied. In the welding process, laser plasma behavior was recorded by a high-speed imaging system. The results show that, with the addition of active flux, the absorption of laser energy and melting efficiency increase. In the laser power of 750 W, effects of active flux on weld depth to width ratio are given by the order: composite active flux > SiO2 > Cr2O3 > TiO2. The effect of composite active flux is the most significant and it can increase the weld depth to width ratio to 85%. Active flux can restrict the laser plasma. With the addition of composite active flux, the projected area of laser plasma obtained obviously reduced, and it can be reduced by 41.39%. Active flux cannot obviously change the main components in weld zone, but can change the grains of austenite and ferrite.
Study the Effect of SiO2 Based Flux on Dilution in Submerged Arc Welding

NASA Astrophysics Data System (ADS)

kumar, Aditya; Maheshwari, Sachin

2017-08-01

This paper highlights the method for prediction of dilution in submerged arc welding (SAW). The most important factors of weld bead geometry are governed by the weld dilution which controls the chemical and mechanical properties. Submerged arc welding process is used generally due to its very easy control of process variables, good penetration, high weld quality, and smooth finish. Machining parameters, with suitable weld quality can be achieved with the different composition of the flux in the weld. In the present study Si02-Al2O3-CaO flux system was used. In SiO2 based flux NiO, MnO, MgO were mixed in various proportions. The paper investigates the relationship between the process parameters like voltage, % of flux constituents and dilution with the help of Taguchi’s method. The experiments were designed according to Taguchi L9 orthogonal array, while varying the voltage at two different levels in addition to alloying elements. Then the optimal results conditions were verified by confirmatory experiments.
Characterization of Mechanical Properties and Residual Stress in API 5L X80 Steel Welded Joints

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

NASA Astrophysics Data System (ADS)

Zhiyong, Li; Srivatsan, T. S.; Yan, LI; Wenzhao, Zhang

2013-02-01

Hybrid laser arc welding combines the advantages of laser welding and arc welding. Ever since its origination in the late 1970s, this technique has gained gradual attention and progressive use due to a combination of high welding speed, better formation of weld bead, gap tolerance, and increased penetration coupled with less distortion. In hybrid laser arc welding, one of the reasons for the observed improvement is an interaction or coupling effect between the plasma arc, laser beam, droplet transfer, and the weld pool. Few researchers have made an attempt to study different aspects of the process to facilitate a better understanding. It is difficult to get a thorough understanding of the process if only certain information in a certain field is provided. In this article, an attempt to analyze the coupling effect of the process was carried out based on a careful review of the research work that has been done which provides useful information from a different prospective.
Considerations on repeated repairing of weldments in Inconel 718 alloy

NASA Technical Reports Server (NTRS)

Bayless, E. O.; Lovoy, C. V.; Mcilwain, M. C.; Munafo, P.

1981-01-01

The effects of repeated weld repairs on the metallurgical characteristics, high cycle fatigue (HCF), and tensile properties of Inconel 718 butt weld joints were determined. A 1/4 in thick plate and a 1/2 in thick plate were used as well as tungsten inert gas welding, and Inconel 718 filler wire. Weld panels were subjected to 2, 6, and 12 repeated repairs and were made in a highly restrained condition. Post weld heat treatments were also conducted with the welded panel in the highly restrained condition. Results indicate that no significant metallurgical anomaly is evident as a result of up to twelve repeated weld repairs. No degradation in fatigue life is noted for up to twelve repeated repairs. Tensile results from specimens which contained up to twelve repeated weld repairs revealed no significant degradation in UTS and YS. However, a significant decrease in elongation is evident with specimens (solution treated and age hardened after welding) which contained twelve repeated repairs. The elongation loss is attributed to the presence of a severe notch on each side (fusion line) of the repair weld bead reinforcement.
On the microstructure analysis of FSW joints of aluminium components made via direct metal laser sintering

NASA Astrophysics Data System (ADS)

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

2017-10-01

Additive Manufacturing (AM), applied to metal industry, is a family of processes that allow complex shape components to be realized from raw materials in the form of powders. The compaction of the powders can be achieved by local melting of the powder bed or by solid state sintering. Direct Metal Laser Sintering (DMLS) is an additive manufacturing process in which a focalized laser beam is the heat source that allows the powders to be compacted. By DMLS it is possible to realize complex shape components. One of the limits of DMLS, as for every additive layer manufacturing techniques, is the unfeasibility to realize large dimension parts. Due to this limit the study of joining process of parts made via ALM is of great interest. One of the most promising options is the Friction Stir Welding (FSW), a solid state welding technique that has been proven to be very effective in the welding of metals difficult to weld, above all aluminium alloys. Since FSW is a solid-state technique, the microstructure of the various zone of the weld bead depends not only by the process itself but also by the parent microstruct ure of the parts to be welded. Furthermore, parts made of aluminium alloy via DMLS have a particular microstructure that is the result of repeated severe thermal cycles. In the present work the authors, starting from the description of the parent microstructure of parts made of AlSi10Mg aluminium alloy, study the microstructure evolution occurred within the joint made by Friction Stir Welding, analysing in details the microstructure of the main well recognized zone of the weld bead. The structure of the parent material is characterized by the presence of melting pools with a very fine microstructure. In the joint the recrystallization, the grain refinement and, above all, the redistribution of intermetallic phases occurs, resulting in an homogenization of the microstructure and in an increase of micro hardness.
Research study on materials processing in space experiment number M512. [adhesion-cohesion properties of liquid metals under weightlessness conditions in Skylab

NASA Technical Reports Server (NTRS)

Tobin, J. M.; Kossowsky, R.

1973-01-01

Adhesion of the melted metals to the adjacent solid metals, and cohesion of the liquid metal to itself appeared to be equally as strong in zero gravity as on earth. Similar cut edge bead periodicity in cut thin plate, and similar periodic chevron patterns in full penetration welds were seen. The most significant practical result is that the design of braze joints for near zero gravity can be very tolerant of dimensional gaps in the joint. This conclusion is based on a comparison of narrow, wide and variable gap widths. Brazing is very practical as a joining or repairing technique for metal structures at zero gravity. The operation of the hardware developed to locate successive small (0.6 cm) diameter cylinders in the focus of the battery powered EB unit, melt the various metal specimens and deploy some liquid metal drops to drift in space, was generally successful. However, the sphericity and surface roughness were far from those of ball bearings.
[Calculating the stark broadening of welding arc spectra by Fourier transform method].

PubMed

Pan, Cheng-Gang; Hua, Xue-Ming; Zhang, Wang; Li, Fang; Xiao, Xiao

2012-07-01

It's the most effective and accurate method to calculate the electronic density of plasma by using the Stark width of the plasma spectrum. However, it's difficult to separate Stark width from the composite spectrum linear produced by several mechanisms. In the present paper, Fourier transform was used to separate the Lorentz linear from the spectrum observed, thus to get the accurate Stark width. And we calculated the distribution of the TIG welding arc plasma. This method does not need to measure arc temperature accurately, to measure the width of the plasma spectrum broadened by instrument, and has the function to reject the noise data. The results show that, on the axis, the electron density of TIG welding arc decreases with the distance from tungsten increasing, and changes from 1.21 X 10(17) cm(-3) to 1.58 x 10(17) cm(-3); in the radial, the electron density decreases with the distance from axis increasing, and near the tungsten zone the biggest electronic density is off axis.
Yb-fibre Laser Welding of 6 mm Duplex Stainless Steel 2205

NASA Astrophysics Data System (ADS)

Bolut, M.; Kong, C. Y.; Blackburn, J.; Cashell, K. A.; Hobson, P. R.

Duplex stainless steel (DSS) is one of the materials of choice for structural and nuclear applications, having high strength and good corrosion resistance when compared with other grades of stainless steel. The welding process used to join these materials is critical as transformation of the microstructure during welding directly affects the material properties. High power laser welding has recently seen an increase in research interest as it offers both speed and flexibility. This paper presents an investigation into the important parameters affecting laser welding of DSS grade 2205, with particular focus given to the critical issue of phase transformation during welding. Bead-on-plate melt-run trials without filler material were performed on 6mm thick plates using a 5 kW Yb-fibre laser. The laser beam was characterized and a Design of Experiment approach was used to quantify the impact of the process parameters. Optical metallographic methods were used to examine the resulting microstructures.
Grain Refinement of AZ31 Magnesium Alloy Weldments by AC Pulsing Technique

NASA Astrophysics Data System (ADS)

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

2012-11-01

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

DTIC Science & Technology

2016-06-01

3 32 ") thick neoprene rubber sheet. The sheet was bonded to the acrylic using 3M Scotch- Weld Neoprene High Performance Rubber and Gasket Adhesive...TABLES Table 1. Natural Frequencies of the 0.5 mm (0.02”) Thick Aluminum Plate ..........19 Table 2. Mean Normalized Strains...1300. A bead of 100% silicone was applied on the bond to prevent water from infiltrating the adhesive. The 3M Scotch- Weld 1300 adhesive kept the
Literature Survey on Weld-Metal Cracking

DTIC Science & Technology

1952-08-01

quench cracking in cast steel. A statistical investigation was made into the causes of quench cracking in low-alloy-steel gun tubes (FlZ). A definite...decreased with increased pouring temperature, finishing temperature, and forging reduction. Spretnak and Wells(F2O) also made a statistical analysis of...per cent to avoid hot cracks and fissures. Lee(I20) made a statistical study of the bead-cracking susceptibility of weld metal deposited with Type 307
Size effect on cold-welding of gold nanowires investigated using molecular dynamics simulations

NASA Astrophysics Data System (ADS)

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

2016-03-01

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

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

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

NASA Astrophysics Data System (ADS)

Shanmugarajan, B.; Padmanabham, G.

2012-11-01

Laser welding investigations were carried out on dissimilar Ti-SS combination. The study is aimed to improve the weld strength and ductility by minimizing harmful intermetallics and taking advantage of high cooling rates in laser welding. Results of continuous wave 3.5 kW CO2 laser welding of totally dissimilar combination of Titanium and stainless steel (304) have been discussed. Bead on plate welding experiments were conducted to identify the laser welding parameters using depth of penetration as criteria. The welding of dissimilar combination has been attempted both autogenously and with interlayers such as Vanadium (V) and Tantalum (Ta) in the form of laser cladding as well as strip. Autogenous welds were carried out by varying the laser power, welding speed and position of the laser beam with respect to the joint centre. The resultant welds are characterized by macrostructure analysis, SEM/EDAX and XRD and as welded tensile test in UTM. The autogenous welds have exhibited extensive cracking even when welded at high speeds or by manipulating the beam position with respect to the joint. Similarly Vandaium as interlayer could not achieve crack free joint. A joint with 40 MPa strength could be made with Ta as interlayer. Results and analysis of these variants of laser welded joints are reported and discussed.
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.
75 FR 68854 - JCA Corporation, Receipt of Petition for Decision of Inconsequential Noncompliance

Federal Register 2010, 2011, 2012, 2013, 2014

2010-11-09

... the shoulder of the tire. If the maximum section width falls within that area, the markings shall appear between the bead and a point one-half the distance from the bead to the shoulder of the tire, on...
Determination of a temperature sensor location for monitoring weld pool size in GMAW

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

Boo, K.S.; Cho, H.S.

1994-11-01

This paper describes a method of determining the optimal sensor location to measure weldment surface temperature, which has a close correlation with weld pool size in the gas metal arc (GMA) welding process. Due to the inherent complexity and nonlinearity in the GMA welding process, the relationship between the weldment surface temperature and the weld pool size varies with the point of measurement. This necessitates an optimal selection of the measurement point to minimize the process nonlinearity effect in estimating the weld pool size from the measured temperature. To determine the optimal sensor location on the top surface of themore » weldment, the correlation between the measured temperature and the weld pool size is analyzed. The analysis is done by calculating the correlation function, which is based upon an analytical temperature distribution model. To validate the optimal sensor location, a series of GMA bead-on-plate welds are performed on a medium-carbon steel under various welding conditions. A comparison study is given in detail based upon the simulation and experimental results.« less
Development of method to remove weld scallop and ceramic backing material of wedge type and its application

NASA Astrophysics Data System (ADS)

Kang, Sung-Koo; Yang, Jong-Soo; Kim, Ho-Kyung

2015-06-01

The weld scallop has been used for joining T-bars. There are a lot of weld scallops in shipbuilding. It is difficult to perform scallop welding due to the inconvenient welding position. This results in many problems such as porosity, slag inclusion, etc. In this study, a new method is devised to remove weld scallops by incorporating a Ceramic Backing Material (CBM). The weld scallop is removed by an elongation of the v groove. In order to insert a CBM into the groove without a weld scallop, a wedge-shaped CBM is developed. The top side of the developed CBM is similar to the shape of a general back bead. The bottom surface has a saw-toothed shape for cutting at a suitable length. This can be attached to the root side of a face plate using adhesive tape, just like a general CBM. Welding experiments in normal and abnormal conditions are carried out and the possibility of burn-through is examined. This CBM's applicability to shipbuilding is verified.
Use of photostress and strain gages to analyze behavior of weldments and use of photostress and strain gages to analyze behavior of an aft skirt test specimen

NASA Technical Reports Server (NTRS)

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

1993-01-01

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

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.)
Effect of shielding gas composition on the properties of hyperbaric GMA welds in duplex steels

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

Ware, N.; Dos Santos, J.F.; Richardson, I.

1994-12-31

By using Ar/He based shielding gas mixtures with a variety of oxygen and nitrogen additions the absorption of active gas components into duplex stainless steels welded under hyperbaric conditions was examined. The pressure levels used corresponded to seawater depths of 100m, 200m and 300m. The GMAW process in the short circuit transfer mode was used for all tests. Both bead-on-plate and ``V`` butt joints were carried out. The effect of variations in the weld metal active gas components on the weld metal chemical composition and phase balance was investigated. In a second set of tests the effect of varying heatmore » inputs on the phase balance and microstructure was assessed.« less
Deformation behavior of laser welds in high temperature oxidation resistant Fe-Cr-Al alloys for fuel cladding applications

NASA Astrophysics Data System (ADS)

Field, Kevin G.; Gussev, Maxim N.; Yamamoto, Yukinori; Snead, Lance L.

2014-11-01

Ferritic-structured Fe-Cr-Al alloys are being developed and show promise as oxidation resistant accident tolerant light water reactor fuel cladding. This study focuses on investigating the weldability and post-weld mechanical behavior of three model alloys in a range of Fe-(13-17.5)Cr-(3-4.4)Al (wt.%) with a minor addition of yttrium using modern laser-welding techniques. A detailed study on the mechanical performance of bead-on-plate welds using sub-sized, flat dog-bone tensile specimens and digital image correlation (DIC) has been carried out to determine the performance of welds as a function of alloy composition. Results indicated a reduction in the yield strength within the fusion zone compared to the base metal. Yield strength reduction was found to be primarily constrained to the fusion zone due to grain coarsening with a less severe reduction in the heat affected zone. For all proposed alloys, laser welding resulted in a defect free weld devoid of cracking or inclusions.
Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes.

PubMed

Sivapirakasam, S P; Mohan, Sreejith; Santhosh Kumar, M C; Thomas Paul, Ashley; Surianarayanan, M

2017-04-01

Background Cr(VI) is a suspected human carcinogen formed as a by-product of stainless steel welding. Nano-alumina and nano-titania coating of electrodes reduced the welding fume levels. Objective To investigate the effect of nano-coating of welding electrodes on Cr(VI) formation rate (Cr(VI) FR) from a shielded metal arc welding process. Methods The core welding wires were coated with nano-alumina and nano-titania using the sol-gel dip coating technique. Bead-on plate welds were deposited on SS 316 LN plates kept inside a fume test chamber. Cr(VI) analysis was done using an atomic absorption spectrometer (AAS). Results A reduction of 40% and 76%, respectively, in the Cr(VI) FR was observed from nano-alumina and nano-titania coated electrodes. Increase in the fume level decreased the Cr(VI) FR. Discussion Increase in fume levels blocked the UV radiation responsible for the formation of ozone thereby preventing the formation of Cr(VI).
Exploring infrared sensoring for real time welding defects monitoring in GTAW.

PubMed

Alfaro, Sadek C A; Franco, Fernand Díaz

2010-01-01

This paper presents an evaluation of an infrared sensor for monitoring the welding pool temperature in a Gas Tungsten Arc Welding (GTAW) process. The purpose of the study is to develop a real time system control. It is known that the arc welding pool temperature is related to the weld penetration depth; therefore, by monitoring the temperature, the arc pool temperature and penetration depth are also monitored. Various experiments were performed; in some of them the current was varied and the temperature changes were registered, in others, defects were induced throughout the path of the weld bead for a fixed current. These simulated defects resulted in abrupt changes in the average temperature values, thus providing an indication of the presence of a defect. The data has been registered with an acquisition card. To identify defects in the samples under infrared emissions, the timing series were analyzed through graphics and statistic methods. The selection of this technique demonstrates the potential for infrared emission as a welding monitoring parameter sensor.
Exploring Infrared Sensoring for Real Time Welding Defects Monitoring in GTAW

PubMed Central

Alfaro, Sadek C. A.; Franco, Fernand Díaz

2010-01-01

This paper presents an evaluation of an infrared sensor for monitoring the welding pool temperature in a Gas Tungsten Arc Welding (GTAW) process. The purpose of the study is to develop a real time system control. It is known that the arc welding pool temperature is related to the weld penetration depth; therefore, by monitoring the temperature, the arc pool temperature and penetration depth are also monitored. Various experiments were performed; in some of them the current was varied and the temperature changes were registered, in others, defects were induced throughout the path of the weld bead for a fixed current. These simulated defects resulted in abrupt changes in the average temperature values, thus providing an indication of the presence of a defect. The data has been registered with an acquisition card. To identify defects in the samples under infrared emissions, the timing series were analyzed through graphics and statistic methods. The selection of this technique demonstrates the potential for infrared emission as a welding monitoring parameter sensor. PMID:22219697
Metal Big Area Additive Manufacturing: Process Modeling and Validation

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

Simunovic, Srdjan; Nycz, Andrzej; Noakes, Mark W

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long rangemore » effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress analysis to evaluate the residual stresses and distortions. In this formulation, we assume that physics is directionally coupled, i.e. the effect of stress of the component on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.« less
Prediction Analysis of Weld-Bead and Heat Affected Zone in TIG welding using Artificial Neural Networks

NASA Astrophysics Data System (ADS)

Saldanha, Shamith L.; Kalaichelvi, V.; Karthikeyan, R.

2018-04-01

TIG Welding is a high quality form of welding which is very popular in industries. It is one of the few types of welding that can be used to join dissimilar metals. Here a weld joint is formed between stainless steel and monel alloy. It is desired to have control over the weld geometry of such a joint through the adjustment of experimental parameters which are welding current, wire feed speed, arc length and the shielding gas flow rate. To facilitate the automation of the same, a model of the welding system is needed. However the underlying welding process is complex and non-linear, and analytical methods are impractical for industrial use. Therefore artificial neural networks (ANN) are explored for developing the model, as they are well-suited for modelling non-linear multi-variate data. Feed-forward neural networks with backpropagation training algorithm are used, and the data for training the ANN taken from experimental work. There are four outputs corresponding to the weld geometry. Different training and testing phases were carried out using MATLAB software and ANN approximates the given data with minimum amount of error.
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.
Dynamic modeling of GMA fillet welding using cross-correlation

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

Hellinga, M.; Huissoon, J.; Kerr, H.

1996-12-31

The feasibility of employing the cross-correlation system identification technique as a dynamic modeling method for the GMAW process was examined. This approach has the advantages of modeling speed, the ability to operate in low signal to noise environments, the ease of digital implementation, and the lack of model order assumption, making it ideal in a welding application. The width of the weld pool was the parameter investigated as a function of torch travel speed. Both on-line and off-line width measurements were used to identify the impulse response. Experimental results are presented and comparisons made with both step and ramp response.
76 FR 28502 - Cooper Tire & Rubber Tire Company, Receipt of Petition for Decision of Inconsequential Noncompliance

Federal Register 2010, 2011, 2012, 2013, 2014

2011-05-17

... one-fourth of the distance from the bead to the shoulder of the tire. If the maximum section width... from the bead to the shoulder of the tire, on at least one sidewall. The markings must be in letters...
On Improving the Quality of Gas Tungsten Arc Welded 18Ni 250 Maraging Steel Rocket Motor Casings

NASA Astrophysics Data System (ADS)

Gupta, Renu N.; Raja, V. S.; Mukherjee, M. K.; Narayana Murty, S. V. S.

2017-10-01

In view of their excellent combination of strength and toughness, maraging steels (18Ni 250 grade) are widely used for the fabrication of large sized solid rocket motor casings. Gas tungsten arc welding is commonly employed to fabricate these thin walled metallic casings, as the technique is not only simple but also provides the desired mechanical properties. However, sometimes, radiographic examination of welds reveals typical unacceptable indications requiring weld repair. As a consequence, there is a significant drop in weld efficiency and productivity. In this work, the nature and the cause of the occurrence of these defects have been investigated and an attempt is made to overcome the problem. It has been found that weld has a tendency to form typical Ca and Al oxide inclusions leading to the observed defects. The use of calcium fluoride flux has been found to produce a defect free weld with visible effect on weld bead finish. The flux promotes the separation of inclusions, refines the grain size and leads to significant improvement in mechanical properties of the weldment.
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.
Inverter-based GTA welding machines improve fabrication

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

Sammons, M.

2000-05-01

While known as precision process, many fabricators using the gas tungsten arc welding (GTAW) process fight several common problems that hinder quality, slow production, frustrate the operator and otherwise prevent the process from achieving its full potential. These include a limited ability to tailor the weld bead profile, poor control of the arc direction and arc wandering, poor arc starting, unstable or inconsistent arcs in the AC mode, high-frequency interference with electronics and tungsten contamination. Fortunately, new GTA welding technology--made possible by advances with inverter-based power sources and micro-processor controls--can eliminate common productivity gremlins. Further, new AC/DC inverter-based GTA powermore » sources provide advanced arc shaping capabilities. As a result, many fabricators adopting this new technology have experienced phenomenal production increases, taken on new types of projects and reduced costs. Most importantly, the operators enjoy welding more.« less
Study of localized corrosion in aluminum alloys by the scanning reference electrode technique

NASA Technical Reports Server (NTRS)

Danford, M. D.

1995-01-01

Localized corrosion in 2219-T87 aluminum (Al) alloy, 2195 aluminum-lithium (Al-Li) alloy, and welded 2195 Al-Li alloy (4043 filler) have been investigated using the relatively new scanning reference electrode technique (SRET). Anodic sites are more frequent and of greater strength in the 2195 Al-Li alloy than in the 2219-T87 Al alloy, indicating a greater tendency toward pitting for the latter. However, the overall corrosion rates are about the same for these two alloys, as determined using the polarization resistance technique. In the welded 2195 Al-Li alloy, the weld bean is entirely cathodic, with rather strongly anodic heat affected zones (HAZ) bordering both sides, indicating a high probability of corrosion in the HAZ parallel to the weld bead.
Bead on Plate Temper Pass Study: Thermal and Microhardness Study

DTIC Science & Technology

2009-09-01

par soudage fournit l’énergie cruciale pour réaliser le recuit de la martensite et, ultérieurement, en restaurer la ductilité et la ténacité; le...thermocouple within different regions of the HAZ. In nearly all cases the thermocouples were suitably positioned with a few being consumed within the fusion...important in the design of weld tempering sequences. For the current combination of HY-80 base plate and AWS 9016G welding consumable , it is the HY-80 base
An Investigation of TIG welding parameters on microhardness and microstructure of heat affected zone of HSLA steel

NASA Astrophysics Data System (ADS)

Musa, M. H. A.; Maleque, M. A.; Ali, M. Y.

2018-01-01

Nowadays a wide variety of metal joining methods are used in fabrication industries. In this study, the effect of various welding parameters of the TIG welding process on microhardness, depth, and microstructure of the heat-affected zone (HAZ) of L450 HSLA steel and optimizing these process parameters following Taguchi experimental design was investigated. The microhardness tended to increase significantly with the increase of welding speed from 1.0 to 2.5 mm/s whereas the width of HAZ decreased. The current and arc voltage was found to be less significant in relative comparison. Microstructures of the welded samples were also studied to analyze the changes in the microstructure of the material in terms of ferrite, pearlite, bainite, and martensite formations. Welding speed was found to be the most significant factors leading to changes in microhardness and metallurgical properties. The increase of welding heat input caused an increase in width (depth) of HAZ and the growth of prior austenite grains and then enlarged the grain size of coarse grain heat affected zone (CGHAZ). However, the amount of martensite in the HAZ decreased accompanied by an opposite change of paint. It was observed that the hardness properties and the microstructural feature of HAZ area was strongly affected by the welding parameters.
The microstructure and fracture behavior of the dissimilar alloy 690-SUS 304L joint with various Nb addition

NASA Astrophysics Data System (ADS)

Lee, H. T.; Jeng, S. L.; Kuo, T. Y.

2003-05-01

This study investigates the microstructure and fracture behavior of dissimilar weldments of alloy 690 and SUS 304L for various additions of niobium (0.1, 1.03, 2.49, and 3.35 wt pct) in the flux. With identical parameters and procedures, weldments were butt welded by the shielding metal arc welding (SMAW) process using three layers, with each layer being deposited in a single pass. The results indicate that the microstructure of the fusion zone was primarily dendritic and that the contents of Ni, Cr, and Fe within this zone remain relatively constant and resemble alloy 690. With Nb addition, it is noted that the microstructure changes from a cellular to columnar dendrite and equiaxed dendrite. Meanwhile, the dendrite arm spacing reduces and the secondary arms grow longer. Moreover, the composition of the interdendritic phase, whose precipitate volume percentage increases from 5 to 25 pct, changes from Al-Ti-O to Nb rich. The spread of the interdendritic phase is less in the root bead than in the cap bead due to the greater influence of base metal dilution in this region. Mechanical tests indicate that Nb addition increases the average hardness of the weldment and reduces its elongation prior to rupture. However, the tensile strength is essentially unchanged by Nb addition. It is found that the average hardness of the root bead is generally lower than the cap bead, and that the tensile specimens all rupture in the fusion zone, with the fracture surfaces exhibiting ductile features. It is noted that the cap bead tends to rupture interdendritically with increasing Nb addition. Finally, fractography shows that the dimples in the root become larger and shallower with Nb addition and are rich with an interdendritic phase.
Comparative study of pulsed Nd:YAG laser welding of AISI 304 and AISI 316 stainless steels

NASA Astrophysics Data System (ADS)

Kumar, Nikhil; Mukherjee, Manidipto; Bandyopadhyay, Asish

2017-02-01

Laser welding is a potentially useful technique for joining two pieces of similar or dissimilar materials with high precision. In the present work, comparative studies on laser welding of similar metal of AISI 304SS and AISI 316SS have been conducted forming butt joints. A robotic control 600 W pulsed Nd:YAG laser source has been used for welding purpose. The effects of laser power, scanning speed and pulse width on the ultimate tensile strength and weld width have been investigated using the empirical models developed by RSM. The results of ANOVA indicate that the developed models predict the responses adequately within the limits of input parameters. 3-D response surface and contour plots have been developed to find out the combined effects of input parameters on responses. Furthermore, microstructural analysis as well as hardness and tensile behavior of the selected weld of 304SS and 316SS have been carried out to understand the metallurgical and mechanical behavior of the weld. The selection criteria are based on the maximum and minimum strength achieved by the respective weld. It has been observed that the current pulsation, base metal composition and variation in heat input have significant influence on controlling the microstructural constituents (i.e. phase fraction, grain size etc.). The result suggests that the low energy input pulsation generally produce fine grain structure and improved mechanical properties than the high energy input pulsation irrespective of base material composition. However, among the base materials, 304SS depict better microstructural and mechanical properties than the 316SS for a given parametric condition. Finally, desirability function analysis has been applied for multi-objective optimization for maximization of ultimate tensile strength and minimization of weld width simultaneously. Confirmatory tests have been conducted at optimum parametric conditions to validate the optimization techniques.
Effect of Welding Process on Microstructure, Mechanical and Pitting Corrosion Behaviour of 2205 Duplex Stainless Steel Welds

NASA Astrophysics Data System (ADS)

Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

An attempt has been made to weld 2205 Duplex stainless steel of 6mm thick plate using conventional gas tungsten arc welding (GTAW) and activated gas tungsten arc welding (A- GTAW) process using silica powder as activated flux. Present work is aimed at studying the effect of welding process on depth of penetration, width of weld zone of 2205 duplex stainless steel. It also aims to observe the microstructural changes and its effect on mechanical properties and pitting corrosion resistance of 2205 duplex stainless steel welds. Metallography is done to observe the microstructural changes of the welds using image analyzer attached to the optical microscopy. Hardness studies, tensile and ductility bend tests were evaluated for mechanical properties. Potentio-dynamic polarization studies were carried out using a basic GillAC electro-chemical system in 3.5% NaCl solution to observe the pitting corrosion behaviour. Results of the present investigation established that increased depth of penetration and reduction of weld width in a single pass by activated GTAW with the application of SiO2 flux was observed when compared with conventional GTAW process. It may be attributed to the arc constriction effect. Microstructure of the weld zones for both the welds is observed to be having combination of austenite and delta ferrite. Grain boundary austenite (GBA) with Widmanstatten-type austenite (WA) of plate-like feature was nucleated from the grain boundaries in the weld zone of A-GTAW process. Mechanical properties are relatively low in activated GTAW process and are attributed to changes in microstructural morphology of austenite. Improved pitting corrosion resistance was observed for the welds made with A-GTAW process.

Liquid carry-over in an injection moulded all-polymer chip system for immiscible phase magnetic bead-based solid-phase extraction

NASA Astrophysics Data System (ADS)

Kistrup, Kasper; Skotte Sørensen, Karen; Wolff, Anders; Fougt Hansen, Mikkel

2015-04-01

We present an all-polymer, single-use microfluidic chip system produced by injection moulding and bonded by ultrasonic welding. Both techniques are compatible with low-cost industrial mass-production. The chip is produced for magnetic bead-based solid-phase extraction facilitated by immiscible phase filtration and features passive liquid filling and magnetic bead manipulation using an external magnet. In this work, we determine the system compatibility with various surfactants. Moreover, we quantify the volume of liquid co-transported with magnetic bead clusters from Milli-Q water or a lysis-binding buffer for nucleic acid extraction (0.1 (v/v)% Triton X-100 in 5 M guanidine hydrochloride). A linear relationship was found between the liquid carry-over and mass of magnetic beads used. Interestingly, similar average carry-overs of 1.74(8) nL/μg and 1.72(14) nL/μg were found for Milli-Q water and lysis-binding buffer, respectively.
Arc Welding of Mg Alloys: Oxide Films, Irregular Weld Shape and Liquation Cracking

NASA Astrophysics Data System (ADS)

Chai, Xiao

The use of Mg alloys for vehicle weight reduction has been increasing rapidly worldwide. Gas-metal arc welding (GMAW) has the potential for mass-production welding of Mg alloys. Recently, the University of Wisconsin demonstrated in bead-on-plate GMAW of Mg alloys that severe spatter can be eliminated by using controlled short circuiting (CSC), and severe hydrogen porosity can be eliminated by removing Mg(OH)2. The present study aimed at actual butt and lap welding of Mg alloys by CSC-GMAW and susceptibility of Mg alloys to weld-edge cracking using the circular-patch welding test. Sound welds were made without spatter and hydrogen porosity butt and lap welding of AZ 31 Mg using CSC-GMAW , with butt welds approaching 100% of the base-metal strength. However, three new significant issues were found to occur easily and degrade the weld quality significantly: 1. formation of oxide films inside butt welds, 2. formation of high crowns on butt welds, and 3. formation of fingers from lap welds. The mechanisms of their formation were established, and the methods for their elimination or reduction were demonstrated. Circular-patch welds were made on most widely used Mg casting alloy AZ91, the most widely used Mg wrought alloy AZ31 with three different Mg filler wires AZ31, AZ61 and AZ92. The susceptibility to cracking along the weld edge was predicted and compared against the experimental results. Such a prediction has not been made for welds of Mg alloys before.
Limit load solution for electron beam welded joints with single edge weld center crack in tension

NASA Astrophysics Data System (ADS)

Lu, Wei; Shi, Yaowu; Li, Xiaoyan; Lei, Yongping

2012-05-01

Limit loads are widely studied and several limit load solutions are proposed to some typical geometry of weldments. However, there are no limit load solutions exist for the single edge crack weldments in tension (SEC(T)), which is also a typical geometry in fracture analysis. The mis-matching limit load for thick plate with SEC(T) are investigated and the special limit load solutions are proposed based on the available mis-matching limit load solutions and systematic finite element analyses. The real weld configurations are simplified as a strip, and different weld strength mis-matching ratio M, crack depth/width ratio a/ W and weld width 2H are in consideration. As a result, it is found that there exists excellent agreement between the limit load solutions and the FE results for almost all the mis-matching ration M, a/ W and ligament-to-weld width ratio ( W-a)/ H. Moreover, useful recommendations are given for evaluating the limit loads of the EBW structure with SEC(T). For the EBW joints with SEC(T), the mis-matching limit loads can be obtained assuming that the components are wholly made of base metal, when M changing from 1.6 to 0.6. When M decreasing to 0.4, the mis-matching limit loads can be obtained assuming that the components are wholly made of base metal only for large value of ( W-a)/ H. The recommendations may be useful for evaluating the limit loads of the EBW structures with SEC(T). The engineering simplifications are given for assessing the limit loads of electron beam welded structure with SEC(T).
Alternative welding reconditioning solutions without post welding heat treatment of pressure vessel

NASA Astrophysics Data System (ADS)

Cicic, D. T.; Rontescu, C.; Bogatu, A. M.; Dijmărescu, M. C.

2017-08-01

In pressure vessels, working on high temperature and high pressure may appear some defects, cracks for example, which may lead to failure in operation. When these nonconformities are identified, after certain examination, testing and result interpretation, the decision taken is to repair or to replace the deteriorate component. In the current legislation it’s stipulated that any repair, alteration or modification to an item of pressurised equipment that was originally post-weld heat treated after welding (PWHT) should be post-weld heat treated again after repair, requirement that cannot always be respected. For that reason, worldwide, there were developed various welding repair techniques without PWHT, among we find the Half Bead Technique (HBT) and Controlled Deposition Technique (CDT). The paper presents the experimental results obtained by applying the welding reconditioning techniques HBT and CDT in order to restore as quickly as possible the pressure vessels made of 13CrMo4-5. The effects of these techniques upon the heat affected zone are analysed, the graphics of the hardness variation are drawn and the resulted structures are compared in the two cases.
Penetration in GTA welding

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

Heiple, C.R.; Burgardt, P.

1990-01-01

The size and shape of the weld bead produced in GTA welding depends on the magnitude and distribution of the energy incident on the workpiece surfaces as well as the dissipation of that energy in the workpiece. The input energy is largely controllable through the welding parameters selected, however the dissipation of that energy in the workpiece is less subject to control. Changes in energy dissipation can produce large changes in weld shape or penetration. Heat transport away from the weld pool is almost entirely by conduction, but heat transport in the weld pool is more complicated. Heat conduction throughmore » the liquid is an important component, but heat transport by convection (mass transport) is often the dominant mechanism. Convective heat transport is directional and changes the weld pool shape from that produced by conduction alone. Surface tension gradients are often the dominant forces driving fluid flow in GTA weld pools. These gradients are sensitive functions of weld pool chemistry and the energy input distribution to the weld. Experimental and theoretical work conducted primarily in the past decade has greatly enhanced our understanding of weld pool fluid flow, the forces which drive it, and its effects on weld pool shape. This work is reviewed here. While less common, changes in energy dissipation through the unmelted portion of the workpiece can also affect fusion zone shape or penetration. These effects are also described. 41 refs., 9 figs.« less
A Design of Experiments Approach Defining the Relationships Between Processing and Microstructure for Ti-6Al-4V

NASA Technical Reports Server (NTRS)

Wallace, Terryl A.; Bey, Kim S.; Taminger, Karen M. B.; Hafley, Robert A.

2004-01-01

A study was conducted to evaluate the relative significance of input parameters on Ti- 6Al-4V deposits produced by an electron beam free form fabrication process under development at the NASA Langley Research Center. Five input parameters where chosen (beam voltage, beam current, translation speed, wire feed rate, and beam focus), and a design of experiments (DOE) approach was used to develop a set of 16 experiments to evaluate the relative importance of these parameters on the resulting deposits. Both single-bead and multi-bead stacks were fabricated using 16 combinations, and the resulting heights and widths of the stack deposits were measured. The resulting microstructures were also characterized to determine the impact of these parameters on the size of the melt pool and heat affected zone. The relative importance of each input parameter on the height and width of the multi-bead stacks will be discussed. .
Micro friction stir lap welding of AISI 430 ferritic stainless steel: a study on the mechanical properties, microstructure, texture and magnetic properties

NASA Astrophysics Data System (ADS)

Mostaan, Hossein; Safari, Mehdi; Bakhtiari, Arash

2018-04-01

In this study, the effect of friction stir welding of AISI 430 (X6Cr17, material number 1.4016) ferritic stainless steel is examined. Two thin sheets with dimensions of 0.4 × 50 × 200 mm3 are joined in lap configuration. Optical microscopy and field emission electron microscopy were used in order to microstructural evaluations and fracture analysis, respectively. Tensile test and microhardness measurements are employed in order to study the mechanical behaviors of welds. Also, vibrational sample magnetometry (VSM) is employed for characterizing magnetic properties of welded samples. Texture analysis is carried out in order to clarify the change mechanism of magnetic properties in the welded area. The results show that AISI 430 sheets are successfully joined considering both, the appearance of the welding bead and the strength of the welded joint. It is found that by friction stir welding of AISI 430 sheets, texture components with easy axes magnetization have been replaced by texture components with harder magnetization axes. VSM analysis showed that friction stir welding leads to increase in residual induction (Br) and coercivity (Hc). This increase is attributed to the grain refining due the friction stir welding and formation of texture components with harder axes of magnetizations.
Application of welding science to welding engineering: A lumped parameter gas metal arc welding dynamic process model

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

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

1997-12-31

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

NASA Astrophysics Data System (ADS)

Yusof, M. F. M.; Ishak, M.; Ghazali, M. F.

2017-09-01

In this paper, the feasibility of using acoustic method to monitor the depth of penetration was investigated by determine the characteristic of the acquired sound throughout the pulse mode laser welding process. To achieve the aim, the sound signal was acquired during the pulsed laser welding process on the 2 mm structural carbon steel plate. During the experiment, the laser peak power and pulse width was set to be varied while welding speed was constantly at 2 mm/s. Result from the experiment revealed that the sound pressure level of the acquired sound was linearly related to the pulse energy as well as the depth of penetration for welding process using 2ms pulse width. However, as the pulse width increase, the sound pressure level show insignificant change with respect to the change in the depth of penetration when the pulse energy reaches certain values. The reported result shows that this was happen due to the occurrence of spatter which suppressed the information associated with the generation of plasma plume as the product of high pulse energy. In this work, it was demonstrated that in some condition, the acoustic method was found to be potentially suitable to be used as a medium to monitor the depth of weld on online basis. To increase the robustness of this method to be used in wider range of parameter, it was believed that some other post processing method is needed in order to extract the specific information associated with the depth of penetration from the acquired sound.
Conduit purging device and method

NASA Technical Reports Server (NTRS)

Wilks, Michael T. (Inventor)

2011-01-01

A device for purging gas comprises a conduit assembly defining an interior volume. The conduit assembly comprises a first conduit portion having an open first end and an open second end and a second conduit portion having an open first end and a closed second end. The open second end of the first conduit portion is disposed proximate to the open first end of the second conduit portion to define a weld region. The device further comprises a supply element supplying a gas to the interior volume at a substantially constant rate and a vent element venting the gas from the interior volume at a rate that maintains the gas in the interior volume within a pressure range suitable to hold a weld bead in the weld region in equilibrium during formation of a weld to join the first conduit portion and the second conduit portion.
Melting Efficiency During Plasma Arc Welding

NASA Technical Reports Server (NTRS)

McClure, J.C.; Evans, D. M.; Tang, W.; Nunes, A. C.

1999-01-01

A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 aluminum. Arc Efficiency was measured calorimetrically and ranged between 48% and 66%. Melting efficiency depends on the weld pool shape. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Higher currents are thought to raise arc pressure and depress the liquid at the bottom of the weld pool causing a more nearly two dimensional heat flow condition.
Hybrid Laser-Arc Welding of 10-mm-Thick Cast Martensitic Stainless Steel CA6NM: As-Welded Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

NASA Astrophysics Data System (ADS)

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

2018-02-01

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

NASA Technical Reports Server (NTRS)

Gamari, F. J.; Moresi, J. L.

1975-01-01

After processing parts for assembly, insulative cup is fitted to bottom of can, then electrolytic solution consisting of white sulfuric acid gel is inserted into can. Pellet is put in can and is fitted tightly into cup. Finally, bead weld is formed between can and header plug.
Flow-orthogonal bead oscillation in a microfluidic chip with a magnetic anisotropic flux-guide array.

PubMed

van Pelt, Stijn; Derks, Roy; Matteucci, Marco; Hansen, Mikkel Fougt; Dietzel, Andreas

2011-04-01

A new concept for the manipulation of superparamagnetic beads inside a microfluidic chip is presented in this paper. The concept allows for bead actuation orthogonal to the flow direction inside a microchannel. Basic manipulation functionalities were studied by means of finite element simulations and results were oval-shaped steady state oscillations with bead velocities up to 500 μm/s. The width of the trajectory could be controlled by prescribing external field rotation. Successful verification experiments were performed on a prototype chip fabricated with excimer laser ablation in polycarbonate and electroforming of nickel flux-guides. Bead velocities up to 450 μm/s were measured in a 75 μm wide channel. By prescribing the currents in the external quadrupole magnet, the shape of the bead trajectory could be controlled.
Characterization of weld imperfections in 2195 Al-Li alloy: Experimental approaches towards mechanisms

NASA Astrophysics Data System (ADS)

Zaidi, Anwer Arif

1997-10-01

2195 Al-Li alloy apparently offers significantly higher strength to weight ratio than the 2219 aluminum alloy. It was discovered that 2195 Al-Li has a greater tendency to crack, generates peculiar kind of porosity, and is vulnerable to deleterious microparticulate emission during welding than its 2219 predecessor. An experimental investigation has been carried to characterize these weld imperfections in 2195 Al-Li alloy. This work presents a scientific account of an analytical study and of the clues it has provided towards an understanding of the weld imperfections in 2195 Al-Li welds. The study begins with the observation of peculiar pore formation in 2195 welds, which occurs not as in the case of 2219 welds upon solidification, but in a thermal ageing process subsequent to solidification. An apparent reaction (DTA) between the fusion zone dendritic surface and nitrogen gas implies a porous fusion zone. Tiny surface melting sites, designated as Blisters, due to its resemblance to skin blisters, testify to the conjunction of outgassing and melting effects and suggest that porosity formation in the solid phase depends upon local melting as well as outgassing. The absence of a dark magnesium rich substance, designated as smut in the immediate vicinity of a crack opening next to a weld repair bead implies either an umbrella of gas emission keeping off a condensate evaporated under the welding arc or, possibly an expulsion of atomized, liquified metal from the crack itself in the form of microparticulate emission. These microparticulate emission from VPPA welds takes various forms herein labeled as smut, snow, and Lava. It is attributed to a gas generating reaction taking place at molten grain boundaries or crack surfaces. The reaction could only be release of hydrogen displaced from lithium hydrides by a coming influx of dissolved nitrogen. There appears to be a close link between porosity, cracking and microparticulate emission. Observations of melting on the surface of repair and E-stop cracks suggest interdendritic melting as the main factor responsible for cracking during welding. Heating in nitrogen reveals a weight loss (TGA) characteristic of an outgassing process before the weight gain thought to be associated with a nitrogen reaction takes over; hence the outgassing process, whatever it is, is thought to be independent of the nitrogen reaction. If the nitrogen contribution to porosity generation is then assigned to the promotion of local melting, the fusion zone fracture of laser weld beads subject to residual stress and heated under nitrogen atmosphere, but not under vacuum nor helium, is explicable. If this has been accomplished, cracking during welding is understood, and control procedures should be implicit in the understanding. (Abstract shortened by UMI.)
FSW between Al alloy and Mg Alloy: the comparative study

NASA Astrophysics Data System (ADS)

Jagadeesha, C. B.

2017-04-01

It is difficult to fusion weld Al alloy to Mg alloy, so by experimental optimization procedure (EOP) optimum parameters for FSW between Al alloy and Mg alloy were determined and experiment conducted using these parameters resulted in not only sound weld but also highest strength weld for 5 mm thickness of the alloys plates. One can arrive to optimum parameters by following the EOP in case of similar and dissimilar materials FSW, such as Al alloy and Mg alloy FSW. It has observed that tensile sample having least thickness intermetallics (IMs) layer has highest strength compared to sample with larger thickness of intermetallics layer and also it has observed that weld of lesser thickness plates have strength higher than welds of larger thickness plates. It has observed that, Vickers hardness in WN i.e. on the region containing layers of IMs is considerably higher, which leads to emerge of new type of laminated composite materials. It has observed that, it is the least thickness IMs layers in the weld are responsible for higher strength of weld not the ductility of the IMs formed owing to the insertion of intermediate material in the weld. It has found that coefficient of friction is =0.25, in case of bead on plate welding of Mg alloy.
Microstructure and fatigue resistance of high strength dual phase steel welded with gas metal arc welding and plasma arc welding processes

NASA Astrophysics Data System (ADS)

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

2013-09-01

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

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

Moore, D.E.

1996-06-01

Investigations to evaluate weld repair of C-{1/2}Mo coke drums without postweld heat treatment (PWHT) are discussed in this paper. These investigations showed that shielded metal-arc welding (SMAW) without PWHT produced heat-affected zones (HAZ) and weld deposits with Charpy V-notch (CVN) impact toughness that exceeded the toughness of ex-service plate material. PWHT de-embrittles strain age-embrittled ex-service plate material. However, warming of drums to 200 F before putting in feed compensates for the omission of the de-embrittling PWHT. Additional testing showed that the de-embrittling PWHT did not significantly improve the fatigue properties of the ex-service plate material. As-welded SMAW repairs were foundmore » to be feasible for coke drums, and repairs have now been in service successfully for up to 2 years. The as-welded SMAW repairs were qualified on the basis of a 300 F preheat using small diameter electrodes for the first pass followed by larger diameter electrodes to temper the HAZ of the first pass. A half-bead technique was not used. Heat input is not precisely controlled as would be required for controlled deposition welding. Following the implementation of SMAW repairs without PWHT, the author extended the work to include as-welded repairs with automatic gas metal-arc welding (GMAW).« less

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

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

NASA Technical Reports Server (NTRS)

Harwig, Dennis D. (Inventor); Hunt, James F. (Inventor); Ryan, Patrick M. (Inventor); Fisher, Walter J. (Inventor)

1993-01-01

A plasma arc welding process for welding metal of increased thickness with one pass includes operating the plasma arc welding apparatus at a selected plasma gas flow rate, travel speed and arc current, to form a weld having a penetration ratio to weld height to weld width, and maintaining the penetration ratio at less than 0.74. Parameters for the plasma gas flow rate, travel speed and arc current are adjusted to a steady state condition during a start up period and maintained during the steady state condition to complete a weld. During a terminal stopping period, the travel speed is stopped and instantaneously replaced by filler wire which adds material to fill the keyhole that had been formed by the welding process. Parameters are subsequently adjusted during the stopping period to terminate the weld in a sound manner.
Definition of the Mathematical Model Coefficients on the Weld Size of Butt Joint Without Edge Preparation

NASA Astrophysics Data System (ADS)

Sidorov, Vladimir P.; Melzitdinova, Anna V.

2017-10-01

This paper represents the definition methods for thermal constants according to the data of the weld width under the normal-circular heat source. The method is based on isoline contouring of “effective power - temperature conductivity coefficient”. The definition of coefficients provides setting requirements to the precision of welding parameters support with the enough accuracy for an engineering practice.
Numerical analysis of the heat transfer and fluid flow in the butt-fusion welding process

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

NASA Astrophysics Data System (ADS)

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

2012-10-01

Two different cases regarding the zinc coating at the lap joint faying surface are selected for studying the influence of zinc vapor on the keyhole dynamics of the weld pool and the final welding quality. One case has the zinc coating fully removed at the faying surface; while the other case retains the zinc coating on the faying surface. It is found that removal of the zinc coating at the faying surface produces a significantly better weld quality as exemplified by a lack of spatters whereas intense spatters are present when the zinc coating is present at the faying surface. Spectroscopy is used to detect the optical spectra emitted from a laser generated plasma plume during the laser welding of galvanized high strength DP980 steel in a lap-joint configuration. A correlation between the electron temperature and defects within the weld bead is identified by using the Boltzmann plot method. The laser weld pool keyhole dynamic behavior affected by a high-pressure zinc vapor generated at the faying surface of galvanized steel lap-joint is monitored in real-time by a high speed charge-coupled device (CCD) camera assisted with a green laser as an illumination source.
Effect of the overlapping factor on the microstructure and mechanical properties of pulsed Nd:YAG laser welded Ti6Al4V sheets

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

Gao, Xiao-Long; Liu, Jing; Zhang, Lin-Jie, E-mail: zhanglinjie@mail.xjtu.edu.cn

2014-07-01

The effect of the overlapping factor on the microstructures and mechanical properties of pulsed Nd:YAG laser welded Ti6Al4V alloy sheets was investigated by microstructural observations, microhardness tests, tensile tests and fatigue tests. A microstructural examination shows that by increasing the overlapping factor, the grains in the fusion zone become coarser, and the width of the heat affected zone increases. As overlapping factor increases, the width of region composed completely of martensite α′ and the secondary α phase in the heat affected zone increases, consequently the gradient of microstructure along the direction from the fusion zone to base metal decreases, somore » does the gradient of microhardness. The results of tensile and fatigue tests reveal that the joints made using medium overlapping factor exhibit better mechanical properties than those welded with low and high overlapping factors. Based on the experimental results, it can be stated that a sound weld of Ti6Al4V alloy can be obtained if an appropriate overlapping factor is used. - Highlights: • The weld quality of Ti6Al4V alloy under various overlapping factors was assessed. • Tensile and fatigue tests were conducted with as-welded specimen. • Localized strain across the weld was measured using DIC photogrammetry system. • A sound weld of Ti6Al4V alloy is obtained by using right overlapping factor.« less
Microstructural Study of 17-4PH Stainless Steel after Plasma-Transferred Arc Welding.

PubMed

Deng, Dewei; Chen, Rui; Sun, Qi; Li, Xiaona

2015-01-29

The improvement of the surface qualities and surface hardening of precipitation hardened martensitic stainless steel 17-4PH was achieved by the plasma-transferred arc welding (PTAW) process deposited with Co-based alloy. The microstructure of the heat affected zone (HAZ) and base metal were characterized by optical microscope (OM), scanning electron microscope (SEM) and transmission electron microscope (TEM). The results show that there are obvious microstructural differences between the base metal and HAZ. For example, base material is transformed from lath martensite to austenite due to the heateffect of the welding process. On the other hand, the precipitate in the matrix (bar-like shape Cr₇C₃ phase with a width of about one hundred nanometres and a length of hundreds of nanometres) grows to a rectangular appearance with a width of about two hundred nanometres and a length of about one micron. Stacking fault could also be observed in the Cr₇C₃ after PTAW. The above means that welding can obviously improve the surface qualities.
Preliminary study on detection technology of the cladding weld of spent fuel storage pool

NASA Astrophysics Data System (ADS)

Qi, Pan; Cui, Hongyan; Feng, Meiming; Shao, Wenbin; Liao, Shusheng; Li, Wei

2018-04-01

As the first barrier of the Spent fuel storage pool, the steel cladding using different sizes (length×width) of 304L stainless steel with 3˜6mm thickness plate argon arc welded together which is direct contacted with boric acid water. Environmental humidity between the back of steel cladding and concrete, makes phosphate, chloride ion overflowed from the concrete that corroded on the weld zone with different mechanism. Part of the corrosion defects can penetrate leaded to leakage of boric acid water in penetration position accelerated crack propagation. In view of the above situation and combined with the actual needs of the power plant, the development of effective underwater nondestructive testing means of the weld area for periodic inspection and monitoring is necessary. A single method may lead to the missing of defects detection due to weld reinforcement unpolished. In this paper, eddy current array (ARRAY) and Alternating Current Field Measurement (ACFM) are adapted to test the limit sensitivity and resolution through by the specimens with artificial defects which make their detection abilities close to satisfy engineering requirements. The preliminary study found that Φ0.5mm through-wall hole and with 2mm length and 0.3mm width through-wall crack in the weld can be good inspected.
Ultrashort pulse laser micro-welding of cyclo-olefin copolymers

NASA Astrophysics Data System (ADS)

Roth, Gian-Luca; Rung, Stefan; Hellmann, Ralf

2017-06-01

We report on the joining of transparent thermoplastic polymers using infrared femtosecond laser pulses. Due to nonlinear absorption, the developed micro-welding process for cyclo-olefin copolymers does not require any intermediate absorbing layers or any surface pre-processing of the welding partners. In view of an optimized and stable micro-welding process, the influence of the welding speed and focal position on both, the quality and shear force strength are investigated. We highlight that welding seam widths of down to 65 μm are feasible for welding speeds of up to 75 mm/s. However, a variation of the welding speed affects the required focal position for a successful joining process. The shear force strength of the welding seam is determined to 37 MPa, which corresponds to 64% of the shear strength of the bulk material and is not affected by the welding speed.
A model for heat and mass input control in GMAW

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

Smartt, H.B.; Einerson, C.J.

1993-05-01

This work describes derivation of a control model for electrode melting and heat and mass transfer from the electrode to the work piece in gas metal arc welding (GMAW). Specifically, a model is developed which allows electrode speed and welding speed to be calculated for given values of voltage and torch-to-base metal distance, as a function of the desired heat and mass input to the weldment. Heat input is given on a per unit weld length basis, and mass input is given in terms of transverse cross-sectional area added to the weld bead (termed reinforcement). The relationship to prior workmore » is discussed. The model was demonstrated using a computer-controlled welding machine and a proportional-integral (PI) controller receiving input from a digital filter. The difference between model-calculated welding current and measured current is used as controller feedback. The model is calibrated for use with carbon steel welding wire and base plate with Ar-CO[sub 2] shielding gas. Although the system is intended for application during spray transfer of molten metal from the electrode to the weld pool, satisfactory performance is also achieved during globular and streaming transfer. Data are presented showing steady-state and transient performance, as well as resistance to external disturbances.« less
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.
Using a laser source to measure the refractive index of glass beads and Debye theory analysis.

PubMed

Li, Shui-Yan; Qin, Shuang; Li, Da-Hai; Wang, Qiong-Hua

2015-11-20

Using a monochromatic laser beam to illuminate a homogeneous glass bead, some rainbows will appear around it. This paper concentrates on the study of the scattering intensity distribution and the method of measuring the refractive index for glass beads based on the Debye theory. It is found that the first rainbow due to the scattering superposition of backward light of the low-refractive-index glass beads can be explained approximately with the diffraction, the external reflection plus the one internal reflection, while the second rainbow of high-refractive-index glass beads is due to the contribution from the diffraction, the external reflection, the direct transmission, and the two internal reflections. The scattering intensity distribution is affected by the refractive index, the radius of the glass bead, and the incident beam width. The effects of the refractive index and the glass bead size on the first and second minimum deviation angle position are analyzed in this paper. The results of the measurements agree very well with the specifications.
Effect of Laser Power and Scan Speed on Melt Pool Characteristics of Commercially Pure Titanium (CP-Ti)

NASA Astrophysics Data System (ADS)

Kusuma, Chandrakanth; Ahmed, Sazzad H.; Mian, Ahsan; Srinivasan, Raghavan

2017-07-01

Selective laser melting (SLM) is an additive manufacturing technique that creates complex parts by selectively melting metal powder layer-by-layer using a laser. In SLM, the process parameters decide the quality of the fabricated component. In this study, single beads of commercially pure titanium (CP-Ti) were melted on a substrate of the same material using an in-house built SLM machine. Multiple combinations of laser power and scan speed were used for single bead fabrication, while the laser beam diameter and powder layer thickness were kept constant. This experimental study investigated the influence of laser power, scan speed, and laser energy density on the melt pool formation, surface morphology, geometry (width and height), and hardness of solidified beads. In addition, the observed unfavorable effect such as inconsistency in melt pool width formation is discussed. The results show that the quality, geometry, and hardness of solidified melt pool are significantly affected by laser power, scanning speed, and laser energy density.
Prediction of Weld Penetration in FCAW of HSLA steel using Artificial Neural Networks

NASA Astrophysics Data System (ADS)

Asl, Y. Dadgar; Mostafa, N. B.; Panahizadeh R., V.; Seyedkashi, S. M. H.

2011-01-01

Flux-cored arc welding (FCAW) is a semiautomatic or automatic arc welding process that requires a continuously-fed consumable tubular electrode containing a flux. The main FCAW process parameters affecting the depth of penetration are welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed. Shallow depth of penetration may contribute to failure of a welded structure since penetration determines the stress-carrying capacity of a welded joint. To avoid such occurrences; the welding process parameters influencing the weld penetration must be properly selected to obtain an acceptable weld penetration and hence a high quality joint. Artificial neural networks (ANN), also called neural networks (NN), are computational models used to express complex non-linear relationships between input and output data. In this paper, artificial neural network (ANN) method is used to predict the effects of welding current, arc voltage, nozzle-to-work distance, torch angle and welding speed on weld penetration depth in gas shielded FCAW of a grade of high strength low alloy steel. 32 experimental runs were carried out using the bead-on-plate welding technique. Weld penetrations were measured and on the basis of these 32 sets of experimental data, a feed-forward back-propagation neural network was created. 28 sets of the experiments were used as the training data and the remaining 4 sets were used for the testing phase of the network. The ANN has one hidden layer with eight neurons and is trained after 840 iterations. The comparison between the experimental results and ANN results showed that the trained network could predict the effects of the FCAW process parameters on weld penetration adequately.
Effect of temporal pulse shaping on the reduction of laser weld defects in a Pd-Ag-Sn dental alloy.

PubMed

Bertrand, C; Poulon-Quintin, A

2011-03-01

To describe the influence of pulse shaping on the behavior of a palladium-based dental alloy during laser welding and to show how its choice is effective to promote good weld quality. Single spots, weld beads and welds with 80% overlapping were performed on Pd-Ag-Sn cast plates. A pulsed Nd:Yag laser was used with a specific welding procedure using all the possibilities for pulse-shaping: (1) the square pulse shape as the default setting, (2) a rising edge slope for gradual heating, (3) a falling edge slope to slow the cooling and (4) a combination of a rising and falling edges called bridge shape. The optimization of the pulse shape is supposed to enhance weldability and produce defect-free welds (cracks, pores…) Vickers microhardness measurements were made on cross sections of the welds. A correlation between laser welding parameters and microstructure evolution was found. Hot cracking and internal porosities were systematically detected when using rapid cooling. The presence of these types of defects was significantly reduced with the slow cooling of the molten pool. The best weld quality was obtained with the use of the bridge shape. The use of a slow cooling ramp is the only way to significantly reduce the presence of typical defects within the welds for this Pd-based alloy studied. Copyright © 2010 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.
Increase of reliability of contact networks of electric transport, due to increase of strength of the joint unit of pipes of different diameters

NASA Astrophysics Data System (ADS)

Sabitov, L. S.; Kashapov, N. F.; Gilmanshin, I. R.; Gatiyatov, I. Z.; Kuznetsov, I. L.

2017-09-01

The feature of the stress state of the supports of the contact networks is the presence of a joint of pipes of different diameters, the ultimate state of which is determined, as a rule, the strength of the weld. The proposed unit allows to increase the reliability and strength of the connection and also exclude the presence of a weld bead on the outer surface of the pipe of smaller diameter in the place of its attachment to the upper end of the support ring.
Simulation and Technology of Hybrid Welding of Thick Steel Parts with High Power Fiber Laser

NASA Astrophysics Data System (ADS)

Turichin, Gleb; Valdaytseva, Ekaterina; Tzibulsky, Igor; Lopota, Alexander; Velichko, Olga

The article devoted to steady state and dynamic simulation of melt pool behavior during hybrid laser-arc welding of pipes and shipbuilding sections. The quasi-stationary process-model was used to determine an appropriate welding mode. The dynamical model of laser welding was used for investigation of keyhole depth and width oscillations. The experiments of pipe steel and stainless steel hybrid laser-MAG welding have been made with 15-kW fiber laser in wide range of welding mode parameters. Comparison of experimentally measured and simulated behavior of penetration depth as well as their oscillation spectra approved the self-oscillation nature of melt pool behavior. The welding mode influence of melt pool stability has also been observed. The technological peculiarities, which allow provide high quality weld seam, has been discussed also.
An inelastic analysis of a welded aluminum joint

NASA Astrophysics Data System (ADS)

Vaughan, Robert E.; Schonberg, William P.

1995-02-01

Butt weld joints are most commonly designed into pressure vessels by using weld material properties that are determined from a tensile test. These properties are provided to the stress analyst in the form of a stress vs strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of multiple pass aluminum 2219-T87 butt welds. The weld specimens are analyzed using classical plasticity theory to provide a basis for modeling the inelastic properties in a finite element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of currently available numerical prediction methods.
Microstructure and Mechanical Properties of Narrow Gap Laser-Arc Hybrid Welded 40 mm Thick Mild Steel.

PubMed

Zhang, Chen; Li, Geng; Gao, Ming; Zeng, XiaoYan

2017-01-26

Both laser-arc hybrid welding and narrow gap welding have potential for the fabrication of thick sections, but their combination has been seldom studied. In this research, 40 mm thick mild steel was welded by narrow gap laser-arc hybrid welding. A weld with smooth layer transition, free of visible defects, was obtained by nine passes at a 6 mm width narrow gap. The lower part of the weld has the lowest mechanical properties because of the lowest amount of acicular ferrite, but its ultimate tensile strength and impact absorbing energy is still 49% and 60% higher than those of base metal, respectively. The microhardness deviation of all filler layers along weld thickness direction is no more than 15 HV 0.2 , indicating that no temper softening appeared during multiple heat cycles. The results provide an alternative technique for improving the efficiency and quality of welding thick sections.
Microstructure and Mechanical Properties of Narrow Gap Laser-Arc Hybrid Welded 40 mm Thick Mild Steel

PubMed Central

Zhang, Chen; Li, Geng; Gao, Ming; Zeng, XiaoYan

2017-01-01

Both laser-arc hybrid welding and narrow gap welding have potential for the fabrication of thick sections, but their combination has been seldom studied. In this research, 40 mm thick mild steel was welded by narrow gap laser-arc hybrid welding. A weld with smooth layer transition, free of visible defects, was obtained by nine passes at a 6 mm width narrow gap. The lower part of the weld has the lowest mechanical properties because of the lowest amount of acicular ferrite, but its ultimate tensile strength and impact absorbing energy is still 49% and 60% higher than those of base metal, respectively. The microhardness deviation of all filler layers along weld thickness direction is no more than 15 HV0.2, indicating that no temper softening appeared during multiple heat cycles. The results provide an alternative technique for improving the efficiency and quality of welding thick sections. PMID:28772469

Surface-active element effects on the shape of GTA, laser, and electron-beam welds

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

Heiple, C.R.; Roper, J.R.; Stagner, R.T.

1983-03-01

Laser and electron-beam welds were passed across selenium-doped zones in 21-6-9 stainless steel. The depth/width (d/w) ratio of a defocused laser weld with a weld pool shape similar to a GTA weld increased by over 200% in a zone where 66 ppm selenium had been added. Smaller increases were observed in selenium-doped zones for a moderately defocused electron beam weld with a higher d/w ratio in undoped base metal. When laser or electron beam weld penetration was by a keyhole mechanism, no change in d/w ratio occurred in selenium-doped zones. The results confirm the surface-tension-driven fluid-flow model for the effectmore » of minor elements on GTA weld pool shape. Other experimental evidence bearing on the effect of minor elements on GTA weld penetration is summarized.« less
Studying the Issues in Laser Joining of Lightweight Materials in a Coach-Peel Joint Configuration

NASA Astrophysics Data System (ADS)

Yang, Guang

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

NASA Astrophysics Data System (ADS)

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

2011-01-01

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

NASA Astrophysics Data System (ADS)

Lan, Liangyun; Kong, Xiangwei; Chang, Zhiyuan; Qiu, Chunlin; Zhao, Dewen

2017-09-01

This paper analyzed the evolution of microstructure, composition, and impact toughness across the fusion line of high-strength bainitic steel weldments with different heat inputs. The main purpose was to develop a convenient method to evaluate the HAZ toughness quickly. The compositions of HAZ were insensitive to higher contents of alloy elements ( e.g., Ni, Mo) in the weld metal because their diffusion distance is very short into the HAZ. The weld metal contained predominantly acicular ferrite at any a heat input, whereas the main microstructures in the HAZ changed from lath martensite/bainite to upper bainite with the increasing heat input. The evolution of HAZ toughness in relation to microstructural changes can be revealed clearly combined with the impact load curve and fracture morphology, although the results of impact tests do not show an obvious change with heat input because the position of Charpy V notch contains the weld metal, HAZ as well as a part of base metal. As a result, based on the bead-on-plate welding tests, the welding parameter affecting the HAZ toughness can be evaluated rapidly.
Microstructural and hardness investigations on a dissimilar metal weld between low alloy steel and Alloy 82 weld metal

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

Chen, Z.R., E-mail: raymix@aliyun.com

The investigation on microstructure and hardness at the fusion boundary (FB) region of a dissimilar metal weld (DMW) between low alloy steel (LAS) A508-III and Alloy 82 weld metal (WM) was carried out. The results indicated that there were two kinds of FBs, martensite FB and sharp FB, with obvious different microstructures, alternately distributed in the same FB. The martensite FB region had a gradual change of elemental concentration across FB, columnar WM grains with high length/width ratios, a thick martensite layer and a wide heat affected zone (HAZ) with large prior austenite grains. By comparison, the sharp FB regionmore » had a relatively sharp change of elemental concentration across the FB, WM grains with low length/width ratios and a narrow HAZ with smaller prior austenite grains. The martensite possessed a K-S orientation relationship with WM grains, while no orientation relationship was found between the HAZ grains and WM grains at the sharp FB. Compared with sharp FB there were much more Σ3 boundaries in the HAZ beside martensite FB. The hardness maximum of the martensite FB was much higher than that of the sharp FB, which was attributed to the martensite layer at the martensite FB. - Highlights: •Martensite and sharp FBs with different microstructures were found in the same FB. •There were high length/width-ratio WM grains and a wide HAZ beside martensite FB. •There were low length/width-ratio WM grains and a narrow HAZ beside sharp FB. •Compared with sharp FB, there were much more Σ3 boundaries in HAZ of martensite FB. •Hardness maximium of martensite FB was much higher than that of sharp FB.« less
DOE Office of Scientific and Technical Information (OSTI.GOV)

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

The welding equipment used for welding iridium containers (clads) at Los Alamos National Laboratory is twenty five years old and is undergoing an upgrade. With the upgrade, there is a requirement for requalification of the welding process, and the opportunity for process improvement. Testing of the new system and requalification will require several welds on iridium test parts and clads, and any efforts to improve the process will add to the need for iridium parts. The extreme high cost of iridium imposes a severe limitation on the extent of test welding that can be done. The 2 inch diameter, 0.027more » inch thick, iridium blank disc that the clad cup is formed from, is useful for initial weld trials, but it costs $5000. The development clad sets needed for final tests and requalification cost $15,000 per set. A solution to iridium cost issue would be to do the majority of the weld development on a less expensive surrogate metal with similar weld characteristics. One such metal is molybdenum. Since its melting index (melting temperature x thermal conductivity) is closest to iridium, welds on molybdenum should be similar in size for a given weld power level. Molybdenum is inexpensive; a single 2 inch molybdenum disc costs only $9. In order to evaluate molybdenum as a surrogate for iridium, GTA welds were first developed to provide full penetration on 0.030 inch thick molybdenum discs at speeds of 20, 25, and 30 inches per minute (ipm). These weld parameters were then repeated on the standard 0.027 inch thick iridium blanks. The top surface and bottom surface (root) width and grain structure of the molybdenum and iridium welds were compared, and similarities were evident between the two metals. Due to material and thickness differences, the iridium welds were approximately 35% wider than the molybdenum welds. A reduction in iridium weld current of 35% produce welds slightly smaller than the molybdenum welds yet showed that current could be scaled according to molybdenum/iridium weld width ratio to achieve similar welds. Further weld trials using various thicknesses of molybdenum determined that 0.024 inch thick molybdenum material would best match the 0.027 inch thick iridium in achieving comparable welds when using the same welding parameters. Across the range of welding speeds, the characteristic weld pool shape and solidification grain structure in the two materials was also similar. With the similarity of welding characteristics confirmed, and the appropriate thickness of molybdenum determined, it has been concluded that the use of molybdenum discs and tube sections will greatly expand the weld testing opportunities prior to iridium weld qualification« less
The numerical simulation of Lamb wave propagation in laser welding of stainless steel

NASA Astrophysics Data System (ADS)

Zhang, Bo; Liu, Fang; Liu, Chang; Li, Jingming; Zhang, Baojun; Zhou, Qingxiang; Han, Xiaohui; Zhao, Yang

2017-12-01

In order to explore the Lamb wave propagation in laser welding of stainless steel, the numerical simulation is used to show the feature of Lamb wave. In this paper, according to Lamb dispersion equation, excites the Lamb wave on the edge of thin stainless steel plate, and presents the reflection coefficient for quantizing the Lamb wave energy, the results show that the reflection coefficient is increased with the welding width increasing,
Research on Microstructure and Properties of Welded Joint of High Strength Steel

NASA Astrophysics Data System (ADS)

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

2018-01-01

BS960 steel plates were welded by Laser-MAG and MAG. The microstructure and properties of the welded joints were investigated by optical microscope, micro-hardness tester, universal tensile testing machine, impact tester, scanning electron microscope (SEM) and fatigue tester. By a series of experiments, the following results were obtained: The grain size of the coarse grain zone with Laser-MAG welded joint is 20μm, and that with MAG welded joint is about 32μm, both of the fine grain region are composed of fine lath martensite and granular bainite; the width of the heat affected region with Laser-MAG is lower than that with MAG. The strength and impact energy of welded joints with Laser-MAG is higher than that with MAG. The conditioned fatigue limit of welded joint with Laser-MAG is 280MPa; however, the conditioned fatigue limit of welded joint with MAG is 250MPa.
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.
Microstructural Study of 17-4PH Stainless Steel after Plasma-Transferred Arc Welding

PubMed Central

Deng, Dewei; Chen, Rui; Sun, Qi; Li, Xiaona

2015-01-01

The improvement of the surface qualities and surface hardening of precipitation hardened martensitic stainless steel 17-4PH was achieved by the plasma-transferred arc welding (PTAW) process deposited with Co-based alloy. The microstructure of the heat affected zone (HAZ) and base metal were characterized by optical microscope (OM), scanning electron microscope (SEM) and transmission electron microscope (TEM). The results show that there are obvious microstructural differences between the base metal and HAZ. For example, base material is transformed from lath martensite to austenite due to the heateffect of the welding process. On the other hand, the precipitate in the matrix (bar-like shape Cr7C3 phase with a width of about one hundred nanometres and a length of hundreds of nanometres) grows to a rectangular appearance with a width of about two hundred nanometres and a length of about one micron. Stacking fault could also be observed in the Cr7C3 after PTAW. The above means that welding can obviously improve the surface qualities. PMID:28787947
Detection of defects in laser welding of AZ31B magnesium alloy in zero-gap lap joint configuration by a real-time spectroscopic analysis

NASA Astrophysics Data System (ADS)

Harooni, Masoud; Carlson, Blair; Kovacevic, Radovan

2014-05-01

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

NASA Astrophysics Data System (ADS)

Jagadeesha, C. B.

2016-12-01

Since its inception no one has done analysis and design of FSW tool. Initial dimensions of FSW tool are decided by educated guess. Optimum stresses on tool pin have been determined at optimized parameters for bead on plate welding on AZ31B-O Mg alloy plate. Fatigue analysis showed that the chosen FSW tool for the welding experiment has not ∞ life and it has determined that the life of FSW tool is 2.66×105 cycles or revolutions. So one can conclude that any arbitrarily decided FSW tool generally has finite life and cannot be used for ∞ life. In general, one can determine the suitability of tool and its material to be used in FSW of the given workpiece materials in advance by this analysis in terms of fatigue life of the tool.
Improving the corrosion properties of magnesium AZ31 alloy GTA weld metal using microarc oxidation process

NASA Astrophysics Data System (ADS)

Siva Prasad, M.; Ashfaq, M.; Kishore Babu, N.; Sreekanth, A.; Sivaprasad, K.; Muthupandi, V.

2017-05-01

In this work, the morphology, phase composition, and corrosion properties of microarc oxidized (MAO) gas tungsten arc (GTA) weldments of AZ31 alloy were investigated. Autogenous gas tungsten arc welds were made as full penetration bead-on-plate welding under the alternating-current mode. A uniform oxide layer was developed on the surface of the specimens with MAO treatment in silicate-based alkaline electrolytes for different oxidation times. The corrosion behavior of the samples was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy. The oxide film improved the corrosion resistance substantially compared to the uncoated specimens. The sample coated for 10 min exhibited better corrosion properties. The corrosion resistance of the coatings was concluded to strongly depend on the morphology, whereas the phase composition and thickness were concluded to only slightly affect the corrosion resistance.
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.
Structure and constitution of glass and steel compound in glass-metal composite

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

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

2014-11-14

The research using methods of optical and scanning electronic microscopy was conducted and it discovered common factors on structures and diffusing zone forming after welding glass C49-1 and steel Ct3sp in technological process of creating new glass-metal composite. Different technological modes of steel surface preliminary oxidation welded with and without glass were investigated. The time of welding was varied from minimum encountering time to the time of stabilizing width of diffusion zone.
Complete Status Report Documenting Development of Friction Stir Welding for Joining Thin Wall Tubing of ODS Alloys

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

Hoelzer, David T.; Bunn, Jeffrey R.; Gussev, Maxim N.

The development of friction stir welding (FSW) for joining thin sections of the advanced oxide dispersion strengthened (ODS) 14YWT ferritic alloy was initiated in Fuel Cycle Research and Development (FCRD), now the Nuclear Technology Research and Development (NTRD), in 2015. The first FSW experiment was conducted in late FY15 and successfully produced a bead-on-plate stir zone (SZ) on a 1 mm thick plate of 14YWT (SM13 heat). The goal of this research task is to ultimately demonstrate that FSW is a feasible method for joining thin wall (0.5 mm thick) tubing of 14YWT.
Influence of laser beam incidence angle on laser lap welding quality of galvanized steels

NASA Astrophysics Data System (ADS)

Mei, Lifang; Yan, Dongbing; Chen, Genyu; Wang, Zhenhui; Chen, Shuixuan

2017-11-01

Based on the characteristics of laser welded structural parts of auto bodies, the influence of variation in laser beam incidence angle on the lap welding performance of galvanized auto-body sheets was studied. Lap welding tests were carried out on the galvanized sheets for auto-body application at different laser beam incidence angles by using the optimal welding parameters obtained through orthogonal experiment. The effects of incidence angle variation on seam appearance, cross-sectional shape, joint mechanical properties and microstructure of weldments were analyzed. In addition, the main factors influencing the value of incidence angle were investigated. According to the results, the weld seams had a good appearance as well as a fine, and uniform microstructure when the laser beam incidence angle was smaller than the critical incidence angle, and thus they could withstand great tensile and shear loads. Moreover, all tensile-shear specimens were fractured in the base material zone. When the laser beam incidence angle was larger than the critical incidence angle, defects like shrinkage and collapse tended to emerge, thereby resulting in the deteriorated weldability of specimens. Meanwhile, factors like the type and thickness of sheet, weld width as well as inter-sheet gap all had a certain effect on the value of laser beam incidence angle. When the sheet thickness was small and the weld width was narrow, the laser beam incidence angle could be increased appropriately. At the same time, small changes in the inter-sheet gap could greatly impact the value of incidence angle. When the inter-sheet gap was small, the laser beam incidence angle should not be too large.
Effects of electrode bevel angle on argon arc properties and weld shape

NASA Astrophysics Data System (ADS)

Dong, W. C.; Lu, S. P.; Li, D. Z.; Y Li, Y.

2012-07-01

A numerical modeling of coupled welding arc with weld pool is established using FLUENT software for moving shielded GTA welding to systematically investigate the effects of electrode bevel angle on the argon arc properties as well as the weld shape on SUS304 stainless steel. The calculated results show that the argon arc is constricted and the peak values of heat flux and shear stress on the weld pool decrease with increasing electrode bevel angle, while the radial distribution of heat flux and shear stress varying slightly. The weld shape is controlled by the pool flow patterns driving by the surface tension, gas shear stress, electromagnetic force and buoyancy. The Marangoni convection induced by surface tension plays an important role on weld shapes. All the weld shapes are wide and shallow with low weld metal oxygen content, while the narrow and deep weld shapes form under high weld metal oxygen content, which is related with the oxygen concentration in the shielding gas. The weld depth/width (D/W) ratio increases with increasing electrode bevel angle for high weld metal oxygen content and is not sensitive to the electrode bevel angle under low weld metal oxygen content. The calculated results for the weld shape, weld size and weld D/W ratio agree well with the experimental ones.
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.

Land Vehicle Tire Qualification

DTIC Science & Technology

2010-03-25

separation -Bead damage / separation -Severe open splices and/or liner separations - Tire induced loss of air -Exposed or broken casing -Bulges in tread ...or sidewall *UNCLASSIFIED* SAE J2014 11 SAE J2014 4.14 Tire Treadlife Durability -10000 miles duration -Evaluate tread wear performance of candidate... tire -Measurements at prescribed intervals - Tread depth at centerline & shoulder -Diameter, section width, tread arc width -Conducted on courses
Investigation of Laser Parameters in Silicon Pulsed Laser Conduction Welding

NASA Astrophysics Data System (ADS)

Shayganmanesh, Mahdi; Khoshnoud, Afsaneh

2016-03-01

In this paper, laser welding of silicon in conduction mode is investigated numerically. In this study, the effects of laser beam characteristics on the welding have been studied. In order to model the welding process, heat conduction equation is solved numerically and laser beam energy is considered as a boundary condition. Time depended heat conduction equation is used in our calculations to model pulsed laser welding. Thermo-physical and optical properties of the material are considered to be temperature dependent in our calculations. Effects of spatial and temporal laser beam parameters such as laser beam spot size, laser beam quality, laser beam polarization, laser incident angle, laser pulse energy, laser pulse width, pulse repetition frequency and welding speed on the welding characteristics are assessed. The results show that how the temperature dependent thermo-physical and optical parameters of the material are important in laser welding modeling. Also the results show how the parameters of the laser beam influence the welding characteristics.
Research on the welding process of aluminum alloy based on high power fiber laser

NASA Astrophysics Data System (ADS)

Zhang, Jian; Zhang, Wei; Pan, Xiaoming; Huang, Shanshi; Liu, Wenwen

2017-08-01

To research the formation and variation principle of the weld seam and molten pool for aluminum alloy high power fiber laser welding, the welding experiments for 5052 aluminum alloy were carried out. The influences of laser power, scanning velocity and protection gas on the welding process were systematically researched. The results show that with the increase of power and scanning velocity, the depth to width ratio first increases and then decreases. The ratio reaches the maximum value at 2.6 KW and 30 mm/s, respectively. When the power located at 2.6 KW to 2.8 KW or the velocity located at 25 mm/s to 30 mm/s, stable deep penetration welding can be obtained. The weld seam shows relative flat appearance and the molten pool presents typical "T shape" topography. Moreover, the protection gas also influences the appearance of the weld seam. Using the independently designed fixture, the quality of the weld seam can be well improved.
Studying heat-affected zone deformations of electric arc welding

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

NASA Astrophysics Data System (ADS)

Khan, M. M. A.; Romoli, L.; Fiaschi, M.; Dini, G.; Sarri, F.

2011-02-01

This paper presents an experimental design approach to process parameter optimization for the laser welding of martensitic AISI 416 and AISI 440FSe stainless steels in a constrained overlap configuration in which outer shell was 0.55 mm thick. To determine the optimal laser-welding parameters, a set of mathematical models were developed relating welding parameters to each of the weld characteristics. These were validated both statistically and experimentally. The quality criteria set for the weld to determine optimal parameters were the minimization of weld width and the maximization of weld penetration depth, resistance length and shearing force. Laser power and welding speed in the range 855-930 W and 4.50-4.65 m/min, respectively, with a fiber diameter of 300 μm were identified as the optimal set of process parameters. However, the laser power and welding speed can be reduced to 800-840 W and increased to 4.75-5.37 m/min, respectively, to obtain stronger and better welds.
Relation between hardness and ultrasonic velocity on pipeline steel welded joints

NASA Astrophysics Data System (ADS)

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

2016-04-01

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

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

Zhou, Kang, E-mail: zhoukang326@126.com, E-mail: melcai@ust.hk; Cai, Lilong, E-mail: zhoukang326@126.com, E-mail: melcai@ust.hk

2014-04-28

In this paper, we developed a general mathematical model to estimate the nugget growth process based on the heat energy delivered into the welds by the resistance spot welding. According to the principles of thermodynamics and heat transfer, and the effect of electrode force during the welding process, the shape of the nugget can be estimated. Then, a mathematical model between heat energy absorbed and nugget diameter can be obtained theoretically. It is shown in this paper that the nugget diameter can be precisely described by piecewise fractal polynomial functions. Experiments were conducted with different welding operation conditions, such asmore » welding currents, workpiece thickness, and widths, to validate the model and the theoretical analysis. All the experiments confirmed that the proposed model can predict the nugget diameters with high accuracy based on the input heat energy to the welds.« less
Weldability and Impact Energy Properties of High-Hardness Armor Steel

NASA Astrophysics Data System (ADS)

Cabrilo, Aleksandar; Geric, Katarina; Jovanovic, Milos; Vukic, Lazic

2018-03-01

In this study, the weldability of high-hardness armor steel by the gas metal arc welding method has been investigated. The study was aimed at determining the weakness points of manual welding compared to automated welding through microhardness testing, the cooling rate, tensile characteristics and nondestructive analysis. Detailed studies were performed for automated welding on the impact energy and microhardness in the fusion line, as the most sensitive zone of the armor steel weld joint. It was demonstrated that the selection of the preheating and interpass temperature is important in terms of the cooling rate and quantity of diffusible and retained hydrogen in the weld joint. The tensile strength was higher than 800 MPa. The width of the heat-affected zone did not exceed 15.9 mm, measured from the weld centerline, while the impact energy results were 74 and 39 J at 20 and - 40 °C, respectively.
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.
Transmissive liquid-crystal device correcting primary coma aberration and astigmatism in laser scanning microscopy

NASA Astrophysics Data System (ADS)

Tanabe, Ayano; Hibi, Terumasa; Ipponjima, Sari; Matsumoto, Kenji; Yokoyama, Masafumi; Kurihara, Makoto; Hashimoto, Nobuyuki; Nemoto, Tomomi

2016-03-01

Laser scanning microscopy allows 3D cross-sectional imaging inside biospecimens. However, certain aberrations produced can degrade the quality of the resulting images. We previously reported a transmissive liquid-crystal device that could compensate for the predominant spherical aberrations during the observations, particularly in deep regions of the samples. The device, inserted between the objective lens and the microscope revolver, improved the image quality of fixed-mouse-brain slices that were observed using two-photon excitation laser scanning microscopy, which was originally degraded by spherical aberration. In this study, we developed a transmissive device that corrects primary coma aberration and astigmatism, motivated by the fact that these asymmetric aberrations can also often considerably deteriorate image quality, even near the sample surface. The device's performance was evaluated by observing fluorescent beads using single-photon excitation laser scanning microscopy. The fluorescence intensity in the image of the bead under a cover slip tilted in the y-direction was increased by 1.5 times after correction by the device. Furthermore, the y- and z-widths of the imaged bead were reduced to 66% and 65%, respectively. On the other hand, for the imaged bead sucked into a glass capillary in the longitudinal x-direction, correction with the device increased the fluorescence intensity by 2.2 times compared to that of the aberrated image. In addition, the x-, y-, and z-widths of the bead image were reduced to 75%, 53%, and 40%, respectively. Our device successfully corrected several asymmetric aberrations to improve the fluorescent signal and spatial resolution, and might be useful for observing various biospecimens.
Microstructure and Tensile Behavior of Laser Arc Hybrid Welded Dissimilar Al and Ti Alloys

PubMed Central

Gao, Ming; Chen, Cong; Gu, Yunze; Zeng, Xiaoyan

2014-01-01

Fiber laser-cold metal transfer arc hybrid welding was developed to welding-braze dissimilar Al and Ti alloys in butt configuration. Microstructure, interface properties, tensile behavior, and their relationships were investigated in detail. The results show the cross-weld tensile strength of the joints is up to 213 MPa, 95.5% of same Al weld. The optimal range of heat input for accepted joints was obtained as 83–98 J·mm−1. Within this range, the joint is stronger than 200 MPa and fractures in weld metal, or else, it becomes weaker and fractures at the intermetallic compounds (IMCs) layer. The IMCs layer of an accepted joint is usually thin and continuous, which is about 1μm-thick and only consists of TiAl2 due to fast solidification rate. However, the IMCs layer at the top corner of fusion zone/Ti substrate is easily thickened with increasing heat input. This thickened IMCs layer consists of a wide TiAl3 layer close to FZ and a thin TiAl2 layer close to Ti substrate. Furthermore, both bead shape formation and interface growth were discussed by laser-arc interaction and melt flow. Tensile behavior was summarized by interface properties. PMID:28788533
Effect of laser welding process on the microstructure, mechanical properties and residual stresses in Ti-5Al-2.5Sn alloy

NASA Astrophysics Data System (ADS)

Junaid, Massab; Khan, Fahd Nawaz; Rahman, Khalid; Baig, Mirza Nadeem

2017-12-01

Pulsed Nd-YAG laser was employed in bead on plate configuration for welding of 1.6 mm thick Ti-5Al-2.5Sn alloy sheet. The effect of laser processing parameters on the weld pool shape, pulse overlap, oxide formation, and microstructure were studied using scanning electron and optical microscope. It was found out that laser peak power had a significant influence on the FZ oxygen contents and grain size whereas, both peak power and heat input per unit length were important in defining the weld pool shape. Processing parameters for full penetration welds with acceptable joint properties and low oxygen contents were selected for further study in terms of residual stresses and mechanical properties. Formation of acicular α and α‧ martensite in fusion and heat affected zone, led to an increase in microhardness by about 55 HV0.2 as compared to base metal. Induced residual stresses were found to be significantly less than the yield strength resulting in plate deformation less than 1 mm. Transverse residual stresses present at different depths below the surface tend to counter effect each other resulting in tensile strength of welded specimen becoming nearly equal to that of the base metal.
Effect of Continuous and Pulsed Current Gas Tungsten Arc Welding on Dissimilar Weldments Between Hastelloy C-276/AISI 321 Austenitic Stainless Steel

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

NASA Astrophysics Data System (ADS)

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

2016-09-01

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

PubMed

Islam, Afroja T; Siddique, Ariful H; Ramulu, T S; Reddy, Venu; Eu, Young-Jae; Cho, Seung Hyun; Kim, CheolGi

2012-12-01

In this work, we demonstrated the alignment of polystyrene latex microspheres (diameter of 1 ~45 μm), bio-functionalized superparamagnetic beads (diameter 2.8 μm), and live cells (average diameter 1 ~2 μm) using an ultrasonic standing wave (USW) in a PDMS microfluidic channel (330 μm width) attached on a Si substrate for bio-medical applications. To generate a standing wave inside the channel, ultrasound of 2.25 MHz resonance frequency (for the channel width) was applied by two ultrasound transducers installed at both sides of the channel which caused the radiation force to concentrate the micro-particles at the single pressure nodal plane of USW. By increasing the frequency to the next resonance condition of the channel, the particles were concentrated in dual nodal planes. Migration time of the micro-particles towards the single nodal plane was recorded as 108 s, 17 s, and 115 s for polystyrene particles of 2 μm diameter, bio-functionalized magnetic beads, and live cells, respectively. These successful alignments of the bio-functionalized magnetic beads along the desired part of the channel can enhance the performance of a sensor which is applicable for the bio-hybrid system and the alignment of live cells without any damage can be used for sample pre-treatment for the application of lab-on-a-chip type bioassays.
Gravitational effects on weld pool shape and microstructural evolution during gas tungsten arc and laser beam welding on 304 stainless steel, nickel, and aluminum-4 wt.% copper alloy

NASA Astrophysics Data System (ADS)

Kang, Namhyun

The objective of the present work was to investigate effects of gravitational (acceleration) level and orientation on Ni 200 alloy (99.5% Ni purity), 304 stainless steel, and Al-4 wt.% Cu alloy during gas tungsten arc welding (GTAW) and laser beam welding (LBW). Main characterization was focused on the weld pool shape, microstructure, and solute distribution as a function of gravitational level and orientation. The welds were divided into two classes, i.e., 'stable' and 'unstable' welds, in view of the variation of weld pool shape as a function of gravitational level and orientation. In general, higher arc current and translational GTAW produced more significant effects of gravitational orientation on the weld pool shape than the case of lower arc current and spot welding. Cross-sectional area (CSA) was a secondary factor in determining the stability of weld pool shape. For the 'stable' weld of 304 stainless steel GTAW, the II-U weld showed less convexity in the pool bottom and more depression of the free surface, therefore producing deeper penetration (10--20%) than the case of II-D weld. The II-D weld of 304 stainless steel showed 31% deeper penetration, 28% narrower width, and more hemispherical shape of the weld pool than the case of II-U weld. For GTAW on 304 stainless steel, gravitational level variation from low gravity (LG ≈ 1.2 go) to high gravity (HG ≈ 1.8 go) caused 10% increase in width and 10% decrease in depth while maintaining the overall weld pool volume. Furthermore, LBW on 304 stainless steels showed mostly constant shape of weld pool as a function of gravitational orientation. GTAW on Ni showed similar trends of weld pool shape compared with GTAW on 304 stainless steel, i.e., the weld pool became unstable by showing more penetration in the II-D weld for slower arc translational velocity (V a) and larger weld pool size. However, the Ni weld pool shape had greater stability of the weld pool shape with respect to the gravitational orientation than the case of 304 stainless steel, i.e., higher current boundary and no humping. Regardless of the gravitational level, the ferrite content and the distribution of the solutes (Cr and Ni) remained constant for GTAW on 304 stainless steel. However, for GTAW on Al-4 wt.% Cu alloys, the gravitational orientation changed the weld pool shape associated with convection flows. In summary, gravity influenced the weld pool shape that was associated with convection flows and weld surface deformation for specific welding conditions. The variation of convection flows and weld pool shape played a role in modifying VS and GL. Solidification orientation and morphology were affected because VS and GL were changed as a function of gravity. Studies of gravity on the welding process are expected to play a significant role in the space-station construction and circumferential pipe welding on the earth. (Abstract shortened by UMI.)
Effects of beam configurations on wire melting and transfer behaviors in dual beam laser welding with filler wire

NASA Astrophysics Data System (ADS)

Ma, Guolong; Li, Liqun; Chen, Yanbin

2017-06-01

Butt joints of 2 mm thick stainless steel with 0.5 mm gap were fabricated by dual beam laser welding with filler wire technique. The wire melting and transfer behaviors with different beam configurations were investigated detailedly in a stable liquid bridge mode and an unstable droplet mode. A high speed video system assisted by a high pulse diode laser as an illumination source was utilized to record the process in real time. The difference of welding stability between single and dual beam laser welding with filler wire was also compartively studied. In liquid bridge transfer mode, the results indicated that the transfer process and welding stability were disturbed in the form of "broken-reformed" liquid bridge in tandem configuration, while improved by stabilizing the molten pool dynamics with a proper fluid pattern in side-by-side configuration, compared to sigle beam laser welding with filler wire. The droplet transfer period and critical radius were studied in droplet transfer mode. The transfer stability of side-by-side configuration with the minium transfer period and critical droplet size was better than the other two configurations. This was attributed to that the action direction and good stability of the resultant force which were beneficial to transfer process in this case. The side-by-side configuration showed obvious superiority on improving welding stability in both transfer modes. An acceptable weld bead was successfully generated even in undesirable droplet transfer mode under the present conditions.
Prediction of the Vickers Microhardness and Ultimate Tensile Strength of AA5754 H111 Friction Stir Welding Butt Joints Using Artificial Neural Network.

PubMed

De Filippis, Luigi Alberto Ciro; Serio, Livia Maria; Facchini, Francesco; Mummolo, Giovanni; Ludovico, Antonio Domenico

2016-11-10

A simulation model was developed for the monitoring, controlling and optimization of the Friction Stir Welding (FSW) process. This approach, using the FSW technique, allows identifying the correlation between the process parameters (input variable) and the mechanical properties (output responses) of the welded AA5754 H111 aluminum plates. The optimization of technological parameters is a basic requirement for increasing the seam quality, since it promotes a stable and defect-free process. Both the tool rotation and the travel speed, the position of the samples extracted from the weld bead and the thermal data, detected with thermographic techniques for on-line control of the joints, were varied to build the experimental plans. The quality of joints was evaluated through destructive and non-destructive tests (visual tests, macro graphic analysis, tensile tests, indentation Vickers hardness tests and t thermographic controls). The simulation model was based on the adoption of the Artificial Neural Networks (ANNs) characterized by back-propagation learning algorithm with different types of architecture, which were able to predict with good reliability the FSW process parameters for the welding of the AA5754 H111 aluminum plates in Butt-Joint configuration.
Microstructure and calorimetric behavior of laser welded open cell foams in CuZnAl shape memory alloy

NASA Astrophysics Data System (ADS)

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

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

NASA Astrophysics Data System (ADS)

Mohandas, T.; Banerjee, D.; Kutumba Rao, V. V.

1999-03-01

The effect of electron beam welding parameters on fusion zone (FZ) microstructure and porosity in a Ti -6.8 Al -3.42 Mo -1.9 Zr -0.21 Si alloy (Russian designation VT 9) has been investigated. It has been observed that the FZ grain width increased continuously with increase in heat input when the base metal was in the β heat-treated condition, while in the α+β heat-treated base metal welds, the FZ grain width increased only after a threshold energy input. The difference is attributed to both the weld thermal cycle and the pinning effect of equiaxed primary alpha on grain growth in the heat-affected zone (HAZ) of α+β heat-treated base metal. Postweld heat treatment (PWHT) in the subtransus and supertransus regions did not alter the columnar grain morphology in the FZ, possibly due to the lack of enough driving force for the formation of new grains by the breaking up of the columnar grains and grain boundary movement for grain growth. As the PWHTs were conducted in a furnace, the role of thermal gradients can be ruled out. Intragranular microstructure in the aswelded condition consisted of hexagonal martensite. The scale of the martensite laths depended on welding speed. The highest porosity was observed at intermediate welding speeds. At low speeds, a majority of pores formed at the fusion boundary, while at high speeds, occurrence of porosity was maximum at the weld center. The trends on porosity can be explained on the basis of solubility of hydrogen in titanium as a function of temperature and the influence of weld thermal cycle on nucleation, growth, and escape of hydrogen gas bubbles. The porosity at slow welding speeds is low because sufficient time exists for the nucleation, growth, and escape of hydrogen gas bubbles, while insufficient time exists for the nucleation of gas bubbles at high welding speeds. The effect of pickling of joint surface, vacuum annealing of the base metal, and successive remelting of the weld metal has also been investigated.

The influence of TIG-Arc physical characteristics on the penetration and weld width under different Ar and He supply conditions

NASA Astrophysics Data System (ADS)

Dai, Hongbin; Shen, Xiuqiang; Wang, Haoran

2018-06-01

In the paper, the 5A03 aluminium alloy was employed to study the influence of TIG arc on the penetration and the weld width. And the split anode method with water-cooled copper plate was used to measure and record the distribution of arc current, under different flow ratio of argon and helium conditions. And a gas supply device controlled by a solenoid valve was employed to obtain the stable TIG welding arc of gas supply alternately at the frequency of 1 Hz and 4 Hz, and then collected the phenomenon of arc alternate by the high-speed camera. The experimental results indicated that the current density at the arc anode center of argon and helium supply alternately with different mixing ratio is lower than that of the pure argon-arc center. Nonetheless, the former is more uniform in current density within 2 mm from the arc center. Furthermore, it presented as a component arc of argon-arc and helium-arc switched, with the condition of argon and helium supply alternately at a frequency of 1 Hz and the arc power density is greater and concentrated, leading to the wider and deeper weld.
Application of YAG Laser TIG Arc Hybrid Welding to Thin AZ31B Magnesium Alloy Sheet

NASA Astrophysics Data System (ADS)

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

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

NASA Astrophysics Data System (ADS)

Jernstroem, Petteri

2003-03-01

Modern lifting equipment is normally constructed using hollow section beams in a telescopic arrangement. Telescopic lifters are used in a variety number of applications including e.g. construction and building maintenance. Also rescue sector is one large application field. It is very important in such applications to use a lightweight and stable beam construction, which gives a high degree of flexibility in working high and width. To ensure a high weld quality of hollow section beams, high efficiency and minimal distortion, a welding process with a high power density is needed. The alternatives, in practice, which fulfill these requirements, are laser welding and hybrid welding. In this paper, the use of hybrid welding process (combination of CO2 laser welding and GMAW) in welding of hollow section beam structure is presented. Compared to laser welding, hybrid welding allows wider joint tolerances, which enables joints to be prepared and fit-up less accurately, aving time and manufacturing costs. A prerequisite for quality and effective use of hybrid welding is, however, a complete understanding of the process and its capabilities, which must be taken into account during both product design and manufacture.
High Power High Efficiency Diode Laser Stack for Processing

NASA Astrophysics Data System (ADS)

Gu, Yuanyuan; Lu, Hui; Fu, Yueming; Cui, Yan

2018-03-01

High-power diode lasers based on GaAs semiconductor bars are well established as reliable and highly efficient laser sources. As diode laser is simple in structure, small size, longer life expectancy with the advantages of low prices, it is widely used in the industry processing, such as heat treating, welding, hardening, cladding and so on. Respectively, diode laser could make it possible to establish the practical application because of rectangular beam patterns which are suitable to make fine bead with less power. At this power level, it can have many important applications, such as surgery, welding of polymers, soldering, coatings and surface treatment of metals. But there are some applications, which require much higher power and brightness, e.g. hardening, key hole welding, cutting and metal welding. In addition, High power diode lasers in the military field also have important applications. So all developed countries have attached great importance to high-power diode laser system and its applications. This is mainly due their low performance. In this paper we will introduce the structure and the principle of the high power diode stack.
Laser Beam Oscillation Strategies for Fillet Welds in Lap Joints

NASA Astrophysics Data System (ADS)

Müller, Alexander; Goecke, Sven-F.; Sievi, Pravin; Albert, Florian; Rethmeier, Michael

Laser beam oscillation opens up new possibilities of influencing the welding process in terms of compensation of tolerances and reduction of process emissions that occur in industrial applications, such as in body-in-white manufacturing. The approaches are to adapt the melt pool width in order to generate sufficient melt volume or to influence melt pool dynamics, e.g. for a better degassing. Welding results are highly dependent on the natural frequency of the melt pool, the used spot diameter and the oscillation speed of the laser beam. The conducted investigations with an oscillated 300 μm laser spot show that oscillation strategies, which are adjusted to the joining situation improve welding result for zero-gap welding as well as for bridging gaps to approximately 0.8 mm. However, a complex set of parameters has to be considered in order to generate proper welding results. This work puts emphasize on introducing them.
Process modeling and parameter optimization using radial basis function neural network and genetic algorithm for laser welding of dissimilar materials

NASA Astrophysics Data System (ADS)

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

2015-11-01

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

NASA Astrophysics Data System (ADS)

Acherjee, Bappa; Kuar, Arunanshu S.; Mitra, Souren; Misra, Dipten

2012-07-01

In this research, a systematic investigation on laser transmission contour welding process is carried out using finite element analysis (FEA) and design of experiments (DoE) techniques. First of all, a three-dimensional thermal model is developed to simulate the laser transmission contour welding process with a moving heat source. The commercial finite element code ANSYS® multi-physics is used to obtain the numerical results by implementing a volumetric Gaussian heat source, and combined convection-radiation boundary conditions. Design of experiments together with regression analysis is then employed to plan the experiments and to develop mathematical models based on simulation results. Four key process parameters, namely power, welding speed, beam diameter, and carbon black content in absorbing polymer, are considered as independent variables, while maximum temperature at weld interface, weld width, and weld depths in transparent and absorbing polymers are considered as dependent variables. Sensitivity analysis is performed to determine how different values of an independent variable affect a particular dependent variable.
Narrow groove welding gas diffuser assembly and welding torch

DOEpatents

Rooney, Stephen J.

2001-01-01

A diffuser assembly is provided for narrow groove welding using an automatic gas tungsten arc welding torch. The diffuser assembly includes a manifold adapted for adjustable mounting on the welding torch which is received in a central opening in the manifold. Laterally extending manifold sections communicate with a shield gas inlet such that shield gas supplied to the inlet passes to gas passages of the manifold sections. First and second tapered diffusers are respectively connected to the manifold sections in fluid communication with the gas passages thereof. The diffusers extend downwardly along the torch electrode on opposite sides thereof so as to release shield gas along the length of the electrode and at the distal tip of the electrode. The diffusers are of a transverse width which is on the order of the thickness of the electrode so that the diffusers can, in use, be inserted into a narrow welding groove before and after the electrode in the direction of the weld operation.
Effects of aging treatment and heat input on the microstructures and mechanical properties of TIG-welded 6061-T6 alloy joints

NASA Astrophysics Data System (ADS)

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

2013-03-01

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

NASA Astrophysics Data System (ADS)

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

2018-06-01

Weld width is commonly used as one of main factors to assess joint performances in laser welding. However, it changes significantly through the thickness direction in conditions of medium or thick plates. In this study, high-power autogenous laser welding was conducted on 7 mm thickness 201 stainless steel to elucidate the factor of whole weld transverse shape critically affecting the mechanical properties with the aim of predicting the performance visually through the weld appearance. The results show that single variation of welding parameters could result in great changes of weld pool figures and subsequently weld transverse shapes. All the obtained welds are composed of austenite containing small amount of cellular dendritic δ-Ferrite. The 0.2% proof stresses of Nail- and Peanut-shaped joint reach 458 MPa and 454 MPa, 88.2% and 87.5% of the base material respectively, while that of Wedge-shaped joint only comes to 371 MPa, 71.5% of the base material. The deterioration effect is believed to be caused by the axial grain zone in the weld center. The fatigue strength of joint P is a bit lower than N, but much better than W. Significant deformation incompatibility through the whole thickness and microstructure resistance to crack initiation should be responsible for the poor performance of W-shaped joints.
Generation rate of carbon monoxide from CO2 arc welding.

PubMed

Ojima, Jun

2013-01-01

CO poisoning has been a serious industrial hazard in Japanese workplaces. Although incomplete combustion is the major cause of CO generation, there is a risk of CO poisoning during some welding operations. The aim of the present study was to evaluate the generation rate of CO from CO2 arc welding under controlled laboratory conditions and estimate the ventilation requirements for the prevention of CO poisoning. Bead on plate welding was carried out with an automatic welding robot on a rolled steel base metal under several conditions. The concentration of emitted CO from the welding was measured by a real-time CO monitor in a well-ventilated laboratory that was free from ambient CO contamination. The generation rate of CO was obtained from the three measurements-the flow rate of the welding exhaust gas, CO concentration in the exhaust gas and the arcing time. Then the ventilation requirement to prevent CO poisoning was calculated. The generation rate of CO was found to be 386-883 ml/min with a solid wire and 331-1,293 ml/min with a flux cored wire respectively. It was found that the CO concentration in a room would be maintained theoretically below the OSHA PEL (50 ppm) providing the ventilation rate in the room was 6.6-25.9 m3/min. The actual ventilation requirement was then estimated to be 6.6-259 m3/min considering incomplete mixing. In order to prevent CO poisoning, some countermeasures against gaseous emission as well as welding fumes should be taken eagerly.
A study on the control of melting ratio to increase mechanical properties of laser welded joints between AISI 440C and AISI 430F

NASA Astrophysics Data System (ADS)

Romoli, L.; Rashed, C. A. A.; Lovicu, G.; Ishak, R.

2015-05-01

Laser beam welding of dissimilar AISI 440C and AISI 430F stainless steels was investigated in a circular constrained configuration. The beam incidence angle and the offset of the focusing position respect to the contact point between the two materials were used as main control parameters to vary the melting ratio inside the seam. The objective of the study is twofold: to avoid surface microcracks related to the high percentage of carbon of the martensitic steel and to enhance the shear strength of the weld by making it less brittle. To reach this scope the effects of incidence angle and offset on weld bead geometry and melting ratio were studied by means of metallographic analyses, microstructure and microhardness characterization. As last step, the weld mechanical strength was tested by tensile-shear stress test on the whole seam. Experiments demonstrated that varying incidence angle and offsetting the focal position is a reliable method to modify the melting ratio and maintaining the expected resistance length at the material interface, as well. It was found that increasing the percentage of ferritic steel into the joint has beneficial effects on the weld quality and on the shear resistance. The critical carbon content determining the mechanical properties in the fusion zone can be calculated by taking into account the melting ratio.
An inelastic analysis of a welded aluminum joint

NASA Astrophysics Data System (ADS)

Vaughan, R. E.

1994-09-01

Butt-weld joints are most commonly designed into pressure vessels which then become as reliable as the weakest increment in the weld chain. In practice, weld material properties are determined from tensile test specimen and provided to the stress analyst in the form of a stress versus strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of welds. The weld specimens are analyzed using classical elastic and plastic theory to provide a basis for modeling the inelastic properties in a finite-element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of prediction methods. The weld considered in this study is a multiple-pass aluminum 2219-T87 butt weld with thickness of 1.40 in. The weld specimen is modeled using the finite-element code ABAQUS. The finite-element model is used to produce the stress-strain behavior in the elastic and plastic regimes and to determine Poisson's ratio in the plastic region. The value of Poisson's ratio in the plastic regime is then compared to experimental data. The results of the comparisons are used to explain multipass weld behavior and to make recommendations concerning the analysis and testing of welds.
An inelastic analysis of a welded aluminum joint

NASA Technical Reports Server (NTRS)

Vaughan, R. E.

1994-01-01

Butt-weld joints are most commonly designed into pressure vessels which then become as reliable as the weakest increment in the weld chain. In practice, weld material properties are determined from tensile test specimen and provided to the stress analyst in the form of a stress versus strain diagram. Variations in properties through the thickness of the weld and along the width of the weld have been suspect but not explored because of inaccessibility and cost. The purpose of this study is to investigate analytical and computational methods used for analysis of welds. The weld specimens are analyzed using classical elastic and plastic theory to provide a basis for modeling the inelastic properties in a finite-element solution. The results of the analysis are compared to experimental data to determine the weld behavior and the accuracy of prediction methods. The weld considered in this study is a multiple-pass aluminum 2219-T87 butt weld with thickness of 1.40 in. The weld specimen is modeled using the finite-element code ABAQUS. The finite-element model is used to produce the stress-strain behavior in the elastic and plastic regimes and to determine Poisson's ratio in the plastic region. The value of Poisson's ratio in the plastic regime is then compared to experimental data. The results of the comparisons are used to explain multipass weld behavior and to make recommendations concerning the analysis and testing of welds.
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.
Investigation on the Effect of Pulsed Energy on Strength of Fillet Lap Laser Welded AZ31B Magnesium Alloys

NASA Astrophysics Data System (ADS)

Salleh, M. N. M.; Ishak, M.; Aiman, M. H.; Idris, S. R. A.; Romlay, F. R. M.

2017-09-01

AZ31B magnesium alloy have been hugely applied in the aerospace, automotive, and electronic industries. However, welding thin sheet AZ31B was challenging due to its properties which is easily to evaporated especially using conventional fusion welding method such as metal inert gas (MIG). Laser could be applied to weld this metal since it produces lower heat input. The application of fiber laser welding has been widely since this type of laser could produce better welding product especially in the automotive sectors. Low power fiber laser was used to weld this non-ferrous metal where pulse wave (PW) mode was used. Double fillet lap joint was applied to weld as thin as 0.6 mm thick of AZ31B and the effect of pulsed energy on the strength was studied. Bond width, throat length, and penetration depth also was studied related to the pulsed energy which effecting the joint. Higher pulsed energy contributes to the higher fracture load with angle of irradiation lower than 3 °
The effect of welding line heat-affected-zone on the formability of tube hydroforming process

NASA Astrophysics Data System (ADS)

ChiuHuang, Cheng-Kai; Hsu, Cheng-En; Lee, Ping-Kun

2016-08-01

Tube hydroforming has been used as a lightweight design approach to reduce CO2 emission for the automotive industry. For the high strength steel tube, the strength and quality of the welding line is very important for a successful tube hydroforming process. This paper aims to investigate the effect of the welding line's strength and the width of the heat-affected zone on the tube thinning during the hydroforming process. The simulation results show that both factors play an important role on the thickness distribution during the tube expansion.
Silver Foam Technologies Healing Research Program

DTIC Science & Technology

2009-09-01

colonization and growth. Because many of these wounds cannot be closed primarily, the surgeon is left with packing the wound open using standard gauze...to standard gauze bandages in clinical use . Two inches in width and length and one quarter inch thick, four inches in width and length and one...incorporation into the foam. Of the agents that were identified and selected only two Zeolite and Silver Glass Beads agents were capable of being
Experimental research on the dynamic behaviors of the keyhole and molten pool in laser deep-penetration welding

NASA Astrophysics Data System (ADS)

Zhang, Yi; Lin, Qida; Yin, Xuni; Li, Simeng; Deng, Jiquan

2018-04-01

Both the morphology and temperature are two important characteristics of the keyhole and the molten pool in laser deep-penetration welding. The modified ‘sandwich’ method was adopted to overcome the difficulty in obtaining inner information about the keyhole and the molten pool. Based on this method, experimental platforms were built for observing the variations in the surface morphology, the longitudinal keyhole profile and the internal temperature. The experimental results of three dynamic behaviors exbibit as follows. The key factor, which makes the pool width go into a quasi-steady state, lies in the balance between the vortex and the sideways flows around the keyhole. Experimental observation shows that the keyhole goes through three stages in laser welding: the rapid drilling stage, the slow drilling stage and the quasi-steady state. The time for achieving a relative fixed keyhole depth is close to the formation time of the maximum pool width. The internal temperatures inside the keyhole and the molten pool first experience a rapid increase, then a decrease and finally go into a quasi-steady state. Compared to that in the unstable stage, the liquid–metal uphill formed in the stable stage of laser welding has less influence on the internal temperature.
Prediction of the Vickers Microhardness and Ultimate Tensile Strength of AA5754 H111 Friction Stir Welding Butt Joints Using Artificial Neural Network

PubMed Central

De Filippis, Luigi Alberto Ciro; Serio, Livia Maria; Facchini, Francesco; Mummolo, Giovanni; Ludovico, Antonio Domenico

2016-01-01

A simulation model was developed for the monitoring, controlling and optimization of the Friction Stir Welding (FSW) process. This approach, using the FSW technique, allows identifying the correlation between the process parameters (input variable) and the mechanical properties (output responses) of the welded AA5754 H111 aluminum plates. The optimization of technological parameters is a basic requirement for increasing the seam quality, since it promotes a stable and defect-free process. Both the tool rotation and the travel speed, the position of the samples extracted from the weld bead and the thermal data, detected with thermographic techniques for on-line control of the joints, were varied to build the experimental plans. The quality of joints was evaluated through destructive and non-destructive tests (visual tests, macro graphic analysis, tensile tests, indentation Vickers hardness tests and t thermographic controls). The simulation model was based on the adoption of the Artificial Neural Networks (ANNs) characterized by back-propagation learning algorithm with different types of architecture, which were able to predict with good reliability the FSW process parameters for the welding of the AA5754 H111 aluminum plates in Butt-Joint configuration. PMID:28774035

Studies on Fusion Welding of High Nitrogen Stainless Steel: Microstructure, Mechanical and corrosion Behaviour

NASA Astrophysics Data System (ADS)

Mohammed, Raffi; Srinivasa Rao, K.; Madhusudhan Reddy, G.

2018-03-01

An attempt has been made in the present investigation to weld high nitrogen steel of 5mm thick plates using various process i.e., shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW) and autogenous electron beam welding (EBW) process. Present work is aimed at studying the microstructural changes and its effects on mechanical properties and corrosion resistance. Microstructure is characterized by optical, scanning electron microscopy and electron back scattered diffraction technique. Vickers hardness, tensile properties, impact toughness and face bend ductility testing of the welds was carried out. Pitting corrosion resistance of welds was determined using potentio-dynamic polarization testing in 3.5%NaCl solution. Results of the present investigation established that SMA welds made using Cr-Mn-N electrode were observed to have a austenite dendritic grain structure in the weld metal and is having poor mechanical properties but good corrosion resistance. GTA welds made using 18Ni (MDN 250) filler wire were observed to have a reverted austenite in martensite matrix of the weld metal and formation of unmixed zone at the fusion boundary which resulted in better mechanical properties and poor corrosion resistance. Fine grains and uniform distribution of delta ferrite in the austenite matrix and narrow width of weld zone are observed in autogeneous electron beam welds. A good combination of mechanical properties and corrosion resistance was achieved for electron beam welds of high nitrogen steel when compared to SMA and GTA welds.
Development of dispersion-strengthened Ni-Cr-ThOz alloys for the space shuttle thermal protection system

NASA Technical Reports Server (NTRS)

Blankenship, C. P.; Saunders, N. T.

1972-01-01

Manufacturing processes were developed for TD-NiCr providing small sheet (45 x 90 cm), and larger sheet (60 x 150 cm) and foil. The alternate alloy, DS-NiCr, was produced by pack-chromizing Ni-ThO2 sheet. Formability criteria are being established for basic sheet forming processes, which are brake forming, corrugation forming, joggling, dimpling, and beading. Resistance spot welding (fusion and solid state), resistance seam welding, solid state diffusion welding, and brazing are included in the joining programs. Major emphasis is centered on an Al-modified Ni-Cr-ThO2 alloy development. These alloys, containing 3 to 5% Al, form the protective Al2O3 scale. This enhances oxidation resistance under reentry conditions. Both TD-NiCrAl and DS-NiCrAl alloys are included. A tentative composition of Ni-16Cr-3.5Al-2ThO2 was selected based on oxidation resistance and fabricability.
Laser-based welding of 17-4 PH martensitic stainless steel in a tubular butt joint configuration with a built-in backing bar

NASA Astrophysics Data System (ADS)

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

2016-08-01

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

NASA Astrophysics Data System (ADS)

Li, Min; Xu, Jiajun; Huang, Yu; Rong, Youmin

2018-05-01

An external magnetic field was used to improve the keyhole stability in full penetration laser welding 316L steel. The increase of magnetic field strength gave rise to a shorter flying time of the spatter, a weaker size and brightness of the spatter, and a larger spreading area of vapor plume. This suggested that the dynamic behavior of the keyhole was stabilized by the external magnetic field. In addition, a stronger magnetic field could result in a more homogeneous distribution of laser energy, which increased the width of the weld zone, and the height of the bottom weld zone from 381 μm (0 mT) to 605 μm (50 mT). Dendrite and cellular crystal near the weld center disappeared, and grain size was refined. The external magnetic field was beneficial to the keyhole stability and improved the joint quality, because the weld pool was stirred by a Lorentz force resulting from the coupling effect of the magnetic field and inner thermocurrent.
Microstructures and Mechanical Properties of Friction Stir Spot Welded Aluminum Alloy AA2014

NASA Astrophysics Data System (ADS)

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

2013-01-01

Friction stir spot welding (FSSW) is a relatively recent development, which can provide a superior alternative to resistance spot welding and riveting for fabrication of aluminum sheet metal structures. In the current work, FSSW experiments were conducted in 3-mm thick sheets of aluminum alloy 2014 in T4 and T6 conditions, with and without Alclad layers. The effects of tool geometry and welding process parameters on joint formation were investigated. A good correlation between process parameters, bond width, hook height, joint strength, and fracture mode was observed. The presence of Alclad layers and the base metal temper condition were found to have no major effect on joint formation and joint strength. Friction stir spot welds produced under optimum conditions were found to be superior to riveted joints in lap-shear and cross-tension tests. The prospects of FSSW in aluminum sheet metal fabrication are discussed.
Weld pool development during GTA and laser beam welding of Type 304 stainless steel; Part II-experimental correlation

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

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

1989-12-01

In part I of the paper, the results of the heat flow and the fluid flow analysis were presented. Here, in Part II of the paper, predictions of the computational model are verified by comparing the numerically predicted and experimentally observed fusion zone size and shape. Stationary gas tungsten arc and laser beam welds were made on Type 304 stainless steel for different times to provide a variety of solidification conditions such as cooling rate and temperature gradient. Calculated temperatures and cooling rates are correlated with the experimentally observed fusion zone structure. In addition, the effect of sulfur on GTAmore » weld penetration was quantitatively evaluated by considering two heats of 304 stainless steel containing 90 and 240 ppm sulfur. Sulfur, as expected, increased the depth/width ratio by altering the surface tension gradient driven flow in the weld pool.« less
Detection of micro gap weld joint by using magneto-optical imaging and Kalman filtering compensated with RBF neural network

NASA Astrophysics Data System (ADS)

Gao, Xiangdong; Chen, Yuquan; You, Deyong; Xiao, Zhenlin; Chen, Xiaohui

2017-02-01

An approach for seam tracking of micro gap weld whose width is less than 0.1 mm based on magneto optical (MO) imaging technique during butt-joint laser welding of steel plates is investigated. Kalman filtering(KF) technology with radial basis function(RBF) neural network for weld detection by an MO sensor was applied to track the weld center position. Because the laser welding system process noises and the MO sensor measurement noises were colored noises, the estimation accuracy of traditional KF for seam tracking was degraded by the system model with extreme nonlinearities and could not be solved by the linear state-space model. Also, the statistics characteristics of noises could not be accurately obtained in actual welding. Thus, a RBF neural network was applied to the KF technique to compensate for the weld tracking errors. The neural network can restrain divergence filter and improve the system robustness. In comparison of traditional KF algorithm, the RBF with KF was not only more effectively in improving the weld tracking accuracy but also reduced noise disturbance. Experimental results showed that magneto optical imaging technique could be applied to detect micro gap weld accurately, which provides a novel approach for micro gap seam tracking.
The Role of Zinc Layer During Wetting of Aluminium on Zinc-coated Steel in Laser Brazing and Welding

NASA Astrophysics Data System (ADS)

Gatzen, M.; Radel, T.; Thomy, C.; Vollertsen, F.

The zinc layer of zinc-coated steel is known to be a crucial factor for the spreading of liquid aluminium on the coated surface. For industrial brazing and welding processes these zinc-coatings enable a fluxless joining between aluminium and steel in many cases. Yet, the reason for the beneficial effect of the zinc to the wetting process is not completely understood. Fundamental investigations on the wetting behaviour of single aluminium droplets on different zinc-coated steel surfaces have revealed a distinct difference between coated surfaces at room temperature and at elevated temperature regarding the influence of different coating thicknesses. In this paper the case of continuous laser brazing and welding processes of aluminium and commercial galvanized zinc-coated steel sheets are presented. It is shown that in the case of bead-on-plate laser beam brazing, the coating thickness has a measureable effect on the resulting wetting angle and length but does not have a significant impact in case of overlap laser beam welding. This might be linked to different heat transfer conditions. The results also strongly indicate that proper initialbreakup of oxide layers is still required to accomplish good wetting on zinc-coated surfaces.
Development of forming and joining technology for TD-NiCr sheet

NASA Technical Reports Server (NTRS)

Torgerson, R. T.

1973-01-01

Forming joining techniques and properties data were developed for thin-gage TD-NiCr sheet in the recrystallized and unrecrystallized conditions. Theoretical and actual forming limit data are presented for several gages of each type of material for five forming processes: brake forming, corrugation forming, joggling, dimpling and beading. Recrystallized sheet can be best formed at room temperature, but unrecrystallized sheet requires forming at elevated temperature. Formability is satisfactory with most processes for the longitudinal orientation but poor for the transverse orientation. Dimpling techniques require further development for both material conditions. Data on joining techniques and joint properties are presented for four joining processes: resistance seam welding (solid-state), resistance spot welding (solid-state), resistance spot welding (fusion) and brazing. Resistance seam welded (solid-state) joints with 5t overlap were stronger than parent material for both material conditions when tested in tensile-shear and stress-rupture. Brazing studies resulted in development of NASA 18 braze alloy (Ni-16Cr-15Mo-8Al-4Si) with several properties superior to baseline TD-6 braze alloy, including lower brazing temperture, reduced reaction with Td-Ni-Cr, and higher stress-rupture properties.
[The reconstruction of welding arc 3D electron density distribution based on Stark broadening].

PubMed

Zhang, Wang; Hua, Xue-Ming; Pan, Cheng-Gang; Li, Fang; Wang, Min

2012-10-01

The three-dimensional electron density is very important for welding arc quality control. In the present paper, Side-on characteristic line profile was collected by a spectrometer, and the lateral experimental data were approximated by a polynomial fitting. By applying an Abel inversion technique, the authors obtained the radial intensity distribution at each wavelength and thus constructed a profile for the radial positions. The Fourier transform was used to separate the Lorentz linear from the spectrum reconstructed, thus got the accurate Stark width. And we calculated the electronic density three-dimensional distribution of the TIG welding are plasma.
Experimental and numerical modeling of heat transfer in directed thermoplates

DOE PAGES

Khalil, Imane; Hayes, Ryan; Pratt, Quinn; ...

2018-03-20

We present three-dimensional numerical simulations to quantify the design specifications of a directional thermoplate expanded channel heat exchanger, also called dimpleplate. Parametric thermofluidic simulations were performed independently varying the number of spot welds, the diameter of the spot welds, and the thickness of the fluid channel within the laminar flow regime. Results from computational fluid dynamics simulations show an improvement in heat transfer is achieved under a variety of conditions: when the thermoplate has a relatively large cross-sectional area normal to the flow, a ratio of spot weld spacing to channel length of 0.2, and a ratio of the spotmore » weld diameter with respect to channel width of 0.3. Lastly, experimental results performed to validate the model are also presented.« less
Experimental and numerical modeling of heat transfer in directed thermoplates

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

Khalil, Imane; Hayes, Ryan; Pratt, Quinn

We present three-dimensional numerical simulations to quantify the design specifications of a directional thermoplate expanded channel heat exchanger, also called dimpleplate. Parametric thermofluidic simulations were performed independently varying the number of spot welds, the diameter of the spot welds, and the thickness of the fluid channel within the laminar flow regime. Results from computational fluid dynamics simulations show an improvement in heat transfer is achieved under a variety of conditions: when the thermoplate has a relatively large cross-sectional area normal to the flow, a ratio of spot weld spacing to channel length of 0.2, and a ratio of the spotmore » weld diameter with respect to channel width of 0.3. Lastly, experimental results performed to validate the model are also presented.« less
The inhomogeneous microstructure and deformation of similar and dissimilar Al-Zn containing Mg friction stir welds

NASA Astrophysics Data System (ADS)

Hiscocks, Jessica

The magnesium-based aluminum-zinc alloys have excellent stiffness to weight ratios, and may be combined by friction stir welding to expand the possible applications. The high aluminum alloy AZ80 in particular has the advantage of being relatively stiff but still extrudable. However limited friction stir welding research is available for this alloy and extrapolation from the extensive work in aluminum alloys is impractical due differences in precipitation behaviour, and magnesium's high plastic anisotropy and tendency to form strong textures during friction stir welding. This work investigates the correlations between local friction stir welded microstructures, textures, residual strains, and the local deformation behaviour based on strain mapping during tensile tests. Covering bead-on-plate and butt configurations, joining of similar and dissimilar materials, and a range of processing conditions, many findings of interest for deformation modelling and industrial applications are presented. Synchrotron x-ray diffraction study of an entire friction stir weld was used to determine texture, residual strain and dislocation density data from a single experiment. A number of unique findings were made, mainly related to the asymmetric distribution of properties both between sides of the weld and through the depth. Particularly in the case of strain measurements, features not detectable at coarser measurement spacing or by line scan are presented and compared for multiple processing conditions. Investigation of the longitudinal material flow during welding showed that even when periodicity in grain size, precipitate distribution, or texture was not observed, periodic changes in texture intensity resulting from compaction of material behind the tool were present, providing evidence that movement of nugget material remained periodic. Strain localisation and fracture behaviour were found to be completely different between good quality similar and dissimilar friction stir welds. For similar magnesium friction stir welds, higher heat input was shown to improve mechanical performance by reducing the residual strain, while for dissimilar friction stir welds, deformation behaviour was found to be more sensitive to the final material distribution in the friction stir weld nugget. For dissimilar welds, even minor changes to the material flow were shown to have a major impact on the tensile performance.
Control of the plume induced during high-power fiber laser welding with a transverse arc

NASA Astrophysics Data System (ADS)

Wu, Shikai; Zou, Jianglin; Xiao, Rongshi; Li, Fei

2015-04-01

In this letter, the addition of the transverse arc into high-power fiber welding is proposed. The effects of the transverse arc on the laser-induced plume, the morphology of the weld, and the stability of the welding process are investigated. The experimental results indicate that, by introducing the transverse arc, the slender plume disappears, the temperature of the plasma plume increases then decreases with the rise in height, the weld width is reduced by around 42%, and the weld depth and the melting area are enhanced by about 28 and 12%, respectively. Moreover, the stability of the welding process is improved remarkably. As concluded from further analysis, the Mie scattering of the incident laser, induced by the particles in the plume, is responsible for the adverse effects induced by the plume. With the addition of the transverse arc, the particles in the plume are gasified and, thus, do not impact the energy transmission of the fiber laser. Consequently, the adverse effects induced by the plume can be significantly suppressed while the laser energy utilization efficiency and the stability of the welding process are improved.
Welding High Strength Modern Line Pipe Steel

NASA Astrophysics Data System (ADS)

Goodall, Graeme Robertson

The effect of modern mechanized girth welding on high strength line pipe has been investigated. The single cycle grain coarsened heat affected zone in three grade 690 line pipe steels and a grade 550 steel has been simulated using a Gleeble thermo-mechanical simulator. The continuous cooling transformation diagrams applicable to the grain coarsened heat affected zone resulting from a range of heat inputs applicable to modern mechanized welding have been established by dilatometry and metallography. The coarse grained heat affected zone was found to transform to lath martensite, bainite, and granular bainite depending on the cooling rate. The impact toughness of the steels was measured using Charpy impact toughness and compared to the toughness of the grain coarsened heat affected zone corresponding to a welding thermal cycle. The ductile to brittle transition temperature was found to be lowest for the steel with the highest hardenability. The toughness resulting from three different thermal cycles including a novel interrupted intercritically reheated grain coarsened (NTR ICR GC HAZ) that can result from dual torch welding at fast travel speed and close torch spacing have been investigated. All of the thermally HAZ regions showed reduced toughness that was attributed to bainitic microstructure and large effective grain sizes. Continuous cooling transformation diagrams for five weld metal chemistries applicable to mechanized pulsed gas metal arc welding of modern high strength pipe steel (SMYS>550 MPa) have been constructed. Welds at heat inputs of 1.5 kJmm-1 and 0.5 kJmm-1 have been created for simulation and analysis. Dilatometric analysis was performed on weld metal specimens cut from single pass 1.5 kJmm-1 as deposited beads. The resulting microstructures were found to range from martensite to polygonal ferrite. There is excellent agreement between the simulated and as deposited weld metal regions. Toughness testing indicates improved energy absorption at -20 °C with increased cooling time.
Strong, Ductile Rotor For Cryogenic Flowmeters

NASA Technical Reports Server (NTRS)

Royals, W. T.

1993-01-01

Improved magnetic flowmeter rotor resists cracking at cryogenic temperatures, yet provides adequate signal to magnetic pickup outside flowmeter housing. Consists mostly of stainless-steel alloy 347, which is ductile and strong at low temperatures. Small bead of stainless-steel alloy 410 welded in groove around circumference of round bar of stainless-steel alloy 347; then rotor machined from bar. Tips of rotor blades contain small amounts of magnetic alloy, and passage of tips detected.
Programmatic Environmental Assessment High Speed Test Track (HSTT) Operations Holloman Air Force Base, New Mexico

DTIC Science & Technology

2007-09-01

include a machine shop, a welding shop, carpenter and wood shop, metal heat treatment shop, bead blast shop, paint shop, non-destructive inspection...annually. In 2005, 227 motors were fired. Sled operation can involve activities such as carrying explosives, testing ejection seats, shooting lasers ...Cinetheodolite-type metric cameras and/or laser tracking equipment are used for aircraft flight trajectories exceeding 500 feet above ground level
Process Parameter Optimization for Wobbling Laser Spot Welding of Ti6Al4V Alloy

NASA Astrophysics Data System (ADS)

Vakili-Farahani, F.; Lungershausen, J.; Wasmer, K.

Laser beam welding (LBW) coupled with "wobble effect" (fast oscillation of the laser beam) is very promising for high precision micro-joining industry. For this process, similarly to the conventional LBW, the laser welding process parameters play a very significant role in determining the quality of a weld joint. Consequently, four process parameters (laser power, wobble frequency, number of rotations within a single laser pulse and focused position) and 5 responses (penetration, width, heat affected zone (HAZ), area of the fusion zone, area of HAZ and hardness) were investigated for spot welding of Ti6Al4V alloy (grade 5) using a design of experiments (DoE) approach. This paper presents experimental results showing the effects of variating the considered most important process parameters on the spot weld quality of Ti6Al4V alloy. Semi-empirical mathematical models were developed to correlate laser welding parameters to each of the measured weld responses. Adequacies of the models were then examined by various methods such as ANOVA. These models not only allows a better understanding of the wobble laser welding process and predict the process performance but also determines optimal process parameters. Therefore, optimal combination of process parameters was determined considering certain quality criteria set.
Reactor vessels: weld cladding - base metal interaction

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

Mager, T.R.; Landerman, E.; Kubit, C.J.

1971-07-01

An underclad anomaly first observed during magnetic particle inspection of a European steam generator and subsequently discovered during inspection of certain reactor vessels manufactured in both the United States and in Europe is shown to be inconsequential for the intended application because of its small size and insignificant expected growth. Metallurgical investigation identifies the anomaly as grain boundary separations in the base metal, restricted in extent to the grain coarsened part of the weld heat-affected zone beneath the weld bead overlap. In all cases the depth of the separations was less than the maximum depth (0.125 inches) of the grainmore » coarsened area. The occurrence of the anomaly depends on the specific weld overlay process. It has been found generally after post-weld stress relief in forging and plate material (SA508 Class 2 composition). Fracture mechanics evaluation of the affected materials shows that the expected growth of the grain boundary separations during the lifetime of the plant is insignificant, being only 0.004 inches maximum as calculated based on conservative assumptions verified by the metallurgical investigation. Since the original size of the grain boundary separations is negligible and its growth is insignificant during the 40-year plant life, the structural integrity of the vessels has not been compromised and the affected vessels are suitable for the use intended.« less
Microstructure and Mechanical Properties of Plasma Arc Brazed AISI 304L Stainless Steel and Galvanized Steel Plates

NASA Astrophysics Data System (ADS)

Jin, Yajuan; Li, Ruifeng; Yu, Zhishui; Wang, Yu

2016-04-01

Plasma arc brazing is used to join the AISI 304L stainless steel and galvanized steel plate butt joints with the CuSi3Mn1 filler wire. The effect of parameters on weld surface appearance, interfacial microstructure, and composition distribution in the joint was studied. The microhardness and mechanical tests were conducted to determine the mechanical properties of the welded specimens. The results indicated that good appearance, bead shape, and sufficient metallurgical bonding could be obtained when the brazing process was performed with a wire feeding speed of 0.8 m/min, plasma gas flow rate of 3.0 l/min, welding current of 100 A, and welding speed of 27 cm/min. During plasma arc brazing process, the top corner of the stainless steel and galvanized steel plate were heated and melted, and the melted quantity of stainless steel was much more than that of the galvanized steel due to the thermal conductivity coefficient difference between the dissimilar materials. The microhardness test results shows that the microhardness value gradually increased from the side of the galvanized steel to the stainless steel in the joint, and it is good for improving the mechanical properties of joint. The tensile strength was a little higher than that of the brazing filler, and the fracture position of weld joint was at the base metal of galvanized steel plate.

Modern fiber laser beam welding of the newly-designed precipitation-strengthened nickel-base superalloys

NASA Astrophysics Data System (ADS)

Naffakh Moosavy, Homam; Aboutalebi, Mohammad-Reza; Seyedein, Seyed Hossein; Goodarzi, Massoud; Khodabakhshi, Meisam; Mapelli, Carlo; Barella, Silvia

2014-04-01

In the present research, the modern fiber laser beam welding of newly-designed precipitation-strengthened nickel-base superalloys using various welding parameters in constant heat input has been investigated. Five nickel-base superalloys with various Ti and Nb contents were designed and produced by Vacuum Induction Melting furnace. The fiber laser beam welding operations were performed in constant heat input (100 J mm-2) and different welding powers (400 and 1000 W) and velocities (40 and 100 mm s-1) using 6-axis anthropomorphic robot. The macro- and micro-structural features, weld defects, chemical composition and mechanical property of 3.2 mm weldments were assessed utilizing optical and scanning electron microscopes equipped with EDS analysis and microhardness tester. The results showed that welding with higher powers can create higher penetration-to-width ratios. The porosity formation was increased when the welding powers and velocities were increased. None of the welds displayed hot solidification and liquation cracks in 400 and 1000 W welding powers, but liquation phenomenon was observed in all the heat-affected zones. With increasing the Nb content of the superalloys the liquation length was increased. The changing of the welding power and velocity did not alter the hardness property of the welds. The hardness of welds decreased when the Ti content declined in the composition of superalloys. Finally, the 400 and 1000 W fiber laser powers with velocity of 40 and 100 m ms-1 have been offered for hot crack-free welding of the thin sheet of newly-designed precipitation-strengthened nickel-base superalloys.
Microstructure and Ductility-Dip Cracking Susceptibility of Circumferential Multipass Dissimilar Weld Between 20MND5 and Z2CND18-12NS with Ni-Base Filler Metal 52

NASA Astrophysics Data System (ADS)

Qin, Renyao; Duan, Zhaoling; He, Guo

2013-10-01

The large circumferential multipass dissimilar weld between 20MND5 steel and Z2CND18-12NS stainless steel welded with FM52 filler material was investigated in terms of the diluted composition, the grain boundary precipitation, and the ductility-dip cracking (DDC) susceptibility of the weld. The diluted composition of the weld is composed of 37 to 47 pct Ni, 21 to 24 pct Cr, and 28 to 40 pct Fe, which are inhomogeneous along the depth and over the width of the deep weld. The carbon content has a distribution in the region of the surface weld from a high level (~0.20 pct) in the zone near 20MND5 steel to a normal level (~0.03 pct) in the zone near Z2CND18-12NS stainless steel. The carbon distribution is corresponding to the grain boundary carbides. The minimum threshold strains for DDC occur in the temperature range of 1223 K to 1323 K (950 °C to 1050 °C), which are 0.5, 0.35, and 0.4 pct for the root weld, middle region, and the surface weld, respectively. The dissimilar weld has the largest susceptibility to the DDC compared to the filler metal 52 and the Inconel 690.
Constitutive model of friction stir weld with consideration of its inhomogeneous mechanical properties

NASA Astrophysics Data System (ADS)

Zhang, Ling; Min, Junying; Wang, Bin; Lin, Jianping; Li, Fangfang; Liu, Jing

2016-03-01

In practical engineering, finite element(FE) modeling for weld seam is commonly simplified by neglecting its inhomogeneous mechanical properties. This will cause a significant loss in accuracy of FE forming analysis, in particular, for friction stir welded(FSW) blanks due to the large width and good formability of its weld seam. The inhomogeneous mechanical properties across weld seam need to be well characterized for an accurate FE analysis. Based on a similar AA5182 FSW blank, the metallographic observation and micro-Vickers hardness analysis upon the weld cross-section are performed to identify the interfaces of different sub-zones, i.e., heat affected zone(HAZ), thermal-mechanically affected zone(TMAZ) and weld nugget(WN). Based on the rule of mixture and hardness distribution, a constitutive model is established for each sub-zone to characterize the inhomogeneous mechanical properties across the weld seam. Uniaxial tensile tests of the AA5182 FSW blank are performed with the aid of digital image correlation(DIC) techniques. Experimental local stress-strain curves are obtained for different weld sub-zones. The experimental results show good agreement with those derived from the constitutive models, which demonstrates the feasibility and accuracy of these models. The proposed research gives an accurate characterization of inhomogeneous mechanical properties across the weld seam produced by FSW, which provides solutions for improving the FE simulation accuracy of FSW sheet forming.
Task IV: Groundshock-Induced Hydrogeologic Response: Volume 2. Hydrologic Response of Deep Based Systems to Blast Loading

DTIC Science & Technology

1994-09-01

north-south. Width of the cap rock is approximately 1.5 miles, length about 3 miles and area about 4.4 square miles. According to Thordarson (1965...The volcanic tuffs making up the mesa are of moderately recent (Miocene) to very recent (Pliocene) origin. Thordarson (1965) identifies 11 layered tuff...various degrees of welded or partially welded tuff can be formed during cooling. The tuff units identified by Thordarson (1965) making up Rainier
Characteristics and performance of the variable polarity plasma arc welding process used in the Space Shuttle external tank

NASA Technical Reports Server (NTRS)

Hung, R. J.; Lee, C. C.; Liu, J. W.

1990-01-01

Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. Flow profiles and power distribution of argon plasma gas as a working fluid to produce plasma arc jet in the VPPA welding process was analyzed. Major loss of heat transfer for flow through the nozzle is convective heat transfer; for the plasma jet flow between the outlet of the nozzle and workpiece is radiative heat transfer; and for the flow through the keyhole of the workpiece is convective heat transfer. The majority of the power absorbed by the keyhole of the workpiece is used for melting the solid metal workpiece into a molten metallic puddle. The crown and root widths and the crown and root heights can be predicted. An algorithm for promoting automatic control of flow parameters and the dimensions of the final product of the welding specification to be used for the VPPA Welding System operated at MSFC are provided.
ARC and Melting Efficiency of Plasma ARC Welds

NASA Technical Reports Server (NTRS)

McClure, J. C.; Nunes, A. C.; Evans, D. M.

1999-01-01

A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 Aluminum. Arc efficiency was measured calorimetrically and ranged between 48% and 66% for the conditions of the welds. Arc efficiency depends in different ways on voltage and current. The voltage effect dominates. Raising voltage while reducing current increases arc efficiency. Longer, higher voltage arcs are thought to transfer a greater portion of arc power to the workpiece through shield gas convection. Melting efficiency depends upon weld pool shape as well as arc efficiency. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Increased plasma gas flow does the same thing. Higher currents are thought to raise arc pressure and depress liquid at the bottom of the weld pool. More arc power then transfers to the workpiece through increasing plasma gas convection. If the power is held constant, the reduced voltage lowers the arc efficiency, while the pool shape change increases the melting efficiency,
Time effect of erosion by solid particle impingement on ductile materials

NASA Technical Reports Server (NTRS)

Rao, P. V.; Buckley, D. H.

1983-01-01

Erosion and morphological studies of several metals and alloys eroded by normal impingement jets of spherical glass beads and angular crushed-glass erodent particles were conducted. Erosion morphology (the width, depth, and width-depth ratio of the pit) was studied in order to fully investigate the effect of time on erosion rate. The eroded surfaces were studied with a scanning electron microscope, and surface profiles were measured with a profilometer. A large amount of experimental data reported in the literature was also analyzed in order to understand the effect of variables such as the type of device, the erodent particle size and shape, the impact velocity, and the abrasive charge on erosion-rate-versus-time curves. In the present experiments the pit-width-versus-time or pit-depth-versus-time curves were similar to erosion-versus-time curves for glass-bead impingement. The pit-depth-rate-versus-time curves were similar to erosion-rate-versus-time curves for crushed-glass impingement. Analysis of experimental data with two forms of glass resulted in four types of erosion-rate-versus-time curves: (1) incubation, acceleration, and steady-state periods (type I), (2) incubation, acceleration, deceleration, and steady-state periods (type III), (3) incubation, acceleration, peak rate, and deceleration periods (type IV), and (4) incubation, acceleration, steady-state, and deceleration periods (type V).
The Light Plane Calibration Method of the Laser Welding Vision Monitoring System

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

PubMed Central

Ginter, Carly C.; DeWitt, Thomas J.; Fish, Frank E.; Marshall, Christopher D.

2012-01-01

Vibrissae (whiskers) are important components of the mammalian tactile sensory system, and primarily function as detectors of vibrotactile information from the environment. Pinnipeds possess the largest vibrissae among mammals and their vibrissal hair shafts demonstrate a diversity of shapes. The vibrissae of most phocid seals exhibit a beaded morphology with repeating sequences of crests and troughs along their length. However, there are few detailed analyses of pinniped vibrissal morphology, and these are limited to a few species. Therefore, we comparatively characterized differences in vibrissal hair shaft morphologies among phocid species with a beaded profile, phocid species with a smooth profile, and otariids with a smooth profile using traditional and geometric morphometric methods. Traditional morphometric measurements (peak-to-peak distance, crest width, trough width and total length) were collected using digital photographs. Elliptic Fourier analysis (geometric morphometrics) was used to quantify the outlines of whole vibrissae. The traditional and geometric morphometric datasets were subsequently combined by mathematically scaling each to true rank, followed by a single eigendecomposition. Quadratic discriminant function analysis demonstrated that 79.3, 97.8 and 100% of individuals could be correctly classified to their species based on vibrissal shape variables in the traditional, geometric and combined morphometric analyses, respectively. Phocids with beaded vibrissae, phocids with smooth vibrissae, and otariids each occupied distinct morphospace in the geometric morphometric and combined data analyses. Otariids split into two groups in the geometric morphometric analysis and gray seals appeared intermediate between beaded- and smooth-whiskered species in the traditional and combined analyses. Vibrissal hair shafts modulate the transduction of environmental stimuli to the mechanoreceptors in the follicle-sinus complex (F-SC), which results in vibrotactile reception, but it is currently unclear how the diversity of shapes affects environmental signal modulation. PMID:22509310
Heat sink effects on weld bead: VPPA process

NASA Technical Reports Server (NTRS)

Steranka, Paul O., Jr.

1990-01-01

An investigation into the heat sink effects due to weldment irregularities and fixtures used in the variable polarity plasma arc (VPPA) process was conducted. A basic two-dimensional model was created to represent the net heat sink effect of surplus material using Duhamel's theorem to superpose the effects of an infinite number of line heat sinks of variable strength. Parameters were identified that influence the importance of heat sink effects. A characteristic length, proportional to the thermal diffusivity of the weldment material divided by the weld torch travel rate, correlated with heat sinking observations. Four tests were performed on 2219-T87 aluminum plates to which blocks of excess material were mounted in order to demonstrate heat sink effects. Although the basic model overpredicted these effects, it correctly indicated the trends shown in the experimental study and is judged worth further refinement.
Heat sink effects on weld bead: VPPA process

NASA Technical Reports Server (NTRS)

Steranka, Paul O., Jr.

1989-01-01

An investigation into the heat sink effects due to weldment irregularities and fixtures used in the variable polarity plasma arc (VPPA) process was conducted. A basic two-dimensional model was created to represent the net heat sink effect of surplus material using Duhamel's theorem to superpose the effects of an infinite number of line heat sinks of variable strength. Parameters were identified that influence the importance of heat sink effects. A characteristic length, proportional to the thermal diffusivity of the weldment material divided by the weld torch travel rate, correlated with heat sinking observations. Four tests were performed on 2219-T87 aluminum plates to which blocks of excess material were mounted in order to demonstrate heat sink effects. Although the basic model overpredicted these effects, it correctly indicated the trends shown in the experimental study and is judged worth further refinement.
Effects of weld damage on the dynamics of energy-absorbing lanyards.

PubMed

Katona, David N; Bennett, Charlie R; McKoryk, Michael; Brisson, Andre L; Sparrey, Carolyn J

2017-12-01

Manufacturers recommend removing fall protection system components from service for any indication of weld spatter or tool damage; however, little is known about the specific effects of lanyard damage on fall arrest dynamics. Thirty-two energy-absorbing lanyards were drop tested after being damaged with weld spatter, plasma torches and cutting tools and compared with new, undamaged lanyards. Two lanyards damaged with a plasma torch failed completely without deploying the energy absorber while weld spatter damage and tool cuts, up to two-thirds through the width of the webbing, had no effect on fall arrest dynamics. The results highlight the catastrophic implications of high-temperature damage to lanyard webbing resulting from plasma torches - which require immediate removal from service. In addition, the integrated energy absorber design in bungee-style lanyards makes them more susceptible to damage anywhere along the length. We therefore recommended against bungee lanyards for ironworkers and welders.
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
A fundamental study on the structural integrity of magnesium alloys joined by friction stir welding

NASA Astrophysics Data System (ADS)

Rao, Harish Mangebettu

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

NASA Astrophysics Data System (ADS)

Liu, L. M.; Zhang, Z. D.; Song, G.; Wang, L.

2007-03-01

Five single oxide fluxes—MgO, CaO, TiO2, MnO2, and Cr2O3—were used to investigate the effect of active flux on the depth/width ratio in AZ31B magnesium alloy. The microstructure and mechanical property of the tungsten inert gas (TIG) welding seam were studied. The oxygen content in the weld seam and the arc images during the TIG welding process were analyzed. A series of emission spectroscopy of weld arc for TIG welding for magnesium with and without flux were developed. The results showed that for the five single oxide fluxes, all can increase the weld penetration effectively and grain size in the weld seam of alternating current tungsten inert gas (ACTIG) welding of the Mg alloy. The oxygen content of the welds made without flux is not very different from those produced with oxide fluxes not considering trapped oxide. However, welds that have the best penetration have a relatively higher oxygen content among those produced with flux. It was found that the arc images with the oxide fluxes were only the enlarged form of the arc images without flux; the arc constriction was not observed. The detection of arc spectroscopy showed that the metal elements in the oxides exist as the neutral atom or the first cation in the weld arc. This finding would influence the arc properties. When TIG simulation was carried out on a plate with flux applied only on one side, the arc image video showed an asymmetric arc, which deviated toward the flux free side. The thermal stability, the dissociation energy, and the electrical conductivity of oxide should be considered when studying the mechanism for increased TIG flux weld penetration.
Study of the welding gas influence on a controlled short-arc GMAW process by optical emission spectroscopy

NASA Astrophysics Data System (ADS)

Wilhelm, G.; Gött, G.; Schöpp, H.; Uhrlandt, D.

2010-11-01

The controlled short-arc processes, variants of the gas metal arc welding (GMAW) process, which have recently been developed, are used to reduce the heat input into the workpiece. Such a process with a wire feeding speed which varies periodically, using a steel wire and a steel workpiece to produce bead-on-plate welds has been investigated. As welding gases CO2 and a mixture of Ar and O2 have been used. Depending on the gas, the properties of the plasma change, and as a consequence the weldseams themselves also differ distinctly. Optical emission spectroscopy has been applied to analyse the plasma. The radial profiles of the emission coefficients of an iron line and an argon line or an atomic oxygen line, respectively, have been determined. These profiles indicate the establishment of a metal vapour arc core which has a broader profile under CO2 but is more focused in the centre for argon. The measured iron line emission was near to its norm maximum in the case of CO2. From this fact, temperatures around 8000 K and a metal vapour molar fraction above 75% in the arc centre could be roughly estimated for this case. Estimations of the electrical conductivity and the arc field indicate that the current path must include not only the metal vapour arc core but also outer hot regions dominated by welding gas properties in the case of argon.
Origins of Line Defects in Self-Reacting Friction Stir Welds and Their Impact on Weld Quality

NASA Technical Reports Server (NTRS)

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

2016-01-01

Friction stir welding (FSWing) is a solid state joining technique which reduces the occurrence of typical defects formed in fusion welds, especially of highly alloyed metals. Although the process is robust for aluminum alloys, occasional reductions in the strength of FSWs have been observed. Shortly after the NASA-MSFC implemented a variation of FSW called self-reacting (SR), low strength properties were observed. At that time, this reduction in strength was attributed to a line defect. At that time, the limited data suggested that the line defect was related to the accumulation of native oxides that form on the weld lands and faying surfaces. Through a series of improved cleaning methods, tool redesign, and process parameter modifications, the reduction in the strength of the SR-FSWs was eliminated. As more data has been collected, the occasional reduction in the strength of SR-FSW still occurs. These occasional reductions indicate a need to reexamine the underlying causes. This study builds off a series of self reacting (SR)-FSWs that were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. A bead on plate SR-FSW was also made in the 1.56 cm thick panel to understand the contribution of the former faying surfaces. Copper tracer studies were used to understand the flow lines associated with the weld tool used. The quality of the SR-FSWs was evaluated from tensile testing at room temperature. Reductions in the tensile strength were observed in some weldments, primarily at higher weld pitch or tool rotations. This study explores possible correlations between line defects and the reduction of strength in SR-FSWs. Results from this study will assist in a better understand of the mechanisms responsible for reduced tensile strength and provide methodology for minimizing their occurrence.
Design, fabrication and test of a pneumatically controlled, renewable, microfluidic bead trapping device for sequential injection analysis applications

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

Shao, Guocheng; Lu, Donglai; Fu, Zhifeng

This paper describes the design, fabrication, and testing of a pneumatically controlled,renewable, microfluidic device for conducting bead-based assays in an automated sequential injection analysis system. The device used a “brick wall”-like pillar array (pillar size: 20 μm length X 50 μm width X 45 μm height) with 5 μm gaps between the pillars serving as the micro filter. The flow channel where bead trapping occurred is 500 μm wide X 75 μm deep. An elastomeric membrane and an air chamber were located underneath the flow channel. By applying pressure to the air chamber, the membrane is deformed and pushed upwardmore » against the filter structure. This effectively traps beads larger than 5 μm and creates a “bed” or micro column of beads that can be perfused and washed with liquid samples and reagents. Upon completion of the assay process, the pressure is released and the beads are flushed out from underneath the filter structure to renew the device. Mouse IgG was used as a model analyte to test the feasibility of using the proposed device for immunoassay applications. Resulting microbeads from an on-chip fluorescent immunoassay were individually examined using flow cytometry. The results show that the fluorescence signal intensity distribution is fairly narrow indicating high chemical reaction uniformity among the beads population. Electrochemical onchip assay was also conducted. A detection limit of 0.1 ng/mL1 ppb was achieved and good device reliability and repeatability were demonstrated. The novel microfluidic-based beadstrapping device thus opens up a new pathway to design micro-bead based biosensor immunoassays for clinical and othervarious applications.« less
An efficient biosensor made of an electromagnetic trap and a magneto-resistive sensor.

PubMed

Li, Fuquan; Kosel, Jürgen

2014-09-15

Magneto-resistive biosensors have been found to be useful because of their high sensitivity, low cost, small size, and direct electrical output. They use super-paramagnetic beads to label a biological target and detect it via sensing the stray field. In this paper, we report a new setup for magnetic biosensors, replacing the conventional "sandwich" concept with an electromagnetic trap. We demonstrate the capability of the biosensor in the detection of E. coli. The trap is formed by a current-carrying microwire that attracts the magnetic beads into a sensing space on top of a tunnel magneto-resistive sensor. The sensor signal depends on the number of beads in the sensing space, which depends on the size of the beads. This enables the detection of biological targets, because such targets increase the volume of the beads. Experiments were carried out with a 6 µm wide microwire, which attracted the magnetic beads from a distance of 60 μm, when a current of 30 mA was applied. A sensing space of 30 µm in length and 6 µm in width was defined by the magnetic sensor. The results showed that individual E. coli bacterium inside the sensing space could be detected using super-paramagnetic beads that are 2.8 µm in diameter. The electromagnetic trap setup greatly simplifies the device and reduces the detection process to two steps: (i) mixing the bacteria with magnetic beads and (ii) applying the sample solution to the sensor for measurement, which can be accomplished within about 30 min with a sample volume in the µl range. This setup also ensures that the biosensor can be cleaned easily and re-used immediately. The presented setup is readily integrated on chips via standard microfabrication techniques. Copyright © 2014 Elsevier B.V. All rights reserved.
Laser-Assisted Stir Welding of 25-mm-Thick HSLA-65 Plate

NASA Astrophysics Data System (ADS)

Williamson, Keith M.

2002-12-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

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

Fuerschbach, P.W.; Hinkley, D.A.

1997-03-01

The effects of Nd:YAG laser beam welding process parameters on the resulting heat input in 304L stainless steel cardiac pacemaker batteries have been studied. By careful selection of process parameters, the results can be used to reduce temperatures near glass-to-metal seals and assure hermeticity in laser beam welding of high reliability components. Three designed response surface experiments were used to compare welding performance with lenses of varying focal lengths. The measured peak temperatures at the glass-to-metal seals varied from 65 to 140 C (149 to 284 F) and depended strongly on the levels of the experimental factors. It was foundmore » that welds of equivalent size can be made with significantly reduced temperatures. The reduction in battery temperatures has been attributed to an increase in the melting efficiency. This increase is thought to be due primarily to increased travel speeds, which were facilitated by high peak powers and low pulse energies. For longer focal length lenses, weld fusion zone widths were found to be greater even without a corresponding increase in the size of the weld. It was also found that increases in laser beam irradiance either by higher peak powers or smaller spot sizes created deeper and larger welds. These gains were attributed to an increase in the laser energy transfer efficiency.« less
Complete Status Report Documenting Weld Development for Thin Wall Tubing of ODS Ferritic Alloys

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

Hoelzer, David T.; Edmondson, Philip D.; Gussev, Maxim N.

Beginning in 2015, research in the FCRD program began the development of FSW for joining thin sections of 14YWT in the form of thin (0.5 mm) plate and ultimately thin wall tubing. In the previous fiscal year, a ~1 mm thick plate, or sheet, of 14YWT was produced by hot rolling with no edge cracking. The initial FSW experiment was performed on the 1 mm thick plate and involved a bead-on-plate weld in which the spinning pin tool is plunged into the plate surface, but does not penetrate the thickness of the plate, and then travels the length of themore » plate. The FSW run successfully produced a bead-on-plate stir zone on the 1 mm thick plate of 14YWT, but no characterization studies of the stir zone were performed by the end of FY15. Therefore, the results presented in this report cover the microstructural analysis of the bead-on-plate stir zone and the initial research task on obtaining tensile properties of the stir zone using the digital image correlation (DIC) approach during testing of miniature tensile specimens to assess the quality of the FSW parameters used in the initial experiment. The results of the microstructural characterization study using optical, scanning electron and scanning transmission electron microscopies showed the grain structure in the SZ to have isotropic and irregular shape but very similar size compared to the highly elongated grains oriented horizontally with the plane of the plate that were observed in the unaffected zone of 14YWT. Several cracks oriented horizontally were observed mostly on the retreating side of the SZ in both the SZ and TMAZ. These cracks may have formed due to insufficient pressure being exerted on the top surface of the plate by the shoulder and pin tool during the FSW run. High resolution STEM-EDS analysis showed the presence of the Y-Ti-O particles in the SZ, but that some particles exhibited coarsening. Overall, the FSW parameters used to produce the bead-on-plate SZ in the 0.1 cm thick plate of 14YWT were nearly optimized. The results of the digital image correlation (DIC) analysis of the two SS-Mini-2 tensile specimens fabricated from the 0.1 cm thick plate of 14YWT showed that the specimens exhibited high strength and good ductility. However, strain localization occurred in one of the specimens during the tensile test that was too close to the grips, which invalidated the data from the DIC analysis. This was surprising since the abrupt crack pop-in that occurred in the 0.1 cm thick plate of 14YWT during fabrication by wire EDM suggested that residual stresses were high. Residual stress measurements and the effects of post weld heat treatment on the FSW quality of joined 14YWT plates will be investigated in the next FW work package.« less
Tensile Properties and Microstructure of Inconel 718 Fabricated with Electron Beam Freeform Fabrication (EBF(sup 3))

NASA Technical Reports Server (NTRS)

Bird, R. Keith; Hibberd, Joshua

2009-01-01

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate two Inconel 718 single-bead-width wall builds and one multiple-bead-width block build. Specimens were machined to evaluate microstructure and room temperature tensile properties. The tensile strength and yield strength of the as-deposited material from the wall and block builds were greater than those for conventional Inconel 718 castings but were less than those for conventional cold-rolled sheet. Ductility levels for the EBF3 material were similar to those for conventionally-processed sheet and castings. An unexpected result was that the modulus of the EBF3-deposited Inconel 718 was significantly lower than that of the conventional material. This low modulus may be associated with a preferred crystallographic orientation resultant from the deposition and rapid solidification process. A heat treatment with a high solution treatment temperature resulted in a recrystallized microstructure and an increased modulus. However, the modulus was not increased to the level that is expected for Inconel 718.
Thermographic Assessment of the HAZ Properties and Structure of Thermomechanically Treated Steel

NASA Astrophysics Data System (ADS)

Górka, Jacek; Janicki, Damian; Fidali, Marek; Jamrozik, Wojciech

2017-12-01

Thermomechanically processed steels are materials of great mechanical properties connected with more than good weldability. This mixture makes them interesting for different types of industrial applications. When creating welded joints, a specified amount of heat is introduced into the welding area and a so called heat-affected zone (HAZ) is formed. The key issue is to reduce the width of the HAZ, because properties of the material in the HAZ are worse than in the base material. In the paper, thermographic measurements of HAZ temperatures were presented as a potential tool for quality assuring the welding process in terms of monitoring and control. The main issue solved was the precise temperature measurement in terms of varying emissivity during a welding thermal cycle. A model of emissivity changes was elaborated and successfully applied. Additionally, material in the HAZ was tested to reveal its properties and connect changes of those properties with heating parameters. The obtained results prove that correctly modeled emissivity allows measurement of temperature, which is a valuable tool for welding process monitoring.
Empirical modeling for intelligent, real-time manufacture control

NASA Technical Reports Server (NTRS)

Xu, Xiaoshu

1994-01-01

Artificial neural systems (ANS), also known as neural networks, are an attempt to develop computer systems that emulate the neural reasoning behavior of biological neural systems (e.g. the human brain). As such, they are loosely based on biological neural networks. The ANS consists of a series of nodes (neurons) and weighted connections (axons) that, when presented with a specific input pattern, can associate specific output patterns. It is essentially a highly complex, nonlinear, mathematical relationship or transform. These constructs have two significant properties that have proven useful to the authors in signal processing and process modeling: noise tolerance and complex pattern recognition. Specifically, the authors have developed a new network learning algorithm that has resulted in the successful application of ANS's to high speed signal processing and to developing models of highly complex processes. Two of the applications, the Weld Bead Geometry Control System and the Welding Penetration Monitoring System, are discussed in the body of this paper.
Adhesion at Entangled Polymer Interfaces: A Unified Approach..

NASA Astrophysics Data System (ADS)

Wool, Richard

2006-03-01

A unified theory of fracture of polymer interfaces was developed which was based on the Rigidity Percolation model of fracture [R.P. Wool, J.Polym.Sci. Part A: Polym Phys., 43,168(2005)]. The polymer fractured critically when the normalized entanglement density p, approached the percolation threshold pc. The fracture energy was found to be G1c ˜ [p-pc]. When applied to interfaces of width X, containing an areal density σ of chains, each contributing L chain entanglements, the percolation term p ˜ σL/X and the percolation threshold was related to σc, Lc, or Xc. For welding of A/A symmetric interfaces, p = σL/X, and pc Lc/M 0, such that when σ/X ˜1/M for randomly distributed chain ends, p˜L ˜ (t/M)^1/2, G/G* = (t/τ*)^1/2, where the weld time τ* ˜ M. When the chain ends are segregated to the surface, σ is constant with time and G/G* = [t/τ*]^1/4. For sub-Tg welding, there exists a surface mobile layer (due to the critical Lindemann Atom fraction) of depth X ˜ 1/δT^ν such that G ˜ δT-2ν, where the critical exponent v = 0.8. For incompatible A/B interfaces of Helfand width d, normalized width w = d/Rge, and entanglement density Nent ˜ d/Le, p ˜ d such that, G1c ˜ [d-dc], G1c ˜ [w-1], and G ˜ [Nent-Nc]. For incompatible A/B interfaces reinforced by an areal density σ of compatibilizer chains, L and X are constant, p ˜ σ, pc ˜σc, such that G1c ˜ [σ-σc], which is in excellent agreement with experimental data.
Investigation of galvanic corrosion in laser-welded stainless steel sheets

NASA Astrophysics Data System (ADS)

Kwok, Chi-Tat; Fong, Siu Lung; Cheng, Fai Tsun; Man, Hau-Chung

2004-10-01

In the present study, bead-on-plate specimens of 1-mm sheets of austenitic and duplex stainless steels were fabricated by laser penetration welding with a 2.5-kW CW Nd:YAG laser. The galvanic corrosion behavior of laser-weldment (LW) against as-received (AR) specimens with an area rato of 1:1 in 3.5% NaCL solution was studied by means of a zero-resistance ammeter. The free corrosion potentials of as-received specimens were found to be considerably higher than those of laser weldments, indicating that the weldments are more active and always act as anodes. The ranking of galvanic current densities (IG) of the couples in ascending order is: AR S31603-LW S31603 < AR S31803-LW S31803 < AR S32760-LW S32760 < AR S30400-LW S30400. For the galvanic couple between AR S30400 and LW S30400, the IG is the highest (78.6 nA/cm2) because large amount of δ-ferrite in the weld zone acts as active sites. On the other hand, the IG of the galvanic couple between AR S31603 and LW S31603 is the lowest (-26 nA/cm2) because no δ-ferrite is present after laser welding. The recorded IG of all couples revealed constantly low values (in the rnage of nA/cm2) and sometimes stayed negative, which indicated polarity reversal.
High-power industrial pulsed CO2 laser

NASA Astrophysics Data System (ADS)

Levin, G. I.

1983-12-01

The use of a pulsed TEA CO2 laser (with maximum average power 1.0 kW; maximum pulse energy 3.5 J; repetition frequency 400-600 Hz; half-width pulse duration 15 microsec; circular-coupling-aperture beam diameter 6, 8, or 12 mm; and beam divergence 10 mrad) in industrial welding applications is investigated experimentally in carbon and stainless steels, Zr, Ti, and Ni of various thicknesses. The power required to melt the metals is found to be about 120-200 W/sq cm, or 5-6 times less than that for CW lasers. It is shown that deep narrow-seam welds with mechanical properties identical to those of the bulk metal can be obtained with little or no intercrystalline corrosion or thermal distortion of the surrounding area. Disadvantages such as the 65-dB noise level, low welding speed, formation of an overlap at the top and a crater at the bottom of the weld, and root porosity are considered the primary limitations on the applicability of the device tested.
A Simplified Model for the Effect of Weld-Induced Residual Stresses on the Axial Ultimate Strength of Stiffened Plates

NASA Astrophysics Data System (ADS)

Chen, Bai-Qiao; Guedes Soares, C.

2018-03-01

The present work investigates the compressive axial ultimate strength of fillet-welded steel-plated ship structures subjected to uniaxial compression, in which the residual stresses in the welded plates are calculated by a thermo-elasto-plastic finite element analysis that is used to fit an idealized model of residual stress distribution. The numerical results of ultimate strength based on the simplified model of residual stress show good agreement with those of various methods including the International Association of Classification Societies (IACS) Common Structural Rules (CSR), leading to the conclusion that the simplified model can be effectively used to represent the distribution of residual stresses in steel-plated structures in a wide range of engineering applications. It is concluded that the widths of the tension zones in the welded plates have a quasi-linear behavior with respect to the plate slenderness. The effect of residual stress on the axial strength of the stiffened plate is analyzed and discussed.
Laser transmission welding of polylactide to aluminium thin films for applications in the food-packaging industry

NASA Astrophysics Data System (ADS)

Pagano, Nunziante; Campana, Giampaolo; Fiorini, Maurizio; Morelli, Raffaele

2017-06-01

Laser transmission welding is a suitable technology to join thin films of similar or dissimilar materials without any addition of chemical solvents or adhesives. This process represents a very important opportunity in the case of packaging applications (for example in food and pharmaceutical sectors) where the realisation of strong welds by avoiding the contact between the thermal source and the processed materials and, furthermore, without using any third material that could contaminate the contents, is reliable and relevant. The aim of this paper is to prove the feasibility of the laser transmission welding of polylactide to aluminium thin films by means of laser transmission welding through the use of a low power pulsed wave fibre laser. Laser joint samples were realised, analysed by optical microscopy to reveal possible defects and to evaluate the weld width and tested to measure the mechanical tensile strength. An accurate relationship between the joint quality and both the welding speed and the k-factor, which represents the delivered energy per unit length and affects the bonding mechanism at the interface, was determined. The achieved feasibility area is extremely narrow and possible only for the higher value of the average power. The joint tensile strength was proven to be in a proportional relationship with the effective bonded area and reached satisfactory values.
Role of Oxygen as Surface-Active Element in Linear GTA Welding Process

NASA Astrophysics Data System (ADS)

Yadaiah, Nirsanametla; Bag, Swarup

2013-11-01

Although the surface-active elements such as oxygen and sulfur have an adverse effect on momentum transport in liquid metals during fusion welding, such elements can be used beneficially up to a certain limit to increase the weld penetration in the gas tungsten arc (GTA) welding process. The fluid flow pattern and consequently the weld penetration and width change due to a change in coefficient of surface tension from a negative value to a positive value. The present work is focused on the analysis of possible effects of surface-active elements to change the weld pool dimensions in linear GTA welding. A 3D finite element-based heat transfer and fluid flow model is developed to study the effect of surface-active elements on stainless steel plates. A velocity in the order of 180 mm/s due to surface tension force is estimated at an optimum concentration of surface-active elements. Further, the differential evolution-based global optimization algorithm is integrated with the numerical model to estimate uncertain model parameters such as arc efficiency, effective arc radius, and effective values of material properties at high temperatures. The effective values of thermal conductivity and viscosity are estimated to be enhanced nine and seven times, respectively, over corresponding room temperature values. An error analysis is also performed to find out the overall reliability of the computed results, and a maximum reliability of 0.94 is achieved.
Features of Wear-Resistant Cast Iron Coating Formation During Plasma-Powder Surfacing

NASA Astrophysics Data System (ADS)

Vdovin, K. N.; Emelyushin, A. N.; Nefed'ev, S. P.

2017-09-01

The structure of coatings deposited on steel 45 by plasma-powder surfacing of white wear-resistant cast iron is studied. The effects of surfacing regime and additional production effects on the welding bath during surfacing produced by current modulation, accelerated cooling of the deposited beads by blowing with air, and accelerated cooling of the substrate with running water on the structure, are determined. A new composition is suggested for powder material for depositing wear-resistant and corrosion-resistant coatings on a carbon steel by the plasma-powder process.
A Vision-Aided 3D Path Teaching Method before Narrow Butt Joint Welding

PubMed Central

Zeng, Jinle; Chang, Baohua; Du, Dong; Peng, Guodong; Chang, Shuhe; Hong, Yuxiang; Wang, Li; Shan, Jiguo

2017-01-01

For better welding quality, accurate path teaching for actuators must be achieved before welding. Due to machining errors, assembly errors, deformations, etc., the actual groove position may be different from the predetermined path. Therefore, it is significant to recognize the actual groove position using machine vision methods and perform an accurate path teaching process. However, during the teaching process of a narrow butt joint, the existing machine vision methods may fail because of poor adaptability, low resolution, and lack of 3D information. This paper proposes a 3D path teaching method for narrow butt joint welding. This method obtains two kinds of visual information nearly at the same time, namely 2D pixel coordinates of the groove in uniform lighting condition and 3D point cloud data of the workpiece surface in cross-line laser lighting condition. The 3D position and pose between the welding torch and groove can be calculated after information fusion. The image resolution can reach 12.5 μm. Experiments are carried out at an actuator speed of 2300 mm/min and groove width of less than 0.1 mm. The results show that this method is suitable for groove recognition before narrow butt joint welding and can be applied in path teaching fields of 3D complex components. PMID:28492481
Out of the SHADOW: watch parts in the spotlight -- laser beam microwelding of delicate watch components

NASA Astrophysics Data System (ADS)

Kramer, Thorsten; Olowinsky, Alexander M.

2003-07-01

Conventional joining techniques like press fitting or crimping require the application of mechanical forces to the parts which, in combination with the tolerances of both parts to be joined, lead to imprecision and poor tensile strength. In contrast, laser beam micro welding provides consistent joining and high flexibility and it acts as an alternative as long as press fitting, crimping, screwing or gluing are not capable of batch production. Different parts and even different metals can be joined in a non-contact process at feed rates of up to 60 m/min and with weld seam lengths from 0.6 mm to 15.7 mm. Due to the low energy input, typically 1 J to 6 J, a weld width as small as 50 μm and a weld depth as small as 20 μm have been attained. This results in low distortion of the joined watch components. Since the first applications of laser beam micro welding of watch components showed promising results, the process has further been enhanced using the SHADOW technique. Aspects of the technique such as tensile strength, geometry and precision of the weld seam as well as the acceptance amongst the -mostly conservative- watch manufacturers have been improved.
A Vision-Aided 3D Path Teaching Method before Narrow Butt Joint Welding.

PubMed

Zeng, Jinle; Chang, Baohua; Du, Dong; Peng, Guodong; Chang, Shuhe; Hong, Yuxiang; Wang, Li; Shan, Jiguo

2017-05-11

For better welding quality, accurate path teaching for actuators must be achieved before welding. Due to machining errors, assembly errors, deformations, etc., the actual groove position may be different from the predetermined path. Therefore, it is significant to recognize the actual groove position using machine vision methods and perform an accurate path teaching process. However, during the teaching process of a narrow butt joint, the existing machine vision methods may fail because of poor adaptability, low resolution, and lack of 3D information. This paper proposes a 3D path teaching method for narrow butt joint welding. This method obtains two kinds of visual information nearly at the same time, namely 2D pixel coordinates of the groove in uniform lighting condition and 3D point cloud data of the workpiece surface in cross-line laser lighting condition. The 3D position and pose between the welding torch and groove can be calculated after information fusion. The image resolution can reach 12.5 μm. Experiments are carried out at an actuator speed of 2300 mm/min and groove width of less than 0.1 mm. The results show that this method is suitable for groove recognition before narrow butt joint welding and can be applied in path teaching fields of 3D complex components.
Optical design and development of a fiber coupled high-power diode laser system for laser transmission welding of plastics

NASA Astrophysics Data System (ADS)

Rodríguez-Vidal, Eva; Quintana, Iban; Etxarri, Jon; Azkorbebeitia, Urko; Otaduy, Deitze; González, Francisco; Moreno, Fernando

2012-12-01

Laser transmission welding (LTW) of thermoplastics is a direct bonding technique already used in different industrial applications sectors such as automobiles, microfluidics, electronics, and biomedicine. LTW evolves localized heating at the interface of two pieces of plastic to be joined. One of the plastic pieces needs to be optically transparent to the laser radiation whereas the other part has to be absorbent, being that the radiation produced by high power diode lasers is a good alternative for this process. As consequence, a tailored laser system has been designed and developed to obtain high quality weld seams with weld widths between 0.7 and 1.4 mm. The developed laser system consists of two diode laser bars (50 W per bar) coupled into an optical fiber using a nonimaging solution: equalization of the beam parameter product (BPP) in the slow and fast axes by a pair of step-mirrors. The power scaling was carried out by means of a multiplexing polarization technique. The analysis of energy balance and beam quality was performed considering ray tracing simulation (ZEMAX) and experimental validation. The welding experiments were conducted on acrylonitrile/butadiene/styrene (ABS), a thermoplastic frequently used in automotive, electronics and aircraft applications, doped with two different concentrations of carbon nanotubes (0.01% and 0.05% CNTs). Quality of the weld seams on ABS was analyzed in terms of the process parameters (welding speed, laser power and clamping pressure) by visual and optical microscope inspections. Mechanical properties of weld seams were analyzed by mechanical shear tests. High quality weld seams were produced in ABS, revealing the potential of the laser developed in this work for a wide range of plastic welding applications.
Residual stress determination in an overlay dissimilar welded pipe by neutron diffraction

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

Woo, Wan Chuck; Em, Vyacheslav; Hubbard, Camden R

2011-01-01

Residual stresses were determined through the thickness of a dissimilar weld overlay pipe using neutron diffraction. The specimen has a complex joining structure consisting of a ferritic steel (SA508), austenitic steel (F316L), Ni-based consumable (Alloy 182), and overlay of Ni-base superalloy (Alloy 52M). It simulates pressurized nozzle components, which have been a critical issue under the severe crack condition of nuclear power reactors. Two neutron diffractometers with different spatial resolutions have been utilized on the identical specimen for comparison. The macroscopic 'stress-free' lattice spacing (d{sub o}) was also obtained from both using a 2-mm width comb-like coupon. The results showmore » significant changes in residual stresses from tension (300-400 MPa) to compression (-600 MPa) through the thickness of the dissimilar weld overlay pipe specimen.« less
Characterization of coarse bainite transformation in low carbon steel during simulated welding thermal cycles

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

Lan, Liangyun, E-mail: lanly@me.neu.edu.cn; State Key Laboratory of Rolling Technology and Automation, Northeastern University, Shenyang 110819; Kong, Xiangwei

2015-07-15

Coarse austenite to bainite transformation in low carbon steel under simulated welding thermal cycles was morphologically and crystallographically characterized by means of optical microscope, transmission electron microscope and electron backscattered diffraction technology. The results showed that the main microstructure changes from a mixture of lath martensite and bainitic ferrite to granular bainite with the increase in cooling time. The width of bainitic laths also increases gradually with the cooling time. For a welding thermal cycle with relatively short cooling time (e.g. t{sub 8/5} is 30 s), the main mode of variant grouping at the scale of individual prior austenite grainsmore » changes from Bain grouping to close-packed plane grouping with the progress of phase transformation, which results in inhomogeneous distribution of high angle boundaries. As the cooling time is increased, the Bain grouping of variants becomes predominant mode, which enlarges the effective grain size of product phase. - Highlights: • Main microstructure changes and the width of lath structure increases with cooling time. • Variant grouping changes from Bain zone to close-packed plane grouping with the transformation. • The change of variant grouping results in uneven distribution of high angle grain boundary. • Bain grouping is main mode for large heat input, which lowers the density of high angle boundary.« less
Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

NASA Astrophysics Data System (ADS)

Stavinoha, Joe N.

The process of producing near net-shape components by material deposition is known as additive manufacturing. All additive manufacturing processes are based on the addition of material with the main driving forces being cost reduction and flexibility in both manufacturing and product design. With wire metal deposition, metal is deposited as beads side-by-side and layer-by-layer in a desired pattern to build a complete component or add features on a part. There are minimal waste products, low consumables, and an efficient use of energy and feedstock associated with additive manufacturing processes. Titanium and titanium alloys are useful engineering materials that possess an extraordinary combination of properties. Some of the properties that make titanium advantageous for structural applications are its high strength-to-weight ratio, low density, low coefficient of thermal expansion, and good corrosion resistance. The most commonly used titanium alloy, Ti-6Al-4V, is typically used in aerospace applications, pressure vessels, aircraft gas turbine disks, cases and compressor blades, and surgical implants. Because of the high material prices associated with titanium alloys, the production of near net-shape components by additive manufacturing is an attractive option for the manufacturing of Ti-6Al-4V alloy components. In this thesis, the manufacturing of cylindrical Ti-6Al-4V alloy specimens by wire metal deposition utilizing the plasma arc welding process was demonstrated. Plasma arc welding is a cost effective additive manufacturing technique when compared to other current additive manufacturing methods such as laser beam welding and electron beam welding. Plasma arc welding is considered a high-energy-density welding processes which is desirable for the successful welding of titanium. Metal deposition was performed using a constant current plasma arc welding power supply, flow-purged welding chamber, argon shielding and orifice gas, ERTi-5 filler metal, and Ti-6Al-4V alloy substrates. Cylindrical weld metal deposits were built by employing an automatic wire feeder, turntable positioner, and vertical torch positioner. A total of four cylindrical weld metal specimens were built with various combinations of essential plasma arc welding process parameters. The temperature of the weld metal deposit was taken with a thermocouple after allowing a specified amount of time to pass before depositing the next weld track. An analytical heat flow model was created that estimated the temperature of the weld metal deposit in relation to the number of tracks deposited. The analytical heat flow model was adjusted to match the experimental data that was obtained and revealed that the rate of production could be increased if the rate of thermal energy losses from the deposit were increased. Cross-sections of the weld metal deposits were examined to observe the effects of thermal energy input on the weld metal macrostructure, microstructure, and grain size. Results from the metallographic inspections revealed an increase in grain size and coarsening of the structure as the number of weld tracks in the deposit increased.

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

NASA Technical Reports Server (NTRS)

Rietz, Ward W., Jr.

2008-01-01

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

PubMed

McNeilly, Jane D; Heal, Mathew R; Beverland, Iain J; Howe, Alan; Gibson, Mark D; Hibbs, Leon R; MacNee, William; Donaldson, Ken

2004-04-01

Epidemiological studies have consistently reported a higher incidence of respiratory illnesses such as bronchitis, metal fume fever (MFF), and chronic pneumonitis among welders exposed to high concentrations of metal-enriched welding fumes. Here, we studied the molecular toxicology of three different metal-rich welding fumes: NIMROD 182, NIMROD c276, and COBSTEL 6. Fume toxicity in vitro was determined by exposing human type II alveolar epithelial cell line (A549) to whole welding fume, a soluble extract of fume or the "washed" particulate. All whole fumes were significantly toxic to A549 cells at doses >63 microg ml(-1) (TD 50; 42, 25, and 12 microg ml(-1), respectively). NIMROD c276 and COBSTEL 6 fumes increased levels of IL-8 mRNA and protein at 6 h and protein at 24 h, as did the soluble fraction alone, whereas metal chelation of the soluble fraction using chelex beads attenuated the effect. The soluble fraction of all three fumes caused a rapid depletion in intracellular glutathione following 2-h exposure with a rebound increase by 24 h. In addition, both nickel based fumes, NIMROD 182 and NIMROD c276, induced significant reactive oxygen species (ROS) production in A549 cells after 2 h as determined by DCFH fluorescence. ICP analysis confirmed that transition metal concentrations were similar in the whole and soluble fractions of each fume (dominated by Cr), but significantly less in both the washed particles and chelated fractions. These results support the hypothesis that the enhanced pro-inflammatory responses of welding fume particulates are mediated by soluble transition metal components via an oxidative stress mechanism.
Contribution a l'etude du comportement en fatigue des aciers inoxydables 13%Cr-4%Ni: Contraintes residuelles de soudage et transformation sous contrainte de l'austenite de reversion

NASA Astrophysics Data System (ADS)

Thibault, Denis

The objectives of the present study are to characterize some of the main parameters affecting fatigue behaviour of 13%Cr-4%Ni martensitic stainless steels used for hydraulic turbines manufacturing. Two aspects are studied: the residual stresses left after autogenous welding of these steels and the stress-assisted transformation of the reformed austenite contained in this alloy. The residual stresses induced by welding were characterized by four different methods: the hole-drilling method, X-ray diffraction, neutron diffraction and the contour method. The state of stress was characterized in two different joints geometries, both using 41ONiMo weld filler metal. The characterization was made before and after post-weld heat treatment. A stress distribution completely different of the stress distribution commonly found in structural steels was measured. Triaxial compression was found in the last bead with a maximum value of approximately 400 MPa. Tensile stress was measured around the heat-affected zone and just below the last weld layer. The low temperature martensitic transformation occuring during weld cooling (˜300°C) explains this unusual stress distribution. The results also showed that the post-weld heat treatment commonly used in the industry is efficient in lowering residual stresses. A maximum stress of about 150 MPa was found after heat treament. The austenite formed during this post-weld heat treatment is mechanically unstable. The results presented in this thesis show that after fatigue crack propagation testing, all the reformed austenite found near the fracture surface has transformed to martensite under cyclic stress loading. These measurements made by X-ray diffraction are confirmed by low-cycle fatigue tests showing that the reformed austenite found in this alloy transforms gradually to martensite during strain cycling. The transformation is completed after 100 cycles. The fatigue crack growth behaviour of the tested alloys does not seem to be influenced by this phenomenon occuring at all values of stress intensity factor. The practical implications of this work on fabrication and repair of hydraulic turbines made of 13%Cr-4%Ni are also discussed in this thesis. Keywords: martensitic stainless steel, fatigue, residual stress, welding
Fracture mechanics approach to estimate fatigue lives of welded lap-shear specimens

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

Lam, Poh -Sang; Pan, Jwo

A full range of stress intensity factor solutions for a kinked crack with finite length is developed as a function of weld width and the sheet thickness. When used with the main crack solutions (global stress intensity factors) in terms of the applied load and the specimen geometric parameters, the fatigue lived of the kinked crack can be estimated for the laser-welded lap-shear specimens. The predicted curve for the load range-fatigue life passes through the cluster of experimental data and is in good agreement. A classical solution associated with an infinitesimal kink is also employed. Furthermore, its life prediction tendsmore » to overestimate the actual fatigue life. In addition, the traditional fatigue life estimation based on structural stress is performed for completeness. As a result, this non-fracture mechanics approach only agrees well with the experimental data under high cyclic load conditions.« less
Fracture mechanics approach to estimate fatigue lives of welded lap-shear specimens

DOE PAGES

Lam, Poh -Sang; Pan, Jwo

2015-06-29

A full range of stress intensity factor solutions for a kinked crack with finite length is developed as a function of weld width and the sheet thickness. When used with the main crack solutions (global stress intensity factors) in terms of the applied load and the specimen geometric parameters, the fatigue lived of the kinked crack can be estimated for the laser-welded lap-shear specimens. The predicted curve for the load range-fatigue life passes through the cluster of experimental data and is in good agreement. A classical solution associated with an infinitesimal kink is also employed. Furthermore, its life prediction tendsmore » to overestimate the actual fatigue life. In addition, the traditional fatigue life estimation based on structural stress is performed for completeness. As a result, this non-fracture mechanics approach only agrees well with the experimental data under high cyclic load conditions.« less
Method for laser spot welding monitoring

NASA Astrophysics Data System (ADS)

Manassero, Giorgio

1994-09-01

As more powerful solid state laser sources appear on the market, new applications become technically possible and important from the economical point of view. For every process a preliminary optimization phase is necessary. The main parameters, used for a welding application by a high power Nd-YAG laser, are: pulse energy, pulse width, repetition rate and process duration or speed. In this paper an experimental methodology, for the development of an electrooptical laser spot welding monitoring system, is presented. The electromagnetic emission from the molten pool was observed and measured with appropriate sensors. The statistical method `Parameter Design' was used to obtain an accurate analysis of the process parameter that influence process results. A laser station with a solid state laser coupled to an optical fiber (1 mm in diameter) was utilized for the welding tests. The main material used for the experimental plan was zinc coated steel sheet 0.8 mm thick. This material and the related spot welding technique are extensively used in the automotive industry, therefore, the introduction of laser technology in production line will improve the quality of the final product. A correlation, between sensor signals and `through or not through' welds, was assessed. The investigation has furthermore shown the necessity, for the modern laser production systems, to use multisensor heads for process monitoring or control with more advanced signal elaboration procedures.
Metallurgical and Corrosion Characterization of POST Weld Heat Treated Duplex Stainless Steel (uns S31803) Joints by Friction Welding Process

NASA Astrophysics Data System (ADS)

Asif M., Mohammed; Shrikrishna, Kulkarni Anup; Sathiya, P.

2016-02-01

The present study focuses on the metallurgical and corrosion characterization of post weld heat treated duplex stainless steel joints. After friction welding, it was confirmed that there is an increase in ferrite content at weld interface due to dynamic recrystallization. This caused the weldments prone to pitting corrosion attack. Hence the post weld heat treatments were performed at three temperatures 1080∘C, 1150∘C and 1200∘C with 15min of aging time. This was followed by water and oil quenching. The volume fraction of ferrite to austenite ratio was balanced and highest pit nucleation resistance were achieved after PWHT at 1080∘C followed by water quench and at 1150∘C followed by oil quench. This had happened exactly at parameter set containing heating pressure (HP):40 heating time (HT):4 upsetting pressure (UP):80 upsetting time (UP):2 (experiment no. 5). Dual phase presence and absence of precipitates were conformed through TEM which follow Kurdjumov-Sachs relationship. PREN of ferrite was decreasing with increase in temperature and that of austenite increased. The equilibrium temperature for water quenching was around 1100∘C and that for oil quenching was around 1140∘C. The pit depths were found to be in the range of 100nm and width of 1.5-2μm.
The influence of process parameters on porosity formation in hybrid LASER-GMA welding of AA6082 aluminum alloy

NASA Astrophysics Data System (ADS)

Ascari, Alessandro; Fortunato, Alessandro; Orazi, Leonardo; Campana, Giampaolo

2012-07-01

This paper deals with an experimental campaign carried out on AA6082 8 mm thick plates in order to investigate the role of process parameters on porosity formation in hybrid LASER-GMA welding. Bead on plate weldments were obtained on the above mentioned aluminum alloy considering the variation of the following process parameters: GMAW current (120 and 180 A for short-arc mode, 90 and 130 A for pulsed-arc mode), arc transfer mode (short-arc and pulsed-arc) and mutual distance between arc and LASER sources (0, 3 and 6 mm). Porosities occurring in the fused zone were observed by means of X-ray inspection and measured exploiting an image analysis software. In order to understand the possible correlation between process parameters and porosity formation an analysis of variance statistical approach was exploited. The obtained results pointed out that GMAW current is significant on porosity formation, while the distance between the sources do not affect this aspect.
Effect of vibration on microstructures and mechanical properties of 304 stainless steel GTA welds

NASA Astrophysics Data System (ADS)

Hsieh, Chih-Chun; Lai, Chien-Hong; Wu, Weite

2013-07-01

This study investigates the microstructures and mechanical properties of 304 stainless steel at various vibration frequencies during simultaneous vibration welding. The experimental results demonstrated that simultaneous vibration welding could accelerate the nucleation and grain refinement of the microstructures. The effect of the grain refinement was more evident at the resonant frequency (375 Hz) and a minimum content of residual δ-ferrite (4.0%). The γ phase grew in the preferential orientation of the (111) direction with and without vibration. The full width at half maximum of the diffraction peak widened after the vibration, which was attributed to the grain refinement. The residual stress could be efficiently removed through simultaneous vibration welding when the amplitude of the vibration was increased. Furthermore, the lowest residual stress (139 MPa) was found when the vibration frequency was 375 Hz. The hardness and Young's modulus exhibited slight increases with low and medium frequencies. The hardness values were increased by 7.6% and Young's modulus was increased by 15% when the vibration frequency was resonant (375 Hz).
Effect of zirconium addition on welding of aluminum grain refined by titanium plus boron

NASA Astrophysics Data System (ADS)

Zaid, A. I. O.

2014-06-01

Aluminum oxidizes freely in ordinary atmosphere which makes its welding difficult and weak, particularly it solidifies in columnar structure with large grains. Therefore, it is anticipated that the effect of addition of some grain refiners to its melt before solidification is worth while investigating as it may enhance its weldabilty and improve its mechanical strength. In this paper, the effect of addition of zirconium at a weight of 0.1% (which corresponds to the peretictic limit on the aluminum-zirconium base phase diagram) to commercially pure aluminum, grain refined by Ti+B on its weldability, using gas tungsten arc welding, GTAW, method which was formerly known as TIG. A constant current level of 30 AC Ampere was used because it removes the oxides during the welding process. Metallographic examination of the weldments of the different combinations of Al with Al and Al with its microalloys: in the heat affected zone, HAZ, and away from it was carried out and examined for HAZ width, porosity, cracks and microhardness. It was found that grain refining by Ti+B or Zr resulted in enhancement of the weldment.
Low temperature corneal laser welding investigated by atomic force microscopy

NASA Astrophysics Data System (ADS)

Matteini, Paolo; Sbrana, Francesca; Tiribilli, Bruno; Pini, Roberto

2009-02-01

The structural modifications in the stromal matrix induced by low-temperature corneal laser welding were investigated by atomic force microscopy (AFM). This procedure consists of staining the wound with Indocyanine Green (ICG), followed by irradiation with a near-infrared laser operated at low-power densities. This induces a local heating in the 55-65 °C range. In welded tissue, extracellular components undergo heat-induced structural modifications, resulting in a joining effect between the cut edges. However, the exact mechanism generating the welding, to date, is not completely understood. Full-thickness cuts, 3.5 mm in length, were made in fresh porcine cornea samples, and these were then subjected to laser welding operated at 16.7 W/cm2 power density. AFM imaging was performed on resin-embedded semi-thin slices once they had been cleared by chemical etching, in order to expose the stromal bulk of the tissue within the section. We then carried out a morphological analysis of characteristic fibrillar features in the laser-treated and control samples. AFM images of control stromal regions highlighted well-organized collagen fibrils (36.2 +/- 8.7 nm in size) running parallel to each other as in a typical lamellar domain. The fibrils exhibited a beaded pattern with a 22-39 nm axial periodicity. Laser-treated corneal regions were characterized by a significant disorganization of the intralamellar architecture. At the weld site, groups of interwoven fibrils joined the cut edges, showing structural properties that were fully comparable with those of control regions. This suggested that fibrillar collagen is not denatured by low-temperature laser welding, confirming previous transmission electron microscopy (TEM) observations, and thus it is probably not involved in the closure mechanism of corneal cuts. The loss of fibrillar organization may be related to some structural modifications in some interfibrillar substance as proteoglycans or collagen VI. Furthermore, AFM imaging was demonstrated to be a suitable tool for attaining three-dimensional information on the fibrillar assembly of corneal stroma. The results suggested that AFM analyses of resin-embedded histological sections subjected to chemical etching provide a rapid and cost-effective response, with an imaging resolution that is quite similar to that of TEM.
A Precise Visual Method for Narrow Butt Detection in Specular Reflection Workpiece Welding

PubMed Central

Zeng, Jinle; Chang, Baohua; Du, Dong; Hong, Yuxiang; Chang, Shuhe; Zou, Yirong

2016-01-01

During the complex path workpiece welding, it is important to keep the welding torch aligned with the groove center using a visual seam detection method, so that the deviation between the torch and the groove can be corrected automatically. However, when detecting the narrow butt of a specular reflection workpiece, the existing methods may fail because of the extremely small groove width and the poor imaging quality. This paper proposes a novel detection method to solve these issues. We design a uniform surface light source to get high signal-to-noise ratio images against the specular reflection effect, and a double-line laser light source is used to obtain the workpiece surface equation relative to the torch. Two light sources are switched on alternately and the camera is synchronized to capture images when each light is on; then the position and pose between the torch and the groove can be obtained nearly at the same time. Experimental results show that our method can detect the groove effectively and efficiently during the welding process. The image resolution is 12.5 μm and the processing time is less than 10 ms per frame. This indicates our method can be applied to real-time narrow butt detection during high-speed welding process. PMID:27649173
A Precise Visual Method for Narrow Butt Detection in Specular Reflection Workpiece Welding.

PubMed

Zeng, Jinle; Chang, Baohua; Du, Dong; Hong, Yuxiang; Chang, Shuhe; Zou, Yirong

2016-09-13

During the complex path workpiece welding, it is important to keep the welding torch aligned with the groove center using a visual seam detection method, so that the deviation between the torch and the groove can be corrected automatically. However, when detecting the narrow butt of a specular reflection workpiece, the existing methods may fail because of the extremely small groove width and the poor imaging quality. This paper proposes a novel detection method to solve these issues. We design a uniform surface light source to get high signal-to-noise ratio images against the specular reflection effect, and a double-line laser light source is used to obtain the workpiece surface equation relative to the torch. Two light sources are switched on alternately and the camera is synchronized to capture images when each light is on; then the position and pose between the torch and the groove can be obtained nearly at the same time. Experimental results show that our method can detect the groove effectively and efficiently during the welding process. The image resolution is 12.5 μm and the processing time is less than 10 ms per frame. This indicates our method can be applied to real-time narrow butt detection during high-speed welding process.
Effect of Heat-Affected Zone on Spot Weldability in Automotive Ultra High Strength Steel Sheet

NASA Astrophysics Data System (ADS)

Nagasaka, Akihiko; Naito, Junya; Chinzei, Shota; Hojo, Tomohiko; Horiguchi, Katsumi; Shimizu, Yuki; Furusawa, Takuro; Kitahara, Yu

Effect of heat-affected zone (HAZ) on spot weldability in automotive hot stamping (HS) steel sheet was investigated for automotive applications. Tensile test was performed on a tensile testing machine at a crosshead speed of 3 mm/min, using spot welded test specimen (Parallel length: 60 mm, Width: 20 mm, Thickness: 1.4 mm, Tab: 20×20 mm). The spot welding test was carried out using spot welded test specimen with welding current (I) of 6.3 kA to 9.5 kA. Hardness was measured with the dynamic ultra micro Vickers hardness tester. In HS steel, has very high strength of 1 500 MPa, tensile strength (TS) and total elongation (TEl) of the spot welded test specimen of HS steel were lower than those of base metal test specimen. The spot welded test specimen broke in the weld. The Vickers hardnesses (HVs) of base metal and fusion zone of hot stamping steel were around HV500. In addition, the hardness of HAZ was under HV300. The difference of hardness between fusion zone and HAZ was around HV200. The hardness distribution acted as a notch. On the other hand, in dual phase (DP) steel, has low strength of 590 MPa, the TS of spot welded test specimen of DP steel was the same as the base metal test specimen because of the breaking of base metal. The TEl of the spot welded test specimen of DP steel was smaller than that of base metal test specimen. In the spot welded test specimen of DP steel, the hardness of base metal was around HV200 and the fusion zone was around HV500. The hardness distribution did not act as a notch. The difference in hardness between base metal and HAZ acted on a crack initiation at HAZ softening.
High-precision and high-speed laser microjoining for electronics and microsystems

NASA Astrophysics Data System (ADS)

Gillner, Arnold; Olowinsky, Alexander; Klages, Kilian; Gedicke, Jens; Sari, Fahri

2006-02-01

The joining processes in electronic device manufacturing are today still dominated by conventional joining techniques like press fitting, crimping and resistance welding. Laser beam joining techniques have been under intensive investigations and subsequently new processes for mass manufacturing and high accuracy assembling were established. With the newly developed SHADOW (R) welding technology technical aspects such as tensile strength, geometry and precision of the weld could be improved. This technology provides highest flexibility in weld geometry with a minimum welding time as well as new possibilities in using application adapted materials. Different parts and even different metals can be joined by a non-contact process. The application of a relative movement between the laser beam and the part to be joined at feed rates of up to 60 m/min produces weld seams with a length from 0.6 mm to 15.7 mm using a pulsed Nd:YAG laser with a pulse duration of up to 50 ms. Due to the low energy input, typically 1 J to 6 J, a weld width as small as 50 μm and a weld depth as small as 20 pm have been attained. This results in low distortion of the joined watch components. Within this paper this new welding process will be explained and several examples of joined components will be presented with respect to fundamentals and the sustainable implementation of the SHADOW (R) welding technique into watch manufacturing and electronic industry. For microsystem applications the laser joining technology is modified to join even silicon and glass parts without any melting based on the formation of a thermally induced oxygen bond. New fields of applications for joining different materials such as steel to brass or steel to copper for electrical interconnects will be discussed. Here the SHADOW (R) welding technique offers new possibilities for the combination of good electrical properties of copper with high mechanical stiffness of steel. The paper will give a closer look to microjoining applications especially using the SHADOW (R) welding technique. Basics of the process as well as its application on dedicated examples will be shown for small parts such as axis-wheel combinations and electrical connectors.
Effect of plasma arc welding variables on fusion zone grain size and hardness of AISI 321 austenitic stainless steel

NASA Astrophysics Data System (ADS)

Kondapalli, S. P.

2017-12-01

In the present work, pulsed current microplasma arc welding is carried out on AISI 321 austenitic stainless steel of 0.3 mm thickness. Peak current, Base current, Pulse rate and Pulse width are chosen as the input variables, whereas grain size and hardness are considered as output responses. Response surface method is adopted by using Box-Behnken Design, and in total 27 experiments are performed. Empirical relation between input and output response is developed using statistical software and analysis of variance (ANOVA) at 95% confidence level to check the adequacy. The main effect and interaction effect of input variables on output response are also studied.
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
Hot-wire Laser Welding of Deep and Wide Gaps

NASA Astrophysics Data System (ADS)

Näsström, J.; Frostevarg, J.; Silver, T.

Heavy section Gas Metal Arc Welding (GMAW) usually requires special edge preparation and several passes. One alternative for increased performance is Laser Arc Hybrid Welding (LAHW). For very thick sheets however, imperfections like root drops or solidification cracks can occur. In this study, other techniques are also studied, including multi-pass filling of deep gaps with wire deposition. A laser is then used to melt the filler and base material. The hot- and cold wire laser welding processes are highly sensitive to wire-laser positioning, where controlled melting of the wire is essential. Apart from a comprehensive literature survey, preliminary experiments were also performed in order to find a novel method variant that can successfully fill deep and wide gaps. The method applied uses a defocused laser that generates the melt pool. A resistance heated wire is fed into the melt pool front in a leading position. This is similar to additive manufacturing techniques such as laser direct metal deposition with wire. A layer height of several millimeters can be achieved and rather low laser power can be chosen. The preliminary experiments were observed using high speed imaging and briefly evaluated by visual examination of the resulting beads. Using a defocused laser beam turned out to have two major advantages; 1. It adds heat to the melt pool in a manner that properly fuses the bottom and walls of the base material. 2. It counteracts difficulties due to an irregularly oscillating filler wire. These early results show that this can be a promising technique for joining thick steels with wide gaps.
Effect of Nickel Contents on the Microstructure and Mechanical Properties for Low-Carbon Bainitic Weld Metals

NASA Astrophysics Data System (ADS)

Mao, Gaojun; Cao, Rui; Yang, Jun; Jiang, Yong; Wang, Shuai; Guo, Xili; Yuan, Junjun; Zhang, Xiaobo; Chen, Jianhong

2017-05-01

Multi-pass weld metals were deposited on Q345 base steel using metal powder-flux-cored wire with various Ni contents to investigate the effects of the Ni content on the weld microstructure and property. The types of the microstructures were identified by optical microscope, scanning electron microscope, transmission electron microscope, and micro-hardness tests. As a focusing point, the lath bainite and lath martensite were distinguished by their compositions, morphologies, and hardness. In particular, a number of black plane facets appearing between lath bainite or lath martensite packets were characterized by laser scanning confocal microscope. The results indicated that with the increase in Ni contents in the range of 0, 2, 4, and 6%, the microstructures in the weld-deposited metal were changed from the domination of the granular bainite to the majority of the lath bainite and/or the lath martensite and the micro-hardness of the weld-deposited metal increased. Meanwhile, the average width of columnar grain displays a decreasing trend and prior austenite grain size decreases while increases with higher Ni content above 4%. Yield strength and ultimate tensile strength decrease, while the reduction in fracture area increases with the decreasing Ni mass fraction and the increasing test temperature, respectively. And poor yield strength in Ni6 specimen can be attributed to elements segregation caused by weld defect. Finally, micro-hardness distribution in correspondence with specimens presents as a style of cloud-map.
Interacting effects of discharge and channel morphology on transport of semibuoyant fish eggs in large, altered river systems

USGS Publications Warehouse

Worthington, Thomas A.; Brewer, Shannon K.; Farless, Nicole; Grabowski, Timothy B.; Gregory, Mark S.

2014-01-01

Habitat fragmentation and flow regulation are significant factors related to the decline and extinction of freshwater biota. Pelagic-broadcast spawning cyprinids require moving water and some length of unfragmented stream to complete their life cycle. However, it is unknown how discharge and habitat features interact at multiple spatial scales to alter the transport of semi-buoyant fish eggs. Our objective was to assess the relationship between downstream drift of semi-buoyant egg surrogates (gellan beads) and discharge and habitat complexity. We quantified transport time of a known quantity of beads using 2–3 sampling devices at each of seven locations on the North Canadian and Canadian rivers. Transport time was assessed based on median capture time (time at which 50% of beads were captured) and sampling period (time period when 2.5% and 97.5% of beads were captured). Habitat complexity was assessed by calculating width:depth ratios at each site, and several habitat metrics determined using analyses of aerial photographs. Median time of egg capture was negatively correlated to site discharge. The temporal extent of the sampling period at each site was negatively correlated to both site discharge and habitat-patch dispersion. Our results highlight the role of discharge in driving transport times, but also indicate that higher dispersion of habitat patches relates to increased retention of beads within the river. These results could be used to target restoration activities or prioritize water use to create and maintain habitat complexity within large, fragmented river systems.

Brownian dynamics of wall tethered polymers in shear flow

NASA Astrophysics Data System (ADS)

Lin, Tiras Y.; Saadat, Amir; Kushwaha, Amit; Shaqfeh, Eric S. G.

2017-11-01

The dynamics of a wall tethered polymer in shear flow is studied using Brownian dynamics. Simulations are performed with bead-spring chains, and the effect of hydrodynamic interactions (HI) is incorporated through Blake's tensor with a finite size bead correction. We characterize the configuration of the polymer as a function of the Weissenberg number by investigating the regions the polymer explores in both the flow-gradient and flow-vorticity planes. The fractional extension in the flow direction, the width in the vorticity direction, and the thickness in the gradient direction are reported as well, and these quantities are found to compare favorably with the experimental data of the literature. The cyclic motion of the polymer is demonstrated through analysis of the mean velocity field of the end bead. We characterize the collision process of each bead with the wall as a Poisson process and extract an average wall collision rate, which in general varies along the backbone of the chain. The inclusion of HI with the wall for a tethered polymer is found to reduce the average wall collision rate. We anticipate that results from this work will be directly applicable to, e.g., the design of polymer brushes or the use of DNA for making nanowires in molecular electronics. T.Y.L. is supported by the Department of Defense (DoD) through the National Defense Science & Engineering Graduate Fellowship (NDSEG) Program.
Temperature control and measurement with tunable femtosecond optical tweezers

NASA Astrophysics Data System (ADS)

Mondal, Dipankar; Goswami, Debabrata

2016-09-01

We present the effects of wavelength dependent temperature rise in a femtosecond optical tweezers. Our experiments involve the femtosecond trapping laser tunable from 740-820 nm at low power 25 mW to cause heating in the trapped volume within a homogeneous solution of sub micro-molar concentration of IR dye. The 780 nm high repetition rate laser acts as a resonant excitation source which helps to create the local heating effortlessly within the trapping volume. We have used both position autocorrelation and equipartion theorem to evaluate temperature at different wavelength having different absorption coefficient. Fixing the pulse width in the temporal domain gives constant bandwidth at spatial domain, which makes our system behave as a tunable temperature rise device with high precision. This observation leads us to calculate temperature as well as viscosity within the vicinity of the trapping zone. A mutual energy transfer occurs between the trapped bead and solvents that leads to transfer the thermal energy of solvents into the kinetic energy of the trap bead and vice-versa. Thus hot solvated molecules resulting from resonant and near resonant excitation of trapping wavelength can continuously dissipate heat to the trapped bead which will be reflected on frequency spectrum of Brownian noise exhibited by the bead. Temperature rise near the trapping zone can significantly change the viscosity of the medium. We observe temperature rise profile according to its Gaussian shaped absorption spectrum with different wavelength.
Influence of modes of metal transfer on grain structure and direction of grain growth in low nickel austenitic stainless steel weld metals

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

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

2015-04-15

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

NASA Astrophysics Data System (ADS)

Weglowski, Marek St.; Błacha, Sylwester; Pilarczyk, Jan; Dutkiewicz, Jan; Rogal, Łukasz

2018-05-01

The electron beam additive manufacturing process with wire is a part of global trend to find fast and efficient methods for producing complex shapes elements from costly metal alloys such as stainless steels, nickel alloys, titanium alloys etc. whose production by other conventional technologies is unprofitable or technically impossible. Demand for additive manufacturing is linked to the development of new technologies in the automotive, aerospace and machinery industries. The aim of the presented work was to carried out research on electron beam additive manufacturing with a wire as a deposited (filler) material. The scope of the work was to investigate the influence of selected technological parameters such as: wire feed rate, beam current, travelling speed, acceleration voltage on stability of the deposition process and geometric dimensions of the padding welds. The research revealed that, at low beam currents, the deposition process is unstable. The padding weld reinforcement is non-uniform. Irregularity of the width, height and straightness of the padding welds can be observed. At too high acceleration voltage and beam current, burn-through of plate and excess penetration weld can be revealed. The achieved results and gained knowledge allowed to produce, based on EBAM with wire process, whole structure from stainless steel.
Optical measurements of flyer plate acceleration by emulsion explosive

NASA Astrophysics Data System (ADS)

Kubota, Shiro; Shimada, Hideki; Matsui, Kikuo; Ogata, Yuji; Seto, Masahiro; Masui, Akira; Wada, Yuji; Liu, Zhi-Yue; Itoh, Shigeru

2001-04-01

This paper presents the study on the application of explosive welding technique to the field of the urgent repair of the gas and water pipe networks. The essential parameters related to the explosive welding are scrutinized from the point of view of the minimizing the damage to the steel pipe after welded explosively with a flyer plate. The emulsion explosive is contained in a rectangular hard-paper box whose bottom is the flyer plate with 100 mm length, 25 mm width and 1.5 mm thickness. The flyer motions of the flyer plates accelerated by emulsion explosive are observed by high-speed photography from the side and front view of the flyer plate. The damage to the pipe by the flyer plate is discussed with the results of the observation of flyer motion and explosive welding test under various experimental conditions. Moreover, one way to control the motion of the flyer plate is proposed. We put a PMMA buffer block into the explosive. The flying process of flyer plate is calculated by the finite different scheme based on the ALE method. The effectiveness of this method is demonstrated by the experimental and numerical studies.
Columnar jointing in vapor-phase-altered, non-welded Cerro Galán Ignimbrite, Paycuqui, Argentina

USGS Publications Warehouse

Wright, Heather M.; Lesti, Chiara; Cas, Ray A.F.; Porreca, Massimiliano; Viramonte, Jose G.; Folkes, Christopher B.; Giordano, Guido

2011-01-01

Columnar jointing is thought to occur primarily in lavas and welded pyroclastic flow deposits. However, the non-welded Cerro Galán Ignimbrite at Paycuqui, Argentina, contains well-developed columnar joints that are instead due to high-temperature vapor-phase alteration of the deposit, where devitrification and vapor-phase crystallization have increased the density and cohesion of the upper half of the section. Thermal remanent magnetization analyses of entrained lithic clasts indicate high emplacement temperatures, above 630°C, but the lack of welding textures indicates temperatures below the glass transition temperature. In order to remain below the glass transition at 630°C, the minimum cooling rate prior to deposition was 3.0 × 10−3–8.5 × 10−2°C/min (depending on the experimental data used for comparison). Alternatively, if the deposit was emplaced above the glass transition temperature, conductive cooling alone was insufficient to prevent welding. Crack patterns (average, 4.5 sides to each polygon) and column diameters (average, 75 cm) are consistent with relatively rapid cooling, where advective heat loss due to vapor fluxing increases cooling over simple conductive heat transfer. The presence of regularly spaced, complex radiating joint patterns is consistent with fumarolic gas rise, where volatiles originated in the valley-confined drainage system below. Joint spacing is a proxy for cooling rates and is controlled by depositional thickness/valley width. We suggest that the formation of joints in high-temperature, non-welded deposits is aided by the presence of underlying external water, where vapor transfer causes crystallization in pore spaces, densifies the deposit, and helps prevent welding.
[Element distribution analysis of welded fusion zone by laser-induced breakdown spectroscopy].

PubMed

Yang, Chun; Zhang, Yong; Jia, Yun-Hai; Wang, Hai-Zhou

2014-04-01

Over the past decade there has been intense activity in the study and development of laser-induced breakdown spectroscopy (LIBS). As a new tool for surface microanalysis, it caused widespread in materials science because of the advantage of rapid and high sensitivity. In the present paper, the distribution of Ni, Mn, C and Si near weld fusion line was analyzed on two kinds of weld sample. Line scanning mode analysis was carried out by three different kinds of methods, namely laser-induced breakdown spectroscopy (LIBS), scanning electron microscope/energy dispersive spectrometer (SEM/EDS) and electron probe X-ray microanalyser (EPMA). The concentration variation trend of Ni and Mn acquired by LIBS is coincident with SEM/EDS and EPMA. The result shows that the content of Ni and Mn was significantly different between weld seam and base metal on both the samples. The content of Ni and Mn was much higher in weld seam than in base metal, and a sharp concentration gradient was analyzed in the fusion zone. According to the distribution of Ni and Mn, all the three methods got a similar value of welded fusion zone width. The concentration variation trend of C and Si acquired by LIBS is not coincident with SEM/EDS and EPMA. The concentration difference between weld seam and base metal was analyzed by LIBS, but had not by SEM/EDS and EPMA, because of the low concentration and slight difference. The concentration gradient of C and Si in fusion zone was shows clearly by LIBS. For higher sensitivity performance, LIBS is much more adapted to analyze low content element than SEM/EDS and EPMA.
Fracture of Polymers and Interfaces: A Universal Molecular Approach

NASA Astrophysics Data System (ADS)

Wool, Richard

2003-03-01

Fracture of polymers, linear or crosslinked, can be viewed as a breaking of molecular connectivity via disentanglement or bond rupture. When treated as a vector percolation phenomenon, we find that it captures the essential physics of fracture and makes broad accurate predictions for strength S, and fracture energy G, of polymers and their interfaces. In the bulk, we find that G ˜ [p-pc], and S ˜ [p-pc]^1/2, where p is the local normalized entanglement density and pc is the percolation threshold. For interfaces, p = nL/w, where n is the areal density of chains of length L ˜M (mol wt) in an interface of width w. For incompatible interfaces of width w, G ˜ [w-wc]; when reinforced with n compatibilizers, G ˜ (n - nc]. For welding, p ˜ L, the welding time tw ˜ L. For adhesion with sticker group X on the polymer and receptor groups Y on the solid, the strength first increases with X, Y and X-Y strength and then decreases after a predictable maximum. For thermosets, the modulus E ˜ [p-pc]^3 and the strength S ˜ [p-pc]^2. Numerous experimental examples are given to support the above universal relations for fracture.
Cross-Beam Laser Joining of AA 6111 to Galvanized Steel in a Coach Peel Configuration

NASA Astrophysics Data System (ADS)

Yang, Guang; Mohammadpour, Masoud; Yazdian, Nima; Ma, Junjie; Carlson, Blair; Wang, Hui-Ping; Kovacevic, Radovan

2017-06-01

Cross-beam laser joining of aluminum alloy 6111 to hot-dip galvanized steel in the coach-peel configuration was investigated with the addition of AA 4047 filler wire. The filler material was not only brazed onto the galvanized steel but also partially fusion-welded with the aluminum panel. Through adjusting the laser power to 3.4 kW, a desirable wetting and spreading of filler wire on both panel surfaces could be achieved, and the thickness of intermetallic layer in the middle section of the interface between the weld bead and steel was less than 2 μm. To better understand the solid/liquid interfacial reaction at the brazing interface, two rotary Gaussian heat source models were introduced to simulate the temperature distribution in the molten pool by using the finite element method. Joint properties were examined in terms of microstructure and mechanical properties. During the tensile test, the fracture of coupons took place at the aluminum side rather than along the interface between the intermetallic layer and steel panel. No failure occurred during the three-point bending test.
Laser transmission welding of Acrylonitrile-Butadiene-Styrene (ABS) using a tailored high power diode-laser optical fiber coupled system

NASA Astrophysics Data System (ADS)

Rodríguez-Vidal, E.; Quintana, I.; Etxarri, J.; Otaduy, D.; González, F.; Moreno, F.

2012-06-01

Laser transmission welding (LTW) of polymers is a direct bonding technique which is already used in different industrial applications sectors such as automobile, microfluidic, electronic and biomedicine. This technique offers several advantages over conventional methods, especially when a local deposition of energy and minimum thermal distortions are required. In LTW one of the polymeric materials needs to be transparent to the laser wavelength and the second part needs to be designed to be absorbed in IR spectrum. This report presents a study of laser weldability of ABS (acrylonitrile/butadiene/styrene) filled with two different concentrations of carbon nanotubes (0.01% and 0.05% CNTs). These additives are used as infrared absorbing components in the laser welding process, affecting the thermal and optical properties of the material and, hence, the final quality of the weld seam. A tailored laser system has been designed to obtain high quality weld seams with widths between 0.4 and 1.0mm. It consists of two diode laser bars (50W per bar) coupled into an optical fiber using a non-imaging solution: equalization of the beam quality factor (M2) in the slow and fast axes by a pair of micro step-mirrors. The beam quality factor has been analyzed at different laser powers with the aim to guarantee a coupling efficiency to the multimode optical fiber. The power scaling is carried out by means of multiplexing polarization technique. The analysis of energy balance and beam quality is performed in two linked steps: first by means ray tracing simulations (ZEMAX®) and second, by validation. Quality of the weld seams is analyzed in terms of the process parameters (welding speed, laser power and clamping pressure) by visual and optical microscope inspections. The optimum laser power range for three different welding speeds is determinate meanwhile the clamping pressure is held constant. Additionally, the corresponding mechanical shear tests were carried out to analyze the mechanical properties of the weld seams. This work provides a detailed study concerning the effect of the material microstructure and laser beam quality on the final weld formation and surface integrity.
Estudio numerico y experimental del proceso de soldeo MIG sobre la aleacion 6063--T5 utilizando el metodo de Taguchi

NASA Astrophysics Data System (ADS)

Meseguer Valdenebro, Jose Luis

Electric arc welding processes represent one of the most used techniques on manufacturing processes of mechanical components in modern industry. The electric arc welding processes have been adapted to current needs, becoming a flexible and versatile way to manufacture. Numerical results in the welding process are validated experimentally. The main numerical methods most commonly used today are three: finite difference method, finite element method and finite volume method. The most widely used numerical method for the modeling of welded joints is the finite element method because it is well adapted to the geometric and boundary conditions in addition to the fact that there is a variety of commercial programs which use the finite element method as a calculation basis. The content of this thesis shows an experimental study of a welded joint conducted by means of the MIG welding process of aluminum alloy 6063-T5. The numerical process is validated experimentally by applying the method of finite element through the calculation program ANSYS. The experimental results in this paper are the cooling curves, the critical cooling time t4/3, the weld bead geometry, the microhardness obtained in the welded joint, and the metal heat affected zone base, process dilution, critical areas intersected between the cooling curves and the curve TTP. The numerical results obtained in this thesis are: the thermal cycle curves, which represent both the heating to maximum temperature and subsequent cooling. The critical cooling time t4/3 and thermal efficiency of the process are calculated and the bead geometry obtained experimentally is represented. The heat affected zone is obtained by differentiating the zones that are found at different temperatures, the critical areas intersected between the cooling curves and the TTP curve. In order to conclude this doctoral thesis, an optimization has been conducted by means of the Taguchi method for welding parameters in order to obtain an improvement on mechanical properties in aluminum metal joint. Los procesos de soldadura por arco electrico representan unas de las tecnicas mas utilizadas en los procesos de fabricacion de componentes mecanicos en la industria moderna. Los procesos de soldeo por arco se han adaptado a las necesidades actuales, haciendose un modo de fabricacion flexible y versatil. Los resultados obtenidos numericamente en el proceso de soldadura son validados experimentalmente. Los principales metodos numericos mas empleados en la actualidad son tres, metodo por diferencias finitas, metodos por elementos finitos y metodo por volumenes finitos. El metodo numerico mas empleado para el modelado de uniones soldadas, es el metodo por elementos finitos, debido a que presenta una buena adaptacion a las condiciones geometricas y de contorno ademas de que existe una diversidad de programas comerciales que utilizan el metodo por elementos finitos como base de calculo. Este trabajo de investigacion presenta un estudio experimental de una union soldada mediante el proceso MIG de la aleacion de aluminio 6063-T5. El metodo numerico se valida experimentalmente aplicando el metodo de los elementos finitos con el programa de calculo ANSYS. Los resultados experimentales obtenidos son: las curvas de enfriamiento, el tiempo critico de enfriamiento t4/3, geometria del cordon, microdurezas obtenidas en la union soldada, zona afectada termicamente y metal base, dilucion del proceso, areas criticas intersecadas entre las curvas de enfriamiento y la curva TTP. Los resultados numericos son: las curvas del ciclo termico, que representan tanto el calentamiento hasta alcanzar la temperatura maxima y un posterior enfriamiento. Se calculan el tiempo critico de enfriamiento t4/3, el rendimiento termico y se representa la geometria del cordon obtenida experimentalmente. La zona afectada termicamente se obtiene diferenciando las zonas que se encuentran a diferentes temperaturas, las areas criticas intersecadas entre las curvas de enfriamiento y la curva TTP. Para finalizar el trabajo de investigacion se ha realizado una optimizacion, con la aplicacion del metodo de Taguchi, de los parametros de soldeo con el objetivo de obtener una mejora sustancial en las propiedades mecanicas de las uniones metalicas de aluminio.
3D nano-structures for laser nano-manipulation

PubMed Central

Seniutinas, Gediminas; Gervinskas, Gediminas; Brasselet, Etienne; Juodkazis, Saulius

2013-01-01

Summary The resputtering of gold films from nano-holes defined in a sacrificial PMMA mask, which was made by electron beam lithography, was carried out with a dry plasma etching tool in order to form well-like structures with a high aspect ratio (height/width ≈ 3–4) at the rims of the nano-holes. The extraordinary transmission through the patterns of such nano-wells was investigated experimentally and numerically. By doing numerical simulations of 50-nm and 100-nm diameter polystyrene beads in water and air, we show the potential of such patterns for self-induced back-action (SIBA) trapping. The best trapping conditions were found to be a trapping force of 2 pN/W/μm2 (numerical result) exerted on a 50-nm diameter bead in water. The simulations were based on the analytical Lorentz force model. PMID:24062979
In situ single cell detection via microfluidic magnetic bead assay

PubMed Central

KC, Pawan; Zhang, Ge; Zhe, Jiang

2017-01-01

We present a single cell detection device based on magnetic bead assay and micro Coulter counters. This device consists of two successive micro Coulter counters, coupled with a high gradient magnetic field generated by an external magnet. The device can identify single cells in terms of the transit time difference of the cell through the two micro Coulter counters. Target cells are conjugated with magnetic beads via specific antibody and antigen binding. A target cell traveling through the two Coulter counters interacts with the magnetic field, and have a longer transit time at the 1st counter than that at the 2nd counter. In comparison, a non-target cell has no interaction with the magnetic field, and hence has nearly the same transit times through the two counters. Each cell passing through the two counters generates two consecutive voltage pulses one after the other; the pulse widths and magnitudes indicating the cell’s transit times through the counters and the cell’s size respectively. Thus, by measuring the pulse widths (transit times) of each cell through the two counters, each single target cell can be differentiated from non-target cells even if they have similar sizes. We experimentally proved that the target human umbilical vein endothelial cells (HUVECs) and non-target rat adipose-derived stem cells (rASCs) have significant different transit time distribution, from which we can determine the recognition regions for both cell groups quantitatively. We further demonstrated that within a mixed cell population of rASCs and HUVECs, HUVECs can be detected in situ and the measured HUVECs ratios agree well with the pre-set ratios. With the simple device structure and easy sample preparation, this method is expected to enable single cell detection in a continuous flow and can be applied to facilitate general cell detection applications such as stem cell identification and enumeration. PMID:28222140
In situ single cell detection via microfluidic magnetic bead assay.

PubMed

Liu, Fan; Kc, Pawan; Zhang, Ge; Zhe, Jiang

2017-01-01

We present a single cell detection device based on magnetic bead assay and micro Coulter counters. This device consists of two successive micro Coulter counters, coupled with a high gradient magnetic field generated by an external magnet. The device can identify single cells in terms of the transit time difference of the cell through the two micro Coulter counters. Target cells are conjugated with magnetic beads via specific antibody and antigen binding. A target cell traveling through the two Coulter counters interacts with the magnetic field, and have a longer transit time at the 1st counter than that at the 2nd counter. In comparison, a non-target cell has no interaction with the magnetic field, and hence has nearly the same transit times through the two counters. Each cell passing through the two counters generates two consecutive voltage pulses one after the other; the pulse widths and magnitudes indicating the cell's transit times through the counters and the cell's size respectively. Thus, by measuring the pulse widths (transit times) of each cell through the two counters, each single target cell can be differentiated from non-target cells even if they have similar sizes. We experimentally proved that the target human umbilical vein endothelial cells (HUVECs) and non-target rat adipose-derived stem cells (rASCs) have significant different transit time distribution, from which we can determine the recognition regions for both cell groups quantitatively. We further demonstrated that within a mixed cell population of rASCs and HUVECs, HUVECs can be detected in situ and the measured HUVECs ratios agree well with the pre-set ratios. With the simple device structure and easy sample preparation, this method is expected to enable single cell detection in a continuous flow and can be applied to facilitate general cell detection applications such as stem cell identification and enumeration.
Compact vacuum insulation embodiments

DOEpatents

Benson, D.K.; Potter, T.F.

1992-04-28

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially point' or line' contacts with the metal wall sheets. In the case of monolithic spacers that form line' contacts, two such spacers with the line contacts running perpendicular to each other form effectively point' contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included. 26 figs.
Compact vacuum insulation

DOEpatents

Benson, D.K.; Potter, T.F.

1993-01-05

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially point'' or line'' contacts with the metal wall sheets. In the case of monolithic spacers that form line'' contacts, two such spacers with the line contacts running perpendicular to each other form effectively point'' contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included.
Compact vacuum insulation

DOEpatents

Benson, David K.; Potter, Thomas F.

1993-01-01

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially "point" or "line" contacts with the metal wall sheets. In the case of monolithic spacers that form "line" contacts, two such spacers with the line contacts running perpendicular to each other form effectively "point" contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included.
Compact vacuum insulation embodiments

DOEpatents

Benson, David K.; Potter, Thomas F.

1992-01-01

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially "point" or "line" contacts with the metal wall sheets. In the case of monolithic spacers that form "line" contacts, two such spacers with the line contacts running perpendicular to each other form effectively "point" contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included.
[Study of the effect of heat source separation distance on plasma physical properties in laser-pulsed GMAW hybrid welding based on spectral diagnosis technique].

PubMed

Liao, Wei; Hua, Xue-Ming; Zhang, Wang; Li, Fang

2014-05-01

In the present paper, the authors calculated the plasma's peak electron temperatures under different heat source separation distance in laser- pulse GMAW hybrid welding based on Boltzmann spectrometry. Plasma's peak electron densities under the corresponding conditions were also calculated by using the Stark width of the plasma spectrum. Combined with high-speed photography, the effect of heat source separation distance on electron temperature and electron density was studied. The results show that with the increase in heat source separation distance, the electron temperatures and electron densities of laser plasma did not changed significantly. However, the electron temperatures of are plasma decreased, and the electron densities of are plasma first increased and then decreased.

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

NASA Astrophysics Data System (ADS)

Mazar Atabaki, Mehdi

There is a high interest for the high strength-to-weight ratio with good ductility for the welds of advanced alloys. The concern about the welding of thick materials (Advanced high strength steels (AHSS) and 5xxx and 6xxx series of aluminum alloys) has stimulated the development of manufacturing processes to overcome the associated issues. The need to weld the dissimilar materials (AHSS and aluminum alloys) is also required for some specific applications in different industries. Hence, the requirement in the development of a state-of-the-art welding procedure can be helpful to fulfill the constraints. Among the welding methods hybrid laser/arc welding (HLAW) has shown to be an effective method to join thick and difficult-to-weld materials. This process benefits from both advantages of the gas metal arc welding (GMAW) and laser welding processes. The interaction of the arc and laser can help to have enough penetration of weld in thick plates. However, as the welding of dissimilar aluminum alloys and steels is very difficult because of the formation of brittle intermetallics the present work proposed a procedure to effectively join the alloys. The reports showed that the explosively welded aluminum alloys to steels have the highest toughness, and that could be used as an "insert" (TRICLAD) for welding the thick plates of AHSS to aluminum alloys. Therefore, the HLAW of the TRICLAD-Flange side (Aluminum alloy (AA 5456)) to the Web side (Aluminum alloys (AA 6061 and AA 5456)) and the TRICLAD-Flange side (ASTM A516) to the Web side (AHSS) was studied in the present work. However, there are many issues related to HLAW of the dissimilar steels as well as dissimilar aluminum alloys that have to be resolved in order to obtain sound welds. To address the challenges, the most recent welding methods for joining aluminum alloys to steels were studied and the microstructural development, mechanical properties, and on-line monitoring of the welding processes were discussed as well. The heat and mass transfer and the issues in joining of dissimilar alloys by the hybrid laser/arc welding process (HLAW) were explicitly explained in details. A finite element model was developed to simulate the heat transfer in HLAW of the aluminum alloys. Two double-ellipsoidal heat source models were considered to describe the heat input of the gas metal arc welding and laser welding processes. An experimental procedure was also developed for joining thick advanced high strength steel plates by using the HLAW, by taking into consideration different butt joint configurations. The geometry of the weld groove was optimized according to the requirements of ballistic test, where the length of the softened heat affected zone should be less than 15.9 mm measured from the weld centerline. Since the main issue in HLAW of the AHSS was the formation of the pores, the possible mechanisms of the pores formation and their mitigation methods during the welding process were investigated. Mitigation methods were proposed to reduce the pores inside in the weld area and the influence of each method on the process stability was investigated by an on-line monitoring system of the HLAW process. The groove angle was optimized for the welding process based on the allowed amount of heat input along the TRICLADRTM interface generated by an explosive welding. The weld was fractured in the heat affected zone of the aluminum side in the tensile test. The microharness was shown that the temperature variation caused minor softening in the heat affected zone satisfying the requirement that the width of the softened heat affected zone in the steel side falls within 15.9 mm far away from the weld centerline. The microstructure analysis showed the presence of tempered martensite at the vicinity of the weld area, which it was a cause of softening in the heat affected zone.
Spectroscopic analysis technique for arc-welding process control

NASA Astrophysics Data System (ADS)

Mirapeix, Jesús; Cobo, Adolfo; Conde, Olga; Quintela, María Ángeles; López-Higuera, José-Miguel

2005-09-01

The spectroscopic analysis of the light emitted by thermal plasmas has found many applications, from chemical analysis to monitoring and control of industrial processes. Particularly, it has been demonstrated that the analysis of the thermal plasma generated during arc or laser welding can supply information about the process and, thus, about the quality of the weld. In some critical applications (e.g. the aerospace sector), an early, real-time detection of defects in the weld seam (oxidation, porosity, lack of penetration, ...) is highly desirable as it can reduce expensive non-destructive testing (NDT). Among others techniques, full spectroscopic analysis of the plasma emission is known to offer rich information about the process itself, but it is also very demanding in terms of real-time implementations. In this paper, we proposed a technique for the analysis of the plasma emission spectrum that is able to detect, in real-time, changes in the process parameters that could lead to the formation of defects in the weld seam. It is based on the estimation of the electronic temperature of the plasma through the analysis of the emission peaks from multiple atomic species. Unlike traditional techniques, which usually involve peak fitting to Voigt functions using the Levenberg-Marquardt recursive method, we employ the LPO (Linear Phase Operator) sub-pixel algorithm to accurately estimate the central wavelength of the peaks (allowing an automatic identification of each atomic species) and cubic-spline interpolation of the noisy data to obtain the intensity and width of the peaks. Experimental tests on TIG-welding using fiber-optic capture of light and a low-cost CCD-based spectrometer, show that some typical defects can be easily detected and identified with this technique, whose typical processing time for multiple peak analysis is less than 20msec. running in a conventional PC.
Effect of dual laser beam on dissimilar welding-brazing of aluminum to galvanized steel

NASA Astrophysics Data System (ADS)

Mohammadpour, Masoud; Yazdian, Nima; Yang, Guang; Wang, Hui-Ping; Carlson, Blair; Kovacevic, Radovan

2018-01-01

In this investigation, the joining of two types of galvanized steel and Al6022 aluminum alloy in a coach peel configuration was carried out using a laser welding-brazing process in dual-beam mode. The feasibility of this method to obtain a sound and uniform brazed bead with high surface quality at a high welding speed was investigated by employing AlSi12 as a consumable material. The effects of alloying elements on the thickness of intermetallic compound (IMC) produced at the interface of steel and aluminum, surface roughness, edge straightness and the tensile strength of the resultant joint were studied. The comprehensive study was conducted on the microstructure of joints by means of a scanning electron microscopy and EDS. Results showed that a dual-beam laser shape and high scanning speed could control the thickness of IMC as thin as 3 μm and alter the failure location from the steel-brazed interface toward the Al-brazed interface. The numerical simulation of thermal regime was conducted by the Finite Element Method (FEM), and simulation results were validated through comparative experimental data. FEM thermal modeling evidenced that the peak temperatures at the Al-steel interface were around the critical temperature range of 700-900 °C that is required for the highest growth rate of IMC. However, the time duration that the molten pool was placed inside this temperature range was less than 1 s, and this duration was too short for diffusion-control based IMC growth.
Cabling design for phased arrays

NASA Technical Reports Server (NTRS)

Kruger, I. D.; Turkiewicz, L.

1972-01-01

The ribbon-cabling system used for the AEGIS phased array which provides minimum cable bulk, complete EMI shielding, rugged mechanical design, repeatable electrical characteristics, and ease of assembly and maintenance is described. The ribbon cables are 0.040-inch thick, and in widths up to 2 1/2 inches. Their terminations are molded connectors that can be grouped in a three-tier arrangement, with cable branching accomplished by a matrix-welding technique.
Fiber laser welding of austenitic steel and commercially pure copper butt joint

NASA Astrophysics Data System (ADS)

Kuryntsev, S. V.; Morushkin, A. E.; Gilmutdinov, A. Kh.

2017-03-01

The fiber laser welding of austenitic stainless steel and commercially pure copper in butt joint configuration without filler or intermediate material is presented. In order to melt stainless steel directly and melt copper via heat conduction a defocused laser beam was used with an offset to stainless steel. During mechanical tests the weld seam was more durable than heat affected zone of copper so samples without defects could be obtained. Three process variants of offset of the laser beam were applied. The following tests were conducted: tensile test of weldment, intermediate layer microhardness, optical metallography, study of the chemical composition of the intermediate layer, fractography. Measurements of electrical resistivity coefficients of stainless steel, copper and copper-stainless steel weldment were made, which can be interpreted or recalculated as the thermal conductivity coefficient. It shows that electrical resistivity coefficient of cooper-stainless steel weldment higher than that of stainless steel. The width of intermediate layer between stainless steel and commercially pure copper was 41-53 μm, microhardness was 128-170 HV0.01.
Interdiffusion behavior of tungsten or rhenium and group 5 and 6 elements and alloys of the periodic table, part 1. [at dissimilar metal joints

NASA Technical Reports Server (NTRS)

Arcella, F. G.

1974-01-01

Arc cast W, CVD W, CVD Re, and powder metallurgy Re materials were hot isostatically pressure welded to ten different refractory metals and alloys (Cb, Cb-1Zr, Ta, Ta-10W, T-111, ASTAR-811C, W-25Re, Mo-50Re, W-30Re-20Mo, ect.) and thermally aged at 10 to the minus 8th power torr at 1200, 1500, 1630, 1800, and 2000 C for 100 to 2000 hours. Electron beam microprobe analysis was used to characterize the interdiffusion zone width of each couple system as a function of age time and temperature. Extrapolations of interdiffusion zone thickness to 10,000 hours were made. Classic interdiffusion analysis was performed for several of the systems by Boltzmann-Matano analysis. A method of inhibiting Kirkendall voids from forming during thermal ageing of dissimilar metal junctions was devised and experimentally demonstrated. An electron beam weld study of Cb-1Zr to Re and W-25Re demonstrated the limited acceptability of these welds.
Laser Cladding of Ultra-Thin Nickel-Based Superalloy Sheets.

PubMed

Gabriel, Tobias; Rommel, Daniel; Scherm, Florian; Gorywoda, Marek; Glatzel, Uwe

2017-03-10

Laser cladding is a well-established process to apply coatings on metals. However, on substrates considerably thinner than 1 mm it is only rarely described in the literature. In this work 200 µm thin sheets of nickel-based superalloy 718 are coated with a powder of a cobalt-based alloy, Co-28Cr-9W-1.5Si, by laser cladding. The process window is very narrow, therefore, a precisely controlled Yb fiber laser was used. To minimize the input of energy into the substrate, lines were deposited by setting single overlapping points. In a design of experiments (DoE) study, the process parameters of laser power, laser spot area, step size, exposure time, and solidification time were varied and optimized by examining the clad width, weld penetration, and alloying depth. The microstructure of the samples was investigated by optical microscope (OM) and scanning electron microscopy (SEM), combined with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDX). Similarly to laser cladding of thicker substrates, the laser power shows the highest influence on the resulting clad. With a higher laser power, the clad width and alloying depth increase, and with a larger laser spot area the weld penetration decreases. If the process parameters are controlled precisely, laser cladding of such thin sheets is manageable.
Laser Cladding of Ultra-Thin Nickel-Based Superalloy Sheets

PubMed Central

Gabriel, Tobias; Rommel, Daniel; Scherm, Florian; Gorywoda, Marek; Glatzel, Uwe

2017-01-01

Laser cladding is a well-established process to apply coatings on metals. However, on substrates considerably thinner than 1 mm it is only rarely described in the literature. In this work 200 µm thin sheets of nickel-based superalloy 718 are coated with a powder of a cobalt-based alloy, Co–28Cr–9W–1.5Si, by laser cladding. The process window is very narrow, therefore, a precisely controlled Yb fiber laser was used. To minimize the input of energy into the substrate, lines were deposited by setting single overlapping points. In a design of experiments (DoE) study, the process parameters of laser power, laser spot area, step size, exposure time, and solidification time were varied and optimized by examining the clad width, weld penetration, and alloying depth. The microstructure of the samples was investigated by optical microscope (OM) and scanning electron microscopy (SEM), combined with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDX). Similarly to laser cladding of thicker substrates, the laser power shows the highest influence on the resulting clad. With a higher laser power, the clad width and alloying depth increase, and with a larger laser spot area the weld penetration decreases. If the process parameters are controlled precisely, laser cladding of such thin sheets is manageable. PMID:28772639
Influence of nanomodification additives on the properties of multilayer composite coating obtained in laser surfacing

NASA Astrophysics Data System (ADS)

Cherepanov, A. N.; Orishich, A. M.; Ovcharenko, V. E.; Malikov, A. G.; Drozdov, V. O.; Pshenichnikov, A. P.

2017-10-01

The paper presents the results of numerical and experimental studies of the process of obtaining a permanent joint of two plates of heterogeneous metals that cannot be welded in the usual way: alloy Grade 4 and steel AISI 321 using a laser beam and an intermediate composite insert. The composite insert was obtained by explosion welding of four thin plates of titanium (Grade 4), niobium, copper, and steel (AISI 321). The insert was placed between the welded plates of titanium and steel, and the steel plate was welded with the steel part of the insert, and the titanium plate was welded with the titanium part of the insert. The plates were welded using a CO2 laser. The connection of metals with the help of explosion is carried out without their melting, so the formation of the brittle intermetallics does not occur in most cases. This ensures the greatest strength of the joints as compared to the joints obtained by other welding methods. To analyze the distribution of thermal fields in the composite insert and welded plates, a numerical study was conducted of the laser welding of steel and titanium plates with the corresponding parts of the insert. The purpose of the study was to determine the rational parameters of welding (laser beam power, speed of its movement, size and position of the focal spot), at which there was no complete melting of the steel and titanium parts of the insert during through penetration of the welded plates. The experimental part of the work is devoted to analysis of formation of the internal boundaries and microstructure of the composite insert and the strength of the permanent joint. It is shown that as a result of the explosion welding, weld seams of different wavelike configuration are formed. The most pronounced wavelike boundary is observed in the steel-copper connection, since these materials have a face-centered cubic lattice and are easily subjected to plastic deformation. At the contact boundaries of the plates, transition diffusion zones with different widths (from 5 to 40 μm) and element concentrations are formed. The hardness in the boundary diffusion zones is higher than in the connected metals, which is due to the diffusion interaction of the materials adjacent to each other. It has been established that the tensile strength of the composite insert is comparable to the maximum strength of Grade 4 alloy (456-511 MPa), and the failure in most cases occurred over the least durable component of the composite material, which is the copper plate, whose strength was significantly increased by cold hardening during explosion welding and diffusion of elements of the contacting plates.
Detection of immunomagnetically captured 4',6-diamidino-2-phenyl-indole (DAPI)-labeled Escherichia coli 0157:H7 by fluorescent microscopic imaging

NASA Astrophysics Data System (ADS)

Tu, Shu-I.; Uknalis, Joseph; Patterson, Deidre; Gehring, Andrew G.

1999-01-01

Live cells of E. coliO157:H7 were captured by goat anti-E. coliO157 serum coated on the surface of polystyrene based immunomagnetic beads (IMB). The captured bacteria were labeled by 4',6-diamidino-2-phenylindole (DAPI), a nucleic acid stain, for observation by epifluorescent microscopy. The beads with captured bacteria were then concentrated by magnetic separators. The efficiency of this magnetic concentration step was less than that of using high speed centrifugation. The antibody-captured and IMB-immobilized bacteria were then applied on HF-treated, bovine serum albumin (BSA)-coated microscope slides mounted on an automated stage, and magnetically aligned before fluorescence distribution was measured by a cooled CCD attached to an inverted microscope. Since the beads were concentrated and linearly aligned along the edge of the magnetic field, image capture along the edge for a few field widths was sufficient to account for most of captured bacteria. We applied this approach to determine the bacterial counts in spiked beef hamburger patties. The results showed that after a 6-hour enrichment, sufficient number of the bacteria could be detected from the samples spiked with 1 CFU of E. coliO157:H7 per gram of the hamburger.
Rheology of welding: experimental constraints

NASA Astrophysics Data System (ADS)

Quane, S. L.; Russell, J. K.; Kennedy, L. A.

2003-04-01

The rheological behavior of pyroclastic deposits during welding is incompletely understood and is based on a surprisingly small number of experimental studies. Previous pioneering experimental studies were done on small (1 cm thick) samples of ash/crystal mixtures under constant load. They established minimum welding temperatures between 600 and 700^oC under loads of 0.7 MPa (˜40 m of ignimbrite) to 3.6 MPa (˜250 m depth of ignimbrite). However, these data are neither sufficiently comprehensive nor coherent enough to fully describe the rheology of pyroclastic mixtures. In addition, previous studies did not examine the microstructural and geometric changes associated with welding compaction. Our goal is to provide accurate and comprehensive constitutive relationships between material properties, temperature, load and strain rate for pyroclastic material undergoing welding. Here we present results from a newly designed experimental apparatus. The experimental apparatus consists of a LoadTrac II fully automated uniaxial compression load frame manufactured by Geocomp Corporation. The load frame has a built in displacement transducer and can run both constant strain rate (10-6 to 0.25 cm/s) and constant load (up to 1150 kg) tests to a maximum displacement of 7.5 cm. The sample assembly comprises 5 cm diameter cylindrical upper and lower pistons (insulating ceramic with steel conductive ends) housed in a copper jacket. Samples are 5 cm diameter cores and can vary in length from 1 to 15 cm depending on experimental needs. A fiber insulated tube furnace capable of reaching temperatures ≈1000^oC surrounds the sample assembly. Temperature is measured using a thermocouple located inside the sample through the bottom piston; the furnace controller is capable of maintaining temperature fluctuations to <5^oC. Deformation experiments are performed on pre-fabricated cylinders of soda-lime glass beads and rhyolitic volcanic ash, as well as, cores of pumiceous rhyodacite. Experimental runs use strain rates of 10-4 and 10-5 cm/s and loads of ˜0 to 4.5 MPa. Experiments are run at temperatures between 400 and 850^oC corresponding to below and above the calorimetric glass transition temperatures of the respective materials. Data deriving from constant load and constant strain rate experiments are being used to constrain rheological models for welding of pyroclastic material.
Influence of Laser Power on the Shape of Single Tracks in Scanner Based Laser Wire Cladding

NASA Astrophysics Data System (ADS)

Barroi, A.; Gonçalves, D. Albertazzi; Hermsdorf, J.; Kaierle, S.; Overmeyer, L.

The shape of the cladding tracks is extremely important for producing layers or structures by adding them sequently. This paper shows the influence of the laser power of a diode laser in the range of 500 to 1000 W on the shapes of single tracks in scanner based laser wire cladding. The scanner was used to oscillate the beam perpendiculary to the welding direction. Stainless steel (ER 318 Si) wire with a 0.6 mm diameter was used as deposition material. Height, width, penetration, molten area and weld seam angles of single tracks were obtained from cross-sections at three different positions of each track. The influence of these different positions on the results depends on the traverse speed. The paper discusses this influence in respect to the heat dissipation in the substrate material.
Study of the structure and properties of laser-welded joints of the Al-Mg-Li alloy

NASA Astrophysics Data System (ADS)

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

2015-12-01

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

NASA Astrophysics Data System (ADS)

Maleque, M. A.; Bello, K. A.; Adebisi, A. A.; Akma, N.

2017-03-01

Tungsten inert gas (TIG) torch is one of the most recently used heat source for surface modification of engineering parts, giving similar results to the more expensive high power laser technique. In this study, ceramic-based embedded composite coating has been produced by precoated silicon carbide (SiC) powders on the AISI 4340 low alloy steel substrate using TIG welding torch process. A design of experiment based on Taguchi approach has been adopted to optimize the TIG cladding process parameters. The L9 orthogonal array and the signal-to-noise was used to study the effect of TIG welding parameters such as arc current, travelling speed, welding voltage and argon flow rate on tribological response behaviour (wear rate, surface roughness and wear track width). The objective of the study was to identify optimal design parameter that significantly minimizes each of the surface quality characteristics. The analysis of the experimental results revealed that the argon flow rate was found to be the most influential factor contributing to the minimum wear and surface roughness of the modified coating surface. On the other hand, the key factor in reducing wear scar is the welding voltage. Finally, a convenient and economical Taguchi approach used in this study was efficient to find out optimal factor settings for obtaining minimum wear rate, wear scar and surface roughness responses in TIG-coated surfaces.
Experimental study on the formation of subaqueous barchan dunes in closed conduits

NASA Astrophysics Data System (ADS)

Alvarez, Carlos A.; Franklin, Erick

2018-06-01

The present paper reports the formation of subaqueous barchan dunes by analyzing the temporal evolution of their main geometrical characteristics (width W, length L and horn lengths Lh). After certain time, the dunes reach an equilibrium state and it is possible to study the relation between W versus L, and the dependence of the dune velocity on L. The barchan dunes were formed from spherical glass and zirconium beads. An initial conical heap of beads was placed on the bottom wall of a rectangular channel and it was entrained by a water turbulent flow. The evolution of the dunes was filmed with a CCD camera placed above the channel and mounted on a traveling system. Our results show that after a characteristic time the dune shape does not change and it travels with a roughly constant velocity. Once the equilibrium state is reach, W and L are measured, showing linear dependence. Furthermore, we show that the dune velocity Vd scales with the inverse of the dune length.
A Summary of the Evaluation of PPG Herculite XP Glass in Punched Window and Storefront Assemblies

DTIC Science & Technology

2013-01-01

frames for all IGU windows extruded from existing dies. The glazing was secured to the frame on all four sides with a 1/2-in bead width of DOW 995...lite and non-laminated IGU debris tests. A wood frame with a 4-in wide slit was placed behind the window to transform the debris cloud into a narrow...speed camera DIC Set-up laser deflection gauge shock tube window wood frame with slit high speed camerawell lit backdrop Debris Tracking Set-up laser
Molecular dynamics study of lubricant depletion by pulsed laser heating

NASA Astrophysics Data System (ADS)

Seo, Young Woo; Rosenkranz, Andreas; Talke, Frank E.

2018-05-01

In this study, molecular dynamics simulations were performed to numerically investigate the effect of pulsed laser heating on lubricant depletion. The maximum temperature, the lubricant depletion width, the number of evaporated lubricant beads and the number of fragmented lubricant chains were studied as a function of laser peak power, pulse duration and repetition rate. A continuous-wave laser and a square pulse laser were simulated and compared to a Gaussian pulse laser. With increasing repetition rate, pulsed laser heating was found to approach continuous-wave laser heating.
Essais de fissuration a froid appliques aux metaux d'apport inoxydables martensitiques 410NiMo

NASA Astrophysics Data System (ADS)

Paquin, Mathieu

Martensitic stainless steels have represented since few years a material of choice for the manufacture of mechanical parts such as hydroelectric turbines. The development of the alloy has led to grades with very low amount of carbon giving them a good weldability. The assembly of these parts, made by autogenous welding, requires the use of materials with low transformation temperature (LTT) such as 410NiMo. These filler metals are also used for assembly by heterogeneous welding of steel parts susceptible to cold cracking. The transformation of austenite to martensite occurring at low temperature, residual stresses from single-pass welding operation are different from those normally found and reduce the risk of cracking. By cons, industrial experience shows that in situation of multipass welding, the risks of cold cracking are still present. This project aimed to determine a cracking test for assessing susceptibility to cold cracking of 13%Cr-4%Ni stainless steel according to the welding procedure, in autogenous welding situation. Literature contains much information about cold cracking phenomena. That phenomena occurs under three conditions. These conditions are: a high diffusible hydrogen level, significant residual stresses and a brittle microstructure. It seems that despite the low mass ratio of carbon (0.022%C) and the low diffusible hydrogen level (< 3 ml/100g) risks of cold cracking remain present during multipass deposits. Use of cracking tests was necessary to assess the sensitivity to cracking of the martensitic stainless steel. Before the work preliminary tests have been made or tested Tekken GBOP and testing to determine that to obtain the most representative of the industrial reality results. Then they have been modified to reverse the compression stress in the seam test to tension by the addition of a second weld. This inversion occurs in multipass welding and has been targeted as an important factor in the occurrence of cold cracking phenomenon. The results of these tests show that Tekken test is not suitable for LTT testing. It was also demonstrated that GBOP test with two juxtaposed seams configuration gave results consistent with the industrial observations. The second stage of the project was to study the cracking test selected. Acoustic emission tests were done during welding and cooling of GBOP test. These tests were conducted in order to detect when the cracking of the test occurred and to validate the method of inspection. This inspection is done after separation of the specimen, by observation of the fracture surface. Usually, cliveage zone on the fracture surface can be associated with cold cracking and dimple zones can be associated with the specimen separation. Through these tests, it was possible to validate this assertion. Then the relevance of the addition of a second weld has been validated by studying the residual stress by the contour method. It was possible to observe an area of the first bead in tension, promoting cracking of the test. Finally, some test runs were made with various filler metals in order to confirm that the utilization of the modified GBOP test for 13%Cr-4%Ni was adequate. A fractographic study of some sample was also made.
Taguchi Optimization of Pulsed Current GTA Welding Parameters for Improved Corrosion Resistance of 5083 Aluminum Welds

NASA Astrophysics Data System (ADS)

Rastkerdar, E.; Shamanian, M.; Saatchi, A.

2013-04-01

In this study, the Taguchi method was used as a design of experiment (DOE) technique to optimize the pulsed current gas tungsten arc welding (GTAW) parameters for improved pitting corrosion resistance of AA5083-H18 aluminum alloy welds. A L9 (34) orthogonal array of the Taguchi design was used, which involves nine experiments for four parameters: peak current ( P), base current ( B), percent pulse-on time ( T), and pulse frequency ( F) with three levels was used. Pitting corrosion resistance in 3.5 wt.% NaCl solution was evaluated by anodic polarization tests at room temperature and calculating the width of the passive region (∆ E pit). Analysis of variance (ANOVA) was performed on the measured data and S/ N (signal to noise) ratios. The "bigger is better" was selected as the quality characteristic (QC). The optimum conditions were found as 170 A, 85 A, 40%, and 6 Hz for P, B, T, and F factors, respectively. The study showed that the percent pulse-on time has the highest influence on the pitting corrosion resistance (50.48%) followed by pulse frequency (28.62%), peak current (11.05%) and base current (9.86%). The range of optimum ∆ E pit at optimum conditions with a confidence level of 90% was predicted to be between 174.81 and 177.74 mVSCE. Under optimum conditions, the confirmation test was carried out, and the experimental value of ∆ E pit of 176 mVSCE was in agreement with the predicted value from the Taguchi model. In this regard, the model can be effectively used to predict the ∆ E pit of pulsed current gas tungsten arc welded joints.
Manually Operated Welding Wire Feeder

NASA Technical Reports Server (NTRS)

Rybicki, Daniel J. (Inventor)

2001-01-01

A manual welding wire feeder apparatus comprising a bendable elongate metal frame with a feed roller mounted at the center thereof for rotation about an axis transverse to the longitudinal axis of the frame. The frame ends are turned up as tabs and each provided with openings in alignment with each other and the mid-width center of the roller surface. The tab openings are sized to accommodate welding wire and each extends to a side edge of the tab, both opening on the same side of the frame, whereby welding wire can be side-loaded onto the frame. On the side of the frame, opposite the roller a lock ring handle is attached tangentially and is rotatable about the attachment point and an axis perpendicular to the frame. The device is grasped in the hand normally used to hold the wire. A finger is placed through the loop ring and the frame positioned across the palm and lower fingers. The thumb is positioned atop the wire so it can be moved from the back of the frame across the roller, and towards the front. In doing so, the wire is advanced at a steady rate in axial alignment with the tab openings and roller. To accommodate different wire diameters the frame is bendable about its center in the plane of the frame axis and wire so as to keep the wire in sufficient tension against the roller and to keep the wire fixed when the frame is tilted and thumb pressure released.

Method of simulating spherical voids for use as a radiographic standard

DOEpatents

Foster, Billy E.

1977-01-01

A method of simulating small spherical voids in metal is provided. The method entails drilling or etching a hemispherical depression of the desired diameter in each of two sections of metal, the sections being flat plates or different diameter cylinders. A carbon bead is placed in one of the hemispherical voids and is used as a guide to align the second hemispherical void with that in the other plate. The plates are then bonded together with epoxy, tape or similar material and the two aligned hemispheres form a sphere within the material; thus a void of a known size has been created. This type of void can be used to simulate a pore in the development of radiographic techniques of actual voids (porosity) in welds and serve as a radiographic standard.
Cooling Rate Determination in Additively Manufactured Aluminum Alloy 2219

NASA Astrophysics Data System (ADS)

Brice, Craig A.; Dennis, Noah

2015-05-01

Metallic additive manufacturing processes generally utilize a conduction mode, welding-type approach to create beads of deposited material that can be arranged into a three-dimensional structure. As with welding, the cooling rates in the molten pool are relatively rapid compared to traditional casting techniques. Determination of the cooling rate in the molten pool is critical for predicting the solidified microstructure and resultant properties. In this experiment, wire-fed electron beam additive manufacturing was used to melt aluminum alloy 2219 under different thermal boundary conditions. The dendrite arm spacing was measured in the remelted material, and this information was used to estimate cooling rates in the molten pool based on established empirical relationships. The results showed that the thermal boundary conditions have a significant effect on the resulting cooling rate in the molten pool. When thermal conduction is limited due to a small thermal sink, the dendrite arm spacing varies between 15 and 35 µm. When thermal conduction is active, the dendrite arm spacing varies between 6 and 12 µm. This range of dendrite arm spacing implies cooling rates ranging from 5 to 350 K/s. Cooling rates can vary greatly as thermal conditions change during deposition. A cooling rate at the higher end of the range could lead to significant deviation from microstructural equilibrium during solidification.
Local divergence and curvature divergence in first order optics

NASA Astrophysics Data System (ADS)

Mafusire, Cosmas; Krüger, Tjaart P. J.

2018-06-01

The far-field divergence of a light beam propagating through a first order optical system is presented as a square root of the sum of the squares of the local divergence and the curvature divergence. The local divergence is defined as the ratio of the beam parameter product to the beam width whilst the curvature divergence is a ratio of the space-angular moment also to the beam width. It is established that the beam’s focusing parameter can be defined as a ratio of the local divergence to the curvature divergence. The relationships between the two divergences and other second moment-based beam parameters are presented. Their various mathematical properties are presented such as their evolution through first order systems. The efficacy of the model in the analysis of high power continuous wave laser-based welding systems is briefly discussed.
CONTROL ROD

DOEpatents

Zinn, W.H.; Ross, H.V.

1958-11-18

A control rod is described for a nuclear reactor. In certaln reactor designs it becomes desirable to use a control rod having great width but relatively llttle thickness. This patent is addressed to such a need. The neutron absorbing material is inserted in a triangular tube, leaving volds between the circular insert and the corners of the triangular tube. The material is positioned within the tube by the use of dummy spacers to achleve the desired absorption pattern, then the ends of the tubes are sealed with suitable plugs. The tubes may be welded or soldered together to form two flat surfaces of any desired width, and covered with sheetmetal to protect the tubes from damage. This design provides a control member that will not distort under the action of outside forces or be ruptured by gases generated within the jacketed control member.
Experimental saltwater intrusion in coastal aquifers using automated image analysis: Applications to homogeneous aquifers

NASA Astrophysics Data System (ADS)

Robinson, G.; Ahmed, Ashraf A.; Hamill, G. A.

2016-07-01

This paper presents the applications of a novel methodology to quantify saltwater intrusion parameters in laboratory-scale experiments. The methodology uses an automated image analysis procedure, minimising manual inputs and the subsequent systematic errors that can be introduced. This allowed the quantification of the width of the mixing zone which is difficult to measure in experimental methods that are based on visual observations. Glass beads of different grain sizes were tested for both steady-state and transient conditions. The transient results showed good correlation between experimental and numerical intrusion rates. The experimental intrusion rates revealed that the saltwater wedge reached a steady state condition sooner while receding than advancing. The hydrodynamics of the experimental mixing zone exhibited similar traits; a greater increase in the width of the mixing zone was observed in the receding saltwater wedge, which indicates faster fluid velocities and higher dispersion. The angle of intrusion analysis revealed the formation of a volume of diluted saltwater at the toe position when the saltwater wedge is prompted to recede. In addition, results of different physical repeats of the experiment produced an average coefficient of variation less than 0.18 of the measured toe length and width of the mixing zone.
Solar diameter measurements from eclipses as a solar variability proxy

NASA Astrophysics Data System (ADS)

Dunham, David W.; Sofia, Sabatino; Guhl, Konrad; Herald, David

The widths of total solar eclipse paths depends on the diameter of the Sun, so if observations are obtained near both the northern and southern limits of the eclipse path, in principle, the angular diameter of the Sun can be measured. Concerted efforts have been made to obtain contact timings from locations near total solar eclipse path edges since the mid 19th century, and Edmund Halley organized a rather successful first effort in 1715. Members of IOTA have been making increasingly sophisticated observations of the Baily's bead phenomena near central solar eclipse path edges since 1970.
Environmental and alloying effects on corrosion of metals and alloys

NASA Astrophysics Data System (ADS)

Liang, Dong

2009-12-01

In the first part of this project, corrosion studies were carried out on 304L stainless steel samples welded with Cr-free consumables, which were developed to minimize the concentration of chromate species in the weld fume. The corrosion properties of Ni-Cu and Ni-Cu-Pd Gas Tungsten Arc (GTA) welds and Shielded Metal Arc (SMA) welds are comparable to those of welds fabricated with SS308L consumable, which is the standard consumable for welding 304L. Although the breakdown potentials of the new welds from both welding processes are lower than that of the SS308L weld, the repassivation potential of these new welds is much higher. Generally, the repassivation potential is a more conservative measure of susceptibility to localized corrosion. Our studies showed that the Ni-Cu and Ni-Cu-Pd welds are more resistant to crevice corrosion than SS308L welds, which is related to the high repassivation potential. Also, addition of Pd improved the corrosion resistance of the new welds, which is consistent with previous studies from button samples and bead-on-plate samples. Other corrosion studies such as creviced and uncreviced long time immersion, atmospheric exposure, and slow strain rate testing suggest that Ni-Cu-Pd welds can be a qualified substitute for SS308 weld. In the second part of this project, efforts are put on the connection between lab and field exposure tests because sometimes the correspondence between lab atmospheric corrosion tests (ASTM B117) and field exposures is poor as a result of differences in the critical conditions controlling chemical and electrochemical reactions on surfaces. Recent studies in atmospheric chemistry revealed the formation of extremely reactive species from interactions between UV light, chloride aerosols above oceans and oxidizing agents such as ozone or peroxide. Atmospheric corrosion of metals can be affected by these species which might be transported long distances in the atmosphere to locations far from oceans. However, these species could be missed in standard laboratory exposures such as ASTM B117. Initial efforts focused on the effects UV radiation, O3, relative humidity on the atmospheric corrosion of bare silver. Later work addressed the corrosion of silver samples deposited with NaCl particles. An exposure chamber that can simulate various environmental effects was built. The effects of UV radiation, O3, and relative humidity were varied separately while keeping the other factors the same level. The corrosion products were analyzed by the galvanostatic reduction method and characterization techniques such as SEM and EDS. It was found that both UV and O3 are necessary for fast corrosion on bare silver and this fast corrosion reaction results from atomic oxygen generated photodegradation of O3. In the presence of UV and O3, relative humidity has little effect on the atmospheric corrosion of bare silver in contrast to conventional atmospheric corrosion. The degree of corrosion is found to increase with O3 concentration. Moreover, a kinetic study of atmospheric corrosion of bare silver found that an incubation time for the atmospheric corrosion attack is needed. This incubation time is related to the chemisorption process of atomic oxygen. Though UV radiation can form reactive atomic oxygen which is more reactive than O3 alone as shown in the last chapter, the enhancement of corrosion by UV is limited for Ag with NaCl particles at low ozone concentration and high RH. The corrosion rate of silver with NaCl particles is found to increase with relative humidity, which is different than the case of bare silver. This indicates that different mechanisms control the atmospheric corrosion of silver. The incubation time for corrosion of silver with NaCl particles is shorter than for bare silver. This result from chemisorption of Cl 2 is favored over that of atomic oxygen. Interestingly, the total corrosion product of silver with NaCl particles is less than that of bare silver. This could be due to limited amount of NaCl and also higher oxidizing power of atomic oxygen. Finally, bare silver samples were exposed in salt spray chamber according to ASTM B117 up to 4 months. Very little corrosion products were detected after exposure, which is attributed to the lack of reactive species such as O and O3 in the environment. (Abstract shortened by UMI.)
Negative feedback in ants: crowding results in less trail pheromone deposition

PubMed Central

Czaczkes, Tomer J.; Grüter, Christoph; Ratnieks, Francis L. W.

2013-01-01

Crowding in human transport networks reduces efficiency. Efficiency can be increased by appropriate control mechanisms, which are often imposed externally. Ant colonies also have distribution networks to feeding sites outside the nest and can experience crowding. However, ants do not have external controllers or leaders. Here, we report a self-organized negative feedback mechanism, based on local information, which downregulates the production of recruitment signals in crowded parts of a network by Lasius niger ants. We controlled crowding by manipulating trail width and the number of ants on a trail, and observed a 5.6-fold reduction in the number of ants depositing trail pheromone from least to most crowded conditions. We also simulated crowding by placing glass beads covered in nest-mate cuticular hydrocarbons on the trail. After 10 bead encounters over 20 cm, forager ants were 45 per cent less likely to deposit pheromone. The mechanism of negative feedback reported here is unusual in that it acts by downregulating the production of a positive feedback signal, rather than by direct inhibition or the production of an inhibitory signal. PMID:23365196
Fabrication of high aspect ratio nanogrid transparent electrodes via capillary assembly of Ag nanoparticles

NASA Astrophysics Data System (ADS)

Kang, Juhoon; Park, Chang-Goo; Lee, Su-Han; Cho, Changsoon; Choi, Dae-Geun; Lee, Jung-Yong

2016-05-01

In this report, we describe the fabrication of periodic Ag nanogrid electrodes by capillary assembly of silver nanoparticles (AgNPs) along patterned nanogrid templates. By assembling the AgNPs into these high-aspect-ratio nanogrid patterns, we can obtain high-aspect-ratio nanogratings, which can overcome the inherent trade-off between the optical transmittance and the sheet resistance of transparent electrodes. The junction resistance between the AgNPs is effectively reduced by photochemical welding and post-annealing. The fabricated high-aspect-ratio nanogrid structure with a line width of 150 nm and a height of 450 nm has a sheet resistance of 15.2 Ω sq-1 and an optical transmittance of 85.4%.In this report, we describe the fabrication of periodic Ag nanogrid electrodes by capillary assembly of silver nanoparticles (AgNPs) along patterned nanogrid templates. By assembling the AgNPs into these high-aspect-ratio nanogrid patterns, we can obtain high-aspect-ratio nanogratings, which can overcome the inherent trade-off between the optical transmittance and the sheet resistance of transparent electrodes. The junction resistance between the AgNPs is effectively reduced by photochemical welding and post-annealing. The fabricated high-aspect-ratio nanogrid structure with a line width of 150 nm and a height of 450 nm has a sheet resistance of 15.2 Ω sq-1 and an optical transmittance of 85.4%. Electronic supplementary information (ESI) available. See DOI: 10.1039/c6nr01896c
Thermal Edge-Effects Model for Automated Tape Placement of Thermoplastic Composites

NASA Technical Reports Server (NTRS)

Costen, Robert C.

2000-01-01

Two-dimensional thermal models for automated tape placement (ATP) of thermoplastic composites neglect the diffusive heat transport that occurs between the newly placed tape and the cool substrate beside it. Such lateral transport can cool the tape edges prematurely and weaken the bond. The three-dimensional, steady state, thermal transport equation is solved by the Green's function method for a tape of finite width being placed on an infinitely wide substrate. The isotherm for the glass transition temperature on the weld interface is used to determine the distance inward from the tape edge that is prematurely cooled, called the cooling incursion Delta a. For the Langley ATP robot, Delta a = 0.4 mm for a unidirectional lay-up of PEEK/carbon fiber composite, and Delta a = 1.2 mm for an isotropic lay-up. A formula for Delta a is developed and applied to a wide range of operating conditions. A surprise finding is that Delta a need not decrease as the Peclet number Pe becomes very large, where Pe is the dimensionless ratio of inertial to diffusive heat transport. Conformable rollers that increase the consolidation length would also increase Delta a, unless other changes are made, such as proportionally increasing the material speed. To compensate for premature edge cooling, the thermal input could be extended past the tape edges by the amount Delta a. This method should help achieve uniform weld strength and crystallinity across the width of the tape.
Effect of Heat Input on Microstructure Evolution and Mechanical Properties in the Weld Heat-Affected Zone of 9Cr-2W-VTa Reduced Activation Ferritic-Martensitic Steel for Fusion Reactor

NASA Astrophysics Data System (ADS)

Moon, Joonoh; Lee, Chang-Hoon; Lee, Tae-Ho; Kim, Hyoung Chan

2015-01-01

The phase transformation and mechanical properties in the weld heat-affected zone (HAZ) of a reduced activation ferritic/martensitic steel were explored. The samples for HAZs were prepared using a Gleeble simulator at different heat inputs. The base steel consisted of tempered martensite and carbides through quenching and tempering treatment, whereas the HAZs consisted of martensite, δ-ferrite, and a small volume of autotempered martensite. The prior austenite grain size, lath width of martensite, and δ-ferrite fraction in the HAZs increased with increase in the heat input. The mechanical properties were evaluated using Vickers hardness and Charpy V-notch impact test. The Vickers hardness in the HAZs was higher than that in the base steel but did not change noticeably with increase in the heat input. The HAZs showed poor impact property due to the formation of martensite and δ-ferrite as compared to the base steel. In addition, the impact property of the HAZs deteriorated more with the increase in the heat input. Post weld heat treatment contributed to improve the impact property of the HAZs through the formation of tempered martensite, but the impact property of the HAZs remained lower than that of base steel.
Structural, mechanical and corrosion studies of Cr-rich inclusions in 152 cladding of dissimilar metal weld joint

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

Wang, Wei, E-mail: wang_wei_310@163.com; Lu, Yonghao, E-mail: lu_yonghao@mater.ustb.edu.cn; Ding, Xianfei, E-mail: xfding@ustb.edu.cn

Microstructures and microhardness at fusion boundary of a weld joint were investigated in a 316 stainless steel/Inconel 182 dissimilar weldment. The results showed that there were two alternately distributed typical fusion boundaries, a narrow random boundary (possessed 15% in length) with a clear sharp interface and an epitaxial fusion one with (100){sub BM}//(100){sub WM} at the joint interface. The composition transition, microstructure and hardness across the fusion boundary strongly depended on the type of the fusion boundary. For the random boundary, there was a clear sharp interface and the composition transition with a width of 100 μm took place symmetricallymore » across the grain boundary. For the epitaxial fusion one, however, there were Type-I and Type-II grain boundaries perpendicular and parallel to the epitaxial fusion boundary, respectively. The composition transition took place in the Inconel 182 weld side. Σ3 boundaries in the HAZ of 316SS side and Σ5 grain boundaries in weld metal were usually observed, despite the type of fusion boundary, however the former was much more in epitaxial fusion boundary. Microhardness was continuously decreased across the random fusion boundary from the side of Inconel 182 to 316SS, but a hardening phenomenon appeared in the epitaxial fusion boundary zone because of its fine cellular microstructure. - Highlights: • Two typical fusion boundaries alternately distributed in the fusion interface • The microstructure, composition and hardness across fusion boundary depended on its type. • Different regions in welded joint have different special CSL value boundaries. • Hardening phenomenon only appeared in the epitaxial fusion boundary.« less
Effect of heat input on microstructure and properties of hybrid fiber laser-arc weld joints of the 800 MPa hot-rolled Nb-Ti-Mo microalloyed steels

NASA Astrophysics Data System (ADS)

Wang, X.-N.; Zhang, S.-H.; Zhou, J.; Zhang, M.; Chen, C.-J.; Misra, R. D. K.

2017-04-01

Hybrid fiber laser-arc welding (HLAW) process was applied to a novel hot-rolled Nb-Ti-Mo microalloyed steels of 8 mm thickness. The steel is primarily used to manufacture automotive and construction machinery components, etc. To elucidate the effect of heat input on geometry, microstructure and mechanical properties, different heat inputs (3.90, 5.20 and 7.75 kJ/cm) were used by changing the welding speeds. With increased heat input, the depth/width of penetration was decreased, and the geometry of fusion zone (FZ) changed to "wine cup-like" shape. In regard to the microstructural constituents, the martensite content was decreased, but granular bainite (GB) content was increased. The main microstructural difference was in the FZ cross-section at 7.75 kJ/cm because of the effect of thermal source on the top and bottom. The microstructure of the top part consisted of GB, grain boundary ferrite, and acicular ferrite, while the bottom part was primarily lath martensite. The hardness distribution was similar for different heat inputs. Hardness in FZ, coarse-grained HAZ and mixed-grained HAZ was higher than the base metal (BM), but for the fine-grained HAZ was similar or marginally less than the base metal (BM). Tensile strain was concentrated in the BM such that the fracture occurred in this region. In summary, the geometry, microstructure, and mechanical properties of weld joints were superior at heat input of 5.20 kJ/cm.
Interdiffusion behavior of tungsten or rhenium and group 5 and 6 elements and alloys of the periodic table. Part 2A: Appendices A-G

NASA Technical Reports Server (NTRS)

Arcella, F. G.

1974-01-01

Arc cast W, CVD, W, CVD Re, and powder metallurgy Re materials were hot isostatically pressure welded to ten different refractory metals and alloys and thermally aged at 10 to the minus 8th power torr at 1200 C, 1500 C, 1630 C, 1800 C, and 2000 C for 100 hours to 2000 hours. Electron beam microprobe analysis was used to characterize the interdiffusion zone width of each couple system as a function of age time and temperature. Each system was least squares fitted to the equation: In (delta X sq/t) = B/T + A, where delta X is net interdiffusion zone width, t is age time, and T is age temperature. Detailed descriptions of experimental and analytical procedures utilized in conducting the experimental program are provided. For Vol. 1, see N74-34046.
Structural transformations in hull material clad by nitrogen stainless steel using various methods

NASA Astrophysics Data System (ADS)

Sagaradze, V. V.; Kataeva, N. V.; Mushnikova, S. Yu.; Khar'kov, O. A.; Kalinin, G. Yu.; Yampol'skii, V. D.

2014-02-01

Specimens of a 10N3KhDMBF shipbuilding hull steel were clad by a 04Kh20N6G11M2AFB nitrogen austenitic steel using various treatment conditions, which included hot rolling, austenitic facing, and explosive welding followed by hot rolling and heat treatment. Between the base and cladding materials, an intermediate layer with variable concentrations of chromium, manganese, and nickel was found, in which a martensitic structure was formed. In all the cases, the strength of bonding of the cladding layer to the hull steel (determined in tests for shear to fracture) was fairly high (σsh = 437-520 MPa). The only exception was the specimen produced by unidirectional facing without subsequent hot rolling (σsh = 308 MPa), in which nonfusions between the faced beads of stainless steel were detected.
Least Cost Test Profile. Volume II.

DTIC Science & Technology

1982-04-01

LAMINATION ON WALL HAS SEPARATED. 61 A) SSRS-625B - ROOF LEAKS A LITTLE. THEY WERE CAULKED AT RIVET POINTS WITH RTV. D-12 TABLE GENERAL COMMENTS ES-57...transported in a 5 ton large truck bed because of width. Flatbed semi trailer requires two forklifts or a large crane and spreader assy to load them. G-4...1"A’d Test Inspection Paragraph Paragraph Cleaning 3.4.2 4.6.4 Welding 3.4.3 4.6.5 Lamination 3.4.4 4.6.6 Interchangeability 3.4.6 4.6.8 Riveting
Effect of Thread and Rotating Speed on Material Flow Behavior and Mechanical Properties of Friction Stir Lap Welding Joints

NASA Astrophysics Data System (ADS)

Ji, Shude; Li, Zhengwei; Zhou, Zhenlu; Wu, Baosheng

2017-10-01

This study focused on the effects of thread on hook and cold lap formation, lap shear property and impact toughness of alclad 2024-T4 friction stir lap welding (FSLW) joints. Except the traditional threaded pin tool (TR-tool), three new tools with different thread locations and orientations were designed. Results showed that thread significantly affected hook, cold lap morphologies and lap shear properties. The tool with tip-threaded pin (T-tool) fabricated joint with flat hook and cold lap, which resulted in shear fracture mode. The tools with bottom-threaded pin (B-tool) eliminated the hook. The tool with reverse-threaded pin (R-tool) widened the stir zone width. When using configuration A, the joints fabricated by the three new tools showed higher failure loads than the joint fabricated by the TR-tool. The joint using the T-tool owned the optimum impact toughness. This study demonstrated the significance of thread during FSLW and provided a reference to optimize tool geometry.
Welding bulk metallic glass using nanostructured reactive multilayer foils

NASA Astrophysics Data System (ADS)

Trenkle, Jonathan C.

We have used Al/Ni reactive foils to weld Zr57Ti 5Cu20Ni8Al10 metallic glasses. The welds are a composite morphology comprised of glass ligaments and intermetallic AlNi (the product of the reactive foil). The presence of the presumably brittle intermetallic (in lieu of the glass) is expected to limit the mechanical properties of the welds. Based on fracture toughness measurements and the crack propagation paths, we conclude that virtually all of the toughness can be ascribed to the presence of the metallic glass ligaments. Increasing the pressure applied during welding increases the fraction of the joint made of these ligaments and so increases the fracture toughness as well. To eliminate the intermetallic from the weld altogether, we attempted to fabricate reactive mulitlayer foils that form an amorphous product by melting and cooling rapidly during a self-propagating reaction. We began with reactive foils with overall composition Zr2Ni but quickly determined that the foils did not fully melt. We then attempted to lower the melting temperature and increase the glass forming ability and the heat of mixing by adding Al and Cu. These foils again did not fully melt. Finally we systematically determined that foils of overall compositions Hf37Ni63, Ni 80P20, and Ni60P40, which are all known binary metallic glasses, will potentially melt during a self-propagating reaction. Knowledge of the phase transformations during a self-propagating reaction is necessary to engineer reactive foils for future applications. Furthermore, reactive foils provide an opportunity to study phase transformations under high heating rates not easily achievable. Characterizing the processes in the reaction zone however is challenging, requiring both temporal resolution better than ˜ 100 mus (the time required for the reaction front to pass a fixed location) and spatial resolution of < 100 mum (the approximate width of the reaction zone). Using synchrotron x-ray radiation, we have studied these phase transformations in situ in Al/Ni multilayers. Unlike previous annealing and quenching studies in these multilayers, we observed no metastable or intermediate phases.
Microhardness, strength and strain field characterization of self-reacting friction stir and plug welds of dissimilar aluminum alloys

NASA Astrophysics Data System (ADS)

Horton, Karla Renee

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. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA2014-T6 plate on the advancing side and an AA2219-T87 plate on the retreating side and a SR-FSW (AA2014-T6 to AA2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures. The initial weld microstructure analysis showed a nugget region with fine grains and a displaced weld seam from the advancing side past the thermo-mechanical affected zone (TMAZ) into the nugget region. The displaced material shared the same hardness as the parent material. Dynamic recrystallization was observed in the SR-FSW zone and the displaced weld seam region. The welds revealed a fine grain structure in the SR-FSW zone with a sharp demarcation seen on the advancing side and fairly diffuse flow observed on the retreating side. The parent material hardness is 145 HV700g with a drop in hardness starting at the HAZ to 130 HV700g. The hardness further drops in the TMAZ to118 HV700g with an increase representing a dispersed interface of AA2014-T6 material to 135 HV700g. The hardness then drops significantly within the nugget region to 85 HV700g followed by an increase through the retreating side TMAZ into the HAZ to 135 HV 700g. There was a sharp increase in the hardness value within the nugget region with the samples that were PWHT showing an increase of 58%. The welded joints were tested for ultimate strength. The testing variations included two specimen widths, two plug sizes (M3 and M5), room temperature and cryogenic testing, and post weld heat treated (PWHT) samples. Initial welds had an average ultimate strength of 370 MPa. There was a slight drop from initial weld strength to plug weld strength of approximately 13.8 MPa was observed with M3 plug strength approximately equal to M5 plug strength. The PWHT strengths at room temperature were slightly higher than non-PWHT of 13.8--20.7 MPa and PWHT strengths were equal to non-PWHT at cryogenic temperature. Non-PWHT had a cryogenic strength enhancement approximately 59.2 MPa and PWHT had a cryogenic strength enhancement of approximately 57.2 MPa in the M3 and M5 plugs. Within the subsets of data collected no major statistical significance in strength behavior was observed between the samples tested at room temperature or between the subsets tested at LN2. In almost all cases, failure occurred on the retreating side of the weld which corresponds to the softer material (AA2219-T87). Exceptions were characterized with flaws (weld defects) in the sample. In these cases, failure occurred on the advancing side, the side where flaws were detected. Ductile fracture was noted in most all samples. Digital image correlation using the ARAMIS system was used to define strain patterns in the weld joint. Strain accumulation was observed in the weld along the retreating side and around the plug. ARAMIS data in comparison to extensometer data shows a very reasonable comparison. The ARAMIS strain gage data showed the retreating side of the major diameter has a greater yield than the advancing side. This behavior is identical to the external electrical resistance strain gages.

Tortuosity measurement and the effects of finite pulse widths on xenon gas diffusion NMR studies of porous media

NASA Technical Reports Server (NTRS)

Mair, R. W.; Hurlimann, M. D.; Sen, P. N.; Schwartz, L. M.; Patz, S.; Walsworth, R. L.

2001-01-01

We have extended the utility of NMR as a technique to probe porous media structure over length scales of approximately 100-2000 microm by using the spin 1/2 noble gas 129Xe imbibed into the system's pore space. Such length scales are much greater than can be probed with NMR diffusion studies of water-saturated porous media. We utilized Pulsed Gradient Spin Echo NMR measurements of the time-dependent diffusion coefficient, D(t), of the xenon gas filling the pore space to study further the measurements of both the pore surface-area-to-volume ratio, S/V(p), and the tortuosity (pore connectivity) of the medium. In uniform-size glass bead packs, we observed D(t) decreasing with increasing t, reaching an observed asymptote of approximately 0.62-0.65D(0), that could be measured over diffusion distances extending over multiple bead diameters. Measurements of D(t)/D(0) at differing gas pressures showed this tortuosity limit was not affected by changing the characteristic diffusion length of the spins during the diffusion encoding gradient pulse. This was not the case at the short time limit, where D(t)/D(0) was noticeably affected by the gas pressure in the sample. Increasing the gas pressure, and hence reducing D(0) and the diffusion during the gradient pulse served to reduce the previously observed deviation of D(t)/D(0) from the S/V(p) relation. The Pade approximation is used to interpolate between the long and short time limits in D(t). While the short time D(t) points lay above the interpolation line in the case of small beads, due to diffusion during the gradient pulse on the order of the pore size, it was also noted that the experimental D(t) data fell below the Pade line in the case of large beads, most likely due to finite size effects.
Droplet-based magnetic bead immunoassay using microchannel-connected multiwell plates (μCHAMPs) for the detection of amyloid beta oligomers.

PubMed

Park, Min Cheol; Kim, Moojong; Lim, Gun Taek; Kang, Sung Min; An, Seong Soo A; Kim, Tae Song; Kang, Ji Yoon

2016-06-21

Multiwell plates are regularly used in analytical research and clinical diagnosis but often require laborious washing steps and large sample or reagent volumes (typically, 100 μL per well). To overcome such drawbacks in the conventional multiwell plate, we present a novel microchannel-connected multiwell plate (μCHAMP) that can be used for automated disease biomarker detection in a small sample volume by performing droplet-based magnetic bead immunoassay inside the plate. In this μCHAMP-based immunoassay platform, small volumes (30-50 μL) of aqueous-phase working droplets are stably confined within each well by the simple microchannel structure (200-300 μm in height and 0.5-1 mm in width), and magnetic beads are exclusively transported into an adjacent droplet through the oil-filled microchannels assisted by a magnet array aligned beneath and controlled by a XY-motorized stage. Using this μCHAMP-based platform, we were able to perform parallel detection of synthetic amyloid beta (Aβ) oligomers as a model analyte for the early diagnosis of Alzheimer's disease (AD). This platform easily simplified the laborious and consumptive immunoassay procedure by achieving automated parallel immunoassay (32 assays per operation in 3-well connected 96-well plate) within 1 hour and at low sample consumption (less than 10 μL per assay) with no cumbersome manual washing step. Moreover, it could detect synthetic Aβ oligomers even below 10 pg mL(-1) concentration with a calculated detection limit of ∼3 pg mL(-1). Therefore, the μCHAMP and droplet-based magnetic bead immunoassay, with the combination of XY-motorized magnet array, would be a useful platform in the diagnosis of human disease, including AD, which requires low consumption of the patient's body fluid sample and automation of the entire immunoassay procedure for high processing capacity.
Magnetic bead detection using domain wall-based nanosensor

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

Corte-León, H., E-mail: hector.corte@npl.co.uk; Royal Holloway University of London, Egham TW20 0EX; Krzysteczko, P.

2015-05-07

We investigate the effect of a single magnetic bead (MB) on the domain wall (DW) pinning/depinning fields of a DW trapped at the corner of an L-shaped magnetic nanodevice. DW propagation across the device is investigated using magnetoresistance measurements. DW pinning/depinning fields are characterized in as-prepared devices and after placement of a 1 μm-sized MB (Dynabeads{sup ®} MyOne{sup ™}) at the corner. The effect of the MB on the DW dynamics is seen as an increase in the depinning field for specific orientations of the device with respect to the external magnetic field. The shift of the depinning field, ΔB{sub dep} = 4.5–27.0 mT,more » is highly stable and reproducible, being significantly above the stochastic deviation which is about 0.5 mT. The shift in the deppinning field is inversely proportional to the device width and larger for small negative angles between the device and the external magnetic field. Thus, we demonstrate that DW-based devices can be successfully used for detection of single micron size MB.« less
Direct torsional actuation of microcantilevers using magnetic excitation

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

Gosvami, Nitya Nand; Nalam, Prathima C.; Tam, Qizhan

2014-09-01

Torsional mode dynamic force microscopy can be used for a wide range of studies including mapping lateral contact stiffness, torsional frequency or amplitude modulation imaging, and dynamic friction measurements of various materials. Piezo-actuation of the cantilever is commonly used, but it introduces spurious resonances, limiting the frequency range that can be sampled, and rendering the technique particularly difficult to apply in liquid medium where the cantilever oscillations are significantly damped. Here, we demonstrate a method that enables direct torsional actuation of cantilevers with high uniformity over wide frequency ranges by attaching a micrometer-scale magnetic bead on the back side ofmore » the cantilever. We show that when beads are magnetized along the width of the cantilever, efficient torsional actuation of the cantilevers can be achieved using a magnetic field produced from a solenoid placed underneath the sample. We demonstrate the capability of this technique by imaging atomic steps on graphite surfaces in tapping mode near the first torsional resonance of the cantilever in dodecane. The technique is also applied to map the variations in the lateral contact stiffness on the surface of graphite and polydiacetylene monolayers.« less
Organ of Corti Micromechanics with Local Electrical Stimulation

NASA Astrophysics Data System (ADS)

Chen, Fangyi; Zheng, Jiefu; Choudhury, Niloy; Jaques, Steve; Nuttall, Alfred L.

2009-02-01

Optical low coherence interferometry is able to both image and measure the vibration of the cellular and non-cellular structures of the organ of Corti in vivo. In this study we applied an electric current to the basal turn from a pair of electrodes, one in scala tympani and the other in scala vestibuli, at the location corresponding to ~17 kHz when interferometry measurements were made. The coherence gate of the interferometer was positioned 1) at the basilar membrane (BM) near the radial location of the outer hair cells (OHCs) (approximately 1/2 the width of the BM) and 2) at the reticular lamina (RL) where the OHCs are located. We confirmed that electrical stimulation with a frequency sweep (12 kHz -25 kHz) caused a mechanical BM displacement with a peak and a traveling wave-like phase delay as we reported previously using laser Doppler velocimetry and reflective beads on the BM. Reflective beads were not used in the current study. The vibration of the RL had little or no phase delay that would characterize a traveling wave. These data suggest a very high compliance system for the electrically activated cellular structure of the organ.
Gas-path leakage seal for a gas turbine

DOEpatents

Wolfe, C.E.; Dinc, O.S.; Bagepalli, B.S.; Correia, V.H.; Aksit, M.F.

1996-04-23

A gas-path leakage seal is described for generally sealing a gas-path leakage-gap between spaced-apart first and second members of a gas turbine (such as combustor casing segments). The seal includes a generally imperforate foil-layer assemblage which is generally impervious to gas and is located in the leakage-gap. The seal also includes a cloth-layer assemblage generally enclosingly contacting the foil-layer assemblage. In one seal, the first edge of the foil-layer assemblage is left exposed, and the foil-layer assemblage resiliently contacts the first member near the first edge to reduce leakage in the ``plane`` of the cloth-layer assemblage under conditions which include differential thermal growth of the two members. In another seal, such leakage is reduced by having a first weld-bead which permeates the cloth-layer assemblage, is attached to the metal-foil-layer assemblage near the first edge, and unattachedly contacts the first member. 4 figs.
Gas-path leakage seal for a gas turbine

DOEpatents

Wolfe, Christopher E.; Dinc, Osman S.; Bagepalli, Bharat S.; Correia, Victor H.; Aksit, Mahmut F.

1996-01-01

A gas-path leakage seal for generally sealing a gas-path leakage-gap between spaced-apart first and second members of a gas turbine (such as combustor casing segments). The seal includes a generally imperforate foil-layer assemblage which is generally impervious to gas and is located in the leakage-gap. The seal also includes a cloth-layer assemblage generally enclosingly contacting the foil-layer assemblage. In one seal, the first edge of the foil-layer assemblage is left exposed, and the foil-layer assemblage resiliently contacts the first member near the first edge to reduce leakage in the "plane" of the cloth-layer assemblage under conditions which include differential thermal growth of the two members. In another seal, such leakage is reduced by having a first weld-bead which permeates the cloth-layer assemblage, is attached to the metal-foil-layer assemblage near the first edge, and unattachedly contacts the first member.
Powered protrusion cutter

DOEpatents

Bzorgi, Fariborz M.

2010-03-09

An apparatus for clipping a protrusion of material is provided. The protrusion may, for example, be a bolt head, a nut, a rivet, a weld bead, or a temporary assembly alignment tab protruding from a substrate surface of assembled components. The apparatus typically includes a cleaver having a cleaving edge and a cutting blade having a cutting edge. Generally, a mounting structure configured to confine the cleaver and the cutting blade and permit a range of relative movement between the cleaving edge and the cutting edge is provided. Also typically included is a power device coupled to the cutting blade. The power device is configured to move the cutting edge toward the cleaving edge. In some embodiments the power device is activated by a momentary switch. A retraction device is also generally provided, where the retraction device is configured to move the cutting edge away from the cleaving edge.
Device for cutting protrusions

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

Bzorgi, Fariborz M

An apparatus for clipping a protrusion of material is provided. The protrusion may, for example, be a bolt head, a nut, a rivet, a weld bead, or a temporary assembly alignment tab protruding from a substrate surface of assembled components. The apparatus typically includes a cleaver having a cleaving edge and a cutting blade having a cutting edge. Generally, a mounting structure configured to confine the cleaver and the cutting blade and permit a range of relative movement between the cleaving edge and the cutting edge is provided. Also typically included is a power device coupled to the cutting blade.more » The power device is configured to move the cutting edge toward the cleaving edge. In some embodiments the power device is activated by a momentary switch. A retraction device is also generally provided, where the retraction device is configured to move the cutting edge away from the cleaving edge.« less
Solid particle impingement erosion characteristics of cylindrical surfaces, pre-existing holes and slits

NASA Technical Reports Server (NTRS)

Rao, P. V.; Buckley, D. H.

1983-01-01

The erosion characteristics of aluminum cylinders sand-blasted with both spherical and angular erodent particles were studied and compared with results from previously studied flat surfaces. The cylindrical results are discussed with respect to impact conditions. The relationship between erosion rate and pit morphology (width, depth, and width to depth ratio) is established. The aspects of (1) erosion rate versus time curves on cylindrical surfaces; (2) long-term exposures; and (3) erosion rate versus time curves with spherical and angular particles are presented. The erosion morphology and characteristics of aluminum surfaces with pre-existing circular cylindrical and conical holes of different sizes were examined using weight loss measurements, scanning electron microscopy, a profilometer, and a depth gage. The morphological features (radial and concentric rings) are discussed with reference to flat surfaces, and the erosion features with spherical microglass beads. The similarities and differences of erosion and morphological features are highlighted. The erosion versus time curves of various shapes of holes are discussed and are compared with those of a flat surface. The erosion process at slits is considered.
Laser Metal Deposition as Repair Technology for a Gas Turbine Burner Made of Inconel 718

NASA Astrophysics Data System (ADS)

Petrat, Torsten; Graf, Benjamin; Gumenyuk, Andrey; Rethmeier, Michael

Maintenance, repair and overhaul of components are of increasing interest for parts of high complexity and expensive manufacturing costs. In this paper a production process for laser metal deposition is presented, and used to repair a gas turbine burner of Inconel 718. Different parameters for defined track geometries were determined to attain a near net shape deposition with consistent build-up rate for changing wall thicknesses over the manufacturing process. Spot diameter, powder feed rate, welding velocity and laser power were changed as main parameters for a different track size. An optimal overlap rate for a constant layer height was used to calculate the best track size for a fitting layer width similar to the part dimension. Deviations in width and height over the whole build-up process were detected and customized build-up strategies for the 3D sequences were designed. The results show the possibility of a near net shape repair by using different track geometries with laser metal deposition.
Detection and monitoring of surface micro-cracks by PPP-BOTDA.

PubMed

Meng, Dewei; Ansari, Farhad; Feng, Xin

2015-06-01

Appearance of micrometer size surface cracks is common in structural elements such as welded connections, beams, and gusset plates in bridges. Brillouin scattering-based sensors are capable of making distributed strain measurements. Pre-pump-pulse Brillouin optical time domain analysis (PPP-BOTDA) provides a centimeter-level spatial resolution, which facilitates detection and monitoring of the cracks. In the work described here, in addition to the shift in Brillouin frequency (distributed strains), change in the Brillouin gain spectrum (BGS) width is investigated for the detection and monitoring of surface micro-cracks. A theoretical analysis was undertaken in order to verify the rationality of the proposed method. The theoretical approach involved simulation of strain within a segment of the optical fiber traversing a crack and use of the simulated strain distribution in the opto-mechanical relations in order to numerically obtain the change in the BGS. Simulations revealed that the increase in crack opening displacements is associated with increase in BGS width and decrease in its peak power. Experimental results also indicated that the increases in crack opening displacements are accompanied with increases in BGS widths. However, it will be difficult to use the decrease in BGS power peak as another indicator due to practical difficulties in establishing generalized power amplitude in all the experiments. The study indicated that, in combination with the shift in Brillouin frequency, the increase in BGS width will provide a strong tool for detection and monitoring of surface micro-crack growths.
A study on fatigue strength reduction factor for small diameter socket welded pipe joints

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

Higuchi, Makoto; Nakagawa, Akira; Hayashi, Makoto

1996-12-01

Factors that may exert influence on the fatigue strength of small diameter socket welded joints of nominal diameter in the 20--50 mm range have been investigated by the fully reversed four-point bending fatigue test with the material, diameter, pipe schedule, throat depth, bead shape, slip-on gap, and root defect as the testing parameters. The fatigue strength of socket joints depended acutely on the diameter. When the diameter is large, the fatigue strength tended to be low and the fracture is of the root-failure mode; when it is small, on the other hand, the fatigue strength is high and the fracturemore » is of the toe-failure mode. Stainless steel proved to be superior to carbon steel; it gave rise to 1.37 times the fatigue strength of the latter for socket joints of nominal diameter 50 mm; the fatigue strength reduction factor determined at 10{sup 7} cycles with respect to the fatigue strength of smooth base metal in the fully reversed fatigue was about 4 for stainless steel and about 5 for carbon steel. The fatigue strength was higher, the larger the Sche number (i.e., the thicker the pipe wall); it was improved markedly by placing one final refinement pass on the toe or by eliminating the slip-on gap. An empirical formula relating the size of the root defect to the fatigue strength reduction has been proposed.« less
Process Modeling and Validation for Metal Big Area Additive Manufacturing

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

Simunovic, Srdjan; Nycz, Andrzej; Noakes, Mark W.

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to acceleratemore » the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.« less
Solid-phase based on-chip DNA purification through a valve-free stepwise injection of multiple reagents employing centrifugal force combined with a hydrophobic capillary barrier pressure.

PubMed

Zhang, Hainan; Tran, Hong Hanh; Chung, Bong Hyun; Lee, Nae Yoon

2013-03-21

In this paper, we demonstrate a simple technique for sequentially introducing multiple sample liquids into microchannels driven by centrifugal force combined with a hydrophobic barrier pressure and apply the technique for performing solid-phase based on-chip DNA purification. Three microchannels with varying widths, all equipped with independent sample reservoirs at the inlets, were fabricated on a hydrophobic elastomer, poly(dimethylsiloxane) (PDMS). First, glass beads were packed inside the reaction chamber, and a whole cell containing the DNA extract was introduced into the widest channel by applying centrifugal force for physical adsorption of the DNA onto the glass beads. Next, washing and elution solutions were sequentially introduced into the intermediate and narrowest microchannels, respectively, by gradually increasing the amount of centrifugal force. Through a precise manipulation of the centrifugal force, the DNA adsorbed onto the glass beads was successfully washed and eluted in a continuous manner without the need to introduce each solution manually. A stepwise injection of liquids was successfully demonstrated using multiple ink solutions, the results of which corresponded well with the theoretical analyses. As a practical application, the D1S80 locus of human genomic DNA, which is widely used for forensic purposes, was successfully purified using the microdevice introduced in this study, as demonstrated through successful target amplification. This will pave the way for the construction of a control-free valve system for realizing on-chip DNA purification, which is one of the most labor-intensive and hard-to-miniaturize components, on a greatly simplified and miniaturized platform employing hydrophobic PDMS.
Structure of flexible and semiflexible polyelectrolyte chains in confined spaces of slit micro/nanochannels.

PubMed

Jeon, Jonggu; Chun, Myung-Suk

2007-04-21

Understanding the behavior of a polyelectrolyte in confined spaces has direct relevance in design and manipulation of microfluidic devices, as well as transport in living organisms. In this paper, a coarse-grained model of anionic semiflexible polyelectrolyte is applied, and its structure and dynamics are fully examined with Brownian dynamics (BD) simulations both in bulk solution and under confinement between two negatively charged parallel plates. The modeling is based on the nonlinear bead-spring discretization of a continuous chain with additional long-range electrostatic, Lennard-Jones, and hydrodynamic interactions between pairs of beads. The authors also consider the steric and electrostatic interactions between the bead and the confining wall. Relevant model parameters are determined from experimental rheology data on the anionic polysaccharide xanthan reported previously. For comparison, both flexible and semiflexible models are developed accompanying zero and finite intrinsic persistence lengths, respectively. The conformational changes of the polyelectrolyte chain induced by confinements and their dependence on the screening effect of the electrolyte solution are faithfully characterized with BD simulations. Depending on the intrinsic rigidity and the medium ionic strength, the polyelectrolyte can be classified as flexible, semiflexible, or rigid. Confined flexible and semiflexible chains exhibit a nonmonotonic variation in size, as measured by the radius of gyration and end-to-end distance, with changing slit width. For the semiflexible chain, this is coupled to the variations in long-range bond vector correlation. The rigid chain, realized at low ionic strength, does not have minima in size but exhibits a sigmoidal transition. The size of confined semiflexible and rigid polyelectrolytes can be well described by the wormlike chain model once the electrostatic effects are taken into account by the persistence length measured at long length scale.
Redistribution of Welding Residual Stresses of Crack Tip Opening Displacement Specimen by Local Compression.

PubMed

Kim, Young-Gon; Song, Kuk-Hyun; Lee, Dong-Hoon; Joo, Sung-Min

2018-03-01

The demand of crack tip opening displacement (CTOD) test which evaluates fracture toughness of a cracked material is very important to ensure the stability of structure under severe service environment. The validity of the CTOD test result is judged using several criterions of the specification standards. One of them is the artificially generated fatigue pre-crack length inside the specimen. For acceptable CTOD test results, fatigue pre-crack must have a reasonable sharp crack front. The propagation of fatigue crack started from the tip of the machined notch, which might have propagated irregularly due to residual stress field. To overcome this problem, test codes suggest local compression method, reversed bending method and stepwise high-R ratio method to reduce the disparity of residual stress distribution inside the specimen. In this paper, the relation between the degree of local compression and distribution of welding residual stress has been analyzed by finite element analyses in order to determine the amount of effective local compression of the test piece. Analysis results show that initial welding residual stress is dramatically varied three-dimensionally while cutting, notch machining and local compressing due to the change of internal restraint force. From the simulation result, the authors find that there is an optimum amount of local compression to modify regularly for generating fatigue pre-crack propagation. In the case of 0.5% compressions of the model width is the most effective for uniforming residual stress distribution.
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.
Fusion boundary microstructure evolution in aluminum alloys

NASA Astrophysics Data System (ADS)

Kostrivas, Anastasios Dimitrios

2000-10-01

A melting technique was developed to simulate the fusion boundary of aluminum alloys using the GleebleRTM thermal simulator. Using a steel sleeve to contain the aluminum, samples were heated to incremental temperatures above the solidus temperature of a number of alloys. In alloy 2195, a 4wt%Cu-1wt%Li alloy, an equiaxed non-dendritic zone (EQZ) could be formed by heating in the temperature range from approximately 630 to 640°C. At temperatures above 640°C, solidification occurred by the normal epitaxial nucleation and growth mechanism. Fusion boundary behavior was also studied in alloys 5454-H34, 6061-T6, and 2219-T8. Additionally, experimental alloy compositions were produced by making bead on plate welds using an alloy 5454-H32 base metal and 5025 or 5087 filler metals. These filler metals contain zirconium and scandium additions, respectively, and were expected to influence nucleation and growth behavior. Both as-welded and welded/heat treated (540°C and 300°C) substrates were tested by melting simulation, resulting in dendritic and EQZ structures depending on composition and substrate condition. Orientation imaging microscopy (OIM(TM)) was employed to study the crystallographic character of the microstructures produced and to verify the mechanism responsible for EQZ formation. OIM(TM) proved that grains within the EQZ have random orientation. In all other cases, where the simulated microstructures were dendritic in nature, it was shown that epitaxy was the dominant mode of nucleation. The lack of any preferred crystallographic orientation relationship in the EQZ supports a theory proposed by Lippold et al that the EQZ is the result of heterogeneous nucleation within the weld unmixed zone. EDS analysis of the 2195 on STEM revealed particles with ternary composition consisted of Zr, Cu and Al and a tetragonal type crystallographic lattice. Microdiffraction line scans on EQZ grains in the alloy 2195 showed very good agreement between the measured Cu composition within the interior of the non-dendritic grains and the corresponding value the Scheil equation predicts for the first solid to form upon solidification for a binary Al-Cu alloy with identical Cu composition. In the context of the alloys, compositions and substrate conditions examined a mechanistic model for EQZ zone formation is proposed, helpful in adjusting base metal compositions and/or substrate conditions to control fusion boundary microstructure.
Surfing along Filopodia: A Particle Transport Revealed by Molecular-Scale Fluctuation Analyses

PubMed Central

Kohler, Felix; Rohrbach, Alexander

2015-01-01

Filopodia perform cellular functions such as environmental sensing or cell motility, but they also grab for particles and withdraw them leading to an increased efficiency of phagocytic uptake. Remarkably, withdrawal of micron-sized particles is also possible without noticeable movements of the filopodia. Here, we demonstrate that polystyrene beads connected by optical tweezers to the ends of adherent filopodia of J774 macrophages, are transported discontinuously toward the cell body. After a typical resting time of 1–2 min, the cargo is moved with alternating velocities, force constants, and friction constants along the surface of the filopodia. This surfing-like behavior along the filopodium is recorded by feedback-controlled interferometric three-dimensional tracking of the bead motions at 10–100 kHz. We measured transport velocities of up to 120 nm/s and transport forces of ∼70 pN. Small changes in position, fluctuation width, and temporal correlation, which are invisible in conventional microscopy, indicate molecular reorganization of transport-relevant proteins in different phases of the entire transport process. A detailed analysis implicates a controlled particle transport with fingerprints of a nanoscale unbinding/binding behavior. The manipulation and analysis methods presented in our study may also be helpful in other fields of cellular biophysics. PMID:25954870

A Novel Inherently Radiopaque Bead for Transarterial Embolization to Treat Liver Cancer - A Pre-clinical Study.

PubMed

Duran, Rafael; Sharma, Karun; Dreher, Matthew R; Ashrafi, Koorosh; Mirpour, Sahar; Lin, MingDe; Schernthaner, Ruediger E; Schlachter, Todd R; Tacher, Vania; Lewis, Andrew L; Willis, Sean; den Hartog, Mark; Radaelli, Alessandro; Negussie, Ayele H; Wood, Bradford J; Geschwind, Jean-François H

2016-01-01

Embolotherapy using microshperes is currently performed with soluble contrast to aid in visualization. However, administered payload visibility dimishes soon after delivery due to soluble contrast washout, leaving the radiolucent bead's location unknown. The objective of our study was to characterize inherently radiopaque beads (RO Beads) in terms of physicomechanical properties, deliverability and imaging visibility in a rabbit VX2 liver tumor model. RO Beads, which are based on LC Bead® platform, were compared to LC Bead. Bead size (light microscopy), equilibrium water content (EWC), density, X-ray attenuation and iodine distribution (micro-CT), suspension (settling times), deliverability and in vitro penetration were investigated. Fifteen rabbits were embolized with either LC Bead or RO Beads + soluble contrast (iodixanol-320), or RO Beads+dextrose. Appearance was evaluated with fluoroscopy, X-ray single shot, cone-beam CT (CBCT). Both bead types had a similar size distribution. RO Beads had lower EWC (60-72%) and higher density (1.21-1.36 g/cc) with a homogeneous iodine distribution within the bead's interior. RO Beads suspension time was shorter than LC Bead, with durable suspension (>5 min) in 100% iodixanol. RO Beads ≤300 µm were deliverable through a 2.3-Fr microcatheter. Both bead types showed similar penetration. Soluble contrast could identify target and non-target embolization on fluoroscopy during administration. However, the imaging appearance vanished quickly for LC Bead as contrast washed-out. RO Beads+contrast significantly increased visibility on X-ray single shot compared to LC Bead+contrast in target and non-target arteries (P=0.0043). Similarly, RO beads demonstrated better visibility on CBCT in target arteries (P=0.0238) with a trend in non-target arteries (P=0.0519). RO Beads+dextrose were not sufficiently visible to monitor embolization using fluoroscopy. RO Beads provide better conspicuity to determine target and non-target embolization compared to LC Bead which may improve intra-procedural monitoring and post-procedural evaluation of transarterial embolization.
Confocal nanoscanning, bead picking (CONA): PickoScreen microscopes for automated and quantitative screening of one-bead one-compound libraries.

PubMed

Hintersteiner, Martin; Buehler, Christof; Uhl, Volker; Schmied, Mario; Müller, Jürgen; Kottig, Karsten; Auer, Manfred

2009-01-01

Solid phase combinatorial chemistry provides fast and cost-effective access to large bead based libraries with compound numbers easily exceeding tens of thousands of compounds. Incubating one-bead one-compound library beads with fluorescently labeled target proteins and identifying and isolating the beads which contain a bound target protein, potentially represents one of the most powerful generic primary high throughput screening formats. On-bead screening (OBS) based on this detection principle can be carried out with limited automation. Often hit bead detection, i.e. recognizing beads with a fluorescently labeled protein bound to the compound on the bead, relies on eye-inspection under a wide-field microscope. Using low resolution detection techniques, the identification of hit beads and their ranking is limited by a low fluorescence signal intensity and varying levels of the library beads' autofluorescence. To exploit the full potential of an OBS process, reliable methods for both automated quantitative detection of hit beads and their subsequent isolation are needed. In a joint collaborative effort with Evotec Technologies (now Perkin-Elmer Cellular Technologies Germany GmbH), we have built two confocal bead scanner and picker platforms PS02 and a high-speed variant PS04 dedicated to automated high resolution OBS. The PS0X instruments combine fully automated confocal large area scanning of a bead monolayer at the bottom of standard MTP plates with semiautomated isolation of individual hit beads via hydraulic-driven picker capillaries. The quantification of fluorescence intensities with high spatial resolution in the equatorial plane of each bead allows for a reliable discrimination between entirely bright autofluorescent beads and real hit beads which exhibit an increased fluorescence signal at the outer few micrometers of the bead. The achieved screening speed of up to 200,000 bead assayed in less than 7 h and the picking time of approximately 1 bead/min allow exploitation of one-bead one-compound libraries with high sensitivity, accuracy, and speed.
Feasibility of granular bed filtration of an aerosol of ultrafine metallic particles including a pressure drop regeneration system.

PubMed

Bémer, D; Wingert, L; Morele, Y; Subra, I

2015-09-01

A process for filtering an aerosol of ultrafine metallic particles (UFP) has been designed and tested, based on the principle of a multistage granular bed. The filtration system comprised a succession of granular beds of varying thickness composed of glass beads of different diameters. This system allows the pressure drop to be regenerated during filtration ("on-line" mode) using a vibrating probe. Tests monitoring the pressure drop were conducted on a "10-L/min" low airflow rate device and on a "100-m(3)/hr" prototype. Granular bed unclogging is automated on the latter. The cyclic operation and filtration performances are similar to that of filter medium-based industrial dust collectors. Filtration of ultrafine metallic particles generated by different industrial processes such as arc welding, metal cutting, or spraying constitutes a difficult problem due to the high filter clogging properties of these particles and to the high temperatures generally encountered. Granular beds represent an advantageous means of filtering these aerosols with difficult properties.
76 FR 14058 - Notice of Inventory Completion: Fremont County Coroner, Riverton, WY

Federal Register 2010, 2011, 2012, 2013, 2014

2011-03-15

... associated funerary objects are 2 fragments of freshwater clam shells, 32 dentalia shell beads, 2 bird bone beads, 8 chokecherry seed beads, 162 bone heishi-style beads, 158 lignite heishi-style beads, 5 fragmentary bone heishi-style beads, 1 shell bead, and 3 chert microflakes. The Sinks Canyon site is located...
Deterministic bead-in-droplet ejection utilizing an integrated plug-in bead dispenser for single bead-based applications

NASA Astrophysics Data System (ADS)

Kim, Hojin; Choi, In Ho; Lee, Sanghyun; Won, Dong-Joon; Oh, Yong Suk; Kwon, Donghoon; Sung, Hyung Jin; Jeon, Sangmin; Kim, Joonwon

2017-04-01

This paper presents a deterministic bead-in-droplet ejection (BIDE) technique that regulates the precise distribution of microbeads in an ejected droplet. The deterministic BIDE was realized through the effective integration of a microfluidic single-particle handling technique with a liquid dispensing system. The integrated bead dispenser facilitates the transfer of the desired number of beads into a dispensing volume and the on-demand ejection of bead-encapsulated droplets. Single bead-encapsulated droplets were ejected every 3 s without any failure. Multiple-bead dispensing with deterministic control of the number of beads was demonstrated to emphasize the originality and quality of the proposed dispensing technique. The dispenser was mounted using a plug-socket type connection, and the dispensing process was completely automated using a programmed sequence without any microscopic observation. To demonstrate a potential application of the technique, bead-based streptavidin-biotin binding assay in an evaporating droplet was conducted using ultralow numbers of beads. The results evidenced the number of beads in the droplet crucially influences the reliability of the assay. Therefore, the proposed deterministic bead-in-droplet technology can be utilized to deliver desired beads onto a reaction site, particularly to reliably and efficiently enrich and detect target biomolecules.
Deterministic bead-in-droplet ejection utilizing an integrated plug-in bead dispenser for single bead-based applications.

PubMed

Kim, Hojin; Choi, In Ho; Lee, Sanghyun; Won, Dong-Joon; Oh, Yong Suk; Kwon, Donghoon; Sung, Hyung Jin; Jeon, Sangmin; Kim, Joonwon

2017-04-10

This paper presents a deterministic bead-in-droplet ejection (BIDE) technique that regulates the precise distribution of microbeads in an ejected droplet. The deterministic BIDE was realized through the effective integration of a microfluidic single-particle handling technique with a liquid dispensing system. The integrated bead dispenser facilitates the transfer of the desired number of beads into a dispensing volume and the on-demand ejection of bead-encapsulated droplets. Single bead-encapsulated droplets were ejected every 3 s without any failure. Multiple-bead dispensing with deterministic control of the number of beads was demonstrated to emphasize the originality and quality of the proposed dispensing technique. The dispenser was mounted using a plug-socket type connection, and the dispensing process was completely automated using a programmed sequence without any microscopic observation. To demonstrate a potential application of the technique, bead-based streptavidin-biotin binding assay in an evaporating droplet was conducted using ultralow numbers of beads. The results evidenced the number of beads in the droplet crucially influences the reliability of the assay. Therefore, the proposed deterministic bead-in-droplet technology can be utilized to deliver desired beads onto a reaction site, particularly to reliably and efficiently enrich and detect target biomolecules.
Heterogeneous immunoassays using magnetic beads on a digital microfluidic platform.

PubMed

Sista, Ramakrishna S; Eckhardt, Allen E; Srinivasan, Vijay; Pollack, Michael G; Palanki, Srinivas; Pamula, Vamsee K

2008-12-01

A digital microfluidic platform for performing heterogeneous sandwich immunoassays based on efficient handling of magnetic beads is presented in this paper. This approach is based on manipulation of discrete droplets of samples and reagents using electrowetting without the need for channels where the droplets are free to move laterally. Droplet-based manipulation of magnetic beads therefore does not suffer from clogging of channels. Immunoassays on a digital microfluidic platform require the following basic operations: bead attraction, bead washing, bead retention, and bead resuspension. Several parameters such as magnetic field strength, pull force, position, and buffer composition were studied for effective bead operations. Dilution-based washing of magnetic beads was demonstrated by immobilizing the magnetic beads using a permanent magnet and splitting the excess supernatant using electrowetting. Almost 100% bead retention was achieved after 7776-fold dilution-based washing of the supernatant. Efficient resuspension of magnetic beads was achieved by transporting a droplet with magnetic beads across five electrodes on the platform and exploiting the flow patterns within the droplet to resuspend the beads. All the magnetic-bead droplet operations were integrated together to generate standard curves for sandwich heterogeneous immunoassays on human insulin and interleukin-6 (IL-6) with a total time to result of 7 min for each assay.
Heterogeneous Immunoassays Using Magnetic beads On a Digital Microfluidic Platform

PubMed Central

Sista, Ramakrishna S.; Eckhardt, Allen E.; Srinivasan, Vijay; Pollack, Michael G.; Palanki, Srinivas; Pamula, Vamsee K.

2009-01-01

A digital microfluidic platform for performing heterogeneous sandwich immunoassays based on efficient handling of magnetic beads is presented in this paper. This approach is based on manipulation of discrete droplets of samples and reagents using electrowetting without the need for channels where the droplets are free to move laterally. Droplet-based manipulation of magnetic beads therefore does not suffer from clogging of channels. Immunoassays on a digital microfluidic platform require the following basic operations: bead attraction, bead washing, bead retention, and bead resuspension. Several parameters such as magnetic field strength, pull force, position, and buffer composition were studied for effective bead operations. Dilution-based washing of magnetic beads was demonstrated by immobilizing the magnetic beads using a permanent magnet and splitting the excess supernatant using electrowetting. Almost 100% bead retention was achieved after 7776 fold dilution-based washing of the supernatant. Efficient resuspension of magnetic beads was achieved by transporting a droplet with magnetic beads across five electrodes on the platform and exploiting the flow patterns within the droplet to resuspend the beads. All the magnetic-bead droplet operations were integrated together to generate standard curves for sandwich heterogeneous immunoassays on Human Insulin and Interleukin-6 (IL-6) with a total time to result of seven minutes for each assay. PMID:19023486
NIST/ISAC standardization study: variability in assignment of intensity values to fluorescence standard beads and in cross calibration of standard beads to hard dyed beads.

PubMed

Hoffman, Robert A; Wang, Lili; Bigos, Martin; Nolan, John P

2012-09-01

Results from a standardization study cosponsored by the International Society for Advancement of Cytometry (ISAC) and the US National Institute of Standards and Technology (NIST) are reported. The study evaluated the variability of assigning intensity values to fluorophore standard beads by bead manufacturers and the variability of cross calibrating the standard beads to stained polymer beads (hard-dyed beads) using different flow cytometers. Hard dyed beads are generally not spectrally matched to the fluorophores used to stain cells, and spectral response varies among flow cytometers. Thus if hard dyed beads are used as fluorescence calibrators, one expects calibration for specific fluorophores (e.g., FITC or PE) to vary among different instruments. Using standard beads surface-stained with specific fluorophores (FITC, PE, APC, and Pacific Blue™), the study compared the measured intensity of fluorophore standard beads to that of hard dyed beads through cross calibration on 133 different flow cytometers. Using robust CV as a measure of variability, the variation of cross calibrated values was typically 20% or more for a particular hard dyed bead in a specific detection channel. The variation across different instrument models was often greater than the variation within a particular instrument model. As a separate part of the study, NIST and four bead manufacturers used a NIST supplied protocol and calibrated fluorophore solution standards to assign intensity values to the fluorophore beads. Values assigned to the reference beads by different groups varied by orders of magnitude in most cases, reflecting differences in instrumentation used to perform the calibration. The study concluded that the use of any spectrally unmatched hard dyed bead as a general fluorescence calibrator must be verified and characterized for every particular instrument model. Close interaction between bead manufacturers and NIST is recommended to have reliable and uniformly assigned fluorescence standard beads. Copyright © 2012 International Society for Advancement of Cytometry.
Influence of Immobilized Biomolecules on Magnetic Bead Plug Formation and Retention in Capillary Electrophoresis

PubMed Central

Henken, Rachel L.; Chantiwas, Rattikan; Gilman, S. Douglass

2012-01-01

Significant changes in the formation and retention of magnetic bead plugs in a capillary during electrophoresis were studied, and it was demonstrated that these effects were due to the type of biological molecule immobilized on the surface of these beads. Three biological molecules, an antibody, an oligonucleotide and alkaline phosphatase, were attached to otherwise identical streptavidin-coated magnetic beads through biotin-avidin binding in order to isolate differences in bead immobilization in a magnetic field resulting from the type of biological molecule immobilized on the bead surface. Alkaline phosphatase also was attached to the magnetic beads using epoxy groups on the bead surfaces (instead of avidin-biotin binding) to study the impact of immobilization chemistry. The formation and retention of magnetic bead plugs were studied quantitatively using light scattering detection of magnetic particles eluting from the bead plugs and qualitatively using microscopy. Both the type of biomolecule immobilized on the magnetic bead surface and the chemistry used to link the biomolecule to the magnetic bead impacted the formation and retention of the bead plugs. PMID:22437880
A highly efficient bead extraction technique with low bead number for digital microfluidic immunoassay

PubMed Central

Tsai, Po-Yen; Lee, I-Chin; Hsu, Hsin-Yun; Huang, Hong-Yuan; Fan, Shih-Kang; Liu, Cheng-Hsien

2016-01-01

Here, we describe a technique to manipulate a low number of beads to achieve high washing efficiency with zero bead loss in the washing process of a digital microfluidic (DMF) immunoassay. Previously, two magnetic bead extraction methods were reported in the DMF platform: (1) single-side electrowetting method and (2) double-side electrowetting method. The first approach could provide high washing efficiency, but it required a large number of beads. The second approach could reduce the required number of beads, but it was inefficient where multiple washes were required. More importantly, bead loss during the washing process was unavoidable in both methods. Here, an improved double-side electrowetting method is proposed for bead extraction by utilizing a series of unequal electrodes. It is shown that, with proper electrode size ratio, only one wash step is required to achieve 98% washing rate without any bead loss at bead number less than 100 in a droplet. It allows using only about 25 magnetic beads in DMF immunoassay to increase the number of captured analytes on each bead effectively. In our human soluble tumor necrosis factor receptor I (sTNF-RI) model immunoassay, the experimental results show that, comparing to our previous results without using the proposed bead extraction technique, the immunoassay with low bead number significantly enhances the fluorescence signal to provide a better limit of detection (3.14 pg/ml) with smaller reagent volumes (200 nl) and shorter analysis time (<1 h). This improved bead extraction technique not only can be used in the DMF immunoassay but also has great potential to be used in any other bead-based DMF systems for different applications. PMID:26858807
Seeds used for Bodhi beads in China

PubMed Central

2014-01-01

Background Bodhi beads are a Buddhist prayer item made from seeds. Bodhi beads have a large and emerging market in China, and demand for the beads has particularly increased in Buddhism regions, especially Tibet. Many people have started to focus on and collect Bodhi beads and to develop a Bodhi bead culture. But no research has examined the source plants of Bodhi beads. Therefore, ethnobotanical surveys were conducted in six provinces of China to investigate and document Bodhi bead plants. Reasons for the development of Bodhi bead culture were also discussed. Methods Six provinces of China were selected for market surveys. Information was collected using semi-structured interviews, key informant interviews, and participatory observation with traders, tourists, and local residents. Barkhor Street in Lhasa was focused on during market surveys because it is one of the most popular streets in China. Results Forty-seven species (including 2 varieties) in 19 families and 39 genera represented 52 types of Bodhi beads that were collected. The most popular Bodhi bead plants have a long history and religious significance. Most Bodhi bead plants can be used as medicine or food, and their seeds or fruits are the main elements in these uses. ‘Bodhi seeds’ have been historically used in other countries for making ornaments, especially seeds of the legume family. Many factors helped form Bodhi bead culture in China, but its foundation was in Indian Buddhist culture. Conclusions As one of the earliest adornment materials, seeds played an important role for human production and life. Complex sources of Bodhi beads have different cultural and historical significance. People bought and collected Bodhi beads to reflect their love and admiration for the plants. Thus, the documentation of Bodhi bead plants can serve as a basis for future investigation of Bodhi bead culture and modern Buddhist culture. PMID:24479788
Seeds used for Bodhi beads in China.

PubMed

Li, Feifei; Li, Jianqin; Liu, Bo; Zhuo, Jingxian; Long, Chunlin

2014-01-30

Bodhi beads are a Buddhist prayer item made from seeds. Bodhi beads have a large and emerging market in China, and demand for the beads has particularly increased in Buddhism regions, especially Tibet. Many people have started to focus on and collect Bodhi beads and to develop a Bodhi bead culture. But no research has examined the source plants of Bodhi beads. Therefore, ethnobotanical surveys were conducted in six provinces of China to investigate and document Bodhi bead plants. Reasons for the development of Bodhi bead culture were also discussed. Six provinces of China were selected for market surveys. Information was collected using semi-structured interviews, key informant interviews, and participatory observation with traders, tourists, and local residents. Barkhor Street in Lhasa was focused on during market surveys because it is one of the most popular streets in China. Forty-seven species (including 2 varieties) in 19 families and 39 genera represented 52 types of Bodhi beads that were collected. The most popular Bodhi bead plants have a long history and religious significance. Most Bodhi bead plants can be used as medicine or food, and their seeds or fruits are the main elements in these uses. 'Bodhi seeds' have been historically used in other countries for making ornaments, especially seeds of the legume family. Many factors helped form Bodhi bead culture in China, but its foundation was in Indian Buddhist culture. As one of the earliest adornment materials, seeds played an important role for human production and life. Complex sources of Bodhi beads have different cultural and historical significance. People bought and collected Bodhi beads to reflect their love and admiration for the plants. Thus, the documentation of Bodhi bead plants can serve as a basis for future investigation of Bodhi bead culture and modern Buddhist culture.
Size segregation in bedload sediment transport at the particle scale

NASA Astrophysics Data System (ADS)

Frey, P.; Martin, T.

2011-12-01

Bedload, the larger material that is transported in stream channels, has major consequences, for the management of water resources, for environmental sustainability, and for flooding alleviation. Most particularly, in mountains, steep slopes drive intense transport of a wide range of grain sizes. Our ability to compute local and even bulk quantities such as the sediment flux in rivers is poor. One important reason is that grain-grain interactions in stream channels may have been neglected. An arguably most important difficulty pertains to the very wide range of grain size leading to grain size sorting or segregation. This phenomenon largely modifies fluxes and results in patterns that can be seen ubiquitously in nature such as armoring or downstream fining. Most studies have concerned the spontaneous percolation of fine grains into immobile gravels, because of implications for salmonid spawning beds, or stratigraphical interpretation. However when the substrate is moving, the segregation process is different as statistically void openings permit downward percolation of larger particles. This process also named "kinetic sieving" has been studied in industrial contexts where segregation of granular or powder materials is often non-desirable. We present an experimental study of two-size mixtures of coarse spherical glass beads entrained by a shallow turbulent and supercritical water flow down a steep channel with a mobile bed. The particle diameters were 4 and 6mm, the channel width 6.5mm and the channel inclination ranged from 7.5 to 12.5%. The water flow rate and the particle rate were kept constant at the upstream entrance. First only the coarser particle rate was input and adjusted to obtain bed load equilibrium, that is, neither bed degradation nor aggradation over sufficiently long time intervals. Then a low rate of smaller particles (about 1% of the total sediment rate) was introduced to study the spatial and temporal evolution of segregating smaller particles. Flows were filmed from the side by a high-speed camera. Using image processing algorithms made it possible to determine the position, velocity and trajectory of both smaller and coarser particles. After a certain time, a quasi-continuous area of smaller beads developed under moving and above quasi-immobile coarser beads (see figure). Results include the time evolution of segregating smaller beads, assessment of percolation velocity and streamwise and vertical velocity depth profiles.
Metal-Containing Polystyrene Beads as Standards for Mass Cytometry

PubMed Central

Abdelrahman, Ahmed I.; Ornatsky, Olga; Bandura, Dmitry; Kinach, Robert; Dai, Sheng; Thickett, Stuart C.; Tanner, Scott

2010-01-01

We examine the suitability of metal-containing polystyrene beads for the calibration of a mass cytometer instrument, a single particle analyser based on an inductively coupled plasma ion source and a time of flight mass spectrometer. These metal-containing beads are also verified for their use as internal standards for this instrument. These beads were synthesized by multiple-stage dispersion polymerization with acrylic acid as a comonomer. Acrylic acid acts as a ligand to anchor the metal ions within the interior of the beads. Mass cytometry enabled the bead-by-bead measurement of the metal-content and determination of the metal-content distribution. Beads synthesized by dispersion polymerization that involved three stages were shown to have narrower bead-to-bead variation in their lanthanide content than beads synthesized by 2-stage dispersion polymerization. The beads exhibited insignificant release of their lanthanide content to aqueous solutions of different pHs over a period of six months. When mixed with KG1a or U937 cell lines, metal-containing polymer beads were shown not to affect the mass cytometry response to the metal content of element-tagged antibodies specifically attached to these cells. PMID:20390041
Metal-Containing Polystyrene Beads as Standards for Mass Cytometry.

PubMed

Abdelrahman, Ahmed I; Ornatsky, Olga; Bandura, Dmitry; Baranov, Vladimir; Kinach, Robert; Dai, Sheng; Thickett, Stuart C; Tanner, Scott; Winnik, Mitchell A

2010-01-01

We examine the suitability of metal-containing polystyrene beads for the calibration of a mass cytometer instrument, a single particle analyser based on an inductively coupled plasma ion source and a time of flight mass spectrometer. These metal-containing beads are also verified for their use as internal standards for this instrument. These beads were synthesized by multiple-stage dispersion polymerization with acrylic acid as a comonomer. Acrylic acid acts as a ligand to anchor the metal ions within the interior of the beads. Mass cytometry enabled the bead-by-bead measurement of the metal-content and determination of the metal-content distribution. Beads synthesized by dispersion polymerization that involved three stages were shown to have narrower bead-to-bead variation in their lanthanide content than beads synthesized by 2-stage dispersion polymerization. The beads exhibited insignificant release of their lanthanide content to aqueous solutions of different pHs over a period of six months. When mixed with KG1a or U937 cell lines, metal-containing polymer beads were shown not to affect the mass cytometry response to the metal content of element-tagged antibodies specifically attached to these cells.
Brownian dynamics simulations with stiff finitely extensible nonlinear elastic-Fraenkel springs as approximations to rods in bead-rod models.

PubMed

Hsieh, Chih-Chen; Jain, Semant; Larson, Ronald G

2006-01-28

A very stiff finitely extensible nonlinear elastic (FENE)-Fraenkel spring is proposed to replace the rigid rod in the bead-rod model. This allows the adoption of a fast predictor-corrector method so that large time steps can be taken in Brownian dynamics (BD) simulations without over- or understretching the stiff springs. In contrast to the simple bead-rod model, BD simulations with beads and FENE-Fraenkel (FF) springs yield a random-walk configuration at equilibrium. We compare the simulation results of the free-draining bead-FF-spring model with those for the bead-rod model in relaxation, start-up of uniaxial extensional, and simple shear flows, and find that both methods generate nearly identical results. The computational cost per time step for a free-draining BD simulation with the proposed bead-FF-spring model is about twice as high as the traditional bead-rod model with the midpoint algorithm of Liu [J. Chem. Phys. 90, 5826 (1989)]. Nevertheless, computations with the bead-FF-spring model are as efficient as those with the bead-rod model in extensional flow because the former allows larger time steps. Moreover, the Brownian contribution to the stress for the bead-FF-spring model is isotropic and therefore simplifies the calculation of the polymer stresses. In addition, hydrodynamic interaction can more easily be incorporated into the bead-FF-spring model than into the bead-rod model since the metric force arising from the non-Cartesian coordinates used in bead-rod simulations is absent from bead-spring simulations. Finally, with our newly developed bead-FF-spring model, existing computer codes for the bead-spring models can trivially be converted to ones for effective bead-rod simulations merely by replacing the usual FENE or Cohen spring law with a FENE-Fraenkel law, and this convertibility provides a very convenient way to perform multiscale BD simulations.
Brownian dynamics simulations with stiff finitely extensible nonlinear elastic-Fraenkel springs as approximations to rods in bead-rod models

NASA Astrophysics Data System (ADS)

Hsieh, Chih-Chen; Jain, Semant; Larson, Ronald G.

2006-01-01

A very stiff finitely extensible nonlinear elastic (FENE)-Fraenkel spring is proposed to replace the rigid rod in the bead-rod model. This allows the adoption of a fast predictor-corrector method so that large time steps can be taken in Brownian dynamics (BD) simulations without over- or understretching the stiff springs. In contrast to the simple bead-rod model, BD simulations with beads and FENE-Fraenkel (FF) springs yield a random-walk configuration at equilibrium. We compare the simulation results of the free-draining bead-FF-spring model with those for the bead-rod model in relaxation, start-up of uniaxial extensional, and simple shear flows, and find that both methods generate nearly identical results. The computational cost per time step for a free-draining BD simulation with the proposed bead-FF-spring model is about twice as high as the traditional bead-rod model with the midpoint algorithm of Liu [J. Chem. Phys. 90, 5826 (1989)]. Nevertheless, computations with the bead-FF-spring model are as efficient as those with the bead-rod model in extensional flow because the former allows larger time steps. Moreover, the Brownian contribution to the stress for the bead-FF-spring model is isotropic and therefore simplifies the calculation of the polymer stresses. In addition, hydrodynamic interaction can more easily be incorporated into the bead-FF-spring model than into the bead-rod model since the metric force arising from the non-Cartesian coordinates used in bead-rod simulations is absent from bead-spring simulations. Finally, with our newly developed bead-FF-spring model, existing computer codes for the bead-spring models can trivially be converted to ones for effective bead-rod simulations merely by replacing the usual FENE or Cohen spring law with a FENE-Fraenkel law, and this convertibility provides a very convenient way to perform multiscale BD simulations.
Formulation and characterization of a compacted multiparticulate system for modified release of water-soluble drugs--part 1--acetaminophen.

PubMed

Cantor, Stuart L; Hoag, Stephen W; Augsburger, Larry L

2009-03-01

The aim of this study was to characterize and evaluate a modified release, multiparticulate tablet formulation consisting of placebo beads and drug-loaded beads. Acetaminophen (APAP) bead formulations containing ethylcellulose (EC) from 40-60% and placebo beads containing 30% calcium silicate and prepared using 0-20% alcohol were developed using extrusion-spheronization and studied using a central composite experimental design. Particle size and true density of beads were measured. Segregation testing was performed using the novel ASTM D6940-04 method on a 50:50 blend of uncoated APAP beads (60%EC) : calcium silicate placebo beads (10% alcohol). Tablets were prepared using an instrumented Stokes-B2 rotary tablet press and evaluated for crushing strength and dissolution rate. Compared with drug beads (60%EC), placebo beads (10% alcohol) were smaller but had higher true densities: 864.8 mum and 1.27 g/cm(3), and 787.1 mum and 1.73 g/cm(3), respectively. Segregation testing revealed that there was approximately a 20% difference in drug content (as measured by the coefficient of variation) between initial and final blend samples. Although calcium silicate-based placebo beads were shown to be ineffective cushioning agents in blends with Surelease(R)-coated APAP beads, they were found to be very compactibile when used alone and gave tablet crushing strength values between 14 and 17 kP. The EC in the APAP bead matrix minimally suppressed the drug release from uncoated beads (t(100%) = 2 h). However, while tablets containing placebo beads reformulated with glycerol monostearate (GMS) showed a slower release rate (t(60%)= 5 h) compared with calcium silicate-based placebos, some coating damage ( approximately 30%) still occurred on compression as release was faster than coated APAP beads alone. While tablets containing coated drug beads can be produced with practical crushing strengths (>8 kP) and low compression pressures (10-35 MPa), dissolution studies revealed that calcium silicate-based placebos are ineffective as cushioning agents. Blend segregation was likely observed due to the particle size and the density differences between APAP beads and calcium silicate-based placebo beads; placebo bead percolation can perhaps be minimized by increasing their size during the extrusion-spheronization process. The GMS- based placebos offer greater promise as cushioning agents for compacted, coated drug beads; however, this requires an optimized compression pressure range and drug bead : placebo bead ratio (i.e., 50:50).
Deterministic bead-in-droplet ejection utilizing an integrated plug-in bead dispenser for single bead–based applications

PubMed Central

Kim, Hojin; Choi, In Ho; Lee, Sanghyun; Won, Dong-Joon; Oh, Yong Suk; Kwon, Donghoon; Sung, Hyung Jin; Jeon, Sangmin; Kim, Joonwon

2017-01-01

This paper presents a deterministic bead-in-droplet ejection (BIDE) technique that regulates the precise distribution of microbeads in an ejected droplet. The deterministic BIDE was realized through the effective integration of a microfluidic single-particle handling technique with a liquid dispensing system. The integrated bead dispenser facilitates the transfer of the desired number of beads into a dispensing volume and the on-demand ejection of bead-encapsulated droplets. Single bead–encapsulated droplets were ejected every 3 s without any failure. Multiple-bead dispensing with deterministic control of the number of beads was demonstrated to emphasize the originality and quality of the proposed dispensing technique. The dispenser was mounted using a plug-socket type connection, and the dispensing process was completely automated using a programmed sequence without any microscopic observation. To demonstrate a potential application of the technique, bead-based streptavidin–biotin binding assay in an evaporating droplet was conducted using ultralow numbers of beads. The results evidenced the number of beads in the droplet crucially influences the reliability of the assay. Therefore, the proposed deterministic bead-in-droplet technology can be utilized to deliver desired beads onto a reaction site, particularly to reliably and efficiently enrich and detect target biomolecules. PMID:28393911

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