Towards real time diagnostics of Hybrid Welding Laser/GMAW

NASA Astrophysics Data System (ADS)

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

2014-02-01

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

Study of weld quality real-time monitoring system for auto-body assembly

NASA Astrophysics Data System (ADS)

Xu, Jun; Li, Yong-Bing; Chen, Guan-Long

2005-12-01

Resistance spot welding (RSW) is widely used for the auto-body assembly in automotive industry. But RSW suffers from a major problem of inconsistent quality from weld to weld. The major problem is the complexity of the basic process that may involve material coatings, electrode force, electrode wear, fit up, etc. Therefore weld quality assurance is still a big challenge and goal. Electrode displacement has proved to be a particularly useful signal which correlates well with weld quality. This paper introduces a novel auto-body spot weld quality monitoring system which uses electrode displacement as the quality parameter. This system chooses the latest laser displacement sensor with high resolution to measure the real-time electrode displacement. It solves the interference problem of sensor mounting by designing special fixture, and can be successfully applied on the portable welding machine. It is capable of evaluating weld quality and making diagnosis of process variations such as surface asperities, shunting, worn electrode and weld expansion with real-time electrode displacement. As proved by application in the workshop, the monitoring system has good stability and reliability, and is qualified for monitoring weld quality in process.

Cold Plasma Welding System for Surgical Skin Closure: In Vivo Porcine Feasibility Assessment.

PubMed

Harats, Moti; Lam, Amnon; Maller, Michael; Kornhaber, Rachel; Haik, Josef

2016-09-29

Cold plasma skin welding is a novel technology that bonds skin edges through soldering without the use of synthetic materials or conventional wound approximation methods such as sutures, staples, or skin adhesives. The cold plasma welding system uses a biological solder applied to the edges of a skin incision, followed by the application of cold plasma energy. The objectives of this study were to assess the feasibility of a cold plasma welding system in approximating and fixating skin incisions compared with conventional methods and to evaluate and define optimal plasma welding parameters and histopathological tissue response in a porcine model. The cold plasma welding system (BioWeld1 System, IonMed Ltd, Yokneam, Israel) was used on porcine skin incisions using variable energy parameters. Wound healing was compared macroscopically and histologically to incisions approximated with sutures. When compared to sutured skin closure, cold plasma welding in specific system parameters demonstrated comparable and favorable wound healing results histopathologically as well as macroscopically. No evidence of epidermal damage, thermal or otherwise, was encountered in the specified parameters. Notably, bleeding, infection, and wound dehiscence were not detected at incision sites. Skin incisions welded at extreme energy parameters presented second-degree burns. Implementation of cold plasma welding has been shown to be feasible for skin closure. Initial in vivo results suggest cold plasma welding might provide equal, if not better, healing results than traditional methods of closure.

Development of automatic through-insulation welding for microelectric interconnections

NASA Technical Reports Server (NTRS)

Arnett, J. C.

1972-01-01

The capability to automatically route, remove insulation from, and weld small-diameter solid conductor wire is presented. This would facilitate the economical small-quantity production of complex miniature electronic assemblies. An engineering model of equipment having this capability was developed and evaluated. Whereas early work in the use of welded magnet wire interconnections was concentrated on opposed electrode systems, and generally used heat to melt the wire insulation, the present method is based on a concentric electrode system and a wire feed system which splits the insulation by application of pressure prior to welding. The work deals with the design, fabrication, and evaluation testing of an improved version of this concentric electrode system. Two different approaches to feeding the wire to the concentric electrodes were investigated. It was concluded that the process is feasible for the interconnection of complex miniature electronic assemblies.

Automated data acquisition technology development:Automated modeling and control development

NASA Technical Reports Server (NTRS)

Romine, Peter L.

1995-01-01

This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing.

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

NASA Technical Reports Server (NTRS)

Michaels, Kerry; Hughes, Greg

1994-01-01

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

Damage Tolerance Assessment of Friction Pull Plug Welds

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

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

Automatic visual monitoring of welding procedure in stainless steel kegs

NASA Astrophysics Data System (ADS)

Leo, Marco; Del Coco, Marco; Carcagnì, Pierluigi; Spagnolo, Paolo; Mazzeo, Pier Luigi; Distante, Cosimo; Zecca, Raffaele

2018-05-01

In this paper a system for automatic visual monitoring of welding process, in dry stainless steel kegs for food storage, is proposed. In the considered manufacturing process the upper and lower skirts are welded to the vessel by means of Tungsten Inert Gas (TIG) welding. During the process several problems can arise: 1) residuals on the bottom 2) darker weld 3) excessive/poor penetration and 4) outgrowths. The proposed system deals with all the four aforementioned problems and its inspection performances have been evaluated by using a large set of kegs demonstrating both the reliability in terms of defect detection and the suitability to be introduced in the manufacturing system in terms of computational costs.

System for evaluating weld quality using eddy currents

DOEpatents

Todorov, Evgueni I.; Hay, Jacob

2017-12-12

Electromagnetic and eddy current techniques for fast automated real-time and near real-time inspection and monitoring systems for high production rate joining processes. An eddy current system, array and method for the fast examination of welds to detect anomalies such as missed seam (MS) and lack of penetration (LOP) the system, array and methods capable of detecting and sizing surface and slightly subsurface flaws at various orientations in connection with at least the first and second weld pass.

Control of arc length during gas metal arc welding

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

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

1994-12-31

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

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.

[Comprehensive evaluation of protective measures in electric welding].

PubMed

Ye, K; Zhao, Z

1995-03-01

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

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

PubMed

Wang, Lin; Gao, Xiangdong; Chen, Ziqin

2018-01-08

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

Unique methods for on-orbit structural repair, maintenance, and assembly

NASA Technical Reports Server (NTRS)

Anderson, Ray; Fuson, Phil

1994-01-01

This paper reviews the MDA independent research and development (IRAD) efforts since 1986 in the development of two distinctly different approaches to on-orbit tube repair: (1) one-piece mechanical tube fittings that are forced, under pressure, onto the tube outer surface to effect the repair; and (2) electron beam weldings as demonstrated with the Paton-developed universal hand tool (UHT) space welding system for the repair of fluid lines and tubular components. Other areas of potential on-orbit repair using the UHT include damage to the flat or curved surfaces of habitation modules and truss assemblies. This paper will also address MDA evaluation of the Paton UHT system for on-orbit coating, cleaning, brazing, and cutting of metals. MDA development of an on-orbit compatible nondestructive evaluation (NDE) system for the inspection of tube welds is an important part of this complete space welding capability and will be discussed in a separate paper.

Mechanical Properties of Friction Stir Welds in A12195-T8

NASA Technical Reports Server (NTRS)

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

1999-01-01

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

Investigation on the hot melting temperature field simulation of HDPE water supply pipeline in gymnasium pool

NASA Astrophysics Data System (ADS)

Cai, Zhiqiang; Dai, Hongbin; Fu, Xibin

2018-06-01

In view of the special needs of the water supply and drainage system of swimming pool in gymnasium, the correlation of high density polyethylene (HDPE) pipe and the temperature field distribution during welding was investigated. It showed that the temperature field distribution has significant influence on the quality of welding. Moreover, the mechanical properties of the welded joint were analyzed by the bending test of the weld joint, and the micro-structure of the welded joint was evaluated by scanning electron microscope (SEM). The one-dimensional unsteady heat transfer model of polyethylene pipe welding joints was established by MARC. The temperature field distribution during welding process was simulated, and the temperature field changes during welding were also detected and compared by the thermo-couple temperature automatic acquisition system. Results indicated that the temperature of the end surface of the pipe does not reach the maximum value, when it is at the end of welding heating. Instead, it reaches the maximum value at 300 sand latent heat occurs during the welding process. It concludes that the weld quality is the highest when the welding pressure is 0.2 MPa, and the heating temperature of HDPE heat fusion welding is in the range of 210 °C-230 °C.

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

NASA Technical Reports Server (NTRS)

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

2000-01-01

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

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

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

Grossbeck, Martin; Qualls, Louis

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

[Hygienic evaluation of new welding processes and welding materials].

PubMed

Gorban', L N

1990-01-01

The possibility of contaminating the breathing air zone with hazardous substances in manual and semi-automated welding increases with the intensity of their formation in the arc zone. This necessitates more comprehensive data on both the specific excreta and the formation intensity of the most hazardous substances, such as hard and gaseous compounds of welding aerosols, with due account of the welding regimen used and electrode diameter, wires, etc. When calculating the effectiveness of both local and general ventilation systems in welding shops, a possibility of a specific one-way hazardous action of some chemical substances (e.g. chromium, fluorine, etc.) should be taken into account.

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

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

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.

Microstructure Characterization and Stress Corrosion Evaluation of Autogenous and Hybrid Friction Stir Welded Al-Cu-Li 2195 Alloy

NASA Technical Reports Server (NTRS)

Li, Zhixian; Arbegast, William J.; Meletis, Efstathios I.

1997-01-01

Friction stir welding process is being evaluated for application on the Al-Cu-Li 2195 Super-Light Weight External Tank of the Space Transportation System. In the present investigation Al-Cu-Li 2195 plates were joined by autogenous friction stir welding (FSW) and hybrid FSW (friction stir welding over existing variable polarity plasma arc weld). Optical microscopy and transmission electron microscopy (TEM) were utilized to characterize microstructures of the weldments processed by both welding methods. TEM observations of autogenous FSW coupons in the center section of the dynamically-recrystallized zone showed an equiaxed recrystallized microstructure with an average grain size of approx. 3.8 microns. No T(sub 1), precipitates were present in the above-mentioned zone. Instead, T(sub B) and alpha precipitates were found in this zone with a lower population. Alternate immersion, anodic polarization, constant load, and slow strain tests were carried out to evaluate the general corrosion and stress-corrosion properties of autogenous and hybrid FSW prepared coupons. The experimental results will be discussed.

B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Russell, Carolyn

2000-01-01

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

Welding, Bonding and Fastening, 1984

NASA Technical Reports Server (NTRS)

Buckley, J. D. (Editor); Stein, B. A. (Editor)

1985-01-01

A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Soceity, and Society of Manufacturing Engineers conference on Welding, Bonding, and Fastening at Langley Research Center, Hampton, VA, on October 23 to 25, 1984 is given. Papers were presented on technology developed in current research programs relevant to welding, bonding, and fastening of structural materials required in fabricating structures and mechanical systems used in the aerospace, hydrospace, and automotive industries. Topics covered in the conference included equipment, hardware and materials used when welding, brazing, and soldering, mechanical fastening, explosive welding, use of unique selected joining techniques, adhesives bonding, and nondestructive evaluation. A concept of the factory of the future was presented, followed by advanced welding techniques, automated equipment for welding, welding in a cryogenic atmosphere, blind fastening, stress corrosion resistant fasteners, fastening equipment, explosive welding of different configurations and materials, solid-state bonding, electron beam welding, new adhesives, effects of cryogenics on adhesives, and new techniques and equipment for adhesive bonding.

Pulsed Magnetic Welding for Advanced Core and Cladding Steel

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

Cao, Guoping; Yang, Yong

2013-12-19

To investigate a solid-state joining method, pulsed magnetic welding (PMW), for welding the advanced core and cladding steels to be used in Generation IV systems, with a specific application for fuel pin end-plug welding. As another alternative solid state welding technique, pulsed magnetic welding (PMW) has not been extensively explored on the advanced steels. The resultant weld can be free from microstructure defects (pores, non-metallic inclusions, segregation of alloying elements). More specifically, the following objectives are to be achieved: 1. To design a suitable welding apparatus fixture, and optimize welding parameters for repeatable and acceptable joining of the fuel pinmore » end-plug. The welding will be evaluated using tensile tests for lap joint weldments and helium leak tests for the fuel pin end-plug; 2 Investigate the microstructural and mechanical properties changes in PMW weldments of proposed advanced core and cladding alloys; 3. Simulate the irradiation effects on the PWM weldments using ion irradiation.« less

Development of optimized techniques and requirements for computer enhancement of structural weld radiographs. Volume 1: Technical report

NASA Technical Reports Server (NTRS)

Adams, J. R.; Hawley, S. W.; Peterson, G. R.; Salinger, S. S.; Workman, R. A.

1971-01-01

A hardware and software specification covering requirements for the computer enhancement of structural weld radiographs was considered. Three scanning systems were used to digitize more than 15 weld radiographs. The performance of these systems was evaluated by determining modulation transfer functions and noise characteristics. Enhancement techniques were developed and applied to the digitized radiographs. The scanning parameters of spot size and spacing and film density were studied to optimize the information content of the digital representation of the image.

Defense Waste Processing Facility Canister Closure Weld Current Validation Testing

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

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

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

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

NASA Astrophysics Data System (ADS)

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

2015-06-01

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

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

NASA Technical Reports Server (NTRS)

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

1986-01-01

A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Society, and Society of Manufacturing Engineers Conference on Welding, Bonding, and Fastening at Langley Research Center, Hampton, VA, on October 23 to 25, 1984 is given. Papers were presented on technology developed in current research programs relevant to welding, bonding, and fastening of structural materials required in fabricating structures and mechanical systems used in the aerospace, hydrospace, and automotive industries. Topics covered in the conference included equipment, hardware and materials used when welding, brazing, and soldering, mechanical fastening, explosive welding, use of unique selected joining techniques, adhesives bonding, and nondestructive evaluation. A concept of the factory of the future was presented, followed by advanced welding techniques, automated equipment for welding, welding in a cryogenic atmosphere, blind fastening, stress corrosion resistant fasteners, fastening equipment, explosive welding of different configurations and materials, solid-state bonding, electron beam welding, new adhesives, effects of cryogenics on adhesives, and new techniques and equipment for adhesive bonding.

Development and characterization of a resistance spot welding aerosol generator and inhalation exposure system.

PubMed

Afshari, Aliakbar; Zeidler-Erdely, Patti C; McKinney, Walter; Chen, Bean T; Jackson, Mark; Schwegler-Berry, Diane; Friend, Sherri; Cumpston, Amy; Cumpston, Jared L; Leonard, H Donny; Meighan, Terence G; Frazer, David G; Antonini, James M

2014-10-01

Limited information exists regarding the health risks associated with inhaling aerosols that are generated during resistance spot welding of metals treated with adhesives. Toxicology studies evaluating spot welding aerosols are non-existent. A resistance spot welding aerosol generator and inhalation exposure system was developed. The system was designed by directing strips of sheet metal that were treated with an adhesive to two electrodes of a spot welder. Spot welds were made at a specified distance from each other by a computer-controlled welding gun in a fume collection chamber. Different target aerosol concentrations were maintained within the exposure chamber during a 4-h exposure period. In addition, the exposure system was run in two modes, spark and no spark, which resulted in different chemical profiles and particle size distributions. Complex aerosols were produced that contained both metal particulates and volatile organic compounds (VOCs). Size distribution of the particles was multi-modal. The majority of particles were chain-like agglomerates of ultrafine primary particles. The submicron mode of agglomerated particles accounted for the largest portion of particles in terms of particle number. Metal expulsion during spot welding caused the formation of larger, more spherical particles (spatter). These spatter particles appeared in the micron size mode and accounted for the greatest amount of particles in terms of mass. With this system, it is possible to examine potential mechanisms by which spot welding aerosols can affect health, as well as assess which component of the aerosol may be responsible for adverse health outcomes.

WELDSMART: A vision-based expert system for quality control

NASA Technical Reports Server (NTRS)

Andersen, Kristinn; Barnett, Robert Joel; Springfield, James F.; Cook, George E.

1992-01-01

This work was aimed at exploring means for utilizing computer technology in quality inspection and evaluation. Inspection of metallic welds was selected as the main application for this development and primary emphasis was placed on visual inspection, as opposed to other inspection methods, such as radiographic techniques. Emphasis was placed on methodologies with the potential for use in real-time quality control systems. Because quality evaluation is somewhat subjective, despite various efforts to classify discontinuities and standardize inspection methods, the task of using a computer for both inspection and evaluation was not trivial. The work started out with a review of the various inspection techniques that are used for quality control in welding. Among other observations from this review was the finding that most weld defects result in abnormalities that may be seen by visual inspection. This supports the approach of emphasizing visual inspection for this work. Quality control consists of two phases: (1) identification of weld discontinuities (some of which may be severe enough to be classified as defects), and (2) assessment or evaluation of the weld based on the observed discontinuities. Usually the latter phase results in a pass/fail judgement for the inspected piece. It is the conclusion of this work that the first of the above tasks, identification of discontinuities, is the most challenging one. It calls for sophisticated image processing and image analysis techniques, and frequently ad hoc methods have to be developed to identify specific features in the weld image. The difficulty of this task is generally not due to limited computing power. In most cases it was found that a modest personal computer or workstation could carry out most computations in a reasonably short time period. Rather, the algorithms and methods necessary for identifying weld discontinuities were in some cases limited. The fact that specific techniques were finally developed and successfully demosntrated to work illustrates that the general approach taken here appears to be promising for commercial development of computerized quality inspection systems. Inspection based on these techniques may be used to supplement or substitute more elaborate inspection methods, such as x-ray inspections.

Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

Pan, Yi; Lados, Diana A.

2017-04-01

Friction stir welding (FSW) is a solid-state process widely used for joining similar and dissimilar materials for critical applications in the transportation sector. Understanding the effects of the process on microstructure and mechanical properties is critical in design for structural integrity. In this study, four aluminum alloy systems (wrought 6061-T651 and cast A356, 319, and A390) were processed in both as-fabricated and pre-weld heat-treated (T6) conditions using various processing parameters. The effects of processing and heat treatment on the resulting microstructures, macro-/micro-hardness, and tensile properties were systematically investigated and mechanistically correlated to changes in grain size, characteristic phases, and strengthening precipitates. Tensile tests were performed at room temperature both along and across the welding zones. A new method able to evaluate weld quality (using a weld quality index) was developed based on the stress concentration calculated under tensile loading. Optimum processing parameter domains that provide both defect-free welds and good mechanical properties were determined for each alloy and associated with the thermal history of the process. These results were further related to characteristic microstructural features, which can be used for component design and materials/process optimization.

Fundamentals and advances in the development of remote welding fabrication systems

NASA Technical Reports Server (NTRS)

Agapakis, J. E.; Masubuchi, K.; Von Alt, C.

1986-01-01

Operational and man-machine issues for welding underwater, in outer space, and at other remote sites are investigated, and recent process developments are described. Probable remote welding missions are classified, and the essential characteristics of fundamental remote welding tasks are analyzed. Various possible operational modes for remote welding fabrication are identified, and appropriate roles for humans and machines are suggested. Human operator performance in remote welding fabrication tasks is discussed, and recent advances in the development of remote welding systems are described, including packaged welding systems, stud welding systems, remotely operated welding systems, and vision-aided remote robotic welding and autonomous welding systems.

Aluminum Lithium Alloy 2195 Fusion Welding Improvements with New Filler Wire

NASA Technical Reports Server (NTRS)

Russell, C.

2001-01-01

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

Vaccum Gas Tungsten Arc Welding, phase 1

NASA Astrophysics Data System (ADS)

Weeks, J. L.; Krotz, P. D.; Todd, D. T.; Liaw, Y. K.

1995-03-01

This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

Vaccum Gas Tungsten Arc Welding, phase 1

NASA Technical Reports Server (NTRS)

Weeks, J. L.; Krotz, P. D.; Todd, D. T.; Liaw, Y. K.

1995-01-01

This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

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

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

During final preparations for start of the PDCF Inner Can (IC) qualification effort, welding was performed on an automated weld system known as the PICN. During the initial weld, using a pedigree canister and plug, a weld defect was observed. The defect resulted in a hole in the sidewall of the canister, and it was observed that the plug sidewall had not been consumed. This was a new type of failure not seen during development and production of legacy Bagless Transfer Cans (FB-Line/Hanford). Therefore, a team was assembled to determine the root cause and to determine if the process couldmore » be improved. After several brain storming sessions (MS and T, R and D Engineering, PDC Project), an evaluation matrix was established to direct this effort. The matrix identified numerous activities that could be taken and then prioritized those activities. This effort was limited by both time and resources (the number of canisters and plugs available for testing was limited). A discovery process was initiated to evaluate the Vendor's IC fabrication process relative to legacy processes. There were no significant findings, however, some information regarding forging/anneal processes could not be obtained. Evaluations were conducted to compare mechanical properties of the PDC canisters relative to the legacy canisters. Some differences were identified, but mechanical properties were determined to be consistent with legacy materials. A number of process changes were also evaluated. A heat treatment procedure was established that could reduce the magnetic characteristics to levels similar to the legacy materials. An in-situ arc annealing process was developed that resulted in improved weld characteristics for test articles. Also several tack welds configurations were addressed, it was found that increasing the number of tack welds (and changing the sequence) resulted in decreased can to plug gaps and a more stable weld for test articles. Incorporating all of the process improvements for the actual can welding process, however, did not result in an improved weld geometry. Several possibilities for the lack of positive response exist, some of which are that (1) an insufficient number of test articles were welded under prototypic conditions, (2) the process was not optimized so that significant improvements were observable over the 'noise', and (3) the in-situ arc anneal closed the gap down too much so the can was unable to exhaust pressure ahead of the weld. Several operational and mechanical improvements were identified. The weld clamps were changed to a design consistent with those used in the legacy operations. A helium puff operation was eliminated; it is believed that this operation was the cause of the original weld defect. Also, timing of plug mast movement was found to correspond with weld irregularities. The timing of the movement was changed to occur during weld head travel between tacks. In the end a three sequential tack weld process followed by a pulse weld at the same current and travel speed as was used for the legacy processes was suggested for use during the IC qualification effort. Relative to legacy welds, the PDC IC weld demonstrates greater fluctuation in the region of the weld located between tack welds. However, canister weld response (canister to canister) is consistent and with the aid of the optical mapping system (for targeting the cut position) is considered adequate. DR measurements and METs show the PDC IC welds to have sufficient ligament length to ensure adequate canister pressure/impact capacity and to ensure adequate stub function. The PDC welding process has not been optimized as a result of this effort. Differences remain between the legacy BTC welds and the PDC IC weld, but these differences are not sufficient to prevent resumption of the current PDC IC qualification effort. During the PDC IC qualification effort, a total of 17 cans will be welded and a variety of tests/inspections will be performed. The extensive data collected during that qualification effort should be of a sufficient population to determine if additional weld process optimization is necessary prior to production release.« less

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.

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

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

Quality evaluation and control of end cap welds in PHWR fuel elements by ultrasonic examination

NASA Astrophysics Data System (ADS)

Choi, M. S.; Yang, M. S.

1991-02-01

The current quality control procedure of nuclear fuel end cap weld is mainly dependent on the destructive metallographic examination. A nondestructive examination technique, i.e., ultrasonic examination, has been developed to identify and evaluate weld discontinuities. A few interesting results of the weld quality evaluation by applying the developed ultrasonic examination technique to PHWR fuel welds are presented. In addition, the feasibility of the weld quality control by the ultrasonic examination is discussed. This study shows that the ultrasonic examination is effective and reliable method for detecting abnormal weld contours and weld discontinuities such as micro-fissure, crack, upset split and expulsion, and can be used as a quality control tool for the end cap welding process.

Moisture contamination and welding parameter effects on flux cored arc welding diffusible hydrogen

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

Kiefer, J.J.

1994-12-31

Gas metal arc (GMAW) and flux cored arc (FCAW) welding are gas shielded semiautomatic processes widely used for achieving high productivity in steel fabrication. Contamination of the shielding has can occur due to poorly maintained gas distribution systems. Moisture entering as a gas contaminant is a source of hydrogen that can cause delayed cold cracking in welds. Limiting heat-affected zone hardness is one method of controlling cracking. Even this is based on some assumptions about the hydrogen levels in the weld. A study was conducted to investigate the effect of shielding gas moisture contamination and welding parameters on the diffusiblemore » hydrogen content of gas shielded flux cored arc welding. The total wire hydrogen of various electrodes was also tested and compared to the diffusible weld hydrogen. An empirical equation has been developed that estimates the diffusible hydrogen in weld metal for gas shielded flux cored arc welding. The equation is suitable for small diameter electrodes and welding parameter ranges commonly used for out-of-position welding. by combining this with the results from the total wire hydrogen tests, it is possible to estimate diffusible hydrogen directly from measured welding parameters, shielding gas dew point, and total hydrogen of the consumable. These equations are also useful for evaluating the effect of welding procedure variations from known baseline conditions.« less

Automated generation of weld path trajectories.

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

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

2003-06-01

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

Prospects of very high power CO{sub 2} laser in welding

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

Goussain, J.C.; Vire, S.

1996-12-31

A 45 kW laser system was recently installed at Institut de Soudure (IS) in France in order to evaluate the possibilities of such high power beams in welding. Some results of welding various materials (Ta6V, C-steel, Cr-Ni alloys), different thicknesses (>30 mm) and large components (several meters) are presented. Some recent installations of high power laser equipment already integrated into production site or under development in shipbuilding and steel fabrication are described. Finally the objectives of an important R and D program launched recently for exploring the different aspects of laser welding in thick section steel fabrication is outlined.

ARC+(Registered Trademark) and ARC PC Welding Simulators: Teach Welders with Virtual Interactive 3D Technologies

NASA Technical Reports Server (NTRS)

Choquet, Claude

2011-01-01

123 Certification Inc., a Montreal based company, has developed an innovative hands-on welding simulator solution to help build the welding workforce in the most simple way. The solution lies in virtual reality technology, which has been fully tested since the early 90's. President and founder of 123 Certification Inc., Mr. Claude Choquet Ing. Msc. IWE. acts as a bridge between the welding and the programming world. Working in these fields for more than 20 years. he has filed 12 patents world-wide for a gesture control platform with leading edge hardware related to simulation. In the summer of 2006. Mr Choquet was proud to be invited to the annual IIW International Weld ing Congress in Quebec City to launch the ARC+ welding simulator. A 100% virtual reality system and web based training center was developed to simulate multi process. multi-materiaL multi-position and multi pass welding. The simulator is intended to train welding students and apprentices in schools or industries. The welding simulator is composed of a real welding e[eetrode holder (SMAW-GTAW) and gun (GMAW-FCAW). a head mounted display (HMD), a 6 degrees of freedom tracking system for interaction between the user's hands and head. as well as external audio speakers. Both guns and HMD are interacting online and simultaneously. The welding simulation is based on the law of physics and empirical results from detailed analysis of a series of welding tests based on industrial applications tested over the last 20 years. The simulation runs in real-time, using a local logic network to determine the quality and shape of the created weld. These results are based on the orientation distance. and speed of the welding torch and depth of penetration. The welding process and resulting weld bc.1d are displayed in a virtual environment with screenplay interactive training modules. For review. weld quality and recorded process values can be displayed and diagnosed after welding. To help in the le.tming process, a learning curve for each student and each Virtual Welding Class'" can be plotted, for an instructor's review or a required third party evaluation.

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

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Cantrell, Mark; Carter, Robert

2003-01-01

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

A Microsample Tensile Test Application: Local Strength of Impact Welds Between Sheet Metals

NASA Astrophysics Data System (ADS)

Benzing, J. T.; He, M.; Vivek, A.; Taber, G. A.; Mills, M. J.; Daehn, G. S.

2017-03-01

Microsample tensile testing was conducted to evaluate the quality of impact welds created by vaporizing foil actuator welding. Tensile test samples with a gauge length of 0.6 mm were electro-discharge machined out of welds created between 1-mm-thick aluminum alloy type 6061 (AA6061) sheets and 6-mm-thick copper (Cu110) plates. Aluminum sheets were used as flyers, while copper plates acted as targets. Flyer sheets in T6 as well as T4 temper conditions were utilized to create welds. Some of the welds made with T4 temper flyers were heat treated to a T6 temper. It was found that the welds made with T4 temper flyers were slightly stronger (max. of 270 MPa) than those produced with T6 temper flyers. Generally, failure propagated in a brittle manner across the weld interface; however, elemental mapping reveals material transfer on either member of the welded system. This work proves the feasibility to apply microsample tensile testing to assess impact welding, even when conducted with flyer sheets of 1 mm or less, and provides insight that is complementary to other test methods.

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.

Weld Nugget Temperature Control in Thermal Stir Welding

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2014-01-01

A control system for a thermal stir welding system is provided. The control system includes a sensor and a controller. The sensor is coupled to the welding system's containment plate assembly and generates signals indicative of temperature of a region adjacent and parallel to the welding system's stir rod. The controller is coupled to the sensor and generates at least one control signal using the sensor signals indicative of temperature. The controller is also coupled to the welding system such that at least one of rotational speed of the stir rod, heat supplied by the welding system's induction heater, and feed speed of the welding system's weld material feeder are controlled based on the control signal(s).

Use of the Plasma Spectrum RMS Signal for Arc-Welding Diagnostics.

PubMed

Mirapeix, Jesus; Cobo, Adolfo; Fuentes, Jose; Davila, Marta; Etayo, Juan Maria; Lopez-Higuera, Jose-Miguel

2009-01-01

A new spectroscopic parameter is used in this paper for on-line arc-welding quality monitoring. Plasma spectroscopy applied to welding diagnostics has typically relied on the estimation of the plasma electronic temperature, as there is a known correlation between this parameter and the quality of the seams. However, the practical use of this parameter gives rise to some uncertainties that could provoke ambiguous results. For an efficient on-line welding monitoring system, it is essential to prevent the appearance of false alarms, as well as to detect all the possible defects. In this regard, we propose the use of the root mean square signal of the welding plasma spectra, as this parameter will be proven to exhibit a good correlation with the quality of the resulting seams. Results corresponding to several arc-welding field tests performed on Inconel and titanium specimens will be discussed and compared to non-destructive evaluation techniques.

Use of the Plasma Spectrum RMS Signal for Arc-Welding Diagnostics

PubMed Central

Mirapeix, Jesus; Cobo, Adolfo; Fuentes, Jose; Davila, Marta; Etayo, Juan Maria; Lopez-Higuera, Jose-Miguel

2009-01-01

A new spectroscopic parameter is used in this paper for on-line arc-welding quality monitoring. Plasma spectroscopy applied to welding diagnostics has typically relied on the estimation of the plasma electronic temperature, as there is a known correlation between this parameter and the quality of the seams. However, the practical use of this parameter gives rise to some uncertainties that could provoke ambiguous results. For an efficient on-line welding monitoring system, it is essential to prevent the appearance of false alarms, as well as to detect all the possible defects. In this regard, we propose the use of the root mean square signal of the welding plasma spectra, as this parameter will be proven to exhibit a good correlation with the quality of the resulting seams. Results corresponding to several arc-welding field tests performed on Inconel and titanium specimens will be discussed and compared to non-destructive evaluation techniques. PMID:22346696

Concentrated autologous plasma protein: a biochemically neutral solder for tissue welding.

PubMed

Stewart, R B; Bleustein, C B; Petratos, P B; Chin, K C; Poppas, D P; Kung, R T

2001-01-01

Xenographic or allographic serum protein solders used for laser welding may have immunologic and/or pathogenic complications. The objective of these studies was to develop a safe, autologous solder. Five methods of preparing concentrated autologous plasma protein solder (CAPPS) were evaluated. Next, the CAPPS was evaluated via (1) thermal denaturation studies using differential scanning calorimetry, (2) tissue welding studies to characterize both acute and healing properties. The optimal concentration method to produce CAPPS rapidly was a dialysis method using chemical (osmotic) forces. The CAPPS showed similar denaturation profiles to serum albumin (SA) solders. Acutely, CAPPS provided comparable breaking strengths to SA solders. At 7 days, there was no significant difference in breaking strength or histology between 50% human SA solder and CAPPS (using a porcine skin model). These studies demonstrate that the CAPPS system provides acceptable acute and chronic properties for laser welding. Copyright 2001 Wiley-Liss, Inc.

Multisensor-based real-time quality monitoring by means of feature extraction, selection and modeling for Al alloy in arc welding

NASA Astrophysics Data System (ADS)

Zhang, Zhifen; Chen, Huabin; Xu, Yanling; Zhong, Jiyong; Lv, Na; Chen, Shanben

2015-08-01

Multisensory data fusion-based online welding quality monitoring has gained increasing attention in intelligent welding process. This paper mainly focuses on the automatic detection of typical welding defect for Al alloy in gas tungsten arc welding (GTAW) by means of analzing arc spectrum, sound and voltage signal. Based on the developed algorithms in time and frequency domain, 41 feature parameters were successively extracted from these signals to characterize the welding process and seam quality. Then, the proposed feature selection approach, i.e., hybrid fisher-based filter and wrapper was successfully utilized to evaluate the sensitivity of each feature and reduce the feature dimensions. Finally, the optimal feature subset with 19 features was selected to obtain the highest accuracy, i.e., 94.72% using established classification model. This study provides a guideline for feature extraction, selection and dynamic modeling based on heterogeneous multisensory data to achieve a reliable online defect detection system in arc welding.

Weld radiograph enigmas

NASA Technical Reports Server (NTRS)

Jemian, Wartan A.

1986-01-01

Weld radiograph enigmas are features observed on X-ray radiographs of welds. Some of these features resemble indications of weld defects, although their origin is different. Since they are not understood, they are a source of concern. There is a need to identify their causes and especially to measure their effect on weld mechanical properties. A method is proposed whereby the enigmas can be evaluated and rated, in relation to the full spectrum of weld radiograph indications. Thie method involves a signature and a magnitude that can be used as a quantitive parameter. The signature is generated as the diference between the microdensitometer trace across the radiograph and the computed film intensity derived from a thickness scan along the corresponding region of the sample. The magnitude is the measured difference in intensity between the peak and base line values of the signature. The procedure is demonstated by comparing traces across radiographs of a weld sample before and after the introduction of a hole and by a system based on a MacIntosh mouse used for surface profiling.

Application of laser ultrasonic method for on-line monitoring of friction stir spot welding process.

PubMed

Zhang, Kuanshuang; Zhou, Zhenggan; Zhou, Jianghua

2015-09-01

Application of a laser ultrasonic method is developed for on-line monitoring of the friction stir spot welding (FSSW) process. Based on the technology of FSSW, laser-generated ultrasonic waves in a good weld and nonweld area are simulated by a finite element method. The reflected and transmitted waves are analyzed to disclose the properties of the welded interface. The noncontact-laser ultrasonic-inspection system was established to verify the numerical results. The reflected waves in the good-weld and nonweld area can be distinguished by time-of-flight. The transmitted waves evidently attenuate in the nonweld area in contrast to signal amplitude in the good weld area because of interfacial impedance difference. Laser ultrasonic C-scan images can sufficiently evaluate the intrinsic character of the weld area in comparison with traditional water-immersion ultrasonic testing results. The research results confirm that laser ultrasonics would be an effective method to realize the characterization of FSSW defects.

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

Surface preparation of Ti-3Al-2.5V alloy tubes for welding using a fiber laser

NASA Astrophysics Data System (ADS)

Kumar, Aniruddha; Gupta, Mool C.

2009-11-01

Ti-3Al-2.5V tubes are widely used in aircraft hydraulic systems. Meticulous surface preparation before welding is necessary to obtain a sound weld involving these alloy tubes. Conventionally this is done by cleaning with environmentally malign toxic chemicals, such as, hydrofluoric acid and nitric acid. This paper describes the laser-cleaning process of the surface of these tubes with a fiber laser as a preparation for pulsed gas tungsten arc welding and results obtained. A simple one-dimensional heat equation has been solved to evaluate the temperature profile of the irradiated surface. It is shown that surface preparation by laser cleaning can be an environmentally friendly alternative process by producing acceptable welds with laser-processed tubes.

Laser welding by dental Nd:YAG device

NASA Astrophysics Data System (ADS)

Fornaini, Carlo; Bertrand, Caroline; Merigo, Elisabetta; Bonanini, Mauro; Rocca, Jean-Paul; Nammour, Samir

2009-06-01

Welding laser was introduced in jewellery during years 70 and, just after, was successfully used also by dental technicians. Welding laser gives a great number of advantages, versus traditional welding and, for this reason, this procedure had a great diffusion in the technician laboratories and stimulated the companies to put in the market more and more evolutes appliances. Some aspects, such great dimensions, high costs and delivery system today still characterize these machines by fixed lenses, which have strictly limited its use only to technician laboratories. The aim of this study is to demonstrate the possibility, by using a fibber-delivered laser normally utilized in the dental office, to make, by dentist himself in his office, welding on different metals and to evaluate advantages and possibilities of this new technique.

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.

Relationship between pulmonary and systemic markers of exposure to multiple types of welding particulate matter.

PubMed

Erdely, Aaron; Salmen-Muniz, Rebecca; Liston, Angie; Hulderman, Tracy; Zeidler-Erdely, Patti C; Antonini, James M; Simeonova, Petia P

2011-09-05

Welding results in a unique and complex occupational exposure. Recent epidemiological studies have shown an increased risk of cardiovascular disease following welding fume exposure. In this study, we compared the induction of pulmonary and systemic inflammation following exposure to multiple types of welding fumes. Mice were exposed to 340μg of manual metal arc stainless steel (MMA-SS), gas metal arc-SS (GMA-SS) or GMA-mild steel (GMA-MS) by pharyngeal aspiration. Mice were sacrificed at 4 and 24h post-exposure to evaluate various parameters of pulmonary and systemic inflammation. Alterations in pulmonary gene expression by a custom designed TaqMan array showed minimal differences between the fumes at 4h. Conversely at 24h, gene expression changes were further increased by SS but not GMA-MS exposure. These findings were associated with the surrogate marker of systemic inflammation, liver acute phase gene induction. Interestingly, stress response genes in cardiovascular tissues were only increased following MMA-SS exposure. These effects were related to the initial level of pulmonary cytotoxicity, as measured by lactate dehydrogenase activity, which was greatest following MMA-SS exposure. In conclusion, varying types of welding fumes elicit quantitatively different systemic inflammatory and/or stress responses. Published by Elsevier Ireland Ltd.

Fiber laser welding of dual-phase galvanized sheet steel (DP590): traditional analysis and new quality assessment techniques

NASA Astrophysics Data System (ADS)

Miller, Stephanie; Pfeif, Erik; Kazakov, Andrei; Baumann, Esther; Dowell, Marla

2016-03-01

Laser welding has many advantages over traditional joining methods, yet remains underutilized. NIST has undertaken an ambitious initiative to improve predictions of weldability, reliability, and performance of laser welds. This study investigates butt welding of galvanized and ungalvanized dual-phase automotive sheet steels (DP 590) using a 10 kW commercial fiber laser system. Parameter development work, hardness profiles, microstructural characterization, and optical profilometry results are presented. Sound welding was accomplished in a laser power range of 2.0 kW to 4.5 kW and travel speed of 2000 mm/min to 5000 mm/min. Vickers hardness ranged from approximately 2 GPa to 4 GPa across the welds, with limited evidence of heat affected zone softening. Decreased hardness across the heat affected zone directly correlated to the appearance of ferrite. A technique was developed to non-destructively evaluate weld quality based on geometrical criteria. Weld face profilometry data were compared between light optical, metallographic sample, and frequency-modulated continuous-wave laser detection and ranging (FMCW LADAR) methods.

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

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

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

1994-12-31

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

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.

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

PubMed

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

2004-04-01

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

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.

Investigations for the improvement of space shuttle main engine electron beam welding equipment

NASA Technical Reports Server (NTRS)

Smock, R. A.; Taylor, R. A.; Wall, W. A., Jr.

1977-01-01

Progress made in the testing, evaluation, and correction of MSFC's 7.5 kW electron beam welder in support of space shuttle main engine component welding is summarized. The objective of this project was to locate and correct the deficiencies in the welder. Some 17 areas were deficient in the 7.5 kW ERI welding system and the associated corrective action was taken to improve its operational performance. An overall improvement of 20 times the original reliability was obtained at full rated capacity after the modifications were made.

Design of cylindrical pipe automatic welding control system based on STM32

NASA Astrophysics Data System (ADS)

Chen, Shuaishuai; Shen, Weicong

2018-04-01

The development of modern economy makes the demand for pipeline construction and construction rapidly increasing, and the pipeline welding has become an important link in pipeline construction. At present, there are still a large number of using of manual welding methods at home and abroad, and field pipe welding especially lacks miniature and portable automatic welding equipment. An automated welding system consists of a control system, which consisting of a lower computer control panel and a host computer operating interface, as well as automatic welding machine mechanisms and welding power systems in coordination with the control system. In this paper, a new control system of automatic pipe welding based on the control panel of the lower computer and the interface of the host computer is proposed, which has many advantages over the traditional automatic welding machine.

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.

Comparative study on the welded structure fatigue strength assessment method

NASA Astrophysics Data System (ADS)

Hu, Tao

2018-04-01

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

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

NASA Technical Reports Server (NTRS)

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

1991-01-01

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

Computerized adaptive control weld skate with CCTV weld guidance project

NASA Technical Reports Server (NTRS)

Wall, W. A.

1976-01-01

This report summarizes progress of the automatic computerized weld skate development portion of the Computerized Weld Skate with Closed Circuit Television (CCTV) Arc Guidance Project. The main goal of the project is to develop an automatic welding skate demonstration model equipped with CCTV weld guidance. The three main goals of the overall project are to: (1) develop a demonstration model computerized weld skate system, (2) develop a demonstration model automatic CCTV guidance system, and (3) integrate the two systems into a demonstration model of computerized weld skate with CCTV weld guidance for welding contoured parts.

Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

NASA Technical Reports Server (NTRS)

McGill, Preston; Burkholder, Jonathan

2012-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Active weld control

NASA Technical Reports Server (NTRS)

Powell, Bradley W.; Burroughs, Ivan A.

1994-01-01

Through the two phases of this contract, sensors for welding applications and parameter extraction algorithms have been developed. These sensors form the foundation of a weld control system which can provide action weld control through the monitoring of the weld pool and keyhole in a VPPA welding process. Systems of this type offer the potential of quality enhancement and cost reduction (minimization of rework on faulty welds) for high-integrity welding applications. Sensors for preweld and postweld inspection, weld pool monitoring, keyhole/weld wire entry monitoring, and seam tracking were developed. Algorithms for signal extraction were also developed and analyzed to determine their application to an adaptive weld control system. The following sections discuss findings for each of the three sensors developed under this contract: (1) weld profiling sensor; (2) weld pool sensor; and (3) stereo seam tracker/keyhole imaging sensor. Hardened versions of these sensors were designed and built under this contract. A control system, described later, was developed on a multiprocessing/multitasking operating system for maximum power and flexibility. Documentation for sensor mechanical and electrical design is also included as appendices in this report.

Development of a chromium-free consumable for joining stainless steels

NASA Astrophysics Data System (ADS)

Sowards, Jeffrey William

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

Analysis And Control System For Automated Welding

NASA Technical Reports Server (NTRS)

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

1994-01-01

Automated variable-polarity plasma arc (VPPA) welding apparatus operates under electronic supervision by welding analysis and control system. System performs all major monitoring and controlling functions. It acquires, analyzes, and displays weld-quality data in real time and adjusts process parameters accordingly. Also records pertinent data for use in post-weld analysis and documentation of quality. System includes optoelectronic sensors and data processors that provide feedback control of welding process.

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

PubMed

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

2012-06-01

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

Metallurgical evaluation of a feedwater nozzle to safe-end weld

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

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

1999-11-01

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

Transverse-Weld Tensile Properties of a New Al-4Cu-2Si Alloy as Filler Metal

NASA Astrophysics Data System (ADS)

Sampath, K.

2009-12-01

AA2195, an Al-Cu-Li alloy in the T8P4 age-hardened condition, is a candidate aluminum armor for future combat vehicles, as this material offers higher static strength and ballistic protection than current aluminum armor alloys. However, certification of AA2195 alloy for armor applications requires initial qualification based on the ballistic performance of welded panels in the as-welded condition. Currently, combat vehicle manufacturers primarily use gas metal arc welding (GMAW) process to meet their fabrication needs. Unfortunately, a matching GMAW consumable electrode is currently not commercially available to allow effective joining of AA2195 alloy. This initial effort focused on an innovative, low-cost, low-risk approach to identify an alloy composition suitable for effective joining of AA2195 alloy, and evaluated transverse-weld tensile properties of groove butt joints produced using the identified alloy. Selected commercial off-the-shelf (COTS) aluminum alloy filler wires were twisted to form candidate twisted filler rods. Representative test weldments were produced using AA2195 alloy, candidate twisted filler rods and gas tungsten arc welding (GTAW) process. Selected GTA weldments produced using Al-4wt.%Cu-2wt.%Si alloy as filler metal consistently provided transverse-weld tensile properties in excess of 275 MPa (40 ksi) UTS and 8% El (over 25 mm gage length), thereby showing potential for acceptable ballistic performance of as-welded panels. Further developmental work is required to evaluate in detail GMAW consumable wire electrodes based on the Al-Cu-Si system containing 4.2-5.0 wt.% Cu and 1.6-2.0 wt.% Si.

Langley Research Center Standard for the Evaluation of Socket Welds

NASA Technical Reports Server (NTRS)

Berry, R. F., Jr.

1985-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2014-07-01

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

INTERNAL REPAIR OF PIPELINES

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

Robin Gordon; Bill Bruce; Ian Harris

2004-04-12

The two broad categories of deposited weld metal repair and fiber-reinforced composite liner repair technologies were reviewed for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Preliminary test programs were developed for both deposited weld metal repair and for fiber-reinforced composite liner repair. Evaluation trials have been conducted using a modified fiber-reinforced composite liner provided by RolaTube and pipe sections without liners. All pipe section specimens failed in areas of simulated damage. Pipe sections containing fiber-reinforcedmore » composite liners failed at pressures marginally greater than the pipe sections without liners. The next step is to evaluate a liner material with a modulus of elasticity approximately 95% of the modulus of elasticity for steel. Preliminary welding parameters were developed for deposited weld metal repair in preparation of the receipt of Pacific Gas & Electric's internal pipeline welding repair system (that was designed specifically for 559 mm (22 in.) diameter pipe) and the receipt of 559 mm (22 in.) pipe sections from Panhandle Eastern. The next steps are to transfer welding parameters to the PG&E system and to pressure test repaired pipe sections to failure. A survey of pipeline operators was conducted to better understand the needs and performance requirements of the natural gas transmission industry regarding internal repair. Completed surveys contained the following principal conclusions: (1) Use of internal weld repair is most attractive for river crossings, under other bodies of water, in difficult soil conditions, under highways, under congested intersections, and under railway crossings. (2) Internal pipe repair offers a strong potential advantage to the high cost of horizontal direct drilling (HDD) when a new bore must be created to solve a leak or other problem. (3) Typical travel distances can be divided into three distinct groups: up to 305 m (1,000 ft.); between 305 m and 610 m (1,000 ft. and 2,000 ft.); and beyond 914 m (3,000 ft.). All three groups require pig-based systems. A despooled umbilical system would suffice for the first two groups which represents 81% of survey respondents. The third group would require an onboard self-contained power unit for propulsion and welding/liner repair energy needs. (4) Pipe diameter sizes range from 50.8 mm (2 in.) through 1,219.2 mm (48 in.). The most common size range for 80% to 90% of operators surveyed is 508 mm to 762 mm (20 in. to 30 in.), with 95% using 558.8 mm (22 in.) pipe. An evaluation of potential repair methods clearly indicates that the project should continue to focus on the development of a repair process involving the use of GMAW welding and on the development of a repair process involving the use of fiber-reinforced composite liners.« less

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

NASA Astrophysics Data System (ADS)

Vyskoč, Maroš; Sahul, Miroslav; Sahul, Martin

2018-04-01

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

Computational simulation of weld microstructure and distortion by considering process mechanics

NASA Astrophysics Data System (ADS)

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

2009-05-01

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

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.)

Adaptive weld control for high-integrity welding applications

NASA Technical Reports Server (NTRS)

Powell, Bradley W.

1993-01-01

An advanced adaptive control weld system for high-integrity welding applications is presented. The system consists of a state-of-the-art weld control subsystem, motion control subsystem, and sensor subsystem which closes the loop on the process. The adaptive control subsystem (ACS), which is required to totally close the loop on weld process control, consists of a multiprocessor system, data acquisition hardware, and three welding sensors which provide measurements from all areas around the torch in real time. The ACS acquires all 'measurables' and feeds offset trims back into the weld control and motion control subsystems to modify the 'controllables' in order to maintain a previously defined weld quality.

Real time computer controlled weld skate

NASA Technical Reports Server (NTRS)

Wall, W. A., Jr.

1977-01-01

A real time, adaptive control, automatic welding system was developed. This system utilizes the general case geometrical relationships between a weldment and a weld skate to precisely maintain constant weld speed and torch angle along a contoured workplace. The system is compatible with the gas tungsten arc weld process or can be adapted to other weld processes. Heli-arc cutting and machine tool routing operations are possible applications.

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

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

Ghosh, D.

1995-02-01

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

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.

SLI Complex Curvature Friction Stir Weld Risk Reduction Program

NASA Technical Reports Server (NTRS)

Hartley, Paula J.; Schneider, Jules; Jones, Chip; Lawless, Kirby; Russell, Carolyn

2003-01-01

The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.

Automatic Welding System of Aluminum Pipe by Monitoring Backside Image of Molten Pool Using Vision Sensor

NASA Astrophysics Data System (ADS)

Baskoro, Ario Sunar; Kabutomori, Masashi; Suga, Yasuo

An automatic welding system using Tungsten Inert Gas (TIG) welding with vision sensor for welding of aluminum pipe was constructed. This research studies the intelligent welding process of aluminum alloy pipe 6063S-T5 in fixed position and moving welding torch with the AC welding machine. The monitoring system consists of a vision sensor using 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. Neural network model for welding speed control were constructed to perform the process automatically. From the experimental results it shows the effectiveness of the control system confirmed by good detection of molten pool and sound weld of experimental result.

Friction Stir Weld System for Welding and Weld Repair

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor); Romine, Peter L. (Inventor); Oelgoetz, Peter A. (Inventor)

2001-01-01

A friction stir weld system for welding and weld repair has a base foundation unit connected to a hydraulically controlled elevation platform and a hydraulically adjustable pin tool. The base foundation unit may be fixably connected to a horizontal surface or may be connected to a mobile support in order to provide mobility to the friction stir welding system. The elevation platform may be utilized to raise and lower the adjustable pin tool about a particular axis. Additional components which may be necessary for the friction stir welding process include back plate tooling, fixturing and/or a roller mechanism.

Quality status display for a vibration welding process

DOEpatents

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

2017-03-28

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

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

NASA Astrophysics Data System (ADS)

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

2014-11-01

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

Closed-Loop Control System for Friction Stir Welding Retractable Pin Tool

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey; Romine, Peter L.; Munafo, Paul M. (Technical Monitor)

2001-01-01

NASA invention disclosure, NASA Case No. MFS-31413, entitled "System for Controlling the Stirring Pin of a Friction Stir Welding Apparatus", (Patent Pending) authored by Jeff Ding, Dr Peter Romine and Pete Oelgoetz, addresses the precision control of the friction stir welding process. The closed-loop control system automatically adjusts the spinning welding pin, real-time, to maintain a precise penetration ligament (i.e., distance between pin-tip and weld panel backside surface). A specific pin length can be maintained while welding constant thickness or tapered material thickness weld panels. The closed-loop control system provides operator data and information relative to the exact position of the welding pin inside the weld joint. This paper presents the closed-loop RPT control system that operates using the auto-feedback of force signals sensed by the tip and shoulder of the welding pin. Significance: The FSW process can be successfully used in a production environment only if there is a method or technique that informs the FSW operator the precise location of the welding pin inside the weld joint. This is essential for applications in aerospace, automotive, pressure vessel, commercial aircraft and other industries.

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.

Vision and spectroscopic sensing for joint tracing in narrow gap laser butt welding

NASA Astrophysics Data System (ADS)

Nilsen, Morgan; Sikström, Fredrik; Christiansson, Anna-Karin; Ancona, Antonio

2017-11-01

The automated laser beam butt welding process is sensitive to positioning the laser beam with respect to the joint because a small offset may result in detrimental lack of sidewall fusion. This problem is even more pronounced in case of narrow gap butt welding, where most of the commercial automatic joint tracing systems fail to detect the exact position and size of the gap. In this work, a dual vision and spectroscopic sensing approach is proposed to trace narrow gap butt joints during laser welding. The system consists of a camera with suitable illumination and matched optical filters and a fast miniature spectrometer. An image processing algorithm of the camera recordings has been developed in order to estimate the laser spot position relative to the joint position. The spectral emissions from the laser induced plasma plume have been acquired by the spectrometer, and based on the measurements of the intensities of selected lines of the spectrum, the electron temperature signal has been calculated and correlated to variations of process conditions. The individual performances of these two systems have been experimentally investigated and evaluated offline by data from several welding experiments, where artificial abrupt as well as gradual deviations of the laser beam out of the joint were produced. Results indicate that a combination of the information provided by the vision and spectroscopic systems is beneficial for development of a hybrid sensing system for joint tracing.

A laser-based vision system for weld quality inspection.

PubMed

Huang, Wei; Kovacevic, Radovan

2011-01-01

Welding is a very complex process in which the final weld quality can be affected by many process parameters. In order to inspect the weld quality and detect the presence of various weld defects, different methods and systems are studied and developed. In this paper, a laser-based vision system is developed for non-destructive weld quality inspection. The vision sensor is designed based on the principle of laser triangulation. By processing the images acquired from the vision sensor, the geometrical features of the weld can be obtained. Through the visual analysis of the acquired 3D profiles of the weld, the presences as well as the positions and sizes of the weld defects can be accurately identified and therefore, the non-destructive weld quality inspection can be achieved.

A Laser-Based Vision System for Weld Quality Inspection

PubMed Central

Huang, Wei; Kovacevic, Radovan

2011-01-01

Welding is a very complex process in which the final weld quality can be affected by many process parameters. In order to inspect the weld quality and detect the presence of various weld defects, different methods and systems are studied and developed. In this paper, a laser-based vision system is developed for non-destructive weld quality inspection. The vision sensor is designed based on the principle of laser triangulation. By processing the images acquired from the vision sensor, the geometrical features of the weld can be obtained. Through the visual analysis of the acquired 3D profiles of the weld, the presences as well as the positions and sizes of the weld defects can be accurately identified and therefore, the non-destructive weld quality inspection can be achieved. PMID:22344308

Enabling high speed friction stir welding of aluminum tailor welded blanks

NASA Astrophysics Data System (ADS)

Hovanski, Yuri

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

Friction Stir Spot Welding of Advanced High Strength Steels

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

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

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

Laser-assisted fibrinogen bonding of umbilical vein grafts.

PubMed

Oz, M C; Williams, M R; Souza, J E; Dardik, H; Treat, M R; Bass, L S; Nowygrod, R

1993-06-01

Despite success with autologous tissue welding, laser welding of synthetic vascular prostheses has not been possible. The graft material appears inert and fails to allow the collagen breakdown and electrostatic bonding that results in tissue welding. To develop a laser welding system for graft material, we repaired glutaraldehyde-tanned human umbilical cord vein graft incisions using laser-assisted fibrinogen bonding (LAFB) technology. Modified umbilical vein graft was incised transversely (1.2 cm). Incisions were repaired using sutures, laser energy alone, or LAFB. For LAFB, indocyanine green dye was mixed with human fibrinogen and the compound applied with forceps onto the weld site prior to exposure to 808 nm diode laser energy (power density 4.8 W/cm 2). Bursting pressures for sutured repairs (126.6 +/- 23.4 mm Hg) were similar to LAFB anastomoses (111.6 +/- 55.0 mm Hg). No evidence of collateral thermal injury to the graft material was noted. In vivo evaluation of umbilical graft bonding with canine arteries demonstrates that LAFB can reliably reinforce sutured anastomoses. The described system for bonding graft material with laser exposed fibrinogen may allow creation or reinforcement of vascular anastomoses in procedures where use of autologous tissue is not feasible.

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

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

Hovanski, Yuri; Carsley, John; Carlson, Blair

2014-01-15

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

Ultrasonic test of resistance spot welds based on wavelet package analysis.

PubMed

Liu, Jing; Xu, Guocheng; Gu, Xiaopeng; Zhou, Guanghao

2015-02-01

In this paper, ultrasonic test of spot welds for stainless steel sheets has been studied. It is indicated that traditional ultrasonic signal analysis in either time domain or frequency domain remains inadequate to evaluate the nugget diameter of spot welds. However, the method based on wavelet package analysis in time-frequency domain can easily distinguish the nugget from the corona bond by extracting high-frequency signals in different positions of spot welds, thereby quantitatively evaluating the nugget diameter. The results of ultrasonic test fit the actual measured value well. Mean value of normal distribution of error statistics is 0.00187, and the standard deviation is 0.1392. Furthermore, the quality of spot welds was evaluated, and it is showed ultrasonic nondestructive test based on wavelet packet analysis can be used to evaluate the quality of spot welds, and it is more reliable than single tensile destructive test. Copyright © 2014 Elsevier B.V. All rights reserved.

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

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

Hovanski, Yuri; Upadhyay, Piyush; Carsley, John

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

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

NASA Technical Reports Server (NTRS)

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

1975-01-01

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

On-line welding quality inspection system for steel pipe based on machine vision

NASA Astrophysics Data System (ADS)

Yang, Yang

2017-05-01

In recent years, high frequency welding has been widely used in production because of its advantages of simplicity, reliability and high quality. In the production process, how to effectively control the weld penetration welding, ensure full penetration, weld uniform, so as to ensure the welding quality is to solve the problem of the present stage, it is an important research field in the field of welding technology. In this paper, based on the study of some methods of welding inspection, a set of on-line welding quality inspection system based on machine vision is designed.

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

NASA Astrophysics Data System (ADS)

Pu, Juan; Yu, Shengfu; Li, Yuanyuan

2017-07-01

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

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

PubMed

Ren, Jie; Wang, Yanrang

2015-12-01

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

Evaluating optical hazards from plasma arc cutting.

PubMed

Glassford, Eric; Burr, Gregory

2018-01-01

The Health Hazard Evaluation Program of the National Institute for Occupational Safety and Health evaluated a steel building materials manufacturer. The employer requested the evaluation because of concerns about optical radiation hazards from a plasma arc cutting system and the need to clarify eye protection requirements for plasma operators, other employees, and visitors. The strength of the ultraviolet radiation, visible radiation (light), and infrared radiation generated by the plasma arc cutter was measured at various distances from the source and at different operating amperages. Investigators also observed employees performing the plasma arc cutting. Optical radiation above safe levels for the unprotected eyes in the ultraviolet-C, ultraviolet-B, and visible light ranges were found during plasma arc cutting. In contrast, infrared and ultraviolet-A radiation levels during plasma arc cutting were similar to background levels. The highest non-ionizing radiation exposures occurred when no welding curtains were used. A plasma arc welding curtain in place did not eliminate optical radiation hazards to the plasma arc operator or to nearby employees. In most instances, the measured intensities for visible light, UV-C, and UV-B resulted in welding shade lens numbers that were lower than those stipulated in the OSHA Filter Lenses for Protection Against Radiant Energy table in 29 CFR 1910.133(a)(5). [1] Investigators recommended using a welding curtain that enclosed the plasma arc, posting optical radiation warning signs in the plasma arc cutter area, installing audible or visual warning cues when the plasma arc cutter was operating, and using welding shades that covered the plasma arc cutter operator's face to protect skin from ultraviolet radiation hazards.

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.

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.

Examinations on Laser Remote Welding of Ultra-thin Metal Foils Under Vacuum Conditions

NASA Astrophysics Data System (ADS)

Petrich, Martin; Stambke, Martin; Bergmann, Jean Pierre

Metal foils are commonly used for catalytic converters, vacuum insulations, in medical and electrical industry as well as for sensor applications and packaging. The investigations in this paper determine the influence of reduced atmospheric pressure during the welding process with a highly brilliant 400 W single-mode fiber laser combined with a 2D-scanning system. The laser beam is transmitted through a highly transparent glass into a vacuum chamber, where AISI 304 stainless steel foils with a thickness of 25 μm, 50 μm and 100 μm are positioned. The effects of reduced atmospheric pressure on the plasma formation are investigated by means of high-speed videography. Furthermore, the geometry of the weld seam is compared to atmospheric conditions as well as means of the process stability and the process efficiency. The welds were also evaluated by means of metallography. The research is a contribution for extending the range of micro welding applications and shows new aspects for future developments.

Upgraded HFIR Fuel Element Welding System

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

Sease, John D

2010-02-01

The welding of aluminum-clad fuel plates into aluminum alloy 6061 side plate tubing is a unique design feature of the High Flux Isotope Reactor (HFIR) fuel assemblies as 101 full-penetration circumferential gas metal arc welds (GMAW) are required in the fabrication of each assembly. In a HFIR fuel assembly, 540 aluminum-clad fuel plates are assembled into two nested annular fuel elements 610 mm (24-inches) long. The welding process for the HFIR fuel elements was developed in the early 1960 s and about 450 HFIR fuel assemblies have been successfully welded using the GMAW process qualified in the 1960 s. Inmore » recent years because of the degradation of the electronic and mechanical components in the old HFIR welding system, reportable defects in plate attachment or adapter welds have been present in almost all completed fuel assemblies. In October 2008, a contract was awarded to AMET, Inc., of Rexburg, Idaho, to replace the old welding equipment with standard commercially available welding components to the maximum extent possible while maintaining the qualified HFIR welding process. The upgraded HFIR welding system represents a major improvement in the welding system used in welding HFIR fuel elements for the previous 40 years. In this upgrade, the new inner GMAW torch is a significant advancement over the original inner GMAW torch previously used. The innovative breakthrough in the new inner welding torch design is the way the direction of the cast in the 0.762 mm (0.030-inch) diameter aluminum weld wire is changed so that the weld wire emerging from the contact tip is straight in the plane perpendicular to the welding direction without creating any significant drag resistance in the feeding of the weld wire.« less

Development of automatic pre-tracking system for fillet weld based on laser trigonometry

NASA Astrophysics Data System (ADS)

Shen, Xiaoqin; Yu, Fusheng

2005-01-01

In this paper, an automatic fillet weld pre-tracking system for welding the work piece of lorry back boards with several bend in haul automobile is developed basing on laser trigonometry. The optical measuring head based on laser-PSD trigonometry is used as position sensor. It is placed in front of the traveling direction of welding wire to get the distances from welding wire to the two side boards of the welding lines, upper board and bottom board of the fillet weld respectively. A chip of AT89S52 is used as the micro controller in this system. The AC servomotors, ball-screws and straight guide rails constitute the sliding table to take welding wire move. The laser-PSD sensors pass through the vertical board, upper board and bottom board of the fillet weld when welding wire moves and then get the distance. The laser-PSD sensors output the analog signals. After A/D conversion, the digital signal is input into AT89S52 and calculated. Then the information of the position and lateral deviation of the welding wire when welding a certain position are gotten to control welding wires. So the weld pre-tracking for welding the work piece with long distance and large bend in haul automobile is realized. The position information is input into EEPROM to be saved for short time after handled by AT89S52. The information is as the welding position information as well as the speed adjusting data of the welding wire when it welds the several bend of the work piece. The practice indicates that this system has high pre-tracking precision, good anti-disturb ability, excellent reliability, easy operating ability and good adaptability to the field of production.

Metallurgical causes for the occurrence of creep damage in longitudinally seam-welded Cr-Mo high-energy piping

NASA Astrophysics Data System (ADS)

Zhou, Gang

A continuous occurrence of catastrophic failures, leaks and cracks of the Cr-Mo steam piping has created widespread utility concern for the integrity and serviceability of the seam-welded piping systems in power plants across USA. Cr-Mo steels are the materials widely used for elevated temperature service in fossil-fired generating stations. A large percentage of the power plant units with the Cr-Mo seam-welded steam piping have been in operation for a long duration such that the critical components of the units have been employed beyond the design life (30 or 40 years). This percentage will increase even more significantly in the near future. There is a strong desire to extend and thus there is a need to assess the remaining life of these units. Thus, understanding of the metallurgical causes for the failures and damage in the Cr-Mo seam-welded piping plays a major role in estimating possible life-extension and decision making on whether to operate, repair or replace. In this study, an optical metallographic method and a Cryo-Crack fractographic method have been developed for characterization and quantification of the damage in seam-welded steam piping. More than 500 metallographic assessments, from more than 25 power plants, have been accomplished using the optical metallographic method, and more than 200 fractographic specimens from 10 power plants have been evaluated using the "Cryo-Crack" fractographic technique. For comparison, "virgin" SA welds were fabricated using the Mohave welding procedure with re-N&T Mohave base metal with both "acid" and "basic" fluxes. The damage mechanism, damage distribution pattern, damage classification, correlation of the damage with the microstructural features of these SA welds and the impurity segregation patterns have been determined. A physical model for cavitation (leading to failure) in Cr-Mo SA weld metals and evaluation methodologies for high energy piping are proposed.

Compression Buckling Behavior of Large-Scale Friction Stir Welded and Riveted 2090-T83 Al-Li Alloy Skin-Stiffener Panels

NASA Technical Reports Server (NTRS)

Hoffman, Eric K.; Hafley, Robert A.; Wagner, John A.; Jegley, Dawn C.; Pecquet, Robert W.; Blum, Celia M.; Arbegast, William J.

2002-01-01

To evaluate the potential of friction stir welding (FSW) as a replacement for traditional rivet fastening for launch vehicle dry bay construction, a large-scale friction stir welded 2090-T83 aluminum-lithium (Al-Li) alloy skin-stiffener panel was designed and fabricated by Lockheed-Martin Space Systems Company - Michoud Operations (LMSS) as part of NASA Space Act Agreement (SAA) 446. The friction stir welded panel and a conventional riveted panel were tested to failure in compression at the NASA Langley Research Center (LaRC). The present paper describes the compression test results, stress analysis, and associated failure behavior of these panels. The test results provide useful data to support future optimization of FSW processes and structural design configurations for launch vehicle dry bay structures.

Closed circuit TV system automatically guides welding arc

NASA Technical Reports Server (NTRS)

Stephans, D. L.; Wall, W. A., Jr.

1968-01-01

Closed circuit television /CCTV/ system automatically guides a welding torch to position the welding arc accurately along weld seams. Digital counting and logic techniques incorporated in the control circuitry, ensure performance reliability.

Joining of polypropylene/polypropylene and glass fiber reinforced polypropylene composites

NASA Astrophysics Data System (ADS)

Zhang, Jianguang

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

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

NASA Technical Reports Server (NTRS)

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

1981-01-01

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

In-field Welding and Coating Protocols

DOT National Transportation Integrated Search

2009-05-12

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

Demonstration of a Large-Scale Tank Assembly via Circumferential Friction Stir Welds

NASA Technical Reports Server (NTRS)

Jones, Clyde S.; Adams, Glynn; Colligan, Kevin

2000-01-01

A collaborative effort between NASA/Marshall Space Flight Center and the Michoud Unit of Lockheed Martin Space Systems Company was undertaken to demonstrate assembly of a large-scale aluminum tank using circumferential friction stir welds. The hardware used to complete this demonstration was fabricated as a study of near-net- shape technologies. The tooling used to complete this demonstration was originally designed for assembly of a tank using fusion weld processes. This presentation describes the modifications and additions that were made to the existing fusion welding tools required to accommodate circumferential friction stir welding, as well as the process used to assemble the tank. The tooling modifications include design, fabrication and installation of several components. The most significant components include a friction stir weld unit with adjustable pin length capabilities, a continuous internal anvil for 'open' circumferential welds, a continuous closeout anvil, clamping systems, an external reaction system and the control system required to conduct the friction stir welds and integrate the operation of the tool. The demonstration was intended as a development task. The experience gained during each circumferential weld was applied to improve subsequent welds. Both constant and tapered thickness 14-foot diameter circumferential welds were successfully demonstrated.

Robotic Welding and Inspection System

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

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

2008-06-01

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

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

NASA Technical Reports Server (NTRS)

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

1999-01-01

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

Automatic programming of arc welding robots

NASA Astrophysics Data System (ADS)

Padmanabhan, Srikanth

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

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

NASA Astrophysics Data System (ADS)

Srikanth, A.; Manikandan, M.

2018-02-01

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

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

PubMed

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

2007-05-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Repair welding of gamma titanium aluminide castings

NASA Astrophysics Data System (ADS)

Kelly, T. J.

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

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

DTIC Science & Technology

2001-12-01

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

Passively damped vibration welding system and method

DOEpatents

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

2013-04-02

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

Closed circuit TV system monitors welding operations

NASA Technical Reports Server (NTRS)

Gilman, M.

1967-01-01

TV camera system that has a special vidicon tube with a gradient density filter is used in remote monitoring of TIG welding of stainless steel. The welding operations involve complex assembly welding tools and skates in areas of limited accessibility.

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

NASA Technical Reports Server (NTRS)

Jones, C. S.; Gangl, K. J.

1986-01-01

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

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.

Multi-mode ultrasonic welding control and optimization

DOEpatents

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

2013-05-28

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

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

NASA Astrophysics Data System (ADS)

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

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

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

PubMed

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

2010-12-01

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

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

NASA Astrophysics Data System (ADS)

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

2015-05-01

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

Automatic Control Of Length Of Welding Arc

NASA Technical Reports Server (NTRS)

Iceland, William F.

1991-01-01

Nonlinear relationships among current, voltage, and length stored in electronic memory. Conceptual microprocessor-based control subsystem maintains constant length of welding arc in gas/tungsten arc-welding system, even when welding current varied. Uses feedback of current and voltage from welding arc. Directs motor to set position of torch according to previously measured relationships among current, voltage, and length of arc. Signal paths marked "calibration" or "welding" used during those processes only. Other signal paths used during both processes. Control subsystem added to existing manual or automatic welding system equipped with automatic voltage control.

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

NASA Astrophysics Data System (ADS)

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

2011-01-01

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

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

NASA Technical Reports Server (NTRS)

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

1987-01-01

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

Automated GMA welding of austenitic stainless steel pipe

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

Tahash, G.J.

1996-12-31

The study focused on reducing weld cycle times of rotatable subassemblies (spools) using automated welding equipment. A unique automatic Gas Metal Arc Welding (GMAW) system was used to produce a series of pipe to pipe welds on 141 mm (5 in.) schedule 80 seamless stainless steel pipe. After manual tack welding, the adaptive control system welded the root pass of the argon gas backed open vee groove circumferential butt joints in the IG rotated position with short circuiting transfer GMAW. The fill and cover passes were welded automatically with spray transfer GMAW. Automatic welding cycle times were found to bemore » 50--80 percent shorter than the current techniques of roll welding with Shielded Metal Arc Welding and manual Gas Tungsten Arc Welding. Weld costs ({Brit_pounds}/m), including amortization, for the various systems were compared. The cost of automated GMA welds was virtually equivalent to the most competitive methods while depositing 75% more filler metal per year. Also investigated were metallurgical effects generated by weld thermal cycling, and the associated effects on mechanical properties of the weld joint. Mechanical properties of the welds met or exceeded those of the base metal. Sensitization of the pipe did not occur in the heat affected zone (HAZ), based on the absence of evidence of intergranular attack in modified Strauss corrosion tests and despite the fact of interpass temperatures well above recommended maximums. Cooling rates of 3--5 C/s in the heat affected zone of the four pass welds were measured by thermocouple technique and found to be within the non-sensitizing range for this alloy.« 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

10-kW-class YAG laser application for heavy components

NASA Astrophysics Data System (ADS)

Ishide, Takashi; Tsubota, S.; Nayama, Michisuke; Shimokusu, Yoshiaki; Nagashima, Tadashi; Okimura, K.

2000-02-01

The authors have put the YAG laser of the kW class to practical use for repair welding of nuclear power plant steam generator heat exchanger tubes, all-position welding of pipings, etc. This paper describes following developed methods and systems of high power YAG laser processing. First, we apply the 6 kW to 10 kW YAG lasers for welding and cutting in heavy components. The beam guide systems we have used are optical fibers which core diameter is 0.6 mm to 0.8 mm and its length is 200 m as standard one. Using these system, we can get the 1 pass penetration of 15 mm to 20 mm and multi pass welding for more thick plates. Cutting of 100 mm thickness plate data also described for dismantling of nuclear power plants. In these systems we carried out the in-process monitoring by using CCD camera image processing and monitoring fiber which placed coaxial to the YAG optical lens system. In- process monitoring by the monitoring fiber, we measured the light intensity from welding area. Further, we have developed new hybrid welding with the TIG electrode at the center of lens for high power. The hybrid welding with TIG-YAG system aims lightening of welding groove allowances and welding of high quality. Through these techniques we have applied 7 kW class YAG laser for welding in the components of nuclear power plants.

Evaluation of Hydrogen Cracking in Weld Metal Deposited Using Cellulosic Electrodes

DOT National Transportation Integrated Search

2005-11-01

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

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

NASA Astrophysics Data System (ADS)

Hamlin, Robert J.

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

Sensors control gas metal arc welding

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

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

1997-04-01

The response time of a trained welder from the time a weld problem is identified to the time action is taken is about one second--especially after a long, uneventful period of welding. This is acceptable for manual welding because it is close to the time it takes for the weld pool to solidify. If human response time were any slower, manual welding would not be possible. However, human response time is too slow to respond to some weld events, such as melting of the contact tube in gas metal arc welding (GMAW), and only automated intelligent control systems can reactmore » fast enough to correct or avoid these problems. Control systems incorporate welding knowledge that enables intelligent decisions to be made about weld quality and, ultimately, to keep welding parameters in the range where only high-quality welds are produced. This article discusses the correlation of electrical signals with contact-tube wear, changes in shielding gas, changes in arc length, and other weld process data.« less

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

NASA Astrophysics Data System (ADS)

Dwi Cahyono, Bagus; Ainur, Chandra

2018-04-01

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

Oxidative stress and reduced responsiveness of challenged circulating leukocytes following pulmonary instillation of metal-rich particulate matter in rats

PubMed Central

2014-01-01

Welding fume is an exposure that consists of a mixture of metal-rich particulate matter with gases (ozone, carbon monoxide) and/or vapors (VOCs). Data suggests that welders are immune compromised. Given the inability of pulmonary leukocytes to properly respond to a secondary infection in animal models, the question arose whether the dysfunction persisted systemically. Our aim was to evaluate the circulating leukocyte population in terms of cellular activation, presence of oxidative stress, and functionality after a secondary challenge, following welding fume exposure. Rats were intratracheally instilled (ITI) with PBS or 2 mg of welding fume collected from a stainless steel weld. Rats were sacrificed 4 and 24 h post-exposure and whole blood was collected. Whole blood was used for cellular differential counts, RNA isolation with subsequent microarray and Ingenuity Pathway Analysis, and secondary stimulation with LPS utilizing TruCulture technology. In addition, mononuclear cells were isolated 24 h post-exposure to measure oxidative stress by flow cytometry and confocal microscopy. Welding fume exposure had rapid effects on the circulating leukocyte population as identified by relative mRNA expression changes. Instillation of welding fume reduced inflammatory protein production of circulating leukocytes when challenged with the secondary stimulus LPS. The effects were not related to transcription, but were observed in conjunction with oxidative stress. These findings support previous studies of an inadequate pulmonary immune response following a metal-rich exposure and extend those findings showing leukocyte dysfunction occurs systemically. PMID:25123171

Oxidative stress and reduced responsiveness of challenged circulating leukocytes following pulmonary instillation of metal-rich particulate matter in rats.

PubMed

Erdely, Aaron; Antonini, James M; Young, Shih-Houng; Kashon, Michael L; Gu, Ja K; Hulderman, Tracy; Salmen, Rebecca; Meighan, Terence; Roberts, Jenny R; Zeidler-Erdely, Patti C

2014-08-15

Welding fume is an exposure that consists of a mixture of metal-rich particulate matter with gases (ozone, carbon monoxide) and/or vapors (VOCs). Data suggests that welders are immune compromised. Given the inability of pulmonary leukocytes to properly respond to a secondary infection in animal models, the question arose whether the dysfunction persisted systemically. Our aim was to evaluate the circulating leukocyte population in terms of cellular activation, presence of oxidative stress, and functionality after a secondary challenge, following welding fume exposure. Rats were intratracheally instilled (ITI) with PBS or 2 mg of welding fume collected from a stainless steel weld. Rats were sacrificed 4 and 24 h post-exposure and whole blood was collected. Whole blood was used for cellular differential counts, RNA isolation with subsequent microarray and Ingenuity Pathway Analysis, and secondary stimulation with LPS utilizing TruCulture technology. In addition, mononuclear cells were isolated 24 h post-exposure to measure oxidative stress by flow cytometry and confocal microscopy. Welding fume exposure had rapid effects on the circulating leukocyte population as identified by relative mRNA expression changes. Instillation of welding fume reduced inflammatory protein production of circulating leukocytes when challenged with the secondary stimulus LPS. The effects were not related to transcription, but were observed in conjunction with oxidative stress. These findings support previous studies of an inadequate pulmonary immune response following a metal-rich exposure and extend those findings showing leukocyte dysfunction occurs systemically.

Automatic Welding System

NASA Astrophysics Data System (ADS)

1982-01-01

Robotic welding has been of interest to industrial firms because it offers higher productivity at lower cost than manual welding. There are some systems with automated arc guidance available, but they have disadvantages, such as limitations on types of materials or types of seams that can be welded; susceptibility to stray electrical signals; restricted field of view; or tendency to contaminate the weld seam. Wanting to overcome these disadvantages, Marshall Space Flight Center, aided by Hayes International Corporation, developed system that uses closed-circuit TV signals for automatic guidance of the welding torch. NASA granted license to Combined Technologies, Inc. for commercial application of the technology. They developed a refined and improved arc guidance system. CTI in turn, licensed the Merrick Corporation, also of Nashville, for marketing and manufacturing of the new system, called the CT2 Optical Trucker. CT2 is a non-contracting system that offers adaptability to broader range of welding jobs and provides greater reliability in high speed operation. It is extremely accurate and can travel at high speed of up to 150 inches per minute.

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

DOT National Transportation Integrated Search

2009-06-16

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

Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

NASA Astrophysics Data System (ADS)

Perez Regalado, Waldo Josue

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

Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

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

Hovanski, Yuri; Upadyay, Piyush; Kleinbaum, Sarah

2017-04-05

One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Although the friction stir scribemore » process is capable of joining dissimilar metals and metal/polymer systems, a more detailed evaluation of several aluminum/steel joints is presented herein to demonstrate the ability to both chemically and mechanically join dissimilar materials.« less

Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

DOE PAGES

Hovanski, Yuri; Upadyay, Piyush; Kleinbaum, Sarah; ...

2017-04-05

One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of impartially joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Finally, although the frictionmore » stir scribe process is capable of joining dissimilar metals and metal/polymer systems, a more detailed evaluation of several aluminum/steel joints is presented herein to demonstrate the ability to both chemically and mechanically join dissimilar materials.« less

Adjustable Bracket For Entry Of Welding Wire

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.; Gutow, David A.

1993-01-01

Wire-entry bracket on welding torch in robotic welding system provides for adjustment of angle of entry of welding wire over range of plus or minus 30 degrees from nominal entry angle. Wire positioned so it does not hide weld joint in view of through-the-torch computer-vision system part of robot-controlling and -monitoring system. Swiveling bracket also used on nonvision torch on which wire-feed-through tube interferes with workpiece. Angle simply changed to one giving sufficient clearance.

Thermal Imaging for Assessment of Electron-Beam Free Form Fabrication (EBF(sup 3)) Additive Manufacturing Welds

NASA Technical Reports Server (NTRS)

Zalameda, Joseph N.; Burke, Eric R.; Hafley, Robert A.; Taminger, Karen M.; Domack, Christopher S.; Brewer, Amy R.; Martin, Richard E.

2013-01-01

Additive manufacturing is a rapidly growing field where 3-dimensional parts can be produced layer by layer. NASA s electron beam free-form fabrication (EBF(sup 3)) technology is being evaluated to manufacture metallic parts in a space environment. The benefits of EBF(sup 3) technology are weight savings to support space missions, rapid prototyping in a zero gravity environment, and improved vehicle readiness. The EBF(sup 3) system is composed of 3 main components: electron beam gun, multi-axis position system, and metallic wire feeder. The electron beam is used to melt the wire and the multi-axis positioning system is used to build the part layer by layer. To insure a quality weld, a near infrared (NIR) camera is used to image the melt pool and solidification areas. This paper describes the calibration and application of a NIR camera for temperature measurement. In addition, image processing techniques are presented for weld assessment metrics.

Development Of Advanced Welding Control System

NASA Technical Reports Server (NTRS)

1990-01-01

Report describes development of next-generation control system for variable-polarity plasma arc (VPPA) welding. When fully developed, system expected to incorporate advanced sensors and adaptive control of position of and current in welding torch.

Advanced fusion welding processes, solid state joining and a successful marriage. [production of aerospace structures

NASA Technical Reports Server (NTRS)

Miller, F. R.

1972-01-01

Joining processes for aerospace systems combine fusion welding and solid state joining during production of metal structures. Detailed characteristics of electron beam welding, plasma arc welding, diffusion welding, inertia welding and weldbond processes are discussed.

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

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

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

PubMed Central

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

2016-01-01

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

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

PubMed

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

2016-08-09

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

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

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.

Erythrocyte antioxidant enzyme activities and lipid peroxidation in the erythrocyte membrane of stainless-steel welders exposed to welding fumes and gases.

PubMed

Imamoglu, Nalan; Yerer, Mükerrem-Betül; Donmez-Altuntas, Hamiyet; Saraymen, Recep

2008-03-01

The erythrocyte antioxidant system (superoxide dismutase, SOD; catalase, CAT) and lipid peroxidation (malondialdehyde, MDA) in the erythrocyte membrane were studied in workers continously exposed to welding fumes and gases, which are thought to be oxidant pollutants. Thirty-five welders using the manual metal arc method on stainless steel and 30 controls were studied. Plasma chromium (Cr), manganese (Mn), and cupper (Cu) levels were determined by atomic absorption spectrophotometer (AAS). The erythrocyte antioxidant system activity and lipid peroxidation in the erythrocyte membrane were evaluated. Not only the possible effects of welding fumes but also the effects of smoking were considered. The plasma concentrations of Cr, Mn, and Cu for the exposed welders were significantly higher compared to the control subjects (p<0.001, p<0.01, p<0.001, respectively,). The erythrocyte CAT (p<0.05) and SOD (p<0.05) enzyme activities were significantly higher in the welders but there were not any significant changes in the MDA levels which reflect the lipid peroxidation in the erythrocyte membrane (p>0.05). Smoking has increased the SOD activity in both controls (p<0.05) and welders (p<0.01) and increased the CAT activity in control subjects (p<0.05). Moreover, regardless of smoking, there were some significant correlations between the duration of the exposure to welding fumes and antioxidant defence system (SOD: p<0.05; CAT: p<0.05). The synergistic effects of smoking and other risk factors (welding fumes and gases), which had been shown previously by some clinical data should also be taken into account. As a consequence, the welders should be warned and informed of the synergistic effects of smoking on the adverse effect of welding fumes and gases.

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

ERIC Educational Resources Information Center

Abrams, Macy L.; And Others

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

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

PubMed

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

2011-02-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-05-01

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

Programmable Automated Welding System (PAWS)

NASA Technical Reports Server (NTRS)

Kline, Martin D.

1994-01-01

An ambitious project to develop an advanced, automated welding system is being funded as part of the Navy Joining Center with Babcock & Wilcox as the prime integrator. This program, the Programmable Automated Welding System (PAWS), involves the integration of both planning and real-time control activities. Planning functions include the development of a graphical decision support system within a standard, portable environment. Real-time control functions include the development of a modular, intelligent, real-time control system and the integration of a number of welding process sensors. This paper presents each of these components of the PAWS and discusses how they can be utilized to automate the welding operation.

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

Optically controlled welding system

NASA Technical Reports Server (NTRS)

Gordon, Stephen S. (Inventor)

1988-01-01

An optically controlled welding system wherein a welding torch having through-the-torch viewing capabilities is provided with an optical beam splitter to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder to make the welding torch responsive thereto. Other features include an actively cooled electrode holder which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm, and a weld pool contour detector comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom, being characteristic of a penetrated or unpenetrated condition of the weld pool.

Welding at the Kennedy Space Center.

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1973-01-01

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

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

NASA Astrophysics Data System (ADS)

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

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

Welding induced residual stress evaluation using laser-generated Rayleigh waves

NASA Astrophysics Data System (ADS)

Ye, Chong; Zhou, Yuanlai; Reddy, Vishnu V. B.; Mebane, Aaron; Ume, I. Charles

2018-04-01

Welding induced residual stress could affect the dimensional stability, fatigue life, and chemical resistance of the weld joints. Ultrasonic method serves as an important non-destructive tool for the residual stress evaluation due to its easy implementation, low cost and wide application to different materials. Residual stress would result in the ultrasonic wave velocity variation, which is the so called acoustoelastic effect. In this paper, Laser/EMAT ultrasonic technique was proposed to experimentally study the relative velocity variation ΔV/V of Rayleigh wave, which has the potential to evaluate surface/subsurface longitudinal residual stress developed during the Gas Metal Arc Welding process. Broad band ultrasonic waves were excited by pulsed Q-Switched Nd: YAG laser. An electromagnetic acoustic transducer (EMAT) attached to the welded plates was used to capture the Rayleigh wave signals propagating along the weld seam direction. Different time of flight measurements were conducted by varying the distance between the weld seam and Rayleigh wave propagating path in the range of 0 to 45 mm. The maximum relative velocity difference was found on the weld seam. With the increasing distance away from the weld seam, the relative velocity difference sharply decreased to negative value. With further increase in distance, the relative velocity difference slowly increased and approached zero. The distribution of relative velocity variations indicates that tensile stress appears in the melted zone as it becomes compressive near the heat-affected zone.

Programmable Positioner For Spot Welding

NASA Technical Reports Server (NTRS)

Roden, William A.

1989-01-01

Welding station mechanized by installing preset indexing system and gear drive. Mechanism includes a low-cost, versatile, single-axis motion control and motor drive to provide fully-automatic weld sequencing and spot-to-spot spacing. Welding station relieves operator of some difficult, tedious tasks and increases both productivity and quality of welds. Results in welds of higher quality and greater accuracy, fewer weld defects, and faster welding operation.

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.

Temperature controlled CO(2) laser welding of soft tissues: urinary bladder welding in different animal models (rats, rabbits, and cats).

PubMed

Lobel, B; Eyal, O; Kariv, N; Katzir, A

2000-01-01

Laser welding of tissues is a method of closure of surgical incisions that, in principle, may have advantages over conventional closure methods. It is a noncontact technique that introduces no foreign body, the closure is continuous and watertight, and the procedure is faster and requires less skill to master. However, in practice, there have been difficulties in obtaining strong and reliable welding. We assumed that the quality of the weld depends on the ability to monitor and control the surface temperature of the welded zone during the procedure. Our objective was to develop a "smart" fiberoptic laser system for controlled temperature welding. We have developed a welding system based on a CO(2) laser and on infrared transmitting AgClBr fibers. This fiberoptic system plays a double role: transmitting laser power for tissue heating and noncontact (radiometric) temperature monitoring and control. The "true" temperature of the heated tissue was determined by using an improved calibration method. We carried out long-studies of CO(2) laser welding of urinary bladders in various animal models. Cystotomies were performed on the animals, and complete closure of the bladder was obtained with a surface temperature of 55 +/- 5 degrees C at the welding site. In early experiments on 31 rats, the success rate was 73%. In later experiments with 10 rabbits and 3 cats, there was an 80% and a 100% success rate, respectively. The success rate in these preliminary experiments and the quality of the weld, as determined histologically, demonstrate that temperature controlled CO(2) laser welding can produce effective welding of tissues. The fiberoptic system can be adapted for endoscopic laser welding. Copyright 2000 Wiley-Liss, Inc.

Prevalence and association of welding related systemic and respiratory symptoms in welders

PubMed Central

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

2003-01-01

Background: The prevalence of welding related respiratory symptoms coexisting with welding related systemic symptoms in welders is unknown. Aims: To determine in a sample of welders the prevalence of coexisting welding related systemic symptoms indicative of metal fume fever (MFF) and welding related respiratory symptoms suggestive of occupational asthma (OA), and the strength and significance of any association between these two groups of symptoms. Methods: A respiratory symptoms questionnaire, a systemic symptoms questionnaire, and a questionnaire on occupational history were administered by telephone to 351 of a sample of 441 welders (79.6%) from two cities in Québec, Canada. Results: The co-occurrence of possible MFF (defined as having at least two symptoms of fever, feelings of flu, general malaise, chills, dry cough, metallic taste, and shortness of breath, occurring at the beginning of the working week, 3–10 hours after exposure to welding fumes) together with welding related respiratory symptoms suggestive of OA (defined as having at least two welding related symptoms of cough, wheezing, and chest tightness) was 5.8%. These two groups of symptoms were significantly associated (χ2 = 18.9, p < 0.001). Conclusion: There is a strong association between welding related MFF and welding related respiratory symptoms suggestive of OA. As such, MFF could be viewed as a pre-marker of welding related OA, a hypothesis that requires further investigation. PMID:12937186

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

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

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

1992-01-01

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

Position detectors, methods of detecting position, and methods of providing positional detectors

DOEpatents

Weinberg, David M.; Harding, L. Dean; Larsen, Eric D.

2002-01-01

Position detectors, welding system position detectors, methods of detecting various positions, and methods of providing position detectors are described. In one embodiment, a welding system positional detector includes a base that is configured to engage and be moved along a curved surface of a welding work piece. At least one position detection apparatus is provided and is connected with the base and configured to measure angular position of the detector relative to a reference vector. In another embodiment, a welding system positional detector includes a weld head and at least one inclinometer mounted on the weld head. The one inclinometer is configured to develop positional data relative to a reference vector and the position of the weld head on a non-planar weldable work piece.

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.

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.

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

PubMed

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

2018-02-07

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

Development of a wear-resistant flux cored wire of Fe-C-Si-Mn-Cr-Ni-Mo-V system for deposit welding of mining equipment parts

NASA Astrophysics Data System (ADS)

Osetkovsky, I. V.; Kozyrev, N. A.; Kryukov, R. E.; Usoltsev, A. A.; Gusev, A. I.

2017-09-01

The effect of introduction of cobalt in the charge of the flux cored wire of Fe-C-Si-Mn-Cr-Ni-Mo-V system operating under abrasive and abrasive-shock loads is studied. In the laboratory conditions samples of flux cored wires were made, deposition was performed, the effect of cobalt on the hardness and the degree of wear was evaluated, metallographic studies were carried out. The influence of cobalt introduced into the charge of the flux cored wire of Fe-C-Si-Mn-Cr-Ni-Mo-V system on the structure, nature of nonmetallic inclusions, hardness and wear resistance of the weld metal was studied. In the laboratory conditions samples flux cored wire were made using appropriate powdered materials. As a carbon-fluorine-containing material dust from gas cleaning units of aluminum production was used. In the course of the study the chemical composition of the weld metal was determined, metallographic analysis was performed, mechanical properties were determined. As a result of the metallographic analysis the size of the former austenite grain, martensite dispersion in the structure of the weld metal, the level of contamination with its nonmetallic inclusions were established.

FSW of Aluminum Tailor Welded Blanks across Machine Platforms

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

Hovanski, Yuri; Upadhyay, Piyush; Carlson, Blair

2015-02-16

Development and characterization of friction stir welded aluminum tailor welded blanks was successfully carried out on three separate machine platforms. Each was a commercially available, gantry style, multi-axis machine designed specifically for friction stir welding. Weld parameters were developed to support high volume production of dissimilar thickness aluminum tailor welded blanks at speeds of 3 m/min and greater. Parameters originally developed on an ultra-high stiffness servo driven machine where first transferred to a high stiffness servo-hydraulic friction stir welding machine, and subsequently transferred to a purpose built machine designed to accommodate thin sheet aluminum welding. The inherent beam stiffness, bearingmore » compliance, and control system for each machine were distinctly unique, which posed specific challenges in transferring welding parameters across machine platforms. This work documents the challenges imposed by successfully transferring weld parameters from machine to machine, produced from different manufacturers and with unique control systems and interfaces.« less

In-Service Performance and Costs of Methods to Control Urban Rail System Noise

DOT National Transportation Integrated Search

1979-12-01

This study evaluates the acoustic and economic effectiveness of five methods of controlling wheel/rail noise and vibration on urban rail transit systems, namely: rail grinding, wheel truing, resilient wheels, ring-damped wheels, and welded vs. jointe...

Grain refinement control in TIG arc welding

NASA Technical Reports Server (NTRS)

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

1975-01-01

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

Optically controlled welding system

NASA Technical Reports Server (NTRS)

Gordon, Stephen S. (Inventor)

1989-01-01

An optically controlled welding system (10) wherein a welding torch (12) having through-the-torch viewing capabilities is provided with an optical beam splitter (56) to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder (15) to make the welding torch responsive thereto. Other features includes an actively cooled electrode holder (26) which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm (28) and a weld pool contour detector (14) comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom being characteristic of a penetrated or unpenetrated condition of the weld pool.

Theory research of seam recognition and welding torch pose control based on machine vision

NASA Astrophysics Data System (ADS)

Long, Qiang; Zhai, Peng; Liu, Miao; He, Kai; Wang, Chunyang

2017-03-01

At present, the automation requirement of the welding become higher, so a method of the welding information extraction by vision sensor is proposed in this paper, and the simulation with the MATLAB has been conducted. Besides, in order to improve the quality of robot automatic welding, an information retrieval method for welding torch pose control by visual sensor is attempted. Considering the demands of welding technology and engineering habits, the relative coordinate systems and variables are strictly defined, and established the mathematical model of the welding pose, and verified its feasibility by using the MATLAB simulation in the paper, these works lay a foundation for the development of welding off-line programming system with high precision and quality.

Lowest cost due to highest productivity and highest quality

NASA Astrophysics Data System (ADS)

Wenk, Daniel

2003-03-01

Since global purchasing in the automotive industry has been taken up all around the world there is one main key factor that makes a TB-supplier today successful: Producing highest quality at lowest cost. The fact that Tailored Blanks, which today may reach up to 1/3 of a car body weight, are purchased on the free market but from different steel suppliers, especially in Europe and NAFTA, the philosophy on OEM side has been changing gradually towards tough evaluation criteria. "No risk at the stamping side" calls for top quality Tailored- or Tubular Blank products. Outsourcing Tailored Blanks has been starting in Japan but up to now without any quality request from the OEM side like ISO 13919-1B (welding quality standard in Europe and USA). Increased competition will automatically push the quality level and the ongoing approach to combine high strength steel with Tailored- and Tubular Blanks will ask for even more reliable system concepts which enables to weld narrow seams at highest speed. Beside producing quality, which is the key to reduce one of the most important cost driver "material scrap," in-line quality systems with true and reliable evaluation is going to be a "must" on all weld systems. Traceability of all process related data submitted to interfaces according to customer request in combination with ghost-shift-operation of TB systems are tomorrow's state-of-the-art solutions of Tailored Blank-facilities.

Contact Thermocouple Methodology and Evaluation for Temperature Measurement in the Laboratory

NASA Technical Reports Server (NTRS)

Brewer, Ethan J.; Pawlik, Ralph J.; Krause, David L.

2013-01-01

Laboratory testing of advanced aerospace components very often requires highly accurate temperature measurement and control devices, as well as methods to precisely analyze and predict the performance of such components. Analysis of test articles depends on accurate measurements of temperature across the specimen. Where possible, this task is accomplished using many thermocouples welded directly to the test specimen, which can produce results with great precision. However, it is known that thermocouple spot welds can initiate deleterious cracks in some materials, prohibiting the use of welded thermocouples. Such is the case for the nickel-based superalloy MarM-247, which is used in the high temperature, high pressure heater heads for the Advanced Stirling Converter component of the Advanced Stirling Radioisotope Generator space power system. To overcome this limitation, a method was developed that uses small diameter contact thermocouples to measure the temperature of heater head test articles with the same level of accuracy as welded thermocouples. This paper includes a brief introduction and a background describing the circumstances that compelled the development of the contact thermocouple measurement method. Next, the paper describes studies performed on contact thermocouple readings to determine the accuracy of results. It continues on to describe in detail the developed measurement method and the evaluation of results produced. A further study that evaluates the performance of different measurement output devices is also described. Finally, a brief conclusion and summary of results is provided.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

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

NASA Astrophysics Data System (ADS)

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

2010-11-01

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

Ultrasonic sensing of GMAW: Laser/EMAT defect detection system

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

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

1992-08-01

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

Inspection apparatus for evaluating a partially completed weld

DOEpatents

Smartt, Herschel B.; Larsen, Eric D.; Johnson, Jonn A.

2001-01-01

An inspection apparatus for evaluating a partially completed weld is described and which is utilized in combination with an automated movable welder which moves across a supporting surface, and wherein the inspection apparatus includes a coupling member mounted on the welder; a frame member mounted on the coupling member; an ultrasonic sensor mounted on the frame member and disposed in ultrasonic sound transmitting relation relative to the partially completed weld; and a drive assembly for adjusting the position of the ultrasonic sensor relative to the partially completed weld.

Welded tie plate feasibility study for ITER central solenoid structure

NASA Astrophysics Data System (ADS)

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

2014-01-01

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

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

PubMed

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

2011-12-01

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

U. S. National Transportation Safety Board (NTSB) reports, recommendations, and responses availability. [Evaluation of fillet-welded reinforcement sleeves

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

Not Available

1980-10-09

Following the ignition of crude oil that leaked from a fractured 22 in. oil pipeline at a levee crossing at Berwick, Louisiana, on 1/2/80, NTSB has recommended that Texaco Pipeline Co., the line owner, review the practice of using fillet-welded reinforcement sleeves for tie-in welds to determine if these sleeves have caused any pipeline failures in its system; notify the pipeline patrol of the location of such existing sleeves and instruct it to examine the areas around these sleeves for signs of leakage; and evaluate existing procdures for leak detection to make these procedures more effective. The American Petroleum Institutemore » has also been urged to notify its member companies of the Berwick accident and the aforementioned recommendations. These pipeline and other safety recommendation letters and reports of accidents, including the determination of the cause of the explosion, burning, and sinking of the Liberian tanker Seatige.« less

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

PubMed Central

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

2017-01-01

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

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

PubMed

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

2017-09-08

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

Competencies in Welding Needed for Agricultural Machinery Maintenance.

ERIC Educational Resources Information Center

Hansen, Herbert Eugene

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

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

Picosecond laser welding of similar and dissimilar materials.

PubMed

Carter, Richard M; Chen, Jianyong; Shephard, Jonathan D; Thomson, Robert R; Hand, Duncan P

2014-07-01

We report picosecond laser welding of similar and dissimilar materials based on plasma formation induced by a tightly focused beam from a 1030 nm, 10 ps, 400 kHz laser system. Specifically, we demonstrate the welding of fused silica, borosilicate, and sapphire to a range of materials including borosilicate, fused silica, silicon, copper, aluminum, and stainless steel. Dissimilar material welding of glass to aluminum and stainless steel has not been previously reported. Analysis of the borosilicate-to-borosilicate weld strength compares well to those obtained using similar welding systems based on femtosecond lasers. There is, however, a strong requirement to prepare surfaces to a high (10-60 nm Ra) flatness to ensure a successful weld.

Process control of laser conduction welding by thermal imaging measurement with a color camera.

PubMed

Bardin, Fabrice; Morgan, Stephen; Williams, Stewart; McBride, Roy; Moore, Andrew J; Jones, Julian D C; Hand, Duncan P

2005-11-10

Conduction welding offers an alternative to keyhole welding. Compared with keyhole welding, it is an intrinsically stable process because vaporization phenomena are minimal. However, as with keyhole welding, an on-line process-monitoring system is advantageous for quality assurance to maintain the required penetration depth, which in conduction welding is more sensitive to changes in heat sinking. The maximum penetration is obtained when the surface temperature is just below the boiling point, and so we normally wish to maintain the temperature at this level. We describe a two-color optical system that we have developed for real-time temperature profile measurement of the conduction weld pool. The key feature of the system is the use of a complementary metal-oxide semiconductor standard color camera leading to a simplified low-cost optical setup. We present and discuss the real-time temperature measurement and control performance of the system when a defocused beam from a high power Nd:YAG laser is used on 5 mm thick stainless steel workpieces.

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

NASA Astrophysics Data System (ADS)

Spies, M.; Rieder, H.; Dillhöfer, A.

2011-06-01

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

Development of a Fiber Laser Welding Capability for the W76, MC4702 Firing Set

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

Samayoa, Jose

2010-05-12

Development work to implement a new welding system for a Firing Set is presented. The new system is significant because it represents the first use of fiber laser welding technology at the KCP. The work used Six-Sigma tools for weld characterization and to define process performance. Determinations of workable weld parameters and comparison to existing equipment were completed. Replication of existing waveforms was done utilizing an Arbitrary Pulse Generator (APG), which was used to modulate the fiber laser’s exclusive continuous wave (CW) output. Fiber laser weld process capability for a Firing Set is demonstrated.

Automatic control system of high precision welding of workpieces in mechanical engineering

NASA Astrophysics Data System (ADS)

Kuznetsov, I. N.; Zvezdin, V. V.; Israfilov, I. H.; Portnov, S. M.

2014-12-01

In this paper, based on the conducted patent research, the system of laser welding control with different geometry of weld and shapes of parts is developed. The method of monitoring the position of the spot of laser radiation in relation to the curved weld is worked out; it is based on the tracking the edges of the welded parts by low-power laser radiation reflected from the surface of the parts. It allows to make the positioning of the focus of laser radiation in relation to the juncture of the welded parts automatically.

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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

DOT National Transportation Integrated Search

2009-03-01

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

Performance Improvement of Friction Stir Welds by Better Surface Finish

NASA Technical Reports Server (NTRS)

Russell, Sam; Nettles, Mindy

2015-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2007-05-01

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

WASTE PACKAGE REMEDIATION SYSTEM DESCRIPTION DOCUMENT

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

N.D. Sudan

2000-06-22

The Waste Package Remediation System remediates waste packages (WPs) and disposal containers (DCs) in one of two ways: preparation of rejected DC closure welds for repair or opening of the DC/WP. DCs are brought to the Waste Package Remediation System for preparation of rejected closure welds if testing of the closure weld by the Disposal Container Handling System indicates an unacceptable, but repairable, welding flaw. DC preparation of rejected closure welds will require removal of the weld in such a way that the Disposal Container Handling System may resume and complete the closure welding process. DCs/WPs are brought to themore » Waste Package Remediation System for opening if the Disposal Container Handling System testing of the DC closure weld indicates an unrepairable welding flaw, or if a WP is recovered from the subsurface repository because suspected damage to the WP or failure of the WP has occurred. DC/WP opening will require cutting of the DC/WP such that a temporary seal may be installed and the waste inside the DC/WP removed by another system. The system operates in a Waste Package Remediation System hot cell located in the Waste Handling Building that has direct access to the Disposal Container Handling System. One DC/WP at a time can be handled in the hot cell. The DC/WP arrives on a transfer cart, is positioned within the cell for system operations, and exits the cell without being removed from the cart. The system includes a wide variety of remotely operated components including a manipulator with hoist and/or jib crane, viewing systems, machine tools for opening WPs, and equipment used to perform pressure and gas composition sampling. Remotely operated equipment is designed to facilitate DC/WP decontamination and hot cell equipment maintenance, and interchangeable components are provided where appropriate. The Waste Package Remediation System interfaces with the Disposal Container Handling System for the receipt and transport of WPs and DCs. The Waste Handling Building System houses the system, and provides the facility, safety, and auxiliary systems required to support operations. The system receives power from the Waste Handling Building Electrical System. The system also interfaces with the various DC systems.« less

A novel pulsed gas metal arc welding system with direct droplet transfer close-loop control

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

Wang, Q.; Li, P.; Zhang, L.

1994-12-31

In pulsed gas metal arc welding (GMAW), a predominant parameter that has to be monitored and controlled in real time for maintaining process stability and ensuring weld quality, is droplet transfer. Based on the close correlation between droplet transfer and arc light radiant flux in GMAW of steel and aluminum, a direct closed-loop droplet transfer control system for pulsed GMAW with arc light sensor has been developed. By sensing the droplet transfer directly via the arc light signal, a pulsed GMAW process with real and exact one-pulse, one-droplet transfer has been achieved. The novel pulsed GMAW machine consists of threemore » parts: a sensing system, a controlling system, and a welding power system. The software used in this control system is capable of data sampling and processing, parameter matching, optimum parameter restoring, and resetting. A novel arc light sensing system has been developed. The sensor is small enough to be clamped to a semiautomatic welding torch. Based on thissensingn system, a closed-loop droplet transfer control system of GMAW of steel and aluminum has been built and a commercial prototype has been made. The system is capable of keeping one-pulse, one-droplet transfer against external interferences. The welding process with this control system has been proved to be stable, quiet, with no spatter, and provide good weld formation.« less

A comparison of the physics of Gas Tungsten Arc Welding (GTAW), Electron Beam Welding (EBW), and Laser Beam Welding (LBW)

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.

1985-01-01

The physics governing the applicability and limitations of gas tungsten arc (GTA), electron beam (EB), and laser beam (LB) welding are compared. An appendix on the selection of laser welding systems is included.

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

DTIC Science & Technology

1984-01-01

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

Design, construction, and characterization of a novel robotic welding fume generator and inhalation exposure system for laboratory animals.

PubMed

Antonini, James M; Afshari, Aliakbar A; Stone, Sam; Chen, Bean; Schwegler-Berry, Diane; Fletcher, W Gary; Goldsmith, W Travis; Vandestouwe, Kurt H; McKinney, Walter; Castranova, Vincent; Frazer, David G

2006-04-01

Respiratory effects observed in welders have included lung function changes, metal fume fever, bronchitis, and a possible increase in the incidence of lung cancer. Many questions remain unanswered regarding the causality and possible underlying mechanisms associated with the potential toxic effects of welding fume inhalation. The objective of the present study was to construct a completely automated, computer-controlled welding fume generation and inhalation exposure system to simulate real workplace exposures. The system comprised a programmable six-axis robotic welding arm, a water-cooled arc welding torch, and a wire feeder that supplied the wire to the torch at a programmed rate. For the initial studies, gas metal arc welding was performed using a stainless steel electrode. A flexible trunk was attached to the robotic arm of the welder and was used to collect and transport fume from the vicinity of the arc to the animal exposure chamber. Undiluted fume concentrations consistently ranged from 90-150 mg/m(3) in the animal chamber during welding. Temperature and humidity remained constant in the chamber during the welding operation. The welding particles were composed of (from highest to lowest concentration) iron, chromium, manganese, and nickel as measured by inductively coupled plasma atomic emission spectroscopy. Size distribution analysis indicated the mass median aerodynamic diameter of the generated particles to be approximately 0.24 microm with a geometric standard deviation (sigma(g)) of 1.39. As determined by transmission and scanning electron microscopy, the generated aerosols were mostly arranged as chain-like agglomerates of primary particles. Characterization of the laboratory-generated welding aerosol has indicated that particle morphology, size, and chemical composition are comparable to stainless steel welding fume generated in other studies. With the development of this novel system, it will be possible to establish an animal model using controlled welding exposures from automated gas metal arc and flux-cored arc welding processes to investigate how welding fumes affect health.

Weld pool oscillation during pulsed GTA welding

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

Aendenroomer, A.J.R.; Ouden, G. den

1996-12-31

This paper deals with weld pool oscillation during pulsed GTA welding and with the possibility to use this oscillation for in-process control of weld penetration. Welding experiments were carried out under different welding conditions. During welding the weld pool was triggered into oscillation by the normal welding pulses or by extra current pulses. The oscillation frequency was measured both during the pulse time and during the base time by analyzing the arc voltage variation using a Fast Fourier Transformation program. Optimal results are obtained when full penetration occurs during the pulse time and partial penetration during the base time. Undermore » these conditions elliptical overlapping spot welds are formed. In the case of full penetration the weld pool oscillates in a low frequency mode (membrane oscillation), whereas in the case of partial penetration the weld pool oscillates in a high frequency mode (surface oscillation). Deviation from the optimal welding conditions occurs when high frequency oscillation is observed during both pulse time and base time (underpenetration) or when low frequency oscillation is observed during both pulse time and base time (overpenetration). In line with these results a penetration sensing system with feedback control was designed, based on the criterion that optimal weld penetration is achieved when two peaks are observed in the frequency distribution. The feasibility of this sensing system for orbital tube welding was confirmed by the results of experiments carried out under various welding conditions.« less

Laser-GMA Hybrid Pipe Welding System

DTIC Science & Technology

2007-11-01

Experimental Results.................................................................................................34 Autogenous Laser Welds...APPENDIX B. Training Manual – Overview of System Components and Software...................... APPENDIX C. NASSCO...17. Autogenous laser welds in different joint configurations (10 mm thick mild steel, 5 mm land

Alternative wavelengths for sutureless laser microvascular anastomosis: a preliminary study on acute samples.

PubMed

Bass, L S; Oz, M C; Libutti, S K; Treat, M R

1992-06-01

Attempts to improve the speed and patency of microvascular anastomosis with laser-assisted techniques have provided a modest reduction in operative time and comparable success rates. Using sutureless microvascular anastomoses, 30 end-to-end anastomoses were created in the rat carotid artery using the gallium-aluminum-arsenide diode laser (808 nm). Indocyanine green and fibrinogen were applied to enhance tissue absorption of the laser energy and strengthen the bond created. These were compared with previously reported welds using the THC:YAG laser (2150 nm). Mean welding times were 140 and 288 s, and mean bursting pressures immediately after welding were 515 and 400 mmHg for the diode and THC:YAG laser groups, respectively. Histologically, both lateral and vertical spread of thermal damage was limited. Since both lasers create welds of adequate initial strength without stay sutures and are faster and easier to use than existing systems, evaluation of long-term patency would be worthwhile.

Residual Stresses and Critical Initial Flaw Size Analyses of Welds

NASA Technical Reports Server (NTRS)

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

2009-01-01

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

Numerical and Experimental Evaluation on the Residual Stresses of Welded Joints

NASA Astrophysics Data System (ADS)

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

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

Evaluation of AISI 4140 Steel Repair Without Post-Weld Heat Treatment

NASA Astrophysics Data System (ADS)

Silva, Cleiton C.; de Albuquerque, Victor H. C.; Moura, Cícero R. O.; Aguiar, Willys M.; Farias, Jesualdo P.

2009-04-01

The present work evaluates the two-layer technique on the heat affected zone (HAZ) of AISI 4140 steel welded with different heat input levels between the first and second layer. The weld heat input levels selected by the Higuchi test were 5/5, 5/10, and 15/5 kJ/cm. The evaluation of the refining and/or tempering of the coarsened grain HAZ of the first layer was carried out using metallographic tests, microhardness measurements, and the Charpy-V impact test. The tempering of the first layer was only reached when the weld heat input ratio was 5/5 kJ/cm. The results of the Charpy-V impact test showed that the two-layer technique was efficient, from the point of view of toughness, since the toughness values reached were greater than the base metal for all weld heat input ratios applied. The results obtained indicate that the best performance of the two-layer deposition technique was for the weld heat input ratio 5/5 kJ/cm employing low heat input.

Methodology for Estimating Thermal and Neutron Embrittlement of Austenitic Stainless Steel Welds During Service in Light Water Reactors

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

Chopra, O. K.; Rao, A. S.

The effect of thermal aging on the degradation of fracture toughness and Charpy-impact properties of austenitic stainless steel (SS) welds has been characterized at reactor temperatures. The solidification behavior and the distribution and morphology of the ferrite phase in SS welds are described. Thermal aging of the welds results in moderate decreases in Charpy-impact strength and fracture toughness. The upper-shelf Charpy-impact energy of aged welds decreases by 50–80 J/cm2. The decrease in fracture toughness J-R curve, or JIc is relatively small. Thermal aging has minimal effect on the tensile strength. The fracture properties of SS welds are insensitive to fillermore » metal; the welding process has a significant effect. The large variability in the data makes it difficult to establish the effect of the welding process on fracture properties of SS welds. Consequently, the approach used for evaluating thermal and neutron embrittlement of austenitic SS welds relies on establishing a lower-bound fracture toughness J-R curve for unaged and aged, and non-irradiated and irradiated, SS welds. The existing fracture toughness J-R curve data for SS welds have been reviewed and evaluated to define lower-bound J-R curve for submerged arc (SA)/shielded metal arc (SMA)/manual metal arc (MMA) welds and gas tungsten arc (GTA)/tungsten inert gas (TIG) welds in the unaged and aged conditions. At reactor temperatures, the fracture toughness of GTA/TIG welds is a factor of about 2.3 higher than that of SA/SMA/MMA welds. Thermal aging decreases the fracture toughness by about 20%. The potential combined effects of thermal and neutron embrittlement of austenitic SS welds are also described. Lower-bound curves are presented that define the change in coefficient C and exponent n of the power-law J-R curve and the JIc value for SS welds as a function of neutron dose. The potential effects of reactor coolant environment on the fracture toughness of austenitic SS welds are also discussed.« less

Evaluation of a method to shield a welding electron beam from magnetic interference

NASA Technical Reports Server (NTRS)

Wall, W. A.

1976-01-01

It is known that electron beams are easily deflected by magnetic and electrostatic fields. Therefore, to prevent weld defects, stray electromagnetic fields are avoided in electron beam welding chambers if at all possible. The successful results of tests conducted at MSFC to evaluate a simple magnetic shield made from steel tubing are reported. Tests indicate that this shield was up to 85 percent effective in reducing magnetic effects on the electron beam of a welding machine. In addition, residual magnetic fields within the shield were so nearly uniform that the net effect on the beam alignment was negligible. It is concluded that the shield, with the addition of a tungsten liner, could be used in production welding.

Laser vision seam tracking system based on image processing and continuous convolution operator tracker

NASA Astrophysics Data System (ADS)

Zou, Yanbiao; Chen, Tao

2018-06-01

To address the problem of low welding precision caused by the poor real-time tracking performance of common welding robots, a novel seam tracking system with excellent real-time tracking performance and high accuracy is designed based on the morphological image processing method and continuous convolution operator tracker (CCOT) object tracking algorithm. The system consists of a six-axis welding robot, a line laser sensor, and an industrial computer. This work also studies the measurement principle involved in the designed system. Through the CCOT algorithm, the weld feature points are determined in real time from the noise image during the welding process, and the 3D coordinate values of these points are obtained according to the measurement principle to control the movement of the robot and the torch in real time. Experimental results show that the sensor has a frequency of 50 Hz. The welding torch runs smoothly with a strong arc light and splash interference. Tracking error can reach ±0.2 mm, and the minimal distance between the laser stripe and the welding molten pool can reach 15 mm, which can significantly fulfill actual welding requirements.

Evaluation of Laser Braze-welded Dissimilar Al-Cu Joints

NASA Astrophysics Data System (ADS)

Schmalen, Pascal; Plapper, Peter

The thermal joining of Aluminum and Copper is a promising technology towards automotive battery manufacturing. The dissimilar metals Al-Cu are difficult to weld due to their different physicochemical characteristics and the formation of intermetallic compounds (IMC), which have reduced mechanical and electric properties. There is a critical thickness of the IMCs where the favored mechanical properties of the base material can be preserved. The laser braze welding principle uses a position and power oscillated laser-beam to reduce the energy input and the intermixture of both materials and therefore achieves minimized IMCs thickness. The evaluation of the weld seam is important to improve the joint performance and enhance the welding process. This paper is focused on the characterization and quantification of the IMCs. Mechanical, electrical and metallurgical methods are presented and performed on Al1050 and SF-Cu joints and precise weld criteria are developed.

Versatile Friction Stir Welding/Friction Plug Welding System

NASA Technical Reports Server (NTRS)

Carter, Robert

2006-01-01

A proposed system of tooling, machinery, and control equipment would be capable of performing any of several friction stir welding (FSW) and friction plug welding (FPW) operations. These operations would include the following: Basic FSW; FSW with automated manipulation of the length of the pin tool in real time [the so-called auto-adjustable pin-tool (APT) capability]; Self-reacting FSW (SRFSW); SR-FSW with APT capability and/or real-time adjustment of the distance between the front and back shoulders; and Friction plug welding (FPW) [more specifically, friction push plug welding] or friction pull plug welding (FPPW) to close out the keyhole of, or to repair, an FSW or SR-FSW weld. Prior FSW and FPW systems have been capable of performing one or two of these operations, but none has thus far been capable of performing all of them. The proposed system would include a common tool that would have APT capability for both basic FSW and SR-FSW. Such a tool was described in Tool for Two Types of Friction Stir Welding (MFS- 31647-1), NASA Tech Briefs, Vol. 30, No. 10 (October 2006), page 70. Going beyond what was reported in the cited previous article, the common tool could be used in conjunction with a plug welding head to perform FPW or FPPW. Alternatively, the plug welding head could be integrated, along with the common tool, into a FSW head that would be capable of all of the aforementioned FSW and FPW operations. Any FSW or FPW operation could be performed under any combination of position and/or force control.

Container weld identification using portable laser scanners

NASA Astrophysics Data System (ADS)

Taddei, Pierluigi; Boström, Gunnar; Puig, David; Kravtchenko, Victor; Sequeira, Vítor

2015-03-01

Identification and integrity verification of sealed containers for security applications can be obtained by employing noninvasive portable optical systems. We present a portable laser range imaging system capable of identifying welds, a byproduct of a container's physical sealing, with micrometer accuracy. It is based on the assumption that each weld has a unique three-dimensional (3-D) structure which cannot be copied or forged. We process the 3-D surface to generate a normalized depth map which is invariant to mechanical alignment errors and that is used to build compact signatures representing the weld. A weld is identified by performing cross correlations of its signature against a set of known signatures. The system has been tested on realistic datasets, containing hundreds of welds, yielding no false positives or false negatives and thus showing the robustness of the system and the validity of the chosen signature.

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.

Virtual environment assessment for laser-based vision surface profiling

NASA Astrophysics Data System (ADS)

ElSoussi, Adnane; Al Alami, Abed ElRahman; Abu-Nabah, Bassam A.

2015-03-01

Oil and gas businesses have been raising the demand from original equipment manufacturers (OEMs) to implement a reliable metrology method in assessing surface profiles of welds before and after grinding. This certainly mandates the deviation from the commonly used surface measurement gauges, which are not only operator dependent, but also limited to discrete measurements along the weld. Due to its potential accuracy and speed, the use of laser-based vision surface profiling systems have been progressively rising as part of manufacturing quality control. This effort presents a virtual environment that lends itself for developing and evaluating existing laser vision sensor (LVS) calibration and measurement techniques. A combination of two known calibration techniques is implemented to deliver a calibrated LVS system. System calibration is implemented virtually and experimentally to scan simulated and 3D printed features of known profiles, respectively. Scanned data is inverted and compared with the input profiles to validate the virtual environment capability for LVS surface profiling and preliminary assess the measurement technique for weld profiling applications. Moreover, this effort brings 3D scanning capability a step closer towards robust quality control applications in a manufacturing environment.

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.

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.

Lay-Up and Consolidation of a Composite Pipe by In Situ Ultrasonic Welding of a Thermoplastic Matrix Composite Tape.

PubMed

Dell'Anna, Riccardo; Lionetto, Francesca; Montagna, Francesco; Maffezzoli, Alfonso

2018-05-11

In this work, the potential of preformed thermoplastic matrix composite tapes for the manufacturing of composite pipes by filament winding assisted by in situ ultrasonic welding was evaluated. Unidirectional tapes of E-glass-reinforcedamorphous poly (ethylene terephthalate) were laid up and consolidated in a filament winding machine that was modified with a set-up enabling ultrasonic welding. The obtained composite specimens were characterized by means of morphological and dynamic mechanical analysis as well as void content evaluation, in order to correlate welding parameters to composite properties.

Lay-Up and Consolidation of a Composite Pipe by In Situ Ultrasonic Welding of a Thermoplastic Matrix Composite Tape

PubMed Central

Dell’Anna, Riccardo; Montagna, Francesco

2018-01-01

In this work, the potential of preformed thermoplastic matrix composite tapes for the manufacturing of composite pipes by filament winding assisted by in situ ultrasonic welding was evaluated. Unidirectional tapes of E-glass-reinforcedamorphous poly (ethylene terephthalate) were laid up and consolidated in a filament winding machine that was modified with a set-up enabling ultrasonic welding. The obtained composite specimens were characterized by means of morphological and dynamic mechanical analysis as well as void content evaluation, in order to correlate welding parameters to composite properties. PMID:29751693

Optimization of operator and physical parameters for laser welding of dental materials.

PubMed

Bertrand, C; le Petitcorps, Y; Albingre, L; Dupuis, V

2004-04-10

Interactions between lasers and materials are very complex phenomena. The success of laser welding procedures in dental metals depends on the operator's control of many parameters. The aims of this study were to evaluate factors relating to the operator's dexterity and the choice of the welding parameters (power, pulse duration and therefore energy), which are recognized determinants of weld quality. In vitro laboratory study. FeNiCr dental drawn wires were chosen for these experiments because their properties are well known. Different diameters of wires were laser welded, then tested in tension and compared to the control material as extruded, in order to evaluate the quality of the welding. Scanning electron microscopy of the fractured zone and micrograph observations perpendicular and parallel to the wire axis were also conducted in order to analyse the depth penetration and the quality of the microstructure. Additionally, the micro-hardness (Vickers type) was measured both in the welded and the heat-affected zones and then compared to the non-welded alloy. Adequate combination of energy and pulse duration with the power set in the range between 0.8 to 1 kW appears to improve penetration depth of the laser beam and success of the welding procedure. Operator skill is also an important variable. The variation in laser weld quality in dental FeNiCr wires attributable to operator skill can be minimized by optimization of the physical welding parameters.

Corrective Action Investigation Plan for Corrective Action Unit 563: Septic Systems, Nevada Test Site, Nevada, with Errata Sheet, Revision 0 (in English; Afrikaans)

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

Alfred Wickline

Corrective Action Unit 563, Septic Systems, is located in Areas 3 and 12 of the Nevada Test Site, which is 65 miles northwest of Las Vegas, Nevada. Corrective Action Unit 563 is comprised of the four corrective action sites (CASs) below: • 03-04-02, Area 3 Subdock Septic Tank • 03-59-05, Area 3 Subdock Cesspool • 12-59-01, Drilling/Welding Shop Septic Tanks • 12-60-01, Drilling/Welding Shop Outfalls These sites are being investigated because existing information on the nature and extent of potential contamination is insufficient to evaluate and recommend corrective action alternatives. Additional information will be obtained by conducting a corrective actionmore » investigation (CAI) before evaluating corrective action alternatives and selecting the appropriate corrective action for each CAS. The results of the field investigation will support a defensible evaluation of viable corrective action alternatives that will be presented in the Corrective Action Decision Document.« less

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

DTIC Science & Technology

1980-08-01

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

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

NASA Technical Reports Server (NTRS)

Russell, Carolyn; Ding, R. Jeffrey

1998-01-01

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

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

PubMed

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

2004-04-01

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

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

NASA Astrophysics Data System (ADS)

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

2000-10-01

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

IR-based spot weld NDT in automotive applications

NASA Astrophysics Data System (ADS)

Chen, Jian; Feng, Zhili

2015-05-01

Today's auto industry primarily relies on destructive teardown evaluation to ensure the quality of the resistance spot welds (RSWs) due to their criticality in crash resistance and performance of vehicles. The destructive teardown evaluation is labor intensive and costly. The very nature of the destructive test means only a few selected welds will be sampled for quality. Most of the welds in a car are never checked. There are significant costs and risks associated with reworking and scrapping the defective welded parts made between the teardown tests. IR thermography as a non-destructive testing (NDT) tool has its distinct advantage — its non-intrusive and non-contact nature. This makes the IR based NDT especially attractive for the highly automated assembly lines. IR for weld quality inspection has been explored in the past, mostly limited to the offline post-processing manner in a laboratory environment. No online real-time RSW inspection using IR thermography has been reported. Typically for postprocessing inspection, a short-pulse heating via xenon flash lamp light (in a few milliseconds) is applied to the surface of a spot weld. However, applications in the auto industry have been unsuccessful, largely due to a critical drawback that cannot be implemented in the high-volume production line - the prerequisite of painting the weld surface to eliminate surface reflection and other environmental interference. This is due to the low signal-to-noise ratio resulting from the low/unknown surface emissivity and the very small temperature changes (typically on the order of 0.1°C) induced by the flash lamp method. An integrated approach consisting of innovations in both data analysis algorithms and hardware apparatus that effectively solved the key technical barriers for IR NDT. The system can be used for both real-time (during welding) and post-processing inspections (after welds have been made). First, we developed a special IR thermal image processing method that utilizes the relative IR intensity change, so that the influence of surface reflection and environment interference can be reduced. Second, for the post-processing inspection, a special induction heater is used to replace the flash lamp, resulting in temperature changes on the order of 10°C. As a result, the signal-to-noise ratio increased by several orders of magnitudes with no surface painting needed, and the inspection results are more accurate and reliable. For real-time inspection, the heat from welding (with temperature exceeding 1000°C) was utilized. Third, "thermal signatures" were identified to uniquely correlate to different weld quality attributes through computational modeling of heat transfer and extensive testing of specially designed ranges of welding conditions. Novel IR image analysis algorithms that automatically and intelligently identify the "thermal signatures" from the IR images and positively determine the weld quality in less than a second were developed.

3D Ultrasonic Non-destructive Evaluation of Spot Welds Using an Enhanced Total Focusing Method

NASA Astrophysics Data System (ADS)

Jasiuniene, Elena; Samaitis, Vykintas; Mazeika, Liudas; Sanderson, Ruth

2015-02-01

Spot welds are used to join sheets of metals in the automotive industry. When spot weld quality is evaluated using conventional ultrasonic manual pulse-echo method, the reliability of the inspection is affected by selection of the probe diameter and the positioning of the probe in the weld center. The application of a 2D matrix array is a potential solution to the aforementioned problems. The objective of this work was to develop a signal processing algorithm to reconstruct the 3D spot weld volume showing the size of the nugget and the defects in it. In order to achieve this, the conventional total focusing method was enhanced by taking into account the directivities of the single elements of the array and the divergence of the ultrasonic beam due to the propagation distance. Enhancements enabled a reduction in the background noise and uniform sensitivity at different depths to be obtained. The proposed algorithm was verified using a finite element model of ultrasonic wave propagation simulating three common spot weld conditions: a good weld, an undersized weld, and a weld containing a pore. The investigations have demonstrated that proposed method enables the determination of the size of the nugget and detection of discontinuities.

Weldability of high toughness Fe-12% Ni alloys containing Ti, Al or Nb

NASA Technical Reports Server (NTRS)

Devletian, J. H.; Stephens, J. R.; Witzke, W. R.

1977-01-01

Three exceptionally high-toughness Fe-12%Ni alloys designed for cryogenic service were welded using the GTA welding process. Evaluation of weldability included equivalent energy (KIed) fracture toughness tests, transverse-weld tensile tests at -196 and 25 C and weld crack sensitivity tests. The Fe-12%Ni-0.25%Ti alloy proved extremely weldable for cryogenic applications, having weld and HAZ properties comparable with those of the wrought base alloy. The Fe-12%Ni-0.5%Al had good weld properties only after the weld joint was heat treated. The Fe-12%Ni-0.25%Nb alloy was not considered weldable for cryogenic use because of its poor weld joint properties at -196 C and its susceptibility to hot cracking.

Reduction of Biomechanical and Welding Fume Exposures in Stud Welding.

PubMed

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

2016-04-01

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

Reduction of Biomechanical and Welding Fume Exposures in Stud Welding

PubMed Central

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

2016-01-01

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

Statistical Analysis of Stress Signals from Bridge Monitoring by FBG System

PubMed Central

Ye, Xiao-Wei; Xi, Pei-Sen

2018-01-01

In this paper, a fiber Bragg grating (FBG)-based stress monitoring system instrumented on an orthotropic steel deck arch bridge is demonstrated. The FBG sensors are installed at two types of critical fatigue-prone welded joints to measure the strain and temperature signals. A total of 64 FBG sensors are deployed around the rib-to-deck and rib-to-diagram areas at the mid-span and quarter-span of the investigated orthotropic steel bridge. The local stress behaviors caused by the highway loading and temperature effect during the construction and operation periods are presented with the aid of a wavelet multi-resolution analysis approach. In addition, the multi-modal characteristic of the rainflow counted stress spectrum is modeled by the method of finite mixture distribution together with a genetic algorithm (GA)-based parameter estimation approach. The optimal probability distribution of the stress spectrum is determined by use of Bayesian information criterion (BIC). Furthermore, the hot spot stress of the welded joint is calculated by an extrapolation method recommended in the specification of International Institute of Welding (IIW). The stochastic characteristic of stress concentration factor (SCF) of the concerned welded joint is addressed. The proposed FBG-based stress monitoring system and probabilistic stress evaluation methods can provide an effective tool for structural monitoring and condition assessment of orthotropic steel bridges. PMID:29414850

Physicochemical Characterization of Simulated Welding Fume from a Spark Discharge System

PubMed Central

Park, Jae Hong; Mudunkotuwa, Imali A.; Kim, Jong Sung; Stanam, Aditya; Thorne, Peter S.; Grassian, Vicki H.; Peters, Thomas M.

2014-01-01

This study introduces spark discharge system (SDS) as a way to simulate welding fumes. The SDS was developed using welding rods as electrodes with an optional coagulation chamber. The size, morphology, composition, and concentration of the fume produced and the concentration of ozone (O3) and nitrogen oxides (NOX) were characterized. The number median diameter (NMD) and total number concentration (TNC) of fresh fume particles were ranged 10–23 nm and 3.1×107–6×107 particles/cm3, respectively. For fresh fume particles, the total mass concentration (TMC) measured gravimetrically ranged 85–760 μg/m3. The size distribution was stable over a period of 12 h. The NMD and TNC of aged fume particles were ranged 81–154 nm and 1.5×106–2.7×106 particles/cm3, respectively. The composition of the aged fume particles was dominated by Fe and O with an estimated stoichiometry between that of Fe2O3 and Fe3O4. Concentrations of O3 and NOX were ranged 0.07–2.2 ppm and 1–20 ppm, respectively. These results indicate that the SDS is capable of producing stable fumes over a long-period that are similar to actual welding fumes. This system may be useful in toxicological studies and evaluation of instrumentation. PMID:25097299

Pulsed ultrasonic stir welding system

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2013-01-01

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

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

NASA Technical Reports Server (NTRS)

Malone, Tina W.; Graham, Benny F.; Gentz, Steven J. (Technical Monitor)

2001-01-01

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

Bladder welding in rats using controlled temperature CO2 laser system.

PubMed

Lobik, L; Ravid, A; Nissenkorn, I; Kariv, N; Bernheim, J; Katzir, A

1999-05-01

Laser tissue welding has potential advantages over conventional suture closure of surgical wounds. It is a noncontact technique that introduces no foreign body and limits the possibility of infections and complications. The closure could be immediately watertight and the procedure may be less traumatic, faster and easier. In spite of these positives laser welding has not yet been approved for wide use. The problem in the clinical implementation of this technique arises from the difficulty in defining the conditions under which a highly reliable weld is formed. We have assumed that the successful welding of tissues depends on the ability to monitor and control the surface temperature during the procedure, thereby avoiding underheating or overheating. The purpose of this work was to develop a laser system for reliable welding of urinary tract tissues under good temperature control. We have developed a "smart" laser system that is capable of a dual role: transmitting CO2 laser power for tissue heating, and noncontact (radiometric) temperature monitoring and control. Bladder opening (cystotomy) was performed in 38 rats. Thirty-three animals underwent laser welding. In 5 rats (control group) the bladder wound was closed with one layer of continuous 6-0 dexon sutures. Reliable welding was obtained when the surface temperature was kept at 71 + 5C. Quality of weld was controlled immediately after operation. The rats were sacrificed on days 2, 10 and 30 for histological study. Bladder closure using the laser welding system was successful in 31/33 (94%) animals. Histological examination revealed an excellent welding and healing of the tissue. Efficiency of laser welding of urinary bladder in rats was confirmed by high survival rate and quality of scar that was demonstrated by clinical and histological examinations. In the future, optimal laser welding conditions will be studied in larger animals, using CO2 lasers and other lasers, with deeper radiation penetration into tissues.

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

PubMed

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

2017-09-15

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

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

PubMed Central

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

2017-01-01

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

Thermal Recovery of Plastic Deformation in Dissimilar Metal Weld

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

Qiao, Dongxiao; Yu, Xinghua; Zhang, Wei

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

A comparison of two types of neural network for weld quality prediction in small scale resistance spot welding

NASA Astrophysics Data System (ADS)

Wan, Xiaodong; Wang, Yuanxun; Zhao, Dawei; Huang, YongAn

2017-09-01

Our study aims at developing an effective quality monitoring system in small scale resistance spot welding of titanium alloy. The measured electrical signals were interpreted in combination with the nugget development. Features were extracted from the dynamic resistance and electrode voltage curve. A higher welding current generally indicated a lower overall dynamic resistance level. A larger electrode voltage peak and higher change rate of electrode voltage could be detected under a smaller electrode force or higher welding current condition. Variation of the extracted features and weld quality was found more sensitive to the change of welding current than electrode force. Different neural network model were proposed for weld quality prediction. The back propagation neural network was more proper in failure load estimation. The probabilistic neural network model was more appropriate to be applied in quality level classification. A real-time and on-line weld quality monitoring system may be developed by taking advantages of both methods.

Robotic and automatic welding development at the Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Jones, C. S.; Jackson, M. E.; Flanigan, L. A.

1988-01-01

Welding automation is the key to two major development programs to improve quality and reduce the cost of manufacturing space hardware currently undertaken by the Materials and Processes Laboratory of the NASA Marshall Space Flight Center. Variable polarity plasma arc welding has demonstrated its effectiveness on class 1 aluminum welding in external tank production. More than three miles of welds were completed without an internal defect. Much of this success can be credited to automation developments which stabilize the process. Robotic manipulation technology is under development for automation of welds on the Space Shuttle's main engines utilizing pathfinder systems in development of tooling and sensors for the production applications. The overall approach to welding automation development undertaken is outlined. Advanced sensors and control systems methodologies are described that combine to make aerospace quality welds with a minimum of dependence on operator skill.

Sensor Control of Robot Arc Welding

NASA Technical Reports Server (NTRS)

Sias, F. R., Jr.

1983-01-01

The potential for using computer vision as sensory feedback for robot gas-tungsten arc welding is investigated. The basic parameters that must be controlled while directing the movement of an arc welding torch are defined. The actions of a human welder are examined to aid in determining the sensory information that would permit a robot to make reproducible high strength welds. Special constraints imposed by both robot hardware and software are considered. Several sensory modalities that would potentially improve weld quality are examined. Special emphasis is directed to the use of computer vision for controlling gas-tungsten arc welding. Vendors of available automated seam tracking arc welding systems and of computer vision systems are surveyed. An assessment is made of the state of the art and the problems that must be solved in order to apply computer vision to robot controlled arc welding on the Space Shuttle Main Engine.

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

NASA Technical Reports Server (NTRS)

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

2017-01-01

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

Welding torch trajectory generation for hull joining using autonomous welding mobile robot

NASA Astrophysics Data System (ADS)

Hascoet, J. Y.; Hamilton, K.; Carabin, G.; Rauch, M.; Alonso, M.; Ares, E.

2012-04-01

Shipbuilding processes involve highly dangerous manual welding operations. Welding of ship hulls presents a hazardous environment for workers. This paper describes a new robotic system, developed by the SHIPWELD consortium, that moves autonomously on the hull and automatically executes the required welding processes. Specific focus is placed on the trajectory control of such a system and forms the basis for the discussion in this paper. It includes a description of the robotic hardware design as well as some methodology used to establish the torch trajectory control.

Weld monitor and failure detector for nuclear reactor system

DOEpatents

Sutton, Jr., Harry G.

1987-01-01

Critical but inaccessible welds in a nuclear reactor system are monitored throughout the life of the reactor by providing small aperture means projecting completely through the reactor vessel wall and also through the weld or welds to be monitored. The aperture means is normally sealed from the atmosphere within the reactor. Any incipient failure or cracking of the weld will cause the environment contained within the reactor to pass into the aperture means and thence to the outer surface of the reactor vessel where its presence is readily detected.

Evaluation of iron aluminide weld overlays for erosion - corrosion resistant boiler tube coatings in low NO{sub x} boilers

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

DuPont, J.N.; Banovic, S.W.; Marder, A.R.

1996-08-01

Low NOx burners are being installed in many fossil fired power plants in order to comply with new Clean Air Regulations. Due to the operating characteristics of these burners, boiler tube sulfidation corrosion is often enhanced and premature tube failures can occur. Failures due to oxidation and solid particle erosion are also a concern. A program was initiated in early 1996 to evaluate the use of iron aluminide weld overlays for erosion/corrosion protection of boiler tubes in Low NOx boilers. Composite iron/aluminum wires will be used with the Gas Metal Arc Welding (GMAW) process to prepare overlays on boiler tubesmore » steels with aluminum contents from 8 to 16wt%. The weldability of the composite wires will be evaluated as a function of chemical composition and welding parameters. The effect of overlay composition on corrosion (oxidation and sulfidation) and solid particle erosion will also be evaluated. The laboratory studies will be complemented by field exposures of both iron aluminide weld overlays and co-extruded tubing under actual boiler conditions.« less

Oxy-Fuel Cutting/Welding. Welding Module 3. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching a four-unit module in oxy-fuel cutting and welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: oxyacetylene welding, oxyacetylene…

Basic Welding Skills. Welding Module 1. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching a six-unit module in basic welding skills. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: the welding profession, personal safety,…

Classification of weld defect based on information fusion technology for radiographic testing system

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

Jiang, Hongquan; Liang, Zeming, E-mail: heavenlzm@126.com; Gao, Jianmin

Improving the efficiency and accuracy of weld defect classification is an important technical problem in developing the radiographic testing system. This paper proposes a novel weld defect classification method based on information fusion technology, Dempster–Shafer evidence theory. First, to characterize weld defects and improve the accuracy of their classification, 11 weld defect features were defined based on the sub-pixel level edges of radiographic images, four of which are presented for the first time in this paper. Second, we applied information fusion technology to combine different features for weld defect classification, including a mass function defined based on the weld defectmore » feature information and the quartile-method-based calculation of standard weld defect class which is to solve a sample problem involving a limited number of training samples. A steam turbine weld defect classification case study is also presented herein to illustrate our technique. The results show that the proposed method can increase the correct classification rate with limited training samples and address the uncertainties associated with weld defect classification.« less

Classification of weld defect based on information fusion technology for radiographic testing system.

PubMed

Jiang, Hongquan; Liang, Zeming; Gao, Jianmin; Dang, Changying

2016-03-01

Improving the efficiency and accuracy of weld defect classification is an important technical problem in developing the radiographic testing system. This paper proposes a novel weld defect classification method based on information fusion technology, Dempster-Shafer evidence theory. First, to characterize weld defects and improve the accuracy of their classification, 11 weld defect features were defined based on the sub-pixel level edges of radiographic images, four of which are presented for the first time in this paper. Second, we applied information fusion technology to combine different features for weld defect classification, including a mass function defined based on the weld defect feature information and the quartile-method-based calculation of standard weld defect class which is to solve a sample problem involving a limited number of training samples. A steam turbine weld defect classification case study is also presented herein to illustrate our technique. The results show that the proposed method can increase the correct classification rate with limited training samples and address the uncertainties associated with weld defect classification.

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.

Friction Stir Welding of Tapered Thickness Welds Using an Adjustable Pin Tool

NASA Technical Reports Server (NTRS)

Adams, Glynn; Venable, Richard; Lawless, Kirby

2003-01-01

Friction stir welding (FSW) can be used for joining weld lands that vary in thickness along the length of the weld. An adjustable pin tool mechanism can be used to accomplish this in a single-pass, full-penetration weld by providing for precise changes in the pin length relative to the shoulder face during the weld process. The difficulty with this approach is in accurately adjusting the pin length to provide a consistent penetration ligament throughout the weld. The weld technique, control system, and instrumentation must account for mechanical and thermal compliances of the tooling system to conduct tapered welds successfully. In this study, a combination of static and in-situ measurements, as well as active control, is used to locate the pin accurately and maintain the desired penetration ligament. Frictional forces at the pin/shoulder interface were a source of error that affected accurate pin position. A traditional FSW pin tool design that requires a lead angle was used to join butt weld configurations that included both constant thickness and tapered sections. The pitch axis of the tooling was fixed throughout the weld; therefore, the effective lead angle in the tapered sections was restricted to within the tolerances allowed by the pin tool design. The sensitivity of the FSW process to factors such as thickness offset, joint gap, centerline offset, and taper transition offset were also studied. The joint gap and the thickness offset demonstrated the most adverse affects on the weld quality. Two separate tooling configurations were used to conduct tapered thickness welds successfully. The weld configurations included sections in which the thickness decreased along the weld, as well as sections in which the thickness increased along the weld. The data presented here include weld metallography, strength data, and process load data.

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

NASA Astrophysics Data System (ADS)

Malikov, A. G.

2017-12-01

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

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.

Building Technology Forecast and Evaluation (BTFE). Volume 2. Evaluation of Two Structural Systems

DTIC Science & Technology

1990-11-01

insulative foam ( expanded polystyrene ) strips between each truss. The assembly is held together with 14-gauge wires welded to the trusses on 2-in. centers...structural load bearing qualities expanded polystyrene . No taping and mudding. Ar. ~J~ .wplrtpd( at each irllnfrnPllo Tile I hin- set or float over

Effect of Weld Tool Geometry on Friction Stir Welded AA2219-T87 Properties

NASA Technical Reports Server (NTRS)

Querin, Joseph A.; Schneider, Judy A.

2008-01-01

In this study, flat panels of AA2219-T87 were friction stir welded (FSWed) using weld tools with tapered pins The three pin geometries of the weld tools included: 0 (straight cylinder), 30 , and 60 angles on the frustum. For each weld tool geometry, the FSW process parameters were optimized to eliminate defects. A constant heat input was maintained while varying the process parameters of spindle rpm and travel speed. This provided a constant heat input for each FSW weld panel while altering the hot working conditions imparted to the workpiece. The resulting mechanical properties were evaluated from tensile test results of the FSW joint.

Automatic weld torch guidance control system

NASA Technical Reports Server (NTRS)

Smaith, H. E.; Wall, W. A.; Burns, M. R., Jr.

1982-01-01

A highly reliable, fully digital, closed circuit television optical, type automatic weld seam tracking control system was developed. This automatic tracking equipment is used to reduce weld tooling costs and increase overall automatic welding reliability. The system utilizes a charge injection device digital camera which as 60,512 inidividual pixels as the light sensing elements. Through conventional scanning means, each pixel in the focal plane is sequentially scanned, the light level signal digitized, and an 8-bit word transmitted to scratch pad memory. From memory, the microprocessor performs an analysis of the digital signal and computes the tracking error. Lastly, the corrective signal is transmitted to a cross seam actuator digital drive motor controller to complete the closed loop, feedback, tracking system. This weld seam tracking control system is capable of a tracking accuracy of + or - 0.2 mm, or better. As configured, the system is applicable to square butt, V-groove, and lap joint weldments.

Restoration of Worn Movable Bridge Props with Use of Bronze Claddings.

PubMed

Viňáš, Ján; Vrabeľ, Marek; Greš, Miroslav; Brezina, Jakub; Sabadka, Dušan; Fedorko, Gabriel; Molnár, Vieroslav

2018-03-21

This article examined the possibility of using CuSn6P claddings in sliding bearing renovation of movable pontoon bridge props. The bronze layer was welded on cylinders of the high-strength steel S355J0WP EN 10155-93, in an inert atmosphere using an automated welding method (gas tungsten arc welding). Pulsed arc welding was used to minimize the effects of heat on the cladding area, while also accounting for the differences in the physical properties of the joined metals. The sliding bearing was created in two layers. The quality of the cladding layer was evaluated by nondestructive and/or destructive tests. The quality of the surface was assessed by visual inspection (visual testing) in accordance with the EN ISO 17637 standard. The quality of the claddings was evaluated by metallographic analysis, performed using light microscopy. The microhardness values of a few weld areas were determined by Vickers tests, performed according to the EN ISO 9015-2 standard. The analyses confirmed that the welding parameters and filler material used resulted in high-quality weld joints with no internal (subsurface) or metallurgical defects.

Restoration of Worn Movable Bridge Props with Use of Bronze Claddings

PubMed Central

Viňáš, Ján; Vrabeľ, Marek; Greš, Miroslav; Brezina, Jakub; Sabadka, Dušan; Fedorko, Gabriel

2018-01-01

This article examined the possibility of using CuSn6P claddings in sliding bearing renovation of movable pontoon bridge props. The bronze layer was welded on cylinders of the high-strength steel S355J0WP EN 10155-93, in an inert atmosphere using an automated welding method (gas tungsten arc welding). Pulsed arc welding was used to minimize the effects of heat on the cladding area, while also accounting for the differences in the physical properties of the joined metals. The sliding bearing was created in two layers. The quality of the cladding layer was evaluated by nondestructive and/or destructive tests. The quality of the surface was assessed by visual inspection (visual testing) in accordance with the EN ISO 17637 standard. The quality of the claddings was evaluated by metallographic analysis, performed using light microscopy. The microhardness values of a few weld areas were determined by Vickers tests, performed according to the EN ISO 9015–2 standard. The analyses confirmed that the welding parameters and filler material used resulted in high-quality weld joints with no internal (subsurface) or metallurgical defects. PMID:29561762

Mechanical properties of weldments in experimental Fe-12Mn-0.2Ti and Fe-12Mn-1Mo-0.2Ti alloys for cryogenic service

NASA Technical Reports Server (NTRS)

Stephens, J. R.; Witzke, W. R.; Devletian, J. H.

1981-01-01

Mechanical properties of weldments in two Fe-12Mn experimental alloys designed for cryogenic service were evaluated. Weldments were made using the GTA welding process. Tests to evaluate the weldments were conducted at -196 C and included: equivalent energy fracture toughness tests; autogenous transverse weld, notched transverse weld, and longitudinal weld tensile tests; and all-weld-metal tensile tests. The Fe-12Mn-0.2Ti and Fe-12Mn-1Mo-0.2Ti alloys proved weldable for cryogenic service, with weld metal and heat-affected zone properties comparable with those of the base metal. Optimum properties were achieved in the base alloys, weld metals, and heat-affected zones after a two-step heat treatment consisting of austenitizing at 900 C followed by tempering at 500 C. The Mo-containing alloy offered a marked improvement in cryogenic properties over those of the Mo-free alloy. Molybdenum increased the amount of retained austenite and reduced the amount of epsilon martensite observed in the microstructure of the two alloys.

Embedded spectroscopic fiber sensor for on-line arc-welding analysis.

PubMed

Mirapeix, Jesús; Cobo, Adolfo; Quintela, Antonio; López-Higuera, José-Miguel

2007-06-01

A new fiber sensor system designed for spectroscopic analysis and on-line quality assurance of arc-welding processes is presented here. Although several different approaches have been considered for the optical capture of plasma emission in arc-welding processes, they tend to be invasive and make use of optical devices such as collimators or photodiodes. The solution proposed here is based on the arrangement of an optical fiber, which is used at the same time as the optical capturing device and also to deliver the optical information to a spectrometer, embedded within an arc-welding torch. It will be demonstrated that, by using the shielding gas as a protection for the fiber end, the plasma light emission is efficiently collected, forming a sensor system completely transparent and noninvasive for the welding operator. The feasibility of the proposed sensor designed to be used as the input optics of a welding quality-assurance system based on plasma spectroscopy will be demonstrated by means of several welding tests.

Viewing Welds By Computer Tomography

NASA Technical Reports Server (NTRS)

Pascua, Antonio G.; Roy, Jagatjit

1990-01-01

Computer tomography system used to inspect welds for root penetration. Source illuminates rotating welded part with fan-shaped beam of x rays or gamma rays. Detectors in circular array on opposite side of part intercept beam and convert it into electrical signals. Computer processes signals into image of cross section of weld. Image displayed on video monitor. System offers only nondestructive way to check penetration from outside when inner surfaces inaccessible.

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.

Out of the Frying Pan into the Fire? A Critical Analysis of the Integrated Children's System

ERIC Educational Resources Information Center

Calder, Martin C.

2004-01-01

Much has been promised from the government about providing a more contemporary and streamlined system for child care at the beginning of the 21st century. In this article Calder critically evaluates the origins of the incoming Integrated Children's System and questions how welding two faulty and discredited systems from the 1990s together can…

Welding of hermetic connectors

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

Hieber, D.E.

1976-08-01

Certain systems use hermetically-sealed multipin connectors welded into a stainless steel support ring. Failure of these hermetic seals during welding continues to be a problem, and similar problems are anticipated on advanced systems. Since the assembly is expensive, and the detection, prevention, and repair of hermetic seal failures is costly, development of an improved welding process is important. Extended service life also requires a lower system leak rate, thus causing an increased need for maintaining the hermetic seal without supplemental epoxy sealing and repair. Experience shows that up to 70 percent of the 10-pin SA1810-2 connectors have gross leaks (greatermore » than 0.003 mm/sup 3//s Standard Temperature and Pressure (STP)) after being welded using established welding processes and without using the epoxy pre-seal process. Acceptable leak rates of less than 0.00001 mm/sup 3//s STP were achieved from 20 SA1810-2 10-pin connectors using heat sinks and an intermittent gas-tungsten-arc (GTA) weld technique. The process developed consists of using a massive copper heat sink with silicon thermal joint compound to maintain control of temperature in the hermetic seal area and using a 12-segment GTA weld with compressed argon gas cooling between weld segments. The process and techniques developed are considered acceptable for welding the SA1810 family of connectors.« less

Welding, V-TECS Guide.

ERIC Educational Resources Information Center

Moore, Charles G.; And Others

This guide provides job-related tasks, performance objectives, performance guides, resources, teaching activities, evaluation standards, and criterion-referenced measures in three units of a welding course. Through the curriculum content of the welding course, the guide helps teachers lead students through the learning process, including the…

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Evaluation in vitro of the tensile strength of crimpable hooks used for stabilization in orthognathic surgery.

PubMed

Andrade Gomes, Nascimento Leonard Euller; Melo, Pithon Matheus; Lacerda, Santos Rogério; D'Albuquerque, Medeiros Paulo Jose

2012-03-01

The aim of this study was to evaluate the tensile strength of crimpable hooks used for arch stabilization in orthognatic surgery. Ninety stainless steel wire (0.019" × 0.026") segments, each measuring 6 cm long, were used and attached to crimpable hooks of different commercial brands. Six groups were formed (n = 10) denominated as follows: control, in which the wire segments were perpendicularly welded by spot welding machine; and the hooks groups M (Morelli), MS (Morelli with weld), TP (TP Ortho), TPS (TP with weld), TPTg (TP-tungsten), TPTgS (TP-tungsten with weld), AO (American Orthodontics), and AOS (American Orthodontics with weld). The test specimen topography was evaluated by scanning electron microscopy before and after the tensile strength tests. After obtaining the results, the analysis of variance and Kruskal-Wallis multiple-comparison tests were applied. Compared with the control group, the AOS ball hooks and those from TPS required a greater amount of force to be displaced along the rectangular arch. The hooks in group M were significantly easier to displace, followed by those from AO. The best ball hooks for clinical application are those from AOS and TPS. Copyright © 2012 Elsevier Inc. All rights reserved.

Proceedings of the Symposium on Welding, Bonding, and Fastening. [production engineering for aircraft and spacecraft structures

NASA Technical Reports Server (NTRS)

Stein, B. A. (Compiler); Buckley, J. D. (Compiler)

1972-01-01

Various technological processes to achieve lightweight reliable joining systems for structural elements of aircraft and spacecraft are considered. Joining methods, combinations of them, and nondestructive evaluation and quality assurance are emphasized.

Wire-Guide Manipulator For Automated Welding

NASA Technical Reports Server (NTRS)

Morris, Tim; White, Kevin; Gordon, Steve; Emerich, Dave; Richardson, Dave; Faulkner, Mike; Stafford, Dave; Mccutcheon, Kim; Neal, Ken; Milly, Pete

1994-01-01

Compact motor drive positions guide for welding filler wire. Drive part of automated wire feeder in partly or fully automated welding system. Drive unit contains three parallel subunits. Rotations of lead screws in three subunits coordinated to obtain desired motions in three degrees of freedom. Suitable for both variable-polarity plasma arc welding and gas/tungsten arc welding.

Evaluation of Weldability for MAG and LASER with Galvannealed Steel.

PubMed

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

2018-03-01

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

Weldability of Advanced High Strength Steels using Ytterbium:Yttrium Aluminium Garnet high power laser for Tailor-Welded Blank applications

NASA Astrophysics Data System (ADS)

Sharma, Rajashekhar Shivaram

Use of a high power Yb:YAG laser is investigated for joining advanced high strength steel materials for use in tailor-welded blank (TWB) applications. TWB's are materials of different chemistry, coating or thicknesses that are joined before metal forming and other operations such as trimming, assembly and painting are carried out. TWB is becoming an important design tool in the automotive industry for reducing weight, improving fuel economy and passenger safety, while reducing the overall costs for the customer. Three advanced high strength steels, TRIP780, DP980 and USIBOR, which have many unique properties that are conducive to achieving these objectives, along with mild steel, are used in this work. The objective of this work is to ensure that high quality welds can be obtained using Yb:YAG lasers which are also becoming popular for metal joining operations, since they produce high quality laser beams that suffer minimal distortion when transported via fiber optic cables. Various power levels and speeds for the laser beam were used during the investigation. Argon gas was consistently used for shielding purposes during the welding process. After the samples were welded, metallographic examination of the fusion and heat-affected zones using optical and scanning electron microscopes were carried out to determine the microstructures as well as weld defects. Optical and scanning electron microscopes were also used to examine the top of welds as well as fracture surfaces. Additionally, cross-weld microhardness evaluations, tensile tests using Instron tester, limited fatigue tests as well as formability evaluations using OSU plane strain evaluation were carried out. The examinations included a 2-factor full factorial design of experiments to determine the impact of coatings on the surface roughness on the top of the welds. Tensile strengths of DP980, TRIP780 and mild steel materials as well as DP980 welded to TRIP780 and mild steel in the rolling direction as well as transverse direction were evaluated. Metallographic examinations determined that most of the fusion zone is martensitic with small regions of bainite and ferrite. High microhardness values of the order of 550--600 Hv were noted in most joints, which are attributed to high alloy content of the fusion zone as well as high rates of cooling typical of laser welds. During tensile, fatigue and formability tests, no fractures in the fusion or heat affected zones were observed. Geometric variability evaluations indicated that coatings such as aluminum (in the case of USIBOR) and galvanized zinc (TRIP780) can affect the variability of the weld zone and the surface roughness on the top of the weld. Excessive variability in the form of weld concavity in the weld zones can lead to fractures in the weld region, even though higher hardness can, to some extent, compensate for these surface irregularities. The 2-factor design of experiments further confirmed that coatings adversely affect the surface roughness on the top of the welds. Although thickness differentials alone do not make a significant impact on surface roughness, together with coatings, they can have an adverse effect on roughness. Tensile tests in the direction of rolling as well as in the transverse direction indicate that TRIP780 seems weaker in the direction of rolling when compared to transverse direction while mild steel is stronger in the direction of rolling. Weldability analyses revealed that the typical melting efficiency is on the order of 50--70% for full penetration welding. Formability tests showed that TR/MS joints fractured in a direction parallel to the weld line when tested with the loads perpendicular to the weld line. Tests have also confirmed that weld speed and power have no impact on the outcome of formability results. Overall, this work conclusively proves that high power Yb:YAG lasers can effectively join high strength materials such as DP980, TRIP780, USIBOR, as well as mild steel, for use in tailor-welded blank applications, contributing to lighter, more fuel-efficient and safer vehicles.

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

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

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

2014-03-24

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

Single and Combined Exposure to Zinc- and Copper-Containing Welding Fumes Lead to Asymptomatic Systemic Inflammation.

PubMed

Markert, Agnieszka; Baumann, Ralf; Gerhards, Benjamin; Gube, Monika; Kossack, Veronika; Kraus, Thomas; Brand, Peter

2016-02-01

Recently, it has been shown that exposure to welding fumes containing both zinc and copper leads to asymptomatic systemic inflammation in humans as shown by an increase of blood C-reactive protein. In the present study, it was investigated which metal is responsible for this effect. Fifteen healthy male subjects were exposed under controlled conditions to welding fumes containing either zinc, or copper, or copper and zinc. For each exposure blood C-reactive protein increased. Copper- and zinc-containing welding fumes are able to induce systemic inflammation.

Effect of electrical spot welding on load deflection rate of orthodontic wires.

PubMed

Alavi, Shiva; Abrishami, Arezoo

2015-01-01

One of the methods used for joining metals together is welding, which can be carried out using different techniques such as electric spot welding. This study evaluated the effect of electric spot welding on the load deflection rate of stainless steel and chromium-cobalt orthodontic wires. In this experimental-laboratory study, load deflection rate of 0.016 × 0.022 inch stainless steel and chromium cobalt wires were evaluated in five groups (n =18): group one: Stainless steel wires, group two: chromium-cobalt wires, group three: stainless steel wires welded to stainless steel wires, group four: Stainless steel wires welded to chromium-cobalt wires, group five: chromium-cobalt wire welded to chromium-cobalt wires. Afterward, the forces induced by the samples in 0.5 mm, 1 mm, 1.5 mm deflection were measured using a universal testing machine. Then mean force measured for each group was compared with other groups. The data were analyzed using repeated measure analysis of variance (ANOVA), one-way ANOVA, and paired t-test by the SPSS software. The significance level was set as 0.05. The Tukey test showed that there were significant differences between the load deflection rates of welded groups compared to control ones (P < 0.001). Considering the limitation of this study, the electric spot welding process performed on stainless steel and chromium-cobalt wires increased their load deflection rates.

Influence of M-TIG and A-TIG Welding Process on Microstructure and Mechanical Behavior of 409 Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Vidyarthy, R. S.; Dwivedi, D. K.; Vasudevan, M.

2017-03-01

The current study investigates the effects of activating flux tungsten inert gas welding (A-TIG) and multipass tungsten inert gas welding (M-TIG) on the weld morphology, angular distortion, microstructures and mechanical properties when welding 8-mm-thick 409 ferritic stainless steel (FSS). SiO2 was used as activating flux for A-TIG welding, while SUPERTIG ER309L was used as filler for M-TIG welding. Bead-on-plate weld trials were carried out to obtain the full penetration by using different combinations of flux coating density, welding speed and welding current. An optical microscope, field emission scanning microscope (FESEM), and x-ray diffractometer were used for the metallurgical characterizations. Vickers hardness, tensile test, Charpy toughness test, and creep behavior test were carried out to evaluate the mechanical properties of the base and weld metals. Experimental results indicate that the A-TIG process can increase the joint penetration and tends to reduce the angular distortion of the 409 FSS weldment. The A-TIG welded joint also exhibited greater mechanical strength. However, a critically low Charpy toughness was measured for the A-TIG weld fusion zone, which was later sufficiently improved after post weld heat treatment (PWHT). It was concluded that PWHT is mandatory for A-TIG welded 409 FSS.

Adhesion of Salmonella Enteritidis and Listeria monocytogenes on stainless steel welds.

PubMed

Casarin, Letícia Sopeña; Brandelli, Adriano; de Oliveira Casarin, Fabrício; Soave, Paulo Azevedo; Wanke, Cesar Henrique; Tondo, Eduardo Cesar

2014-11-17

Pathogenic microorganisms are able to adhere on equipment surfaces, being possible to contaminate food during processing. Salmonella spp. and Listeria monocytogenes are important pathogens that can be transmitted by food, causing severe foodborne diseases. Most surfaces of food processing industry are made of stainless steel joined by welds. However currently, there are few studies evaluating the influence of welds in the microorganism's adhesion. Therefore the purpose of the present study was to investigate the adhesion of Salmonella Enteritidis and L. monocytogenes on surface of metal inert gas (MIG), and tungsten inert gas (TIG) welding, as well as to evaluate the cell and surface hydrophobicities. Results demonstrated that both bacteria adhered to the surface of welds and stainless steel at same levels. Despite this, bacteria and surfaces demonstrated different levels of hydrophobicity/hydrophilicity, results indicated that there was no correlation between adhesion to welds and stainless steel and the hydrophobicity. Copyright © 2014 Elsevier B.V. All rights reserved.

Friction Stir Welding Development

NASA Technical Reports Server (NTRS)

Romine, Peter L.

1998-01-01

The research of this summer was a continuation of work started during the previous summer faculty fellowship period. The Friction Stir Welding process (FSW) patented by The Welding Institute (TWI), in Great Britain, has become a popular topic at the Marshall Space Flight Center over the past year. Last year it was considered a novel approach to welding but few people took it very seriously as a near term solution. However, due to continued problems with cracks in the new aluminum-lithium space shuttle external tank (ET), the friction stir process is being mobilized at full speed in an effort to mature this process for the potential manufacture of flight hardware. It is now the goal of NASA and Lockheed-Martin Corporation (LMC) to demonstrate a full-scale friction stir welding system capable of welding ET size barrel sections. The objectives this summer were: (1) Implementation and validation of the rotating dynamometer on the MSFC FSW system; (2) Collection of data for FSW process modeling efforts; (3) Specification development for FSW implementation on the vertical weld tool; (4) Controls and user interface development for the adjustable pin tool; and (5) Development of an instrumentation system for the planishing process. The projects started this summer will lead to a full scale friction stir welding system that is expected to produce a friction stir welded shuttle external tank type barrel section. The success of this could lead to the implementation of the friction stir process for manufacturing future shuttle external tanks.

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

Friction-Stir Welding of Large Scale Cryogenic Fuel Tanks for Aerospace Applications

NASA Technical Reports Server (NTRS)

Jones, Clyde S., III; Venable, Richard A.

1998-01-01

The Marshall Space Flight Center has established a facility for the joining of large-scale aluminum-lithium alloy 2195 cryogenic fuel tanks using the friction-stir welding process. Longitudinal welds, approximately five meters in length, were made possible by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and the spindle travel system will be described in this paper. Process controls and real-time data acquisition will also be described, and were critical elements contributing to successful weld operation.

Reed Valve Regulates Welding Back-Purge Pressure

NASA Technical Reports Server (NTRS)

Coby, J. Ben, Jr.; Weeks, Jack L.

1991-01-01

Simple modification yields welds of better quality. Reed valve halves fluctuations in pressure in back-purge chamber attached to workpiece undergoing keyhole plasma arc welding. Identical to one used in fuel system of two-cycle gasoline engine. Backbead smoother, and weld penetrates more uniformly.

Integration of NASA-sponsored studies on aluminum welding

NASA Technical Reports Server (NTRS)

Masubuchi, K.

1972-01-01

The results are presented of numerous studies relating to aluminum alloy welding. The subjects covered include: (1) effects of porosity on weld joint performance, (2) sources of porosity, (3) weld thermal effects, (4) residual stresses and distortion, and (5) manufacturing process system control.

Stability evaluation of short-circuiting gas metal arc welding based on ensemble empirical mode decomposition

NASA Astrophysics Data System (ADS)

Huang, Yong; Wang, Kehong; Zhou, Zhilan; Zhou, Xiaoxiao; Fang, Jimi

2017-03-01

The arc of gas metal arc welding (GMAW) contains abundant information about its stability and droplet transition, which can be effectively characterized by extracting the arc electrical signals. In this study, ensemble empirical mode decomposition (EEMD) was used to evaluate the stability of electrical current signals. The welding electrical signals were first decomposed by EEMD, and then transformed to a Hilbert-Huang spectrum and a marginal spectrum. The marginal spectrum is an approximate distribution of amplitude with frequency of signals, and can be described by a marginal index. Analysis of various welding process parameters showed that the marginal index of current signals increased when the welding process was more stable, and vice versa. Thus EEMD combined with the marginal index can effectively uncover the stability and droplet transition of GMAW.

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

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

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

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

1995-12-31

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

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

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Evaluating the Properties of Dissimilar Metal Welding Between Inconel 625 and 316L Stainless Steel by Applying Different Welding Methods and Consumables

NASA Astrophysics Data System (ADS)

Kourdani, Ahmad; Derakhshandeh-Haghighi, Reza

2018-04-01

The current work was carried out to characterize welding of Inconel 625 superalloy and 316L stainless steel. In the present study, shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW) with two types of filler metals (ERNiCrMo-3 and ERSS316L) and an electrode (ENiCrMo-3) were utilized. This paper describes the selection of the proper welding method and welding consumables in dissimilar metal joining. During solidification of ERNiCrMo-3 filler metal, Nb and Mo leave dendritic cores and are rejected to inter-dendritic regions. However, ERSS316L filler metal has small amounts of elements with a high tendency for segregation. So, occurrence of constitutional super-cooling for changing the solidification mode from cellular to dendritic or equiaxed is less probable. Using GTAW with lower heat input results in higher cooling rate and finer microstructure and less Nb segregation. The interface between weld metal and base metal and also unmixed zones was evaluated by scanning electron microscopy and energy dispersive X-ray (EDX) analysis. Microhardness measurements, tensile test, and Charpy impact test were performed to see the effect of these parameters on mechanical properties of the joints.

Aging Degradation of Austenitic Stainless Steel Weld Probed by Electrochemical Method and Impact Toughness Evaluation

NASA Astrophysics Data System (ADS)

Singh, Raghuvir; Das, Goutam; Mahato, B.; Singh, P. K.

2017-03-01

The present study discriminates the spinodal decomposition and G-phase precipitation in stainless steel welds by double loop electrochemical potentio-kinetic reactivation method and correlates it with the degradation in toughness property. The welds produced with different heat inputs were aged up to 10,000 hours at 673 K to 723 K (400 to 450 °C) and evaluated subsequently for the degree of sensitization (DOS) and impact toughness. The DOS values obtained were attributed to the spinodal decomposition and precipitation of G-phase. Study shows that the DOS correlates well with the impact toughness of the 304LN weld. Prolonged aging at 673 K and 723 K (400 °C and 450 °C) increased the DOS values while the impact toughness was decreased. The weld fabricated at 1 kJ/mm of heat input, produced higher DOS, compared to that at 3 kJ/mm. The geometrical location along the weld is shown to influence the DOS; higher values were obtained at the root than at the topside of the weld. Vermicular and columnar microstructure, in addition to the spinodal decomposition and G-phase precipitation, observed in the root side of the weld appear risky for the impact toughness.

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

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

Certification of a weld produced by friction stir welding

DOEpatents

Obaditch, Chris; Grant, Glenn J

2013-10-01

Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Electron beam weld development on a Filter Pack Assembly

NASA Astrophysics Data System (ADS)

Dereskiewicz, J. P.

1994-06-01

A continuous electron beam welding procedure was developed to replace the manual gas tungsten arc welding procedure on the Filter Pack Assembly. A statistical study was used to evaluate the feasibility of electron beam welding 6061-T6 aluminum covers to A356 cast weldments throughout the joint tolerance range specified on product drawings. Peak temperature exposures were not high enough to degrade the heat sensitive electrical components inside the cast weldment. Actual weldments with alodine coating on the weld joint area were successfully cleaned using a nonmetallic fiberglass brush cleaning method.

Weldability of high-toughness iron - 12 percent-nickel alloys with reactive metal additions of titanium, aluminum, or niobium

NASA Technical Reports Server (NTRS)

Delvetian, J. H.; Stephens, J. R.; Witzke, W. R.

1977-01-01

Three exceptionally high toughness Fe-12Ni alloys designed for cryogenic service were welded by using the gas tungsten arc welding process. Evaluation of their weldability included equivalent energy fracture toughness tests, transverse weld tensile tests at -196 and 25 C, and weld crack sensitivity tests. The Fe-12Ni-0.25Ti alloy proved extremely weldable for cryogenic applications, having weld and heat affected zone properties comparable to those of the wrought base alloy. The Fe-12Ni-0.5Al alloy had good weld properties only after the weld joint was heat treated. The Fe-12Ni-0.25Nb alloy was not considered weldable for cryogenic use because of its poor weld joint properties at -196 C and its susceptibility to hot cracking.

Vibration welding system with thin film sensor

DOEpatents

Cai, Wayne W; Abell, Jeffrey A; Li, Xiaochun; Choi, Hongseok; Zhao, Jingzhou

2014-03-18

A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.

Defect Detectability Improvement for Conventional Friction Stir Welds

NASA Technical Reports Server (NTRS)

Hill, Chris

2013-01-01

This research was conducted to evaluate the effects of defect detectability via phased array ultrasound technology in conventional friction stir welds by comparing conventionally prepped post weld surfaces to a machined surface finish. A machined surface is hypothesized to improve defect detectability and increase material strength.

Evaluating the SCC resistance of underwater welds in sodium tetrathionate

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

White, R.A.; Angeliu, T.M.

1997-12-01

The susceptibility of welds to stress corrosion cracking (SCC) is enhanced by the surface residual tensile stresses generated by the typical welding process. However, underwater plasma transferred arc (PTA) welding has been shown to produce compressive surface residual stresses, an encouraging result if repairs of cracked boiling water reactor (BWR) components are to be made without further endangering them to SCC. This program was designed to verify that underwater PTA welds are resistant to SCC and to determine if underwater PTA welding could mitigate SCC in potentially susceptible welds. This was achieved by exposing various welds on solution annealed (SA)more » and SA + thermally sensitized 304 stainless steel at 25 C in a solution of 1.5 gm/liter of sodium sulfide added to 0.05M sodium tetrathionate, titrated to a pH of 1.25 with H{sub 2}SO{sub 4}. The autogeneous welds were produced using gas tungsten arc (GTA) and plasma transferred arc (PTA) welding under atmospheric conditions, and PTA welding underwater. After 1 hour of sodium tetrathionate exposure, GTA and air PTA welds exhibited SCC while the underwater PTA weld heat affected zones were more resistant. Underwater PTA welds bisecting a GTA weld eliminated the cracking in the GTA weld heat affected zone under certain conditions. The lack of IG cracking in the region influenced by the underwater PTA weld is consistent with the measurement of compressive surface residual stresses inherent to the underwater welding process.« less

Technology of welding aluminum alloys-IV

NASA Technical Reports Server (NTRS)

Ginez, R.; Lewis, J. R.; Millett, A. U.; Saenger, K. A.; Skelly, J. K.; Standiford, V. E.; Whiteman, J. O.

1978-01-01

Skate-weld carriage and track assembly were developed for controlled fusion welding on compound-curvature surfaces. Unlike fixed-position carriage used for vertical, horizontal, and circumferential welding, carriage has suspension system that permits angular positioning of weld head on carriage. It also has carriage-and-drive track mechanism capable of traveling over compound curvatures. Carriage is designed with universal mounting platform so that slim tools, weld heads, or X-ray units can be interchanged without need for realinement.

Mars Atmosphere Effects on Arc Welds: Phase 1

NASA Technical Reports Server (NTRS)

Courtright, Z. S.

2016-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2012-06-01

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

Research on Kinematic Trajectory Simulation System of KUKA Arc Welding Robot System

NASA Astrophysics Data System (ADS)

Hu, Min

2017-10-01

In this paper, the simulation trajectory simulation of KUKA arc welding robot system is realized by means of VC platform. It is used to realize the teaching of professional training of welding robot in middle school. It provides teaching resources for the combination of work and study and integration teaching, which enriches the content of course teaching.

Pattern of deposition of stainless steel welding fume particles inhaled into the respiratory systems of Sprague-Dawley rats exposed to a novel welding fume generating system.

PubMed

Yu, I J; Kim, K J; Chang, H K; Song, K S; Han, K T; Han, J H; Maeng, S H; Chung, Y H; Park, S H; Chung, K H; Han, J S; Chung, H K

2000-07-27

In order to investigate occupational diseases related to welding fume exposure, such as nasal septum perforation, pneumoconiosis and manganese intoxication, we built a welding fume exposure system that included a welding fume generator, exposure chamber and fume collector. The fume concentrations in the exposure chamber were monitored every 15 min during a 2-h exposure. Fume (mg/m(3)) concentrations of major metals, including Fe, Mn, Cr, and Ni were found to be consistently maintained. An acute inhalation toxicity study was conducted by exposing male Sprague-Dawley rats to the welding fumes generated in this apparatus by stainless steel arc welding. The rats were exposed in the inhalation chamber to a welding fume with a concentration of 62 mg/m(3) total suspended particulates for 4 h. Animals were sacrificed at 4 h and at 1, 3, 7, 10, and 14 days after exposure. Histopathological examinations were conducted on the animals' upper respiratory tracts, including the nasal pathway and the conducting airway, and on the gas exchange region including the alveolar ducts, alveolar sacs, and alveoli. Diameters of fume particles varied from 0.02 to 0.81 microm and were distributed log normally, with a mean diameter of 0.1 microm and geometric standard deviation of 1.42. Rats exposed to the welding fume for 4 h did not show any significant respiratory system toxicity. The mean particle diameter of 0.1 microm resulted in little adsorption of the welding fume particles in the upper respiratory tract. Particle adsorption took place principally in the lower respiratory tracts, including bronchioles, alveolar ducts, alveolar sacs, and alveoli.

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

Effect of Bainitic Microstructure on Ballistic Performance of Armour Steel Weld Metal Using Developed High Ni-Coated Electrode

NASA Astrophysics Data System (ADS)

Pramanick, A. K.; Das, H.; Reddy, G. M.; Ghosh, M.; Nandy, S.; Pal, T. K.

2018-05-01

Welding of armour steel has gained significant importance during the past few years as recent civilian and military requirements demand weld metal properties matching with base metal having good ballistic performance along with high strength and toughness at - 40 °C as per specification. The challenge of armour steel welding therefore lies in controlling the weld metal composition which is strongly dependent on welding electrode/consumables, resulting in desired weld microstructure consisting of lower bainite along with retained austenite. The performance of butt-welded armour steel joints produced by the developed electrodes was evaluated using tensile testing, ballistic testing, impact toughness at room temperature and subzero temperature. Microstructures of weld metals are exclusively characterized by x-ray diffraction technique, scanning electron microscope and transmission electron microscopy with selected area diffraction pattern. Experimental results show that weld metal with relatively lower carbon, higher manganese and lower nickel content was attributed to lower bainite with film type of retained austenite may be considered as a most covetable microstructure for armour steel weld metal.

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy

PubMed Central

Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

2013-01-01

Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force. PMID:28788430

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

Effect of Bainitic Microstructure on Ballistic Performance of Armour Steel Weld Metal Using Developed High Ni-Coated Electrode

NASA Astrophysics Data System (ADS)

Pramanick, A. K.; Das, H.; Reddy, G. M.; Ghosh, M.; Nandy, S.; Pal, T. K.

2018-04-01

Welding of armour steel has gained significant importance during the past few years as recent civilian and military requirements demand weld metal properties matching with base metal having good ballistic performance along with high strength and toughness at - 40 °C as per specification. The challenge of armour steel welding therefore lies in controlling the weld metal composition which is strongly dependent on welding electrode/consumables, resulting in desired weld microstructure consisting of lower bainite along with retained austenite. The performance of butt-welded armour steel joints produced by the developed electrodes was evaluated using tensile testing, ballistic testing, impact toughness at room temperature and subzero temperature. Microstructures of weld metals are exclusively characterized by x-ray diffraction technique, scanning electron microscope and transmission electron microscopy with selected area diffraction pattern. Experimental results show that weld metal with relatively lower carbon, higher manganese and lower nickel content was attributed to lower bainite with film type of retained austenite may be considered as a most covetable microstructure for armour steel weld metal.

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy.

PubMed

Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

2013-12-18

Friction Stir Welding (FSW) is a solid-state joining process; i.e. , no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force.

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.

Technology of welding aluminum alloys-I

NASA Technical Reports Server (NTRS)

Harrison, J. R.; Korb, L. J.; Oleksiak, C. E.

1978-01-01

Systems approach to high-quality aluminum welding uses square-butt joints, kept away from sharp contour changes. Intersecting welds are configured for T-type intersections rather than crossovers. Differences in panel thickness are accommodated with transition step areas where thickness increases or decreases within weld, but never at intersection.

Instructional Guidelines. Welding.

ERIC Educational Resources Information Center

Fordyce, H. L.; Doshier, Dale

Using the standards of the American Welding Society and the American Society of Mechanical Engineers, this welding instructional guidelines manual presents a course of study in accordance with the current practices in industry. Intended for use in welding programs now practiced within the Federal Prison System, the phases of the program are…

Ultrasonic Phased Array Simulations of Welded Components at NASA

NASA Technical Reports Server (NTRS)

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

2009-01-01

Comprehensive and accurate inspections of welded components have become of increasing importance as NASA develops new hardware such as Ares rocket segments for future exploration missions. Simulation and modeling will play an increasing role in the future for nondestructive evaluation in order to better understand the physics of the inspection process, to prove or disprove the feasibility for an inspection method or inspection scenario, for inspection optimization, for better understanding of experimental results, and for assessment of probability of detection. This study presents simulation and experimental results for an ultrasonic phased array inspection of a critical welded structure important for NASA future exploration vehicles. Keywords: nondestructive evaluation, computational simulation, ultrasonics, weld, modeling, phased array

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.

Application of TRIZ Methodology in Diffusion Welding System Optimization

NASA Astrophysics Data System (ADS)

Ravinder Reddy, N.; Satyanarayana, V. V.; Prashanthi, M.; Suguna, N.

2017-12-01

Welding is tremendously used in metal joining processes in the manufacturing process. In recent years, diffusion welding method has significantly increased the quality of a weld. Nevertheless, diffusion welding has some extent short research and application progress. Therefore, diffusion welding has a lack of relevant information, concerned with the joining of thick and thin materials with or without interlayers, on welding design such as fixture, parameters selection and integrated design. This article intends to combine innovative methods in the application of diffusion welding design. This will help to decrease trial and error or failure risks in the welding process being guided by the theory of inventive problem solving (TRIZ) design method. This article hopes to provide welding design personnel with innovative design ideas under research and for practical application.

Metallography of Battery Resistance Spot Welds

NASA Technical Reports Server (NTRS)

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

2015-01-01

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

Infrared Thermography For Welding

NASA Technical Reports Server (NTRS)

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

1992-01-01

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

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

PubMed

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

2013-01-01

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

Automatic orbital GTAW welding: Highest quality welds for tomorrow's high-performance systems

NASA Technical Reports Server (NTRS)

Henon, B. K.

1985-01-01

Automatic orbital gas tungsten arc welding (GTAW) or TIG welding is certain to play an increasingly prominent role in tomorrow's technology. The welds are of the highest quality and the repeatability of automatic weldings is vastly superior to that of manual welding. Since less heat is applied to the weld during automatic welding than manual welding, there is less change in the metallurgical properties of the parent material. The possibility of accurate control and the cleanliness of the automatic GTAW welding process make it highly suitable to the welding of the more exotic and expensive materials which are now widely used in the aerospace and hydrospace industries. Titanium, stainless steel, Inconel, and Incoloy, as well as, aluminum can all be welded to the highest quality specifications automatically. Automatic orbital GTAW equipment is available for the fusion butt welding of tube-to-tube, as well as, tube to autobuttweld fittings. The same equipment can also be used for the fusion butt welding of up to 6 inch pipe with a wall thickness of up to 0.154 inches.

Electron beam, laser beam and plasma arc welding studies

NASA Technical Reports Server (NTRS)

Banas, C. M.

1974-01-01

This program was undertaken as an initial step in establishing an evaluation framework which would permit a priori selection of advanced welding processes for specific applications. To this end, a direct comparison of laser beam, electron beam and arc welding of Ti-6Al-4V alloy was undertaken. Ti-6Al-4V was selected for use in view of its established welding characteristics and its importance in aerospace applications.

Nine percent nickel steel heavy forging weld repair study. [National Transonic Wind Tunnel fan components

NASA Technical Reports Server (NTRS)

Young, C. P., Jr.; Gerringer, A. H.; Brooks, T. G.; Berry, R. F., Jr.

1978-01-01

The feasibility of making weld repairs on heavy section 9% nickel steel forgings such as those being manufactured for the National Transonic Facility fan disk and fan drive shaft components was evaluated. Results indicate that 9% nickel steel in heavy forgings has very good weldability characteristics for the particular weld rod and weld procedures used. A comparison of data for known similar work is included.

Energy reduction for the spot welding process in the automotive industry

NASA Astrophysics Data System (ADS)

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

2007-07-01

When performing spot welding on galvanised metals, higher welding force and current are required than on uncoated steels. This has implications for the energy usage when creating each spot weld, of which there are approximately 4300 in each passenger car. The paper presented is an overview of electrode current selection and its variance over the lifetime of the electrode tip. This also describes the proposed analysis system for the selection of welding parameters for the spot welding process, as the electrode tip wears.

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

X-ray online detection for laser welding T-joint of Al-Li alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Bu, Xing; Qin, Tao; Yu, Haisong; Chen, Jie; Wei, Yanhong

2017-05-01

In order to detect weld defects in laser welding T-joint of Al-Li alloy, a real-time X-ray image system is set up for quality inspection. Experiments on real-time radiography procedure of the weldment are conducted by using this system. Twin fillet welding seam radiographic arrangement is designed according to the structural characteristics of the weldment. The critical parameters including magnification times, focal length, tube current and tube voltage are studied to acquire high quality weld images. Through the theoretical and data analysis, optimum parameters are settled and expected digital images are captured, which is conductive to automatic defect detection.

Charge Weld Effects on High Cycle Fatigue Behavior of a Hollow Extruded AA6082 Profile

NASA Astrophysics Data System (ADS)

Nanninga, N.; White, C.; Dickson, R.

2011-10-01

Fatigue properties of specimens taken from different locations along the length of a hollow AA6082 extrusion, where charge weld (interface between successive billets in multi-billet extrusions) properties and the degree of coring (accumulation of highly sheared billet surface material at back end of billet) are expected to vary, have been evaluated. The fatigue strength of transverse specimens containing charge welds is lower near the front of the extrusion where the charge weld separation is relatively large. The relationship between fatigue failure and charge weld separation appears to be directly related to charge weld properties. The lower fatigue properties of the specimens are likely associated with early overload fatigue failure along the charge weld interface. Coring does not appear to have significantly affected fatigue behavior.

Apparatus for the concurrent ultrasonic inspection of partially completed welds

DOEpatents

Johnson, John A.

2000-01-01

An apparatus for the concurrent nondestructive evaluation of partially completed welds is described and which is used in combination with an automated welder and which includes an ultrasonic signal generator mounted on the welder and which generates an ultrasonic signal which is directed toward one side of the partially completed welds; an ultrasonic signal receiver mounted on the automated welder for detecting ultrasonic signals which are transmitted by the ultrasonic signal generator and which are reflected or diffracted from one side of the partially completed weld or which passes through a given region of the partially completed weld; and an analysis assembly coupled with the ultrasonic signal receiver and which processes the ultrasonic signals received by the ultrasonic signal receiver to identify welding flaws in the partially completed weld.

Irradiation embrittlement characterization of the EUROFER 97 material

NASA Astrophysics Data System (ADS)

Kytka, M.; Brumovsky, M.; Falcnik, M.

2011-02-01

The paper summarizes original results of irradiation embrittlement study of EUROFER 97 material that has been proposed as one candidate of structural materials for future fusion energy systems and GEN IV. Test specimens were manufactured from base metal as well as from weld metal and tested in initial unirradiated condition and also after neutron irradiation. Irradiation embrittlement was characterized by testing of toughness properties at transition temperature region - static fracture toughness and dynamic fracture toughness properties, all in sub-size three-point bend specimens (27 × 4 × 3 mm 3). Testing and evaluation was performed in accordance with ASTM and ESIS standards, fracture toughness KJC and KJd data were also evaluated with the "Master curve" approach. Moreover, J- R dependencies were determined and analyzed. The paper compares unirradiated and irradiated properties as well as changes in transition temperature shifts of these material parameters. Discussion about the correlation between static and dynamic properties is also given. Results from irradiation of EUROFER 97 show that this steel - base metal as well as weld metal - is suitable as a structural material for reactor pressure vessels of innovative nuclear systems - fusion energy systems and GEN IV. Transition temperature shifts after neutron irradiation by 2.5 dpa dose show a good agreement in the case of EUROFER 97 base material for both static and dynamic fracture toughness tests. From the results it can be concluded that there is a low sensitivity of weld metal to neutron irradiation embrittlement in comparison with EUROFER 97 base metal.

Orbital friction stir weld system

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor); Carter, Robert W. (Inventor)

2001-01-01

This invention is an apparatus for joining the ends of two cylindrical (i.e., pipe-shaped) sections together with a friction stir weld. The apparatus holds the two cylindrical sections together and provides back-side weld support as it makes a friction stir weld around the circumference of the joined ends.

Sensor control of robot arc welding

NASA Technical Reports Server (NTRS)

Sias, F. R., Jr.

1985-01-01

A basic problem in the application of robots for welding which is how to guide a torch along a weld seam using sensory information was studied. Improvement of the quality and consistency of certain Gas Tungsten Arc welds on the Space Shuttle Main Engine (SSME) that are too complex geometrically for conventional automation and therefore are done by hand was examined. The particular problems associated with space shuttle main egnine (SSME) manufacturing and weld-seam tracking with an emphasis on computer vision methods were analyzed. Special interface software for the MINC computr are developed which will allow it to be used both as a test system to check out the robot interface software and later as a development tool for further investigation of sensory systems to be incorporated in welding procedures.

Metallurgical effects on titanium by laser welding on dental stone.

PubMed

Fujioka, Sonosuke; Kakimoto, Kazutoshi; Inoue, Taro; Okazaki, Joji; Komasa, Yutaka

2003-12-01

It is not known for certain that dental stone components influence titanium welding. In this study, we investigated metallurgical problems caused by laser welding on dental stones using wrought commercial pure (CP) titanium. A pulsed Nd:YAG laser irradiated a number of specimens' surfaces which were fixed on either a dental hard stone or a titanium plate. The metallurgical properties of the weld were evaluated using the Vickers hardness test, microstructure observation, fractured surface observation and quantitative analysis of oxygen and hydrogen. In the weld formed on the dental stone there was an increase in hardness, the existence of an acicular structure and a brittle fractured surface, and an increase in the oxygen and hydrogen concentrations compared with base metal. In the weld formed on the titanium plate, these changes were not observed. Therefore, it was demonstrated that laser welding on dental stones made the welds brittle.

Laser Ablation Cleaning of Self-Reacting Friction Stir Weld Seam Surfaces: A Preliminary Evaluation

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Russell, C. K.; Brooke, S. A.; Parry, Q.; Lowrey, N. M.

2014-01-01

Anodized aluminum panels were cleaned by three lasers at three separate sites with a view to determining whether more economical laser cleaning might supplant current manual cleaning methods for preparation of surfaces to be welded by the self-reacting friction stir process. Uncleaned panels yielded welds exhibiting residual oxide defect (ROD) and failing at very low stresses along the trace of the weld seam. Manually cleaned panels yielded welds without ROD; these welds failed at nominal stress levels along an angled fracture surface not following the weld seam trace. Laser cleaned panels yielded welds failing at intermediate stress levels. The inadequacy of the laser cleaning processes leaves questions: Was the anodized aluminum test too stringent to represent actual cleaning requirements? Were the wrong laser cleaning techniques/parameters used for the study? Is the laser cleaning mechanism inadequate for effective preweld surface cleaning?

Survey report: control technology for autobody repair and painting shops at Church Brother's Collision Repair, Greenwood, Indiana, October 10-11, 1991

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

Heitbrink, W.A.; Cooper, T.C.; Edmonds, M.A.

1992-03-01

A study was made to evaluate and document the effectiveness of a metal inert gas (MIG) welder with built in ventilation to control potentially hazardous conditions at Church Brother's Collision Repair (SIC-7531), Greenwood, Indiana. Air contaminant exposures were measured during a 1 hour repair job while using a ventilated MIG welder and while using a conventional MIG welder. The ventilation system of the MIG did reduce worker exposure to welding fumes. However, the sampling was done on a single repair job, thus limiting the conclusions which can be drawn from the study. Some welding fumes were not captured by themore » ventilated welder, suggesting that the MIG with ventilation provided incomplete control of the generated fumes. In some cases the metal on the other side of the welding area became sufficiently hot to generate its own fumes. The car body itself appears to block the capture of these fumes by the ventilated MIG welder. When welding inside the car without the ventilated welder, the fumes generated were more concentrated than those generated by welding outside of the car under similar conditions. There is a decreased dilution of the fumes inside the car due to a lack of air movement. The authors conclude that while the control technique appeared to lessen exposure to welding fumes, additional investigation is needed to verify the data.« less

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

NASA Astrophysics Data System (ADS)

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

2016-06-01

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

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

Federal Register 2010, 2011, 2012, 2013, 2014

2010-10-13

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

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.

Analysis of the Corrosion Behavior of an A-TIG Welded SS 409 Weld Fusion Zone

NASA Astrophysics Data System (ADS)

Vidyarthy, R. S.; Dwivedi, D. K.

2017-11-01

AISI 409 (SS 409) ferritic stainless steel is generally used as the thick gauge section in freight train wagons, in ocean containers, and in sugar refinery equipment. Activating the flux tungsten inert gas (A-TIG) welding process can reduce the welding cost during fabrication of thick sections. However, corrosion behavior of the A-TIG weld fusion zone is a prime concern for this type of steel. In the present work, the effect of the A-TIG welding process parameters on the corrosion behavior of a weld fusion zone made of 8-mm-thick AISI 409 ferritic stainless-steel plate has been analyzed. Potentiodynamic polarization tests were performed to evaluate the corrosion behavior. The maximum corrosion potential ( E corr) was shown by the weld made using a welding current of 215 A, a welding speed of 95 mm/min, and a flux coating density of 0.81 mg/cm2. The minimum E corr was observed in the weld made using a welding current of 190 A, a welding speed of 120 mm/min, and a flux coating density of 1.40 mg/cm2. The current study also presents the inclusive microstructure-corrosion property relationships using the collective techniques of scanning electron microscopy, energy-dispersive x-ray spectroscopy, and x-ray diffraction.

State-of-technology for joining TD-NiCr sheet.

NASA Technical Reports Server (NTRS)

Holko, K. H.; Moore, T. J.; Gyorgak, C. A.

1972-01-01

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding (EBW), gas-tungsten arc welding (GTAW), diffusion welding (DFW), resistance spot welding (RSW), resistance seam welding (RSEW), and brazing. Roll welding (RW) and explosion welding (EXW) have not been developed to the point where they can be used to make sound welds in TD-NiCr. Joining work that has previously been done on TD-NiCr by various organizations, both privately supported and under Air Force and NASA contracts, is described in this summary. Current work is also described that is being done at General Dynamics/Convair (under NASA contract) and at NASA/Lewis to develop and evaluate DFW, RSW, RSEW, and brazing. Preliminary comparisons of joining processes are made for typical applications. A brief description of the manufacture of TD-NiCr sheet by a recently standardized process (under NASA contract) also is given.

Naval Research Reviews. Volume XXXIII. Number 2,

DTIC Science & Technology

1981-01-01

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

Retention Strength of Conical Welding Caps for Fixed Implant-Supported Prostheses.

PubMed

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

This study evaluated the retention strength of welding caps for Ankylos standard abutments using a pull-out test. Each sample consisted of an implant abutment and its welding cap. The tests were performed with a Zwick Roell testing machine with a 1-kN load cell. The retention strength of the welding caps increased with higher abutment diameters and higher head heights and was comparable or superior to the values reported in the literature for the temporary cements used in implant dentistry. Welding caps provide a reliable connection between an abutment and a fixed prosthesis without the use of cement.

Laser weld jig. [Patent application

DOEpatents

Van Blarigan, P.; Haupt, D.L.

1980-12-05

A system is provided for welding a workpiece along a predetermined weld line that may be of irregular shape, which includes the step of forming a lip on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members. Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reusable jig forming the lip, and with the jig constructed to detachably hold parts to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

Robotic Variable Polarity Plasma Arc (VPPA) Welding

NASA Technical Reports Server (NTRS)

Jaffery, Waris S.

1993-01-01

The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.

Robotic Variable Polarity Plasma Arc (VPPA) welding

NASA Astrophysics Data System (ADS)

Jaffery, Waris S.

1993-02-01

The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.

High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

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

Zhang, Jingyi; Upadhyay, Piyush; Hovanski, Yuri

Friction-stir-welding (FSW) is a cost-effective and high quality joining process for aluminum alloys (especially heat-treatable allo ys) that has been applied successfully in the aerospace industry. However, the full potential of FSW on more cost-sensitive applications is still limited by the production rate, namely the welding speed of the process. The majority of literature evaluating FSW of aluminum alloys is based on welds made in the range of welding speeds around hundreds of millimeters per minute, and only a handful are at a moderate speed of 1 m/min. In this study we present a microstructural analysis of friction stir weldedmore » AA7075-T6 blanks with welding speeds up to 3 m/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. Results are coupled with welding parameters to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high speed processing.« less

Subtask 12B1: Welding development for V-Cr-Ti alloys

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

King, J.F.; Goodwin, G.M.; Grossbeck, M.L.

1995-03-01

Development of the metallurgical and technological basis for the welding of thick sections of V-Cr-Ti alloys. The weldability and weldment properties of the V-5Cr-5Ti alloy have been evaluated. Results for the Sigmajig test of the vanadium alloy were similar to the cracking resistance of stainless steels, and indicates hot-cracking is unlikely to be a problem. Subsize Charpy test results for GTA weld metal in the as-welded condition have shown a significant reduction in toughness compared to the base metal. The weld metal toughness properties were restored to approximately that of the base metal after exposure to a PWHT 950{degrees}C. Themore » subsize Charpy toughness results for the EB weld metal from this same heat of vanadium alloy has shown significant improvement in properties compared to the GTA weld metal and the base metal. Further testing and analysis will be conducted to more fully characterize the properties of weld metal for each welding process and develop a basic understanding of the cause of the toughness decrease in the GTA welds. 5 figs., 1 tab.« less

SMAW Ceramic Weld Backing Evaluation

DTIC Science & Technology

1982-03-01

marked similarity to the open root technique in that the " keyhole " technique, commnly used to maxmize penetration with SMAW open root welding , was also...melt into the sides of the bevel and penetrate into the root opening to form a keyhole . Once the keyhole was established, normal welding current was...hot start to melt through the taper, welding proceeded to the keyhole . Once in the keyhole , the electrode was positioned in front of the puddle but not

Welding And Cutting A Nickel Alloy By Laser

NASA Technical Reports Server (NTRS)

Banas, C. M.

1990-01-01

Technique effective and energy-efficient. Report describes evaluation of laser welding and cutting of Inconel(R) 718. Notes that electron-beam welding processes developed for In-718, but difficult to use on large or complex structures. Cutting of In-718 by laser fast and produces only narrow kerf. Cut edge requires dressing, to endure fatigue.

Computer Programs For Automated Welding System

NASA Technical Reports Server (NTRS)

Agapakis, John E.

1993-01-01

Computer programs developed for use in controlling automated welding system described in MFS-28578. Together with control computer, computer input and output devices and control sensors and actuators, provide flexible capability for planning and implementation of schemes for automated welding of specific workpieces. Developed according to macro- and task-level programming schemes, which increases productivity and consistency by reducing amount of "teaching" of system by technician. System provides for three-dimensional mathematical modeling of workpieces, work cells, robots, and positioners.

Gravimetric and analytical evaluation of welding fume in an automobile part manufacturing factory.

PubMed

Mansouri, N; Atbi, F; Moharamnezhad, N; Rahbaran, D A; Alahiari, M

2008-12-28

Welding is one of the most exercised industrial processes which welders are exposed to chemical and physical Hazardous agents. This study was conducted to evaluate occupational and environmental exposures to aerosols generated by welding processes in a factory. A total of 28 samples of aerosols were collected at 4 different locations including indoor, outdoor, source of welding and the stacks using a high volume pump with a volumetric flow rate of 112 lit/min calibrated with a dry gas meter. The samples were collected on round 110 mm fiber glass filters, measured gravimetrically, extracted using nitric acid and analyzed with atomic absorption spectroscopy method for heavy metals including Fe, Mn, Ni, Cr3+, Cr+6, Co, and Zn. Gravimetric measuring has shown the mean values of indoor air: 1.33 mg/m3, breathing zone of the welders using coated electrodes and CO2: 7.25 mg/m3 and 6.45 mg/m3 respectively and in ventilation exhausts: 95.07 mg/m3. The mean values of Fe, Mn, and Ni were 0.8, 0.041, and 0.00 mg/m3 in indoor air, 2.7, 0.18, and 0.15 mg/m3 in breathing zone of welders used coated electrodes, and 1.75, 0.08, and 0.22 mg/m3 in breathing zone of welders used CO2 welding respectively. The concentrations of Cr3+, Cr+6, Co, and Zn were too low to be detected. The welders were exposed to high concentration of metallic fumes, which raise the risk of pulmonary dysfunction and other health disorders. Using suitable respiratory masks and Appling the effective local ventilation system may improve the working condition.

Shielded Metal Arc Welding. Welding Module 4. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching an eight-unit module in shielded metal arc welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: safety; theory, power sources, and…

Gas Tungsten Arc Welding. Welding Module 6. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching a three-unit module in gas tungsten arc welding. The module has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The basic principles involved in gas tungsten arc welding, supplies, and applications are covered. The materials included…

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

Federal Register 2010, 2011, 2012, 2013, 2014

2012-09-18

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

Analysis of weld geometry and liquid flow in laser transmission welding between polyethylene terephthalate (PET) and Ti6Al4V based on numerical simulation

NASA Astrophysics Data System (ADS)

Ai, Yuewei; Zheng, Kang; Shin, Yung C.; Wu, Benxin

2018-07-01

The laser transmission welding of polyethylene terephthalate (PET) and titanium alloy Ti6Al4V involving the evaluating of the resultant geometry and quality of welds is investigated using a fiber laser in this paper. A 3D transient numerical model considering the melting and fluid flow is developed to predict the weld geometry and porosity formation. The temperature field, molten pool and liquid flow are simulated with varying laser power and welding speed based on the model. It is observed that the weld geometry predictions from the numerical simulation are in good agreement with the experimental data. The results show that the porosity consistently appears in the high temperature region due to the decomposition of PET. In addition, it has also been found that the molten pool with a vortex flow pattern is formed only in the PET layer and the welding processing parameters have significant effects on the fluid flow, which eventually affects the heat transfer, molten pool geometry and weld formation. Consequently, it is shown adopting appropriate welding processing parameters based on the proposed model is essential for the sound weld without defects.

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

NASA Astrophysics Data System (ADS)

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

2016-12-01

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

External Tank - The Structure Backbone

NASA Technical Reports Server (NTRS)

Welzyn, Kenneth; Pilet, Jeffrey C.; Diecidue-Conners, Dawn; Worden, Michelle; Guillot, Michelle

2011-01-01

The External Tank forms the structural backbone of the Space Shuttle in the launch configuration. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. Choice of lightweight materials both for structure and thermal conditioning was necessary. The tank is large, and unique manufacturing facilities, tooling, handling, and transportation operations were required. Weld processes and tooling evolved with the design as it matured through several block changes, to reduce weight. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the 40 year program. The final configuration and tank weight enabled international space station assembly in a high inclination orbit allowing international cooperation with the Russian Federal Space Agency. Numerous process controls were implemented to assure product quality, and innovative proof testing was accomplished prior to delivery. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. Processing improvements included development and use of low spray guns for foam application, additional human factors considerations for production, use of high fidelity mockups during hardware processing with video review, improved tank access, extensive use of non destructive evaluation, and producibility enhancements. Design improvements included redesigned bipod fittings, a bellows heater, a feedline camera active during ascent flight, removal of the protuberance airload ramps, redesigned ice frost ramps, and titanium brackets replaced aluminum brackets on the liquid oxygen feedline. Post flight assessment improved due to significant addition of imagery assets, greatly improving situational awareness. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when Katrina damaged the manufacturing facility. Numerous lessons from these efforts are documented within the paper.

46 CFR 56.30-5 - Welded joints.

Code of Federal Regulations, 2010 CFR

2010-10-01

... systems and should be checked when designing for these systems. (c) Socket welds (Modifies 127.3.3A.). (1) Each socket weld must conform to ASME B16.11 (incorporated by reference; see 46 CFR 56.01-2), to... approximately one-sixteenth inch between the end of the pipe and the bottom of the socket must be provided...

46 CFR 56.30-5 - Welded joints.

Code of Federal Regulations, 2012 CFR

2012-10-01

... systems and should be checked when designing for these systems. (c) Socket welds (Modifies 127.3.3A.). (1) Each socket weld must conform to ASME B16.11 (incorporated by reference; see 46 CFR 56.01-2), to... approximately one-sixteenth inch between the end of the pipe and the bottom of the socket must be provided...

46 CFR 56.30-5 - Welded joints.

Code of Federal Regulations, 2011 CFR

2011-10-01

... systems and should be checked when designing for these systems. (c) Socket welds (Modifies 127.3.3A.). (1) Each socket weld must conform to ASME B16.11 (incorporated by reference; see 46 CFR 56.01-2), to... approximately one-sixteenth inch between the end of the pipe and the bottom of the socket must be provided...

46 CFR 56.30-5 - Welded joints.

Code of Federal Regulations, 2013 CFR

2013-10-01

... systems and should be checked when designing for these systems. (c) Socket welds (Modifies 127.3.3A.). (1) Each socket weld must conform to ASME B16.11 (incorporated by reference; see 46 CFR 56.01-2), to... approximately one-sixteenth inch between the end of the pipe and the bottom of the socket must be provided...

46 CFR 56.30-5 - Welded joints.

Code of Federal Regulations, 2014 CFR

2014-10-01

... systems and should be checked when designing for these systems. (c) Socket welds (Modifies 127.3.3A.). (1) Each socket weld must conform to ASME B16.11 (incorporated by reference; see 46 CFR 56.01-2), to... approximately one-sixteenth inch between the end of the pipe and the bottom of the socket must be provided...

Programmable Automated Welding System (PAWS): Control of welding through software and hardware

NASA Technical Reports Server (NTRS)

Kline, Martin D.; Doyle, Thomas E.

1994-01-01

The ATD phase of the PAWS program ended in November 1992 and the follow-on ManTech program was started in September 1993. The system will be industrially hardened during the first year of this program. Follow-on years will focus upon the transition into specific end-user sites. These implementations will also expand the system into other welding processes (e.g. FCAW, GTAW, PAW). In addition, the architecture is being developed for application to other non-welding robotic processes (e.g. inspection, surface finishing). Future development is anticipated to encompass hardening for extreme environments, expanded exception handling techniques, and application to a range of manipulators.

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

NASA Astrophysics Data System (ADS)

Lakshminarayanan, A. K.; Balasubramanian, V.

2012-04-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Advanced Metalworking Solutions for Naval Systems that go in Harm’s Way

DTIC Science & Technology

2009-01-01

friction stir welding (FSW) and advanced machining and casting techniques to produce a prototype Automated weld seam facing on DDG 1000 ships will...transportable friction stir welding (FSW) machine. FSW is a solid state joining technology that offers benefits over traditional welding for several...addition, by locating FSW operation at the construction yard, the aluminum panels that will be friction stir - welded are built to the size needed instead

Effect of plasma welding parameters on the flexural strength of Ti-6Al-4V alloy.

PubMed

Lyra e Silva, João Paulo; Fernandes Neto, Alfredo Júlio; Raposo, Luís Henrique Araújo; Novais, Veridiana Resende; de Araujo, Cleudmar Amaral; Cavalcante, Luisa de Andrade Lima; Simamoto Júnior, Paulo Cezar

2012-01-01

The aim of this study was to assess the effect of different plasma arc welding parameters on the flexural strength of titanium alloy beams (Ti-6Al-4V). Forty Ti-6Al-4V and 10 NiCr alloy beam specimens (40 mm long and 3.18 mm diameter) were prepared and divided into 5 groups (n=10). The titanium alloy beams for the control group were not sectioned or subjected to welding. Groups PL10, PL12, and PL14 contained titanium beams sectioned and welded at current 3 A for 10, 12 or 14 ms, respectively. Group NCB consisted of NiCr alloy beams welded using conventional torch brazing. After, the beams were subjected to a three-point bending test and the values obtained were analyzed to assess the flexural strength (MPa). Statistical analysis was carried out by one-way ANOVA and Tukey's HSD test at 0.05 confidence level. Significant difference was verified among the evaluated groups (p<0.001), with higher flexural strength for the control group (p<0.05). No significant differences was observed among the plasma welded groups (p>0.05). The NCB group showed the lowest flexural strength, although it was statistically similar to the PL 14 group (p>0.05). The weld depth penetration was not significantly different among the plasma welded groups (p=0.05). Three representative specimens were randomly selected to be evaluated under scanning electron microcopy. The composition of the welded regions was analyzed by energy dispersive X-ray spectroscopy. This study provides an initial set of parameters supporting the use of plasma welding during fabrication of titanium alloy dental frameworks.

Evaluation of pitting corrosion resistance of high-alloyed stainless steels welds for FGD plants in Korea

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

Baek, K.K.; Sung, H.J.; Im, C.S.

1998-12-31

For successful application of high-alloyed stainless steels for Flue Gas Desulfurization (FGD) plants, pitting corrosion resistance of arc welds of N-added 6%Mo austenitic stainless steels (UNS N 08367) and super duplex stainless steels (UNS S 32550) made with various filler metals were evaluated using the Green Death solution. For Gas Tungsten Arc (GTA) and Gas Metal Arc (GMA) welds of N 08367, Critical Pitting Temperature (CPT) of base metal was 65--70 C, whereas weld made by ERNiCrMo-3 filler metal yielded CPT of 50 C. Welds made by ERNiCrMo-10 or ERNiCrMo-4 filler metals showed CPT of 60--65 C and 65--70C, respectively.more » For GTA and GMA welds of S 32550, CPT of welds made by ERNiCrMo-3 was 45--50 C, indicating that the filler metal can provide pitting corrosion resistance matching the S 32550 alloy. Thus, a proper pitting corrosion resistance of weldments of high-alloy stainless steels can be achieved by selecting filler metals having at least +10 higher Pitting Resistance Equivalent Number (PRE{sub N}) value than the base metal regardless of the type of arc welding process. The over-alloyed filler metals would compensate preferential segregation of Cr, MO along the dendrite boundary, which made the dendrite core more susceptible to pitting. Nitrogen addition to the GTA welds of N 08367 made with ERNiCrMo-3 failed to improve pitting corrosion resistance, which was attributed to the precipitation of nitrogen in the weld metal in the form of Nb-nitride.« less

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

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.

Laser weld jig

DOEpatents

Van Blarigan, Peter; Haupt, David L.

1982-01-01

A system is provided for welding a workpiece (10, FIG. 1) along a predetermined weld line (12) that may be of irregular shape, which includes the step of forming a lip (32) on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members (34, 36). Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space (17) at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig (24) forming the lip, and with the jig constructed to detachably hold parts (22, 20) to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

Automatic monitoring of the alignment and wear of vibration welding equipment

DOEpatents

Spicer, John Patrick; Cai, Wayne W.; Chakraborty, Debejyo; Mink, Keith

2017-05-23

A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host machine, a check station, and a welding robot. At least one displacement sensor is positioned with respect to one of the welding equipment and the check station. The robot moves the horn and anvil via an arm to the check station, when a threshold condition is met, i.e., a predetermined amount of time has elapsed or a predetermined number of welds have been completed. The robot moves the horn and anvil to the check station, activates the at least one displacement sensor, at the check station, and determines a status condition of the welding equipment by processing the received signals. The status condition may be one of the alignment of the vibration welding equipment and the wear or degradation of the vibration welding equipment.

High Power Laser Beam Welding of Thick-walled Ferromagnetic Steels with Electromagnetic Weld Pool Support

NASA Astrophysics Data System (ADS)

Fritzsche, André; Avilov, Vjaceslav; Gumenyuk, Andrey; Hilgenberg, Kai; Rethmeier, Michael

The development of modern high power laser systems allows single pass welding of thick-walled components with minimal distortion. Besides the high demands on the joint preparation, the hydrostatic pressure in the melt pool increases with higher plate thicknesses. Reaching or exceeding the Laplace pressure, drop-out or melt sagging are caused. A contactless electromagnetic weld support system was used for laser beam welding of thick ferromagnetic steel plates compensating these effects. An oscillating magnetic field induces eddy currents in the weld pool which generate Lorentz forces counteracting the gravity forces. Hysteresis effects of ferromagnetic steels are considered as well as the loss of magnetization in zones exceeding the Curie temperature. These phenomena reduce the effective Lorentz forces within the weld pool. The successful compensation of the hydrostatic pressure was demonstrated on up to 20 mm thick plates of duplex and mild steel by a variation of the electromagnetic power level and the oscillation frequency.

Friction Stir Welding of Dissimilar Al/Al and Al/Non-Al Alloys: A Review

NASA Astrophysics Data System (ADS)

Wang, Xiangbin; Pan, Yi; Lados, Diana A.

2018-05-01

Friction stir welding is a solid-state welding technique that has many advantages over traditional fusion welding, and has been widely adopted in the aerospace and automotive industries. This article reviews research developments in friction stir welding of dissimilar alloys systems, including combinations of aluminum alloys with Mg alloys, Cu, and steel. Microstructural evolution, hardness, tensile and fatigue properties, residual stresses, and corrosion behavior of dissimilar welds will be reported. The effects of processing parameters such as tool rotation and traverse speeds, tool position, material position, and tool geometry on the weld quality are also presented. Discussions on future research directions in friction stir welding will also be provided in the context of existing literature and future high-integrity applications.

Microscopic Evaluation of Friction Plug Welds- Correlation to a Processing Analysis

NASA Technical Reports Server (NTRS)

Rabenberg, Ellen M.; Chen, Poshou; Gorti, Sridhar

2017-01-01

Recently an analysis of dynamic forge load data from the friction plug weld (FPW) process and the corresponding tensile test results showed that good plug welds fit well within an analytically determined processing parameter box. There were, however, some outliers that compromised the predictions. Here the microstructure of the plug weld material is presented in view of the load analysis with the intent of further understanding the FPW process and how it is affected by the grain structure and subsequent mechanical properties.

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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

NASA Astrophysics Data System (ADS)

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

2016-02-01

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

Digital Radiography Qualification of Tube Welding

NASA Technical Reports Server (NTRS)

Carl, Chad

2012-01-01

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

Attachment of lead wires to thin film thermocouples mounted on high temperature materials using the parallel gap welding process

NASA Technical Reports Server (NTRS)

Holanda, Raymond; Kim, Walter S.; Pencil, Eric; Groth, Mary; Danzey, Gerald A.

1990-01-01

Parallel gap resistance welding was used to attach lead wires to sputtered thin film sensors. Ranges of optimum welding parameters to produce an acceptable weld were determined. The thin film sensors were Pt13Rh/Pt thermocouples; they were mounted on substrates of MCrAlY-coated superalloys, aluminum oxide, silicon carbide and silicon nitride. The entire sensor system is designed to be used on aircraft engine parts. These sensor systems, including the thin-film-to-lead-wire connectors, were tested to 1000 C.

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

NASA Astrophysics Data System (ADS)

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

2015-05-01

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

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

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

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

2015-05-22

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

Optical Arc-Length Sensor For TIG Welding

NASA Technical Reports Server (NTRS)

Smith, Matthew A.

1990-01-01

Proposed subsystem of tungsten/inert-gas (TIG) welding system measures length of welding arc optically. Viewed by video camera, in one of three alternative optical configurations. Length of arc measured instead of inferred from voltage.

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

NASA Astrophysics Data System (ADS)

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

2013-10-01

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

Physical and cognitive effects of virtual reality integrated training.

PubMed

Stone, Richard T; Watts, Kristopher P; Zhong, Peihan; Wei, Chen-Shuang

2011-10-01

The objective of this study was to evaluate the cognitive and physical impact of virtual reality (VR) integrated training versus traditional training methods in the domain of weld training. Weld training is very important in various industries and represents a complex skill set appropriate for advanced training intervention. As such, there has been a long search for the most successful and most cost-effective method for training new welders. Participants in this study were randomly assigned to one of two separate training courses taught by sanctioned American Welding Society certified welding instructors; the duration of each course was 2 weeks. After completing the training for a specific weld type, participants were given the opportunity to test for the corresponding certification. Participants were evaluated in terms of their cognitive and physical parameters, total training time exposure, and welding certification awards earned. Each of the four weld types taught in this study represented distinct levels of difficulty and required the development of specialized knowledge and skills. This study demonstrated that participants in the VR integrated training group (VR50) performed as well as, and in some cases, significantly outperformed, the traditional welding (TW) training group.The VR50 group was found to have a 41.6% increase in overall certifications earned compared with the TW group. VR technology is a valuable tool for the production of skilled welders in a shorter time and often with more highly developed skills than their traditionally trained counterparts. These findings strongly support the use ofVR integrated training in the welding industry.

Influence of tool geometry and processing parameters on welding defects and mechanical properties for friction stir welding of 6061 Aluminium alloy

NASA Astrophysics Data System (ADS)

Daneji, A.; Ali, M.; Pervaiz, S.

2018-04-01

Friction stir welding (FSW) is a form of solid state welding process for joining metals, alloys, and selective composites. Over the years, FSW development has provided an improved way of producing welding joints, and consequently got accepted in numerous industries such as aerospace, automotive, rail and marine etc. In FSW, the base metal properties control the material’s plastic flow under the influence of a rotating tool whereas, the process and tool parameters play a vital role in the quality of weld. In the current investigation, an array of square butt joints of 6061 Aluminum alloy was to be welded under varying FSW process and tool geometry related parameters, after which the resulting weld was evaluated for the corresponding mechanical properties and welding defects. The study incorporates FSW process and tool parameters such as welding speed, pin height and pin thread pitch as input parameters. However, the weld quality related defects and mechanical properties were treated as output parameters. The experimentation paves way to investigate the correlation between the inputs and the outputs. The correlation between inputs and outputs were used as tool to predict the optimized FSW process and tool parameters for a desired weld output of the base metals under investigation. The study also provides reflection on the effect of said parameters on a welding defect such as wormhole.

UAH mathematical model of the variable polarity plasma ARC welding system calculation

NASA Technical Reports Server (NTRS)

Hung, R. J.

1994-01-01

Significant advantages of Variable Polarity Plasma Arc (VPPA) welding process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. A mathematical model is presented to analyze the VPPA welding process. Results of the mathematical model were compared with the experimental observation accomplished by the GDI team.

Gas Metal Arc Welding. Welding Module 5. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching an eight-unit module in gas metal arc welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: safety and testing, gas metal arc…

Correlation of Flux Composition and Inclusion Characteristics With Submerged Arc Weld Metal Properties in HY-100 Steel

DTIC Science & Technology

1993-09-01

chemistries are complex, the welding engineer needs to obtain the correct CCT diagram for the alloy system in question. Once the CCT diagram is estimated...the CCT diagram must be pertinent to the particular chemistry of the weld metal, especially when the weld metal composition varies with flux

Automatic monitoring of vibration welding equipment

DOEpatents

Spicer, John Patrick; Chakraborty, Debejyo; Wincek, Michael Anthony; Wang, Hui; Abell, Jeffrey A; Bracey, Jennifer; Cai, Wayne W

2014-10-14

A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.

Fracture Mechanics Evaluation of B-1 Materials. Volume I. Text

DTIC Science & Technology

1976-10-01

4V Microstructures 2-37 P.4-1 TIG Welding Setup 2-60 2.4-2 Macrographs Showing Transverse Cross- 2-61 Sections of Typical Weld Joints 2.4-3 Diffusion...concavity. k. PAW welding parameters were: Keyhole Mode (First Pass) 1fWelding-Amperage - 185 Pilot Arc Amperage - P5 1/5" Diameter Tungsten -P% Thoria...of tooling employed. 2. •𔃼󈧿 r a • 4 .fA A A ~ . - 4N. I 141Eb,~..0 1171 :41ýI t4, 1. r "I j, O~ vN;I ___4 A Ad2 Figuire 2.4-1i TIG Welding , Setup

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.

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.

Thermal welding vs. cold knife tonsillectomy: a comparison of voice and speech.

PubMed

Celebi, Saban; Yelken, Kursat; Celik, Oner; Taskin, Umit; Topak, Murat

2011-01-01

To compare acoustic, aerodynamic and perceptual voice and speech parameters in thermal welding system tonsillectomy and cold knife tonsillectomy patients in order to determine the impact of operation technique on voice and speech. Thirty tonsillectomy patients (22 children, 8 adults) participated in this study. The preferred technique was cold knife tonsillectomy in 15 patients and thermal welding system tonsillectomy in the remaining 15 patients. One week before and 1 month after surgery the following parameters were estimated: average of fundamental frequency, Jitter, Shimmer, harmonic to noise ratio, formant frequency analyses of sustained vowels. Perceptual speech analysis and aerodynamic measurements (maximum phonation time and s/z ratio) were also conducted. There was no significant difference in any of the parameters between cold knife tonsillectomy and thermal welding system tonsillectomy groups (p>0.05). When the groups were contrasted among themselves with regards to preoperative and postoperative rates, fundamental frequency was found to be significantly decreased after tonsillectomy in both of the groups (p<0.001). First formant for the vowel /a/ in the cold knife tonsillectomy group and for the vowel /i/ in the thermal welding system tonsillectomy group, second formant for the vowel /u/ in the thermal welding system tonsillectomy group and third formant for the vowel /u/ in the cold knife tonsillectomy group were found to be significantly decreased (p<0.05). The surgical technique, whether it is cold knife or thermal welding system, does not appear to affect voice and speech in tonsillectomy patients. Copyright © 2010 Elsevier Ireland Ltd. All rights reserved.

Double-Sided Single-Pass Submerged Arc Welding for 2205 Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Luo, Jian; Yuan, Yi; Wang, Xiaoming; Yao, Zongxiang

2013-09-01

The duplex stainless steel (DSS), which combines the characteristics of ferritic steel and austenitic steel, is used widely. The submerged arc welding (SAW) method is usually applied to join thick plates of DSS. However, an effective welding procedure is needed in order to obtain ideal DSS welds with an appropriate proportion of ferrite (δ) and austenite (γ) in the weld zone, particularly in the melted zone and heat-affected zone. This study evaluated the effectiveness of a high efficiency double-sided single-pass (DSSP) SAW joining method for thick DSS plates. The effectiveness of the converse welding procedure, characterizations of weld zone, and mechanical properties of welded joint are analyzed. The results show an increasing appearance and continuous distribution feature of the σ phase in the fusion zone of the leading welded seam. The converse welding procedure promotes the σ phase to precipitate in the fusion zone of leading welded side. The microhardness appears to significantly increase in the center of leading welded side. Ductile fracture mode is observed in the weld zone. A mixture fracture feature appears with a shear lip and tears in the fusion zone near the fusion line. The ductility, plasticity, and microhardness of the joints have a significant relationship with σ phase and heat treatment effect influenced by the converse welding step. An available heat input controlling technology of the DSSP formation method is discussed for SAW of thick DSS plates.

Fusion welding of a modern borated stainless steel

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

Robino, C.V.; Cieslak, M.J.

1997-01-01

Experiments designed to assess the fabrication and service weldability of 304B4A borated stainless steel were conducted. Welding procedures and parameters for manual gas tungsten arc (GTA) welding, autogenous electron beam (EB) welding and filler-added EB welding were developed and found to be similar to those for austenitic stainless steels. Following the procedure development, four test welds were produced and evaluated by microstructural analysis and Charpy impact testing. Further samples were used for determination of the postweld heat treatment (PWHT) response of the welds. The fusion zone structure of welds in this alloy consists of primary austenite dendrites with an interdendriticmore » eutectic-like austenite/boride constituent. Welds also show an appreciable partially molten zone that consists of the austenite/boride eutectic surrounding unmelted austenite islands. The microstructure of the EB welds was substantially finer than that of the GTA welds, and boride coarsening was not observed in the solid state heat-affected zone (HAZ) of either weld type. The impact toughness of as-welded samples was found to be relatively poor, averaging less than 10 J for both GTA and EB welds. For fusion zone notched GTA and EB samples and centerline notched EB samples, fracture generally occurred along the boundary between the partially molten and solid-state regions of the HAZ. The results of the PWHT study were very encouraging, with typical values of the impact energy for HAZ notched samples approaching 40 J, or twice the minimum code-acceptable value.« less

Improved microstructure and mechanical properties in gas tungsten arc welded aluminum joints by using graphene nanosheets/aluminum composite filler wires.

PubMed

Fattahi, M; Gholami, A R; Eynalvandpour, A; Ahmadi, E; Fattahi, Y; Akhavan, S

2014-09-01

In the present study, different amounts of graphene nanosheets (GNSs) were added to the 4043 aluminum alloy powders by using the mechanical alloying method to produce the composite filler wires. With each of the produced composite filler wires, one all-weld metal coupon was welded using the gas tungsten arc (GTA) welding process. The microstructure, mechanical properties and fracture surface morphology of the weld metals have been evaluated and the results are compared. As the amount of GNSs in the composition of filler wire is increased, the microstructure of weld metal was changed from the dendritic structure to fine equiaxed grains. Furthermore, the tensile strength and microhardness of weld metal was improved, and is attributed to the augmented nucleation and retarded growth. From the results, it was seen that the GNSs/Al composite filler wire can be used to improve the microstructure and mechanical properties of GTA weld metals of aluminum and its alloys. Copyright © 2014 Elsevier Ltd. All rights reserved.

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.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Effects of welding heat and travel speed on the impact property and microstructure of FC welds

NASA Astrophysics Data System (ADS)

Lee, Jeong Soo; Jeong, Sang Hoon; Lim, Dong Yong; Yun, Jin Oh; Kim, Myung Hyun

2010-10-01

This paper is concerned with the effects of welding heat (current x voltage = W) and travel speed (v) on the impact property and microstructure of FC (flux cored) welds. Two sets of plate were welded under different welding conditions such as higher W, v and lower W, v, while maintaining identical heat input. We evaluated the effects of each factor by Charpy impact test and observation of the microstructure, and then compared these data with the results of the numerical temperature analysis. The size of the re-heated zone was increased as the v value decreased, and the results of numerical analysis also revealed the same tendency. Cooling rate of welds (both of as-welded and re-heated zones) decreased as the W value increased. Despite identical heat input conditions, the use of lower W and v made the microstructure finer and increased the volume fraction of AF, thereby leading to a substantial improvement of the impact property.

Replacement of seam welded hot reheat pipe using narrow groove GTA machine welding

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

Richardson, R.R.; Yanes, J.; Bryant, R.

1995-12-31

Southern California Edison, recognizing a potential safety concern, scrutinized its existing seam welded hot reheat pipe manufactured by the same supplier as that which failed. Alternatives were narrowed to two in dealing with the installed seam welded pipe. The overriding consideration, however, was one of safety. With this in mind, the utility company evaluated replacement of the seam welded hot reheat pipe with seamless pipe or increasing the frequency of its inspection program. Although increased inspection was much costly, pipe replacement was chosen due to potential safety concerns with seam welded pipe even with more frequent inspection. The utility companymore » then proceeded to determine the most effective method to complete this work. Analysis showed machine-made (automatic) gas tungsten arc welds (GTAW) as the method of choice due to cleanliness and superior mechanical properties. In conjunction with this method, the narrow groove (3{degree} bevel) weld joint as opposed to the traditional groove (37 1/2{degree} bevel) was shown to provide significant technical advantages.« less

Effects of heat input on the pitting resistance of Inconel 625 welds by overlay welding

NASA Astrophysics Data System (ADS)

Kim, Jun Seok; Park, Young IL; Lee, Hae Woo

2015-03-01

The objective of this study was to establish the relationship between the dilution ratio of the weld zone and pitting resistance depending on the heat input to welding of the Inconel alloy. Each specimen was produced by electroslag welding using Inconel 625 as the filler metal. In the weld zone of each specimen, dendrite grains were observed near the fusion line and equiaxed grains were observed on the surface. It was also observed that a melted zone with a high Fe content was formed around the fusion line, which became wider as the welding heat input increased. In order to evaluate the pitting resistance, potentiodynamic polarization tests and CPT tests were conducted. The results of these tests confirmed that there is no difference between the pitting resistances of each specimen, as the structures of the surfaces were identical despite the effect of the differences in the welding heat input for each specimen and the minor dilution effect on the surface.

Comparisons between TiO2- and SiO2-flux assisted TIG welding processes.

PubMed

Tseng, Kuang-Hung; Chen, Kuan-Lung

2012-08-01

This study investigates the effects of flux compounds on the weld shape, ferrite content, and hardness profile in the tungsten inert gas (TIG) welding of 6 mm-thick austenitic 316 L stainless steel plates, using TiO2 and SiO2 powders as the activated fluxes. The metallurgical characterizations of weld metal produced with the oxide powders were evaluated using ferritoscope, optical microscopy, and Vickers microhardness test. Under the same welding parameters, the penetration capability of TIG welding with TiO2 and SiO2 fluxes was approximately 240% and 292%, respectively. A plasma column made with SiO2 flux exhibited greater constriction than that made with TiO2 flux. In addition, an anode root made with SiO2 flux exhibited more condensation than that made with TiO2 flux. Results indicate that energy density of SiO2-flux assisted TIG welding is higher than that of TiO2-flux assisted TIG welding.

Onorbit electron beam welding experiment definition

NASA Technical Reports Server (NTRS)

1989-01-01

The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.

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.

Detection and assessment of flaws in friction stir welded metallic plates

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

Experimental investigation and optimization of welding process parameters for various steel grades using NN tool and Taguchi method

NASA Astrophysics Data System (ADS)

Soni, Sourabh Kumar; Thomas, Benedict

2018-04-01

The term "weldability" has been used to describe a wide variety of characteristics when a material is subjected to welding. In our analysis we perform experimental investigation to estimate the tensile strength of welded joint strength and then optimization of welding process parameters by using taguchi method and Artificial Neural Network (ANN) tool in MINITAB and MATLAB software respectively. The study reveals the influence on weldability of steel by varying composition of steel by mechanical characterization. At first we prepare the samples of different grades of steel (EN8, EN 19, EN 24). The samples were welded together by metal inert gas welding process and then tensile testing on Universal testing machine (UTM) was conducted for the same to evaluate the tensile strength of the welded steel specimens. Further comparative study was performed to find the effects of welding parameter on quality of weld strength by employing Taguchi method and Neural Network tool. Finally we concluded that taguchi method and Neural Network Tool is much efficient technique for optimization.

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'.

FORMATION MECHANISM FOR THE NANOSCALE AMORPHOUS INTERFACE IN PULSE-WELDED AL/FE BIMETALLIC SYSTEM

DOE PAGES

Li, Jingjing; Yu, Qian; Zhang, Zijiao; ...

2016-05-20

Pulse or impact welding traditionally has been referred to as “solid-state” welding. By integrating advanced interface characterizations and diffusion calculations, we report that the nanoscale amorphous interface in the pulse-welded Al/Fe bimetallic system is formed by rapid heating and melting of a thin Al layer at the interface, diffusion of iron atoms in the liquid aluminum, and subsequent rapid quenching with diffused iron atoms in solution. This finding challenges the commonly held belief regarding the solid-state nature of the impact-based welding process for dissimilar metals. Elongated ultra-fine grains with high dislocation density and ultra-fine equiaxed grains also are observed inmore » the weld interface vicinity on the steel and aluminum sides, respectively, which further confirms that melting and the resulted recrystallization occurred on the aluminum side of the interface.« less

FORMATION MECHANISM FOR THE NANOSCALE AMORPHOUS INTERFACE IN PULSE-WELDED AL/FE BIMETALLIC SYSTEM

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

Li, Jingjing; Yu, Qian; Zhang, Zijiao

Pulse or impact welding traditionally has been referred to as “solid-state” welding. By integrating advanced interface characterizations and diffusion calculations, we report that the nanoscale amorphous interface in the pulse-welded Al/Fe bimetallic system is formed by rapid heating and melting of a thin Al layer at the interface, diffusion of iron atoms in the liquid aluminum, and subsequent rapid quenching with diffused iron atoms in solution. This finding challenges the commonly held belief regarding the solid-state nature of the impact-based welding process for dissimilar metals. Elongated ultra-fine grains with high dislocation density and ultra-fine equiaxed grains also are observed inmore » the weld interface vicinity on the steel and aluminum sides, respectively, which further confirms that melting and the resulted recrystallization occurred on the aluminum side of the interface.« less

Formation mechanism for the nanoscale amorphous interface in pulse-welded Al/Fe bimetallic systems

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

Li, Jingjing; Yu, Qian; Zhang, Zijiao

Pulse or impact welding traditionally has been referred to as “solid-state” welding. By integrating advanced interface characterizations and diffusion calculations, we report that the nanoscale amorphous interface in the pulse-welded Al/Fe bimetallic system is formed by rapid heating and melting of a thin Al layer at the interface, diffusion of iron atoms in the liquid aluminum, and subsequent rapid quenching with diffused iron atoms in solution. This finding challenges the commonly held belief regarding the solid-state nature of the impact-based welding process for dissimilar metals. Elongated ultra-fine grains with high dislocation density and ultra-fine equiaxed grains also are observed inmore » the weld interface vicinity on the steel and aluminum sides, respectively, which further confirms that melting and the subsequent recrystallization occurred on the aluminum side of the interface.« less

Immunotoxicology of arc welding fume: Worker and experimental animal studies

PubMed Central

Zeidler-Erdely, Patti C.; Erdely, Aaron; Antonini, James M.

2015-01-01

Arc welding processes generate complex aerosols composed of potentially hazardous metal fumes and gases. Millions of workers worldwide are exposed to welding aerosols daily. A health effect of welding that is of concern to the occupational health community is the development of immune system dysfunction. Increased severity, frequency, and duration of upper and lower respiratory tract infections have been reported among welders. Specifically, multiple studies have observed an excess mortality from pneumonia in welders and workers exposed to metal fumes. Although several welder cohort and experimental animal studies investigating the adverse effects of welding fume exposure on immune function have been performed, the potential mechanisms responsible for these effects are limited. The objective of this report was to review both human and animal studies that have examined the effect of welding fume pulmonary exposure on local and systemic immune responses. PMID:22734811

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

NASA Astrophysics Data System (ADS)

Daavari, Morteza; Vanini, Seyed Ali Sadough

2015-09-01

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

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

NASA Astrophysics Data System (ADS)

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

2014-12-01

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

Effect of Thermal Aging and Test Temperatures on Fracture Toughness of SS 316(N) Welds

NASA Astrophysics Data System (ADS)

Dutt, B. Shashank; Babu, M. Nani; Shanthi, G.; Moitra, A.; Sasikala, G.

2018-03-01

The effect of thermal aging and test temperatures on fracture toughness (J 0.2) of SS 316(N) weld material has been studied based on J-R curve evaluations. The aging of the welds was carried out at temperatures 370, 475 and 550 °C and for durations varying from 1000 to 20,000 h. The fracture toughness (J-R curve) tests were carried out at 380 and 550 °C for specimens after all aging conditions, including as-weld condition. The initiation fracture toughness (J 0.2) of the SS 316(N) weld material has shown degradation after 20,000-h aging durations and is reflected in all the test temperatures and aging temperatures. The fracture toughness after different aging conditions and test temperatures, including as-weld condition, was higher than the minimum specified value for this class of welds.

Solid state welding processes for an oxide dispersion strengthened nickel-chromium-aluminum alloy

NASA Technical Reports Server (NTRS)

Moore, T. J.

1975-01-01

Solid-state welding processes were evaluated for joining TD-NiCrAl (Ni-16Cr-4Al-2ThO2) alloy sheet. Both hot-press and resistance spot welding techniques were successfully applied in terms of achieving grain growth across the bond line. Less success was achieved with a resistance seam welding process. In stress-rupture shear and tensile shear tests of lap joints at 1100 C, most failures occurred in the parent material, which indicates that the weld quality was good and that the welds were not a plane of weakness. The overall weld quality was not as good as previously attained with TD-NiCr, probably because the presence of alumina at the faying surfaces and the developmental TD-NiCrAl sheet, which was not of the quality of the TD-NiCr sheet in terms of surface flatness and dimensional control.

Thermal welding of biological tissues derived from porcine aorta for manufacturing bioprosthetic cardiac valves.

PubMed

Figueiredo, Rubem L P; Dantas, Maria Sylvia Silva; Oréfice, Rodrigo L

2011-08-01

Sutures in cardiac valve bioprostheses have several disadvantages as they have to be manually processed and the suturing region is always a mechanically weak spot. Thermal welding of biological tissues has been evaluated as a means of replacing sutures by the direct application of heat to tissues. The mechanical strength of the welds increased up to 50°C and with lower degrees of humidity and longer times of welding. Chemical fixation was essential for the stability of the weld during re-hydration. The average mechanical strength of the welds (0.87 MPa) was lower than the strength of sutures (1.36 MPa) but some results showed strengths that were similar to sutures. Raman and electron micrographs showed that weld formation is primarily associated with chemical bonds between collagen fibers rather than chain flow and interpenetration.

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

NASA Technical Reports Server (NTRS)

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

2009-01-01

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

Evaluation of Forces on the Welding Probe of the Automated Retractable Pin-Tool (RPT)

NASA Technical Reports Server (NTRS)

Ding, R. J.

2001-01-01

The NASA invention entitled 'The Hydraulic Controlled Auto-Adjustable Pin Tool for Friction Stir Welding' (US Patent 5,893,507), better known as the Retractable Pin-Tool (RPT), has been instrumented with a load-detecting device allowing the forces placed on the welding probe to be measured. As the welding probe is plunged into the material, the forces placed on the probe can now be characterized. Of particular interest are those forces experienced as the welding probe comes within close proximity to the back-up anvil. For a given material, it is believed that unique forces are generated relative to the distance between the welding probe and the anvil. The forces have been measured and characterized for several materials, and correlations have been made between these forces and the pin's position relative to the backside of the weld material.

Effect of laser wavelength and protein solder concentration on acute tissue repair using laser welding: initial results in a canine ureter model.

PubMed

Wright, E J; Poppas, D P

1997-01-01

Successful tissue approximation can be performed using low power laser energy combined with human albumin solder. In vitro studies were undertaken to investigate the acute repair strengths achieved using different laser wavelengths. Furthermore, we evaluated the change in repair strength with that resulted from changes in protein solder concentration. Intraluminal bursting pressure following ureterotomy repair was measured for the following laser wavelengths: 532, 808, 1,320, 2,100, and 10,600 nm. The tissue absorption characteristics of the 808-nm diode and the KTP-532-nm lasers required the addition of the exogenous chromophores indocyanine green and fluorescein, respectively. A 40% human albumin solder was incorporated in the repair of a 1.0-cm longitudinal defect in the canine ureter. Following determination of an optimal welding wavelength, human albumin solder of varying concentrations (25%, 38%, 45%, and 50%) were prepared and tested. The 1,320-nm YAG laser achieved the highest acute bursting pressure and was the most effective in this model. Of the concentrations of albumin tested, 50% human albumin yielded the greatest bursting pressures. We conclude that of the laser wavelengths evaluated, the 1,320-nm YAG achieves the strongest tissue weld in the acute ex vivo dog ureter model. In addition, when this laser system is used, the acute strength of a photothermal weld appears to be directly proportional to the concentration of human albumin solder in the range of 25 to 50%.

Weld Residual Stress and Distortion Analysis of the ARES I-X Upper Stage Simulator (USS)

NASA Technical Reports Server (NTRS)

Raju, Ivatury; Dawicke, David; Cheston, Derrick; Phillips, Dawn

2008-01-01

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. While the main focus of this paper is a discussion of the weld modeling procedures and results for the USS, a short summary of the CIFS assessment is provided.

Biological effects of emissions from resistance spot welding of zinc-coated material after controlled exposure of healthy human subjects.

PubMed

Gube, Monika; Kraus, Thomas; Lenz, Klaus; Reisgen, Uwe; Brand, Peter

2014-06-01

Do emissions from a resistance spot welding process of zinc-coated materials induce systemic inflammation in healthy subjects after exposure for 6 hours? Twelve healthy male subjects were exposed once for 6 hours either to filtered ambient air or to welding fume from resistance spot welding of zinc-coated material (mass concentration approximately 100 μg m). Biological effects were measured before, after, and 24 hours after exposure. At the concentrations used in this study, however, the suspected properties of ultrafine particles did not lead to systemic inflammation as reflected by high-sensitivity C-reactive protein or other endpoint parameters under consideration. Ultrafine particles from a resistance spot welding process of zinc-covered materials with a number concentration of about 10 cm and a mass concentration of about 100 μg m did not induce systemic inflammation.

Efficacy of dry-ice blasting in preventive maintenance of auto robotic assemblies

NASA Astrophysics Data System (ADS)

Baluch, Nazim; Mohtar, Shahimi; Abdullah, Che Sobry

2016-08-01

Welding robots are extensively applied in the automotive assemblies and `Spot Welding' is the most common welding application found in the auto stamping assembly manufacturing. Every manufacturing process is subject to variations - with resistance welding, these include; part fit up, part thickness variations, misaligned electrodes, variations in coating materials or thickness, sealers, weld force variations, shunting, machine tooling degradation; and slag and spatter damage. All welding gun tips undergo wear; an elemental part of the process. Though adaptive resistance welding control automatically compensates to keep production and quality up to the levels needed as gun tips undergo wear so that the welds remain reliable; the system cannot compensate for deterioration caused by the slag and spatter on the part holding fixtures, sensors, and gun tips. To cleanse welding robots of slag and spatter, dry-ice blasting has proven to be an effective remedy. This paper describes Spot welding process, analyses the slag and spatter formation during robotic welding of stamping assemblies, and concludes that the dry ice blasting process's utility in cleansing of welding robots in auto stamping plant operations is paramount and exigent.

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.

Metallographic Preparation of Space Shuttle Reaction Control System Thruster Electron Beam Welds for Electron Backscatter Diffraction

NASA Technical Reports Server (NTRS)

Martinez, James

2011-01-01

A Space Shuttle Reaction Control System (RCS) thruster failed during a firing test at the NASA White Sands Test Facility (WSTF), Las Cruces, New Mexico. The firing test was being conducted to investigate a previous electrical malfunction. A number of cracks were found associated with the fuel closure plate/injector assembly (Fig 1). The firing test failure generated a flight constraint to the launch of STS-133. A team comprised of several NASA centers and other research institutes was assembled to investigate and determine the root cause of the failure. The JSC Materials Evaluation Laboratory was asked to compare and characterize the outboard circumferential electron beam (EB) weld between the fuel closure plate (Titanium 6Al-4V) and the injector (Niobium C-103 alloy) of four different RCS thrusters, including the failed RCS thruster. Several metallographic challenges in grinding/polishing, and particularly in etching were encountered because of the differences in hardness, ductility, and chemical resistance between the two alloys and the bimetallic weld. Segments from each thruster were sectioned from the outboard weld. The segments were hot-compression mounted using a conductive, carbon-filled epoxy. A grinding/polishing procedure for titanium alloys was used [1]. This procedure worked well on the titanium; but a thin, disturbed layer was visible on the niobium surface by means of polarized light. Once polished, each sample was micrographed using bright field, differential interference contrast optical microscopy, and scanning electron microscopy (SEM) using a backscatter electron (BSE) detector. No typical weld anomalies were observed in any of the cross sections. However, areas of large atomic contrast were clearly visible in the weld nugget, particularly along fusion line interfaces between the titanium and the niobium. This prompted the need to better understand the chemistry and microstructure of the weld (Fig 2). Energy Dispersive X-Ray Spectroscopy (EDS) was used to confirm the chemical composition of the variations in contrast in these areas. Niobium alloys generally require exposure to more aggressive chemical reagents than titanium alloys for etching because of niobium s chemical resistance; therefore, the titanium portion of the sample was etched first. A five second immersion in Kroll s reagent revealed a general microstructure on the titanium portion of the sample; however, the titanium heat affected zone closest to the weld, was over-etched due to higher concentrations of refined grains and an increase in eta-phase. The Kroll s etchant also revealed some microstructure in the weld nugget itself; the niobium portion of the sample remained unetched.

Multi objective Taguchi optimization approach for resistance spot welding of cold rolled TWIP steel sheets

NASA Astrophysics Data System (ADS)

Tutar, Mumin; Aydin, Hakan; Bayram, Ali

2017-08-01

Formability and energy absorption capability of a steel sheet are highly desirable properties in manufacturing components for automotive applications. TWinning Induced Plastisity (TWIP) steels are, new generation high Mn alloyed steels, attractive for the automotive industry due to its outstanding elongation (%40-45) and tensile strength (~1000MPa). So, TWIP steels provide excellent formability and energy absorption capability. Another required property from the steel sheets is suitability for manufacturing methods such as welding. The use of the steel sheets in the automotive applications inevitably involves welding. Considering that there are 3000-5000 welded spots on a vehicle, it can be interpreted that one of the most important manufacturing method is Resistance Spot Welding (RSW) for the automotive industry. In this study; firstly, TWIP steel sheet were cold rolled to 15% reduction in thickness. Then, the cold rolled TWIP steel sheets were welded with RSW method. The welding parameters (welding current, welding time and electrode force) were optimized for maximizing the peak tensile shear load and minimizing the indentation of the joints using a Taguchi L9 orthogonal array. The effect of welding parameters was also evaluated by examining the signal-to-noise ratio and analysis of variance (ANOVA) results.

Comparative Studies on microstructure, mechanical and corrosion behaviour of DMR 249A Steel and its welds

NASA Astrophysics Data System (ADS)

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

2018-03-01

DMR249A Medium strength (low carbon) Low-alloy steels are used as structural components in naval applications due to its low cost and high availability. An attempt has been made to weld the DMR 249A steel plates of 8mm thickness using shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW). Welds were characterized for metallography to carry out the microstructural changes, mechanical properties were evaluated using vickers hardness tester and universal testing machine. Potentio-dynamic polarization tests were carried out to determine the pitting corrosion behaviour. Constant load type Stress corrosion cracking (SCC) testing was done to observe the cracking tendency of the joints in a 3.5%NaCl solution. Results of the present study established that SMA welds resulted in formation of relatively higher amount of martensite in ferrite matrix when compared to gas tungsten arc welding (GTAW). It is attributed to faster cooling rates achieved due to high thermal efficiency. Improved mechanical properties were observed for the SMA welds and are due to higher amount of martensite. Pitting corrosion and stress corrosion cracking resistance of SMA welds were poor when compared to GTA welds.

An evaluation of welding processes to reduce hexavalent chromium exposures and reduce costs by using better welding techniques.

PubMed

Keane, Michael J

2014-01-01

A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr(6+)) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr(6+) were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr(6+) emissions, and greatly reduce costs relative to SMAW.

An Evaluation of Welding Processes to Reduce Hexavalent Chromium Exposures and Reduce Costs by Using Better Welding Techniques

PubMed Central

Keane, Michael J

2014-01-01

A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr6+) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr6+ were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr6+ emissions, and greatly reduce costs relative to SMAW. PMID:25574138

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

NASA Technical Reports Server (NTRS)

Fragomeni, James M.

1996-01-01

In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.

Fatigue Crack Growth in Peened Friction Stir Welds

NASA Technical Reports Server (NTRS)

Forth, Scott C.; Hatamleh, Omar

2008-01-01

Friction stir welding induces residual stresses that accelerates fatigue crack growth in the weld nugget. Shot peening over the weld had little effect on growth rate. Laser peening over the weld retarded the growth rate: Final crack growth rate was comparable to the base, un-welded material. Crack tunneling evident from residual compressive stresses. 2195-T8 fracture surfaces were highly textured. Texturing makes comparisons difficult as the material system is affecting the data as much as the processing. Material usage becoming more common in space applications requiring additional work to develop useful datasets for damage tolerance analyses.

Prediction of guided wave scattering by defects in rails using numerical modelling

NASA Astrophysics Data System (ADS)

Long, Craig S.; Loveday, Philip W.

2014-02-01

A guided wave based monitoring system for welded freight rail, has previously been developed. The current arrangement consists of alternating transmit and receive stations positioned roughly 1 km apart, and is designed to reliably detect complete breaks in a rail. Current research efforts are focused on extending this system to include a pulse-echo mode of operation in order to detect, locate, monitor and possibly characterize damage, before a complete break occurs. For monitoring and inspection applications, it is beneficial to be able to distinguish between scattering defects which do not represent damage (such as welds) and cracks which could result in rail breaks. In this paper we investigate the complex interaction between selected propagating modes and various weld and crack geometries in an attempt to relate scattering behaviour to defect geometry. An efficient hybrid method is employed which models the volume containing the defect with conventional solid finite elements, while the semi-infinite incoming and outgoing waveguides are accounted for using the SAFE method. Four candidate modes, suitable for long range propagation, are identified and evaluated. A weighted average reflection coefficient is used as a measure to quantify mode conversion between these four modes, and results are represented graphically in the form of reflection maps. The results show that it should be possible to distinguish between a large crack in the crown of the rail and a weld. We also show that there may be difficulties associated with reliably identifying cracks in the web as well as cracks in the crown which occur at a thermite weld. We suspect that it will be difficult to detect damage in the foot of the rail.

Prediction and Monitoring Systems of Creep-Fracture Behavior of 9Cr-1Mo Steels for Teactor Pressure Vessels

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

Potirniche, Gabriel; Barlow, Fred D.; Charit, Indrajit

2013-11-26

A recent workshop on next-generation nuclear plant (NGNP) topics underscored the need for research studies on the creep fracture behavior of two materials under consideration for reactor pressure vessel (RPV) applications: 9Cr-1Mo and SA-5XX steels. This research project will provide a fundamental understanding of creep fracture behavior of modified 9Cr-1Mo steel welds for through modeling and experimentation and will recommend a design for an RPV structural health monitoring system. Following are the specific objectives of this research project: Characterize metallurgical degradation in welded modified 9Cr-1Mo steel resulting from aging processes and creep service conditions; Perform creep tests and characterize themore » mechanisms of creep fracture process; Quantify how the microstructure degradation controls the creep strength of welded steel specimens; Perform finite element (FE) simulations using polycrystal plasticity to understand how grain texture affects the creep fracture properties of welds; Develop a microstructure-based creep fracture model to estimate RPVs service life; Manufacture small, prototypic, cylindrical pressure vessels, subject them to degradation by aging, and measure their leak rates; Simulate damage evolution in creep specimens by FE analyses; Develop a model that correlates gas leak rates from welded pressure vessels with the amount of microstructural damage; Perform large-scale FE simulations with a realistic microstructure to evaluate RPV performance at elevated temperatures and creep strength; Develop a fracture model for the structural integrity of RPVs subjected to creep loads; and Develop a plan for a non-destructive structural health monitoring technique and damage detection device for RPVs.« less

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

NASA Astrophysics Data System (ADS)

Macwan, A.; Chen, D. L.

2016-04-01

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

Immersion probe arrays for rapid pipeline weld inspection

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

Lebsack, S.; Heckhauser, H.

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

Filler metal selection for welding a high nitrogen stainless steel

NASA Astrophysics Data System (ADS)

Du Toit, Madeleine

2002-06-01

Cromanite is a high-strength austenitic stainless steel that contains approximately 19% chromium, 10% manganese, and 0.5% nitrogen. It can be welded successfully, but due to the high nitrogen content of the base metal, precautions have to be taken to ensure sound welds with the desired combination of properties. Although no matching filler metals are currently available, Cromanite can be welded using a range of commercially available stainless steel welding consumables. E307 stainless steel, the filler metal currently recommended for joining Cromanite, produces welds with mechanical properties that are generally inferior to those of the base metal. In wear applications, these lower strength welds would probably be acceptable, but in applications where full use is made of the high strength of Cromanite, welds with matching strength levels would be required. In this investigation, two welding consumables, ER2209 (a duplex austenitic-ferritic stainless steel) and 15CrMn (an austenitic-manganese hardfacing wire), were evaluated as substitutes for E307. When used to join Cromanite, 15CrMn produced welds displaying severe nitrogen-induced porosity, and this consumable is therefore not recommended. ER2209, however, outperformed E307, producing sound porosity-free welds with excellent mechanical properties, including high ductility and strength levels exceeding the minimum limits specified for Cromanite.

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.

Plasma Charge Current for Controlling and Monitoring Electron Beam Welding with Beam Oscillation

PubMed Central

Trushnikov, Dmitriy; Belenkiy, Vladimir; Shchavlev, Valeriy; Piskunov, Anatoliy; Abdullin, Aleksandr; Mladenov, Georgy

2012-01-01

Electron beam welding (EBW) shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which substantially limits the operation speed of these systems and has a negative effect on weld joint quality. The purpose of this study is to develop a method for operational control of the electron beam focus during welding in the deep penetration mode. The method uses the plasma charge current signal as an additional informational parameter. This parameter allows identification of the electron beam focus regime in electron-beam welding without application of additional low-frequency scanning of focus. It can be used for working out operational electron beam control methods focusing exactly on the welding. In addition, use of this parameter allows one to observe the shape of the keyhole during the welding process. PMID:23242276

Pipeline welding goes mechanized

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

Beeson, R.

1999-11-01

Spread four has bugs in the cornfield--but not to worry. The bug referred to here is a mechanized welding bug, specifically a single welding head, computer-aided gas metal arc (GMAW) system from CRC-Evans Automatic Welding powered by a Miller Electric XMT{reg{underscore}sign} 304 inverter-based welding machine. The bug operator and owner of 32 inverters is Welded Construction, L.P., of Perrysburgh, Ohio. Spread four is a 147-mile stretch of the Alliance Pipeline system (Alliance) cutting through the cornfields of northeast Iowa. While used successfully in Canada and Europe for onshore and offshore pipeline construction for 30 years, this is the first large-scalemore » use of mechanized welding in the US on a cross-country pipeline. On longer, larger-diameter and thicker-wall pipe projects--the Alliance mainline has 1,844 miles of pipe, most of it 36-in. diameter with a 0.622-in. wall thickness--mechanized GMAW offers better productivity than manual shielded metal arc welding (SMAW). In addition, high-strength steels, such as the API 5L Grade X70 pipe used on the Alliance, benefit from the low-hydrogen content of certain solid and tubular wire electrodes.« less

Plasma charge current for controlling and monitoring electron beam welding with beam oscillation.

PubMed

Trushnikov, Dmitriy; Belenkiy, Vladimir; Shchavlev, Valeriy; Piskunov, Anatoliy; Abdullin, Aleksandr; Mladenov, Georgy

2012-12-14

Electron beam welding (EBW) shows certain problems with the control of focus regime. The electron beam focus can be controlled in electron-beam welding based on the parameters of a secondary signal. In this case, the parameters like secondary emissions and focus coil current have extreme relationships. There are two values of focus coil current which provide equal value signal parameters. Therefore, adaptive systems of electron beam focus control use low-frequency scanning of focus, which substantially limits the operation speed of these systems and has a negative effect on weld joint quality. The purpose of this study is to develop a method for operational control of the electron beam focus during welding in the deep penetration mode. The method uses the plasma charge current signal as an additional informational parameter. This parameter allows identification of the electron beam focus regime in electron-beam welding without application of additional low-frequency scanning of focus. It can be used for working out operational electron beam control methods focusing exactly on the welding. In addition, use of this parameter allows one to observe the shape of the keyhole during the welding process.

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

DTIC Science & Technology

1982-06-29

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

Production of ozone and reactive oxygen species after welding.

PubMed

Liu, H H; Wu, Y C; Chen, H L

2007-11-01

Many toxic substances including heavy metals, ozone, carbon monoxide, carbon dioxide, and nitrogen oxides are generated during welding. Ozone (O(3)) is a strong oxidant that generates reactive oxygen species (ROS) in tissue, and ambient ROS exposure associated with particles has been determined to cause DNA damage. Ozone is produced within 30 seconds during welding. However, the length of time that O(3) remains in the air after welding is completed (post-welding) is unknown. The current study aimed to assess the distributions of ambient ROS and O(3) before the start of welding (pre-welding), during welding, and after welding. The highest O(3) levels, equal to 195 parts per billion (ppb), appeared during welding. Ozone levels gradually decreased to 60 ppb 10 minutes after the welding was completed. The highest ROS level was found in samples taken during welding, followed by samples taken after the welding was completed. The lowest ROS level was found in samples taken before the welding had started. Ozone and ROS levels were poorly correlated, but a similar trend was found for O(3) and ROS levels in particles (microM/mg). Although particles were not generated after welding, ROS and O(3) still persisted for more than 10 minutes. Meanwhile, because O(3) continues after welding, how long the occupational protective system should be used depends on the welding materials and the methods used. In addition, the relationship between metal fumes and ROS generation during the welding process should be further investigated.

Evaluation of Shipbuilding CAD/CAM/CIM Systems - Phase II (Requirements for Future Systems)

DTIC Science & Technology

1997-02-01

INNOVATION MARINE INDUSTRY STANDARDS WELDING INDUSTRIAL ENGINEERING EDUCATION AND TRAINING THE NATIONAL SHIPBUILDING RESEARCH PROGRAM February 1997 NSRP 0479...an analysis of CAD/CAM/CIM in shipyards, ship-design software firms, and alIied industries in Europe, Japan and the U.S. The purpose of the analysis...possible: Black and Veatch Hitachi Ariake Works Industrial Technology Institute Intergraph Corporation Kockums Computer Systems Mitsubishi Heavy Industries

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.

An Evaluation of Noise Levels in College Welding Laboratories and Its Effect on Student Hearing.

ERIC Educational Resources Information Center

Pontynen, Burton Ahlstrom

The purpose of this study was to determine what noise levels existed at selected work stations in college welding laboratories while students were working and whether this noise exposure had any effect on the hearing acuity of students. Audiometric tests were administered to an experimental group of welding students in the noise of a welding…

A Project to Initiate a Competency-Based Welding Program in Five Missouri Area Vocational Schools for Students with Special Needs and Varying Abilities. Final Report.

ERIC Educational Resources Information Center

Evans, Shirley J.; Evans, Gerald

A project was conducted to demonstrate the effectiveness of competency-based, individualized instruction as a teaching technique in vocational welding programs for students with varying backgrounds, abilities, and special needs. Five Missouri area vocational schools participated in the project by field testing and evaluating welding instructional…

Microstructure and Residual Stress Distributions Under the Influence of Welding Speed in Friction Stir Welded 2024 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Moghadam, Danial Ghahremani; Farhangdoost, Khalil; Nejad, Reza Masoudi

2016-06-01

Friction stir welding was conducted on 8-mm-thick plates made of AA2024-T351 aluminum alloy at tool traverse speeds between 8 and 31.5 mm/minutes and tool rotational speed between 400 and 800 rpm. Metallographic analyses and mechanical tests including hardness, tensile, residual stress, and fracture toughness tests were carried out to evaluate the microstructural and mechanical properties of the joints as a function of the process parameters. The finite element simulation of the FSW process was also performed using a thermal model. The hardness test results show that the increase in rotational speed or decrease in traverse speed of the tool would cause a decrease in weld zone hardness. The best tensile properties are obtained at rotational/traverse speed ratio between 20 and 32. Also, the longitudinal residual stress profiles were evaluated by employing X-ray diffraction method. The numerical and experimental results showed that the increase in a traverse or rotational speed would increase the residual stress of the weld zone. From the fracture toughness results, it was found that the welding process decreases the joints fracture toughness 18 to 49 pct with respect to the base metal.

Effect of Friction Stir Processing on Microstructure and Mechanical Properties of AZ91C Magnesium Cast Alloy Weld Zone

NASA Astrophysics Data System (ADS)

Hassani, Behzad; Karimzadeh, Fathallah; Enayati, Mohammad Hossein; Sabooni, Soheil; Vallant, Rudolf

2016-07-01

In this study, friction stir processing (FSP) was applied to the GTAW (TIG)-welded AZ91C cast alloy to refine the microstructure and optimize the mechanical properties of the weld zone. Microstructural investigation of the samples was performed by optical microscopy and the phases in the microstructure were determined by x-ray diffraction (XRD). The microstructural evaluations showed that FSP destroys the coarse dendritic microstructure. Furthermore, it dissolves the secondary hard and brittle β-Mg17Al12 phase existing at grain boundaries of the TIG weld zone. The closure and decrease in amount of porosities along with the elimination of the cracks in the microstructure were observed. These changes were followed by a significant grain refinement to an average value of 11 µm. The results showed that the hardness values increased to the mean ones, respectively, for as-cast (63 Hv), TIG weld zone (67 Hv), and stir zone (79 Hv). The yield and ultimate strength were significantly enhanced after FSP. The fractography evaluations, by scanning electron microscopy (SEM), indicated to a transition from brittle to ductile fracture surface after applying FSP to the TIG weld zone.

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

PubMed Central

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-01-01

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique–ultrasonic spot welding (USW)–at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with “river-flow” patterns and characteristic fatigue striations. PMID:28772809

Gas metal arc welding fume generation using pulsed current

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

Castner, H.R.

1994-12-31

This paper describes a study of the effects of pulsed welding current on the amount of welding fume and ozone produced during gas metal arc welding (GMAW) using a range of welding procedures and pulse parameters. The results reported in this paper show that pulsed current can reduce GMAW fumes compared to steady current. This research also shows that welding parameters need to be properly controlled if pulsed current is to be used to reduce welding fumes. Fume and ozone generation rates were measured during this study for GMAW of mild steel using copper-coated ER70S-3 electrode wire and 95%Ar-5%CO{sub 2}more » and 85%Ar-15%CO{sub 2} shielding gases. Welds were made with both steady current and pulsed current over a wide range of welding parameters. Fume generation rates for steady current were found to be typically between 0.2 g/min and 0.8 g/min which agrees with other researchers. No significant difference was found in the chemical composition of welding fumes from pulsed current compared to the composition of fumes generated by steady current. New technology that can reduce arc welding fumes is of significant interest to a wide range of companies that use arc welding processes and this research should assist these users in evaluating the potential for the application of this technology to their own operations.« less

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy.

PubMed

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-04-25

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique-ultrasonic spot welding (USW)-at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with "river-flow" patterns and characteristic fatigue striations.

Advanced Metalworking Solutions For Naval Systems That Go In Harm’s Way

DTIC Science & Technology

2015-01-01

destroyers USS Momsen (DDG 92) and USS Preble (DDG 88) are underway in formation. U.S. Navy photo Front cover: Ingalls Shipbuilding welding photo...applies a variety of innovative welding technologies to address the challenges associated with joining weapon system components. Joining Technologies...friction stir welding process to manufacture edge-cooled naval electronic cold plate assemblies. The modular, high- performance, and scalable

Optical radiation hazards of laser welding processes. Part 1: Neodymium-YAG laser.

PubMed

Rockwell, R J; Moss, C E

1983-08-01

High power laser devices are being used for numerous metalworking processes such as welding, cutting and heat treating. Such laser devices are totally enclosed either by the manufacturer or the end-user. When this is done, the total laser system is usually certified by the manufacturer following the federal requirements of the Code of Federal Regulations (CFR) 1040.10 and 10.40.11 as a Class I laser system. Similarly, the end-user may also reclassify an enclosed high-power laser into the Class I category following the requirements of the American National Standards Institute (ANSI) Z-136.1 (1980) standard. There are, however, numerous industrial laser applications where Class IV systems are required to be used in an unenclosed manner. In such applications, there is concern for both ocular and skin hazards caused by direct and scattered laser radiation, as well as potential hazards caused by the optical radiation created by the laser beam's interaction with the metal (i.e. the plume radiation). Radiant energy measurements are reported for both the scattered laser radiation and the resultant plume radiations which were produced during typical unenclosed Class IV Neodymium-YAG laser welding processes. Evaluation of the plume radiation was done with both radiometric and spectroradiometric measurement equipment. The data obtained were compared to applicable safety standards.

Digital control and data acquisition for high-value GTA welding

NASA Astrophysics Data System (ADS)

George, T. G.; Franco-Ferreira, E. A.

Electric power for the Cassini space probe will be provided by radioisotope thermoelectric generators (RTG's) thermally driven by General-Purpose Heat Source (GPHS) modules. Each GPHS module contains four, 150-g, pellets of Pu-238O2, and each of the four pellets is encapsulated within a thin-wall iridium-alloy shell. GTA girth welding of these capsules is performed at Los Alamos National Laboratory (LANL) on an automated, digitally-controlled welding system. Baseline design considerations for system automation and strategies employed to maximize process yield, improve process consistency, and generate required quality assurance information are discussed. Design of the automated girth welding system was driven by a number of factors which militated for precise parametric control and data acquisition. Foremost among these factors was the extraordinary value of the capsule components. In addition, DOE order 5700.6B, which took effect on 23 Sep. 1986, required that all operations adhere to strict levels of process quality assurance. A detailed technical specification for the GPHS welding system was developed on the basis of a joint LANL/Westinghouse Savannah River Company (WSRC) design effort. After a competitive bidding process, Jetline Engineering, Inc., of Irvine, California, was selected as the system manufacturer. During the period over which four identical welding systems were fabricated, very close liason was maintained between the LANL/WSRC technical representatives and the vendor. The level of rapport was outstanding, and the end result was the 1990 delivery of four systems that met or exceeded all specification requirements.

Urine chromium as an estimator of air exposure to stainless steel welding fumes.

PubMed

Sjögren, B; Hedström, L; Ulfvarson, U

1983-01-01

Welding stainless steel with covered electrodes, also called manual metal arc welding, generates hexavalent airborne chromium. Chromium concentrations in air and post-shift urine samples, collected the same arbitrarily chosen working day, showed a linear relationship. Since post-shift urine samples reflect chromium concentrations of both current and previous stainless steel welding fume exposure, individual urine measurements are suggested as approximate although not exact estimators of current exposure. This study evaluates the practical importance of such measurements by means of confidence limits and tests of validity.

Fracture toughness, tensile and stress corrosion cracking properties of Alloy 600, Alloy 690 and their welds in water

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

Brown, C.M.; Mills, W.J.

1996-10-01

The fracture toughness and tensile properties of Alloy 600, Alloy 690 and their welds, EN82H and EN52, were characterized in 54 and 338 C water with an elevated hydrogen content. Results were compared with air data to evaluate the effect of low and high temperature water on mechanical properties. In addition, the stress corrosion cracking (SCC) behavior of EN82H and EN52 welds was evaluated in 360 C water with high hydrogen. Elastic-plastic J{sub c} fracture toughness testing revealed that the fracture resistance of all test materials was exceptionally high in 54 and 338 C air and 338 C water, demonstratingmore » that fracture properties were essentially unaffected by the high temperature water environment. In 54 C water, however, J{sub c} values for EN82H and EN52 welds were reduced by an order of magnitude, and Alloy 690 showed a five-fold decrease in J{sub c}. Tensile properties for all test materials were essentially unaffected by the water environment, except for the total elongation for EN82H welds which was significantly reduced in 54 C water. At a strain rate of 5 x 10{sup 6} sec{sup {minus}1} in low temperature water, there appears to be sufficient time for environmental interactions to restrict ductility in EN82H welds. Constant-load testing of precracked weld specimens in 360 C water resulted in extensive intergranular SCC in EN82H welds loaded to K{sub I} levels between 35 and 55 MPa {radical}m, whereas no SCC occurred in EN52 welds under comparable test conditions.« less

Exposure to welding fumes increases lung cancer risk among light smokers but not among heavy smokers: evidence from two case-control studies in Montreal.

PubMed

Vallières, Eric; Pintos, Javier; Lavoué, Jérôme; Parent, Marie-Élise; Rachet, Bernard; Siemiatycki, Jack

2012-08-01

We investigated relationships between occupational exposure to gas and arc welding fumes and the risk of lung cancer among workers exposed to these agents throughout the spectrum of industries. Two population-based case-control studies were conducted in Montreal. Study I (1979-1986) included 857 cases and 1066 controls, and Study II (1996-2001) comprised 736 cases and 894 controls. Detailed job histories were obtained by interview and evaluated by an expert team of chemist-hygienists to estimate degree of exposure to approximately 300 substances for each job. Gas and arc welding fumes were among the agents evaluated. We estimated odds ratios (ORs) and 95% confidence intervals (CIs) of lung cancer using logistic regression, adjusting for smoking history and other covariates. The two studies provided similar results, so a pooled analysis was conducted. Among all subjects, no significant association was found between lung cancer and gas welding fumes (OR = 1.1; 95% CI = 0.9-1.4) or arc welding fumes (OR = 1.0; 95% CI = 0.8-1.2). However, when restricting attention to light smokers, there was an increased risk of lung cancer in relation to gas welding fumes (OR = 2.9; 95% CI = 1.7-4.8) and arc welding fumes (OR = 2.3; 95% CI = 1.3-3.8), with even higher OR estimates among workers with the highest cumulative exposures. In conclusion, there was no detectable excess risk of lung cancer due to welding fumes among moderate to heavy smokers; but among light smokers we found an excess risk related to both types of welding fumes.

Exposure to welding fumes increases lung cancer risk among light smokers but not among heavy smokers: evidence from two case–control studies in Montreal

PubMed Central

Vallières, Eric; Pintos, Javier; Lavoué, Jérôme; Parent, Marie-Élise; Rachet, Bernard; Siemiatycki, Jack

2012-01-01

We investigated relationships between occupational exposure to gas and arc welding fumes and the risk of lung cancer among workers exposed to these agents throughout the spectrum of industries. Two population-based case–control studies were conducted in Montreal. Study I (1979–1986) included 857 cases and 1066 controls, and Study II (1996–2001) comprised 736 cases and 894 controls. Detailed job histories were obtained by interview and evaluated by an expert team of chemist–hygienists to estimate degree of exposure to approximately 300 substances for each job. Gas and arc welding fumes were among the agents evaluated. We estimated odds ratios (ORs) and 95% confidence intervals (CIs) of lung cancer using logistic regression, adjusting for smoking history and other covariates. The two studies provided similar results, so a pooled analysis was conducted. Among all subjects, no significant association was found between lung cancer and gas welding fumes (OR = 1.1; 95% CI = 0.9–1.4) or arc welding fumes (OR = 1.0; 95% CI = 0.8–1.2). However, when restricting attention to light smokers, there was an increased risk of lung cancer in relation to gas welding fumes (OR = 2.9; 95% CI = 1.7–4.8) and arc welding fumes (OR = 2.3; 95% CI = 1.3–3.8), with even higher OR estimates among workers with the highest cumulative exposures. In conclusion, there was no detectable excess risk of lung cancer due to welding fumes among moderate to heavy smokers; but among light smokers we found an excess risk related to both types of welding fumes. PMID:23342253

Offline motion planning and simulation of two-robot welding coordination

NASA Astrophysics Data System (ADS)

Zhang, Tie; Ouyang, Fan

2012-03-01

This paper focuses on the two-robot welding coordination of complex curve seam which means one robot grasp the workpiece, the other hold the torch, the two robots work on the same workpiece simultaneously. This paper builds the dual-robot coordinate system at the beginning, and three point calibration method of two robots' relative base coordinate system is presented. After that, the non master/slave scheme is chosen for the motion planning, the non master/slave scheme sets the poses versus time function of the point u on the workpiece, and calculates the two robot end effecter trajectories through the constrained relationship matrix automatically. Moreover, downhand welding is employed which can guarantee the torch and the seam keep in good contact condition all the time during the welding. Finally, a Solidworks-Sim Mechanics simulation platform is established, and a simulation of curved steel pipe welding is conducted. The results of the simulation illustrate the welding process can meet the requirements of downhand welding, the joint displacement curves are smooth and continuous and no joint velocities are out of working scope.

Crack Resistance of Welded Joints of Pipe Steels of Strength Class K60 of Different Alloying Systems

NASA Astrophysics Data System (ADS)

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

2018-03-01

The crack resistance of welded joints of pipe steels of strength class K60 and different alloying systems is studied. The parameter of the crack tip opening displacement (CTOD) is shown to be dependent on the size of the austenite grains and on the morphology of bainite in the superheated region of the heat-affected zone of the weld. The crack resistance is shown to be controllable due to optimization of the alloying system.

Application of Digital Radiography to Weld Inspection for the Space Shuttle External Fuel Tank

NASA Technical Reports Server (NTRS)

Ussery, Warren

2009-01-01

This slide presentation reviews NASA's use of digital radiography to inspect the welds of the external tanks used to hold the cryogenic fuels for the Space Shuttle Main Engines. NASA has had a goal of replacing a significant portion of film used to inspect the welds, with digital radiography. The presentation reviews the objectives for converting to a digital system from film, the characteristics of the digital system, the Probability of detection study, the qualification and implementation of the system.

Automatic non-destructive system for quality assurance of welded elements in the aircraft industry

NASA Astrophysics Data System (ADS)

Chady, Tomasz; Waszczuk, Paweł; Szydłowski, Michał; Szwagiel, Mariusz

2018-04-01

Flaws that might be a result of the welding process have to be detected, in order to assure high quality thus reliability of elements exploited in aircraft industry. Currently the inspection stage is conducted manually by a qualified workforce. There are no commercially available systems that could support or replace humans in the flaw detection process. In this paper authors present a novel non-destructive system developed for quality assurance purposes of welded elements utilized in the aircraft industry.

Study of residual stresses in CT test specimens welded by electron beam

NASA Astrophysics Data System (ADS)

Papushkin, I. V.; Kaisheva, D.; Bokuchava, G. D.; Angelov, V.; Petrov, P.

2018-03-01

The paper reports result of residual stress distribution studies in CT specimens reconstituted by electron beam welding (EBW). The main aim of the study is evaluation of the applicability of the welding technique for CT specimens’ reconstitution. Thus, the temperature distribution during electron beam welding of a CT specimen was calculated using Green’s functions and the residual stress distribution was determined experimentally using neutron diffraction. Time-of-flight neutron diffraction experiments were performed on a Fourier stress diffractometer at the IBR-2 fast pulsed reactor in FLNP JINR (Dubna, Russia). The neutron diffraction data estimates yielded a maximal stress level of ±180 MPa in the welded joint.

Characterization of GTA weldments in 10Ni-8CO-2Cr-1MO steel

NASA Technical Reports Server (NTRS)

Stonesifer, F. R.; Smith, H. L.

1972-01-01

This study of 10Ni-8Co-2Cr-1Mo steel includes evaluations of tensile, impact, hardness, fracture toughness properties, and metallographic features. Base plate and three weldments in one-inch thicknesses were examined to compare as-welded properties with those obtained after reaging, and results of welding the 10%Ni alloy with 9-4-20 wire as opposed to a matching weld wire composition. Critical crack sizes are calculated for the material. The most desirable weld properties are obtained using the matching weld wire and a reaging cycle. However, the improvement gained through reaging is probably not sufficient to justify the additional cost for most practical applications.

The laser welding technique applied to the non precious dental alloys procedure and results.

PubMed

Bertrand, C; Le Petitcorps, Y; Albingre, L; Dupuis, V

2001-03-10

The laser welding technique was chosen for its versatility in the repair of dental metal prosthesis. The aim of this research is to assess the accuracy, quality and reproducibility of this technique as applied to Ni-Cr-Mo and Cr-Co-Mo alloys often used to make prosthesis The alloy's ability to weld was evaluated with a pulsed Nd-Yag Laser equipment. In order to evaluate the joining, various cast wires with different diameters were used. The efficiency of the joining was measured with tensile tests. In order to understand this difference, metallographic examinations and X-Ray microprobe analysis were performed through the welded area and compared with the cast part. It was found that a very slight change in the chemistry of the Ni-Cr alloys had a strong influence on the quality of the joining. The Co-Cr alloy presented an excellent weldability. A very important change in the microstructure due to the effect of the laser was pointed out in the welding zone, increasing its micro-hardness. The higher level of carbon and boron in one of the two Ni-Cr was found to be responsible for its poor welding ability. However for the others, the maximum depth of welding was found to be around 2mm which is one of the usual thicknesses of the components which have to be repaired.

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

PubMed

Araque, Oscar; Arzola, Nelson; Hernández, Edgar

2018-04-12

This research deals with the fatigue behavior of butt-welded joints, by considering the geometry and post-welding cooling cycles, as a result of cooling in quiet air and immersed in water. ASTM A-36 HR structural steel was used as the base metal for the shielded metal arc welding (SMAW) process with welding electrode E6013. The welding reinforcement was 1 mm and 3 mm, respectively; axial fatigue tests were carried out to determine the life and behavior in cracks propagation of the tested welded joints, mechanical characterization tests of properties in welded joints such as microhardness, Charpy impact test and metallographic analysis were carried out. The latter were used as input for the analysis by finite elements which influence the initiation and propagation of cracks and the evaluation of stress intensity factors (SIF). The latter led to obtaining the crack propagation rate and the geometric factor. The tested specimens were analyzed, by taking photographs of the cracks at its beginning in order to make a count of the marks at the origin of the crack. From the results obtained and the marks count, the fatigue crack growth rate and the influence of the cooling media on the life of the welded joint are validated, according to the experimental results. It can be concluded that the welded joints with a higher weld reinforcement have a shorter fatigue life. This is due to the stress concentration that occurs in the vicinity of the weld toe.